Performance Motion Devices Prodigy Series User manual

Performance Motion Devices, Inc.
80 Central Street
Boxborough, MA 01719
Revision 1.2, December 2009
Prodigy
®
/CME PC/104
User’s Guide

ii Prodigy/CME PC/104 User’s Guide
NOTICE
This document contains proprietary and confidential information of Performance Motion Devices, Inc., and is pro-
tected by federal copyright law. The contents of this document may not be disclosed to third parties, translated, copied,
or duplicated in any form, in whole or in part, without the express written permission of PMD.
The information contained in this document is subject to change without notice. No part of this document may be
reproduced or transmitted in any form, by any means, electronic or mechanical, for any purpose, without the express
written permission of PMD.
Copyright 1998–2009 by Performance Motion Devices, Inc.
Prodigy, Magellan, ION, Magellan/ION, Pro-Motion, C-Motion, and VB-Motion are registered trademarks of
Performance Motion Devices, Inc.

Prodigy/CME PC/104 User’s Guide iii
Warranty
PMD warrants performance of its products to the specifications applicable at the time of sale in accordance with
PMD’s standard warranty. Testing and other quality control techniques are utilized to the extent PMD deems necessary
to support this warranty. Specific testing of all parameters of each device is not necessarily performed, except those
mandated by government requirements.
Performance Motion Devices, Inc. (PMD) reserves the right to make changes to its products or to discontinue any
product or service without notice, and advises customers to obtain the latest version of relevant information to verify,
before placing orders, that information being relied on is current and complete. All products are sold subject to the
terms and conditions of sale supplied at the time of order acknowledgement, including those pertaining to warranty,
patent infringement, and limitation of liability.
Safety Notice
Certain applications using semiconductor products may involve potential risks of death, personal injury, or severe
property or environmental damage. Products are not designed, authorized, or warranted to be suitable for use in life
support devices or systems or other critical applications. Inclusion of PMD products in such applications is under-
stood to be fully at the customer's risk.
In order to minimize risks associated with the customer’s applications, adequate design and operating safeguards must
be provided by the customer to minimize inherent procedural hazards.
Disclaimer
PMD assumes no liability for applications assistance or customer product design. PMD does not warrant or represent
that any license, either express or implied, is granted under any patent right, copyright, mask work right, or other in-
tellectual property right of PMD covering or relating to any combination, machine, or process in which such products
or services might be or are used. PMD’s publication of information regarding any third party’s products or services
does not constitute PMD’s approval, warranty or endorsement thereof.

iv Prodigy/CME PC/104 User’s Guide
Related Documents
Magellan
®
Motion Processor User’s Guide
Complete description of the Magellan Motion Processor features and functions with detailed theory of its
operation.
Magellan
®
Motion Processor Programmer’s Command Reference
Descriptions of all Magellan Motion Processor commands, with coding syntax and examples, listed alpha-
betically for quick reference.
Prodigy
®
/CME Programmer’s Reference
Descriptions of all Prodigy/CME product commands, with software architecture overview, command syn-
tax, and examples.
C-Motion
®
Engine Development Tools Manual
Description of the C-Motion Engine, development environment, and software tools.
Pro-Motion
®
User’s Guide
User’s guide to Pro-Motion, the easy-to-use motion system development tool and performance optimizer.
Pro-Motion is a sophisticated, easy-to-use program which allows all motion parameters to be set and/or
viewed, and allows all features to be exercised.

