Delta Tau PMAC MINI PCI, PMAC PCI, PMAC PCI LITE, PMAC VME, TURBO PMAC VME User Manual

^1 USER MANUAL

^2 PMAC

^3 Programmable Multi-Axis Controller

^4 3Ax-602264-xUxx

^5 June 28, 2007

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

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

Copyright Information

© 2007 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.

REVISION HISTORY

REV. DESCRIPTION DATE CHG APPVD

1 CORRECTION TO PID EQUATION, P. 108 06/28/07 CP S. MILICI

PMAC User Manual

Table of Contents

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

Flexibility..............................................................................................................................................................1

Configuration for a Task.......................................................................................................................................1

PMAC is a Computer............................................................................................................................................1

Manual Layout ..........................................................................................................................................................2

Conventions Used in this Manual.........................................................................................................................2

Safety Summary ........................................................................................................................................................2

Keep Away from Live Circuits..............................................................................................................................2

Live Circuit Contact Procedures ..........................................................................................................................2

Electrostatic Sensitive Devices .............................................................................................................................3

Magnetic Media....................................................................................................................................................3

Related Technical Documentation ............................................................................................................................3

Technical Support .....................................................................................................................................................3

By Telephone ........................................................................................................................................................3

By Fax and E-Mail................................................................................................................................................3

Bulletin Board Service (BBS) ...............................................................................................................................3

GETTING STARTED WITH PMAC........................................................................................................................5

Preparing the Card.....................................................................................................................................................5

E-Point Jumpers ...................................................................................................................................................5

Card Number Jumpers..........................................................................................................................................5

Communications Baud Rate Jumpers...................................................................................................................6

PCbus Address Jumpers .......................................................................................................................................6

STDbus Address Jumpers .....................................................................................................................................6

PMAC VME Interface Setup.................................................................................................................................6

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

Analog Circuit Jumpers........................................................................................................................................7

Re-initialization Jumper .......................................................................................................................................7

Standard and Option 5 PMACs ............................................................................................................................7

PMAC with Options 4A, 5A, and 5B.....................................................................................................................8

Connecting PMAC to the Host Computer.................................................................................................................8

Bus Connection.....................................................................................................................................................8

Serial Port Connection .........................................................................................................................................8

Installing the PMAC Executive Program..............................................................................................................9

Establishing Host Communications......................................................................................................................9

Terminal Mode Communications..........................................................................................................................9

Connecting PMAC to the System..............................................................................................................................9

Machine Connectors...........................................................................................................................................10

Connecting the Analog Power Supply ................................................................................................................10

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

Amplifier Connection..........................................................................................................................................11

Auxiliary Connections ........................................................................................................................................11

Software Setup for a Motor.....................................................................................................................................12

Encoder I-Variables............................................................................................................................................13

Motor I-Variables ...............................................................................................................................................13

Motor Activation.................................................................................................................................................13

For PMAC-Commutated Motors Only................................................................................................................13

For Motors Not Commutated By PMAC.............................................................................................................14

For All Types of Motors......................................................................................................................................14

Testing the Output and Polarity..........................................................................................................................16

Non-PMAC Commutated Motors........................................................................................................................16

Overtravel Limit Polarity....................................................................................................................................16

Setting up the Servo Loop ...................................................................................................................................17

Closing the Loop.................................................................................................................................................17

Jogging Moves....................................................................................................................................................17

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PMAC User Manual

Power-Up Mode..................................................................................................................................................18

Homing Search Move .........................................................................................................................................18

Setting up a Coordinate System ..............................................................................................................................19

Defining an Axis .................................................................................................................................................19

Scaling an Axis ...................................................................................................................................................19

Multiple Axes ......................................................................................................................................................19

Writing a Motion Program ......................................................................................................................................19

Using the Program Editor ..................................................................................................................................20

Executing a Motion Program ..................................................................................................................................20

Starting the Program ..........................................................................................................................................20

Stopping the Program.........................................................................................................................................20

Refining the Program .........................................................................................................................................20

Writing and Executing a PLC Program...................................................................................................................21

Starting the PLC Program..................................................................................................................................21

Stopping the PLC Program.................................................................................................................................21

PMAC FEATURES...................................................................................................................................................23

Executing Motion Programs....................................................................................................................................23

Executing PLC Programs........................................................................................................................................23

Servo Loop Update..................................................................................................................................................23

Commutation Update ..............................................................................................................................................23

Housekeeping..........................................................................................................................................................23

Communicating With the Host............................................................................................................................23

Task Priorities ....................................................................................................................................................24

TALKING TO PMAC...............................................................................................................................................25

Basic Aspects of Communicating with PMAC.......................................................................................................25

Communications Ports ............................................................................................................................................25

Active Response Port ..........................................................................................................................................25

Serial Interface ...................................................................................................................................................25

PC Bus Interface.................................................................................................................................................27

STD Bus Interface...............................................................................................................................................27

VME Bus Interface..............................................................................................................................................27

Giving Commands to PMAC ..................................................................................................................................27

PMAC Processing of Commands........................................................................................................................27

Command Acknowledgement..............................................................................................................................28

Data Response ....................................................................................................................................................28

Data Integrity .....................................................................................................................................................28

Data Response Format .......................................................................................................................................28

On-Line (Immediate) Commands............................................................................................................................29

Types of On-Line Commands..............................................................................................................................29

Motor-Specific Commands .................................................................................................................................29

Coordinate-System-Specific Commands.............................................................................................................29

Global Commands ..............................................................................................................................................30

Buffered (Program) Commands ..............................................................................................................................30

Rotary Motion Program Buffer...........................................................................................................................30

Multiple-Card Applications.....................................................................................................................................31

Bus Communications ..........................................................................................................................................31

Simultaneous Commands....................................................................................................................................31

Serial Communications.......................................................................................................................................31

Serial Card Addressing.......................................................................................................................................32

Setting Up the Addresses ....................................................................................................................................32

Multi-Card Mode Variable .................................................................................................................................33

Addressed-Card Actions .....................................................................................................................................33

Simultaneous Addressing....................................................................................................................................33

Handling Data Response ....................................................................................................................................33

Power-Up State...................................................................................................................................................34

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Control-Character Commands ...........................................................................................................................34

Resetting PMAC .....................................................................................................................................................35

PMAC Reset Actions...........................................................................................................................................35

PMAC Re-initialization Actions: Standard CPU................................................................................................35

PMAC Re-initialization Actions: Flash CPU .....................................................................................................36

Re-initialize Command .......................................................................................................................................37

TROUBLESHOOTING............................................................................................................................................39

PMAC Card Troubleshooting .................................................................................................................................39

General ...............................................................................................................................................................39

Bus Communications ..........................................................................................................................................39

Serial Communications.......................................................................................................................................39

Commutation Troubleshooting................................................................................................................................39

Servo Loop and Jogging Troubleshooting...............................................................................................................39

Homing Search Troubleshooting.............................................................................................................................40

No Movement at All ............................................................................................................................................40

Movement, But Sluggish. ....................................................................................................................................40

Runaway Condition ............................................................................................................................................40

Brief Movement, Then Stop.................................................................................................................................40

Motion Program Troubleshooting...........................................................................................................................40

INPUT/OUTPUT: CONNECTING PMAC TO THE MACHINE.......................................................................41

Capabilities and Features.........................................................................................................................................41

Quadrature Encoder Inputs (JMACH Port).............................................................................................................41

Single-Ended vs. Differential..............................................................................................................................41

Differential Encoders..........................................................................................................................................42

Analog Encoders.................................................................................................................................................42

Power Supply and Isolation................................................................................................................................43

Wiring Techniques..............................................................................................................................................43

Encoder Signal Sampling....................................................................................................................................43

Digital Delay Filter ............................................................................................................................................44

Error Detection...................................................................................................................................................44

