artisan PMAC2-Lite Quick user guide

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^1 HARDWARE REFERENCE MANUAL
^2 PMAC2-Lite
^3 Programmable Multi-Axis Controller
^4 4xx-602406-xHxx
^5 July 17, 2003
Single Source Machine Control Power // Flexibility // Ease of Use
21314 Lassen Street Chatsworth, CA 91311 // Tel. [phone] Fax. [phone] // www.deltatau.com
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Copyright Information
© 2003 Delta Tau Data Systems, Inc. All rights reserved.
This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses are
unauthorized without written permission of Delta Tau Data Systems, Inc. Information contained
in this manual may be updated from time-to-time due to product improvements, etc., and may not
conform in every respect to former issues.
To report errors or inconsistencies, call or email:
Delta Tau Data Systems, Inc. Technical Support
Phone: [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.deltatau.com
Operating Conditions
All Delta Tau Data Systems, Inc. motion controller products, accessories, and amplifiers contain
static sensitive components that can be damaged by incorrect handling. When installing or
handling Delta Tau Data Systems, Inc. products, avoid contact with highly insulated materials.
Only qualified personnel should be allowed to handle this equipment.
In the case of industrial applications, we expect our products to be protected from hazardous or
conductive materials and/or environments that could cause harm to the controller by damaging
components or causing electrical shorts. When our products are used in an industrial
environment, install them into an industrial electrical cabinet or industrial PC to protect them
from excessive or corrosive moisture, abnormal ambient temperatures, and conductive
materials. If Delta Tau Data Systems, Inc. products are exposed to hazardous or conductive
materials and/or environments, we cannot guarantee their operation.
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PMAC2-Lite Hardware Reference Manual
Table of Contents
INTRODUCTION.......................................................................................................................................................1
Overview .......................................................................................................................................................................1
Board Configuration......................................................................................................................................................1
Base Version.........................................................................................................................................................1
Option 2: Dual Ported RAM.................................................................................................................................1
Option 5: CPU & Memory Configurations...........................................................................................................2
Option 6: Extended Servo Algorithm....................................................................................................................2
Option 7: Plate Mounting.....................................................................................................................................2
Option 8: High-Accuracy Clock Crystal...............................................................................................................2
Option 9: Serial Port Configuration.....................................................................................................................2
Option 10: Firmware Version Specification.........................................................................................................2
Option 12: Analog-to-Digital Converters.............................................................................................................2
Option 16: Battery-Backed Parameter Memory...................................................................................................3
Hardware Updates .........................................................................................................................................................3
Compatibility Issues......................................................................................................................................................4
PMAC2-LITE E-POINT DESCRIPTIONS..............................................................................................................5
E0: Firmware Reload Enable.........................................................................................................................................5
E1: Servo and Phase Clock Direction Control...............................................................................................................5
E2: CPU Frequency Select ............................................................................................................................................5
E3: Normal/Re-initializing Power-Up/Reset.................................................................................................................5
E4: CPU Frequency Select ............................................................................................................................................6
E5 – E6: (Reserved for Future Use)...............................................................................................................................6
E7 – E10: Host Interrupt Signal Select.........................................................................................................................6
E11-12: JEQU Port Configuration.................................................................................................................................7
E13: Encoder Sample Clock Direction Control.............................................................................................................7
E14: Watchdog Disable Jumper ....................................................................................................................................7
E17 – E18: Serial Port Select.........................................................................................................................................8
E20: Battery-Backed RAM Enable...............................................................................................................................8
E111-114: Command Output Disable State...................................................................................................................9
DIP Switch Block S1: ISA-BUS Address Select........................................................................................................10
HOST PC-AT I/O ADDRESS MAP.........................................................................................................................11
PMAC2-LITE MATING CONNECTORS .............................................................................................................13
J1 (JANA)/Analog (Option 12)...................................................................................................................................13