Prodigy/CME PC/104 User’s Guide v
Table of Contents
Chapter 1. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Prodigy Family Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Prodigy/CME PC/104 Card Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Accessory Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Recommended Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7 Software Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.8 Preparing the Card for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.9 Connection Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.10 Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.11 First-Time System Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.12 Developing User Application Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Chapter 2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Card Function Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Magellan Motion Processor Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 Magellan-Controlled Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 C-Motion Engine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5 Communications Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.6 General Card Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.7 Signal Processing and Hardware Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.8 Software Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 3. Accessing Card Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Resource Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Accessing the Communications Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3 Accessing On-Card Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.4 Accessing Magellan-Attached Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.5 PRP Communication Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 4. Electrical Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 User-Settable Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3 Connections Summary—Motor Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.5 Environmental and Electrical Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.6 Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.7 User I/O Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Chapter 5. Interconnect Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.1 IM-1000 Interconnect Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2 IM-600 Interconnect Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.3 DC-1000 SSI Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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Prodigy/CME PC/104 User’s Guide vii
List of Figures
1-1 Prodigy/CME PC/104 Card Component Location, front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1-2 Prodigy/CME PC/104 Card Component Location, back view . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1-3 Switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1-4 Serial Port Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1-5 Serial and Ethernet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1-6 Two Ways to Locate the Code on the Prodigy/CME PC/104 Card . . . . . . . . . . . . . . . . . . . . . . . . .29
2-1 Prodigy/CME PC/104 Card Internal Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2-2 On-card Dual-ported Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2-3 Overview of C-Motion Engine Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3-1 Outgoing and Returning PRP header formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
3-2 Example Network Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
3-3 Example Prodigy/CME PC/104 Architecture with Ethernet Device Testers . . . . . . . . . . . . . . . .62
3-4 Host Controller & On-card Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
3-5 Host Controller & Magellan-attached Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
3-6 PRP Message over Serial Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
4-1 Components and layout, front of card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
4-2 Prodigy/CME PC/104 Card Component Location, back view . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
4-3 Switch Settings by Output Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
4-4 Sync I/O connector to three cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
4-5 Prodigy/CME mechanical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
5-1 IM-1000 location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
5-2 IM-600 location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5-3 DC-1000 location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
5-4 DC-1000 mounted on Prodigy/CME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

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Prodigy/CME PC/104 User’s Guide 9
1
1.Installation
In This Chapter
Prodigy Family Overview
Prodigy/CME PC/104 Card Types
Software
Accessory Products
Installation Sequence
Recommended Hardware
Software Installation
Preparing the Card for Installation
Connection Summary
Applying Power
First-Time System Verification
Developing User Application Code
1.1 Prodigy Family Overview
The Prodigy
®
Family of Motion Control Cards provide high-performance control of DC brush, brushless DC,
microstepping, and step (pulse & direction) motors. They are available in three form factors; PCI bus, PC/104 bus, and
Stand-Alone, and allow multiple forms of communication including PCI bus, PC/104 bus, serial, CANbus, and
Ethernet. All Prodigy cards are based on PMD’s Magellan
®
Motion Processors, which perform high speed motion
control functions such as profile generation, servo loop closure, pulse & direction signal generation, and many other
real-time functions. Certain versions of Prodigy cards include a C-Motion
®
Engine (CME), which allows the user to
offload application code from the host onto the motion card.
The following product selector table summarizes the various members of the Prodigy motion card family and associated
Users Guide documentation.
Prodigy P/N Bus/Format C-Motion Engine User Guide
PR8258x20 PC/104 No Prodigy-PC/104 User’s Guide
PR8358x20 PC/104 Yes Prodigy/CME PC/104 User’s Guide
PR9258x20 PCI No Prodigy-PCI User’s Guide
PR9358x20 PCI Yes Prodigy/CME PCI User’s Guide
PR13x58x20 Stand-Alone Yes Prodigy/CME Stand-Alone User’s Guide

Installation
10 Prodigy/CME PC/104 User’s Guide
1
1.2 Prodigy/CME PC/104 Card Types
This manual provides a complete User’s Guide for the Prodigy/CME PC/104 cards. For documentation on other
members of the Prodigy Family please consult the appropriate documentation.
Prodigy/CME PC/104 cards come in four different configurations depending on the number of axes supported on
the card (from 1 to 4). The following table provides information on the specific card versions that are available. It
shows the relationship between card part numbers, Magellan Motion Processor part numbers contained on the card,
the number of axes supported, and the type of motors supported. In the motor type column, “all motor types” means
DC brush, brushless DC, microstepping, and step (pulse & direction) motors.
1.2.1 Supported Motor Types
The Prodigy/CME PC/104 cards support four different motor types; DC Brush, Brushless DC, step motors with a
microstepping output, and step motors with a pulse and direction output. Below is a summary of each of these four
motor types
DC Brush: output is a single-phase motor command, either in PWM (pulse width modulated), or analog (± 10V)
output format. The output is intended to control DC Brush motors, or brushless DC motors with an amplifier that
performs commutation.
Brushless DC: output is multi-phase motor command signals, either in PWM (pulse width modulated), or analog
(± 10V) output format, using Hall-based or sinusoidal commutation. The output is intended to interface with
brushless DC amplifiers and motors.
Microstepping: output is multi-phase analog (± 10V) or PWM (pulse width modulation) waveforms. The output is
intended to control 2- or 3-phase step motors using amplifiers which accept this command format.
Pulse & direction: output is standard pulse & direction signals intended to interface with amplifiers which accept
this command format.
For information on motor output formats and other information, see the Magellan Motion Processor User’s Guide.
1.3 Software
Four major software packages are provided with the Prodigy/CME PC/104 cards:
Pro-Motion
®
,an interactive Windows-based exerciser & software development tool
C-Motion
®
, a C-language library that allows you to create motion applications using the C programming language
C-Motion
®
Engine Development Tools, a set of development resources that allow you to create, download, and
monitor programs loaded in the Prodigy/CME PC/104 card’s C-Motion Engine
VB-Motion
®
, a set of Active-X objects that lets you create motion applications using the BASIC Programming
language
Here is more information on each of these software packages:
Prodigy/CME PC/104
Card P/N Magellan P/N
Number of
Axes Motor Type
PR8358120 MC58120 1 All motor types
PR8358220 MC58220 2 All motor types
PR8358320 MC58320 3 All motor types
PR8358420 MC58420 4 All motor types

