^1 HARDWARE REFERENCE MANUAL
^2 PMAC2 PCI Lite
Preliminary Documentation
^3 PMAC 2 PCI Lite Bus Expansion Card
^4 4XX-603658-xHxx
^5 November 5, 2003
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
Copyright Information
© 2003 Delta Tau Data Systems, Inc. All rights reserved.
This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses are
unauthorized without written permission of Delta Tau Data Systems, Inc. Information contained
in this manual may be updated from time-to-time due to product improvements, etc., and may not
conform in every respect to former issues.
To report errors or inconsistencies, call or email:
Delta Tau Data Systems, Inc. Technical Support
Phone: (818) 717-5656
Fax: (818) 998-7807
Email: support@deltatau.com
Website: http://www.deltatau.com
Operating Conditions
All Delta Tau Data Systems, Inc. motion controller products, accessories, and amplifiers contain
static sensitive components that can be damaged by incorrect handling. When installing or
handling Delta Tau Data Systems, Inc. products, avoid contact with highly insulated materials.
Only qualified personnel should be allowed to handle this equipment.
In the case of industrial applications, we expect our products to be protected from hazardous or
conductive materials and/or environments that could cause harm to the controller by damaging
components or causing electrical shorts. When our products are used in an industrial
environment, install them into an industrial electrical cabinet or industrial PC to protect them
from excessive or corrosive moisture, abnormal ambient temperatures, and conductive materials.
If Delta Tau Data Systems, Inc. products are directly exposed to hazardous or conductive
materials and/or environments, we cannot guarantee their operation.
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
Table of Contents
INTRODUCTION.......................................................................................................................................................1
Overview...................................................................................................................................................................1
Board Configuration..................................................................................................................................................1
Base Version.........................................................................................................................................................1
Option 2: Dual-Ported RAM.................................................................................................................................1
Option 3: USB1.1 Communications Port..............................................................................................................1
Option 5: CPU and Memory Configurations........................................................................................................2
Option 6: Extended Servo Algorithm....................................................................................................................2
Option 6L: Multi-block Lookahead Firmware......................................................................................................2
Option 7: Plate Mounting.....................................................................................................................................2
Option 8A: High-Accuracy Clock Crystal............................................................................................................2
Option 10: Firmware Version Specification.........................................................................................................2
Option 12: Analog-to-Digital Converters.............................................................................................................2
Option 16: Battery-Backed Parameter Memory...................................................................................................3
HARDWARE SETUP.................................................................................................................................................5
Watchdog Timer Jumper.......................................................................................................................................5
CPU Frequency Control Jumpers.........................................................................................................................5
Re-Initialization Jumper .......................................................................................................................................5
Power-Up State Jumpers......................................................................................................................................5
Firmware Load Jumper........................................................................................................................................5
Flash Memory Bank Select Jumpers.....................................................................................................................5
Encoder Sample Clock Source Jumpers...............................................................................................................5
Serial Port Selection Jumper................................................................................................................................6
Output Disable State Jumpers ..............................................................................................................................6
Amplifier Enable / EQU Jumper...........................................................................................................................6
Resistor Pack Configuration......................................................................................................................................7
Termination Resistors........................................................................................................................................... 7
Pull-Up/Pull-Down Resistors ...............................................................................................................................7
Connections...............................................................................................................................................................8
Mounting...............................................................................................................................................................8
Power Supply Connection.....................................................................................................................................8
Machine Port Connections ...................................................................................................................................8
Display Port..........................................................................................................................................................8
Multiplexer Port....................................................................................................................................................9
I/O Port.................................................................................................................................................................9
Serial Ports...........................................................................................................................................................9
A/D-Converter Port ..............................................................................................................................................9
Handwheel Port....................................................................................................................................................9
COMMUNICATIONS SETUP................................................................................................................................11
FLEX CPU BOARD JUMPER DESCRIPTIONS..................................................................................................13
E1: Watchdog Disable Jumper................................................................................................................................14
