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:
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.
Non-Turbo CPU Base Configuration...................................................................................................................3
Non-Turbo CPU Further Options.........................................................................................................................3
Turbo CPU Base Configuration...........................................................................................................................3
Turbo CPU Further Options.................................................................................................................................3
Power-Up State Jumpers......................................................................................................................................5
OPERATION OF THE FLEX CPU..........................................................................................................................7
Operation as Non-Turbo CPU..............................................................................................................................7
Operation as a Turbo CPU...................................................................................................................................9
FLEX CPU BOARD JUMPER DESCRIPTIONS..................................................................................................11
E2: Dual-Ported RAM Port Select......................................................................................................................11
The Flex CPU piggyback board (Part # 300-603605-10x) for the PMAC/PMAC2 and Turbo
PMAC/PMAC2 families of boards provides new high-end capabilities for these controllers and uses
newer components with longer product lifetimes. It can be manufactured in a wide variety of
configurations, and can be used in the following products:
• PMAC(1)-PC
• PMAC(1)-PCI
• PMAC(1)-VME
• PMAC2-PC
• PMAC2-PCI
• PMAC2-VME
• Turbo PMAC(1)-PC
• Turbo PMAC(1)-PCI
• Turbo PMAC(1)-VME
• Turbo PMAC2-PC
• Turbo PMAC2-PCI
• Turbo PMAC2-VME
On the regular (non-Turbo) PMAC(1) and PMAC2 boards, the Flex CPU is provided automatically when
any of the following CPU options are ordered:
• Option 5AF: 40 MHz CPU with 128k x 24 internal SRAM
• Option 5CF: 80 MHz CPU with 128k x 24 internal SRAM
• Option 5EF: 160 MHz CPU with 128k x 24 internal SRAM
The Flex CPU board is not provided if Option 4x or 5x is not ordered, or if Option 4A, 5A, 5B, or 5C is
ordered.
On Turbo PMAC(1) and Turbo PMAC2 boards, the Flex CPU may be provided when any of the
following CPU options is ordered:
• Option 5C0: 80 MHz DSP56303 CPU with 8k x 24 internal SRAM, 256k x 24 external SRAM
• Option 5C3: 80 MHz DSP56303 CPU with 8k x 24 internal SRAM, 1M x 24 external SRAM
• Option 5D0: 100 MHz DSP56309 CPU with 34k x 24 internal SRAM, 256k x 24 external SRAM
• Option 5D3: 100 MHz DSP56309 CPU with 34k x 24 internal SRAM, 1M x 24 external SRAM
In these cases, however, the older Turbo only CPU piggyback board may also be provided.
On Turbo PMAC(1) and Turbo PMAC2 boards, the Flex CPU will be provided automatically when either
of the following CPU options is ordered:
• Option 5E0: 160 MHz DSP56309 CPU with 128k x 24 internal SRAM, 256k x 24 external SRAM
• Option 5E3: 160 MHz DSP56309 CPU with 128k x 24 internal SRAM, 1M x 24 external SRAM
Introduction 1
Page 6
Flex CPU Piggyback Board Hardware Reference
2 Introduction
Page 7
Flex CPU Piggyback Board Hardware Reference
BOARD CONFIGURATION
Non-Turbo CPU Base Configuration
When assembled for a non-Turbo CPU, the DSP IC in U1 of the Flex CPU board contains all of the
memory required for operation. Therefore, there are no ICs installed in the locations for external RAM:
U11, U12, U13, U14, U15, and U16.
The CPU is available in several speed options: 40 MHz (Option 5AF), 80 MHz (Option 5CF), and 160
MHz (Option 5EF). The maximum frequency of operation is indicated with a sticker on the CPU in U1.
When the Flex CPU is built for ISA-bus or VME-bus baseboards, the P3 connector consists of a 36-pin
header on the solder side for direct connection to the baseboard, and a 10-pin header on the component
side for cable connection of the extra signals required for dual-ported RAM interface. When the Flex
CPU is built for PCI-bus baseboards the P3 connector consists only of a 56-pin header on the solder side
for direct connection of all signals to the baseboard.
