Parker Compumotor AT6200 User manual

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Compumotor
Compumotor Division
Parker Hannifin Corporation
p/n 88-014541-02A October 1997
AT6200 & AT6400
Indexer
Installation Guide
P
R
O
G
R
A
M
M
A
B
L
E
I
N
P
U
T
S
4-AXIS CONTROLLER
AT6400
AC INPUT
CONNECTOR TO MAIN BOARD
P
R
O
G
R
A
M
M
A
B
L
E
O
U
T
P
U
T
S
J
O
Y
S
T
I
C
K
AUXILIARY
3POS
3NEG
3HOM
GND
4POS
4NEG
4HOM
GND
SHLD
ENCODER 4
TRIGGERS
STATUS
TRG-A
GND
TRG-B
GND
TRG-C
GND
TRG-D
GND
SHLD
ENCODER 3
LIM 3/4
+5V
GND
+5V
OUT-P
IN-P
GND
AUX-P
P-CUT
GND
ENCODER 2
SHLD
GND
Z-
Z+
B-
B+
A-
A+
+5V
SHLD
GND
Z-
Z+
B-
B+
A-
A+
+5V
SHLD
GND
Z-
Z+
B-
B+
A-
A+
+5V
SHLD
GND
Z-
Z+
B-
B+
A-
A+
+5V
ENCODER 1 LIM 1/2
1POS
1NEG
1HOM
GND
2POS
2NEG
2HOM
GND
SHLD
GREEN : READY
RED : NOT READY
OFF : NO POWER
D
R
I
V
E
1
D
R
I
V
E
2
D
R
I
V
E
3
D
R
I
V
E
4

6000 Series products and the information in this user guide are the proprietary property of Parker Hannifin Corporation or its licensers, and
may not be copied, disclosed, or used for any purpose not expressly authorized by the owner thereof.
Since Parker Hannifin constantly strives to improve all of its products, we reserve the right to change this user guide and software and
hardware mentioned therein at any time without notice.
In no event will the provider of the equipment be liable for any incidental, consequential, or special damages of any kind or nature
whatsoever, including but not limited to lost profits arising from or in any way connected with the use of the equipment or this user guide.
© 1995-7, Parker Hannifin Corporation
All Rights Reserved
User Information
WARNING
6000 Series products are used to control electrical and mechanical
components of motion control systems. You should test your motion
system for safety under all potential conditions. Failure to do so can result
in damage to equipment and/or serious injury to personnel.
! !
North America and Asia:
Compumotor Division of Parker Hannifin
5500 Business Park Drive
Rohnert Park, CA 94928
Telephone: [phone] or [phone]
Fax: [phone]
FaxBack: [phone] or [phone]
BBS: [phone]
e-mail: [email protected]
Internet: http://www.compumotor.com
Europe (non-German speaking) :
Parker Digiplan
21 Balena Close
Poole, Dorset
England BH17 7DX
Telephone: [phone]
Fax: [phone]
Germany, Austria, Switzerland:
HAUSER Elektronik GmbH
Postfach: 77607-1720
Robert-Bosch-Str. 22
D-77656 Offenburg
Telephone: [phone]
Fax: [phone]
Technical Assistance
Contact your local automation technology center (ATC) or distributor, or ...
Motion Architect is a registered trademark of Parker Hannifin Corporation.
Motion Builder, CompuCAM and DDE6000 are trademarks of Parker Hannifin Corporation.
Microsoft and MS-DOS are registered trademarks, and Windows, DDE and NetDDE are trademarks of Microsoft Corporation.
Motion Toolbox is a trademark of Snider Consultants, Inc.
LabVIEW is a registered trademark of National Instruments Corporation.
Motion & Control
E-mail: [e-mail]
Product Feedback Welcome

Change Summary
AT6n00 Installation Guide
88-014541-02
REV. A
The following is a summary of the primary technical changes to this installation guide for the AT6200 and AT6400
products, collectively referred to as the “AT6n00” products. The part number of this guide changed to reflect the changes
required to make the AT6n00 CE-compatible. This book, p/n 88-014541-02A, supersedes 88-014541-01B.
Topic Description
CE Installation Instructions The AT6n00 may now conform to the EMC, LVD, and Marking Directives necessary for
CE compliance when it is installed per the instructions in Appendix A*. The ultimate
responsibility for ensuring that the CE requirements for the system are met rests with
the system builder.
This CE compliance is valid for Serial Numbers 971101xxxx and greater. Also valid for
Serial Numbers prior to this if CE sticker is present on the unit.
*Note: The AT6400-AUX1-DC and AT6200-AUX1-DC versions of the AT6n00 are not
guaranteed to be CE compliant.
General Specifications Corrections:
• The current requirement for the AT6n00 PC card was changed from 3.5A to 1.8A.
• The current requirement for the AT6200 AC Auxiliary board and the AT6400-240
AC Auxiliary board was changed from 0.3A to .75A.
Drive Connections Addition: Diagrams were added to show how to connect to Linearserv, Dynaserv,
Zeta, S, OEM650, and PDS drives.
Deletion: The diagram showing how to connect to the PK2 drive was removed.
Encoder Connections Addition: Wire colors were added for Compumotor OS and RS Series motors.
Output Connections Correction: Diagram for Connection to a Sourcing Input now shows OUT-P pulled
up by external power supply.
Input Power Correction: Removed reference to AT6200 from 240VAC Input diagram. Also,
• The current requirement for the AT6n00 PC card was changed from 3.5A to 1.8A.
• The current requirement for the AT6200 AC Auxiliary board and the AT6400-240
AC Auxiliary board was changed from 0.3A to .75A.
Troubleshooting Correction: Solution 2b. for "Motion Does Not Occur" problem was corrected from
"Set LSPOS to a value less than LSNEG." to "Set LSPOS to a value greater than LSNEG."
Back Cover Quick Reference Correction: The current requirement for the AT6200 AC Auxiliary board and the
AT6400-240 AC Auxiliary board was changed from 0.3A to .75A.

