AES BeBoPr++ User manual

BEBOPR++
USER MANUAL
Copyright © AES allround embedded services 2012-2014
Author: as Laarhoven
Version: 1.4.9
Date: April 09, 2014

e oPr++ User Manual
Disclaimer, Warranties and Liability
Disclaimer
UNLESS OTHERWISE MUTUALLY AGREED TO Y THE PARTIES IN WRITING, LICENSOR OFFERS THE
PRODUCT AS-IS AND MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND CONCERNING
THE PRODUCT, EXPRESS, IMPLIED, STATUTORY OR OTHERWISE, INCLUDING, WITHOUT
LIMITATION, WARRANTIES OF TITLE, MERCHANTI ILITY, FITNESS FOR A PARTICULAR PURPOSE,
NONINFRINGEMENT, OR THE A SENCE OF LATENT OR OTHER DEFECTS, ACCURACY, OR THE
PRESENCE OF A SENCE OF ERRORS, WHETHER OR NOT DISCOVERA LE. SOME JURISDICTIONS
DO NOT ALLOW THE EXCLUSION OF IMPLIED WARRANTIES, SO SUCH EXCLUSION MAY NOT APPLY
TO YOU.
Warranties
THERE IS NO WARRANTY FOR THIS DESIGN, TO THE EXTENT PERMITTED Y APPLICA LE LAW.
EXCEPT WHEN OTHERWISE STATED IN WRITING THE COPYRIGHT HOLDERS AND/OR OTHER
PARTIES PROVIDE THE DESIGN “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESSED
OR IMPLIED, INCLUDING, UT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTA ILITY AND FITNESS
FOR A PARTICULAR PURPOSE. THE ENTIRE RISK AS TO THE QUALITY AND PERFORMANCE OF THE
DESIGN IS WITH YOU. SHOULD THE DESIGN PROVE DEFECTIVE, YOU ASSUME THE COST OF ALL
NECESSARY SERVICING, REPAIR OR CORRECTION.
Limitation on Liability
EXCEPT TO THE EXTENT REQUIRED Y APPLICA LE LAW, IN NO EVENT WILL LICENSOR E LIA LE
TO YOU ON ANY LEGAL THEORY FOR ANY SPECIAL, INCIDENTAL, CONSEQUENTIAL, PUNITIVE OR
EXEMPLARY DAMAGES ARISING OUT OF THE USE OF THIS PRODUCT, EVEN IF LICENSOR HAS EEN
ADVISED OF THE POSSI ILITY OF SUCH DAMAGES.
Beware: Just like the BeagleBone itself, this BeBoPr++
ex ansion board may be totally unsuitable for any ur ose!
Only use it if you fully understand the risks involved and
have taken ro er measures to revent ersonal injury
and/or material damage.
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Table Of Contents
Disclaimer, Warranties and Liability.......................................................................2
Disclaimer..................................................................................................2
Warranties .................................................................................................2
Limitation on Liability....................................................................................2
Table Of Contents............................................................................................3
Introduction...................................................................................................5
Getting Started...............................................................................................6
The Third Generation........................................................................................7
What has changed.........................................................................................7
What did not change....................................................................................10
e oPr++ Features..........................................................................................11
Generic I/O view.........................................................................................11
3D printer specific I/O view...........................................................................12
NC router specific I/O view............................................................................13
Software......................................................................................................14
Linux operating system.................................................................................14
3D-printer software.....................................................................................14
LinuxCNC..................................................................................................15
Other NC Applications...................................................................................15
The Cape.....................................................................................................16
Power......................................................................................................16
Configuration EEPROM..................................................................................16
Daughter modules.......................................................................................17
Connections..................................................................................................19
Power Connections......................................................................................19
Stepper Motor Connections............................................................................20
Stepper signals connector..............................................................................20
Thermistor connectors..................................................................................21
Limit switch connectors................................................................................21
PWM / analogue outputs................................................................................21
PWM Power Outputs........................................................................................22
e oPr++ improvements................................................................................22
Free-wheeling diodes...................................................................................23
Power dissipation........................................................................................23
Analogue inputs.............................................................................................25
Signal Conditioning......................................................................................25
Protection.................................................................................................26
Scaling.....................................................................................................26
Voltage inputs............................................................................................26
Thermistor curve........................................................................................26
Plug-in stepper drivers.....................................................................................28
I/O enable....................................................................................................30
Indicator LEDs...............................................................................................31
Power LEDs................................................................................................32
Status LEDs...............................................................................................32
Input signal LEDs.........................................................................................32
Output signal LEDs.......................................................................................32
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Switches......................................................................................................33
Fuses..........................................................................................................34
Jumpers......................................................................................................35
I2C and Emergency Stop...................................................................................36
Emergency Stop Input...................................................................................36
I2C us.....................................................................................................36
Specifications (preliminary)...............................................................................37
Connectors...................................................................................................38
Mating Connectors..........................................................................................40
I/O connectors:..........................................................................................40
Power connectors:.......................................................................................41
Troubleshooting.............................................................................................42
References...................................................................................................43
oard dimensions...........................................................................................44
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e oPr++ User Manual
Introduction
The BeBoPr++ is the third generation of BeBoPr boards. It integrates the original/classic
BeBoPr and the Bridge that was necessary to use the BeBoPr with the BeagleBone Black.