Non-Turbo CPU Further Options
The Option 16 battery-backed parameter RAM provides a bank of non-volatile memory for the controller.
Its key components are RAM ICs in U17, U18, and U19, and a battery in BT1
Turbo CPU Base Configuration
When assembled for a Turbo CPU section, the Flex CPU board contains external RAM ICs in locations
U11, U12, U13, U14, U15, U16. With the standard memory configuration (Option 5x0), these ICs fill the
smaller footprint in these locations, leaving an open pin on the board on each end of each side.
When the Flex CPU is built for ISA-bus or VME-bus baseboards, the P3 connector consists of a 36-pin
header on the solder side for direct connection to the baseboard, and a 10-pin header on the component
side for cable connection of the extra signals required for dual-ported RAM interface. When the Flex
CPU is built for PCI-bus baseboards the P3 connector consists only of a 56-pin header on the solder side
for direct connection of all signals to the baseboard.
Turbo CPU Further Options
If an expanded memory configuration (Option 5x3) is ordered, larger RAM ICs are installed in locations
U11, U12, U13, U14, U15, U16, occupying the full footprints in these locations
If the Option 9T auxiliary serial port is ordered for the Turbo PMAC controller, an RS-232 serial port is
provided on the CPU board to supplement the serial port on the baseboard. The key components are ICs
in U28 and U29, and the connector J8.
The Option 16A battery-backed parameter RAM provides a bank of non-volatile memory for the
controller. Its key components are RAM ICs in U17, U18, and U19, and a battery in BT1
Board Configuration 3
Page 8
Flex CPU Piggyback Board Hardware Reference
4 Board Configuration
Page 9
Flex CPU Piggyback Board Hardware Reference
HARDWARE SETUP
Flex CPU Board Jumper Configuration
Watchdog Timer Jumper
Jumper E1 on the Turbo CPU board 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. E1 should be put ON
only to debug problems with the watchdog timer circuit.
Dual-Ported RAM Source Jumper
Jumper E2 must connect pins 1 and 2 to access dual-ported RAM (non-Turbo addresses $Dxxx, Turbo
addresses $06xxxx) from the baseboard. If it is desired to use the Option 2 DPRAM on the baseboard,
jumper E2 must be in this setting. All Delta Tau base boards except the PMAC(1)-PC board have the
option for installing DPRAM on the base board.
Jumper E2 must connect pins 2 and 3 to access dual-ported RAM (non-Turbo addresses $Dxxx, Turbo
addresses $06xxxx) through the JEXP expansion port. If it is desired to use DPRAM on an external
accessory board, jumper E2 must be in this setting. The PMAC(1)-PC base board (part # 602191-10x)
does not have the option for installing on-board DPRAM; it requires the external Option 2 DPRAM board
(part #602240-10x) for this functionality. Use of this DPRAM board, interfacing through the JEXP port,
requires E2 to connect pins 2 and 3.
Power-Up State Jumpers
Jumper E4 on the Turbo CPU board must be OFF, jumper E5 must be ON, and jumper E6 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 E7 on the CPU board is ON during power-up/reset, the board comes up in “bootstrap mode,”
which permits loading 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 automatically detect that the
board is in bootstrap mode and ask you what file you want to download as the new firmware.
Jumper E7 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.
Installation
The Flex CPU board installs on the base controller board using the P1 and P3 stack connectors on the
solder side of the CPU board. The CPU board can be further secured to the base board with a standoff
and screw through the central hole. When a complete PMAC or Turbo PMAC controller is purchased,
this assembly is done at the factory. In the case of retrofits or updates to existing controllers, this
assembly is easy to do in the field.
ESD Warning: The Flex CPU board and PMAC controller boards contain static-sensitive components.
Make sure proper ESD protection is employed.
Hardware Setup 5
Page 10
Flex CPU Piggyback Board Hardware Reference
6 Hardware Setup
Page 11
Flex CPU Piggyback Board Hardware Reference
OPERATION OF THE FLEX CPU
Operation as Non-Turbo CPU
When used as a non-Turbo CPU, the Flex CPU board operates in a manner that is fundamentally
compatible with older CPU designs. However, there are a few issues to note:
• The Flex CPU requires the use of V1.17 or newer firmware. There are few differences between the
previous V1.16H firmware and the V1.17 firmware other than the addition of internal support for the
Flex CPU design.
