Delta Tau TURBO CLIPPER User Manual

Single Source Machine Control

……………………………………………..…...……………….

Power // Flexibility // Ease of Use

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

^1 HARDWARE REFERENCE MANUAL

^2 Turbo PMAC Clipper

^3Turbo PMAC Clipper

^4 4xx-603871-xAxx

^5April 15, 2014

DELTA TAU

Data Systems, Inc.

NEW IDEAS IN MOTION …

Turbo PMAC Clipper

Copyright Information

© 2014 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
directly exposed to hazardous or conductive materials and/or environments, we cannot
guarantee their operation.

Turbo PMAC Clipper

A Warning identifies hazards that could result in personal injury or
death. It precedes the discussion of interest.

Warning

Caution

A Caution identifies hazards that could result in equipment damage. It
precedes the discussion of interest.

Note

A Note identifies information critical to the understanding or use of
the equipment. It follows the discussion of interest.

Safety Instructions

Qualified personnel must transport, assemble, install, and maintain this equipment. Properly qualified
personnel are persons who are familiar with the transport, assembly, installation, and operation of
equipment. The qualified personnel must know and observe the following standards and regulations:

IEC364resp.CENELEC HD 384 or DIN VDE 0100
IEC report 664 or DIN VDE 0110
National regulations for safety and accident prevention or VBG 4

Incorrect handling of products can result in injury and damage to persons and machinery. Strictly adhere
to the installation instructions. Electrical safety is provided through a low-resistance earth connection. It
is vital to ensure that all system components are connected to earth ground.

This product contains components that are sensitive to static electricity and can be damaged by incorrect
handling. Avoid contact with high insulating materials (artificial fabrics, plastic film, etc.). Place the
product on a conductive surface. Discharge any possible static electricity build-up by touching an
unpainted, metal, grounded surface before touching the equipment.

Keep all covers and cabinet doors shut during operation. Be aware that during operation, the product has
electrically charged components and hot surfaces. Control and power cables can carry a high voltage,
even when the motor is not rotating. Never disconnect or connect the product while the power source is
energized to avoid electric arcing.

Turbo PMAC Clipper

REVISION HISTORY

REV.

DESCRIPTION

DATE

CHG

APPVD

9

Changed name of manual to Turbo PMAC Clipper

11/03/09

CP

DD

10

Adjusted diagram on P.31

12/16/09

CP

SM

11

Added pulse and direction setup, updated fifth motor setup

06/10/10

RN

SM

12

Updated power supply information

03/17/12

GS

SM

13

General formatting and corrections

04/15/14

MC

RN

Note

Older revision correction notes have been removed for clarity.

Turbo PMAC Clipper

Table of Contents

INTRODUCTION ................................................................................................................................. 9

Documentation ........................................................................................................................................ 9

Downloadable Turbo PMAC Script ....................................................................................................... 10

SPECIFICATIONS ............................................................................................................................. 11

Part Number .......................................................................................................................................... 11

Options ................................................................................................................................................. 12

Environmental Specifications ................................................................................................................ 13

Electrical Specifications ........................................................................................................................ 13

Digital Power Supply ....................................................................................................................... 13

DAC Outputs Power Supply.............................................................................................................. 13

Flags Power Supply.......................................................................................................................... 13

RECEIVING AND UNPACKING ...................................................................................................... 14

Use of Equipment .................................................................................................................................. 14

MOUNTING ........................................................................................................................................ 15

Physical Specifications .......................................................................................................................... 16

Board Dimensions and Layout .......................................................................................................... 16

CONNECTIONS AND SOFTWARE SETUP .................................................................................... 17

TB1: Power Supply Input ...................................................................................................................... 17

J2: Serial Port ........................................................................................................................................ 18

J3: Machine Connector (JMACH1 Port) ................................................................................................ 19

Setting up Quadrature Encoders ....................................................................................................... 22

Setting up Sinusoidal Encoders ......................................................................................................... 22

Counts per User Units ...................................................................................................................... 24

Wiring the DAC Output .................................................................................................................... 25

Amplifier Enable Signal (AENAn/DIRn) ........................................................................................... 26

Amplifier Fault Signal (FAULT-) ...................................................................................................... 27

Optional Analog Inputs .................................................................................................................... 28

Analog Inputs Setup.......................................................................................................................... 28

J4: Machine Connector (JMACH2 Port) ................................................................................................ 29

Overtravel Limits and Home Switches .............................................................................................. 30