By integrating the Bridge, the BeBoPr++ stays compatible with both the original BeagleBone
and the BeagleBone Black. It also reduces complexity and manufacturing costs.
This manual tries to pro ide all information necessary to install, operate and troubleshoot
the BeBoPr++ .
This manual is still work-in-progress. Partly the content may still refer to the original
BeBoPr and may not be applicable on the BeBoPr++. Please do not hesitate to report errors
and/or send other (constructi e) feedback to the author ([email protected]).
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Getting Started
Although the e oPr may seem to have an overwhelming number of connectors, one can start
with only a power supply and a eagle one attached. This way some of the functionality can
be tested to get familiar with the board and before integrating it into the final configuration.
Step 1 - First get a eagle one that has been working before, so that you don't run into
US or networking configuration issues. Don't connect any cables or other capes
to the eagle one†. If the eagle one was powered from the US cable
previously, do not connect that cable to the eagle one yet.
Step 2 - Find a DC power supply that can deliver at around 1 Ampere or 10 Watt at some
voltage in the range from 12 to 24 Volts. Even a car battery might do for now.
Step 3 - If not done so already, prepare a power cable that connects to your supply on
one side, and attach a power plug (see “Power connectors:”on page 41) to the
other side of that cable. Make sure that the negative pole of the supply connects
to pin 1 of the connector on the e oPr.
Step 4 - Take the e oPr and only connect the power cable. Do not install the
eagle one yet. Now turn the supply on. Only the green LED close to the power
connector should light.
Step 5 - Use a small screwdriver or some other metallic object to short two adjacent pins
on one of the limit switch connectors‡. Shorting the left pin (pin 1) to the middle
pin should light the yellow LED next to the connector. This step verifies that the
step down voltage converter on the e oPr is working. A voltmeter should
measure 5.00 +/- 0.05 Volts on the outer two pins of each limit switch
connector.
Step 6 - Now turn the power off, wait one minute and then attach the eagle one to the
e oPr. Take note of the orientation and make sure all of the pins of the header
connectors on the e oPr are inserted in the connectors on the eagle one.
Start by aligning the eagle one onto the pins before applying pressure to
engage the connectors. Have a look from all sides and make sure all pins are
inserted. e gentle!
Step 7 - Now turn the supply on again. Immediately the two green LEDs on the e oPr
should light, as well as some of the blue LEDs on the eagle one. You can now
connect a network cable or US cable.
Step 8 - Wait for the eagle one to boot. Use the console cable if available to view the
boot process. Shortly after Linux has started, the yellow status LED on the
e oPr should start blinking synchronously with the heartbeat LED on the
eagle one.
At this point, the eagle one is running a suitable kernel and the device tree overlay was
loaded successfully. This procedure can always be used as a first test to diagnose problems.
† The only exception being a serial console cable. Connect that to the eagle one if available to follow the
boot process and ease debugging.
‡ Don't worry, even shorting the wrong two pins on these connectors will not harm the board.