ABOUT THIS BOOK
Chapter 1. Installation
What You Should Have (ship kit).................................2
Before You Begin ....................................................2
Electrical Noise.................................................2
Airborne Contaminants.......................................2
General Specifications.............................................3
Configuration/Customization—Optional DIP Switch Settings..4
PC Card Installation.................................................5
Mounting ...............................................................6
System Electrical Connections..................................7
Grounding System.............................................7
Verify Factory-Wired Connections ........................8
AUX Board Cable...............................................8
Pulse Cut-Off (P-CUT) — Emergency Stop Switch....8
Motor Drivers....................................................9
End-of-Travel and Home Limit Inputs...................11
Encoders.......................................................12
Joystick & Analog Inputs .................................13
Trigger Inputs.................................................14
General-Purpose Programmable Inputs & Outputs. 15
Input Power....................................................19
Lengthening I/O Cables....................................20
Installation Test....................................................21
What's Next?........................................................22
Chapter 2. Troubleshooting
Troubleshooting Basics...........................................24
Reducing Electrical Noise..................................24
Diagnostic LEDs..............................................24
Test Program ..................................................24
Motion Architect's Panel Module .........................25
Technical Support............................................25
Common Problems & Solutions .................................25
Problem/Cause/Solution Table............................25
Interrupt & Address Selection.............................27
Downloading Errors (downloading the operating
system)...................................................27
Product Return Procedure .......................................28
Appendix A: CE Installation Guide..................29
Index...............................................................35
Purpose of This Book
This book describes how to install and troubleshoot the AT6200 and AT6400 hardware.
Programming related issues are covered in the 6000 Series Programmer's Guide and the 6000
Series Software Reference.
“AT6n00”
Hereafter, the AT6200 and AT6400 are referred to collectively as the “AT6n00.”
What You Should Know
To install and troubleshoot the AT6n00, you should have a fundamental understanding of:
• IBM PC-compatible computer hardware and software operations
• Basic electronics concepts (such as voltage, switches, current, etc.)
• Basic motion control concepts (such as torque, velocity, distance and force)
Related Publications•6000 Series Software Reference, Parker Hannifin Corporation, Compumotor Division;
part number 88-012966-01
•6000 Series Programmer’s Guide, Parker Hannifin Corporation, Compumotor Division;
part number 88-014540-01
• Current Parker Compumotor Motion Control Catalog
• Operations user guide for the IBM-compatible PC-AT computer
• Schram, Peter (editor). The National Electric Code Handbook (Third Edition). Quincy,
MA: National Fire Protection Association

ii AT6200/AT6400 Installation Guide
AT6n00 Indexer: CE Compliance
Product Type: AT6200-120/240, AT6400-AUX1-120V, and AT6400-AUX1-240V
The above products have been demonstrated to be CE compliant, per the following directives,
when installed according to the instructions in Appendix A of this Installation Guide.
• 89/336/EEC Electromagnetic Compatibility Directive (EMC)
• 72/23/EEC Low Voltage Directive (LVD)
• 93/68/EEC CE Marking Directive
AT6n00 Indexers, when installed according to just the procedures in the main body of this
Installation Guide, may not necessarily comply with the LVD or EMC directives. To install
an AT6n00 Indexer so that it complies with the LVD and EMC directives, you must follow
the additional procedures described in Appendix A, under CE Installation Instructions. In some
installations, additional measures may be required. If you do not follow these instructions,
the protection of the product may be impaired. The ultimate responsibility for ensuring that
the CE requirements for the system are met rests with the system builder.
This CE compliance is valid for units with Serial Numbers 971101xxxx and greater. It is
also valid for Serial Numbers prior to this if the CE sticker is present on the unit.
Note: The AT6200-AUX1-DC and AT6400-AUX1-DC versions of the AT6n00 have not been
demonstrated to be CE compliant. Following the installation instructions in Appendix A will
improve performance, but does not ensure CE compliance for the AT6200-AUX1-DC and
AT6400-AUX1-DC.

1
CHAPTER ONE
Installation
IN THIS CHAPTER
• Product ship kit list
• General specifications table
• PC card installation procedures
• Mounting procedures
• Electrical connection procedures (including specifications)
• Installation test procedures
• Preparation for what to do next