E2: Dual-Ported Ram Port Select............................................................................................................................14
E4 – E6: Power-Up/Reset Load Source..................................................................................................................14
E7: Firmware Reload Enable ..................................................................................................................................14
E10A, B, C: Flash Memory Bank Select.................................................................................................................14
JUMPER DESCRIPTIONS......................................................................................................................................15
E2: CPU Frequency Select......................................................................................................................................15
E3: Normal/Re-Initializing Power-Up/Reset...........................................................................................................15
E4: CPU Frequency Select......................................................................................................................................15
E5 – E6: (Reserved for Future Use)........................................................................................................................15
E13 - E14: Encoder Sample Clock Direction Control............................................................................................16
Table Of Contents i
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
E17 - E18: Serial Port Type Selection....................................................................................................................16
E111-118: Command Output Disable State............................................................................................................17
MATING CONNECTORS.......................................................................................................................................19
CPU Board Connectors...........................................................................................................................................19
J2 (JEXP)/Expansion..........................................................................................................................................19
Baseboard Connectors.............................................................................................................................................19
J1 (JANA)/Analog (Option 12) ...........................................................................................................................19
J2 (JTHW)/Multiplexer Port...............................................................................................................................19
J3 (JIO)/Digital I/O............................................................................................................................................19
J5 (JRS232)/RS-232 Serial Communications......................................................................................................19
J5A (JRS422)/RS-422 Serial Communications...................................................................................................19
J6 (JDISP)/Display.............................................................................................................................................19
J7 (JHW)/Auxiliary Channel...............................................................................................................................19
J8 (JEQU)/Position Compare.............................................................................................................................19
J9 (JMACH1)/Machine Port 1............................................................................................................................20
J10 (JMACH2)/Machine Port 2..........................................................................................................................20
BASE BOARD CONNECTOR PINOUTS..............................................................................................................21
J1 (JANA) Analog Input Port Connector................................................................................................................21
J2 (JTHW) Multiplexer Port Connector..................................................................................................................22
J3 (JI/O) General Input/Output Connector..............................................................................................................23
J5 (JRS232) Serial Port Connector..........................................................................................................................24
J5A (RS422) Serial Port Connector ........................................................................................................................24
JRS422 (26-PIN Connector)...............................................................................................................................24
J6 (JDISP) Display Connector ................................................................................................................................25
J7 (JHW) Handwheel Encoder Connector...............................................................................................................25
J8 (JEQU) Position Compare Output Connector.....................................................................................................26
J9 (JMACH1) Connector Description.....................................................................................................................26
J9 JMACH1 Connector.......................................................................................................................................26
J10 (JMACH2) Connector Description...................................................................................................................29
J10 JMACH2 Connector.....................................................................................................................................29
TB1 (2/4-Pin Terminal Block)................................................................................................................................33
TB2 (3-Pin Terminal Block) ...................................................................................................................................33
ii Table of Contents
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
INTRODUCTION
Overview
The PMAC2 PCI Lite is a member of the PMAC2 family of boards optimized for interface to three or
four sinewave or direct PWM servo drives and to pulse-and-direction stepper drives. It has four channels
of servo interface circuitry, but its software is capable of eight axes of control. It is software compatible
with the PMAC2-PC and the PMAC2 Mini.
The PMAC2 PCI Lite is a full-sized PCI-bus expansion card. While the PMAC2 PCI Lite is capable of
PCI bus communications, with or without the optional on-board dual-ported RAM, it does not need to be
inserted into a PCI expansion slot. Communications can be done through the standard on-board RS-232
serial port; standalone operation is possible.
Board Configuration
Base Version
• The base version of the PMAC2 PCI Lite provides a 1-1/2-slot board with:
• 40 MHz DSP563xx CPU
• 128k x 24 zero-wait-state SRAM active memory
• 512k x 8 flash memory for user backup and firmware
• Latest released firmware version (requires V1.17 or newer firmware)
• RS-232/422 serial interface, 33 MHz PCI (PC) bus interface
• Four channels axis interface circuitry, each including:
• Three output command signal sets, configurable as either:
□ Two serial data streams to external DACs, 1 pulse-and-direction
□ Three PWM top-and-bottom pairs
• 3-channel differential/single-ended encoder input
• Nine input flags, two output flags
• Interface to two external serial ADCs, 8 to 18-bits
• Two channels supplemental interface circuitry, each including:
• 2-channel differential/single-ended encoder input
• One output command signal set, configurable as
pulse-&-direction or PWM top-and-bottom pair
• Display, muxed I/O, direct I/O interface ports
• Buffered expansion port.
• Clock crystal with ± 100 ppm accuracy.
