ADLINK Technology PCI-8154 User manual

Advance Technologies; Automate the World.
Manual Rev. 2.00
Revision Date: February 22, 2006
Part No: 50-11146-1000
PCI-8154
Advanced & Modulized
4-Axis Servo / Stepper
Motion Control Card
User’s Manual

Copyright 2007 ADLINK TECHNOLOGY INC.
All Rights Reserved.
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, spe-
cial, 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.
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.
Trademarks
NuDAQ, NuIPC, DAQBench are registered trademarks of ADLINK
TECHNOLOGY INC.
Product names mentioned herein are used for identification pur-
poses only and may be trademarks and/or registered trademarks
of their respective companies.

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Please contact us should you require any service or assistance.
ADLINK TECHNOLOGY INC.
Web Site: http://www.adlinktech.com
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Table of Contents i
Table of Contents
Table of Contents..................................................................... i
List of Tables........................................................................... v
List of Figures........................................................................ vi
1 Introduction ........................................................................ 1
1.1 Features............................................................................... 4
1.2 Specifications....................................................................... 6
1.3 Supported Software............................................................. 8
Programming Library ......................................................8
MotionCreatorPro ...........................................................8
1.4 Available Terminal Board..................................................... 8
2 Installation .......................................................................... 9
2.1 Package Contents ............................................................... 9
2.2 PCI-8154 Outline Drawing................................................. 10
2.3 PCI-8154 Hardware Installation......................................... 11
Hardware configuration .................................................11
PCI slot selection ..........................................................11
Installation Procedures .................................................11
Troubleshooting4: .........................................................11
2.4 Software Driver Installation................................................ 13
2.5 CN3 Pin Assignments: Main Connector ............................ 13
2.6 K1/K2 Pin Assignments: Simultaneous Start/Stop ............ 15
2.7 JP2 to JP9 Jumper Setting for Pulse Output ..................... 15
2.8 SW1 Card Index Selection................................................. 16
2.9 CN4 Manual Pulsar............................................................ 17
3 Signal Connections.......................................................... 19
3.1 Pulse Output Signals OUT and DIR .................................. 20
3.2 Encoder Feedback Signals EA, EB and EZ....................... 23
3.3 Origin Signal ORG............................................................. 26
3.4 End-Limit Signals PEL and MEL........................................ 27
3.5 In-position Signal INP ........................................................ 28
3.6 Alarm Signal ALM.............................................................. 29
3.7 Deviation Counter Clear Signal ERC................................. 30
3.8 General-purpose Signal SVON.......................................... 31

ii Table of Contents
3.9 General-purpose Signal RDY ............................................ 32
3.10 Multi-Functional output pin: DO/CMP ................................ 33
3.11 Multi-Functional input pin: DI/LTC/SD/PCS/CLR/EMG...... 34
3.12 Pulser Input Signals PA and PB (PCI-8154)...................... 35
3.13 Simultaneously Start/Stop Signals STA and STP.............. 36
4 Operation Theory.............................................................. 39
4.1 Classifications of Motion Controller.................................... 39
Voltage motion control interface ...................................39
Pulse motion control interface ......................................40
Network motion control interface ..................................40
Software real-time motion control kernel ......................41
DSP motion control kernel ............................................41
ASIC motion control kernel ...........................................41
Compare Table of all motion control types ...................42
PCI-8154 motion controller type ...................................42
4.2 Motion Control Modes........................................................ 43
Coordinate system ........................................................43
Absolute and relative position move .............................44
Trapezoidal speed profile .............................................45
S-curve and Bell-curve speed profile ............................46
Velocity mode ...............................................................48
One axis position mode ................................................49
Two axes linear interpolation position mode .................50
Two axes circular interpolation mode ...........................51
Continuous motion ........................................................52
Home Return Mode ......................................................55
Home Search Function .................................................62
Manual Pulser Function ................................................63
Simultaneous Start Function .........................................63
Speed Override Function ..............................................64
Position Override Function ...........................................65
4.3 The motor driver interface.................................................. 66
Pulse Command Output Interface ................................66
Pulse feedback input interface ......................................69
In position signal ...........................................................71
Servo alarm signal ........................................................71
Error clear signal ...........................................................72
Servo ON/OFF switch ...................................................72
Servo Ready Signal ......................................................73