2 AT6200/AT6400 Installation Guide
What You Should Have (ship kit)
Part Name Part Number
If an item is missing,
call the factory (see
phone numbers on
inside front cover).
One of the following line items:
AT6200 120/240VAC version (with ship kit)...................AT6200-120/240
AT6200 DC version (with ship kit)..................................AT6200-AUX1-DC
AT6400 120VAC version (with ship kit)..........................AT6400-AUX1-120V
AT6400 240VAC version (with ship kit)..........................AT6400-AUX1-240V
AT6400 DC version (with ship kit)..................................AT6400-AUX1-DC
Ship kit: High density cable, 5-foot (standard).................71-012832-05
High density cable, 15-foot (optional)................71-012832-15
(2) 10-foot, 15 D - 25 D drive cables.................71-010432-10
120VAC power cord............................................44-000054-01
240VAC EIA power cord connector
(AT6400-240 only).............................................. 43-011905-01
Mounting clips (AC version only)......................53-012068-02
Mounting screws (AC version only)..................51-006037-01
Ferrite absorber beads (2 included)..................47-015956-01
Cable clamp (1 included, in 2 pieces)...............53-016131-01
(This installation guide)......................................88-014541-02
6000 Series Software Reference ......................88-012966-01
6000 Series Programmer’s Guide .....................88-014540-01
Motion Architect diskettes: Disk 1.............95-013070-01
Disk 2.............95-013070-02
Drivers & Samples Disk...............95-016324-01
Before You Begin
WARNINGS
The AT6n00 is used to control your system's electrical and mechanical components.
Therefore, you should test your system for safety under all potential conditions. Failure to do
so can result in damage to equipment and/or serious injury to personnel.
Always remove power to the computer before:
• Installing or removing the AT6n00 PC card
• Adjusting the DIP switches on the AT6n00 PC card after it is installed in the computer
• Connecting electrical devices to the AT6n00 PC card after it is installed in the computer
Recommended Installation Process
• Review the general specifications.
• Install the AT6n00 card.
• Mount the AUX box.
• Connect all electrical system components.
• Test the installation.
• Mount the motor and couple the load.
• Program your motion control functions. Programming instructions are provided in the
6000 Series Programmer's Guide and the 6000 Series Software Reference. We
recommend using the programming tools provided in Motion Architect for Windows
(found in your ship kit). You can also benefit from an optional iconic programming
interface call Motion Builder (sold separately).
Electrical Noise Minimization Guidelines
• Do not route high-voltage wires and low-level signals in the same conduit.
• Ensure that all components are properly grounded.
• Ensure that all wiring is properly shielded.
• Noise suppression guidelines are provided on page 20 and in Appendix A.

Chapter 1. Installation 3
General Specifications
Parameter Specification
Power
AT6n00 PC Card......................................................5VDC @ 1.8A from the PC-AT bus
AT6200 AC AUX Board (AC or DC input).............90-264VAC, 50/60Hz, 0.75A @ 240VAC, single-phase; or connect an external power
source (5VDC ±5% @ 1.6A) to a +5V terminal on the AUXILIARY connector
AT6400-120V AUX Board (AC or DC input)..........90-132VAC, 50/60Hz, 1.5A @120VAC, single-phase; or connect an external power source
(5VDC ±5% @ 1.6A) to a +5V terminal on the AUXILIARY connector
AT6400-240V AUX Board (AC or DC input)..........90-264VAC, 50/60Hz, 0.75A @ 240VAC, single-phase; or connect an external power
source (5VDC ±5% @ 1.6A) to a +5V terminal on the AUXILIARY connector
AT6n00-DC AUX Board .........................................+5VDC (±5%) @ 1.6A
Status LEDs/fault detection......................................Refer to Status LEDs in Chapter 2
Environmental
Operating Temperature ..........................................32-122°F (0-50°C)
Storage Temperature...............................................-22-185°F (-30-85°C)
Humidity...................................................................0-95% non-condensing
Performance
Position Range.........................................................±2,147,483,648 steps
Velocity Range.........................................................1-1,600,000 steps/sec
Acceleration Range..................................................1-24,999,975 steps/sec2
Stepping Accuracy...................................................±0 steps from preset total
Velocity Accuracy ...................................................±0.02% of maximum rate
Velocity Repeatability .............................................±0.02% of set rate
Motion Algorithm Update Rate................................2 ms
Calculation to determine contouring deviation from an arc
(due to straight-line approximation to a curve):
Error in steps = (Vp ∗ t
2)2
r
Where: Vp= steps/sec, r= radius in steps, t= system update period (2 msec)
Inputs ALL INPUTS ARE OPTICALLY ISOLATED
Home, POS/NEG Limits, Trigger, P-CUT............HCMOS compatible*; internal 6.8 KΩpull-ups to AUX-P terminal (wired at factory to +5V);
voltage range is 0-24V.
Joystick inputs: Axes Select, Velocity Select, ......HCMOS-compatible*; internal 6.8 KΩpull-ups to 5V; voltage range is 0-24V.
Trigger, Release, & Auxiliary
Drive Fault and In-Position......................................HCMOS-compatible*; internal 1.0 KΩpull-up to 5V; voltage range is 0-5V.
Analog (joystick connector).....................................Voltage range = 0-2.5VDC, 8-bit A/D converter.
Input voltage must not exceed 5V.
Encoder.....................................................................Differential comparator accepts two-phase quadrature incremental encoders with
differential (recommended) or single-ended outputs.
Maximum voltage = 5VDC. Switching levels (TTL-compatible): Low ≤0.4V, High ≥2.4V.
Maximum frequency = 1.6 MHz. Minimum time between transitions = 625 ns.
24 General-Purpose Programmable .....................HCMOS compatible* with internal 6.8 KΩpull-ups to IN-P terminal (wired to +5V terminal
at factory). Voltage range = 0-24V. 50-pin plug is compatible with OPTO-22™ signal
conditioning equipment.
Outputs ALL OUTPUTS ARE OPTICALLY ISOLATED
24 General-Purpose Programmable......................Open collector output with 4.7 KΩpull-ups. Can be pulled up by connecting OUT-P to +5V,
or to user-supplied voltage of up to 24V. Max. voltage in the OFF state (not sinking
current) = 24V, max. current in the ON state (sinking) = 30mA. 50-pin plug is compatible
with OPTO-22™ signal conditioning equipment.
Step, Direction, Shutdown.......................................Differential line driver output. Signal high ≥3.5VDC @ +30mA, signal low ≤1.0VDC @
-30mA. +output for each differential driver is active high; -output for each driver is active
low. Step pulse width range is 0.3 µs to 20 µs (depends on the value of the PULSE
command—default is 0.3 µs).
+5V Output................................................................+5V terminals are available on the ENCODER and AUXILIARY connectors. Load limit (total
load for all I/O connections): 1.5A for the AT6400-120, 1.0A for the AT6400-240 and the
AT6200 AC version. Load limit for the DC versions of the AUX boards depends on your
external +5V power supply.
* HCMOS-compatible switching voltage levels: Low ≤1.00V, High ≥3.25V.
TTL-compatible switching voltage levels: Low ≤0.4V, High ≥2.4V.