Installation
Prodigy/CME PC/104 User’s Guide 11
1
1.3.1 Pro-Motion
Pro-Motion is a sophisticated, easy-to-use exerciser program which allows all card parameters to be set and/or viewed,
and allows all card features to be exercised. Pro-Motion features include:
• Motion oscilloscope graphically displays processor parameters in real-time
• Axis Wizard to automate axis setup and configuration
• Interactive DC brush and brushless DC tuning
• Project window for accessing motion resources and connections
• Ability to save and load current settings
• Distance and time units conversion
• Motor-specific parameter setup
• Axis shuttle performs continuous back and forth motion between two positions
• C-Motion Engine monitor/debug window
• C-Motion Engine user application code download
• Device window for configuring PMD-based card and digital drive products
Pro-Motion is described in the Pro-Motion User’s Guide.
1.3.2 C-Motion
C-Motion provides a convenient set of callable routines comprising the code required for controlling the Magellan
Motion Processor, whether running on a separate host computer such as a PC, or running on the Prodigy/CME card
in the C-Motion Engine. C-Motion includes the following features:
• Magellan axis virtualization
• Ability to communicate to multiple PMD motion cards or modules
• Ability to communicate via PCI bus, PC/104 bus, serial, CANbus, or Ethernet
• Provided as source code, allowing easy compilation & porting onto various run-time environments
including PC, microprocessor, embedded card, or C-Motion Engine
• Can be easily linked to any C/C++ application
C-Motion is described in the Magellan Motion Processor Programmer’s Command Reference.
1.3.3 C-Motion Engine Development Tools
The C-Motion Engine Development Tools includes a source code editor, compiler, linker, and Pro-Motion-based code
management & monitoring tools that allow the user to quickly and easily develop applications that will run on a device
equipped with a C-Motion Engine. The C-Motion Engine Development Tools includes the following features:
• Complete toolset for creation of user-specific applications running on the motion card
• Open source compiler and C libraries
• Interactive Development Environment
• Supports PCI bus, PC/104 bus, RS232/RS485, CANbus, and Ethernet communications