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The Third Generation
This chapter summarizes the differences between the original BeBoPr and the BeBoPr++. It
contains useful information for users that already own a BeBoPr or are otherwise familiar
with the BeBoPr specifications.
What has changed
Board layout
The e oPr++ has gotten a complete new board layout. All SMD components were moved from
the bottom side to the top side. There are no longer components underneath the board,
reducing the overall board height and manufacturing costs.
The choice of components makes it no longer possible to solder the board only a soldering
iron. As the board was never officially offered as DIY kit, this shouldn't be an issue.
Ele ated BeagleBone mounting
With the BeBoPr Bridge, the distance between the eagle one and the e oPr was increased.
This allowed access to the serial console connector on the eagle one as well as the US host
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Illustration 1 - BeBoPr++ R1 prototype

e oPr++ User Manual
port, HDMI connector and uSD card slot while mounted on the e oPr. This feature was
propagated into the design of the e oPr++. Extended pin-header connectors create a similar
gap between e oPr++ and eagle one.
Wide input power range
The step down converter has been re-designed to operate from a DC supply voltage in the
range from 12 to 24 Volts. It's still using the same (proven) step down converter as before but
some of the components have changed so that it now can operate at 24 Volts too.
More power for heaters
Since the input supply voltage is also used for the heater outputs, these can now generate
more heat (power) without exceeding the maximum allowed currents. The input power
connector has also been replaced by a type that allows 16A (instead of 12A) of continuous
current. Now it is possible to control a heated build platform and an extruder simultaneously
without exceeding the maximum current specifications.
Single fuse
The expensive and hard to get SMD fuses on the three PWM outputs have been replaced by a
single 5×20 mm fuse. This fuse is now placed into the board's input power line.
Input power LED
A green LED located near the input power connector indicates the presence of supply power.
It will not light if the fuse has blown. This LED replaces the three green LEDs
I2C connector
The eagle one's I2C2 bus is now routed to a 4 pin connector, no need to solder wires directly
to the board any more. This allows I/O expansion or connection of a simple I2C LCD. A level
shifter allows connection of 3.3 or 5 Volt powered devices without chance of damaging the
eagle one.
Emergency Stop input
The e oPr now also has a hardware emergency stop (ESTOP) input. Activation of the ESTOP
signal negates the I/O enable without depending on the software. The ESTOP immediately
disables the PWM outputs and stepper signals. A red LED signals the ESTOP state.
If preferred, the ESTOP signal can be configured to latch (remain active once asserted) until
it's cleared by software (negation of the I/O enable signal). Closing a jumper on the e oPr
activates the latch.
The ESTOP signal should connect to a normally closed contact or some open collector / open
drain type sensor. When not used, a jumper or piece of wire can replace the sensor. An
external opto coupler / isolator can be used to interface to 24 Volt signals.
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Impro ed PWM outputs
The PWM output stages have been redesigned to generate less heat in the output switches
(FETs) and allow up to 32 kHz PWM switching frequency without significant losses. The TO220
FETs have been replaced by SMD parts with lower RDSon. The 'heated-bed' output now can
deliver 120 Watt (10 A) at 12 Volt, or up to 200 Watt (8 A) at 24 Volt. Most heated build
platform can now connect without the need for an external mechanical or solid state relay.
All PWM outputs now have on-board free-wheeling diodes as described in the section named
“PWM / analogue outputs“. These diodes protect the FETs (and the rest of the board) from
the voltage spikes that occur when switching at high speed or with inductive loads†.
I/O enable LED
This LED indicates that the I/O devices are 'live'. An inadvertently de-activated I/O enable
will prevent the I/O signals to function properly. This was not always obvious and hard to
debug, now this signal's state is directly visible.
Larger bypass capacitor for stepper modules
The bulk capacitance that bypasses the stepper motors power supply has been increased. A
high quality 220 uF/50V electrolytic capacitor has been added. This should prevent damage
to the Pololu stepper driver modules caused from over-voltage spikes generated by the
motors.
Reset button
The location of the reset button was moved to the opposite side of the board. It's now
situated next to the power button, beneath the power jack on the eagle one.