J2 (JTHW)/Multiplexer Port........................................................................................................................................13
J3 (JIO)/Digital I/O......................................................................................................................................................13
J4 (JMACRO)/MACRO Digital Data..........................................................................................................................13
J5 (JRS232)/RS-232 Serial Communications..............................................................................................................13
J5A (JRS422)/RS-422 Serial Communications...........................................................................................................13
J6 (JDISP)/Display......................................................................................................................................................13
J7 (JHW)/Auxiliary Channel.......................................................................................................................................14
J8 (JEQU)/Position Compare ......................................................................................................................................14
J9 (JMACH1)/Machine Port 1.....................................................................................................................................14
J10 (JMACH2)/Machine Port 2...................................................................................................................................14
J11 (JEXP)/Expansion.................................................................................................................................................14
PMAC2-LITE CONNECTOR PINOUTS...............................................................................................................15
J1 (JANA) Analog Input Port Connector ....................................................................................................................15
J2 (JTHW) Multiplexer Port Connector ......................................................................................................................16
J3 (JIO) General Input/Output Connector ...................................................................................................................17
J4 (JMACRO) MACRO Network Ring Interface Connector......................................................................................18
Table of Contents i
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PMAC2-Lite Hardware Reference Manual
J5 (JRS232) Serial Port Connector..............................................................................................................................19
J5A (JRS422) RS422 Serial Port Connector ...............................................................................................................20
J6 (JDISP) Display Connector.....................................................................................................................................21
J7 (JHW) Handwheel Encoder Connector...................................................................................................................21
J8 (JEQU) Position Compare Output Connector.........................................................................................................22
J9 (JMACH1) Servo Channel 1 & 2 Connector ..........................................................................................................23
J10 (JMACH2) Servo Channel 3 & 4 Connector ........................................................................................................27
TB1 (2/4-Pin Terminal Block).....................................................................................................................................30
TB2 (4-Pin Terminal Block)........................................................................................................................................31
ii Table of Contents
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PMAC2-Lite Hardware Reference Manual
INTRODUCTION
Overview
The PMAC2-Lite is a member of the PMAC2 family of boards optimized for interface to three or four
sinewave or direct PWM servo drives and to pulse-and-direction stepper drives. It has two channels of
servo interface circuitry, but its software is capable of eight axes of control. It is completely software
compatible with the PMAC2-PC and the Mini-PMAC2.
The PMAC2-Lite is a full-sized ISA-bus expansion card, with a small piggyback board containing the
CPU board. While the PMAC2-Lite is capable of ISA bus communications, with or without the optional
on-board dual-ported RAM, it does not need to be inserted into an ISA expansion slot. Communications
can be done through the standard on-board RS-232 serial port. Standalone operation is possible.
Board Configuration
Base Version
The base version of the PMAC2-Lite provides a 2/3-slot board with:
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40 MHz DSP56002 CPU
128k x 24 zero-wait-state SRAM active memory
512k x 8 flash memory for user backup and firmware
Latest released firmware version
RS-232 serial interface, ISA (PC) bus interface
One 16-node MACRO interface IC
Four channels axis interface circuitry, each including:
Three output command signal sets, configurable as either:
!" Two serial data streams to external DACs, one pulse-and-direction
!" Three PWM top-and-bottom pairs
3-channel differential/single-ended encoder input
Nine input flags, 2 output flags
Interface to two external serial ADCs, 8 to 18 bits
Two channels supplemental interface circuitry, each including:
Two-channel differential/single-ended encoder input
One output command signal set, configurable as
pulse-&-direction or PWM top-and-bottom pair
Display, MACRO, muxed I/O, direct I/O interface ports
PID/notch/feedforward servo algorithms
1-year warranty from date of shipment
One manual per set of one to four PMACs shipped
Cables, mounting plates, mating connectors not included
Option 2: Dual Ported RAM
Dual-ported RAM provides a high-speed communications path for bus communications with the host
computer through a bank of shared memory. DPRAM is advised if more than 100 data items per second
are to be passed between the controller and the host computer in either direction.
Introduction 1
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PMAC2-Lite Hardware Reference Manual
Option 2 provides an on-board 8k x 16 bank of dual-ported RAM. The key component on the board is
U23.
Option 5: CPU & Memory Configurations
If the 40MHz CPU that comes standard does not have sufficient computational power, faster versions are
available as options. These options provide faster CPU ICs in U7 and faster SRAM ICs in U58, U59, and
U60.
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Option 5B provides a 60MHz CPU with zero-wait-state SRAM active memory.
Option 5C provides an 80MHz CPU with zero-wait-state SRAM active memory.
Option 6: Extended Servo Algorithm
The standard PID servo algorithm with feedforward and notch filter is suitable for most applications.
Systems with difficult dynamics, especially with significant flexibility, may require a more powerful
servo algorithm, such as the Extended Servo Algorithm (ESA).