Installation
12 Prodigy/CME PC/104 User’s Guide
1
The C-Motion Engine development tools are described in the C-Motion Development Tools Manual.
1.3.4 VB Motion
VB-Motion provides a complete set of methods and properties for developing applications in Visual Basic using a
dynamically loaded library (DLL) containing PMD library software. The DLL may also be used from any language
capable of calling C language DLL procedures, but no special software support is provided.
VB-Motion includes the following features:
• Magellan axis virtualization
• Ability to communicate to multiple PMD motion cards or Modules
• Ability to communicate via PCI bus, PC/104 bus, serial, CANbus, or Ethernet
• Provided as a single DLL and Visual Basic .NET source code for easy porting onto various PC
environments
VB Motion is documented in the Prodigy/CME Programmer’s Reference.
1.4 Accessory Products
The Prodigy/CME PC/104 cards can be enhanced with the addition of any or all of the hardware accessory products
described in the following table.
Component Part
Number Description
PW-2001-KIT-01.R Power supply & cable set. This is a US Domestic & International wall adapter power supply
and associated cable that plugs in the Prodigy/CME PC/104 card and provides power
through its Power Connector. If the card receives power through the PC/104 bus then
this accessory is not necessary.
Cable-2003-01.R 50-pin ribbon cable. This 3 foot long cable connects the right and left motion connectors
(GP Connector) to identical connectors on a receiving card such as the IM-1000 breakout
interconnect card, and it connects the Option Connector to an identical connector on a
receiving card such as the IM-600 breakout interconnect card.
Cable-4301-01.R 10-pin serial header cable. This 1 foot cable plugs into the card’s 10-pin serial header con-
nector and provides a single female DB-9 output with dual serial signals. It can be con-
nected to Cable-4355-01.R to provide dual DB-9 serial outputs.
Cable-4355-01.R Dual serial cable. This 5 foot long “Y” cable connects to the DB-9 output of Cable-4301-
01.R and provides two female DB-9 connectors suitable for connection to a PC serial port
or USB-to-serial converter.
Cable-4701-01.R CANbus header to RJ45 connector. This 1 foot cable plugs into the card’s 8-pin CANbus
header connector and provides an RJ45 output.
Cable-RJ45-02-R CANbus and Ethernet cable. This 2 meter cable connects to the card’s CANbus or Ether-
net outputs. It has RJ45 connectors on both ends.
TRM-RJ45-02.R CANbus terminator. This is an RJ45 terminator that may be used to electrically terminate
a CANbus network string.
Adapt-RJ45T-01.R CANbus splitter. This Y configuration splitter duplicates the CANbus RJ45 connections
into two identical RJ45 connectors, making it easy to connect the card in a daisy chain con-
figuration.
Cable-4505-01.R Ethernet header to RJ45 cable. This 5 foot cable plugs into the card’s 10-pin Ethernet
header connector and provides an RJ45 output.
Cable-4371-01.R 20-pin ribbon cable. This 3 foot long cable connects the Pulse & Direction connector to an
identical connector on a receiving card such as on the IM-600 breakout interconnect card.
DC-1000 Parallel encoder input adaptor. This daughter card module allows parallel-word and other
encoders which use the SSI interface format to be directly connected.

Installation
Prodigy/CME PC/104 User’s Guide 13
1
For information on ordering these accessory products, please contact your PMD representative.
1.5 Installation Overview
1Before using the card, the software must be installed. See Section1.7, “Software Installation,” on page14
for instructions on installing the software.
2For a normal installation of a Prodigy/CME PC/104 card, you will need to configure the card for the
specific motor hardware to which it will be connected. See Section1.8, “Preparing the Card for
Installation,” on page14 for a description of configuring the cards.
3Next, connect the system’s motors, encoders, amplifiers, and sensors to operate the motion hardware.
See Section1.9, “Connection Summary,” on page17 for a description of the available connections and
options for the Prodigy/CME PC/104 card.
4See Section5.3, “DC-1000 SSI Option Card,” on page92 if installing the DC-1000.
5Connect the Prodigy/CME PC/104 card to the host PC via an Ethernet cable and a Serial cable. During
first time setup Ethernet communications will be used, but during development or standard operation of
the card you can use any of the available communication options; serial, CANbus, or Ethernet. See
Section1.9, “Connection Summary,” on page17 for a description of the communications connections
and options.
6Once this hardware configuration is complete, the final step to finish the installation is to perform a
functional test of the finished system. See Section1.11, “First-Time System Verification,” on page21 for
a description of this procedure.
Once these steps have been accomplished, the installation is complete, and the card is ready for operation.
1.6 Recommended Hardware
To install a Prodigy/CME PC/104 card, the following hardware is recommended.
• Intel (or compatible) processor, Pentium or better, 300 MB of available disk space, 256MB of available
RAM, and a CD-ROM drive. The supported PC operating systems are Windows XP/Vista.
• One to four pulse and direction, PWM, or analog-input amplifiers. The type of amplifier depends on the
type of motor being used.
• One to four step, DC brush, or brushless DC motors.
These motors may or may not provide encoder position feedback signals, depending on the type of
motor being used. Encoder feedback is a requirement for DC brush and brushless DC motors. For step
motors, it’s an option.
• Motion Connectors as required to connect the card to the amplifiers and the motors you have selected.
IM-1000 Breakout interconnect module provides convenient jack-screw type terminators for the
left and right 50-pin GP Connectors. Used with Cable-2003-01.R.
IM-600 Breakout interconnect module provides convenient jack-screw type terminators for the
50-pin Option Connector. Used with Cable-2003-01.R.
Adapt-USB232-01.R This adapter provides USB to serial conversion. It is useful for connecting to the Prodigy/
CME’s DB-9 serial port from a USB port.
Component Part
Number Description