Sensor power
The 5 Volts on the limit sensor input connectors is no longer controlled by the eagle one but
available as soon as board input power is present. This supply can be used for many limit
switches that need a supply to function (e.g. optical sensors or three wire industrial proximity
sensors) or special functions that need 5 Volt when the eagle one is not present or has been
powered down.
† For EMC reasons it may still be necessary to mount an anti-parallel free-wheeling diode directly on the load.
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What did not change
Dimensions
The board dimensions and mounting hole pattern have remained the same.
Connectors
All connectors have remained the same and are compatible with the original e oPr
connectors†. The locations on the board haven't changed either, making the e oPr++ a plug-
in replacement for e oPr+ boards or e oPr-with- ridge combinations.
The new connectors (for the I2C bus and the ESTOP input) are located between the reset
button and the stepper motor power connector, beneath the RJ45 connector of the
eagle one.
Software Compatibility
The hardware is backwards compatible with the e oPr+ and e oPr with ridge. No software
changes should be necessary to operate a e oPr++ with the software designed for a e oPr+
or e oPr-with- ridge.
† When using the extra current that the e oPr++ can deliver compared to the e oPr and e oPr+ boards, the
power plugs and wiring should to be changed to handle the extra current. Read more on this subject in Mating
Connectors on page 40.
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e oPr++ User Manual
BeBoPr++ Features
Although designed as 3D printer controller, the BeBoPr++ can be used for many other
applications. This chapter describes the interfaces in a generic way first, followed by
mapping these features on 3D printer hardware.
Generic I/O iew
Analogue inputs (3x)
Three analogue inputs accept a 0 - 3.6 Volt input range. The inputs are protected against
over-voltage: Accidental shorts between thermistor wires and the 12 Volt supply voltage will
not destroy the eagle one.
The input filter scales (by a factor 0.5) and limits the analogue input signals to the
eagle one's 0 - 1.8 Volt range.
Instead of using the troublesome eagle one's on-chip ADC, a more stable 12-bit ADS1015 is
present on the e oPr++. It operates in parallel to the eagle one's ADC and uses a standard
Linux driver.
Analogue (PWM) outputs (3x)
Three high power outputs are connected to the processor's PWM devices. These outputs can
also be used as digital outputs, to control a relay, a motor, or other DC load.
Digital inputs (6x)
Six digital inputs can be used for simple logic signals, or to connect switches or opto sensors
directly. The three pin connectors also provide a +5 Volt signal for sensors that need a supply
voltage. The supply is protected against short-circuits by a thermal fuse.
Digital outputs (12x)
Twelve +5 Volt TTL/CMOS level compatible outputs are available on a header connector.
These outputs can be switched to tristate via software and by an active low disable signal.
Supply
The board can operate from a single power supply that provides a DC voltage in the range
12 to 24 Volts. If re uired, the stepper drivers can operate from a different supply than that
is used for the board. An efficient step down converter generates the 5 Volt supply for the
BeagleBone. This makes the BeBoPr++ compatible with almost any kind of DC power
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e oPr++ User Manual
source. Choose between a cheap ATX power supply, a simple laptop 18-20 Volt adapter, an
adjustable lab bench supply, an industrial 24 Volt supply or whatever is available and can
deliver sufficient power for your application.
3D printer specific I/O iew
Stepper outputs
The e oPr has no integrated stepper drivers, but offers four sockets that accept Pololu,
StepStick or other compatible modules. If these modules are used, the motors connect to the
connectors next to the module sockets on the e oPr.
Applications requiring 5 axes, or more powerful stepper drivers, can connect these off-board
drivers to the connector that is located between the Pololu sockets and that carries all
relevant signals for up to 5 axes.
Limit switch inputs
These inputs accept a mix of mechanical switches and/or optical-sensors. They can connect
directly to slow changing input signals because of the Schmitt Trigger inputs. Each input has a
5 Volt supply pin for external sensors that need power to operate. This supply can deliver 0.3A
for all inputs combined and is short circuit protected by a thermal fuse.
Power outputs
Three powerful outputs can generate PWM signals for motors and/or heaters, or analogue
signals for laser power control. These outputs can be controlled directly by the high
resolution PWM controllers in the AM335X processor, or via GPIO signals for bit-bang or simple
on/off control.
