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
04/03/07
CP
S. SATTARI
2
CLEARED FOR RELEASE
12/07/07
CP
S.SATTARI
3
REVISED GENERAL PURPOSE IO CONNECTOR
ADDED MULTIPLEXED IO PORT INFO
ADDED PANASONIC PROGRAM SETUP INFO
ADDED PARAMETER PASSING INFO ON REALTIME
EXPRESS NETWORK
01/29/09
CP
S.SATTARI
4
CORRECTION IN J5 PIN-OUT TABLE
UPDATED WIRING FOR HANDWHEEL PORT IMAGE
Base Version ........................................................................................................................................ 2
Macro Ring Connector Options ............................................................................................................ 2
Using PMAC Motor Backlash Feature ................................................................................................ 42
Reading/Writing A4N/A5N Drive Parameters over the network .......................................................... 43
Accessing Returning Data from A4N/A5N Drives .............................................................................. 45
Using Absolute Feedback With A4N/A5N Drives ............................................................................... 47
Detecting Errors on A4N/A5N Network ............................................................................................. 47
Table of Contents
Turbo PMAC2 Realtime Express Controller
1
INTRODUCTION
Overview
The Turbo PMAC2 Realtime Express Controller is a member of the Turbo PMAC family of
boards optimized for interface to the system through Panasonic’s Realtime Express Network. It
can command up to 32 axes through Realtime Express Network. This controller is also capable of
communicating and control of MACRO drives and IO modules if ordered with the MACRO
option.
The Turbo PMAC2 Realtime Express Controller is a stand-alone unit which can be
communicated with via RS-232, USB or Ethernet connections, with or without the optional dualported RAM.
This controller is also capable of Fieldbus communications when the appropriate option is
ordered. The form factor of this connection is dependent on which Fieldbus protocol is being
utilized and it supports the following protocols:
The protocol is dependent upon which hardware and option are selected. The hardware cannot be
programmed for an alternate protocol including master/slave.
Compatibility
This controller can be used to control Panasonic A4N/A5N Drives over the Realtime Express
network. This network utilizes the Ethernet type CAT-5 cable as the communication medium, but
should not be connected to any other Ethernet network.
Note
Currently, the controller only supports single block slave nodes.
If ordered with the MACRO option, this controller can control MACRO drives and I/O devices
over either the fiber optic MACRO ring or copper MACRO ring.
Introduction
Turbo PMAC2 Realtime Express Controller
2
Configuration
Base Version
The base version of the Turbo PMAC2 Realtime Express Controller 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)
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 pre-requisites.
Introduction
Turbo PMAC2 Realtime Express Controller
3
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.
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 two 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.
Introduction
Turbo PMAC2 Realtime Express Controller
4
9-3862-2-0
Turbo PMAC2 Realtime Express
Communication Options
CF
A
F
H
H
C0 - Opt. 5C0 80MHz
DSP563xx CPU
256Kx24 SRAM
1Mx8 flash*
(Standard)C3 - Opt. 5C3 80MHz
DSP563xx CPU
1024Kx24 SRAM
4Mx8 flash*
F3 - Opt. 5F3 240MHz
DSP563xx CPU
1024Kx24 SRAM
4Mx8 flash*
CPU / Memory / Firmware
Options
C
2 - PMAC2 (Standard)*
D
D
0 - No Option
3 - Opt. 18A
Electronic board
Identification
AB
B
LK
00 - No Additional* Options
xx - Factory assigned digitsfor Additional* Options
K
L
Factory Assigned 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.
Based on the different options of Turbo PMAC 2 Realtime Express Controller, there will be a
single line part number which is used for ordering and identification. The part number is assigned
based on the following chart:
For detailed information on any of these options, please refer to the previous section of this
manual.
Introduction
Turbo PMAC2 Realtime Express Controller
5
HARDWARE SETUP
Receiving and Unpacking
Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment.
When the Turbo PMAC2 Realtime Express Controller 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 controller.
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 controller received is the same as the part number
listed on the purchase order.
4. Inspect the controller 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 it is stored in a
location conforming 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, non-
flammable 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 Realtime Express Controller 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 controller. 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
Turbo PMAC2 Realtime Express Controller
6
The controller is mounted to the back panel with four M4 screws and internal-tooth lock washers.
It is important that the teeth break through any anodization on the controller’s mounting gears to
provide a good electrically conductive path in as many places as possible. Mount the controller on
the back panel so there is airflow at both the top and bottom areas of the controller (at least three
inches).