Wiring the Limits and Flags ............................................................................................................. 30

Limits and Flags [Axis 1- 4] Suggested M-Variables ........................................................................ 33

Step and Direction PFM Output (To External Stepper Amplifier) ...................................................... 34

Compare Equal Outputs ................................................................................................................... 35

J7: Machine Connector (JMACH3 Port) ................................................................................................ 36

J8: Thumbwheel Multiplexer Port (JTHW Port) ..................................................................................... 37

Thumbwheel Port Digital Inputs and Outputs ................................................................................... 38

J9: General-Purpose Digital Inputs and Outputs (JOPT Port) ................................................................. 39

General Purpose I/Os (J6) Suggested M-Variables ........................................................................... 41

J10: Handwheel and Pulse/Dir Connector (JHW/PD Port)...................................................................... 42

Table of Contents vi

Turbo PMAC Clipper

J12: Ethernet Communications Port ....................................................................................................... 43

J13: USB Communications Port ............................................................................................................ 43

JP11: OPT-11 Shunt .............................................................................................................................. 43

LED Indicators ...................................................................................................................................... 43

DRIVE - MOTOR SETUP ................................ .................................................................................. 44

Filtered PWM Output (Analog ±10V) .................................................................................................... 45

Clock Settings, Output Mode, Command Limit .................................................................................. 46

Flag Control, Ixx24 .......................................................................................................................... 47

I2T Protection: Ixx57, Ixx58 ............................................................................................................. 47

Open Loop Test: Encoder/Decode ................................................................................................ .... 47

Position-Loop PID Gains: Ixx30…Ixx39 ........................................................................................... 49

True DAC Output (±10V)...................................................................................................................... 50

Clock Settings, Output Mode ............................................................................................................ 50

Flag Control, Ixx24 .......................................................................................................................... 50

I2T Protection: Ixx57, Ixx58 ............................................................................................................. 50

Open Loop Test: Encoder/Decode ................................................................................................ .... 51

Position-Loop PID Gains: Ixx30…Ixx39 ........................................................................................... 52

Pulse and Direction Output (PFM) ................................ ......................................................................... 54

PFM Clock Settings Example ........................................................................................................... 54

PFM Setup Example ......................................................................................................................... 55

Writing directly to the PFM register ................................................................................................. 55

Issuing Open-Loop Commands ......................................................................................................... 56

Issuing Closed-Loop Commands ....................................................................................................... 56

Setup of a Fifth Motor Using Opt-12 on the Clipper Board .................................................................... 59

LASER CONTROL OUTPUT ............................................................................................................ 61

Understanding Option-11A Capabilities ................................................................................................ 62

Clock Settings ................................................................................................................................ ....... 63

Controlling the output ............................................................................................................................ 64

TROUBLESHOOTING ...................................................................................................................... 66

Serial Number and Board Revisions Identification ................................................................................. 66

Write-Protect Disable – E8 Jumper ........................................................................................................ 67

Changing IP Address, Gateway IP, Gateway Mask ........................................................................... 68

Enabling ModBus ................................................................................................ ............................. 69

Reloading Boot and Communication Firmware ................................................................................ 70

Reloading PMAC firmware – E13 Jumper ........................................................................................ 71

Re-initialization jumper (Factory Reset) ........................................................................................... 73

Watchdog Timer................................................................................................................................ .... 73

APPENDIX A: E-POINT JUMPERS ................................................................................................. 74

E0: Forced Reset Control ................................................................ ...................................................... 74

E1 – E2: Serial Port Selection (rev 102 and below only) ....................................................................... 74

E3: Normal/Re-Initializing Power-Up/Reset ......................................................................................... 74

E4: Watchdog Disable Jumper .............................................................................................................. 74

Table of Contents vii

Turbo PMAC Clipper

E5: Reserved for factory use only ......................................................................................................... 74

E6: ADC Inputs Enable ........................................................................................................................ 75

E7 – E8: USB/Ethernet Reset Jumpers ................................................................................................ .. 75

E10 – E12: Flash IC Jumpers ................................................................................................................ 75

E13: Power-Up/Reset Load Source ....................................................................................................... 76

E14- E17: Ports Direction Control ......................................................................................................... 76

APPENDIX B: SCHEMATICS .......................................................................................................... 77

Table of Contents viii

Turbo PMAC Clipper

The Turbo PMAC Clipper can be interfaced with several
different type of encoders and it supports three types of
outputs:

 Analog ±10V 12-bit Filtered PWM
 Analog ±10V 18-bit True DAC (Optional)
 Pulse Frequency Modulation (PFM)

INTRODUCTION

The Turbo PMAC Clipper is a multi-axis stand-alone controller. It has the full power of Turbo PMAC2
CPU and provides a minimum of 4 axes of servo or stepper control. It comes with 32 general-purpose
digital I/O points, handwheel port, USB, Ethernet and RS-232 communications links.
The optional axis expansion board provides a set of four additional servo channels and extra I/O ports.