Optically Isolated Dedicated Digital Input Flags (JMACH Port)............................................................................45

Flag Wiring.........................................................................................................................................................45

Overtravel Limit Inputs.......................................................................................................................................45

Home Flag Input.................................................................................................................................................45

Amplifier Fault Input ..........................................................................................................................................45

Flag Isolation .....................................................................................................................................................45

Dedicated Digital Output Flags (JMACH, JEQU Ports) .........................................................................................45

Amplifier-Enable/Direction Output ....................................................................................................................45

Amplifier Enable/Disable Use ............................................................................................................................46

Transition............................................................................................................................................................46

Sinking Drivers ...................................................................................................................................................46

Sourcing Drivers.................................................................................................................................................46

Polarity Control..................................................................................................................................................46

Direction Bit Use ................................................................................................................................................47

General-Purpose Use .........................................................................................................................................47

Compare-Equals Outputs ...................................................................................................................................47

Optically Isolated Analog Outputs (JMACH Port) .................................................................................................48

Connections ........................................................................................................................................................48

Isolation..............................................................................................................................................................48

Drive Capability .................................................................................................................................................48

General-Purpose Use .........................................................................................................................................48

General-Purpose Digital Inputs and Outputs (JOPTO Port)....................................................................................48

Software Access ..................................................................................................................................................48

Standard Sinking Outputs ...................................................................................................................................48

Option for Sourcing Outputs...............................................................................................................................49

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PMAC User Manual

Input Source/Sink Control ..................................................................................................................................49

Thumbwheel Multiplexer Port I/O (JTHW Port) ....................................................................................................49

Multiplexed Uses ................................................................................................................................................49

Non-Multiplexed Uses ........................................................................................................................................50

Control-Panel Port I/O (JPAN Port)........................................................................................................................50

Discrete Inputs....................................................................................................................................................50

Alternate Use ......................................................................................................................................................50

Reset Input ..........................................................................................................................................................50

Handwheel Inputs ...............................................................................................................................................50

Analog Input .......................................................................................................................................................51

Display Port Outputs (JDISP Port)..........................................................................................................................52

SETTING UP A MOTOR.........................................................................................................................................53

What is a Motor?.....................................................................................................................................................53

Defining the Motor..................................................................................................................................................53

Motor I-Variables ...............................................................................................................................................53

Activating the Motor ...............................................................................................................................................53

Does PMAC Commutate this Motor? .................................................................................................................53

Address I-Variables ............................................................................................................................................53

Hex vs. Decimal Reporting .................................................................................................................................54

Selecting the Output(s)........................................................................................................................................54

Selecting the Position Loop Feedback................................................................................................................54

Selecting the Velocity Loop Feedback ................................................................................................................54

Dual Feedback Systems ......................................................................................................................................54

Accuracy vs. Stability..............................................................................................................................................55

Selecting the Master Position Source .................................................................................................................56

Selecting the Flag Register.................................................................................................................................56

Selecting the Power-Up Mode ............................................................................................................................56

Types of Position Sensors .......................................................................................................................................56

Quadrature Encoder Feedback ..........................................................................................................................56

Hardware Changes.............................................................................................................................................58

Software Changes ...............................................................................................................................................58

Parallel Position Feedback ................................................................................................................................58

Parallel Absolute Feedback................................................................................................................................60

Linear Displacement Transducer Feedback.......................................................................................................60

Analog Position Feedback..................................................................................................................................61

Resolver Feedback..............................................................................................................................................62

Absolute Power-Up Position...................................................................................................................................62

Absolute Position Range.....................................................................................................................................62

Parallel-Data Position........................................................................................................................................63

Resolver Position................................................................................................................................................63

Axis Offset...........................................................................................................................................................64

Encoder Offset ....................................................................................................................................................65

Encoder Conversion Table......................................................................................................................................65

Incremental Encoder Entries..............................................................................................................................68

1/T Interpolation.................................................................................................................................................68

Parallel-Bit Interpolation ...................................................................................................................................68

No Interpolation..................................................................................................................................................68

Acc-28 Analog-to-Digital Conversion Register Entries .....................................................................................68

Parallel Position Feedback Conversion .............................................................................................................70

Time-Base Conversion Entries ...........................................................................................................................73

Triggered Time-Base Conversion Entries ..........................................................................................................74

Exponential-Filter Entries ..................................................................................................................................75

Setting up the Encoder Conversion Table...........................................................................................................76

Further Position Processing.....................................................................................................................................78

Software Position Extension ...............................................................................................................................78

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PMAC User Manual

Axis Position Scaling ..........................................................................................................................................79

Leadscrew Compensation...................................................................................................................................79

Backlash Compensation......................................................................................................................................82

Torque Compensation Tables.............................................................................................................................84

SETTING UP PMAC COMMUTATION ...............................................................................................................87

Introduction .............................................................................................................................................................87

Incremental Encoder Feedback Requirement..........................................................................................................87

Phase Referencing...................................................................................................................................................87

Two-Analog-Output Requirement...........................................................................................................................87

Basic Parameter Specification.................................................................................................................................88

Counts per Commutation Cycle..........................................................................................................................88

Angle Between Phases ........................................................................................................................................88

Permanent Magnet Brushless Motor Commutation ................................................................................................89

Getting the Polarity Right...................................................................................................................................89

Power-on Phasing Search ..................................................................................................................................89

Phasing Referenced to Absolute Sensor .............................................................................................................92

Phasing Referenced to Hall-Effect Sensor..........................................................................................................94

Phase Advance....................................................................................................................................................95

Switched Reluctance Motor Commutation..............................................................................................................96

AC Induction Motor Commutation .........................................................................................................................96

Setting the Slip Gain ...........................................................................................................................................96

Setting the Magnetization Current......................................................................................................................97

Experimental Setting of Induction Motor Parameters........................................................................................98

Open-Loop Microstepping Commutation ...........................................................................................................99

Setting the I-Variables ......................................................................................................................................100

Using the Motor................................................................................................................................................101

User-Written Commutation Algorithm .................................................................................................................101

Memory Space, Software Interface, and Program Restrictions........................................................................101

CLOSING THE SERVO LOOP ............................................................................................................................103

The Purpose of the Servo Loop.............................................................................................................................103

Servo Update Rate.................................................................................................................................................103

Reasons to Increase Rate..................................................................................................................................103

Reasons to Decrease Rate.................................................................................................................................103

Ramifications of Changing the Rate .................................................................................................................103

Amplifier Types ....................................................................................................................................................104

Velocity-Mode Amplifiers .................................................................................................................................104

Torque-Mode Amplifiers...................................................................................................................................104

Voltage-Mode Amplifiers..................................................................................................................................105

Sinusoidal-Input Amplifiers ..............................................................................................................................105

Pulse-and-Direction Amplifiers........................................................................................................................106

Hydraulic Servo Amplifiers ..............................................................................................................................106

PID Servo Filter ....................................................................................................................................................106

How the PID Filter Works................................................................................................................................106

Tuning the PID Filter .......................................................................................................................................107

Actual PID Algorithm.......................................................................................................................................108

Notch Filters..........................................................................................................................................................108

Automatic Notch Specification..........................................................................................................................109

Manual Notch Specification..............................................................................................................................109

Other Uses of the Notch Filter..........................................................................................................................110

Extended (Pole-Placement) Servo Filter ...............................................................................................................111

User-Written Servo Filter......................................................................................................................................111

What is needed to write the Filter.....................................................................................................................112

Download and Enable Procedure.....................................................................................................................112

Memory Space, Software Interface, and Program Restrictions.............................................................................112

Usable Data Spaces..........................................................................................................................................112

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PMAC User Manual

Interface to Other Firmware.............................................................................................................................112

Restrictions .......................................................................................................................................................113

