Advantech ADAM-5240 User manual

ADAM-5240
4-axis Stepping/Pulse-type
Servo Motor Control Module
User Manual

ADAM-5240 User Manual ii
Copyright
This documentation and the software included with this product are
copyrighted 2007 by Advantech Co., Ltd. All rights are reserved.
Advantech Co., Ltd. reserves the right to make improvements in the
products described in this manual at any time without notice.
No part of this manual may be reproduced, copied, translated or
transmitted in any form or by any means without the prior written
permission of Advantech Co., Ltd. Information provided in this manual is
intended to be accurate and reliable. However, Advantech Co., Ltd.
assumes no responsibility for its use, nor for any infringements of the
rights of third parties which may result from its use.
CE notification
The ADAM-5240, developed by ADVANTECH CO., LTD., has passed
the CE test for environmental specifications when shielded cables are
used for external wiring. We recommend the use of shielded cables. This
kind of cable is available from Advantech. Please contact your local sup-
plier for ordering information.
Printed in Taiwan September 2008

iii
Product Warranty (2 years)
Advantech warrants to you, the original purchaser, that each of its prod-
ucts will be free from defects in materials and workmanship for two years
from the date of purchase.
This warranty does not apply to any products which have been repaired or
altered by persons other than repair personnel authorized by Advantech,
or which have been subject to misuse, abuse, accident or improper instal-
lation. Advantech assumes no liability under the terms of this warranty as
a consequence of such events.
Because of Advantech’s high quality-control standards and rigorous test-
ing, most of our customers never need to use our repair service. If an
Advantech product is defective, it will be repaired or replaced at no
charge during the warranty period. For out-of-warranty repairs, you will
be billed according to the cost of replacement materials, service time and
freight. Please consult your dealer for more details.
If you think you have a defective product, follow these steps:
1. Collect all the information about the problem encountered. (For
example, CPU speed, Advantech products used, other hardware
and software used, etc.) Note anything abnormal and list any
onscreen messages you get when the problem occurs.
2. Call your dealer and describe the problem. Please have your man-
ual, product, and any helpful information readily available.
3. If your product is diagnosed as defective, obtain an RMA (return
merchandize authorization) number from your dealer. This allows
us to process your return more quickly.
4. Carefully pack the defective product, a fully-completed Repair and
Replacement Order Card and a photocopy proof of purchase date
(such as your sales receipt) in a shippable container. A product
returned without proof of the purchase date is not eligible for war-
ranty service.
5. Write the RMA number visibly on the outside of the package and
ship it prepaid to your dealer.

ADAM-5240 User Manual iv
Technical Support and Assistance
Step 1. Visit the Advantech web site at www.advantech.com/support
where you can find the latest information about the product.
Step 2. Contact your distributor, sales representative, or Advantech's cus-
tomer service center for technical support if you need additional
assistance. Please have the following information ready before
you call:
- Product name and serial number
- Description of your peripheral attachments
- Description of your software (operating system, version, appli-
cation software, etc.)
- A complete description of the problem
- The exact wording of any error messages
Packing List
Before setting up the system, check that the items listed below are
included and in good condition. If any item does not accord with the
table, please contact your dealer immediately.
• ADAM-5240
Safety Precaution - Static Electricity
Follow these simple precautions to protect yourself from harm and the
products from damage.
1. To avoid electrical shock, always disconnect the power from your
PC chassis before you work on it. Don't touch any components on
the CPU card or other cards while the PC is on.
2. Disconnect power before making any configuration changes. The
sudden rush of power as you connect a jumper or install a card may
damage sensitive electronic components.

