ADLINK Technology PCIe-7856 User manual

Leading EDGE COMPUTING
PCIe-7856/7853
Master-Slave Distributed Motion
and I/O Master Controller
User’s Manual
Manual Rev.: 1.1
Revision Date: Sept. 17, 2020
Part No: 50-15113-1010

ii Revision History
Leading EDGE COMPUTING
Revision History
Revision Release Date Description of Change(s)
1.0 2020-02-27 Initial release
1.1 2020-09-17 Add PCIe-7853; integrate HSL System
documentation

Preface iii
PCIe-7856/7853
Preface
Copyright © 2020 ADLINK Technology Inc.
This document contains proprietary information protected by copy-
right. All rights are reserved. No part of this manual may be repro-
duced by any mechanical, electronic, or other means in any form
without prior written permission of the manufacturer.
Disclaimer
The information in this document is subject to change without prior
notice in order to improve reliability, design, and function and does
not represent a commitment on the part of the manufacturer.
In no event will the manufacturer be liable for direct, indirect,
special, incidental, or consequential damages arising out of the
use or inability to use the product or documentation, even if
advised of the possibility of such damages.
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bility to global environmental preservation
through compliance with the European Union's
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enforced measures to ensure that our products,
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When products are at their end of life, our customers are encour-
aged to dispose of them in accordance with the product disposal
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Battery Labels (for products with battery)
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iv Preface
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Trademarks
Product names mentioned herein are used for identification pur-
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of their respective companies.
Conventions
Take note of the following conventions used throughout this
manual to make sure that users perform certain tasks and
instructions properly.
NOTE:
NOTE:
Additional information, aids, and tips that help users perform
tasks.
CAUTION:
Information to prevent minor physical injury, component dam-
age, data loss, and/or program corruption when trying to com-
plete a task.
WARNING:
Information to prevent serious physical injury, component
damage, data loss, and/or program corruption when trying to
complete a specific task.

v
PCIe-7856/7853
Table of Contents
Preface.................................................................................... iii
List of Figures........................................................................ ix
List of Tables.......................................................................... xi
1 Introduction ........................................................................ 1
1.1 Specifications....................................................................... 3
1.2 Supported Software ............................................................. 4
2 Installation .......................................................................... 5
2.1 Package Contents ............................................................... 5
2.2 PCIe-7856 Mechanical Drawing .......................................... 6
2.3 Driver Installation ................................................................. 7
2.3.1 PCIe-7856 .................................................................. 7
2.3.2 PCIe-7853 .................................................................. 7
2.4 Troubleshooting ................................................................... 7
2.5 Signal Connections.............................................................. 7
2.5.1 Connecting HSL/MNET Slave Modules...................... 8
2.5.2 RJ45 Pin Assignments ............................................... 9
2.5.3 HSL and Motionnet LED Indicators .......................... 10
2.6 SW1 Card ID Switch Settings ............................................ 11
3 MNET Master-Slave Motion System ............................... 13
3.1 MNET System Specifications ............................................ 14
3.1.1 Wiring Cables ........................................................... 15
3.1.2 MNET System Communication ................................ 16
3.2 MNET Motion Modules ...................................................... 18
3.2.1 Motion Module Mechanical Drawings....................... 20
4 HSL Slave Modules.......................................................... 23

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4.1 HSL Slave I/O Modules...................................................... 24
4.1.1 Discrete I/O Module .................................................. 24
4.1.2 Analog I/O Modules .................................................. 25
4.2 General Specifications ....................................................... 26
4.2.1 Digital I/O Modules ................................................... 26
4.2.2 Analog I/O Modules .................................................. 27
4.2.3 HSL Module DIP Switch ........................................... 28
4.2.4 Daughter Board/Module Dimensions........................ 29
4.2.5 Wiring Diagrams ....................................................... 32
4.2.6 Terminal Base Motion Control Modules.................... 36
4.2.7 Managing Slave Indexes in an HSL Network ........... 43
5 MotionCreatorPro 2 (MCP2)............................................. 47
5.1 About MCP2....................................................................... 47
5.2 How to Run MCP2 ............................................................. 47
5.3 MCP2 Features.................................................................. 48
5.3.1 Main Menu ................................................................ 48
5.3.2 HSL Distributed I/O Manager.................................... 51
5.3.3 MNET Distributed Motion Manager .......................... 53
5.4 MCP2 Error Codes............................................................. 62
6 Scan Time Table................................................................ 63
6.1 Full-duplex Mode ............................................................... 63
7 HSL LinkMaster Utility...................................................... 65
7.1 Software Installation........................................................... 66
7.2 ADLINK HSL LinkMaster Utility.......................................... 67
8 HSL Function Library ....................................................... 73
8.1 List of Functions................................................................. 73
8.2 Initialization and System Information ................................. 76
8.3 Error Codes........................................................................ 81
8.4 Timer Control ..................................................................... 84

vii
PCIe-7856/7853
8.5 Discrete I/O........................................................................ 87
8.6 Analog I/O.......................................................................... 96
9 How to Program with HSL Function Library................ 103
9.1 Programming with HSL DLL ............................................ 103
Important Safety Instructions............................................ 107
Getting Service.................................................................... 109