4 AT6200/AT6400 Installation Guide
Configuration/Customization—Optional DIP Switch Settings
DIP Switch SW1
Factory Default Setting Shown
AT6n00 PC Card
DIP Switch SW2
Factory Default Setting Shown
1 512 200 OFF
2 256 100 OFF
3 128 80 ON
46440ON
53220ON
6 16 10 ON
788ON
Switch # Binary Value Default Setting
Decimal Hex
Switch # Interrupt Description Default Setting
1 IRQ3 Serial Port (COM4) OFF
2 IRQ4 Serial Port (COM3) OFF
3 IRQ5 Parallel Printer OFF
4 IRQ7 Parallel Printer OFF
5 IRQ10 Unassigned OFF
6 IRQ11 Unassigned OFF
7 IRQ12 Unassigned OFF
8 IRQ15 Unassigned OFF
Switches are positive-true (ON selects the interrupt setting).
Only one switch may be ON at one time.
000-255 000-0FF Used by AT mother-board
496-511 1F0-1FF Hard Disk (AT)
512-527 200-20F Game Controller
528-543 210-21F Expansion Unit
568-571 238-23B Bus Mouse
572-575 23C-23F Alternate Bus Mouse
624-639 270-27F Parallel Printer Port
688-734 2B0-2DF EGA Card
736-743 2E0-2E7 GPIB
744-751 2E8-2EF Serial Port (4)
760-767 2F8-2FF Serial Port (2)
768-799 300-31F Prototype Card
800-815 320-32F Hard Disk (XT)
888-895 378-37F Parallel Printer
896-911 380-38F SDLC
928-943 3A0-3AF SDLC
944-955 3B0-3BB Monochrome Card
956-959 3BC-3BF Parallel Printer
960-975 3C0-3CF EGA Card
976-991 3D0-3DF CGA Card
1000-1007 3E8-3EF Serial Port (3)
1008-1015 3F0-3F7 Floppy Disk
1016-1023 3F8-3FF Serial Port (1)
Computer I/O Address Space Map
Address Range Description
Decimal Hex
N
O
N
O
= ON position
INTERRUPTS (SW2) ADDRESS (SW1, switches 1-7)
Switches are negative-true (OFF selects the address
value). The sum of the binary values of DIP switches
1-7 comprise the PC card's device address. The
device address must be an even multiple of eight.
Switch #8 ON = 16-Bit Transfer Mode (default)
Switch #8 OFF = 8-Bit Transfer Mode
TRANSFER MODE (SW1, switch 8)
The 16-bit transfer mode offers higher performance than the 8-bit mode.
Switch #8
Default Settings
Address = 300 Hex (768 Decimal)
Transfer Mode = 16-Bit
Interrupts Selected = None
NOTE
If you change the Address or
Interrupt settings and you intend
to use Motion Architect, be sure to
configure the same settings in
Motion Architect's Terminal or
Panel Modules.
7654321876543218

Chapter 1. Installation 5
PC Card Installation
Step 1 Turn off the power to the computer.
Step 2 Remove the computer's cover to access the internal slots where peripheral cards are added.
Step 3 Select an expansion slot in your PC and remove the sheet metal bracket that covers the
associated external access slot. Save the screw. On IBM AT and IBM AT-compatible
computers, this is at the rear access panel where all external connections are made. This
bracket is replaced by the bracket on the end of the AT6n00 card.
Step 4 Select a 16-bit slot to install the AT6n00 card.
CAUTION
While handling the AT6n00 card, be sure to observe proper grounding techniques to prevent
damage from electro-static discharge (ESD).
Step 5 Insert the bottom corner of the AT6n00 PC card into the card guide slot near the front of the
computer. Ease both ends of the card simultaneously down into the computer until the card's
edge connector reaches the computer's mating connector (see drawing below). Adjust the card
until the edge connectors align and press it down into the mating connector.
Computer
Chassis
AT6n00
PC Card
PCA Card
Guide
Edge
Connector
Mounting
Screw
Mounting
Bracket
Step 6 Using the screw that secured the original access slot cover bracket, fasten the AT6n00
mounting bracket to the computer chassis (see drawing above).