The output closest to the board power input connector J20 is dimensioned to deliver 120 W to
200 W, depending on the voltage used (10A @ 12 Volts or 8A @ 24 Volts). The other two
outputs can deliver 4A each (50 W @ 12 Volts or 100 W at 24 Volts). Note that the combined
current drawn should not exceed the 16 A specification!.
The power switching FETs have very low RDSon and are driven by MOSFET drivers. They can
operate at high switching frequencies with relatively low switching losses.
Connecting inductive loads can cause all kinds of trouble, ranging from HF noise up to a
damaged e oPr. Always use a free-wheeling diode directly over the load. This keeps the
current loop (coil!) as small as possible and reduces the area polluted by the EMI noise.
Use of high current loads may require forced air cooling of the board (FETs, diodes and fuse).
This prevents parts from overheating, melting the solder and possibly destroying the e oPr,
your home or even worse. Make sure to also read the chapter on “FET power dissipation”.
Always be careful, start conservative and test. Increasing power only if you feel comfortable
with the results of the previous step.
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Warning: Some of the components can get very hot, too hot to touch! If in doubt, use a
moistened finger before probing a package†.
Never ever leave your system unattended when playing with these kinds of high currents!
The intention is to generate heat, but sometimes the heat will appear at an unexpected
location: An oxidized connector, a connector screw not tightened properly, a bad solder joint.
Any place with some resistance becomes important!
Thermistor Inputs
The analog inputs are used for thermistors that measure the temperature of the temperature
controlled devices, often the heated build platform (HP or bed) and up to two extruder(s)
NC router specific I/O iew
A router will use the stepper signals and limit switches just like a 3D-printer. The power
outputs and analog inputs are free to use for other purposes.
† e careful and don't use a 'wet' finger as that may cause shorts!
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e oPr++ User Manual
Software
The BeBoPr++ can be used with all BeagleBone ersions. The classic (white) and the
BeagleBone Black are both hardware compatible with the BeBoPr++.
The BeBoPr++ cape's on-board EEPROM holds configuration information for both the 3.2
kernel (I/O multiplexer settings) and the de ice tree based 3.8 kernels. The board identifies
itself as 'cape-bebopr-brdg'.
Linux operating system
BeagleBone (classic)
The first eagle one used kernel 3.2. This kernel used information from the EEPROM on the
e oPr to configure the I/O properly. The 3.8 kernel used for the will also work on this
eagle one.
BeagleBone Black
The uses device tree overlays to configure the processor's I/O subsystem. The proper
overlay is selected by configuration information in the EEPROM on the e oPr. The
eagle one lack needs kernel 3.8 or later.
3D-printer software
Open source BeBoPr code
An open source code repository to build a 3D printer with the e oPr++ is available at
https://github.com/modmaker/ e oPr. This code uses one of the PRU coprocessors for the
step pulse generation and can freely be changed.
PRU stepper code
Each e oPr++ comes with a license for use of the PRUSS stepper driver firmware. This
stepper driver is proprietary code that runs on a PRU co-processor and is stored in the
e oPr++'s on-board EEPROM. The driver handles deterministic and accurate timing of the
stepper pulses for all four axes simultaneously. It also generates the acceleration and
deceleration ramps. Via the API†, custom applications can easily generate accurate stepper
† The API can be found in the open source e oPr code.
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motor control without needing extra hardware or highly specialized real-time code.
LinuxCNC
LinuxCNC has been around for a long time. Originally Intel X86 only, was developed to control
mills, lathes and routers. Since the port to the eagle one, its also being used for 3D
printers. oth orthogonal (XYZ) types and Kossel style delta printers.
As an alternative for the e oPr code, open source purists will probably like LinuxCNC more.
It has support for the e oPr since the original (first) e oPr and all software, including the
PRU stepper code is open source. As a community effort, it evolves faster than the e oPr 3D
printer code.
Other NC Applications
What has been written about 3D-printer software above also applies for other numerical
control applications. eing it a simple router, a laser engraver or another dedicated machine.
These applications will probably not need the PWM heater outputs from the e oPr. ut often
they need to control devices like a spindle, coolant fluid pump or laser power supply. These
can then be controlled from the otherwise unused outputs.