Alternative Uses for User-Written Servo ..........................................................................................................113

Simple User-Written Servo Example ................................................................................................................113

C Program to Convert .LOD File to PMAC Format........................................................................................114

MAKING THE APPLICATION SAFE ................................................................................................................117

Responsibility for the Safety of a Control System ................................................................................................117

Hardware Overtravel Limit Switches....................................................................................................................117

Software Overtravel Limits...................................................................................................................................118

Following Error Limits..........................................................................................................................................118

Fatal Following Error Limit.............................................................................................................................118

Warning Following Error Limit .......................................................................................................................118

Integrated Following Error Protection ............................................................................................................118

Velocity Limits......................................................................................................................................................119

Acceleration Limits...............................................................................................................................................119

Command Output Limits.......................................................................................................................................120

Integrated Current (I2T) Protection .......................................................................................................................120

Amplifier Enable and Fault Lines .........................................................................................................................121

Watchdog Timer....................................................................................................................................................122

Hardware Stop Command Inputs ..........................................................................................................................122

Host-Generated Stop Commands..........................................................................................................................122

Program Checksums..............................................................................................................................................123

Firmware Checksum.........................................................................................................................................123

User-Program Checksum .................................................................................................................................123

Communications Data Integrity Features..............................................................................................................123

BASIC MOTOR MOVES.......................................................................................................................................125

Commanding Some Basic Moves for the Motor...................................................................................................125

Jogging Move Control...........................................................................................................................................125

Jog Acceleration ...............................................................................................................................................125

Jog Speed..........................................................................................................................................................125

Jog Commands..................................................................................................................................................125

Homing Search Move Control...............................................................................................................................128

Homing Acceleration ........................................................................................................................................128

Homing Speed...................................................................................................................................................128

Home Trigger Condition...................................................................................................................................128

Specify Flag Set ................................................................................................................................................128

Software Capture Option..................................................................................................................................128

Trigger Signals and Edges.....................................................................................................................................129

Torque-Mode Triggering..................................................................................................................................129

Home Command ...................................................................................................................................................130

On-Line Command............................................................................................................................................130

Monitoring for Finish .......................................................................................................................................130

Homing from a PLC Program ...............................................................................................................................131

Motion vs. PLC Program Homing.........................................................................................................................131

Zero-Move Homing...........................................................................................................................................131

Homing into a Limit Switch ..............................................................................................................................132

Multi-Step Homing Procedures ........................................................................................................................133

Storing the Home Position................................................................................................................................135

Open-Loop Moves.................................................................................................................................................136

SETTING UP A COORDINATE SYSTEM..........................................................................................................137

Coordinating Multiple Motions.............................................................................................................................137

What is a Coordinate System?...............................................................................................................................137

What is an Axis? ...................................................................................................................................................137

One-to-One Matching.......................................................................................................................................137

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Multiple-Motor Axes.........................................................................................................................................137

Phantom Axes ...................................................................................................................................................138

Axis Definition Statements ...................................................................................................................................138

Matching Motor to Axis....................................................................................................................................138

Scaling and Offset.............................................................................................................................................138

Axis Types ............................................................................................................................................................139

Cartesian Axis...................................................................................................................................................139

Rotary Axis .......................................................................................................................................................139

Feedrate Axis....................................................................................................................................................139

Axis-Motor Position Re-matching ........................................................................................................................139

What Is Coordinate System Time-Base?...........................................................................................................141

COMPUTATIONAL FEATURES.........................................................................................................................143

Advanced Computational Features........................................................................................................................143

Computational Priorities........................................................................................................................................143

Numerical Values..................................................................................................................................................145

Internal Formats...............................................................................................................................................145

Receiving Values...............................................................................................................................................145

Examples...........................................................................................................................................................146

Reporting Values ..............................................................................................................................................146

Addresses ..............................................................................................................................................................147

Variables ...............................................................................................................................................................147

I-Variables........................................................................................................................................................147

Value Assignment..............................................................................................................................................148

P-Variables............................................................................................................................................................149

Array Capabilities ............................................................................................................................................149

Special-Use P-Variable ....................................................................................................................................150

Q-Variables ...........................................................................................................................................................150

Allotting Q-Variables........................................................................................................................................150

Addressing a Q-Variable Set ............................................................................................................................151

Array Capabilities ............................................................................................................................................152

Special-Use Q-Variables ..................................................................................................................................153

M-Variables...........................................................................................................................................................153

M-Variable Definitions.....................................................................................................................................153

Limited Range...................................................................................................................................................154

Using M-Variables............................................................................................................................................154

Operators...............................................................................................................................................................154

Arithmetic Operators........................................................................................................................................154

Modulo Operator..............................................................................................................................................154

Logical Operators.............................................................................................................................................155

Functions ...............................................................................................................................................................155

SIN ....................................................................................................................................................................155

COS...................................................................................................................................................................155

TAN...................................................................................................................................................................155

ASIN..................................................................................................................................................................156

ACOS ................................................................................................................................................................156

ATAN ................................................................................................................................................................156

ATAN2 ..............................................................................................................................................................156

LN .....................................................................................................................................................................157

EXP...................................................................................................................................................................157

SQRT.................................................................................................................................................................157

ABS ...................................................................................................................................................................157

INT....................................................................................................................................................................157

Expressions ...........................................................................................................................................................158

Data .......................................................................................................................................................................158

Variable Value Assignment Statement..................................................................................................................158

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PMAC User Manual

I-Variable Default Value Assignment...............................................................................................................158

Synchronous M-Variable Value Assignment.....................................................................................................158

Syntax................................................................................................................................................................160

Execution ..........................................................................................................................................................160

Special Boolean Feature...................................................................................................................................160

Limitations ........................................................................................................................................................160

Comparators ..........................................................................................................................................................161

Conditions .............................................................................................................................................................161

Simple Conditions.............................................................................................................................................161

Compound Conditions ......................................................................................................................................162

Single-Line Condition Actions..........................................................................................................................162

Multiple-Line Conditions..................................................................................................................................162

Timers ...................................................................................................................................................................162

Computational Considerations ..............................................................................................................................163

WRITING PROGRAMS FOR PMAC..................................................................................................................165

Writing a Motion Program ....................................................................................................................................165

Flow Control.....................................................................................................................................................165

G-Codes............................................................................................................................................................165

Modal Commands.............................................................................................................................................165

Move Commands ..............................................................................................................................................165

Motion Program Trajectories ................................................................................................................................166

Linear Blended Moves ..........................................................................................................................................166

Acceleration Parameters ..................................................................................................................................166

Acceleration Limit ............................................................................................................................................166

Feedrate or Move-Time Specification...................................................................................................................168

Short Moves ......................................................................................................................................................169

Long Moves.......................................................................................................................................................169

Feedrate Axes ...................................................................................................................................................174

Velocity Limit....................................................................................................................................................174

The Blending Function .....................................................................................................................................174

Rapid-Mode Moves...........................................................................................................................................175

Motion Program Move-Until-Trigger ...................................................................................................................175

Circular Blended Moves........................................................................................................................................176

Specifying the Interpolation Plane....................................................................................................................176

Circle Modes.....................................................................................................................................................177

Center Vector....................................................................................................................................................177

Radius Size Specification ..................................................................................................................................178

No Center Specification....................................................................................................................................178

Feedrate Axes ...................................................................................................................................................179

Circle Radius Errors.........................................................................................................................................179

Move Segmentation...........................................................................................................................................179

PVT-Mode Moves.................................................................................................................................................179

Mode Statement ................................................................................................................................................179

Move Statements ...............................................................................................................................................179

PMAC Calculations..........................................................................................................................................180

Problems in Stepping........................................................................................................................................180

Use to Create Arbitrary Profiles.......................................................................................................................180

Use in Contouring.............................................................................................................................................180

