Delta Tau TURBO PMAC2 VME ULTRALITE User Manual

^1 HARDWARE REFERENCE MANUAL

^2 Turbo PMAC2 VME Ultralite

^3 Programmable Multi-Axis Controller

^4 4Ax-603616-xHxx

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

21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com

^5 May 26 2004

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: (818) 717-5656 Fax: (818) 998-7807 Email: support@deltatau.com 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.

Turbo PMAC2 VME Ultralite

Table of Contents

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

Board Configuration................................................................................................................................................1

Base Version.......................................................................................................................................................1

MACRO Ring Connector Options ......................................................................................................................1

Option 1: Additional MACRO Interface Ics......................................................................................................2

Option 2: Dual-Ported RAM .............................................................................................................................2

Option 5: CPU and Memory Configurations ....................................................................................................2

Option 7: Plate Mounting..................................................................................................................................3

Option 8: High-Accuracy Clock Crystal ...........................................................................................................3

Option 9: Auxiliary Serial Port .........................................................................................................................3

Option 10: Firmware Version Specification......................................................................................................3

Option 16A: Battery-Backed Parameter Memory.............................................................................................3

Option 18A: Electronic Identification ...............................................................................................................3

JUMPER DESCRIPTION........................................................................................................................................5

E0: Reset Lock Enable...........................................................................................................................................6

E1: Card 0 (Clock Direction) Select.......................................................................................................................6

E2: 40/60 MHz Operation......................................................................................................................................6

E3: Re-Initialization on Reset Control...................................................................................................................6

E4-E6: (Reserved for Future Use)..........................................................................................................................6

E10A, B, C: Flash Memory Bank Select.................................................................................................................6

E17 – E18: Serial Port Select.................................................................................................................................7

E19: Watchdog Disable Jumper..............................................................................................................................7

E20 – E22: Power-Up/Reset Load Source..............................................................................................................7

E23: Firmware Reload Enable ................................................................................................................................7

E40: Electrical/Optical MACRO Input Select ........................................................................................................7

SOFTWARE SETUP ................................................................................................................................................9

PMAC I-Variables ..................................................................................................................................................9

MATING CONNECTORS.....................................................................................................................................11

J1: JTAG/OnCE (for Factory Use Only): 10-pin IDC Header.......................................................................11

J2 (JTHW)/Multiplexer Port.............................................................................................................................11

J3 (JIO)/Digital I/O..........................................................................................................................................11

J5 (JRS232)/RS-232 Serial Communications...................................................................................................11

J5A (JRS422)/RS-422 Serial Communications.................................................................................................11

J6 (JDISP)/Display...........................................................................................................................................11

J7 (JHW)/Auxiliary Channel ............................................................................................................................11

J9: JISP (for Factory Use Only): 8-pin SIP Connector ..................................................................................11

J11 (JEXP)/Expansion......................................................................................................................................11

J14: MACRO Electrical Input Connector: 8-pin RJ-45 Socket.......................................................................11

J17: MACRO Electrical Output Connector: 8-pin RJ-45 Socket....................................................................11

P1: VME Bus 3U Connector ............................................................................................................................11

P2: VME Bus 3U Connector ............................................................................................................................11

TB1: JPWR Power Supply Connector: 2-point Terminal Block......................................................................11

TB2: WD Watchdog Output Connector: 4-point Terminal Block ...................................................................11

U4: MACRO Fiber Optic Transceiver: Double SC Fiber-Optic Socket .........................................................11

CONNECTOR PINOUTS ......................................................................................................................................13

J2 (JTHW) Multiplexer Port Connector................................................................................................................13

J3 (JI/O) General Input/Output Connector............................................................................................................14

J3/JIO (40-Pin Header) ....................................................................................................................................14

J5 (JRS232) Serial Port Connector........................................................................................................................15

J5/JRS232 (10-Pin Header)..............................................................................................................................15

Table of Contents i

Turbo PMAC2 VME Ultralite

J5A: RS422 Serial Port Connector........................................................................................................................16

J5A/JRS422 (26-Pin Header)...........................................................................................................................16

J6 (JDISP) Display Connector ..............................................................................................................................17

J6/JDISP (14-Pin Header) ...............................................................................................................................17

J7 (JHW) Handwheel Encoder Connector............................................................................................................17

J7/JHW (20-Pin Header)..................................................................................................................................17

TB1 (2/4-Pin Terminal Block)..............................................................................................................................17

TB2 (4-Pin Terminal Block).................................................................................................................................18

MACRO Interface Connectors..............................................................................................................................18

Option A: Fiber Optic Transceiver..................................................................................................................18

Option C: RJ-45 Phone Jack Connectors........................................................................................................18

SCHEMATICS........................................................................................................................................................19

ii Table of Contents

Turbo PMAC2 VME Ultralite

INTRODUCTION

The Turbo PMAC2 VME 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. It can also support up to 32 channels of off-board axis interface circuitry through its expansion port, connected to Acc-24P or Acc-24P2 boards.

The Turbo PMAC2 VME Ultralite is a VME-bus card. This card is capable of VME bus communications, with or without the optional dual-ported RAM. Standalone operation is also possible and communications can be done through RS-232 or RS-422.