Unlike 3D printers and small routers, a real mill or big router will require more powerful
stepper motors than will fit on the e oPr In that case, instead of using the Pololu kind of
plug-in stepper modules, off-board power stepper drivers can be used. This way LinuxCNC can
control up to 5-axis that connect via a flat-cable to the e oPr.
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The Cape
Power
The on-board switching step-down converter creates the 5 Volts DC required for the
eagle one, e oPr and (external) digital inputs.
Configuration EEPROM
The e oPr uses an on-board EEPROM to identify itself to the eagle one.
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Illustration 2: - BeBoPr features on an early prototype

e oPr++ User Manual
For 3.2 kernels (used by the original eagle one), the pinmux configuration is read from the
EEPROM during kernel start-up. All inputs and outputs are configured accordingly (this
requires kernel 3.2.16 or later).
The 3.8 kernels used by the eagle one lack have a different way to set the pinmux
configuration. During boot the cape's identifier is read from the EEPROM and the
corresponding Device Tree Overlay is loaded. The DT overlay defines the configuration of the
inputs and outputs, as wel as the configuration of various subsystems from the processor.
The EEPROM address of the e oPr cape is factory set to 0x54.
Daughter modules
The e oPr cape is designed to act as base board for the eagle one module and (optionally)
the stepper driver modules as shown in the illustration below.
ecause of the board size and the amount of cables needed to connects all devices to the
e oPr, the stacking order has been reversed, and the eagle one sits on top of the cape
instead of the other way around. The cape has four mounting holes for attachment to a flat
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Illustration 3: BeBoPr - daughter modules

e oPr++ User Manual
surface. Spacers with a minimum height of 4 mm are needed to prevent shorting pins on the
bottom side of the cape.
Although eagle one and its capes are designed to form a stack of undetermined height,
there can only be a single e oPr and a single eagle one in the stack. The eagle one is
always the first board of a stack, and the e oPr cape is always the last, because neither
board has stack-through connectors.
Other capes can be stacked between the e oPr and the eagle one, but not all
combinations will work properly. This depends on the signals used by the other capes.
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Connections
Power Connections
J18 – Stepper driver power. Connect a 12-24 Volt DC (+/- 10%) regulated power supply. Can be
left unconnected if no Pololu-like stepper drivers modules are used.
J20 – oard power. Connect a 12-24 Volt DC regulated power supply. This is the supply for the
eagle one and the high-power PWM outputs.
oth connectors have the ground on pin 1 and the supply / plus on pin 2.
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Illustration 4: BeBoPr cape - connectors

e oPr++ User Manual
WARNING: Do not exceed the maximum specified current for these connectors.
WARNING: Do not connect power to the DC INPUT (P5) jack on the eagle one once mounted
on the e oPr. This will most likely damage the e oPr and/or the supply connected to the
DC INPUT.
Stepper Motor Connections
If the e oPr has the stepper driver modules on board, the four stepper motors connect to
J15, J16, J17 and J19. In that case connector J5 is hidden underneath the driver modules and
can not be used.
J15 – X-axis, pins 1&2 motor coil-A, pins 3&4 motor coil-
J16 – Y-axis, pins 1&2 motor coil-A, pins 3&4 motor coil-
J17 – Z-axis, pins 1&2 motor coil-A, pins 3&4 motor coil-
J19 – E-axis, pins 1&2 motor coil-A, pins 3&4 motor coil-
Stepper signals connector
J5 – all stepper signals are present on this connector. It connects directly to the 15 pin sub-D
connector of a T 6560-4V5 3A stepper driver board sold on e- ay.
Pin nr Direction Signal AM3359 pin
1 GND
2 in/out EXT_VCC (sense)
3 out #STEPPER_IO_SELECT
4 out Z_ENA_BUF V5
5 out Y_ENA_BUF T4
6 out E_DIR_BUF U9
7 out E_STP_BUF R6
8 out Z_DIR_BUF R5
9 out Z_STP_BUF U5
10 out Y_DIR_BUF T3
11 out Y_STP_BUF T2
12 out X_DIR_BUF R4
13 out X_STP_BUF R3
14 out E_ENA_BUF V9
15 out X_ENA_BUF T1
16 N/C
Table 1: J5 stepper dri er signals
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