Table of Contents iii
Servo alarm reset switch ..............................................73
4.4 Mechanical switch interface............................................... 74
Original or home signal .................................................74
End-Limit switch signal .................................................74
Slow down switch .........................................................74
Positioning Start switch .................................................75
Counter Clear switch ....................................................75
Counter Latch switch ....................................................75
Emergency stop input ...................................................75
4.5 The Counters..................................................................... 76
Command position counter ...........................................76
Feedback position counter ............................................77
Command and Feedback error counter ........................77
General purpose counter ..............................................78
Target position recorder ................................................78
4.6 The Comparators............................................................... 79
Soft end-limit comparators ............................................79
Command and feedback error counter comparators ....79
General comparator ......................................................79
Trigger comparator .......................................................80
4.7 Other Motion Functions ..................................................... 81
Backlash compensation and slip corrections ................81
Vibration restriction function .........................................81
Speed profile calculation function .................................82
4.8 Interrupt Control................................................................. 83
4.9 Multiple Card Operation..................................................... 87
5 MotionCreatorPro............................................................. 89
5.1 Execute MotionCreatorPro ................................................ 89
5.2 About MotionCreatorPro.................................................... 90
5.3 MotionCreatorPro Introduction........................................... 91
Main Menu ....................................................................91
Select Menu ..................................................................92
Card Information Menu .................................................93
Configuration Menu ......................................................94
Single Axis Operation Menu .......................................100
Two-Axis and Four-Axis Operation Menu ...................108
2D_Motion Menu ........................................................112
Help Menu ..................................................................119

iv Table of Contents
6 Function Library.............................................................. 121
6.1 List of Functions............................................................... 122
6.2 C/C++ Programming Library............................................ 131
6.3 System and Initialization.................................................. 132
6.4 Pulse Input/Output Configuration..................................... 136
6.5 Velocity mode motion....................................................... 139
6.6 Single Axis Position Mode ............................................... 142
6.7 Linear Interpolated Motion............................................... 146
6.8 Circular Interpolation Motion............................................ 155
6.9 Helical Interpolation Motion.............................................. 162
6.10 Home Return Mode.......................................................... 166
6.11 Manual Pulser Motion...................................................... 169
6.12 Motion Status................................................................... 172
6.13 Motion Interface I/O ......................................................... 174
6.14 Interrupt Control............................................................... 182
6.15 Position Control and Counters......................................... 186
6.16 Position Compare and Latch............................................ 191
6.17 Continuous motion........................................................... 196
6.18 Multiple Axes Simultaneous Operation............................ 198
6.19 General-Purpose DIO...................................................... 201
6.20 Soft Limit.......................................................................... 203
6.21 Backlash Compensation / Vibration Suppression............ 205
6.22 Speed Profile Calculation................................................. 207
6.23 Return Code..................................................................... 211
7 Connection Example ...................................................... 213
7.1 General Description of Wiring.......................................... 213
7.2 Terminal Board User Guide............................................. 213
Warranty Policy ................................................................... 215

List of Tables v
List of Tables
Table 2-1: CN3 Pin Assignments: Main Connector ................. 13
Table 2-2: K1/K2 Pin Assignments: Simultaneous Start/Stop . 15
Table 2-3: SW1 Card Index ..................................................... 16
Table 2-4: CN4 Manual Pulsar ................................................ 17
Table 4-1: Motion Interrupt Source Bit Settings ....................... 84
Table 4-2: Error Interrupt return codes .................................... 85
Table 6-1: Data type definitions ............................................. 131

vi List of Figures
List of Figures
Figure 1-1: PCI-8154 Block Diagram........................................... 2
Figure 1-2: Flow chart for building an application ........................ 3
Figure 2-1: PCB Layout of the PCI-8154 ................................... 10