Documentation

In conjunction with this user manual, the Turbo Software Reference Manual and Turbo PMAC User

Manual are essential for proper use, motor setup, and configuration of the Turbo PMAC Clipper. It is

highly recommended to refer to the latest revision of the manuals found on Delta Tau’s website, under

Support>documentation>Manuals: Delta Tau Manuals

Introduction 9

Turbo PMAC Clipper

Caution

Some code examples require the user to input specific information
pertaining to their system hardware. When user information is
required, a commentary ending with –User Input is inserted.

Caution

All PLC examples are stated in PLC number 1. It is the user’s
responsibility to arrange their application PLCs’ properly and handle

power-on sequencing for various tasks.

Caution

Often times, downloadable example codes use suggested M-variables,

it is the user’s responsibility to make sure they are downloaded, or

perform necessary changes to use the intended registers.

Downloadable Turbo PMAC Script

This manual contains downloadable code samples in Turbo PMAC script. These examples can be copied
and pasted into the editor area in the Pewin32pro2. Care must be taken when using pre-configured Turbo
PMAC code, some information may need to be updated to match hardware and system specific
configurations. Downloadable Turbo PMAC Scripts are enclosed in the following format:

// TURBO PMAC SCRIPT EXAMPLE
P1=0 ; Set P1=0 at download
Open PLC 1 Clear ; Open PLC Buffer 1, clear contents
CMDP"Turbo PMAC Clipper Manual Test PLC" ; Send unsolicited response to host port
P1=P1+1 ; Counter using variable P1
Disable PLC 1 ; Disable plc 1
Close ; Close open buffer

It is the user’s responsibility to use the PLC examples presented in this manual properly. That is,
incorporating the statement code in the application configuration, and handling tasks in a sequential
manner. For example, with serial absolute encoders, setting up the global control registers should be
executed before trying to read absolute position, and absolute phase referencing. Furthermore, other PLC
programs (which would be trying to move motors) should be disabled until these functions are executed.

Introduction 10

Turbo PMAC Clipper

SPECIFICATIONS

Part Number

Connections and Software Setup 11

Turbo PMAC Clipper

Options

CPU Options

 C0: 80MHz Turbo PMAC2 CPU (standard)

8Kx24 internal memory, 256Kx24 SRAM , 1MB flash memory

 C3: 80MHz Turbo PMAC2 CPU

8Kx24 internal memory, 1Mx24 SRAM, 4M flash memory

 F3: 240MHz Turbo PMAC2 CPU

192Kx24 internal memory, 1Mx24 SRAM, 4M flash memory

Communication Options

 Opt.2 Dual Port RAM (required for NC software/applications)
 Opt.15F Modbus Communication for additional I/O’s.
 Opt.EX JEXPA & JEXPB stack long pins
 Opt.C4 JEXPA & JEXPB stack and connectors long pins for breakout board option

Axis Output

 18-bit true DAC or 12-bit filtered PWM (default) ±10V analog output
 Pulse And Direction (PFM)

Encoder Input

 Four encoder inputs, and two handwheel quadrature input (default)
 Additional four encoder inputs (Acc-1P) and two handwheel encoder (Acc-1P Option1)

Digital Inputs/Outputs

 32 general-purpose TTL-level I/O points (default)
 Additional 8 general-purpose I/O and multiplexed I/O (Acc-1P Option1)

Analog Inputs

 Two 12-bit analog inputs, and a 12-bit filtered PWM (±10V) outputs (Opt.12)
 Additional two 12-bit analog inputs, and a 12-bit filtered PWM (±10V) outputs (Acc-1P Option2)

Host Communication

 USB 2.0, Ethernet 100 Base T, RS232 (default)