Caution:
Units 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]).
Mechanical Drawing
The figures below show the mounting dimensions of the controller.
Note:
For more detailed drawings (SolidWorks, eDrawings, DXF), visit our
website at http://www.deltatau.com.
Hardware Setup
Turbo PMAC2 Realtime Express Controller
7
12345678
9101112131415
12345678910111213
141516171819202122232425
12345678910111213141516171819202122232425
26
1
2
3
4
5
6
7
8
9
10
12345
6789
12345
6789
Handwheel
DAC output
ADC Input
Pulse and Direction
J8 AUXJ5 General I/OJ10 JTHW
MACRO
RJ45
OUT
IN
MACRO
FIBER
OUT
IN
ETHERNET
USB
FIELDBUS
SETUP
FIELDBUS
RDY
RUN
ERR
STA/MOD
FIELDBUS
INTERFACE
RS-232
FW LOAD
RE-INIT
24VDC
INPUT
GND
+24VDC
8 Sinking/Sourcing Digital Inputs
4 Sourcing/Sinking Digital Outputs
Watchdog relay contacts
1 Sinking/Sourcing Input
8 Inputs / 8 Outputs
TTL Level
(typically used to
create multiplexed I/O
with accessory boards)
The Macro Connector will be used to form a
ring between all the MACRO components of
the system.
For RJ-45 connector, standard CAT-5 or CAT-
6 cables with standard RJ-45 connection can
be used to form the ring.
For FIBER option, fiber cable with SC-style
connectors is used as communication medium
between the MACRO stations
Ethernet connection can be used either for
communication between the unit and a PC as
user interface or with MODBUS option it can
be configured as MODBUS MASTER or
SLAVE for expanding the control solution.
USB connection can be used either for
communication between the unit and a PC as
user interface.
FIELDBUS connector gets connected directly
to the Hilscher module inside the unit and the
SyCon software for setting up the module
The FIELDBUS connector is the main
connector between the Hilscher module and
the optional FieldBus network. Please check
the pin out configuration section carefully.
Serial Connection (RS-
232) can be used to talk to
the CPU directly. Since the
parser on this port can be
turned off, it can also be
used for communicating to
the 3rd party devices over
RS-232
By holding FW LOAD micro-switch while
power-up, you can place the card in
Bootstrap mode for loading firmware
By holding RE-INIT micro-switch while power-
up, the card will load the factory default
settings instead of saved settings on FLASH
24VDC
0.75 A continues
1.8 A start up
TX
RX
The TX and RX connectors get connected to
A4N/A5N Drives from Panasonic.
System Wiring
Hardware Setup
Turbo PMAC2 Realtime Express Controller
8
Push-button Switches
There are two push-button switches located at the bottom of the unit next to the 24V power
supply input. These buttons are accessible for reinitializing the board back to factory default
settings and loading new firmware revisions.
FW LOAD switch
The FW LOAD switch is used to download new firmware to the controller. In order to use this
switch, you need to hold the switch pressed while powering up the system. This will cause the
system to go to bootstrap mode, after which you can use Delta Tau’s Executive software to
download the new firmware to the controller.
RE-INIT switch
The RE-INIT switch will cause the controller to reset to factory default settings. To use this
function, you need to hold down the switch while powering up the system. This will stop the
controller to load your settings from the EEPROM and load factory default settings instead.
Although your settings is not loaded once you power up holding the RE-INIT switch, your
settings are still available in the EEPROM, until you overwrite them with a SAVE command.
Caution:
Loading the factory default settings for this specific controller will stop the
normal functioning of the system over the MACRO and/or Realtime
Express Ring. To get the controller to communicate over the ring, you
need to download the backup settings file available from Delta Tau’s
website at http://www.deltatau.com.
Connections
USB Connection, J1
This connector is used in conjunction with USB A-B cable, which can be purchased from any
computer store. The A connector is connected to a PC or hub device and the B connector plugs
into the J1-USB port. USB drivers are always included in the latest software packages from Delta
Tau’s website at http://www.deltatau.com.
Note:
Since the USB connector will connect the ground on the
controller and computer together, make sure that computer and
the controller have the same voltage ground, i.e., that they are
connected to the same power line.
Hardware Setup
Turbo PMAC2 Realtime Express Controller
9
Pin #
Symbol
Function
1
VCC
N.C.