6 AT6200/AT6400 Installation Guide
Mounting
This mounting procedure will not ensure CE compliance. Refer to Appendix A for specific
CE installation instructions.
To mount the AUX board, you must first attach the mounting brackets. The mounting
brackets and 6-32 (0.25-inch) mounting screws are provided in the ship kit. Do not use screws
longer than 0.25 inches; they protrude too far into the box and may damage the AUX board.
Observe the following mounting precautions:
• Mount the AUX board within the reach of the supplied 5-foot indexer-to-AUX cable.
You may not lengthen or shorten this cable. You can order custom cables up
to 15 feet from Compumotor's Custom Products Group at [phone]. A 15-foot
cable is available (part number 71-012832-15).
• If you mount the AUX board in an enclosure with other equipment, be sure to maintain
at least 6 inches of unrestricted air-flow space around the board. The maximum
allowable ambient temperature directly below the AUX board is 122°F (50°C). Fan
cooling may be necessary if adequate air flow is not provided.
5.50 (139.70)
1.25
(31.75)
2.13 (54.10)
2.00 (50.80)0.25 (6.35)
1.25
(31.75)
0.375 (9.53)
10.10
(256.54)
11.20
(284.48)
Optional Mounting
Tab Location Provision for #10
Mounting Screws
(
4 Plcs.
)
0.20
(5.08) 0.75 (19.05)
Mounting brackets
and 6-32 (0.25-inch)
mounting screws
are provided in the
ship kit.
AC Input AUX Boards DC Input AUX Boards
Provision for #6
Mounting Screws
5.50 (139.70)
1.25
(31.75)
0.55
(13.97)
0.20
(5.08)
11.60
(294.64)
10.70
(271.78)
11.20
(284.48)
0.75 (19.05) 0.20 (5.08)
1.50
(38.10)
2.13
(54.10)
Environmental Considerations
Temperature Operate the AT6n00 in ambient temperatures between 32°F (0°C) and 122°F (50°C)
Humidity Keep below 95%, non-condensing.
Airborne
Contaminants,
Liquids
Particulate contaminants, especially electrically conductive material, such as metal shavings
and grinding dust, can damage the AT6n00. Do not allow liquids or fluids to come in contact
with the AT6n00 card, its AUX board, or its cables.

Chapter 1. Installation 7
System Electrical Connections
Appendix A provides guidelines on how to install the AT6n00 to comply with
CE requirements. This will minimize the AT6n00's emissions and maximize the
AT6n00's immunity to externally generated electromagnetic interference.
Grounding System
TRIGGERS
SHLD
GND
GND
GND
GND
P
R
O
G
R
A
M
M
A
B
L
E
I
N
P
U
T
S
P
R
O
G
R
A
M
M
A
B
L
E
O
U
T
P
U
T
S
J
O
Y
S
T
I
C
K
AUXILIARY
GND
GND
GND
ENCODER 1
SHLD
GND
LIMITS 1/2
SHLD
GND
GND
Pin #8
(SHLD)
SHLD
Terminal
Even numbered
pins on I/O
connectors are
GND pins
AC Connector Ground Pin
GND Pins and Terminals
ENCODER 2
SHLD
GND
ENCODER 3
SHLD
GND
ENCODER 4
SHLD
GND
LIMITS 3/4
SHLD
GND
GND
1
8
9
15
DRIVE 1
DRIVE 2
DRIVE 3
DRIVE 4
EARTH
Isolated
Ground
SHLD
Terminal
SHLD
Terminal
SHLD
Terminal
SHLD
Terminal
SHLD
Terminal
SHLD
Terminal
Pin #14 (GND)
Mounting
Slot
1
8
9
15
1
8
9
15
1
8
9
15

8 AT6200/AT6400 Installation Guide
Verify Factory-Wired Connections
P-CUT connected to GND.
If this connection is broken, step pulses to all axes are stopped
(independent of the microprocessor).
+5V connected to AUX-P.
Provides +5V power to the pull-up resistor for the
POS/NEG, HOM, TRG, and P-CUT inputs.
AUXILIARY
+5V
GND
+5V
OUT-P
IN-P
GND
AUX-P
P-CUT
GND
1
+5V connected to OUT-P and IN-P.
Provides +5V power to the pull-up resistors for the
general-purpose programmable outputs (OUT-P) &
inputs (IN-P) on the 50-pin headers.
AUX Board Cable
AUX
Board
PC-AT
High Density Cable
provided in ship kit
Green: High density cable connected
OFF: Cable not connected properly
LED
This cable installation procedure will not ensure CE compliance. Refer to Appendix A for
specific CE installation instructions.
Pulse Cut-Off (P-CUT) — Emergency Stop Switch
Internal Schematic
P-CUT connected to GND (normally-closed switch).
If this connection is opened, step pulses to all axes are
stopped (independent of the microprocessor).
NOTE: If the P-CUT input is not grounded when motion
is commanded, motion will not occur and the error
message “WARNING: PULSE CUTOFF ACTIVE” will
be displayed in the terminal emulator.
AUXILIARY
+5V
GND
+5V
OUT-P
IN-P
GND
AUX-P
P-CUT
GND
1
+5V connected to AUX-P (sourcing current).
Provides +5V power to the P-CUT pull-up resistor. As an alternative,
you can connect AUX-P to an external power supply of up to 24VDC.
NOTE: AUX-P is also the pull-up for the POS/NEG, HOM & TRG inputs.
SINKING CURRENT: To make P-CUT sink current, connect AUX-P to
GND.
HCMOS compatible:
Low ≤1.00V; High ≥3.5V
ISO GND
74HCxx
6.8 KΩ
47 KΩ
+5VDC