Stackable Accessories

 ACC-1P PC/104-format Channel 5-8 board
 ACC-8AS 4-channel dual 16-bit true-DAC output board
 ACC-8ES 4-channel dual 18-bit true-DAC output board
 ACC-8FS 4-channel direct-PWM output board
 ACC-8TS 4-channel ADC-interface board
 ACC-51S 2/4-channel high-resolution encoder interpolator board
 ACC-84S 4-channel serial encoder interface. The supported protocols:

 SSI Synchronous Serial Interface
 EnDat 2.2 EnDat 2.2 interface from HEIDENHAIN
 BiSS B Renishaw Biss B Unidirectional
 BiSS C Renishaw Biss C Unidirectional
 Yaskawa Yaskawa Sigma II and Sigma III feedback support
 Panasonic Panasonic Feedback Style
 Tamagawa Tamagawa Feedback Style
 Mitutoyo Mitutoyo Feedback Style

Connections and Software Setup 12

Turbo PMAC Clipper

Description

Specification

Notes

Operating Temperature

0°C to 45°C

Storage Temperature

-25°C to 70°C

Humidity

10% to 95 %

Non-Condensing

WARNING

Boards with revisions 103 and below have the following
requirement:

Mininumum 10 msec rise time
6A @ +5V (±5%) (30 W)
The Clipper Board and other stackable accessories each require a

1A @ 5VDC power supply for normal operation; however, the
Clipper board has an in-rush current requirement that can reach
3A, so a 6A @ 5VDC power supply is recommended.

Environmental Specifications

Electrical Specifications

Digital Power Supply

The +5V and ground reference lines from the power supply should be connected to TB1 terminal block of
the Turbo PMAC Clipper board using 18 AWG stranded wire. The power requirement (± 5%) is:

+5 V (20W) @ 4 A (Eight-channel configuration with a typical load of encoders)

DAC Outputs Power Supply

The ±12V lines from the supply, including the ground reference, can be brought in either from the TB1
terminal block or from the JMACH1 connector.

+12 to +15 V (4.5W) @ 0.30 A (Eight-channel configuration with a typical load of encoders)

-12 to -15 V (3.8W) @ 0.25 A (Eight-channel configuration with a typical load of encoders)

Flags Power Supply

Each channel of PMAC has five dedicated digital inputs on the machine connector: PLIMn, MLIMn
(overtravel limits), HOMEn (home flag), FAULTn (amplifier fault), and USERn. A power supply from 5
to 24V must be used to power the circuits related to these inputs. This power supply can be the same
used to Turbo PMAC Clipper and can be connected from the TB1 terminal block or the J3 (JMACH1)
connector.

Connections and Software Setup 13

Turbo PMAC Clipper

RECEIVING AND UNPACKING

Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the
Turbo PMAC Clipper is received, there are several things to be done immediately:

 Observe the condition of the shipping container and report any damage immediately to the

commercial carrier that delivered the board.

 Remove the Turbo PMAC Clipper from the shipping container and remove all packing materials.

Check all shipping material for connector kits, documentation, or other small pieces of
equipment. Be aware that some connector kits and other equipment pieces may be quite small
and can be accidentally discarded if care is not used when unpacking the equipment. The
container and packing materials may be retained for future shipment.

 Verify that the part number of the board received is the same as the part number listed on the

purchase order.

 Inspect for external physical damage that may have been sustained during shipment and report

any damage immediately to the commercial carrier that delivered the board.

 Electronic components in this product are design-hardened to reduce static sensitivity. However,

use proper procedures when handling the equipment.

 If the Turbo PMAC Clipper is to be stored for several weeks before use, be sure that it is stored in

a location that conforms to published storage humidity and temperature specifications.

Use of Equipment

The following restrictions will ensure the proper use of the Turbo PMAC Clipper:

 The components built into electrical equipment or machines can be used only as integral

components of such equipment.

 The Turbo PMAC Clipper must not be operated on power supply networks without a ground or

with an asymmetrical ground.

 If the Turbo PMAC Clipper is used in residential areas, or in business or commercial premises,

implement additional filtering measures.

 The Turbo PMAC Clipper may be operated only in a closed switchgear cabinet, taking into

account the ambient conditions defined in the environmental specifications.

Delta Tau guarantees the conformance of the Turbo PMAC Clippers with the standards for industrial
areas stated in this manual, only if Delta Tau components (cables, controllers, etc.) are used.

Connections and Software Setup 14

Turbo PMAC Clipper

Caution

Unit must be installed in an enclosure that meets the environmental IP
rating of the end product (ventilation or cooling may be necessary to
prevent enclosure ambient from exceeding 45° C [113° F]).