Splined Moves.......................................................................................................................................................181

How They Work ................................................................................................................................................182

Added Pieces.....................................................................................................................................................183

Quantifying the Position Adjustment ................................................................................................................183

5-Point Spline Correction.................................................................................................................................183

Non-Uniform Spline..............................................................................................................................................183

Cutter Radius Compensation.................................................................................................................................184

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Defining the Plane of Compensation................................................................................................................184

Defining the Magnitude of Compensation ........................................................................................................184

Turning on Compensation ................................................................................................................................185

Turning off Compensation ................................................................................................................................185

How PMAC Introduces Compensation.............................................................................................................185

Treatment of Compensated inside Corners.......................................................................................................186

Treatment of Outside Corners ..........................................................................................................................187

Treatment of Full Reversal ...............................................................................................................................189

Note on Full Circles..........................................................................................................................................189

Speed of Compensated Moves...........................................................................................................................190

Changes in Compensation ................................................................................................................................190

How PMAC Removes Compensation................................................................................................................191

Failures in Cutter Compensation .....................................................................................................................193

Single-Stepping While in Compensation...........................................................................................................194

Lookahead ........................................................................................................................................................195

Axis Transformation Matrices...............................................................................................................................195

Setting Up the Matrices ....................................................................................................................................195

Using the Matrices............................................................................................................................................195

Calculation Implications........................................................................................................................................196

Examples...........................................................................................................................................................196

Entering a Motion Program...................................................................................................................................198

Learning a Motion Program ..................................................................................................................................198

Motion Program Structure.....................................................................................................................................199

Basic Move Specifications ................................................................................................................................199

Defaults.............................................................................................................................................................199

Controlling Parameters ....................................................................................................................................199

Simultaneous Moves on Multiple Axes .............................................................................................................199

Sequential Moves..............................................................................................................................................200

Adding Logic.....................................................................................................................................................200

Line Labels .......................................................................................................................................................200

GOTO Command..............................................................................................................................................200

Adding Variables and Calculations.......................................................................................................................200

Subroutines and Subprograms...............................................................................................................................201

Passing Arguments to Subroutines ...................................................................................................................201

What Has Been Passed? ...................................................................................................................................201

PRELUDE Subprogram Calls ..........................................................................................................................202

Running a Motion Program...................................................................................................................................202

Pointing to the Program ...................................................................................................................................203

Running the Program .......................................................................................................................................203

Stepping the Program.......................................................................................................................................203

What PMAC Checks For...................................................................................................................................203

Implementing a Machine-Tool Style Program......................................................................................................203

G, M, T, and D-Codes.......................................................................................................................................204

Standard G-Codes ............................................................................................................................................204

Spindle Programs .............................................................................................................................................208

Standard M-Codes............................................................................................................................................209

Default Conditions............................................................................................................................................211

Rotary Motion Program Buffers............................................................................................................................211

Defining a Rotary Buffer...................................................................................................................................211

Preparing to Run ..............................................................................................................................................212

Opening for Entry.............................................................................................................................................212

Staying Ahead of Executing Line ......................................................................................................................212

Closing and Deleting Buffers............................................................................................................................213

How PMAC Executes a Motion Program .............................................................................................................213

Calculating Ahead ............................................................................................................................................213

Starting Calculations........................................................................................................................................214

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PMAC User Manual

Calculation of Subsequent Moves.....................................................................................................................214

Implications of Calculating Ahead ...................................................................................................................216

SYNCHRONIZING PMAC TO EXTERNAL EVENTS.....................................................................................219

Features to Help Synchronize Motion...................................................................................................................219

Position Following (Electronic Gearing)...............................................................................................................219

Position Following I-Variables ........................................................................................................................219

Changing Ratios on the Fly ..............................................................................................................................220

Superimposing Following on Programmed Moves...........................................................................................220

Time-Base Control (Electronic Cams) ..................................................................................................................220

What Is Time-Base Control?.............................................................................................................................220

Real-Time Input Frequency ..............................................................................................................................221

Constraints on Selection of RTIF......................................................................................................................221

How It Works ....................................................................................................................................................222

Instructions for Using an External Time-Base Signal ......................................................................................222

Time-Base Example ..........................................................................................................................................224

Triggered Time Base.............................................................................................................................................225

Instructions for the Triggered Time-Base.........................................................................................................226

Triggered Time-Base Example .........................................................................................................................226

Set up and Definitions.......................................................................................................................................227

Motion Program ...............................................................................................................................................227

PLC Program ...................................................................................................................................................227

Synchronizing PMAC to Other PMACs ...............................................................................................................228

Clock Timing.....................................................................................................................................................228

Sharing Clock Signals.......................................................................................................................................228

Connections ......................................................................................................................................................228

External Time Base...........................................................................................................................................229

Motion Program Timing...................................................................................................................................229

Minimizing Initial Offset...................................................................................................................................229

Position-Capture Functions ...................................................................................................................................230

Setting the Trigger Condition ...........................................................................................................................230

Using for Homing .............................................................................................................................................230

Using in User Program ....................................................................................................................................230

Offset from Motor Position...............................................................................................................................230

Position-Compare Functions .................................................................................................................................231

Required M-Variables ......................................................................................................................................231

Preloading the Compare Position ....................................................................................................................231

Offset from Motor Position...............................................................................................................................232

Synchronous M-Variable Assignment ..................................................................................................................232

WRITING A PLC PROGRAM..............................................................................................................................233

PLC Programs .......................................................................................................................................................233

When to Use......................................................................................................................................................233

Common Uses ...................................................................................................................................................233

32 PLC Programs ..................................................................................................................................................233

Entering a PLC Program..................................................................................................................................233

Opening the Buffer............................................................................................................................................234

Downloading the Program ...............................................................................................................................234

Closing the Buffer .............................................................................................................................................234

Erasing the Program ........................................................................................................................................234

PLC Program Structure .........................................................................................................................................235

Calculation Statements .....................................................................................................................................235

Conditional Statements.....................................................................................................................................235

Level-Triggered Conditions..............................................................................................................................235

Edge-Triggered Conditions ..............................................................................................................................235

WHILE Loops ...................................................................................................................................................236

Precise Timing..................................................................................................................................................237

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PMAC User Manual

Compiled PLC Programs.......................................................................................................................................237

Execution of Compiled PLCs............................................................................................................................238

Preparing Compiled PLCs................................................................................................................................238

Variable Value Assignment Statements ............................................................................................................240

Integrating PLC Files ............................................................................................................................................243

Link Address File..............................................................................................................................................243

Executing the Compiler ....................................................................................................................................243

Compiler Errors................................................................................................................................................244

Compiler Processing ........................................................................................................................................244

Downloading the Compiled Code to PMAC.........................................................................................................245

Running the Compiled PLCs.............................................................................................................................245

WRITING A HOST COMMUNICATIONS PROGRAM...................................................................................247

Communicating From a Host Computer ...............................................................................................................247

Polled vs. Interrupt-Based Communications ....................................................................................................247

Serial Port Communications.............................................................................................................................247

Setting up the Interface.....................................................................................................................................247

Host Port Bus (PC/STDbus) Communications......................................................................................................249

Host Port Structure...........................................................................................................................................249

Base Address Selection .....................................................................................................................................249

Register Functions............................................................................................................................................249

Registers for Simple Polled Communications...................................................................................................249

Setting up the Port ............................................................................................................................................249

Sending a Character .........................................................................................................................................250

Reading a Character.........................................................................................................................................250

Using the PMAC PC/STD to Interrupt the Host Computer...................................................................................250

What Signals Can Be Used...............................................................................................................................250

Selecting a Host Interrupt Line (PMAC PC or Lite).........................................................................................252

Selecting a Host Interrupt Line (PMAC STD) ..................................................................................................252

Interrupt Functions...........................................................................................................................................252