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List of Figures ix
PCIe-7856/7853
List of Figures
Figure 1-1: PCIe-7856 Block Diagram ............................................... 2
Figure 2-1: PCIe-7856 Mechanical Drawing ...................................... 6
Figure 2-2: LED Indicators on the PCIe-7856 .................................. 10
Figure 3-1: MNET Distributed Motion Control System ..................... 13
Figure 3-2: MNET System Communication Sequence .................... 17
Figure 3-3: MNET-MIA with MINAS A4 Servo Driver....................... 20
Figure 3-4: MNET-4XMO-(C) Mechanical Diagram ......................... 21
Figure 4-1: HSL Module DIP Switch Location.................................. 28
Figure 8-1: Type 1............................................................................ 89
Figure 8-2: Type 2............................................................................ 89
Figure 8-3: Type 3............................................................................ 90
Figure 9-1: Programming Flow....................................................... 103

xListofFigures
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List of Tables xi
PCIe-7856/7853
List of Tables
Table 3-1: MNET System Specifications ........................................ 14
Table 3-2: MNET Motion Module Series......................................... 18
Table 4-1: HSL Discrete I/O Module Series.................................... 24
Table 4-2: HSL Discrete I/O Module Selection Guide..................... 24
Table 4-3: HSL Analog I/O Module Series...................................... 25
Table 4-4: HSL Analog I/O Module Selection Guide....................... 25
Table 4-5: Digital I/O Module .......................................................... 26
Table 4-6: Analog I/O Modules ....................................................... 27

xii List of Tables
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Introduction 1
PCIe-7856/7853
1 Introduction
As industrial machine automation continues to advance, designers
require not only centralized control systems but also distributed
solutions to develop more complex machine applications. Distrib-
uted solutions provide many benefits such as lower maintenance,
reduced wiring, and easy integration of vast numbers of modules.
Motionnet (MNET) and High Speed Link (HSL) are innovative dis-
tributed motion and I/O technologies that enable time-deterministic
scanning of thousands of I/O points within milliseconds using the
master-slave architecture. The MNET bus further improves distrib-
uted motion control capability by providing control of up to 256
axes plus minimal command execution time for single-axis control.
The PCIe-7856 is a PCI Express interface card with two ports for
MNET and HSL systems for distributed motion and I/O modules
for a wide variety of machine automation applications.
HSL technology allows thousands of I/O points to be scanned at
the millisecond level in real time by means of the master-slave
architecture. Commercial Ethernet cables with RJ45 connectors
are used for simplified setup of HSL slave modules as close as
possible to sensor devices, resulting in dramatic wiring reduction.
System integrators can greatly benefit from an HSL network
because it integrates discrete I/O and analog I/O modules. This
local network features rapid-response, real-time scanning.
An MNET system is a distributed motion solution for machine sys-
tems. MNET is an innovative distributed motion technology which
provides distributed motion axis control of up to 256 axes for any
servo/stepper motor controlled using mater-slave architecture.
This not only facilitates general purpose 4-axis motion control, but
also allows up to 64 specific single-axis motion control modules to
be scanned at the millisecond level in real time.

2Introduction
Leading EDGE COMPUTING
MNET and HSL features:
 Flexible, comprehensive, extendable distributed motion and
I/O solution based on PC architecture or embedded platform.
Convenient wiring for remote distributed motion and I/O
modules, inc. multiple-axis motion control modules, single-
axis motion control modules, discrete I/Os, and analog I/Os.
Saves space, reduces wiring, and lowers costs due to ease
of maintenance.
Fast, time-deterministic scanning with hundreds of discrete
I/O points (up to 2,016 points).
Rapid, real-time scanning to support high-speed and high-
response motion control of up to 256 axes.
The PCIe-7856 block diagram is as follows.
Figure 1-1: PCIe-7856 Block Diagram