MOUNTING

The location of the Turbo PMAC Clipper is important. Installation should be in an area that is protected
from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and other contaminants.
Exposure to these can reduce the operating life and degrade performance of the board.

Several other factors should be carefully evaluated when selecting a location for installation:

 For effective cooling and maintenance, the Turbo PMAC Clipper should be mounted on a

smooth, non- flammable vertical or horizontal surface.

 At least 100 mm (0.4 inches) top and bottom clearance must be provided for air flow.
 Temperature, humidity and Vibration specifications should also be taken in account.

The Turbo PMAC Clipper can be mounted as a stand-alone controller using standoffs. At each of the
four corners of the board and at the center edges, there are mounting holes that can be used for this.

The order of the Acc-1P or other stacked accessories with respect to the Clipper Board does not matter.
If the Turbo PMAC Clipper is mounted to a back panel, the back panel should be unpainted and
electrically conductive to allow for reduced electrical noise interference. The back panel should be
machined to accept the standoffs pattern of the board.
The board can be mounted to the back panel using four standoffs and internal-tooth lock washers. It is

important that the teeth break through any anodization on the board’s mounting gears to provide a good

electrically conductive path in as many places as possible. Mount the board on the back panel so there is
airflow at both the top and bottom areas of the board (at least 0.4 inches).

Connections and Software Setup 15

Turbo PMAC Clipper

Physical Specifications

Board Dimensions and Layout

Top View

Rev106

Connections and Software Setup 16

Turbo PMAC Clipper Hardware Reference Manual

WARNING

Installation of electrical equipment is subject to many regulations
including national, state, local, and industry guidelines and rules.
The following are general recommendations but it is important
that the integration be carried out in accordance with all
regulations pertaining to the installation.

TB1 (JPWR): Power Supply

4-Pin Terminal Block

Pin#

Symbol

Function

Description

Notes 1 GND

Common

Digital Common

2

+5V

Input

Logic Voltage

Supplies all PMAC digital circuits

3

+12V

Input

DAC Supply Voltage

Ref to Digital GND

4

-12V

Input

DAC Supply Voltage

Ref to Digital GND

Note

For +5V and GND, 18 gauge (AWG) stranded wire is recommended.
For +12V and -12V, a minimum of 22 gauge (AWG) stranded wire is
recommended.

CONNECTIONS AND SOFTWARE SETUP

TB1: Power Supply Input

This 4-pin terminal block is used to bring the 5VDC logic power and +/-12VDC DAC supply into the
Turbo PMAC Clipper.

Connections and Software Setup 17

Turbo PMAC Clipper Hardware Reference Manual

J2 (JRS232) Serial Port Connector

10-Pin Header

56341

2

9107

8

Pin#

Symbol

Function

Description

Notes

1

PHASE

Output

Phasing Clock

2

DTR

Bidirect

Data Terminal Ready

Tied to "DSR"

3

TXD/

Output

Send Data

Host receive data

4

CTS

Input

Clear to Send

Host ready bit

5

RXD/

Input

Receive Data

Host transmit data

6

RTS

Output

Request to Send

PMAC ready bit

7

DSR

Bidirect

Data Set Ready

Tied to "DTR"

8

SERVO

Output

Servo Clock

9

GND

Common

Digital Common

10

+5V

Output

+5Vdc Supply

Power supply out

I54

Baud Rate

I54

Baud Rate

8

9600

12

38,400

9

14,400

13

57,600

10

19,200

14

76,800

11

28,800

15

115,200

J2: Serial Port

This connector allows communicating with Turbo PMAC Clipper from a host computer through a RS­232 port. Delta Tau provides the Accessory 3L cable that connects the PMAC to a DB-9 connector. This
port can be used as a primary communication mean or employed as a secondary port that allows
simultaneous communication.

10-pin female flat cable connector T&B Ansley P/N 609-1041
Standard flat cable stranded 10-wire T&B Ansley P/N 171-10

The baud rate for the RS-232 serial port is set by variable I54. At power-up reset, The Turbo PMAC
Clipper sets the active baud based on the setting of I54 and the CPU speed I52. Note that the baud rate
frequency is divided down from the CPU’s operational frequency. The factory default baud rate is 38400.
This baud rate will be selected automatically on re-initialization of the Clipper, either in hardware power
cycle or in software using the $$$*** command.