Setting Up .........................................................................................................................................................255

Finding an Open Interrupt Line........................................................................................................................255

Hardware Considerations.................................................................................................................................255

Initializing the PC’s PIC...................................................................................................................................255

Vectoring ..........................................................................................................................................................256

Setting up the Host Request Function...............................................................................................................256

Initializing the PMAC PIC................................................................................................................................256

Unmasking Interrupts .......................................................................................................................................256

Using the Interrupts..........................................................................................................................................257

Restoring Previous Vectors ..............................................................................................................................257

VMEbus Communications ....................................................................................................................................257

Setting up The Base Address for PMAC VME ..................................................................................................257

Address Modifier ..............................................................................................................................................258

Address Modifier Do Not Care Bits..................................................................................................................259

PMAC Base Address Bits..................................................................................................................................259

Interrupt Level ..................................................................................................................................................259

Interrupt Vector Number ..................................................................................................................................259

Dual-Ported RAM Base Address ......................................................................................................................259

DPRAM Enable ................................................................................................................................................260

Address Bus Width............................................................................................................................................260

Saving These Setup Values ...............................................................................................................................260

Setting up VME Dual-Ported RAM (Option 2V)..................................................................................................261

Starting Address................................................................................................................................................261

Talking to PMAC VME through the Mailbox Registers....................................................................................262

Sending Commands to PMAC VME through Mailbox Registers......................................................................263

Reading Data from PMAC VME through Mailbox Registers...........................................................................264

Table of Contents xi

PMAC User Manual

Example ............................................................................................................................................................266

Dual-Ported RAM Communications.....................................................................................................................267

Uses of DPRAM................................................................................................................................................267

Using Multiple PMAC VME Cards on the VME bus........................................................................................268

Data Integrity Checks .......................................................................................................................................270

Data Gathering.................................................................................................................................................272

Real-Time Data Gathering through Dual-Ported RAM....................................................................................273

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PMAC User Manual

Table of Figures

Figure 1 PMAC Motion Controller Custom Gate Array IC ........................................................................................41

Figure 2 PMAC Encoder Input Circuitry ....................................................................................................................42

Figure 3 Encoder Digital Delay Filter .........................................................................................................................44

Figure 4 Using the PMAC Control Panel Analog (Wiper) Input.................................................................................52

Figure 5 Address I-Variables.......................................................................................................................................55

Figure 6 PMAC Pulse and Direction Output ...............................................................................................................55

Figure 7 PMAC 1/T Extension....................................................................................................................................57

Figure 8 Interpolated Encoder Feedback.....................................................................................................................59

Figure 9 Encoder Conversion Table Process...............................................................................................................65

Figure 10 Configure Encoder Conversion Table Editing Screen.................................................................................66

Figure 11 Conversion Table Example for Time-Base Entry .......................................................................................74

Figure 12 PMAC Position Processing .........................................................................................................................79

Figure 14 Two Dimensional Compensation Table......................................................................................................82

Figure 15 PMAC Commutation...................................................................................................................................88

Figure 16 Hall Effect Waveform Diagram ..................................................................................................................94

Figure 17 PMAC/PMAC2 Direct Microstepping System ...........................................................................................99

Figure 18 PMAC PID and NOTCH Servo Filter.......................................................................................................107

Figure 19 PMAC PID Servo Loop Modifiers............................................................................................................107

Figure 20 Extended Control Alogorithm Block Diagram..........................................................................................111

Figure 21 Motor x Motion Variables.........................................................................................................................127

Figure 22 Homing Search Move Trajectory..............................................................................................................128

Figure 23 PMAC Coordinate Definition ...................................................................................................................140

Figure 24 PMAC Multitasking Example...................................................................................................................146

Figure 25 PMAC Memory Mapping .........................................................................................................................149

Figure 26 Coordinate System Variables ....................................................................................................................167

Figure 27 Automatic S Curve Acceleration...............................................................................................................168

Figure 28 Linear Mode Trajectories (Sheet 1 of 4) ...................................................................................................170

Figure 29 Linear Mode Trajectories (Sheet 2 of 4) ..................................................................................................171

Figure 30 Linear Mode Trajectories (Sheet 3 of 4) ...................................................................................................172

Figure 31 Linear Mode Trajectories (Sheet 4 of 4) ...................................................................................................173

Figure 32 PMAC Circular Interpolation....................................................................................................................178

Figure 33 PVT Mode Contouring (Hermite Spline)..................................................................................................180

Figure 34 PVT Segment Shapes................................................................................................................................181

Figure 35 Splined Moves (All Segments at Same Time)...........................................................................................181

Figure 36 Cubic Spline Trajectories..........................................................................................................................182

Figure 37 PMAC Transition Point Moves (PVT Mode, Parabolic Velocity)............................................................182

Figure 38 Compensation – Inside Corner..................................................................................................................185

Figure 39 Compensation Outside Corner ..................................................................................................................186

Figure 40 Inside Corner Cutter Compensation..........................................................................................................187

Figure 41 Outside Corner Cutter Compensation Sharp Angle ..................................................................................188

Figure 42 Outside Corner Cutter Compensation – Shallow Angle............................................................................188

Figure 43 Reversal in Cutter Compensation..............................................................................................................189

Figure 44 Failure When Compensation Extends Full Circle .....................................................................................190

Figure 45 Cutter Compensation Change of Direction ...............................................................................................191

Figure 46 Cutter Compensation Change of Direction – No Intersection...................................................................191

Figure 47 Removing Compensation – Inside Corner ................................................................................................192

Figure 48 Removing Compensation – Outside Corner..............................................................................................193

Figure 49 Failures in Cutter Compensation...............................................................................................................194

Figure 50 PMAC Motion Program Recalculation .....................................................................................................214

Figure 51 PMAC Motion Program Recalculation .....................................................................................................219

Figure 52 Position Following Parameters..................................................................................................................220

Figure 53 PMAC PC/VME Custom Gate Array (DSPGATE) Encoder Functions ...................................................231

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PMAC User Manual

Figure 54 PMAC PC/PMAC Lite Interrupt Structure ...............................................................................................253

Figure 55 PMAC STD Interrupt Structure ................................................................................................................254

Figure 56 PMAC VME Communications Flow Diagram .........................................................................................269

Figure 57 Dual-ported RAM Data Gathering Format................................................................................................274

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PMAC User Manual

Table of Contents xv

PMAC User Manual

INTRODUCTION

The Delta Tau Data Systems, Inc. Programmable Multi-Axis Controller (PMAC) is a family of high­performance servo motion controllers capable of commanding up to eight axes of motion simultaneously
with a high level of sophistication. Through the power of a Digital Signal Processor (DSP), PMAC offers a
price-performance ratio for multi-axis control that was not previously available. Motorola’s DSP56001 is
the CPU for PMAC, and it handles all the calculations for all eight axes.

There are four hardware versions of PMAC: the PMAC PC, the PMAC Lite, the PMAC VME, and the
PMAC STD. These cards differ from each other in their form factor, the nature of the bus interface, and in
the availability of certain I/O ports. All versions of the card have identical on-board firmware, so PMAC
programs written for one version will run on any other version. The PMAC STD has a different memory
mapping of some I/O.

Any version of PMAC may run as a standalone controller, or it may be commanded by a host computer,
either over a serial port or over a bus port.

Flexibility

As a general purpose controller, PMAC can serve in a wide variety of applications, from those requiring
sub-micro inch precision to those needing hundreds of kilowatts or horsepower. Its diverse uses include
robotics, machine tools, paper and lumber processing, assembly lines, food processing, printing, packaging,
material handling, camera control, automatic welding, silicon wafer processing, laser cutting, and many
others.