• PID/notch/feedforward servo algorithms
• 1-year warranty from date of shipment
• One Manuals CD-ROM per set of one to four PMACs in shipment
(Cables, mounting plates, mating connectors not included)
Option 2: Dual-Ported RAM
Dual-ported RAM provides a high-speed communications path for bus communications with the host
computer through a bank of shared memory. DPRAM is advised if more than 100 data items per second
are to be passed between the controller and the host computer in either direction.
Option 2 provides an on-board 8k x 16 bank of dual-ported RAM for PCI or USB. The key component
on the board is U1.
Option 3: USB1.1 Communications Port
If using the PMAC-PCI Lite in a standalone application, use this port because it faster than the standard
RS232/422 communications. Use of this port disables the PCI port.
Introduction 1
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
Option 5: CPU and Memory Configurations
If the 40 MHz CPU (80 MHz DSP 56002 equivalent) that comes standard does not have sufficient
computational power, faster versions are available as options. These options provide a faster CPU IC in
U127, and unlike past CPU upgrades, will not require any additional memory chips.
• Option 5CF provides an 80 MHz CPU (160 MHz DSP 56002 equivalent) with zero-wait-state SRAM
active memory. Requires V1.17 or newer firmware.
• Option 5EF provides a 160 MHz CPU (320 MHz DSP 56002 equivalent) with zero-wait-state SRAM
active memory. Requires V1.17 or newer firmware.
Option 6: Extended Servo Algorithm
The standard PID servo algorithm with feedforward and notch filter is suitable for most applications.
Systems with difficult dynamics, especially with significant flexibility, may require a more powerful
servo algorithm, such as the Extended Servo Algorithm (ESA).
• 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). This option requires a one-time purchase of the Acc-25
program, which is necessary for tuning the Option-6 firmware.
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 (without
changing the path) to ensure that axis limits are not violated.
Option 7: Plate Mounting
If the PMAC2 PCI Lite is used as a PCI bus expansion board, the standard hardware is used for proper
mounting of the board in the bus. However, if it is not installed in a PCI expansion slot, other provisions
must be made for mounting.
Option 7 provides a mounting plate connected to the PMAC2 PCI Lite with standoffs. It is used to install
the PMAC2 PCI Lite in standalone applications.
Option 8A: High-Accuracy Clock Crystal
The PMAC2 PCI Lite has a clock crystal (component Y1) of nominal frequency 19.6608 MHz (~20
MHz). The standard crystal’s accuracy specification is +/-100 ppm. Long-term velocity accuracy is
limited by the accuracy of the crystal, unless an external time base is used.
Option 8A provides a nominal 19.6608 MHz crystal with a +/-15 ppm accuracy specification.
Option 10: Firmware Version Specification
Normally the PMAC2 PCI Lite is provided with the newest released firmware version. A label on the
U61 flash memory IC on the CPU board shows the firmware version loaded at the factory.
Option 10 provides for a user-specified firmware version.
Option 12: Analog-to-Digital Converters
With Option 12, eight or 16 channels of on-board multiplexed analog-to-digital converters can be
installed. One or two of these converters are read every phase interrupt. The analog inputs are not
optically isolated, and each can have a 0 – 5V input range, or a +/-2.5V input range, individually
selectable.
Option 12 provides an 8-channel 12-bit A/D converter. The key components on the board are U28 and
connector J1.
Option 12A provides an additional 8-channel 12-bit A/D converter. The key component on the board is
U29.
2 Introduction
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
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 16 provides a 16k x 24 bank of battery-backed parameter RAM in components U84, U85, U86,
with the battery in BT1.
Introduction 3
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
4 Introduction
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
HARDWARE SETUP
Watchdog Timer Jumper
Jumper E19 must be OFF for the watchdog timer to operate. This is an important safety feature, so it is
vital that this jumper be OFF in normal operation. E19 should be put ON only to debug problems with
the watchdog timer circuit.
CPU Frequency Control Jumpers
If variable I46 is set to the default value of zero, jumpers E2 and E4 on the base PMAC2 PCI Lite 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.
• If jumpers E2 and E4 are both OFF, the CPU will operate at a 40MHz frequency.
• If E2 is ON and E4 is OFF, the CPU will operate at a 60MHz frequency.
• If E2 is OFF and E4 is ON, the CPU will operate at an 80MHz frequency.