Introduction 1
1 Introduction
The PCI-8154 is an advanced & modulized 4-axis motion control-
ler card with a PCI interface. It can generate high frequency pulses
(6.55MHz) to drive stepper or servomotors. As a motion controller,
it can provide 4-axis linear and circular interpolation and continu-
ous interpolation for continuous velocity. Also, changing position/
speed on the fly is available with a single axis operation.
Multiple PCI-8154 cards can be used in one system. Incremental
encoder interfaces on all eight axes provide the ability to correct
positioning errors generated by inaccurate mechanical transmis-
sions.
The PCI-8154 is a completely new design. This carrier board has
4-axis pulse train output control channels. For additional functions,
such as high-speed triggering or distributed I/O control, you can
add on a daughter board based on requirement. This board has
position compare function. Like the line scan application, the appli-
cation needs motion controller to generate high speed triggering
pulse and gain the high resolution images. In this situation, you
can adopt a DB-8150 to extend the function on PCI-8154. In addi-
tion to motion control, sensors and actuators are key elements in
machine automation. There typically needs to I/O to integrate the
sensors and actuators in the controller. ADLINK also provides you
another way to connect these devices: distributed I/O. Using
daughter board, distributed I/O can be achieved with PCI-8154.
This cost-effective configuration can reduce wiring effort and phys-
ical controller size.
Figure 1-1 shows the functional block diagram of the PCI-8154
card. The motion control functions include trapezoidal and S-curve
acceleration/deceleration, linear and circular interpolation between
two axes and continuous motion positioning, and 13 home return
modes. All these functions and complex computations are per-
formed internally by the ASIC, thus it can save CPU loading.
The PCI-8154 also offers three user-friendly functions.
1. Card Index Setting:

2Introduction
The card index value of the PCI-8154 can be set with a DIP
switch to a value between 0 and 15. This is useful for machine
makers if the whole control system is very huge.
2. Emergency Input
An emergency input pin can be wired to an emergency button
to stop sending pulse output once activated.
3. Software’s Security Protection
To secure applications, a 16-bit value can be set in the
EEPROM to prevent copying of custom programs.
Figure 1-1: PCI-8154 Block Diagram

Introduction 3
MotionCreatorPro is a Windows-based application development
software package included with the PCI-8154. MotionCreatorPro
is useful for debugging a motion control system during the design
phase of a project. An on-screen display lists all installed axes
information and I/O signal status of the PCI-8154.
Windows programming libraries are also provided for C++ compil-
ers and Visual Basic. Sample programs are provided to illustrate
the operations of the functions.
Figure 1-2 illustrates a flow chart of the recommended process in
using this manual in developing an application. Refer to the
related chapters for details of each step.
Figure 1-2: Flow chart for building an application

4Introduction
1.1 Features
The following list summarizes the main features of the PCI-8154
motion control system.
X32-bit PCI bus Plug-and-Play (Universal)
X4 axes of step and direction pulse output for controlling
stepping or servomotor
XMaximum output frequency of 6.55MPPS
XPulse output options: OUT/DIR, CW/CCW, AB phase
XPulse input options: CW/CCW, AB phase x1, x2, x4
XMaximum pulse input frequency of 3.2Mhz in CW/CCW or
AB phase X1 mode (AB phase x4 can reach 6.5Mhz).
XProgrammable acceleration and deceleration time for all
modes
XTrapezoidal and S-curve velocity profiles for all modes
X2 to 4 axes linear interpolation
X2 axes circular interpolation
XContinuous interpolation for contour following motion
XChange position and speed on the fly
X13 home return modes with auto searching
XHardware backlash compensator and vibration suppression
X2 software end-limits for each axis
X28-bit up/down counter for incremental encoder feedback
XHome switch, index signal (EZ), positive, and negative end
limit switches interface on all axes
X4-axis high speed position latch input
X4-axis position compare and trigger output
XAll digital input and output signals are 2500Vrms isolated
XProgrammable interrupt sources
XSimultaneous start/stop motion on multiple axes
XManual pulser input interface
XCard index selection
XSecurity protection on EERPOM

Introduction 5
XDedicated emergency input pin for wiring
XSoftware supports a maximum of up to 12 PCI-8154 cards
operation in one system
XCompact PCB design
XIncludes MotionCreatorPro, a Microsoft Windows-based
application development software
XPCI-8154 libraries and utilities for Windows 2000/XP/Vista.