To change the baud rate setting on the Turbo PMAC Clipper, set I54 to the corresponding value of
desired frequency. Restart the software (Pewin32Pro2), and adjust to the correct baud rate in the
communication setup window. Then issue a SAVE and a reset ($$$), or recycle power on the Clipper. For
odd baud rate settings, refer to the Turbo Software Reference Manual.

Connections and Software Setup 18

Turbo PMAC Clipper Hardware Reference Manual

J3 (JMACH1): Machine Port Connector

50-Pin Header

495047484546434441423940373835363334313229302728252623242122192017181516131411129107856341

2

Pin#

Symbol

Function

Description

Notes

1

+5V

Output

+5V Power

For encoders, 1

2

+5V

Output

+5V Power

For encoders, 1

3

GND

Common

Digital Common

For encoders, 1

4

GND

Common

Digital Common

For encoders, 1

5

CHA1

Input

Encoder A Channel Positive

2

6

CHA2

Input

Encoder A Channel Positive

2

7

CHA1/

Input

Encoder A Channel Negative

2,3

8

CHA2/

Input

Encoder A Channel Negative

2,3

9

CHB1

Input

Encoder B Channel Positive

2

10

CHB2

Input

Encoder B Channel Positive

2

11

CHB1/

Input

Encoder B Channel Negative

2,3

12

CHB2/

Input

Encoder B Channel Negative

2,3

13

CHC1

Input

Encoder C Channel Positive

2

14

CHC2

Input

Encoder C Channel Positive

2

15

CHC1/

Input

Encoder C Channel Negative

2,3

16

CHC2/

Input

Encoder C Channel Negative

2,3

17

CHA3

Input

Encoder A Channel Positive

2

18

CHA4

Input

Encoder A Channel Positive

2

19

CHA3/

Input

Encoder A Channel Negative

2,3

20

CHA4/

Input

Encoder A Channel Negative

2,3

21

CHB3

Input

Encoder B Channel Positive

2

22

CHB4

Input

Encoder B Channel Positive

2

23

CHB3/

Input

Encoder B Channel Negative

2,3

24

CHB4/

Input

Encoder B Channel Negative

2,3

25

CHC3

Input

Encoder C Channel Positive

2

26

CHC4

Input

Encoder C Channel Positive

2

27

CHC3/

Input

Encoder C Channel Negative

2,3

J3: Machine Connector (JMACH1 Port)

The primary machine interface connector is JMACH1, labeled J3 on the Turbo PMAC Clipper. It
contains the pins for four channels of machine I/O: analog outputs, incremental encoder inputs, amplifier
fault and enable signals and power-supply connections.

Connections and Software Setup 19

Turbo PMAC Clipper Hardware Reference Manual

28

CHC4/

Input

Encoder C Channel Negative

2,3

29

DAC1

Output

Analog Output Positive 1

4

30

DAC2

Output

Analog Output Positive 2

4

31

DAC1/

Output

Analog Output Negative 1

4,5

32

DAC2/

Output

Analog Output Negative 2

4,5

33

AENA1/

Output

Amplifier-Enable 1

34

AENA2/

Output

Amplifier -Enable 2

35

FAULT1/

Input

Amplifier -Fault 1

6

36

FAULT2/

Input

Amplifier -Fault 2

6

37

DAC3

Output

Analog Output Positive 3

4

38

DAC4

Output

Analog Output Positive 4

4

39

DAC3/

Output

Analog Output Negative 3

4,5

40

DAC4/

Output

Analog Output Negative 4

4,5

41

AENA3/

Output

Amplifier -Enable 3

42

AENA4/

Output

Amplifier -Enable 4

43

FAULT3/

Input

Amplifier -Fault 3

6

44

FAULT4/

Input

Amplifier -Fault 4

6

45

ADCIN_1

Input

Analog Input 1

Option-12 required

46

ADCIN_2

Input

Analog Input 2

Option-12 required

47

FLT_FLG_V

Input

Amplifier Fault pull-up V+

48

GND

Common

Digital Common

49

+12V

Input

DAC Supply Voltage

7

50

-12V

Input

DAC Supply Voltage

7

Note

 Note 1: These lines can be used as +5V power supply inputs to power

PMAC’s digital circuitry.

 Note 2: Referenced to digital common (GND). Maximum of ±12V

permitted between this signal and its complement.

 Note 3: Leave this input floating if not used (i.e. digital single-ended

encoders).