• If I46 is set to a value greater than zero, E2 and E4 are not used. The CPU frequency is set to 10MHz
(I46+1)
Re-Initialization Jumper
If E3 is off during power-up/reset, the controller will load its last saved set-up parameters from flash
memory into active memory. This is the setting for normal operation.
If E3 is on during power-up/reset, the controller will load its factory-default set-up parameters from
firmware into active memory. Generally, this is done only if communications cannot be established with
the card when it comes up in normal operational mode.
Power-Up State Jumpers
Jumper E20 must be OFF, jumper E21 must be ON, and jumper E22 must be ON, in order for the CPU to
copy the firmware from flash memory into active RAM on power-up/reset. This is necessary for normal
operation of the card. (Other settings are for factory use only.)
Firmware Load Jumper
If jumper E23 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 E23 must be OFF during power-up/reset for the board to come up in normal operational mode.
Flash Memory Bank Select Jumpers
The flash-memory IC in location U10 on the Flex CPU 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 E10A, E10B, and E10C 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.
Encoder Sample Clock Source Jumpers
Jumper E13 controls the source of the SCLK encoder-sampling clock for each servo IC. The default
setting, No Jumper Installed, means that the SCLK signal comes from the servo IC and is output on the
JMACH connectors. This setting is suitable for all but a few special applications.
Hardware Setup 5
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
Serial Port Selection Jumper
Jumpers E17 and E18 control which serial-port connector is used. If E17 and E18 connect their pins 1
and 2, the 10-pin RS-232 port connector J5 is used. If E17 and E18 connect their pins 2 and 3, the 26-pin
RS-422 port connector J5A is used. The RS-422 port must be used if several cards are to be daisychained together on a single multi-drop cable.
Output Disable State Jumpers
Jumpers E111 through E114 control the hardware state of the digital command output signals for each
channel when the amplifier enable signal for that channel is in the disable state (false). Jumper E11n (n =
1 to 4) controls the output signals for channel n on the board.
If E11n is off (default), the command output signals for channel n are still active when the amplifier
enable signal is in the disable state. The Turbo PMAC software should be commanding a net zero
command to be output on these signals, and the amplifier-enable signal should be used by the amplifier so
that no command output will cause action if it is receiving a disable signal. The Off setting should be
used when DAC output format is selected for the channel.
If E11n is on, the command output signals for channel n are tri-stated when the amplifier-enable signal is
in the disable state. This setting is used only with direct-PWM power-block amplifiers that do not use
amplifier enable to gate the PWM signals, and in which the zero-command format of 50% top on-time,
and 50% bottom on-time cannot be tolerated in the disable state.
Amplifier Enable / EQU Jumper
WARNING
The jumper setting must match the type of driver IC, or damage to the IC will
result.
Jumpers E11 and E12 control the polarity of the AENA and EQU lines. Their default setting is 1 to 2
which applies GND to pin 10 of U93 AENA/EQUn driver IC. This is used for 74ACT563, 74ACT573,
and ULN2803 model sinking chips.
To source the AENA and EQU lines, apply +V to pin 10 of U93, jump pin 2 to 3. This is used for
UDN2891 model sourcing chip.
Note:
If using ULN2803 or UDN2981 model chips, be sure to plug pin 1 of chip into
socket starting at pin 2.
6 Hardware Setup
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
Resistor Pack Configuration
Termination Resistors
The PMAC2 PCI Lite provides sockets for termination resistors on differential input pairs coming into the
board. As shipped, there are no resistor packs in these sockets. If these signals are brought long distances
into the PMAC2 PCI Lite board and ringing at signal transitions is a problem, SIP resistor packs may be
mounted in these sockets to reduce or eliminate the ringing.
All termination resistor packs have independent resistors (no common connection) with each resistor
using two adjacent pins. The following table shows which packs are used to terminate each input device:
Input Pack Pack Size Input Pack Pack Size
Encoder 1 RP60 6-pin ADC 1 & 2 RP60 8-pin
Encoder 2 RP62 6-pin ADC 3 & 4 RP61 8-pin
Encoder 3 RP66 6-pin ADC 5 & 6 RP121 8-pin
Encoder 4 RP68 6-pin ADC 7 & 8 RP122 8-pin
Encoder 5 RP107 6-pin Fault 1 & 2 RP63 6-pin
Encoder 6 RP111 6-pin Fault 3 & 4 RP64 6-pin
Encoder 7 RP108 6-pin Fault 5 & 6 RP124 6-pin
Encoder 8 RP112 6-pin Fault 7 & 8 RP125 6-pin
SCLK12&34 RP52 6-pin SCLK56&78 RP113 6-pin
Pull-Up/Pull-Down Resistors
The differential input signal pairs to the PMAC2 PCI Lite 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 kohm pull-up resistor to +5V. This cannot
be changed.