• Due to more advanced processor logic and the internal integration of all memory, the Flex CPU will
operate significantly faster than older non-Turbo CPU designs, even for equivalent CPU frequencies.
The Flex CPU in a non-Turbo configuration will generally operate more than twice as fast as older
non-Turbo CPUs running at the same frequency.
This will result in significantly faster cycle times for background tasks such as PLC programs (the
frequency of interrupt-driven foreground tasks is not affected, although the increased computational
speeds permit higher frequencies for these tasks). Generally, this will not be a problem, but if
existing programs controlled timing by computational delay (e.g. number of loops waiting),
operational differences may occur.
• The operational frequency of the CPU can now be set in software by new variable I46. If this
variable is set to 0, PMAC firmware looks at the jumpers (E48 on a PMAC(1), E2 and E4 on a
PMAC2) to set the operational frequency, retaining backward compatibility for 40, 60, and 80 MHz
operation.. If I46 is set to a value greater than 0, the operational frequency is set to 10MHz * (I46 +
1), regardless of the jumper setting. If the desired operational frequency is higher than the maximum
rated frequency for that CPU, the operational frequency will be reduced to the rated maximum. It is
always possible to operate the Flex CPU board at a frequency below its rated maximum.
On a Flex CPU board configured for Option 5AF with 40 MHz maximum frequency, I46 should be
set to 3 to operate the CPU at its maximum rated frequency.
On a Flex CPU board configured for Option 5CF with 80 MHz maximum frequency, I46 should be
set to 7 to operate the CPU at its maximum rated frequency.
On a Flex CPU board configured for Option 5EF with 160 MHz maximum frequency, I46 should be
set to 15 to operate the CPU at its maximum rated frequency.
I46 is only used at power-up/reset, so to change the operational frequency, set a new value of I46,
issue a SAVE command to store this value in non-volatile flash memory, then issue a $$$ command
to reset the controller.
To determine the frequency at which the CPU is actually operating, issue the TYPE command to the
PMAC. The PMAC will respond with five data items, the last of which is CLK Xn, where n is the
multiplication factor from the 20 MHz crystal frequency (not 10 MHz). n should be equivalent to
(I46+1)/2 if I46 is not requesting a frequency greater than the maximum rated for that CPU board. n
will be “2” for 40 MHz operation, 4 for 80 MHz operation, and 8 for 160 MHz operation.
• If the CPU’s operational frequency has been determined by (a non-zero setting of) I46, the serial
communications baud rate is determined at power-up/reset by variable I54 alone according to the
following table:
Note that these values can be different from those used on PMAC2 boards with jumper-set CPU
frequencies (see below).
• If the saved value of I46 is 0, so the CPU’s operational frequency is determined by jumper settings,
then the serial baud rate is determined by a combination of the setting of jumpers E44-E47 and the
CPU frequency on a PMAC(1) board, as shown in the following table. These settings maintain
backward compatibility.
E44 E45 E46 E47 Baud Rate
for
20MHz
N ON ON ON Disabled Disabled Disabled
OFF ON ON ON 300 600 900
ON OFF ON ON 400* 800* 1200
OFF OFF ON ON 600 1200 1800
ON ON OFF ON 800* 1600* 2400
OFF ON OFF ON 1200 2400 3600
ON OFF OFF ON 1600* 3200* 4800
OFF OFF OFF ON 2400 4800 7200
ON ON ON OFF 3200* 6400* 9600
OFF ON ON OFF 4800 9600 14400
ON OFF ON OFF 6400* 12800* 19200
OFF OFF ON OFF 9600 19200 28800
ON ON OFF OFF 12800* 25600* 38400
OFF ON OFF OFF 19200 38400 57600
ON OFF OFF OFF 25600* 51200* 76800
OFF OFF OFF OFF 38400 76800 115200
* Not an exact baud rate
Baud Rate
for
40MHz
Baud Rate
for
60MHz
8 Operation of the Flex CPU
Page 13
Flex CPU Piggyback Board Hardware Reference
For a PMAC2 board with a saved value of 0 for I46, the serial baud rate is determined by the combination
of I54 and the CPU frequency on a PMAC2 board as shown in the following table. These settings
maintain backward compatibility.