Option 6 provides firmware in the PMAC2-Lite that replaces the standard PID servo algorithm with
the Extended Servo Algorithm.
Option 7: Plate Mounting
If the PMAC2-Lite is used as an ISA bus expansion board, the standard hardware provides for proper
mounting of the board in the bus. However, if it is not installed in an ISA expansion slot, other provisions
must be made for mounting.
Option 7 provides a mounting plate connected to the PMAC2-Lite with standoffs. It is used to install
the PMAC2-Lite in standalone applications.
Option 8: High-Accuracy Clock Crystal
The PMAC2-Lite has a clock crystal (component Y1) of nominal frequency 19.6608MHz (~20MHz).
The standard crystal’s accuracy specification is +/-100 ppm. Long-term velocity accuracy is limited by
the accuracy of the crystal, unless an external time base is used.
Option 8A provides a nominal 19.6608MHz crystal with a +/-15 ppm accuracy specification.
Option 9: Serial Port Configuration
The original standard PMAC2-Lite (602406-100) included a single RS-232 serial port. Optionally, this
could be converted to RS-422, and a second serial port can be added. On the Universal PMAC2-Lite
(602406-101 and newer), both the RS-232 and RS-422 ports come standard. Jumpers E17 and E18 select
which port is used.
On the original PMAC2-Lite, Option 9L replaces main RS-232 port with an RS-422 port on a small
piggyback board. This option is not available on the Universal PMAC2-Lite.
Option 10: Firmware Version Specification
Normally, the newest released firmware version is provided with the PMAC2-Lite. A label on the U61
flash memory IC on the CPU board shows the firmware version loaded at the factory.
Option 10 provides for a user-specified firmware version.
Option 12: Analog-to-Digital Converters
Option 12 permits the installation of 8 or 16 channels of on-board multiplexed analog-to-digital
converters. One or two of these converters are read every phase interrupt. The analog inputs are not
optically isolated, and each can have a 0 – 5V input range, or a +/-2.5V input range, individually
selectable.
2 Introduction
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PMAC2-Lite Hardware Reference Manual
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Option 12 provides an 8-channel 12-bit A/D converter. The key components on the board are U28
and connector J1.
Option 12A provides an additional 8-channel 12-bit A/D converter. The key component on the board
is U29.
Option 16: Battery-Backed Parameter Memory
The contents of the standard memory are not retained through a power-down or reset unless they have
been saved to flash memory first. Option 16 provides supplemental battery-backed RAM for real-time
parameter storage that is ideal for holding machine state parameters in case of an unexpected power-
down.
Option 16 provides a 16k x 24 bank of battery-backed parameter RAM in components U84, U85,
U86, with the battery in BT1.
Hardware Updates
Significant upgrades were made to the PMAC2-Lite board between the original 602406-100 version and
the 602406-101 version. These included replacement of obsolescent circuitry, feature enhancement, and
changes for more cost-effective manufacturing. The upgrades include:
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80 MHz CPU: The new PMAC2-Lite supports the Option 5C 80 MHz CPU for high-end operations.
Supplemental Battery-Backed Parameter Memory: The new PMAC2-Lite supports the Option 16
supplemental battery-backed parameter memory to complement the flash-backed main memory.
Raised Bottom Edge: The bottom edge of the board has been raised so that it can clear high-profile
parts on the PC mother board – up to 25mm (1 inch) high.
Standard RS-422 Serial Port: An RS-422 serial interface, which formerly required the Option 9L
piggyback board, now is standard. Jumpers E17 and E18 must be set properly to select between the
RS-232 port and the RS-422 port.
Improved ADC Protection Circuitry: The protection circuitry for the Option 12 A/D converters no
longer has the potential to distort the input slightly near 5V.
Encoder-Loss Detection Circuitry: Circuitry that detects the loss of differential encoders has been
added.
Improved Position Compare Drive: The socket for U74 has been enlarged to 20 pins to support the
74ACT563 and 573 high-speed CMOS drivers for the JEQU port as well as the slower 18-pin 24V
driver ICs. In addition, a 2A fuse has been added to the +V input on the JEQU port.
Increased Use of Surface Mount Technology: Several components have been changed from
through-hole to surface-mount, for better part availability and lower cost.