The - inputs of each differential pair each have a hard-wired 2.2 kohm resistor to +5V; each has another
2.2 kohm 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 used for unconnected inputs to prevent the pick-up of spurious noise. It is permissible for
differential line-driver inputs.
If this socketed resistor is configured as a pull-up resistor (by reversing the SIP pack in the socket), the
two parallel 2.2 kohm resistors act as a single 1.1 kohm pull-up resistor, holding the line at +5V in the
absence of an external signal. This configuration is required if encoder-loss detection is desired; or if
complementary open-collector drivers are used. It is permissible for differential line-driver inputs even
without encoder loss detection.
If Pin 1 of the resistor pack (marked by a dot on the pack) matches Pin 1 of the socket (marked by a wide
white line on the front side of the board and a square solder pin on the back side of the board), then the
pack is configured as a bank of pull-down resistors. If the pack is reversed in the socket, it is configured
as a bank of pull-up resistors.
Hardware Setup 7
PMAC2 PCI Lite Hardware Reference Manual – Preliminary Documentation
The following table lists the pull-up/pull-down resistor pack for each input device:
Device Resistor Pack Device Resistor Pack
Encoder 1 RP43 ADC/Fault1&2 RP58
Encoder 2 RP48 ADC/Fault3&4 RP59
Encoder 3 RP44 ADC/Fault5&6 RP119
Encoder 4 RP49 ADC/Fault7&8 RP120
Encoder 5 RP104 SCLK12&34 RP62
Encoder 6 RP109 SCLK56&78 RP123
Encoder 7 RP105
Encoder 8 RP110
Connections
Mounting
The PMAC2 PCI Lite can be mounted in one of two ways: in the PCI bus, or using standoffs.
1. PCI bus: To mount in the PCI bus, simply insert the P1 card-edge connector into the PCI socket. If
there is a standard PC-style housing, a bracket at the end of the PMAC2 PCI Lite board can be used to
screw into the housing to hold the board down firmly.
2. Standoffs: At each of the Four Corners of the PMAC2 PCI Lite board, there are mounting holes that
can be used to mount the board on standoffs.
Power Supply Connection
The standard PMAC2 PCI Lite requires only 5V power: 3A in a 4-channel configuration, 4A in an 8channel configuration (with Option 1). If the Option 12 A/D converters are installed, a –12V supply is
also required. In this case, a +12V supply also can be passed through the card and out to the analog
devices feeding the A/D converters.
The power can be provided in several ways:
• Bus connector: If the PMAC2 PCI Lite is mounted in an electrically active PCI bus slot, it draws its
5V and +/-12V power from the bus automatically.
• Terminal block: The TB1 2/4-point terminal block can be used to bring in 5V power, especially in
standalone applications. Point 1 is GND; Point 2 is +5V. Points 3 and 4 are needed only if the
Option-12 A/D converters are ordered.
• JMACH connectors: Up to 2A may be brought in through each 100-pin JMACH connector from an
Acc-8 board or its equivalent, provided the cable is 500mm (20 inches) or less in length.
Machine Port Connections
The PMAC2 PCI Lite has a 100-pin high-density header for each pair of servo interface channels.
Through this connector, pass all of the digital signals to and from the amplifier, encoder, and flags for the
two channels. Typically, this header is connected with a matching Delta Tau Acc-8 family 2-channel
breakout board or equivalent through a provided 100-pin flat cable.
The machine port connectors are:
• J9 (JMACH1) Board Channels 1 & 2
• J10 (JMACH2) Board Channels 3 & 4
Display Port
The J6 (JDISP) display port provides a 14-pin IDC header for connection to the Acc-12 family of
displays. Flat cables are provided with each of these displays for direct connection between the display
and this port.
8 Hardware Setup
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