Delta Tau TURBO PMAC2 ETHERNET ULTRALITE User Manual

^1 HARDWARE REFERENCE MANUAL

Turbo PMAC2 Eth Ultralite

^3 Programmable Multi-Axis Controller

^4 4xx-603862-1xx

^5 February 15, 2010

Single Source Machine Control Power // Flexibility // Ease of Use 21314 Lassen Street Chatsworth, CA 91311 // Tel. [phone] Fax. [phone] // www.deltatau.com

Copyright Information

© 2010 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	NEW MANUAL CREATION	06/27/08	CP	S. SATTARI
2	REVISED PART NUMBER DEFINITION, P. 4	01/28/09	CP	S.SATTARI
	UPDATED MECHANICAL DRAWING, P. 6
	UPDATED SYSTEM WIRING, P. 7
	UPDATED J5 & J8 PINOUTS/CONNECTORS, P.12,14
	ADDED J10 INFORMATION, P. 18
3	CORRECTION IN J5 PIN-OUT TABLE	02/15/10	CP	S.SATTARI
	UPDATED WIRING FOR HANDWHEEL PORT IMAGE

Turbo PMAC2 Eth Ultralite Manual

Table of Contents
INTRODUCTION ........................................................................................................................................	1
Overview ....................................................................................................................................................	1
Configuration..............................................................................................................................................	1
Base Version ...........................................................................................................................................	1
Part Number Definition ..............................................................................................................................	4
HARDWARE SETUP..................................................................................................................................	5
Receiving and Unpacking...........................................................................................................................	5
Mounting ....................................................................................................................................................	5
Mechanical Drawing...................................................................................................................................	6
System Wiring ............................................................................................................................................	7
Pushbutton Switches...................................................................................................................................	8
FW LOAD switch ....................................................................................................................................	8
RE-INIT switch........................................................................................................................................	8
Connections ................................................................................................................................................	8
USB Connection, J1 ................................................................................................................................	8
Ethernet / Modbus Connection, J2..........................................................................................................	9
Fieldbus Setup Connector, J3 ...............................................................................................................	10
Fieldbus Connection, J4 (Fieldbus option required) ............................................................................	10
General Purpose I/O Connection, J5....................................................................................................	12
Auxiliary Connector, J8 ........................................................................................................................	14
24 VDC Power Supply Input, J9 ...........................................................................................................	17
MACRO Connector...............................................................................................................................	18
Thumbwheel Multiplexer Port (JTHW Port), J10 .................................................................................	18
SOFTWARE SETUP .................................................................................................................................	21
Host Communications ..............................................................................................................................	21
Pewin32PRO2 Communication Setup...................................................................................................	21

TABLE OF CONTENTS

i

Turbo PMAC2 Eth Ultralite Manual

Introduction

Overview

The Turbo PMAC2 Eth Ultralite is a member of the Turbo PMAC family of boards optimized for interface to the system through the MACRO ring and therefore does not contain on-board axis interface circuitry (which is what makes it Ultralite). It can command up to 32 axes through the MACRO ring.

The Turbo PMAC2 Eth Ultralite is a stand-alone unit which can be communicated with via RS232, USB or Ethernet connections. However, the dual-ported RAM can only be accessed over USB or Ethernet for high speed communication with the controller.

This controller is also capable of Fieldbus communications when the appropriate option is ordered. The pin out of this connection is dependent on which Fieldbus protocol is being utilized and it supports the following protocols:

•	ProfiBus Master	Opt-G1
•	ProfiBus Slave	Opt-G2
•	DeviceNet Master	Opt-G3
•	DeviceNet Slave	Opt-G4
•	CANopen Master	Opt-G5
•	CANopen Slave	Opt-G6
•	CC-Link Slave	Opt-GB

The protocol is dependent upon which hardware and therefore option is selected. The hardware cannot be programmed for an alternate protocol including master/slave.

Additional I/O points are available through a Thumbwheel port which supports multiplexed I/O devices such as ACC-34AA or Opto-22 digital I/O modules.