v Table of Contents
Contents
Chapter 1 Introduction ..................................................... 2
1.1 Features ............................................................................. 2
1.2 Applications ...................................................................... 5
1.3 Accessories........................................................................ 5
Chapter 2 Signal Connections .......................................... 8
2.1 I/O Connector Pin Assignments........................................ 8
2.2 Pin Assignments................................................................ 9
Figure 2.1:I/O Connector Pin Assignments ................... 9
Table 2.1:I/O Connector Signal Description ............... 10
Table 2.1:I/O Connector Signal Description ............... 11
Table 2.1:I/O Connector Signal Description ............... 12
2.3 Output Pulse Definition................................................... 13
Figure 2.2:Output Signal Loop for Drive Pulses ......... 13
Table 2.2:JP1~8 Jumpers ............................................. 13
Figure 2.3:Photo Coupler Input Interface .................... 14
Figure 2.4:Line Driver Input Interface ........................ 14
2.4 General Purposed Output ................................................ 15
Figure 2.5:General Purpose Output ............................. 15
2.5 Over Traveling Limit Switch Input................................. 15
Figure 2.6:Movement Limit Input Signals .................. 16
Figure 2.7:Photo Sensor in the Limit Input Signal ...... 16
2.6 Deceleration/Instantaneous Stop Switch Input ............... 17
Figure 2.8:Deceleration/Instantaneous Stop Input ....... 17
2.7 General Purposed Input for Servo Drives ....................... 18
Figure 2.9:Input Signal for Servo Motor ..................... 18
2.8 Encoder Input .................................................................. 19
Figure 2.10:Circuit Diagram of Encoder Feedback ..... 19
Figure 2.11:Differential-output Line Driver ................ 20
Figure 2.12:Open Collector Output Encoder ............... 20
2.9 External Pulse Control Input........................................... 21
Figure 2.13:External Drive Operation Signals ............ 21
Figure 2.14:Example of Connecting to Jog ................. 21
2.10 Emergency Stop Input (EMG) ........................................ 22
Figure 2.15:Emergency Stop Input Signal ................... 22
Table 2.3:Jumper Settings of JP9 ................................ 22
2.11 External Power Input (VEX)........................................... 22
2.12 Interrupt Setting............................................................... 23
Figure 2.16:Circuit Diagram of Interrupt Setting ........ 23
2.13 Connection Examples for Motor Drivers ........................ 24
2.13.1 Connection to Step Motor Drivers ............................... 24
Figure 2.17:Connecting to KR515M Drive ................. 24
Figure 2.18:Connecting to UPK Step Drive ................ 25
2.13.2 Connection to Servo Motor Drivers ............................. 26
Figure 2.19:MINAS X Series AC Servo Motor Drive 26

ADAM-5240 User Manual vi
2.14 Field Wiring Considerations ........................................... 27
2.15 I/O Signal Timing............................................................ 28
2.15.1 Power On RESET ........................................................ 28
Figure 2.20:Timing Diagram of Power On Reset ........ 28
2.15.2 Individual Axis Driving ............................................... 28
Figure 2.21:Individual Axis Driving ........................... 28
2.15.3 Interpolation Driving ................................................... 29
Figure 2.22:Timing Diagram of Interpolation Driving 29
2.15.4 Input Pulse Timing ....................................................... 29
Figure 2.23:Quadrature Pulse of Encoder Input .......... 29
Figure 2.24:Timing Diagram of Up/Down Pulse Input 29
2.15.5 Instantaneous Stop Timing .......................................... 30
Figure 2.25:External Instantaneous Stop Signal .......... 30
Figure 2.26:Instantaneous Stop Instruction ................. 30
2.15.6 Deceleration Stop Timing ............................................ 30
Figure 2.27:External Deceleration/Stop Signal ........... 30
Figure 2.28:Deceleration/Stop Instruction ................... 30
2.16 TTL Level Position Compare Output.............................. 31
Table 2.4:Jumper Settings of JP10 .............................. 31
Appendix A Specifications ................................................. 34
A.1 Axes................................................................................. 34
A.2 Digital Input/Output ........................................................ 35
A.3 Input Pulse for Encoder Interface.................................... 36
A.4 External Signals Driving ................................................. 36
A.5 Other Functions ............................................................... 37
A.6 General ............................................................................ 37
Appendix B Block Diagram ............................................... 40
Appendix C Cable Pin Assignments ................................. 42
Appendix D Wiring with Third-Party Motor Drivers .... 44
Figure D.1:Mitsubishi MR-J2S Series Motor Driver .. 44
Figure D.2:Oriental LIMO EZMC Motor Driver ........ 45
Figure D.3:Panasonic MINAS-A Series Motor Driver 46
Figure D.4:Yaskawa SGDM Series Motor Driver ....... 47