• With the Flex CPU, the card number (0 – 15) for serial addressing of multiple cards on a daisy-chain
Baud Rate for
60 MHz CPU
Baud Rate for
80 MHz CPU
serial cable is determined by variable I0, even on PMAC(1) boards. This has always been the case
for PMAC2 boards, but with other CPU boards, the card number on PMAC(1) boards has been
determined by the settings of jumpers E40 – E43. Jumpers E40 – E43 on a PMAC(1) board with the
Flex CPU still determine the “direction” of the phase and servo clocks: all of these jumpers must be
ON for the card to use its internally generated clock signals and to output these on the serial port
connector; if any of these jumpers is OFF, the card will expect to input these clock signals from the
serial port connector, and its watchdog timer will trip immediately if it does not receive these signals.
Operation as a Turbo CPU
When used as a Turbo CPU, the Flex CPU is fully compatible with older CPU designs. It does permit
higher-speed configurations (Option 5Ex at 160 MHz), which offer significantly higher performance both
due to increased operation frequency and added internal memory.
Variable I52 determines the actual operating frequency of the Turbo CPU. The operational frequency is
set to 10MHz * (I52 + 1). I52 should be set to 7 to operate an Option 5Cx board at its maximum rated
frequency of 80 MHz; it should be set to 9 to operate an Option 5Dx board at its maximum rated
frequency of 100 MHz; it should be set to 15 to operate an Option 5Ex board at is maximum rated
frequency of 160 MHz.
I52 is used only at power-up/reset, so to change the operational frequency, set a new value of I52, issue a
SAVE command to store this value in non-volatile flash memory, then issue a $$$ command to reset the
controller.
Operation of the Flex CPU 9
Page 14
Flex CPU Piggyback Board Hardware Reference
10 Operation of the Flex CPU
Page 15
Flex CPU Piggyback Board Hardware Reference
FLEX CPU BOARD JUMPER DESCRIPTIONS
E1: Watchdog Disable Jumper
E Point and
Description Default
Physical Layout
E1
Jump pin 1 to 2 to disable Watchdog timer (for test
purposes only).
Remove jumper to enable Watchdog timer.
E2: Dual-Ported RAM Port Select
E Point and
Physical Layout
E2
Jump pin 1 to 2 to access DPRAM from baseboard.
Jump pin 2 to 3 to access DPRAM through JEXP
expansion port (PMAC(1)-PC with Option 2 DPRAM
board).
Description Default
E4 – E6: Power-Up/Reset Load Source
E Point and
Physical Layout
E6
Remove jumper E4;
jump E5 pin 1 to 2;
jump E6 pin 2 to 3;
to read flash IC on power-up/reset
Other combinations are for factory use only ; the boa r d
will not operate in any other configuration.
Description Default
No jumper installed
Pins 2 and 3 jumpered
(with PMAC(1)-PC base
board only)
Pins 1 and 2 jumpered
(when used on all other
base boards)
No E4 jumper installed;
E5 and E6 jump pin 1 to 2
E4
E7: Firmware Reload Enable
E Point and
Physical Layout
E7
Jump pin 1 to 2 to reload firmware through serial or
bus port.
Remove jumper for normal operation.
Flex CPU Board Jumper Descriptions11
Description Default
No jumper installed
Page 16
Flex CPU Piggyback Board Hardware Reference
E10A, B, C: Flash Memory Bank Select
E Point and
Physical Layout
E10A
E10C
Description Default
Remove all 3 jumpers to select flash memory bank
with factory-installed firmware.