Configuration

Base Version

The base version of the Turbo PMAC2 Eth Ultralite provides:

•80 MHz DSP56303 CPU

•128k x 24 SRAM compiled/assembled program memory

•128k x 24 SRAM user data memory

•1M x 8 flash memory for user backup & firmware

•32k x 16 bank of dual-ported RAM

•Latest released firmware version

•RS-232 serial interface, USB 2.0 & Ethernet Communication

•(No on-board axis interface circuitry)

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Turbo PMAC2 Eth Ultralite Manual

•Two channels supplemental interface circuitry, each including: o 2-channel differential/single-ended encoder input

o One output command signal set, configurable as pulse-and-direction or PWM top-and-bottom pair

•Direct I/O interface port

•1-year warranty from date of shipment

(Cables not included)

Macro Ring Connector Options

If a MACRO interface is desired (which is the usual reason for use of the board), at least one of the MACRO connector options must be selected.

•Option A provides the MACRO-ring fiber optic SC-style interface connector. The key component on the board is U49.

•Option C provides the MACRO-ring RJ-45 electrical interface connectors. The key components on the board are CN3 and CN4.

Option 1: Additional MACRO Interface ICs

•Option 1A provides the first additional MACRO interface IC (2 total) for 16 additional MACRO nodes, eight additional servo nodes and eight additional I/O nodes (32 nodes total, 16 servo and 16 I/O). The key component on the board is U41.

•Option 1B provides the second additional MACRO interface IC (3 total) for 16 additional MACRO nodes, eight additional servo nodes and eight additional I/O nodes (48 nodes total, 24 servo and 24 I/O). The key component on the board is U42. Option 1A is a pre-requisite.

•Option 1C provides the third additional MACRO interface IC (4 total) for 16 additional MACRO nodes, eight additional servo nodes and 8 additional I/O nodes (64 nodes total, 32 servo and 32 I/O). The key component on the board is U43. Options 1A and 1B are prerequisites.

Option 5: CPU and Memory Configurations

Different versions of Option 5 provide different CPU speeds and main memory sizes. Only one Option 5xx may be selected for the board. The CPU is a DSP563xx IC as component U1. The CPU is available in two speed options: 80MHz CPU is a DSP56303 (Option 5C0), 240 MHz CPU is a DSP56321 (Option 5F3). The maximum frequency of operation is indicated with a sticker on the CPU in U1.

The compiled/assembled-program memory SRAM ICs are located in U30, U31, and U32. These ICs form the active memory for the firmware, compiled PLCs, and user-written phase/servo algorithms. These can be 128k x 8 ICs (for a 128k x 24 bank), fitting in the smaller footprint, or they can be the larger 512k x 8 ICs (for a 512k x 24 bank), fitting in the full footprint. The userdata memory SRAM ICs are located in U27, U28, and U29. These ICs form the active memory for user motion programs, uncompiled PLC programs, and user tables and buffers. These can be 128k x 8 ICs (for a 128k x 24 bank), fitting in the smaller footprint, or they can be the larger 512k x 8 ICs (for a 512k x 24 bank), fitting in the full footprint.

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Turbo PMAC2 Eth Ultralite Manual

The flash memory IC is located in U26. This IC forms the non-volatile memory for the board’s firmware, the user setup variables, and for user programs, tables, and buffers. It can be 1M x 8, 2M x 8, or 4M x 8 in capacity.

•Option 5C0: Default CPU speed and memory configuration: 80MHz DSP56303 CPU (8Kx24 internal memory), 128Kx24 SRAM compiled/assembled program memory, 128Kx24 SRAM user data memory, 1Mx8 flash memory.

•Option 5C3: Default CPU speed and memory configuration: 80MHz DSP56303 CPU (8Kx24 internal memory), expanded 512Kx24 SRAM compiled/assembled program memory, expanded 512Kx24 SRAM user data memory, 4Mx8 flash memory.

•Option 5F3: 240MHz DSP56321 CPU (192Kx24 internal memory), expanded 512Kx24 SRAM compiled/assembled program memory, expanded 512Kx24 SRAM user data memory, 4Mx8 flash memory.

Option 10: Firmware Version Specification

Normally the Turbo PMAC2 Eth Ultralite is provided with the newest released firmware version. The response to the VERSION query command shows which firmware revision is presently installed. Option 10 provides for a user-specified firmware version.

Option 12: Analog-to-Digital and Digital-to-Analog Converters

Option 12 permits the installation of 2 channels of on-board analog-to-digital converters and one channel of on-board digital-to-analog converter.