Expanded JMACRO Connector: The J4 JMACRO connector has been expanded from 26 pins to 34
pins, separating the input and output lines to reduce crosstalk, and permitting a straight flat-cable
connection to the ACC-24P2 MACRO Driver/Receiver board.
Tristatable Servo Output Signals: Jumpers E111 through E114 permit the user to tristate the servo
command output signals automatically for channels 1 through 4, respectively, when the amplifier-
enable signal for the channel is in the disable state.
In-System-Programmable Logic: Interface logic ICs can now be programmed when installed in the
PMAC2-Lite, permitting elimination of sockets for higher reliability, and easier manufacturing and
upgradability.
Introduction 3
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PMAC2-Lite Hardware Reference Manual
Compatibility Issues
The new PMAC2-Lite can be operated in a manner that is 100% compatible with the old PMAC2-Lite.
The board is shipped from the factory with settings for 100% compatible operation. To ensure an
operation is compatible, double-check the following settings:
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Raised Bottom Edge: The higher bottom edge moves the lower left mounting hole for standoffs up
12.7 mm (0.5 in). If using standoff mounting, and the matching mounting hole cannot be moved,
contact Delta Tau for free offset standoffs.
Serial Port Choice: Because both RS-232 and RS-422 ports are always provided, jumpers must be
set correctly to use the port of choice. Jumpers E17 and E18 must connect pins 1 and 2 to use the RS-
232 port on the J4 connector; to use the RS-422 port on the J4A connector, they must connect pins 2
and 3
Surface Mount DIP Switch: Instead of a single 12-point DIP switch S1, there is an 8-point DIP
switch S1A and a 4-point DIP switch S1B. New S1A switches 1-8 correspond to old S1 switches 1-8,
respectively; new S1B switches 1-4 correspond to old S1 switches 9-12, respectively.
TriState Output Jumpers: Jumpers E111-E114 should be all OFF so that the servo output signals
stay enabled (not tristated) when the amplifier-enable signal for the channel is in the disable state.
Firmware Reload: Putting jumper E3 ON is now for re-initialization to factory default values only.
Firmware reload is set up by jumping pins 2 and 3 of E0.
Position Compare Driver IC: If an 18-pin ULN2803A or UDN2981A driver IC is installed in the
20-pin U74 DIP socket, it should be mounted in the right-most 18 pins.
4 Introduction
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PMAC2-Lite Hardware Reference Manual
PMAC2-LITE E-POINT DESCRIPTIONS
E0: Firmware Reload Enable
E Point &
Physical Layout Location Description Default
E0
(1)
(2)
(3)
Remove jumper for normal operation
Jump pin 1 to 2 to reload firmware
through serial or bus port.
Jump pin 2 to 3 to lock PMAC2 in
reset state (for factory use only).
No jumper
installed
Note: On –100 versions of the PMAC2-Lite, the firmware reload function was accomplished by putting
jumper E3 ON and giving the board a <CTRL-O> command.
E1: Servo and Phase Clock Direction Control
E Point &
Physical Layout Location Description Default
E1
Remove jumper for PMAC2-Lite to
use its internally generated servo and
phase clock signals and to output these
signals on the J5 serial port connector.
Jump pins 1 and 2 for PMAC2-Lite to
expect to receive its servo and phase
clock signals on the J5 serial port
connector.
No jumper
installed
Note: If the E1 jumper is ON and the servo and phase clocks are not brought in on the J5 serial port, the
watchdog timer will trip immediately.
E2: CPU Frequency Select
E Point &
Physical Layout Location Description Default
E2
Remove jumper for 40MHz operation
(E4 OFF also) or for 80MHz operation
(E4 ON).
Jump pin 1 to 2 for 60MHz operation
(E4 OFF).
No jumper
installed (standard
or Opt 5C)
Jumper installed
(Opt 5B)
E3: Normal/Re-initializing Power-Up/Reset
E Point &
Physical Layout Location Description Default
E3
Jump pin 1 to 2 to re-initialize on
power-up/reset, loading factory default
settings.
Remove jumper for normal power-
up/reset, loading user-saved settings.
No jumper
installed
Note: On –100 versions of the PMAC2-Lite board, this jumper was used both for re-initialization and for
firmware reload. With this jumper ON, after power-up/reset, a <CTRL-R> command would load factory
default settings; a <CTRL-O> command would prepare the card for loading of new firmware. Now E0
permits loading of new firmware.
PMAC2-Lite E-Point Descriptions 5
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