Configuration for a Task

PMAC is configured for a particular application by choice of the hardware set (through options and
accessories), configuration of parameters, and the writing of motion and PLC programs. Each PMAC
possesses firmware capable of controlling eight axes. The eight axes can be associated all together for
completely coordinated motion; each axis can be put in its own coordinate system for eight completely
independent operations; any intermediate arrangement of axes into coordinate systems is also possible.

The PMAC CPU communicates with the axes through specially designed custom gate array ICs, referred to
as DSPGATES. Each of these ICs can handle four analog output channels, four encoders as input, and four
analog-derived inputs from accessory boards. One PMAC can utilize from one to four of these gate array
ICs, so specifying the hardware configuration amounts to counting the numbers and types of inputs and
outputs. Up to 16 PMAC may be ganged together with complete synchronization, for a total of 128 axes.

PMAC is a Computer

It is important to realize that PMAC is a full computer in its own right, capable of standalone operation
with its own stored programs. Furthermore, it is a real-time, multitasking computer that can prioritize tasks
and have the higher priority tasks pre-empt those of lower priority (most personal computers are not
capable of this). Even when used with a host computer, the communications should be thought of as those
from one computer to another, not as computer to peripheral. In these applications, the ability of to run
multiple tasks simultaneously, properly prioritized, can take a tremendous burden off the host computer
(and its programmer), both in terms of processor time, and of task-switching complexity.

Introduction 1

PMAC User Manual

Manual Layout

This manual provides a quick step-by-step guide for the beginner setting up a typical system, as well as
explaining how to use the various features available on PMAC. It is organized by subject (safety, I/O,
servos, trajectories, etc.) to allow quick access by the area of concern. The subjects are ordered by the
typical sequence of events to go through to set up a system.

The commands are organized in alphabetical order, and the variables, registers, jumpers and connectors are
in numerical order. There is extensive cross-referencing between the chapters. Any variable, command,
register, jumper, or connector mentioned in chapter 2 is covered in more detail in the appropriate reference
chapters.

Reading the chapters, there may be topics or depth of coverage not needed at the time. Simply skip these
chapters and proceed to a chapter that is of more immediate use.

This manual assumes the system integrator who is responsible for this installation knows the basics of
working in a Microsoft
machine tool technology, and the PMAC motion control board. If any questions about a particular aspect
of the installation arise, do not attempt the task until a thorough understanding is gained. Feel free to
contact Technical Support at any time during installation. Refer to the Technical Support section below for
information on contacting our technical support department.

®

Windows environment and has more than a basic understanding of electronics,

Conventions Used in this Manual

The following conventions are used throughout the manual:

<ENTER>
<CTRL+F4>

OPEN PROGRAM

Warning

Caution

Note

Text inside arrows is used to represent keyboard keys or key
combinations.

Mono-spaced is used for code listings.
Information that, if not observed, may cause serious injury or death.

Information that, if not observed, may cause damage to equipment or
software.
A note concerning special functions or information of special interest.

Safety Summary

The following are general safety precautions not related to any specific procedures and therefore may not
appear elsewhere in this publication. These are recommended precautions that personnel must understand
and apply during many phases of operation and maintenance.

Keep Away from Live Circuits

Do not replace components or make adjustments inside equipment with power applied. Under certain
conditions, dangerous potentials may exist when power has been turned off due to charges retained by
capacitors. To avoid casualties, always remove power, discharge, and ground a circuit before touching it.

Live Circuit Contact Procedures

Never attempt to remove a person from a live circuit with bare hands. To do so is to risk sure and sudden
death. If a person is connected to a live circuit, the following steps should be taken:

Call for help immediately.
De-energize the circuit, if possible.
Use a wood or fiberglass hot stick to pull the person free of the circuit.
Apply cardiopulmonary resuscitation (CPR) if the person has stopped breathing or is in cardiac arrest.
Obtain immediate medical assistance.

2 Introduction

PMAC User Manual

Electrostatic Sensitive Devices

Various circuit card assemblies and electronic components may be classified as Electrostatic Discharge
(ESD) sensitive devices. Equipment manufacturers recommend handling all such components in
accordance with the procedures described in Appendix A. Failure to do so may void THE warranty.

Magnetic Media

Do not place or store magnetic media (tapes, discs, etc.) within ten feet of any magnetic field.

Related Technical Documentation

Manual Number Manual Title

3A0-602204-363 PMAC and PMAC2 Software Reference
3A0-602191-363 PMAC PC Hardware Reference Manual
3A0-602274-363 PMAC Lite Hardware Reference Manual
3A0-602244-363 PMAC STD Hardware Reference Manual
3A0-602199-363 PMAC VME Hardware Reference Manual
3A0-602812-363 PMAC Mini Hardware Reference Manual

Technical Support

Delta Tau is happy to respond to any questions or concerns regarding PMAC. Contact the Delta Tau
Technical Support Staff by the following methods:

By Telephone

For immediate service, contact the Delta Tau Technical Support Staff by telephone Monday through
Friday. Our support line hours and telephone numbers are listed below.

By Fax and E-Mail

Fax or E-Mail a request or problem to us overnight and we will deal with it the following business day.
Our Fax numbers and E-Mail addresses are listed below. Supply all pertinent equipment set-up
information.

Bulletin Board Service (BBS)

In addition, messages can be left on one of the Bulletin Board Services (BBSs). The BBSs are provided for
customers, distributors, representatives, and integrators, et al. Download and upload files and read posted
bulletins and Delta Tau newsletters. Messages may be left for anyone who is a member/user of the Bulletin
Board System(s). A modem and Procomm-Plus or similar communications program is all that is needed to
use this service. Many download-upload protocols such as Z-Modem are supported.

Delta Tau Data Systems, Inc. Technical Support

Phone: [phone]

Fax: [phone]

Email: [e-mail]

Website: http://www.deltatau.com

Delta Tau Europa AG

Rheinweg 4

CH-8200 Schaffhausen

Switzerland
PH: 41 (0) 52 625 20 88
FX: 41 (0) 52 625 44 82

Email: [e-mail]

Introduction 3

PMAC User Manual

PMAC Japan

3-6-7, Nihonbashi Ningyocho

Chuo-Ku

Tokyo 103

Japan
PH: 011-81-3-3665-6421
FX: 011-81-3-3665-6888

Email: [e-mail]

Website: www.Pmac-japan.co.jp

4 Introduction

PMAC User Manual

GETTING STARTED WITH PMAC

PMAC is a very flexible controller, suitable for many different types of applications, with different types of
hosts, amplifiers, motors, and sensors. As such, the card must be configured for a specific application,
using both hardware and software features, in order to run that application properly. (PMAC is shipped
from the factory with defaults set in hardware and software setup to be satisfactory for the most common
application types.) This section explains this configuration process for the inexperienced user.

Note:

The PMAC Setup (PS) program that is provided on the Executive program diskette
walks you through each of these steps in an interactive fashion. Use of that program
may enable some to skip this part of the manual.

By following this procedure, those unfamiliar with PMAC should be able to get the
card going quickly and reliably. Once more acquainted with the card, these tasks
may be performed in a different order and some of the checking steps may be
skipped to perform the installation more quickly.

The Getting Started section is a quick introduction to exercise the basic functionality
of the card. Each of the areas dealt with in this section is also covered in later
chapters in more detail.

Preparing the Card

First, inspect the card for any signs of damage. PMAC was thoroughly tested, burned in, and tested again
(including actually running motors), before it left the factory, but there always exists the (remote)
possibility of shipping damage. If any visible damage is seen, report this to Delta Tau immediately.

E-Point Jumpers

On the PMAC, there are many jumpers (pairs of metal prongs) called E-points (on the bottom board of the
PMAC STD they are called W-points). Some have been shorted together; others have been left open.
These jumpers customize the hardware features of the board for a given application. The PMAC was
shipped with jumpers configured for the needs of a typical user, so it can be started initially without
changing any jumpers. However, we will check a few jumpers here to make sure they are correct before
we start.