Chapter 1. Installation 9
Motor Drivers
PIN OUTS & SPECIFICATIONS (15-pin DRIVE Connector)
15 D
Pin # Cable (71-010432-10) Color/25 D Pin # In/Out Name Description
1 Red/1 OUT Step (+) Differential output. Step (pulse) output to the drive. Step + signal is active high.
Signal levels: Low ≤1.0VDC @ -30mA, High ≥3.5VDC @ +30mA.
2 Green/2 OUT Direction (+) Differential output. High signal on Direction + specifies motion in the positive
direction; Low signal on Direction + specifies motion in the negative direction.
Signal levels: Low ≤1.0VDC @ -30mA, High ≥3.5VDC @ +30mA.
3— — Reserved -----------------------
4 Gray/10 IN In-Position Used for digital servo drives to indicate that the motor has reached the target
position. HCMOS switching levels (Low ≤1.0V, High ≥3.25V). Voltage range: 0-5V.
5 Yellow/9 IN Drive Fault An active-high (current not flowing) signal that tells the AT6n00 a drive has faulted.
HCMOS switching levels (Low ≤1.0V, High ≥3.25V). You can use the DRFLVL
command to change the active level to low (current flowing) if desired. NOTE: The
Drive Fault input will not be recognized until the input functions are enabled with the
INFEN1 command.
6— — Reserved -----------------------
7 — OUT +5V Isolated +5V.
8 Bare Wire/5 — Shield Connected to chassis (earth) ground within the AT6n00.
9 Black/14 IN Step Return (-) Differential output. Step (pulse) output to the drive. Step - signal is active low.
10 White/15 IN Direction Return (-) Differential output. Low signal on Direction - specifies motion in the positive
direction; High signal on Direction - specifies motion in the negative direction.
11 Blue/16 OUT Shutdown (+) Differential output. This signal is used to turn off current in the motor windings. High
signal on Shutdown + indicates the motor winding current should be off.
Signal levels: Low ≤1.0VDC @ -30mA, High ≥3.5VDC @ +30mA.
12 Purple/17 IN Shutdown Return(-) Differential output. This signal is used to turn off current in the motor windings. Low
signal on Shutdown - indicates the motor winding current should be off.
13 Orange/21 — Ground Isolated logic ground
14 Brown/22 — Ground Isolated logic ground
15 — — Reserved -----------------------
INTERNAL SCHEMATICS
Step, Direction & Shutdown Outputs
+5VDC
GND
15-Pin
DRIVE Connector
Step +
Direction +
Shutdown +
Step -
Direction -
Shutdown -
Shutdown Output Circuit Current Flow
(Active vs. Inactive)
Shutdown +
Shutdown -
Current
Flow
(Active)
Current
Flow
(Active)
Current
Flow
(Inactive)
Current
Flow
(Inactive)
Drive Fault and In-Position Inputs
+5VDC
GND
74HCxx
1 KΩ
15-Pin
DRIVE Connector
Drive Fault or
In-Position
Ground
(pin 13 or 14)
15-Pin
DRIVE Connector
+5VDC
GND
+5VDC
GND
+5VDC
GND
CONNECTIONS
15-pin D
Connector
Drive Motor
Plug-compatible with most
Compumotor and Digiplan drives
(exceptions are illustrated below).
Connect to DRIVE connector
25-pin D
Connector
Connect to drive
10-foot cables provided in ship kit (p/n 71-010432-10).
Maximum recommended cable length is 50 feet.
Pin outs and cable color code provided in table below.
71-010432-10
WARNING
Make sure the drive is off before
connecting it to the AT6n00.

10 AT6200/AT6400 Installation Guide
Motor Driver Connections (cont'd)
Direction Return (pin 10) Direction Return (pin 15)
Step + (pin 1) Step + (pin 1)
Direction + (pin 2) Direction + (pin 2)
Drive Fault (pin 5) Fault Output (pin 9)
Step Return (pin 9) Step Return (pin 14)
Shutdown Return (pin 12) Shutdown Return (pin 17)
Ground (pin 13 or 14) Fault Return (pin 21)
AT6n00
(DRIVE Connector)
Connecting a ZETA, S, OEM650 or PDS Drive
Shutdown + (pin 11) Shutdown + (pin 16)
Shield (pin 8)
ZETA, S, OEM650 or PDS Drive
(25-pin Connector)
Order the 71-010432-10 10-foot cable for plug compatibility with ZETA, S, OEM650, and PDS.
Direction Return (pin 10) Direction Return (pin 15)
Step + (pin 1) Step + (pin 3)
Direction + (pin 2) Direction + (pin 4)
Drive Fault (pin 5) ISO Fault + (pin 22)
Step Return (pin 9) Step Return (pin 14)
Shutdown Return (pin 12) Shutdown Return (pin 13)
Ground (pin 13 or 14) Fault Return (pin 23)
AT6n00
(DRIVE Connector)
OEM670SD Drive
Connecting an OEM670SD Drive
Shutdown + (pin 11) Shutdown + (pin 12)
Shield (pin 8)
Direction – (pin 10) Direction – (pin 19)
Step + (pin 1) Step + (pin 45)
Direction + (pin 2) Direction + (pin 20)
Drive Fault (pin 5) Servo Ready + (pin 15)
Step – (pin 9) Step – (pin 46)
Shutdown – (pin 12) Servo On + (pin 24)
Ground (pin 13) Servo Ready – (pin 16)
AT6n00
Connecting a Dynaserv Drive
Shutdown + (pin 11) Servo On – (pin 23)
Shield (pin 8)
Dynaserv
(50-pin DN1 Connector)
Order the 71-012985-10 10-foot cable for easy plug compatibility with the Dynaserv.
B – (pin 5) B – (pin 30)
A + (pin 8) A – (pin 14)
B + (pin 6) B + (pin 29)
A – (pin 7) A + (pin 13)
Z – (pin 3) Z – (pin 44)
Z + (pin 4) Z + (pin 43)
DRIVE ConnectorENCODER Connector
In Position + (pin 4) In Position + (pin 27)
Ground (pin 14) In Position – (pin 28)
Direction – (pin 10) Direction – (pin 37)
Step + (pin 1) Step + (pin 15)
Direction + (pin 2) Direction + (pin 13)
Drive Fault (pin 5) Servo Ready + (pin 31)
Step – (pin 9) Step – (pin 39)
Shutdown – (pin 12) Servo On + (pin 1)
Ground (pin 13) Servo Ready – (pin 26)
AT6n00
Connecting a Linearserv Drive
Ground (pin 14) Servo On – (pin 5)
Linearserv
(50-pin CN1 Connector)
B – (pin 5) B – (pin 43)
A + (pin 8) A – (pin 41)
B + (pin 6) B + (pin 19)
A – (pin 7) A + (pin 17)
Z – (pin 3) Z – (pin 45)
Z + (pin 4) Z + (pin 21)
DRIVE ConnectorENCODER Connector
In Position + (pin 4) In Position + (pin 7)
Shield (pin 8)
AT6n00
(DRIVE Connector)
Step + (pin 1)
PKH130M Drive
Direction + (pin 2)
Drive Fault (pin 5)
Shutdown Return (pin 12)
Direction Return (pin 10)
Step Return (pin 9)
Ground (pin 13 or 14)
Shield (pin 8)
Clock (pin 6)
Direction (pin 5)
Fault (pin 2)
Reset (pin 7)
0V (pin 8)
Connecting a PKH130M Drive

