ADLINK Technology PCIe-8154 User manual

Advance Technologies; Automate the World.
PCIe-8154
4-Axis Servo/Stepper
Motion Control Card
User’s Manual
Manual Rev.: 2.00
Revision Date: Oct. 7, 2015
Part No: 50-11258-1000

ii
Revision History
Revision Release Date Description of Change(s)
2.00 Oct. 7, 2015 Initial Release

Preface iii
PCIe-8154
Preface
Copyright 2015 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, 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.
Environmental Responsibility
ADLINK is committed to fulfill its social responsibility to global
environmental preservation through compliance with the Euro-
pean Union's Restriction of Hazardous Substances (RoHS) direc-
tive and Waste Electrical and Electronic Equipment (WEEE)
directive. Environmental protection is a top priority for ADLINK.
We have enforced measures to ensure that our products, manu-
facturing processes, components, and raw materials have as little
impact on the environment as possible. When products are at their
end of life, our customers are encouraged to dispose of them in
accordance with the product disposal and/or recovery programs
prescribed by their nation or company.
Trademarks
Product names mentioned herein are used for identification pur-
poses only and may be trademarks and/or registered trademarks
of their respective companies.

iv Preface
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.

Table of Contents v
PCIe-8154
Table of Contents
Preface.................................................................................... iii
List of Tables.......................................................................... ix
List of Figures........................................................................ xi
1 Introduction ........................................................................ 1
1.1 Features............................................................................... 3
1.2 Specifications....................................................................... 4
1.3 Supported Software ............................................................. 5
Programming Library ...................................................... 6
MotionCreatorPro ........................................................... 6
1.4 Available Terminal Board..................................................... 6
1.5 PCB Layout......................................................................... 7
1.6 CN2 Pin Assignments: Main Connector .............................. 7
1.7 K1/K2 Pin Assignments: Simultaneous Start/Stop ............ 10
1.8 P1 Manual Pulse Generator .............................................. 10
1.9 CN5 Pin Assignments: TTL I/O.......................................... 11
2 Getting Started ................................................................. 13
2.1 Package Contents ............................................................. 13
2.2 PCIe-8154 Hardware Installation....................................... 13
Hardware Configuration ................................................ 13
PCIe Slot Selection ....................................................... 13
Installation Procedures ................................................. 14
Troubleshooting: ........................................................... 14
2.3 Software Driver Installation................................................ 14
2.4 JP2 to JP8 Jumper Setting for Pulse Output ..................... 15
2.5 SW1 Card Index Selection................................................. 15
2.6 Signal Connections............................................................ 16
2.6.1 Pulse Output Signals OUT and DIR on CN2 ............ 16

vi Table of Contents
2.6.2 Encoder Feedback Signals EA, EB and EZ.............. 18
2.6.3 Origin Signal ORG .................................................... 21
2.6.4 End-Limit Signals PEL and MEL............................... 22
2.6.5 In-Position Signal INP............................................... 23
2.6.6 Alarm Signal ALM ..................................................... 24
2.6.7 Deviation Counter Clear Signal ERC........................ 25
2.6.8 General-purpose Signal SVON................................. 26
2.6.9 General-purpose Signal RDY ................................... 27
2.6.10 Multi-Functional Output Pin: DO/CMP ...................... 28
2.6.11 Multi-Functional Input Pin:
DI/LTC/SD/PCS/CLR/EMG....................................... 29
2.6.12 Manual Pulse Generator Input Signals PA and PB .. 30
2.6.13 Simultaneous Start/Stop Signals STA and STP ....... 31
2.6.14 General Purpose TTL I/O EDI And EDO .................. 33
A Appendix: MotionCreatorPro............................................35
A.1 About MotionCreatorPro .................................................... 35
A.2 Initiating MotionCreatorPro ................................................ 35
A.3 MotionCreatorPro Introduction........................................... 36
Main Menu .................................................................... 36
Select Menu .................................................................. 37
Card Information Menu ................................................. 38
Configuration Menu ...................................................... 39
Single Axis Operation Menu ......................................... 43
Two-Axis and Four-Axis Operation Menu ..................... 51
2D_Motion Menu .......................................................... 56
Help Menu .................................................................... 61
B Appendix: Function Library Reference............................63
B.1 Data Types......................................................................... 63
Function Naming ........................................................... 63
B.2 List of Functions................................................................. 64