 Note 4: ±10V, 10 mA max, referenced to common ground (GND).
 Note 5: Leave floating if not used. Do not tie to GND.

 Note 6: Functional polarity controlled by variable Ixx24. Must be

conducting to 0V (usually GND) to produce a 0 in PMAC software.
Automatic fault function can be disabled with Ixx24.

 Note 7: Can be used to provide input power when the TB1 connector is

not being used.

Connections and Software Setup 20

Turbo PMAC Clipper Hardware Reference Manual

Note

Use an encoder cable with high quality shield.

Channel A

Channel B

50-pin female flat cable connector T&B Ansley P/N 609-5041
Standard flat cable stranded 50-wire T&B Ansley P/N 171-50
Phoenix varioface module type FLKM 50 (male pins) P/N 22 81 08 9

The standard encoder inputs on the Turbo PMAC Clipper are designed for differential quadrature type
signals.

Quadrature encoders provide two digital signals to determine the position of the motor. Each nominally
with 50% duty cycle, and nominally 1/4 cycle apart. This format provides four distinct states per cycle of
the signal, or per line of the encoder. The phase difference of the two signals permits the decoding
electronics to discern the direction of travel, which would not be possible with a single signal.

Typically, these signals are 5V TTL/CMOS level whether they are single-ended or differential.
Differential signals can enhance noise immunity by providing common mode noise rejection. Modern
design standards virtually mandate their use in industrial systems.

Connections and Software Setup 21

Turbo PMAC Clipper Hardware Reference Manual

Encoder shield

25 23

24

21

22

19

20

17

18

15

16

13

14

11

12

9

10

7

8

5

6

3

4

1

2

B-

C-

C+

B+

A-

A+

GND

+5V

J3(JMACH1)

Note

 For single-ended encoders, leave the complementary signal pins

floating – do not ground them. Alternately, some open collector
single ended encoders may require tying the negative pins to
ground in series with a 1-2 KOhm resistors.

 Some motor manufacturers bundle the hall sensors with the

motor-lead cable. The hall sensors must be brought into J7
connector.

Differential Quadrature Encoder Wiring for Channel #1

Setting up Quadrature Encoders

Digital Quadrature Encoders use the 1/T incremental entry in the encoder conversion table. Position and
velocity pointers should, by default, be valid and in most cases no software setup is required, activating
(Ixx00=1) the corresponding channel is sufficient to see encoder counts in the position window when the
motor/encoder shaft is moved by hand.

I100,4,100 = 1 ; Servo IC0 Channels 1-4 activated
I500,4,100 = 1 ; Servo IC0 Channels 5-8 activated (First Acc-1P)
I900,4,100 = 1 ; Servo IC0 Channels 9-12 activated (Second Acc-1P)

Setting up Sinusoidal Encoders

For sinusoidal position feedback, the Acc-51S, sine wave input interpolator, stacks on top of the Turbo
PMAC Clipper or on top of the Acc-1P 5-8 axis board. Channels 1 – 4 of the ACC-51S correspond to
PMAC channels 1 – 4 if the ACC-51S is connected to the main Turbo PMAC Clipper; channels 1 – 4 of
the ACC-51S correspond to PMAC channels 5 – 8 if the ACC-51S is connected to the ACC-1P board.

Connections and Software Setup 22

Turbo PMAC Clipper Hardware Reference Manual

Note

 ACC-51S channels 1 – 4 become PMAC channels 1 – 4 if ACC-

51S jumper E1 connects pins 2 and 3.

 ACC-51S channels 1 – 4 become PMAC channels 5 – 8 if ACC

51S jumper E1 connects pins 1 and 2.

Encoder Conversion Table Setup Example, Channel 1

1. Conversion Type: High res. interpolator, PMAC2 Style

2. Enter Source Address (see table below)

3. Enter A/D Converter Address (see table below)

4. A/D Bias: always zero

Channel #

Source

Address

A/D converter

Address

Channel #

Source

Address

A/D converter

Address

1

$78000

$78800

5 $78100

$78808

2

$78008

$78802

6 $78108

$7880A

3

$78010

$78804

7 $78110

$7880C

4

$78018

$78806

8 $78118

$7880E

Note

Results are found in the processed data address, which the position
and velocity feedback pointers (Ixx03, Ixx04) are usually assigned to.

The Sinusoidal position feedback is set up through the Encoder Conversion Table (ECT) as a high
resolution interpolation entry.