2
D-
DATA-
3
D+
DATA+
4
GND
Ground
5
SHELL
Shield
6
SHELL
Shield
J2
RJ-45 Female Connector
1
Pin #
Symbol
Function
1
TX+
Transmit line
2
TX-
Transmit line
3
Unused
4
Unused
5
Unused
6
Unused
7
RX +
Receive line
8
RX -
Receive line
Amber LED
Activity
Blinking indicates transmit/receive activity
Green LED
Link
Solid Green indicates a valid connection
Ethernet / Modbus Connection, J2
This connector is used for Ethernet communications from the Turbo PMAC2 Eth Ultralite to a PC
or into an Ethernet network. The default IP address for all Delta Tau products with Ethernet
communication capability is 192.6.94.5 which can be changed later with the proper software
provided by Delta Tau.
This port can support Modbus communication and can act as either Server or Client on a Modbus
Network. There are four sockets available on this port and each of them can be configured as
Modbus Server/ Modbus Client / PMAC ASCII or PMAC INTR. If you want to use this port for
communication purposes with the controller, you need to set at least one of the sockets to PMAC
ASCII.
Note:
Delta Tau Systems strongly recommends the use of RJ45 CAT5e or better
shielded cable.
Newer network cards have the Auto-MDIX feature that eliminates the need
for crossover cabling by performing an internal crossover when a straight
cable is detected during the auto-negotiation process.
For older network cards, one end of the link must perform media dependent
interface (MDI) crossover (MDIX), so that the transmitter on one end of the
data link is connected to the receiver on the other end of the data link (a
crossover/patch cable is typically used). If an RJ45 hub is used, then a regular
straight cable must be implemented.
Maximum length for Ethernet cable should not exceed 100m (330ft).
Hardware Setup
Turbo PMAC2 Realtime Express Controller
10
J3
10- pin Male Flat ribbon header
connector (IDC)
123456789
10
Pin #
Symbol
Function
1
N.A.
N.C.
2
HilDTR
Data terminal ready (DTR)
3
HilTxD-
Transmit Data (TXD)
4
HilCTS
Clear to Send (CTS)
5
HilRxD-
Receive Data (RXD)
6
HilRTS
Request to Send (RTS)
7
HilDSR
Data Set Ready (DSR)
8
N.A.
N.C.
9
GND
Signal Ground
10
+5V
+5 VDC output
Profibus
J4
DB9 Female
12345
6789
Pin #
Symbol
Function
1
N.C.
2
+5VDC
Positive Power Supply
3
RXD/TXD-P RS 485
Receive / Send Data –P
4
CNTR-P
Control Counter TTL
5
DGND*
Reference Ground *
6
+5VDC
Positive Power Supply
7
N.C.
8
RXD/TXD-N RS 485
Receive / Send Data -N
9
N.C.
* E8 jumper should be in 1-2 position
Fieldbus Setup Connector, J3
This connector is a 10-pin female flat cable connector that is directly connected to the Fieldbus
communication device installed in the system based on order options. Use SyCon program to set
up the communication module. SyCon is a universal Fieldbus configuration tool developed by
Hilscher Corporation used to configure the PMAC Gateway. Delta Tau has licensed SyConas part
of the PMAC Gateway product. The Hilscher license agreement, which will be presented during
the installation process, still applies.
Besides being able to configure Fieldbus systems like ProfiBus, DeviceNet, CANopen, and
ControlNET, SyCon can also configure Interbus, SDS, etc. The usefulness is that SyCon becomes
a common tool providing consistent user interface for all protocols for both masters and slaves.
SyCon checks the dependencies between the devices, checks for configuration conflicts and
warns of possible errors. Some protocols support standardized files containing information about
all features and limitations of the slave device. SyCon uses these files for the configuration.
After the configuration, switch SyCon into a diagnostic mode. In diagnostic mode, you can
monitor status information of all devices connected to the network. For example, the node list or
slave diagnostic information can be monitored. If a slave is not operating correctly, it will be
displayed in a different color, normally red. The base address for master modules is located at
memory location $6D000 and for slave modules at $6D700.
This Female DB-9 connector is connected to the Fieldbus module inside the board and the
communication to the network will be conducted through this port. This will have different pin
out descriptions based on the module installed in the controller.
Hardware Setup
Turbo PMAC2 Realtime Express Controller
11
Hardware Setup
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