Use other configuration to select one of the 7 other
flash memory banks
No jumpers installed
12 Flex CPU Board Jumper Descriptions
Page 17
Flex CPU Piggyback Board Hardware Reference
CONNECTOR SUMMARY
J2: JEXP Expansion Port (50-pin IDC header for Delta Tau accessory boards)
J5: JTAG/OnCE Port (for factory use only)
J6: JSIO Port (for factory use only)
J7: JISP Port (for factory use only)
J8: Auxiliary Serial Port (10-pin IDC header)*
P1: Stack Connector (Internal connections to main PMAC board)
P3: Stack Connector (Internal connections to main PMAC board)
*Pinout shown in next section
Connector Summary 13
Page 18
Flex CPU Piggyback Board Hardware Reference
14 Connector Summary
Page 19
Flex CPU Piggyback Board Hardware Reference
CONNECTOR PINOUTS
J8 JRS232 (10-Pin Connector)
Front View
Pin # Symbol Function Description Notes
1 N.C. No Connect
2 DTR Bidirect Data Terminal Ready Tied to DSR
3 TXD/ Input Receive Data Host transmit data
4 CTS Input Clear to Send Host ready bit
5 RXD/ Output Send Data Host receive data
6 RTS Output Request to Send PMAC ready bit
7 DSR Bidirect Data Set Ready Tied to DTR
8 N.C. No Connect
9 GND Common PMAC Common
10 +5V Output +5VDC Supply Power supply out
The JRS232 connector provided with Option 9T on a Turbo PMAC is an auxiliary serial port that can be
used independently of the standard main serial port and other communications ports. It can be connected
with a straight-across flat cable to a DB-9 connector with the standard RS-232 pinout.
Connector Pinouts 15
Page 20
THIS DOCUMENT IS THE CONFIDENTIAL PROPERTY OF DELTA TAU
THIS DOCUMENT IS THE CONFIDENTIAL PROPERTY OF DELTA TAU
DATA SYSTEMS INC. AND IS LOANED SUBJECT TO RETURN UPON
DATA SYSTEMS INC. AND IS LOANED SUBJECT TO RETURN UPON
DEMAND. TITLE TO THIS DOCUMENT IS NEVER SOLD OR
DEMAND. TITLE TO THIS DOCUMENT IS NEVER SOLD OR
TRANSFERRED FOR ANY REASON. THIS DOCUMENT IS TO BE USED
TRANSFERRED FOR ANY REASON. THIS DOCUMENT IS TO BE USED
ONLY PURSUANT TO WRITTEN LICENSE OR WRITTEN INSTRUCTIONS
ONLY PURSUANT TO WRITTEN LICENSE OR WRITTEN INSTRUCTIONS
OF DELTA TAU DATA SYSTEMS INC. ALL RIGHTS TO DESIGNS AND
OF DELTA TAU DATA SYSTEMS INC. ALL RIGHTS TO DESIGNS AND
INVENTIONS ARE RESERVED BY DELTA TAU DATA SYSTEMS INC.
INVENTIONS ARE RESERVED BY DELTA TAU DATA SYSTEMS INC.
POSSESSION OF THIS DOCUMENT INDICATES ACCEPTANCE OF THE
POSSESSION OF THIS DOCUMENT INDICATES ACCEPTANCE OF THE
ABOVE AGREEMENT.
ABOVE AGREEMENT.
DD
J5
(JTAG/OnCE)
J5
TSI
1
GND
2
TSO
3
GND
4
TCK
5
GND
6
N.C.
7
RST-
9
TMS
10
+3.3V
11
N.C.
12
DE-
13
TRST-
14
HEADER14_NO8
CTSRTS-
INIT-
N.C.
(.100 MOLEX)
JUMP `J6' PIN 6 TO 7
TO LOAD `isp' PART
CC
+3.3V
BSCAN-
BB
GUARD BAND
GND
AA
GND
J6
(jsio)
J6
+5V
1
TXD
2
RXD
3
4
5
6
GND
7
8
HEA_SIP 8
J7
(jisp)
J7
1
TDO
2
TDI
3
4
TMS
6
GND
7
TCK
8
HSIP8NO5
GND
PRAMCS-
DRAMCS-
FLASHCS-
+3P3V
1
3
C85
C83
C84
.1UF
.1UF
.1UF
E2 1-to-2 is for DPR on base board
E2 2-to-3 is for DPR on expansion board