Advantech PCI-1240 User manual

PCI-1240
4-Axis PCI Stepping/Pulse-type
Servo Motor Control Card
PCI-1240U
4-Axis Universal PCI Stepping/
Pulse-type Servo Motor Control
Card
User Manual

PCI-1240/PCI-1240U User Manual ii
Copyright
This documentation and the software included with this product are
copyrighted 2005 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.
Acknowledgments
PC-LabCard is a trademark of Advantech Co., Ltd. IBM and PC are
trademarks of International Business Machines Corporation. MS-DOS,
Windows®, Microsoft®Visual C++ and Visual BASIC are trademarks of
Microsoft® Corporation. Intel®and Pentium®are trademarks of Intel
Corporation. Delphi and C++Builder are trademarks of Inprise
Corporation.
CE notification
The PCI-1240/PCI-1240U, 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
supplier for ordering information.
Part No. 2003124001 Edition 2.1
Printed in Taiwan October 2006

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.

PCI-1240/PCI-1240U 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.
• PCI-1240 or PCI-1240U card
• Companion CD-ROM (DLL driver included)
• User Manual
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 Installation Guide .............................................................. 6
1.4 Accessories........................................................................ 6
Chapter 2 Installation ....................................................... 8
2.1 Unpacking ......................................................................... 8
2.2 Driver Installation ............................................................. 9
Figure 2.1:The Setup Screen of Advantech Automation
Software 10
Figure 2.2:Different options for Driver Setup ............. 11
2.3 Hardware Installation ..................................................... 12
Chapter 3 Signal Connections ........................................ 14
3.1 I/O Connector Pin Assignments...................................... 14
3.2 Location of Jumpers and DIP switch .............................. 14
Figure 3.1:I/O Connector Pin Assignments for PCI-1240
& PCI-1240U 15
Table 3.1:PCI-1240/PCI-1240U I/O Connector Signal
Description (part 1) 16
Table 3.1:PCI-1240/PCI-1240U I/O Connector Signal
Description (part 2) 17
Table 3.1:PCI-1240/PCI-1240U I/O Connector Signal
Description (part 3) 18
Figure 3.2:Location of Jumpers and DIP switch on PCI-
1240/PCI-1240U 19
Table 3.2:BoardID register .......................................... 19
Table 3.3:BoardID setting ............................................ 19
3.3 Output Pulse Definition (nP+P, nP+N, nP-P, nP-N)....... 20
Figure 3.3:Output Signal Loop for Drive Pulses ......... 20
Table 3.4:Jumper table of JP1~8 ................................. 20
Figure 3.4:Photo Coupler Input Interface .................... 21
Figure 3.5:Line Driver Input Interface ........................ 21
3.4 General Purposed Output (nOUT7 ~ nOUT4)................ 22
Figure 3.6:Circuit Diagram for General Purposed Output
22
3.5 Over Traveling Limit Switch Input (nLMT+, nLMT-)... 22
Figure 3.7:Circuit Diagram for Movement Limit Input
Signals 22
Figure 3.8:Example of photo sensor used in the limit input
signal 23
3.6 Deceleration/Instantaneous Stop Switch Input (nIN1 ~ 3) .
23
Figure 3.9:Circuit Diagram of Deceleration/Instanta-
neous Stop Input