2
CHAPTER
1
Introduction
This chapter introduces ADAM-5240
and lists features and specifications.

ADAM-5240 User Manual 2
Chapter 1 Introduction
ADAM-5240 4-Axis Stepping/Pulse-type Servo Motor Control Card is
designed for general-purpose motion applications. The card simplifies
stepping and pulse-type servo motor control.
The cards’ intelligent NOVA MCX314AS motion ASIC builds in a vari-
ety of motion control functions, such as 2/3-axis linear interpolation, 2-
axis circular interpolation, T/S-curve acceleration/deceleration rate and
more. In addition, the next generation chip, MCX314AS is lead-free and
not only increases the 2/3-axis linear interpolation range and the number
of output pulses, but also provides the “Go Home” function.
1.1 Features
ADAM-5240 provides users with the most requested motor control func-
tions as seen below:
• Independent 4-axis motion control
• Support hand wheel and jog function
• 2/3-axis linear interpolation function
• 2-axis circular interpolation function
• Continuous interpolation function
• Programmable T/S-curve acceleration and deceleration
• Up to 4MPPS pulse output for each axis
• Two pulse output types: Up/Down or Pulse/Direction
• Up to 1 MHz encoder input for each axis
• Two encoder pulse input types: A/B phase or Up/Down
• Position management and software limit switch function
• Free Motion Utility bundled for configuration and diagnosis
• "Go home” functions
The Advantech ADAM-5240 offers the following main features:
Individual Control for 4 Axes
Each of the axes has identical capabilities, and is controlled by the same
method of operation with constant speed, trapezoidal or S-curve driving.

3 Chapter1
Programmable T/S-curve Acceleration and Deceleration
Each of four axes can be preset individually with S-curve or trapezoidal
acceleration/deceleration rates. When using S-curve acceleration to con-
trol driving speed, output pulse is generated in parabolic-shaped accelera-
tion or deceleration curves, and the triangular curve phenomenon will not
occur through the NOVA MCX314AS-motion ASIC design concept.
Linear and Circular Interpolation
Any two or three axes can be selected to execute linear interpolation driv-
ing and any two axes can be selected to execute circular arc interpolation
control. The interpolation speed range is from 1 PPS to 4 MPPS.
Powerful Position Management Function
Each axis is equipped with a 32-bit logical position counter and a 32-bit
real position counter. The logical position counter counts the axis’ pulse
output number and the real position counter is recorded with the feedback
pulse from the outside encoder or linear scale.
Speed Control
The speed range of the pulse output is from 1PPS to 4MPPS for constant
speed, trapezoidal or S-curve acceleration/deceleration driving. The
accuracy of the frequency of the pulse output is less than +/- 0.1% (at
CLK=16 MHz). The speed of driving pulse output can be freely changed
during the driving.
Bit Pattern Interpolation
Any 2 or 3 axes can be selected to perform the bit pattern interpolation,
and the interpolation data is calculated by CPU; CPU writes the bit data
into MCX314AS. Then, MCX314AS outputs pulses continuously at the
preset driving speed. So, the user can process any interpolation curve by
this mode.
Continuous Interpolation
Different interpolation methods can be used continuously, for example:
Linear interpolationÆCircular interpolationÆLinear interpolation.
The maximum driving speed of performing continuous interpolation is 2
MPPS.

ADAM-5240 User Manual 4
Constant Vector Speed Control
This function performs a constant vector speed. During the interpolation
driving, MCX314AS can set a 1.414 times pulse cycle for 2-axis simulta-
neous pulse output, and a 1.732-time pulse cycle for 3-axis simultaneous
pulse output that keep the constant speed during driving.
Position Control
Each axis has a 32-bit logic position counter and a 32-bits real position
counter. The logic position counter counts the output pulse numbers, and
the real position counter counts the feedback pulse numbers from the
external encoder or linear scale.
Compare Register and Software Limit
Each axis has two 32-bit compare registers for logical position counter
and real position counter. The comparison result can be read from the sta-
tus registers. The comparison result can be notified by an interrupt signal.
These registers can be also functioned as software limits.
Driving by External Signal
It is possible to control each axis by external signals. The +/- direction
fixed pulse driving and continuous driving can be also performed through
the external signals. This function is used for JOG or teaching modes, and
will share the CPU load.
Input/ Output Signal
Each axis has 4 points of input signals to perform deceleration and stop in
driving. These input signals are for high-speed near-by home search,
home search and z-phase search during the home returning. Each axis is
with 8 output points for general output.
Servo Motor Feedback Signals
Each axis includes input pins for servo feedback signals such as in-posi-
tioning, close loop positioning control and servo alarm.