The analog inputs are not optically isolated, and each can have a +/- 10V input range, or a +/-5V input range if differential signal is used, individually selectable with a 12-bit resolution.

The analog output is a 12-bit DAC have +/-10V output range.

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Turbo PMAC2 Eth Ultralite Manual

Part Number Definition

Based on the different options available for the Turbo PMAC 2 Eth Ultralite, there will be a single line part number used for ordering and identification. The assigned part number is based on the following chart:

Turbo PMAC2 ETH Ultralite					A	B		C	D	E	F	G	H	J	K	L
5	-	3	8	6	2		-	2				-		0

A B C

C0 - Opt. 5C0 80MHz DSP 563xx CPU 256Kx24 SRAM 1 Mx8 flash*

(Standard)

C3 - Opt. 5C3 80MHz DSP 563xx CPU 1024Kx24 SRAM 4 Mx8 flash*

F3 - Opt. 5F3 240MHz DSP 563xx CPU 1024Kx24 SRAM 4 Mx8 flash*

2 - PMAC2 (Standard)*

D

0 - No Option

3- Opt. 18A

Electronic board Identification

CPU / Memory / Firmware

Options

E

2 - Opt. A

MACRO -ring

fiber optic interface

3 - Opt. C

MACRO -ring

RJ -45 electrical interf.

F

4 - No Option

(Standard)

5 - Opt. 2B

Dual Port. RAM

6 - Opt. 15F

ModBus Comm.

7 - Opt. 2B & Opt. 15F

Dual Port. RAM

&

ModBus Comm.

Communication Options

*If Opt. 10xx (specific firmware version) or any other Additional Option is required, contact factory for digits K and L (Factory Assigned digits).

If Opt . 10xx is not ordered the latest firmware is used.

			G				J
	2 – Opt. 1A 8 servo, 6 I/O					0 - No Options
			and 2 communic. Nodes			1	- Opt. G1
			(Standard)
	3 – Opt. 1B 16 servo, 12 I/O						Profibus Master
			and 4 communic. nodes			2	- Opt. G2
	4 – Opt. 1C 24 servo, 18 I/O
							Profibus Slave
			and 6 communic. nodes
	5 – Opt. 1D 32 servo, 24 I/O					3	- Opt. G3
			and 8 communic. nodes				DeviceNet Master
	Axis / MACRO Node Options					4	- Opt. G4
							DeviceNet Slave
			H			5	- Opt. G5
							CanOpen Master
			0 - No Options			6	- Opt. G6
			1 - Opt. 12				CanOpen Slave
						7	- Opt. GB
			2 -channels12-bit
			A /D converter &				CC-Link Slave
			1 12-bit D/A converter
							Other Options
			K			L

00 - No Additional* Options

xx - Factory assigned digits

H

for Additional* Options

Factory Assigned Options

For detailed information on any of these options, please refer to the previous section of this manual.

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Turbo PMAC2 Eth Ultralite Manual

Hardware Setup

Receiving and Unpacking

Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the Turbo PMAC2 Eth Ultralite is received, do the following immediately:

1.Inspect the condition of the shipping container and report any damage immediately to the commercial carrier that delivered the drive.

2.Remove the controller from the shipping container and remove all packing materials. Check all shipping material for connector kits, documentation, diskettes, CD ROM, 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.

3.Verify that the part number of the drive received is the same as the part number listed on the purchase order.

4.Inspect the drive for external physical damage that may have been sustained during shipment and report any damage immediately to the commercial carrier that delivered the controller.

5.Electronic components in this controller are design-hardened to reduce static sensitivity. However, use proper procedures when handling the equipment.

6.If the controller 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 stated in this manual.

Mounting

The location of the control 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 control.

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

•For effective cooling and maintenance, the control should be mounted on a smooth, nonflammable vertical surface.

•At least 3 inches (76mm) top and bottom clearance must be provided for airflow. At least 0.4 inches (10mm) clearance is required between controls (each side).

•Temperature, humidity and vibration specifications should also be taken in account.

The Turbo PMAC2 Eth Ultralite can be mounted with a traditional 2-hole panel mount, one U shape/notch on the bottom and one pear shaped hole on top.

The controller 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 mounting bolt pattern of the drive. Make sure that all metal chips are cleaned up before the controller is mounted so there is no risk of getting metal chips inside the controller.

HARDWARE SETUP

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