PCI-1240/PCI-1240U User Manual vi
Signal 23
3.7 General Purposed Input for Servo Drives (nINPOS,
nALARM)24
Figure 3.10:Input Signal for Servo Motor ................... 24
3.8 Encoder Input (nECAP, nECAN, nECBP, nECBN, nINOP,
nINON)25
Figure 3.11:Circuit Diagram of Encoder Feedback ..... 25
Figure 3.12:Example of Connection Diagram for Differ-
ential-output Line Driver 26
Figure 3.13:Example of Connection for Open Collector
Output Encoder 26
3.9 External Pulse Control Input (nEXOP+, nEXOP-)......... 27
Figure 3.14:Circuit Diagram of the External Drive Oper-
ation Signals 27
Figure 3.15:Example of Connecting to Jog ................. 27
3.10 Emergency Stop Input (EMG) ........................................ 28
Figure 3.16:Circuit Diagram of Emergency Stop Input
Signal 28
Table 3.5:Jumper Settings of JP9 ................................ 28
3.11 External Power Input (VEX)........................................... 28
3.12 Interrupt Setting............................................................... 29
Figure 3.17:Circuit diagram of interrupt setting .......... 29
3.13 Connection Examples for Motor Drivers ........................ 30
3.13.1 Connection to Step Motor Drivers ............................... 30
Figure 3.18:Example of Connecting to KR515M Drive ..
30
Figure 3.19:Example of Connecting to UPK Step Drive .
31
3.13.2 Connection to Servo Motor Drivers ............................. 32
Figure 3.20:Example of MINAS X series AC servo Motor
Drive 32
3.14 Field Wiring Considerations ........................................... 33
3.15 I/O Signal Timing............................................................ 34
3.15.1 Power On RESET ........................................................ 34
Figure 3.21:Timing Diagram of Power On RESET .... 34
3.15.2 Individual Axis Driving ............................................... 34
Figure 3.22:Timing diagram of Individual Axis Driving
34
3.15.3 Interpolation Driving ................................................... 35
Figure 3.23:Timing diagram of Interpolation Driving . 35
3.15.4 Input Pulse Timing ....................................................... 35
Figure 3.24:Timing diagram of Quadrature Pulse of En-
coder Input 35
Figure 3.25:Timing diagram of UP/DOWN Pulse Input .
35
3.15.5 Instantaneous Stop Timing .......................................... 36
Figure 3.26:Timing diagram of External Instantaneous

vii Table of Contents
Stop Signal 36
Figure 3.27:Timing diagram of Instantaneous Stop In-
struction 36
3.15.6 Deceleration Stop Timing ............................................ 36
Figure 3.28:Timing diagram of External Deceleration/
Stop Signal 36
Figure 3.29:Timing diagram of Deceleration/Stop In-
struction 36
3.16 TTL Level Position Compare Output
(PCI-1240U only)37
Table 3.6:Jumper Settings of JP10 .............................. 37
Appendix A Specifications ................................................. 40
A.1 Axes................................................................................. 40
A.2 Digital Input/Output ........................................................ 41
A.3 Input Pulse for Encoder Interface.................................... 42
A.4 External Signals Driving ................................................. 42
A.5 Other Functions ............................................................... 43
A.6 General ............................................................................ 43
Appendix B Block Diagram ............................................... 46
Appendix C Register Structure and
Format 48
C.1 Overview ......................................................................... 48
C.2 I/O Port Address Map ..................................................... 48
Table C.1:PCI-1240/PCI-1240U WRITE register func-
tion 49
Table C.2:PCI-1240/PCI-1240U WRITE register format
50
Table C.3:PCI-1240/PCI-1240U READ register function
51
Table C.4:PCI-1240/PCI-1240U READ register format .
52
C.3 MCX314/MCX314AS WRITE Registers: WR0 ~ WR7 53
C.4 Clear Interrupt Register: CLRINT .................................. 53
Table C.5:Clear Interrupt Register: CLRINT - Write
BASE +10 53
C.5 Pulse Generator Mode/Status Register: PGM/PGSTA ... 53
Table C.6:Pulse Generator Mode/Status Register: PGM/
PGMSTA - Write/Read BASE +14 54
Table C.7:Pulse Generator Mode - PGMn3 ................. 54
Table C.8:Pulse Generator Signal Connection Mode .. 55
Table C.9:Driving Axis for Software Programmable
Mode 55
C.6 MCX314/MCX314AS READ Registers: RR0 ~ RR7.... 55
C.7 Interrupt Status Register: INTSTA ................................. 56
Table C.10:Interrupt Status Register: INTSTA - Read
BASE +10 56
C.8 Board ID Register: BDID................................................ 56
Table C.11:Board ID Register: BDID - Read BASE +12
56