Connections and Software Setup 23

Turbo PMAC Clipper Hardware Reference Manual

Note

At this point of the setup, you should be able to move the
motor/encoder shaft by hand and see ‘motor’ counts in the position
window.

The equivalent Turbo PMAC script code for 8-channel entries

// Channel 1
I8000=$FF8000 ; High resolution interpolator (Clipper & Acc-51S)
I8001=$078800 ; A/D converter address (Clipper & Acc-51S)
I8002=$000000 ; Bias Term and Entry result (Clipper & Acc-51S)
// Channel 2
I8003=$FF8008 ; High resolution interpolator (Clipper & Acc-51S)
I8004=$078802 ; A/D converter address (Clipper & Acc-51S)
I8005=$000000 ; Bias Term and Entry result (Clipper & Acc-51S)
// Channel 3
I8006=$FF8010 ; High resolution interpolator (Clipper & Acc-51S)
I8007=$078804 ; A/D converter address (Clipper & Acc-51S)
I8008=$000000 ; Bias Term and Entry result (Clipper & Acc-51S)
// Channel 4
I8009=$FF8018 ; High resolution interpolator (Clipper & Acc-51S)
I8010=$078806 ; A/D converter address (Clipper & Acc-51S)
I8011=$000000 ; Bias Term and Entry result (Clipper & Acc-51S)
// Channel 5
I8012=$FF8100 ; High resolution interpolator (Acc-1P & Acc-51S)
I8013=$078808 ; A/D converter address (Acc-1P & Acc-51S)
I8014=$000000 ; Bias Term and Entry result (Acc-1P & Acc-51S)
// Channel 6
I8015=$FF8108 ; High resolution interpolator (Acc-1P & Acc-51S)
I8016=$07880A ; A/D converter address (Acc-1P & Acc-51S)
I8017=$000000 ; Bias Term and Entry result (Acc-1P & Acc-51S)
// Channel 7
I8018=$FF8110 ; High resolution interpolator (Acc-1P & Acc-51S)
I8019=$07880C ; A/D converter address (Acc-1P & Acc-51S)
I8020=$000000 ; Bias Term and Entry result (Acc-1P & Acc-51S)
// Channel 8
I8021=$FF8118 ; High resolution interpolator (Acc-1P & Acc-51S)
I8022=$07880E ; A/D converter address (Acc-1P & Acc-51S)
I8023=$000000 ; Bias Term and Entry result (Acc-1P & Acc-51S)

Position and Velocity feedback pointers should now be set to the corresponding ECT result:

I103=$3503 I104=$3503 ; (Clipper & Acc-51S)
I203=$3506 I204=$3506 ; (Clipper & Acc-51S)
I303=$3509 I304=$3509 ; (Clipper & Acc-51S)
I403=$350C I404=$350C ; (Clipper & Acc-51S)
I503=$350F I504=$350F ; (Acc-1P & Acc-51S)
I603=$3512 I604=$3512 ; (Acc-1P & Acc-51S)
I703=$3515 I704=$3515 ; (Acc-1P & Acc-51S)
I803=$3518 I804=$3518 ; (Acc-1P & Acc-51S)

Counts per User Units

With the interpolation of x 4096 in Turbo PMAC, there are 128 (4096/32) motor counts per sine/cosine
cycles. Motor counts can be monitored in the motor position window upon moving the motor by hand.
Examples:
A 1024 Sine/Cosine periods per revolution of a rotary encoder produces 1024 x 128 = 131,072 cts/rev.
A 20 μm linear encoder resolution produces 128/0.02 = 6400 cts/mm.

Connections and Software Setup 24

Turbo PMAC Clipper Hardware Reference Manual

25 23

Analog

Device

COM

DAC1+

49

50

47

48

45

46

43

44

41

42

39

40

37

38

35

36

33

34

31

32

29

30

27

28 26

Single Ended DAC Output

J3 (JMACH1)

Analog

Device

COM

DAC1-

DAC1+

25 2349

50

47

48

45

46

43

44

41

42

39

40

37

38

35

36

33

34

31

32

29

30

27

28 26

Differential DAC Output

J3 (JMACH1)

Note

The analog outputs are intended to drive high-impedance inputs with
no significant current draw (10mA max). The 220 output resistors

will keep the current draw lower than 50 mA in all cases and prevent
damage to the output circuitry, but any current draw above 10 mA can
result in noticeable signal distortion.

Wiring the DAC Output

Example for Clipper Channel #1

Connections and Software Setup 25