Chapter 1. Installation 11
End-of-Travel and Home Limit Inputs
NOTES
• Motion will not occur on a particular axis until you do one of the following:
- Install end-of-travel (POS & NEG) limit switches
- Disable the limits with the LHØ command (recommended only if load is not coupled)
- Change the active level of the limits with the LHLVL command
• Refer to the Basic Operations Setup chapter in the 6000 Series Programmer's Guide for
in-depth discussions about using end-of-travel limits and homing.
CONNECTIONS & INTERNAL SCHEMATICS
AUXILIARY
LIMITS
P
OS
& NE
G
connected to
G
ND
(
normally-closed sw
i
tches
)
.
Mount each switch such that the load forces it to open before it
reaches the physical travel limit (leave enough room for the load to
stop). When the load opens the switch, the axis stops at the decel
value set with the LHAD command. The motor will not be able to
move in that same direction until you clear the limit (close the
switch) and execute a move in the opposite direction (or you can
disable the limits with the LH command, but this is recommended
only if the motor is not coupled to the load). The active level
(default is active low) can be changed with the LHLVL command.
HOM connected to GND (normally-open switch).
The home limit input is used during a homing move, which is
initiated with the HOM command. After initiating the homing move,
the controller waits for the home switch to close, indicating that the
load has reached the “home” reference position. The active level
(default is active low) can be changed with the HOMLVL command.
Internal Schematic
1POS
1NEG
1HOM
GND
2POS
2NEG
2HOM
GND
SHLD
1
HCMOS compatible:
Low ≤1.00V; High ≥3.5V
ISO GND
74HCxx
+5V
GND
+5V
OUT-P
IN-P
GND
AUX-P
P-CUT
GND
1
+5V connected to AUX-P (sourcing current).
Provides +5V power to the POS, NEG, and HOM input pull-up
resistors. As an alternative, you can connect AUX-P to an external
power supply of up to 24VDC.
NOTE: AUX-P is also the pull-up for the P-CUT & TRG inputs.
SINKING CURRENT: To make these inputs sink current, connect
AUX-P to GND.
+5VDC
ISO GND
74HCxx
74HCxx
74HCxx
74HCxx
74HCxx
6.8 KΩResistors
47 KΩ
Resistors Chassis
GND
PIN OUTS & SPECIFICATIONS (9-pin LIMITS Connectors)
Pin # In/Out Name, Axes 1 & 2 Name, Axes 3 & 4 Description
9
8
7
6
5
4
3
2
1
IN
IN
IN
—
IN
IN
IN
—
—
1POS
1NEG
1HOM
GND
2POS
2NEG
2HOM
GND
SHLD
3POS
3NEG
3HOM
GND
4POS
4NEG
4HOM
GND
SHLD
Positive-direction end-of-travel limit input.
Negative-direction end-of-travel limit input.
Home limit input.
Isolated ground.
Positive-direction end-of-travel limit input.
Negative-direction end-of-travel limit input.
Home limit input.
Isolated ground.
Shield —Internally connected to chassis ground (earth).
Specification for all limit inputs
HCMOS compatible (voltage levels: Low ≤
1.00V, High ≥3.25V); internal 6.8 KΩpull-
ups to AUX-P terminal (AUX-P is wired at
factory to +5V); voltage range is 0-24V.
Active level for POS & NEG is set with the
LHLVL command (default is active low,
requiring normally-closed switch).
Active level for HOM is set with the
HOMLVL command (default is active low,
requiring normally-open switch).