6Introduction
1.2 Specifications
Applicable Motors:
XStepping motors
XAC or DC servomotors with pulse train input servo drivers
Performance:
XNumber of controllable axes: 4
XMaximum pulse output frequency: 6.55MPPS, linear, trape-
zoidal, or S-Curve velocity profile drive
XInternal reference clock: 19.66MHz
X28-bit up/down counter range: 0-268, 435, 455 or –134,
217, 728 to +134, 217, 727
XPosition pulse setting range (28-bit): -134, 217, 728 to
+134, 217, 728
XPulse rate setting range (Pulse Ratio = 1: 65535):
Z0.1 PPS to 6553.5 PPS. (Multiplier = 0.1)
Z1 PPS to 65535 PPS. (Multiplier = 1)
Z100 PPS to 6553500 PPS. (Multiplier = 100)

Introduction 7
I/O Signales:
XInput/Output signals for each axis
XAll I/O signal are optically isolated with 2500Vrms isolation
voltage
XCommand pulse output pins: OUT and DIR
XIncremental encoder signals input pins: EA and EB
XEncoder index signal input pin: EZ
XMechanical limit/home signal input pins: ±EL, ORG
XComposite pins: DI / LTC (Latch) / SD (Slow-down) / PCS
(Position Change Signal) / CLR (Clear) / EMG (Emergency
Input)
XServomotor interface I/O pins: INP, ALM, and ERC
XGeneral-purposed digital output pin: SVON, DO
XGeneral-purposed digital input pin: RDY, GDI
XPulse signal input pin: PA and PB (with Isolation)
XSimultaneous Start/Stop signal: STA and STP
General Specifications
XConnectors: 100-pin SCSI-type connector
XOperating Temperature: 0°C - 50°C
XStorage Temperature: -20°C - 80°C
XHumidity: 5 - 85%, non-condensing
Power Consumption
XSlot power supply (input): +5V DC ±5%, 900mA max
XExternal power supply (input): +24V DC ±5%, 500mA max
XExternal power supply (output): +5V DC ±5%, 300mA, max
PCI-8154 Dimensions (PCB size):
X185mm(L) X 100 mm(W)

8Introduction
1.3 Supported Software
1.3.1 Programming Library
Windows 2000/XP/Vista DLLs are provided for the PCI-8154.
These function libraries are shipped with the board.
1.3.2 MotionCreatorPro
This Windows-based utility is used to setup cards, motors, and
systems. It can also aid in debugging hardware and software prob-
lems. It allows users to set I/O logic parameters to be loaded in
their own program. This product is also bundled with the card.
Refer to Chapter 5 for more details.
1.4 Available Terminal Board
ADLINK provides the servo & steppers use terminal board for
easy connection. For steppers, we provide DIN-100S which is pin-
to-pin terminal board. For servo users, ADLINK offers DIN-814M,
DIN-814M-J3A, DIN-814Y and DIN-814P-A4. The suitable servos
are listed as follows:
Mitsubishi J2 Super DIN-814M
Mitsubishi J3A DIN-814M-J3A
Yaskawa Sigma II DIN-814Y
Panasonic MINAS A4 DIN-814P-A4

Installation 9
2 Installation
This chapter describes how to install PCI-8154. Please follow
these steps below:
XCheck what you have (section 2.1)
XCheck the PCB (section 2.2)
XInstall the hardware (section 2.3)
XInstall the software driver (section 2.4)
XUnderstanding the I/O signal connections (chapter 3) and
their operation (chapter 4)
XUnderstanding the connector pin assignments (the remain-
ing sections) and wiring the connections
2.1 Package Contents
In addition to this User’s Guide, the package also includes the fol-
lowing items:
XPCI-8154: advanced 4-axis Servo / Stepper Motion Control
Card
XADLINK All-in-one Compact Disc
Note: The terminal board is an optional accessory and would not
be included in PCI-8154 package.
If any of these items are 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.

10 Installation
2.2 PCI-8154 Outline Drawing
Figure 2-1: PCB Layout of the PCI-8154
XCN3: Input / Output Signal Connector (100-pin)
XK1 / K2: Simultaneous Start / Stop Connector
XCN4: Manual Pulsar
XSW1: DIP switch for card index selection (0-15)
XJP2-JP9: Pulse output selection jumper (Line Driver / Open
Collector)