5 Chapter1
Interrupt Signals
Interrupt signals can be generated when: (1). The start / finish of a con-
stant speed drive during the trapezoidal driving, (2). The end of driving,
and (3). The compare result once higher / lower the border-lines of the
position counter range. An interrupt signal can be also generated during
the interpolation driving.
Real Time Monitoring
During the driving, the present status such as logical position, real
position, drive speed, acceleration / deceleration, status of accelerating /
decelerating and constant driving can be read.
1.2 Applications
• Precise X-Y-Z position control
• Precise rotation control
• Packaging and assembly equipment
• Machine control with up to 4 axes
• Semiconductor pick and place and testing equipment
• Other stepping/pulse-type servo motor applications
1.3 Accessories
Advantech offers a complete set of accessory products to support the
ADAM-5240 card. These accessories include:
Wiring Cable
• PCL-10251 The PCL-10251 shielded cable is specially designed for
ADAM-5240 card to provide higher resistance to noise.
To achieve a better signal quality, the signal wires are
twisted in such away as to form a “twisted-pair cable”,
reducing cross talk and noise from other signal sources.
Wiring Boards
• ADAM-3952 The ADAM-3952 is a 50-pin SCSI wiring terminal
module for DIN-rail mounting. This terminal module
can allow easy yet reliable access to individual pin
connections for the ADAM-5240 card.

ADAM-5240 User Manual 6

2
CHAPTER
2
Signal Connections
This chapter provides useful informa-
tion about how to connect input and
output signals to the ADAM-5240 via
the I/O connector.

ADAM-5240 User Manual 8
Chapter 2 Signal Connections
2.1 I/O Connector Pin Assignments
The I/O connector on the ADAM-5240 is a 100-pin connector that
enables you to connect to accessories with the PCL-10251 shielded cable.
Figure 3.1 shows the pin assignments for the 100-pin I/O connector on
the ADAM-5240, and Table 3-1 shows its I/O connector signal descrip-
tion.
Note The PCL-10251 shielded cable is especially
designed for the ADAM-5240 to reduce noise in
the analog signal lines.

9 Chapter2
2.2 Pin Assignments
Figure 2.1: I/O Connector Pin Assignments

ADAM-5240 User Manual 10
Table 2.1: I/O Connector Signal Description
Signal Name Reference Direction Description
VEX - Input External Power (12~24VDC)
EMG - Input Emergency Stop (for all axes)
XLMT+ - Input + Direction Limit at X axis
XLMT- - Input - Direction Limit at X axis
XIN1 - Input Deceleration/Instant Stop at X axis
XIN2 - Input Deceleration/Instant Stop at X axis
XIN3 - Input Deceleration/Instant Stop at X axis
YLMT+ - Input + Direction Limit at Y axis
YLMT- - Input - Direction Limit at Y axis
YIN1 - Input Deceleration/Instant Stop at Y axis
YIN2 - Input Deceleration/Instant Stop at Y axis
YIN3 - Input Deceleration/Instant Stop at Y axis
XINPOS - Input In-Position input at X axis
XALARM - Input Servo Error at X axis
XECAP - Input Encoder Phase A at X axis
XECAN - Input Encoder Phase A at X axis
XECBP - Input Encoder Phase B at X axis
XECBN - Input Encoder Phase B at X axis
XIN0P - Input Encoder Phase Z at X axis
XIN0N - Input Encoder Phase Z at X axis
YINPOS - Input In-Position input at Y axis
YALARM - Input Servo Error at Y axis
YECAP - Input Encoder Phase A at Y axis
YECAN - Input Encoder Phase A at Y axis
YECBP - Input Encoder Phase B at Y axis
YECBN - Input Encoder Phase B at Y axis
YIN0P - Input Encoder Phase Z at Y axis
YIN0N - Input Encoder Phase Z at Y axis
XEXOP+ - Input Jog at the + Direction of X axis
XEXOP- - Input Jog at the - Direction of X axis
YEXOP+ - Input Jog at the + Direction of Y axis
YEXOP- - Input Jog at the - Direction of Y axis
GND - - Ground
XOUT4 GND Output Common Output at X axis (CMP+)
XOUT5 GND Output Common Output at X axis (CMP-)