12 AT6200/AT6400 Installation Guide
Encoders
CONNECTIONS & INTERNAL SCHEMATICS
ENCODER Connector
Shield Shield Shield
Ground Black Black
Z Channel – Orange/White (n/a)
Z Channel +
Orange Blue
B Channel – Green/White (n/a)
B Channel +
Green Brown
A Channel – Brown/White (n/a)
A Channel +
Brown White
+5VDC Red Red
Internal Schematic
Colors for Compumotor-supplied Encoders:
-E Series encoders
-RE encoder on OS motor (OSxxx-xxx-RE)
-RC encoder on OS motor (OSxxx-xxx-RC)
-EC encoder on RS motor (RSxxx-xxx-EC)
Encoders on OEM Series motors (except 57 size)
Incremental
Encoder
Max. Cable Length is 100 feet.
Use 22 AWG wire.
SHLD
GND
Z–
Z+
B–
B+
A–
A+
+5V
1
GND
+1.8VDC
22 KΩ
22 KΩ
+5VDC
Same Circuit
as A Channel
Chassis GND
+5VDC
9
Colors for -HJ encoder on OS motor (OSxxx-xxx-HJ),
and 57-size OEM Series encoders.
(These are single-ended encoders.)
PIN OUTS & SPECIFICATIONS (9-pin ENCODER Connectors)
Pin # In/Out Name Description
1
2
3
4
5
6
7
8
9
-----
-----
IN
IN
IN
IN
IN
IN
OUT
SHLD
GND
Z–
Z+
B–
B+
A–
A+
+5V
Shield —Internally connected to chassis ground (earth).
Isolated logic ground.
Z– Channel quadrature signal input.
Z+ Channel quadrature signal input.
B– Channel quadrature signal input.
B+ Channel quadrature signal input.
A– Channel quadrature signal input.
A+ Channel quadrature signal input.
+5VDC output to power the encoder.
Specification for all encoder inputs
Differential comparator accepts two-phase quadrature
incremental encoders with differential (recommended) or
single-ended outputs. Max. frequency is1.6 MHz.
Minimum time between transitions is 625 ns.
TTL-compatible voltage levels: Low ≤0.4V, High ≥2.4V.
Maximum input voltage is 5VDC.
Requirements for Non-Compumotor Encoders
• Use incremental encoders with two-phase quadrature output. An index or Z channel
output is optional. Differential outputs are recommended.
• It must be a 5V encoder to use the AT6n00's +5V output. Otherwise, it must be separately
powered with TTL-compatible (low ≤0.4V, high ≥2.4V) or open-collector outputs.
• The decoded quadrature resolution should be less than the motor resolution by a factor of
four to take advantage of the AT6n00's position maintenance capability.
• If you are using a single-ended encoder, leave the A–, B–and Z– terminals unconnected
on the AT6n00.

Chapter 1. Installation 13
Joystick & Analog Inputs
CONNECTIONS
SHLD
+5VDC
Analog Channel 1
Analog Channel 2
Velocity Select
Axes Select
Joystick Release
Joystick Trigger
GND
Velocity Select
Axes Select
N.O. Momentary
Joystick Trigger
Joystick potentiometers are 5K Ω with
60 ° of usable travel adjusted to span
0 Ω to 1K Ω .
N.C. Momentary
Joystick Release
1KΩResistors *
5KΩ
X Axis
5KΩ
Y Axis
Joystick Auxiliary
Joystick Aux.
Joystick
The 1K Ω resistors for velocity select,
axes select, joystick trigger, & joystick
auxiliary are for noise suppression only.
*
J
O
Y
S
T
I
C
K
23
1
2
16
15
17
18
19
14
8
Feedrate Control (Using a Potentiometer)
1KΩ
1KΩ
+5VDC
Analog Channel
GND
J
O
Y
S
T
I
C
K
23
14
*
8
* Pins 1, 2, 3 or 4
SHLD
Joystick
INTERNAL SCHEMATICS
25-Pin
JOYSTICK Connector
ISO GND
74HCxx
6.8 KΩ
47 KΩ
Input
Terminal
(Pins 15-19)
Ground
Terminal
(Pin 14)
+5VDC
150 KΩ
49.9 KΩ0.1 µF
10.0 KΩ35 V
35 V
This input circuit applies to Axes Select, Velocity Select,
Joystick Release, Joystick Trigger, & Joystick Auxiliary.
Analog Channel
Input Terminal
(Pins 1-4)
Ground
Terminal
(Pin 14)
+5VDC +5VDC
ISO GND
8 Channel
8-bit A/D
Converter
Analog Channel Input CircuitJoystick Input Circuit
HCMOS compatible:
Low ≤1.00V; High ≥3.5V
25-Pin
JOYSTICK Connector
PIN OUTS & SPECIFICATIONS
Pin In/Out Name Description
1 IN Analog Channel 1 Analog input for feedrate control or joystick control of axis. Voltage range is 0-2.5VDC, 8-bit A/D
converter. CAUTION: Input voltage must not exceed 5VDC.
2 IN Analog Channel 2 (same description as pin 1 above).
3 IN Analog Channel 3 (same description as pin 1 above).
4 IN Analog Channel 4 (same description as pin 1 above).
8 — Shield Shield (chassis ground).
14 — Ground Ground (isolated).
15 IN Axes Select If using one joystick, you can use this input to alternately control axes 1 & 2 or axes 3 & 4. *
16 IN Velocity Select Input to select high or low velocity range (as defined with the JOYVH or JOYVL commands). *
17 IN Joystick Release When low (grounded), joystick mode can be enabled. When high (not grounded), program
execution will continue with the first command after the joystick enable (JOY) statement. *
18 IN Joystick Trigger Status of this active-low input can be read by a program (using the INO or TINO commands) to
control program flow, or to enter the AT6n00 into joystick mode. *
19 IN Joystick Auxiliary Status of this active-low input can be read by a program (using the INO or TINO commands) to
control program flow. *
23 OUT +5VDC (out) +5VDC power output.
* Input voltage range for pins 15-19 is 0-24VDC. HCMOS compatible (switching voltage levels: Low ≤1.00V, High ≥3.25V).