In the Hardware Reference manual for the specific version of the board is a map of the jumper locations
and a detailed description of each jumper’s function. Check the jumpers according to the instructions and
refer to the map. For more detailed instructions on changing a setting, refer to the detailed jumper
descriptions.

Card Number Jumpers

The PMAC was preset in the factory at card number (software address) 0 by the jumper configuration of
E40 - E43 on the PMAC PC, -Lite, and -VME which should all be ON (for the PMAC STD this is
controlled by DIP switches SW1-1 to SW1-4 which should all be OFF).

The card number is important for two reasons. First, if several cards are daisy-chained together on the
serial interface, it is the software addressing that determines which card should send data and receive
commands. Second, card 0 creates its own servo clock signal; all the other cards receive the servo clock
signal from the outside as a synchronizing signal. If they do not receive it, they will shut down.

Each set of synchronized PMAC cards must have one, and only one, card 0. For the initial setup with
PMAC, it is advised that the card be set at software address 0. If this must be changed, refer to the detailed
E-point description.

Getting Started with PMAC 5

PMAC User Manual

Communications Baud Rate Jumpers

The PMAC was shipped configured to be able to communicate either over the bus interface, or over the
serial interface at 9600 baud. The communications setting is controlled by jumpers E44-E47 on the PMAC
PC, Lite, and VME, and by DIP switches SW1-5 to SW1-8 on the PMAC STD.

If communicating over the bus port for the initial setup of the board, the settings of these jumpers is not
important. However, if the initial communications is over the serial port, make sure these jumpers enable
the serial port and provide the baud rate desired. (The Setup program and Executive program do have
automatic baud rate search algorithms.

As sent from the factory, E44 and E47 should be OFF, while E45 and E46 should be ON (on PMAC STD,
SW1-5 and SW1-8 should be ON; SW1-6 and SW1-8 should be OFF). PMAC can receive commands
from both the bus and serial ports. (Keep commands on the two ports from overlapping.) PMAC powers
up or resets in a mode to respond over the serial interface, but any character received over the bus interface
changes the mode so it will respond over the bus interface instead. A <CTRL-Z> character received over
the serial port changes PMAC back to responding over the serial port. If the default jumper setting must be
changed, refer to the detailed E-point description.

PCbus Address Jumpers

PMAC PC and PMAC Lite are shipped from the factory set to communicate over the PC-bus at I/O address
528 decimal (210 hex). This setting is controlled by jumpers E91-E92 and E66-E71 located on the
rightmost of the lower-edge bank of jumpers (for this default address, E91-E92 are ON, E66 is OFF, E67­E70 are ON, and E71 is off). Unless there is a conflict at this address, start using the first card at this
address. If the address must be changed, change the jumpers as shown in the detailed E-point descriptions
in the Hardware Reference manual.

STDbus Address Jumpers

PMAC STD is shipped from the factory set to communicate over the STD-bus at I/O address 61,584
decimal (F090 hex). This setting is controlled by jumpers W11 to W22 on the bottom circuit board (for
this default address, W11-W14 are OFF, W15-W18 are ON, W19 is OFF, W20-W21 are ON, and W22 is
OFF). Unless there is a conflict at this address, start using the first card at this address. If the address must
be changed, change the jumpers as shown in the detailed E-and W-point descriptions in the Hardware
Reference manual.

PMAC VME Interface Setup

The VMEbus interface is set up by writing to PMAC registers through the serial port. If using the PMAC
VME, the initial development is done by communicating to the PMAC over the serial port from an IBM­PC or compatible host. Follow the directions for using the serial port. Information for setting up the VME
bus interface is provided in the Writing a Host Communications Program section of this manual.

Encoder Jumpers

PMAC can take either non-differential (single-ended A, B, C) or differential inputs (A, A/, B, B/, C, C/)
from encoders. As shipped from the factory, the card is set up for non-differential encoders, individually
selectable by jumpers E18-E21 (not available on PMAC Lite or PMAC STD) and E24-E27. In this setup
with pins 1 and 2 of each E-point connected, the main signal line is pulled up to +5V with a 470 ohm
resistor, and the complementary lines are held at +2.5V with 1 kohm pull-up and pull-down resistors,
allowing them to be a steady comparison point for the signal lines. If using single-ended encoders, leave
the complementary lines (A/, B/, and C/) floating, so PMAC can hold them at 2.5V. Do not ground these
inputs.

6 Getting Started with PMAC

PMAC User Manual

If using single-ended encoders, have the jumpers set up for non-differential. If using differential encoders
with open-collector drivers on each channel (this is rare), have the jumpers set up for differential (pins 2
and 3 connected, providing an effective 500 ohm pull-up on the complementary line). If using encoders
with differential line drivers, the jumpers can be set either way, although it is preferable to have them set
for differential to balance the lines.

Note:

If not using a certain encoder input, it is better to leave it jumpered for single-ended
input; otherwise it is much more likely to pick up extraneous noise as count
information.

Analog Circuit Jumpers

On PMAC, the analog output circuitry can be optically isolated from the digital logic circuitry for noise
reduction purposes. PMAC is shipped from the factory with the circuits optically isolated (E85, E87, and
E88 OFF). It is recommended that the card be used in this configuration, but it is possible to jumper the
bus supply voltage (+/- 12V) over to the analog circuitry by putting these jumpers ON, defeating the optical
isolation, but eliminating the need for an separate power source.

Isolated Setup

With the optical isolation in effect, it is necessary to provide separate power supply to the analog output
circuitry. On the JMACH connectors, the A+15V analog supply should be brought in on pin 59, the A-15V
analog supply on pin 60, and the analog ground (AGND) on pin 58. (Jumper E89 should be ON, and
Jumper E90 should connect Pins 1 and 2 to permit this +15V to pull up the limit-switch and other optically
isolated inputs, which is required for PMAC to command motion. PMAC is shipped with E89 and E90 in
this configuration.) Most amplifiers provide supply outputs for this purpose. Alternatively, an external
supply may be used.

Non-Isolated Setup

The +12V and -12V bus supplies may be used to power the analog output circuitry by jumpering them
across to the analog side with E85 (+12V), E87 (Analog GND), and E88 (-12V); however, this defeats the
isolation and connects the whole computer electrically to the amplifier. This is not recommended and
should only be done for low power systems. To power the flags from the bus +12V supply as well, Jumper
E90 must be moved to connect Pins 2 and 3, so the +12V can pull up the limit-switch and other optically
isolated inputs.

Re-initialization Jumper

If the card powers up or resets with jumper E51 in its default state (OFF for PMAC PC, Lite, and VME;
ON for PMAC STD), PMAC will go through its normal reset cycle, utilizing the setup parameters (such as
I-variables that were previously saved in EAROM.

Standard and Option 5 PMACs

If a PMAC with the Standard or Option 5 CPU powers up or resets with E51 in the non-default state (ON
for PMAC PC, Lite, and VME; OFF for PMAC STD), PMAC will re-initialize as it resets, utilizing the
factory default parameters. Usually, this setting will be used only if the card software and parameters are
so confused that even basic communications is impossible. For startup, make sure this jumper is in its
default state.

Getting Started with PMAC 7

PMAC User Manual

PMAC with Options 4A, 5A, and 5B

If the jumper E51 is ON when a PMAC with the Option CPU executes its reset cycle, PMAC enters a
special re-initialization mode that permits the downloading of new firmware. In this mode, the PMAC can
communicate over the serial port only at a baud rate of 38,400, regardless of the setting of the baud rate
jumpers. Bus communications is also possible on PMAC with bootstrap version 1.01 and newer (most
PMAC have one of these versions). To verify the bootstrap version, type the command VER while
communicating to PMAC in bootstrap mode.