PCI-1240/PCI-1240U User Manual viii
Appendix D Cable Pin Assignments ................................. 58
Appendix E Wiring with Third-Party Motor Drivers .... 60
Figure E.1:Wiring Diagram with Mitsubishi MR-J2S Se-
ries Motor Driver 60
Figure E.2:Wiring Diagram with Oriental LIMO EZMC
Series Motor Driver 61
Figure E.3:Wiring Diagram with Panasonic MINAS-A
Series Motor Driver 62
Figure E.4:Wiring Diagram with Yaskawa SGDM Series
Motor Driver 63

2
CHAPTER
1
Introduction
This chapter introduces PCI-1240 and
PCI-1240U and lists their features and
detailed specifications.

PCI-1240/PCI-1240U User Manual 2
Chapter 1 Introduction
PCI-1240 and PCI-1240U 4-Axis Stepping/Pulse-type Servo Motor Con-
trol Cards are designed for general-purpose extreme motion applications.
The cards are high-speed 4-Axis motion control cards for the PCI (1240)/
Universal PCI (1240U) bus that simplifies stepping and pulse-type servo
motor control, giving you added performance from your motors.
The cards’ intelligent NOVA MCX314/MCX314AS motion ASIC builds
in a variety of motion control functions, such as 2/3-axis linear interpola-
tion, 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.
PCI-1240 and PCI-1240U performs these motion control functions with-
out processor load during driving. For advanced applications, we supply
Windows DLL drivers and user-friendly examples to decrease your pro-
gramming load. Moreover, through a free bundled PCI-1240 motion util-
ity, you can complete configuration and diagnosis easily.
1.1 Features
PCI-1240/PCI-1240U provides users with the most requested motor con-
trol functions 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
• BoardID Switch
• Free Motion Utility bundled for configuration and diagnosis

3 Chapter1
• "Go home” functions (PCI-1240U only)
• Universal PCI Bus for both 3.3 and 5 V PCI slots (PCI-1240U only)
The Advantech PCI-1240/PCI-1240U offers the following main features:
Individual Control for 4 Axes
Each of the four axes has identical function capabilities, and is controlled
by the same method of operation with constant speed, trapezoidal or
S-curve driving.
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 MCX314/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.

PCI-1240/PCI-1240U User Manual 4
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 MCX314/MCX314AS. Then, MCX314/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.
Constant Vector Speed Control
This function performs a constant vector speed. During the interpolation
driving, MCX314/MCX314AS can set a 1.414 times pulse cycle for 2-
axis simultaneous 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.

5 Chapter1
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.
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

PCI-1240/PCI-1240U User Manual 6
1.3 Installation Guide
Before you install your PCI-1240/PCI-1240U card, please make sure you
have the following necessary components:
• PCI-1240 or PCI-1240U DAS card
• PCI-1240/PCI-1240U’s User Manual
• Driver Software
Advantech PCI-1240/PCI-1240U DLL drivers (Included in the com-
panion CD-ROM)
• Motion Utility
Advantech PCI-1240/PCI-1240U Motion Utility (Included in the com-
panion CD-ROM)
• PCL-10251 Wiring cable
• 2pcs ADAM-3952 Wiring board
• Personal computer or workstation with a PCI-bus slot
After you have got the necessary components and maybe some accesso-
ries for enhanced operation of your Motion card, you can then begin the
installation procedure.
1.4 Accessories
Advantech offers a complete set of accessory products to support the
PCI-1240/PCI-1240U card. These accessories include:
Wiring Cable
• PCL-10251 The PCL-10251 shielded cable is specially designed for
PCI-1240/PCI-1240U 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 PCI-1240/PCI-1240U card.

2
CHAPTER
2
Installation
This chapter gives users a package item
checklist, proper instructions about
unpacking and step-by-step procedures
for both driver and card installation.

