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

^1 USER MANUAL

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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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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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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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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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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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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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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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

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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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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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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

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

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

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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

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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 DB- 9-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, 3A0- 2SETUP-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 (Acc8D 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