To bypass the download operation in this mode, send a <CONTROL-R> character to PMAC. This puts
PMAC in the normal operational mode with the existing firmware. Factory default values for I-variables,
conversion table settings, and bus addresses for DPRAM and VME are copied from the firmware section of
flash memory into active memory. The saved values of these values are not used, but they are kept in the
user section of flash memory.

For more information on PMAC bootstrap mode and downloading new firmware, refer to the PROM
Update Specification sheet included with the PROM.

Connecting PMAC to the Host Computer

Bus Connection

Caution:

With the board plugged into the bus, it will pull +5V power from the bus
automatically. In this case, there must be no external +5V supply, or the two
supplies will fight each other, possibly causing damage.

With computer power off, plug the PMAC into an open bus slot. The PMAC Lite requires one slot on the
bus, the PMAC PC requires 1-1/2 slots (permitting a half-size board in the next slot), the PMAC VME
requires two slots (one double slot), and the PMAC STD requires two slots for the 4-channel version, and
three slots for the 8-channel version.

Serial Port Connection

For serial communications, use a serial cable to connect the PC’s COM port to the PMAC serial port
connector (J4 on PMAC PC, -Lite, and -VME; J1 on PMAC STD’s bottom board). Delta Tau provides
cables for this purpose: Acc-3D connects PMAC PC or VME to a DB-25 connector; Acc-3L connects
PMAC Lite to a DB-9 connector; and Acc-3S connects PMAC STD to a DB-25 connector. Standard DB­9-to-DB-25 or DB-25-to-DB-9 adapters may be needed for a particular setup.

If using the Acc-26 Serial Communications converter, connect from the PC COM port to Acc-26 with a
standard DB-9 or DB-25 cable, and from Acc-26 to PMAC using the cable provided with Acc-26. Since
the serial ports on PMAC PC and PMAC VME are RS-422, this accessory can provide the level conversion
between RS-232 and RS-422 (communications is possible without this conversion, but at reduced noise
margin). Because the conversion is optically isolated, the accessory also helps prevent noise and ground
loop problems.

Note:

If the PMAC is not plugged into a bus, it will need an external 5V supply to power
its digital circuits. The +5V line from the supply should be connected to pin 1 or 2
of the JMACH connector (usually through the terminal block), and the digital
ground to pin 3 or 4.

8 Getting Started with PMAC

PMAC User Manual

Installing the PMAC Executive Program

The initial communications to the card will be done with Delta Tau’s PMAC Executive program (PE) or
the accompanying PMAC Setup (PS) program, which are provided on a diskette (Acc-9D or 9W). The
diskette contains an Install utility to make this easy. Refer to the Executive Program section in the Pewin
User’s Manual, 3A0-0PEWIN-363, for details.

Establishing Host Communications

Either the Executive or Setup program can be used to establish initial communications with the card. Both
programs have menus that tell the PC where to expect to find the PMAC and how to communicate with it at
that location. If it is told to look for PMAC on the bus, also tell it the PMAC base address on the bus (this
was set up with jumpers on PMAC). If it is told to look for PMAC on a COM port, tell it that the baud rate
(this was set up with jumpers or switches on the PMAC). The Executive program (Acc-9W) does have an
automatic baud rate search to find out how the card is set up.

Instructions for setting up the communications are given in detail in the PMAC Executive for Windows
User’s manual, 3A0-0PEWIN-363, p1 Setup Manual, 3A0-1SETUP-363, and P2 Setup Manual, 3A0­2SETUP-363. Refer to those manuals for more explanation.

Once the program has been told where and how to communicate with PMAC, it will attempt to find PMAC
at that address by sending a query command and waiting for the response. If it gets the expected type of
response, it will report that it has found PMAC.

If it does not get the expected type of response after several attempts, it will report that it has not found
PMAC.

Terminal Mode Communications

Once the program reports that it has found PMAC, and a key has been pressed to escape the Found/Not­Found window, the program should be in terminal emulation mode, so that the PC is acting as a dumb
terminal to PMAC. Check to see if a response is received by typing I10<CR> (<CR> means carriage
return, the Enter or Return key). PMAC should respond with a six or seven digit number. Now type

III<CR>. PMAC should respond with a beep, signifying an unrecognized command and the error-code
ERR003 if the I-variable I6 is set to its default value of three. For more information on the error-codes,

refer to the explanation of I-Variable I6 in PMAC and PMAC2 Software Reference Manual.

Next, if satisfied that communications with the card is at a basic level, type a P <CR> (case does not
matter). This command requests a position. PMAC should respond with a number, probably a 0. Now
type a <CONTROL-F. Eight numbers (one for each axis) should appear since <CONTROL-F> requests
following error from all eight motors; some or all may be 0.

Note:

Even with encoder counts as read-out (no scaling) PMAC position is displayed with
fractional counts.

Connecting PMAC to the System

Once the basic operation of the card and the host communications have been established, it is time to
connect PMAC to the amplifier, motor, and feedback device.

Of course, most PMAC systems will have more than one motor attached. The process described here can
be repeated for multiple motors. As our example here, we will discuss the setup of motor #1. The
procedure is parallel for any other motors.

Getting Started with PMAC 9

PMAC User Manual

There are many combinations of amplifier types, motor types and feedback device types that can be
connected to PMAC, each requiring a somewhat different procedure. The easiest connection is that of a
DC motor and amplifier with an incremental encoder. That is what is described first here. Other options
will be discussed later, or in other sections.

Typically, connections are made to a terminal block that is attached to the JMACH connector by a flat
cable (Acc- 8D or 8P). The pinout numbers on the terminal block are the same as those on the JMACH
connector for PMAC PC. Make sure PMAC is un-powered while the connections are being made. Leave
any loads disconnected from the motor at this point.

Machine Connectors

The primary machine interface connector is JMACH1 (J8 on PMAC PC, J11 on PMAC Lite, P2 on PMAC
VME, J4 on PMAC STD top board). It contains the pins for four channels of machine I/O: analog outputs,
incremental encoder inputs, and associated input and output flags, plus power-supply connections. These
four channels can be used for two to four motors, depending on the configuration. Our example will use
this connector.

The next machine interface connector is JMACH2 (J7 on PMAC PC, P2A on PMAC VME, J4 on the
middle board of an 8-channel PMAC STD, not available on a PMAC Lite). It is essentially identical to the
JMACH1 connector for two to four more axes. It is present only if the PMAC card has been fully
populated to handle eight axes (Option 1), because it interfaces the optional extra components.

Note:

While the numbering scheme for the pins on machine connectors on PMAC VME is
different from that for PMAC PC, the physical arrangement is the same, and PMAC
VME can use the same terminal numbers on the terminal block board.

Connecting the Analog Power Supply

The analog output circuitry on PMAC is optically isolated from the digital computation circuitry, and so
requires a separate power supply. This is brought in on the JMACH connector. The positive supply (+12
to +15 volts) should be brought in on the A+15V line on pin 59. The negative supply (-12 to -15V) should
be brought in on the A-15V line on pin 60. The analog common should be brought in on the AGND line on
pin 58.

Typically, this supply can come from the servo amplifier. Many commercial amplifiers provide such a
supply. If this is not the case, an external supply may be used. Even with an external supply, the AGND
line should be tied to the amplifier common.

As mentioned before, it is possible to get the power for the analog circuits from the bus, but doing so
defeats optical isolation. In this case, no new connections need to be made. However, be sure jumpers
E85, E87, E88, E89, and E90 are set up for this circumstance as explained previously in the Preparing the
Card section. (The card is not shipped from the factory in this configuration.)

Incremental Encoder Connection

Each JMACH 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. If the PMAC is not plugged
into a bus and drawing its +5V and GND from the bus, use these pins to bring in +5V and GND from the
power supply.

10 Getting Started with PMAC