Introduction 3
PCIe-7856/7853
1.1 Specifications
PCIe-7856 PCIe-7853
Bus PCI Express x1, Plug and Play
Master Controller
Dedicated Motion Controller N/A
Motionnet ASIC master control
(80 MHz external clock) N/A
Dedicated I/O Controller:
HSL ASIC master control (48 MHz external Clock)
Interface
Motion
RS-485 with transformer
isolation N/A
Half duplex communication N/A
2.5/5/10/20 Mbps transmission
rate can be set by software
(20 Mbps default)
N/A
HSL
RS-422 with transformer isolation
Full duplex communication
3/6/12 Mbps transmission rate can be set by software
(6 Mbps default)
Connectors
RJ45 connector x4 (MRJ45
connector for Motionnet;
HRJ45 connector for HSL)
RJ-45 connector x2
(HRJ45 connector for HSL)
Interrupt Status read back
Storage
Temperature -20°C to +80°C (-4°F to 176°F)
Power
Consumption
+3.3 V @ 1.2 A (typical)
+5 V @ 1.5 A (typical)
Dimensions 119.5 mm x 100.2 mm (L x W) (4.66” x 3.9”)
Operating Systems Windows 10/8/7 (32/64 bit)
Software
Compatibility
VB, VC++, BCB, Delphi,
VB.net, C# compatible VB6, VC++, C# compatible
Various sample programs with source codes
Software
Recommendations APS SDK HSL LinkMaster Utility
Certifications FCC Part 15 B / EN 55032&55035

4Introduction
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1.2 Supported Software
Program Library
ADLINK provides Windows WDM drivers and DLL function librar-
ies for the PCIe-7856. These function libraries are shipped with
the board and they support Windows 7/8/10 (32/64-bit).

Installation 5
PCIe-7856/7853
2 Installation
This chapter describes how to install and set up the PCIe-7856.
Please follow these steps:
Check the product for any sign of defect or damage (use
Figure 2-1 on page 6 as a reference).
Install software drivers (Section 2.3, page 7).
Understand the I/O signal connections and how to use them
(Section 2.5 on page 7).
2.1 Package Contents
In addition to this User’s Guide, the package also includes the fol-
lowing item:
PCIe-7856: Distributed Motion and I/O Master Controller x1
or
PCIe-7853: High Speed Link Master Controller Controller x1
If any part of the item is missing or damaged, contact the dealer
from whom you purchased the product. Save the shipping materi-
als and carton to ship or store the product in the future.
Signal connections of all I/O’s are described later in this chapter.
Refer to the contents of this chapter before wiring any cables
between the PCIe-7856 and any slave module.

6Installation
Leading EDGE COMPUTING
2.2 PCIe-7856 Mechanical Drawing
Figure 2-1: PCIe-7856 Mechanical Drawing
MRJ45: MNET connection port
HRJ45: HSL connection port
SW1: Card identification switch
LEDGR1: HSL/Motionnet Scan LEDs
106.65 100.36
126.31
119.91
121.81
SW1
MRJ45
HRJ45
LEDGR1
Dimensions: mm

Installation 7
PCIe-7856/7853
2.3 Driver Installation
2.3.1 PCIe-7856
Open a web browser and navigate to the PCIe-7856/7853 product
web page (https://www.adlinktech.com/Products/Motion_Control/
DistributedMotionControl/PCIe-7856_7853). Under Technical
Resources, select Driver to see the list of available drivers. After
downloading the required ZIP file, extract and double-click the
enclosed executable file to run the installer. Follow the installation
steps and, after installation is complete, restart the PC.
2.3.2 PCIe-7853
Open a web browser and navigate to the PCIe-7856/7853 product
web page (https://www.adlinktech.com/Products/Motion_Control/
DistributedMotionControl/PCIe-7856_7853). Under Technical
Resources, select Driver to see the list of available drivers.
Download the HSL LinkMaster Utility for the PCIe-7853 and install
it, following the onscreen instructions.
2.4 Troubleshooting
If the system doesn’t boot or if the PCIe board exhibits any erratic
behavior, it is most likely caused by an interrupt conflict. After con-
firming the issue wasn’t caused by a simple oversight, the solution
can be found by consulting the BIOS documentation that comes
with your system. Check the Windows control panel on the con-
nected PC to see if the card is listed by the system. If not, check
the PCIe settings in the BIOS or use another PCIe slot.
2.5 Signal Connections
Signal connections of all I/O’s are described in the following two
sub-sections. Please review this information before wiring any
cables between the PCIe-7856 and slave modules.

8Installation
Leading EDGE COMPUTING
2.5.1 Connecting HSL/MNET Slave Modules
Wiring for MNET Motion Slave Modules
Wiring for HSL I/O Slave Modules
Ethernet Cable (CAT5e Recommended)
MNET Slave Modules
Ethernet Cable
MRJ45
HSL Slave Modules
Ethernet Cable
HRJ45
HSL Slave Modules
Ethernet Cable
HRJ45