PCI-1240/PCI-1240U User Manual 8
Chapter 2 Installation
2.1 Unpacking
After receiving your PCI-1240/PCI-1240U package, please inspect its
contents first. The package should contain the following items:
;PCI-1240/PCI-1240U card
;Companion CD-ROM (DLL driver included)
;User’s Manual
The PCI-1240/PCI-1240U card harbors certain electronic components
vulnerable to electrostatic discharge (ESD). ESD could easily damage the
integrated circuits and certain components if preventive measures are not
carefully paid attention to. Before removing the card from the anti-
static plastic bag, you should take following precautions to ward off
possible ESD damage:
• Touch the metal part of your computer chassis with your hand to
discharge static electricity accumulated on your body. Or one can also
use a grounding strap.
• Touch the antistatic bag to a metal part of your computer chassis before
opening the bag.
• Take hold of the card only by the metal bracket when removing it out of
the bag.
After taking out the card, first you should:
• Inspect the card for any possible signs of external damage (loose or
damaged components, etc.). If the card is visibly damaged, please
notify our service department or our local sales representative immedi-
ately. Avoid installing a damaged card into your system.
Also pay extra caution to the following aspects to ensure proper
installation:
Avoid physical contact with materials that could
hold static electricity such as plastic, vinyl and
Styrofoam.

9 Chapter2
2.2 Driver Installation
We recommend you to install the driver before you install the
PCI-1240/PCI-1240U card into your system, since this will guarantee
a smooth installation process.
The 32-bit DLL driver Setup program for the card is included on the
companion CD-ROM that is shipped with your DAS card package. Please
follow the steps below to install the driver software:
Step 1: Insert the companion CD-ROM into your CD-ROM drive.
Step 2: The Setup program will be launched automatically if you have
the autoplay function enabled on your system. When the Setup
Program is launched, you’ll see the following Setup Screen.
Whenever you handle the card, grasp it only by
its edges. DO NOT TOUCH the exposed metal
pins of the connector or the electronic compo-
nents.
Note Keep the antistatic bag for future use. You might
need the original bag to store the card if you
have to remove the card from PC or transport it
elsewhere.
Note If the autoplay function is not enabled on your
computer, use Windows Explorer or Windows
Run command to execute SETUP.EXE on the
companion CD-ROM.

PCI-1240/PCI-1240U User Manual 10
Figure 2.1: The Setup Screen of Advantech Automation Software
Step 3: Select the PCI-1240/PCI-1240U DLL Drivers option.
Step 4: Select the proper Windows OS option according to your operating
system. Just follow the installation instructions step by step to
complete your DLL driver setup.

11 Chapter2
Figure 2.2: Different options for Driver Setup
Step 5: Then setup the PCI-1240/PCI-1240U Motion Utility automati-
cally.
For further information on driver-related issues, an online version of
Software Manual is available by accessing the following path:
Start\Advantech Automation\Motion\PCI-1240\
The example source codes could be found under the corresponding instal-
lation folder such as the default installation path:
\Program Files\Advantech\Motion\PCI-1240\Examples\

PCI-1240/PCI-1240U User Manual 12
2.3 Hardware Installation
After the DLL driver installation is completed, you can now go on to
install the PCI-1240/PCI-1240U card in any PCI slot on your computer.
But it is s
uggested that you should refer to the computer user manual or related
documentations if you have any doubt. Please follow the steps below to
install the card on your system.
Step 1: Turn off your computer and unplug the power cord and cables.
Step 2: Remove the cover of your computer.
Step 3: Remove the slot cover on the back panel of your computer.
Step 4: Touch the metal part on the surface of your computer to neutralize
the static electricity that might be on your body.
Step 5: Insert the PCI-1240/PCI-1240U card into a PCI slot. Hold the
card only by its edges and carefully align it with the slot. Insert
the card firmly into place. Use of excessive force must be
avoided, otherwise the card might be damaged.
Step 6: Fasten the bracket of the PCI card on the back panel rail of the
computer with screws.
Step 7: Connect appropriate accessories (100-pin cable, wiring terminals,
etc. if necessary) to the PCI card.
Step 8: Replace the cover of your computer chassis. Re-connect the
cables you removed in step 2.
Step 9: Plug in the power cord and turn on the computer.
Note Make sure you have installed the driver first
before you install the card (please refer to 2.2
Driver Installation)
TURN OFF your computer before installing or
removing any components on the computer.