Table of Contents vii
PCIe-8154
B.3 System and Initialization .................................................... 68
B.4 Pulse Input/Output Configuration....................................... 72
B.5 Velocity mode motion ........................................................ 74
B.6 Single Axis Position Mode ................................................. 77
B.7 Linear Interpolated Motion ................................................. 81
B.8 Circular Interpolation Motion.............................................. 89
B.9 Helical Interpolation Motion ............................................... 95
B.10 Home Return Mode ........................................................... 99
B.11 Manual Pulse Generator Motion ...................................... 102
B.12 Motion Status................................................................... 105
B.13 Motion Interface I/O ......................................................... 106
B.14 Interrupt Control............................................................... 114
B.15 Position Control and Counters......................................... 117
B.16 Position Compare and Latch ........................................... 123
B.17 Continuous motion........................................................... 127
B.18 Multiple Axes Simultaneous Operation............................ 129
B.19 General-Purpose DIO ...................................................... 132
B.20 Soft Limit.......................................................................... 134
B.21 Backlash Compensation / Vibration Suppression............ 136
B.22 Speed Profile Calculation ................................................ 138
B.23 Extended General Purpose TTL Input/Output ................. 141
B.24 Return Code .................................................................... 143
C Appendix: Connection Example....................................145
C.1 General Description of Wiring.......................................... 145
C.2 Terminal Board User Guide ............................................. 145
Important Safety Instructions............................................ 147
Getting Service.................................................................... 149

viii Table of Contents
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List of Tables ix
PCIe-8154
List of Tables
Table 1-1: P1 Manual Pulse Generator ................................... 11
Table 2-1: SW1 Card Index ..................................................... 16
Table 2-2: Pulse Output Signals on CN3 ................................. 17
Table 2-3: OUT or DIR Output by Jumper ............................... 17
Table 2-4: EA, EB, and EZ Pin Assignments ........................... 19
Table 2-5: Device/Encoder/Power Connection ........................ 20
Table 2-6: ORG0-ORG3 Pin Assignments .............................. 21
Table 2-7: End-Limit Signal Pin Assignment ........................... 22
Table 2-8: INP Signal Connection ........................................... 23
Table 2-9: Alarm Signal Connection ........................................ 24
Table 2-10: ERC Connection ..................................................... 25
Table 2-11: SVON Connection .................................................. 26
Table 2-12: RDY Signal Connection .......................................... 27
Table 2-13: DO/CMP Connection .............................................. 28
Table 2-14: DI/LTC/SD/PCS/CLR/EMG Connection ................. 29
Table 2-15: Manual Pulse Generator Input Signal Connection . 30

xListofTables
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List of Figures xi
PCIe-8154
List of Figures
Figure 1-1: PCIe-8154 Block Diagram .......................................... 2
Figure 1-2: PCB Layout ................................................................ 7
Figure 1-3: IDE 44-pin Connector Assignment ........................... 12
Figure 1-4: DSUB 37-pin Connector Assignment ....................... 12
Figure 2-1: Jumper Settings........................................................ 15
Figure 2-2: OUT and DIR Axis Signals ....................................... 17
Figure 2-3: OUT/DIR through J2/J3 Connection......................... 18
Figure 2-4: EA, EB, and EZ Input Circuits .................................. 19
Figure 2-5: Line Driver Connection Output Circuit ...................... 20
Figure 2-6: Device/Encoder Connection Circuit.......................... 21
Figure 2-7: ORG Input Circuit ..................................................... 22
Figure 2-8: End-Limit Signals Circuit .......................................... 23
Figure 2-9: INP Signal Circuit ..................................................... 24
Figure 2-10: Input Alarm Circuit .................................................... 25
Figure 2-11: ERC Circuit............................................................... 26
Figure 2-12: SVON Circuit ............................................................ 27
Figure 2-13: RDY Circuit............................................................... 28
Figure 2-14: DO/CMP Circuit ........................................................ 29
Figure 2-15: DI/LTC/SD/PCS/CLR/EMG Circuit ........................... 30
Figure 2-16: Manual Pulse Generator Input Signal Circuit ........... 31
Figure 2-17: STA & STP Connection ............................................ 32
Figure 2-18: STA & STP Connection With External Start/Stop..... 32
Figure 2-19: EDI And EDO Circuit ................................................ 33

xii List of Figures
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Introduction 1
PCIe-8154
1 Introduction
The PCIe-8154 is an advanced & modulized 4-axis motion control-
ler card with a PCIe 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
continuous interpolation for continuous velocity. Also, changing
position/speed on the fly is available with a single axis operation.
Multiple PCIe-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 PCIe-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 PCIe-8154. In
addition 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 PCIe-8154.
This cost-effective configuration can reduce wiring effort and phys-
ical controller size.
Figure 1-1 shows the functional block diagram of the PCIe-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 PCIe-8154 also offers three user-friendly functions.
1. Card Index Setting:

2Introduction
The card index value of the PCIe-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: PCIe-8154 Block Diagram
PCIe Bus
Servo Driver
Interface
Mechanical
Interface
Pulse I/O Latch
Input
Compare
Output
PCI Bus
Controller
FPGA
Pulser
(P1)
STA/STP (K1/K2)
PCL 6046
Isolation
DC/DC
CN1
Ext +24V
Ext +5V +5V
CN2
OUT
DIR
EA,EB,EZ
-EL, +EL
SD
ORG
INP,ALM
ERC
SVON
RDY
LTC3
LTC4
CMP1
CMP2
TTL IN/OUT
(CN5)

Introduction 3
PCIe-8154
MotionCreatorPro is a Windows-based application development
software package included with the PCIe-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 PCIe-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.
1.1 Features
The following list summarizes the main features of the PCIe-8154
motion control system.
XPCIe 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

4Introduction
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 manual pulse generator input interface
XCard index selection
XSecurity protection on EERPOM
XDedicated emergency input pin for wiring
XSoftware supports a maximum of up to 12 PCIe-8154 cards
operation in one system
XCompact PCB design
XIncludes MotionCreatorPro, a Microsoft Windows-based
application development software
XPCIe-8154 libraries and utilities for Windows XP/7/8.1
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 5
PCIe-8154
I/O Signals:
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
X16 TTL level DO and 16TTL level DI
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
PCIe-8154 Dimensions (PCB size):
X185 (L) X 98.4 (H) mm
1.3 Supported Software

6Introduction
Programming Library
Windows XP/7/8.1 DLLs are provided for the PCIe-8154. These
function libraries are shipped with the board.
MotionCreatorPro
The pre-loaded Windows-based utility sets up cards, motors, and
systems, and can aid in debugging hardware and software prob-
lems. Users can set I/O logic parameters to be loaded in their own
program.
For more information, please see “MotionCreatorPro” on page 35.
1.4 Available Terminal Board
ADLINK provides steppers with the DIN-100S pin-to-pin terminal
board. For servo users, the DIN-814M, DIN-814M-J3A, DIN-814Y
and DIN-814P-A4 are provided, with suitable servos as follows:
Mitsubishi J2 Super DIN-814M
Mitsubishi J3A DIN-814M-J3A
Yaskawa Sigma II DIN-814Y
Panasonic MINAS A4 DIN-814P-A4

Introduction 7
PCIe-8154
1.5 PCB Layout
Figure 1-2: PCB Layout
XCN2: Input / Output Signal Connector (100-pin)
XK1 / K2: Simultaneous Start / Stop Connector
XP1: Manual Pulse generator
XSW1: DIP switch for card index selection (0-15)
XJ1-J8: Pulse output selection jumper (Line Driver / Open
Collector)
XCN5: TTL I/O Connector
1.6 CN2 Pin Assignments: Main Connector
NOTE:
NOTE:
All dimensions shown are in millimeters (mm) unless otherwise
stated.
98.4
185

8Introduction
CN2 is the main connector for motion control I/O signals.
#Name I/O Function #Name I/O Function
1VDD O
+5V power
supply output 51 VDD O +5V power supply output
2 EXGND - Ext. power
ground 52 EXGND - Ext. power
ground
3 OUT0+ O Pulse signal (+) 53 OUT2+ O Pulse signal (+)
4 OUT0- O Pulse signal (-) 54 OUT2- O Pulse signal (-)
5 DIR0+ O Dir. signal (+) 55 DIR2+ O Dir. signal (+)
6 DIR0- O Dir. signal (-) 56 DIR2- O Dir. signal (-)
7 SVON0 O Servo On/Off 57 SVON2 O Servo On/Off
8ERC0O
Dev. ctr, clr.
Signal 58 ERC2 O Dev. ctr, clr. signal
9 ALM0 I Alarm signal 59 ALM2 I Alarm signal
10 INP0 I In-position signal 60 INP2 I In-position signal
11 RDY0 I Multi-purpose
Input signal 61 RDY2 I Multi-purpose Input signal
12 EXGND Ext. power
ground 62 EXGND Ext. power ground
13 EA0+ I Encoder A-
phase (+) 63 EA2+ I Encoder A-
phase (+)
14 EA0- I Encoder A-
phase (-) 64 EA2- I Encoder A- phase (-)
15 EB0+ I Encoder B-
phase (+) 65 EB2+ I Encoder B- phase (+)
16 EB0- I Encoder B-
phase (-) 66 EB2- I Encoder B-
phase (-)
17 EZ0+ I Encoder Z-
phase (+) 67 EZ2+ I Encoder Z-
phase (+)
18 EZ0- I Encoder Z-
phase (-) 68 EZ2- I Encoder Z- phase (-)
19 VDD O +5V power
supply output 69 VDD O +5V power supply output
20 EXGND - Ext. power
ground 70 EXGND - Ext. power
ground
21 OUT1+ O Pulse signal (+) 71 OUT3+ O Pulse signal (+)