Board Configuration

Base Version

The base version of the Turbo PMAC2 VME Ultralite provides –

• 80 MHz DSP56303 CPU (120 MHz PMAC equivalent)

• 128k x 24 SRAM compiled/assembled program memory (5C0)

• 128k x 24 SRAM user data memory (5C0)

• 1M x 8 flash memory for user backup & firmware (5C0)

• Latest released firmware version

• RS-232/422 serial interface, PCI bus interface

• One 16-node MACRO interface IC

• MACRO ring circuitry (without connectors; see Opts. A and C)

• (No on-board axis interface circuitry)

• Two channels supplemental interface circuitry, each including:

• 2-channel differential/single-ended encoder input

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

pair

• Display, MACRO, muxed I/O, direct I/O interface ports

• PID/notch/feedforward servo algorithms

• Extended pole-placement servo algorithms

• 1-year warranty from date of shipment

• One manual per set of one to four PMACs in shipment

(Cables, mounting plates, mating connectors 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 U4.

• Option C provides the MACRO-ring RJ-45 electrical interface connectors. The key components on

the board are J14 and J17.

Introduction 1

Turbo PMAC2 VME Ultralite

Option 1: Additional MACRO Interface Ics

The basic board has one MACRO interface IC and space for three more. Variations of Option 1 fill these spaces as follows:

• Option 1A provides the first additional MACRO interface IC (two 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 U23.

• Option 1B provides the second additional MACRO interface IC (three 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 U24. Option 1A is a pre-requisite.

• Option 1C provides the third additional MACRO interface IC (four total) for 16 additional MACRO

nodes, eight additional servo nodes and eight additional I/O nodes (64 nodes total, 32 servo and 32 I/O). The key component on the board is U25. Options 1A and 1B are pre-requisites.

Option 2: Dual-Ported RAM

Dual-ported RAM provides a high-speed communications path for bus communications with the host computer through a bank of shared memory. DPRAM is advised if more than about 100 data items per second are to be passed between the controller and the host computer in either direction. Option 2 provides a 32k x 16 bank of dual-ported RAM. The key component on the board is U191.

Option 5: CPU and Memory Configurations

The various 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 U56. The CPU is available in several speed options: 80 MHz CPU is a DSP56303 (Option 5Cx), 100 MHz CPU is a DSP56309 (Option 5Dx), and 160 MHz CPU is a DSP56311 (Option 5Ex). The maximum frequency of operation is indicated with a sticker on the CPU in U56.

The compiled/assembled-program memory SRAM ICs are located in U40, U43, and U47. 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 user-data memory SRAM ICs are located in U39, U42, and U46. 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 U45. 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: 80MHz DSP56303 CPU (8Kx24 internal memory), expanded 512Kx24 SRAM

compiled/assembled program memory, expanded 512Kx24 RAM user data memory, 4Mx8 flash memory.

• Option 5D0: 100MHz DSP56309 CPU (34Kx24 internal memory), 128Kx24 SRAM

compiled/assembled program memory, 128Kx24 SRAM user data memory, 1Mx8 flash memory.

2 Introduction

Turbo PMAC2 VME Ultralite

• Option 5D3: 100MHz DSP56309 CPU (34Kx24 internal memory), expanded 512Kx24 SRAM

compiled/assembled program memory, expanded 512Kx24 SRAM user data memory, 4Mx8 flash memory.

• Option 5E0 160MHz DSP56311 CPU (128Kx24 internal memory), 128Kx24 SRAM

compiled/assembled program memory, 128Kx24 SRAM user data memory, 1Mx8 flash memory.

• Option 5E3: 160MHz DSP56311 CPU (128Kx24 internal memory), expanded 512Kx24 SRAM

compiled/assembled program memory, expanded 512Kx24 SRAM user data memory, 4Mx8 flash memory.

Option 7: Plate Mounting

Option 7 provides a mounting plate connected to the PMAC with standoffs. It is used to install the PMAC in standalone applications.

Option 8: High-Accuracy Clock Crystal

The Turbo PMAC2 VME Ultralite has a clock crystal (component Y5 of nominal frequency 19.6608 MHz (~20 MHz). The standard crystal’s accuracy specification is +/-100 ppm. Option 8A provides a nominal 19.6608 MHz crystal with a +/-15 ppm accuracy specification.

Option 9: Auxiliary Serial Port

The Turbo PMAC2 VME Ultralite comes standard with a single serial port, configurable as RS-232 or RS-422. Optionally a second serial port can be added. Option 9T adds an auxiliary RS-232 port in the CPU section.

Option 10: Firmware Version Specification

Normally the Turbo PMAC2 VME Ultralite is provided with the newest released firmware version. A label on the U45 flash memory IC shows the firmware version loaded at the factory. Option 10 provides for a user-specified firmware version.

Option 16A: Battery-Backed Parameter Memory

The contents of the standard memory are not retained through a power-down or reset unless they have been saved to flash memory first. Option 16A provides a 32k x 24 bank of battery-backed parameter RAM in components U41, U44, and U48 for real-time parameter storage. This is ideal for holding machine state parameters in case of an unexpected power-down. The battery is located at component BT1.

Option 18A: Electronic Identification

Option 18A provides a module at location U67 that contains an electronic identification feature.

Introduction 3

Turbo PMAC2 VME Ultralite

4 Introduction

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