11 Chapter2
Table 2.1: I/O Connector Signal Description
Signal Name Reference Direction Description
XOUT6 GND Output Common Output at X axis (Server on)
XOUT7 GND Output Common Output at X axis (Reset)
XP+P GND Output Output pulse CW/Pulse+ of X-axis
XP+N GND Output Output pulse CW/ Pulse- of X-axis
XP-P GND Output Output pulse CCW/DIR+ of X-axis
XP-N GND Output Output pulse CCW/DIR- of X-axis
GND - - Ground
YOUT4 GND Output Common Output at Y axis (CMP+)
YOUT5 GND Output Common Output at Y axis (CMP-)
YOUT6 GND Output Common Output at Y axis (Server on)
YOUT7 GND Output Common Output at Y axis (Reset)
YP+P GND Output Output pulse CW/Pulse+ of Y-axis
YP+N GND Output Output pulse CW/Pulse- of Y-axis
YP-P GND Output Output pulse CCW/DIR+ of Y-axis
YP-N GND Output Output pulse CCW/DIR- of Y-axis
VEX - Input External Power (DC12~24V)
ZLMT+ - Input + Direction Limit at Z axis
ZLMT- - Input - Direction Limit at Z axis
ZIN1 - Input Deceleration/Instant Stop at Z axis
ZIN2 - Input Deceleration/Instant Stop at Z axis
ZIN3 - Input Deceleration/Instant Stop at Z axis
ULMT+ - Input + Direction Limit at U axis
ULMT- - Input - Direction Limit at U axis
UIN1 - Input Deceleration/Instant Stop at U axis
UIN2 - Input Deceleration/Instant Stop at U axis
UIN3 - Input Deceleration/Instant Stop at U axis
ZINPOS - Input Positioning Complete at Z axis
ZALARM - Input Servo Error at Z axis
ZECAP - Input Encoder Phase A at Z axis
ZECAN - Input Encoder Phase A at Z axis
ZECBP - Input Encoder Phase B at Z axis
ZECBN - Input Encoder Phase B at Z axis
ZIN0P - Input Encoder Phase Z at Z axis
ZIN0N - Input Encoder Phase Z at Z axis
UINPOS - Input Positioning Complete at U axis

ADAM-5240 User Manual 12
Table 2.1: I/O Connector Signal Description
Signal Name Reference Direction Description
UALARM - Input Servo Error at U axis
UECAP - Input Encoder Phase A at U axis
UECAN - Input Encoder Phase A at U axis
UECBP - Input Encoder Phase B at U axis
UECBN - Input Encoder Phase B at U axis
UIN0P - Input Encoder Phase Z at U axis
UIN0N - Input Encoder Phase Z at U axis
ZEXOP+ - Input Jog at the + Direction of Z axis
ZEXOP- - Input Jog at the - Direction of Z axis
UEXOP+ - Input Jog at the + Direction of U axis
UEXOP- - Input Jog at the - Direction of U axis
GND - - Ground
ZOUT4 GND Output Common Output at Z axis (CMP+)
ZOUT5 GND Output Common Output at Z axis (CMP-)
ZOUT6 GND Output Common Output at Z axis (Server
on)
ZOUT7 GND Output Common Output at Z axis (Reset)
ZP+P GND Output Output pulse CW/Pulse+ of Z-axis
ZP+N GND Output Output pulse CW/Pulse- of Z-axis
ZP-P GND Output Output pulse CCW/DIR+ of Z-axis
ZP-N GND Output Output pulse CCW/DIR- of Z-axis
GND - - Ground
UOUT4 GND Output Common Output at U axis (CMP+)
UOUT5 GND Output Common Output at U axis (CMP-)
UOUT6 GND Output Common Output at U axis (Server
on)
UOUT7 GND Output Common Output at U axis (Reset)
UP+P GND Output Output pulse CW/Pulse+ of U-axis
UP+N GND Output Output pulse CW/Pulse- of U-axis
UP-P GND Output Output pulse CCW/DIR+ of U-axis
UP-N GND Output Output pulse CCW/DIR- of U-axis

13 Chapter2
2.3 Output Pulse Definition
The output pulse command of ADAM-5240 is from MCX314AS chip.
The pulse command has two types. One is in Up/Down mode and another
is in Pulse/Direction mode. While nP+P is differential from nP+N and
nP-P is differential from nP-N. After system reset, the nP+P and nP-P is
low level, and this invert output (nP+N, nP-N) is high level, and the
de-fault setting of pulse output mode is Up/Down. User can change the
output mode into Pulse/Direction mode by writing specified command
system register.
Figure 2.2: Output Signal Loop for Drive Pulses
From the circuit shown above (Figure 3-3), the default output mode is dif-
ferential output. For single ended output use, user can change jumpers
JP1~8 to +5V. Note that you should prevent from the noise interference
when using jumpers JP1~8 to output internal +5V to external device.
Table 2.2: JP1~8 Jumpers
Jumper JP1JP2JP3JP4JP5JP6JP7JP8
Output Sig-
nal XP+P XP-P YP+P YP-P ZP+P ZP-P UP+P UP-P
IC Output
(Line Driver
Output)
Pin2 and Pin 3 short (Default)
+5V
Output Pin1 and Pin 2 shor

ADAM-5240 User Manual 14
The following figure 3-4 and 3-5 show the examples of input circuitry
connection for both photo coupler and motor driver respectively.
Figure 2.3: Photo Coupler Input Interface
Figure 2.4: Line Driver Input Interface