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14 Prodigy/CME PC/104 User’s Guide
1
Two GP Connector cable (PMD p/n Cable-2003-01.R, 50-pin ribbon cable) will be required, and for
brushless DC motors as well as step motors driven in microstepping mode, a third Cable-2003-01.R will
be required connected to the card’s Option Connector. See Section4.3, “Connections Summary—Motor
Amplifiers,” on page80 for more information on setting up these connections.
1.7 Software Installation
Two CD-ROMs comprise the software distribution for Prodigy/CME cards. All software applications are designed to
work with Windows XP/Vista.
• Pro-Motion: The Pro-Motion disk is located in its own Pro-Motion box, and contains the software
associated with the Pro-Motion Optimized Motion System Development software.
• PMD Prodigy/CME SDK: The PMD Prodigy/CME SDK disk is located separately, and contains the
C-Motion Engine development tools, the C-Motion source libraries, and VB-Motion Libraries.
To install the software:
1Insert the Pro-Motion disk into the CD-ROM drive of your computer.
• If autorun is enabled, the installation process will begin when the CD-ROM is inserted.
• If autorun is not enabled, go to the next step.
2On the Start menu, click Run.
3In the Open text box, type D:\setup.exe.
where D: is the drive letter of your computer’s CD-ROM drive.
4Follow the on-screen prompts to complete the installation process.
Once installation of Pro-Motion is complete, insert the PMD Prodigy/CME SDK disk, and follow the same
procedure above as for Pro-Motion installation.
Upon completion of the installation process for Pro-Motion and PMD Prodigy/CME SDK, the following
components will be installed:
• Pro-Motion – an application for communicating to, and exercising the installed card. Refer to the Pro-
Motion User’s Guide for operating instructions.
• C-Motion – source code which may be used for developing motion applications in C/C++ based on the
Magellan Motion Processor.
• VB-Motion – Active-X DLLs and example source code which may be used for developing motion
applications in Visual Basic based on the Magellan Motion Processor.
• PDF versions of the Prodigy/CME PC/104 User’s Guide, Prodigy/CME Programmer’s Reference, C-Motion
Development Tools Manual, Magellan Motion Processor Programmer’s Command Reference, and Magellan Motion
Processor User’s Guide. The Adobe Acrobat Reader is required for viewing these files. If the Adobe Acrobat
Reader is not installed on your computer, it may be freely downloaded from http://www.adobe.com.
1.8 Preparing the Card for Installation
Figure 1-1 on page 15 shows the location of the resistor packs RS1, RS2, RS3, along with other components such as
connectors. The front or top side of the card is shown, with the main- Prodigy/CME PC/104 connectors at the

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Prodigy/CME PC/104 User’s Guide 15
1
bottom. These items are listed in the table below. Connectors and user-adjustable components are located both on the
front and the back side of the card, so be sure to double check the orientation of the diagram to locate components.
Figure 1-1:
Prodigy/CME
PC/104 Card
Component
Location, front
view
Figure 1-2:
Prodigy/CME
PC/104 Card
Component
Location, back
view
Card Components
The following table describes the components on the card (as shown in Figure 1-1) and their functionality.
J19
J1
J9
J16 J17 J15
J12
J6 J5
RS3
J20
RS2
RS1
J21
J18
Ethernet
LEDs
Heartbeat
LED
Label Located Description
RS1 - RS3 front side Resistor packs
SW1
J3
J4
J2

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16 Prodigy/CME PC/104 User’s Guide
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1.8.1 Resistor Pack Settings
The Prodigy/CME PC/104 card has minimal user-adjustable settings. Most settings are software configurable. To
prepare the card for installation, the user-specified resistor pack options should be checked, as described in the
following table.
1.8.2 Motor Output Configuration
There are two configurations for setting up the motor output pins on the Prodigy/CME PC/104 GP Connector:
These motor output pins can be set up for use with DC Brush, Brushless DC, and microstepping motors, or the motor
output pins can be set for pulse & direction motors. The default setting is for all motors to be set for DC Brush,
Brushless DC, and microstepping.
The switch bank SW1 controls these settings, which apply on a per-axis basis. The following table describes the correct
switch setting for each output type. Figure 1-3 on page 17 provides a diagram of SW1, and Figure 1-1 on page 15
shows the location of SW-1 on the Prodigy/CME PC/104 card.
SW1 back side Motor output configuration
J1 front side Extension Connector
J2 back side Reserved
J3, J4 back side Synch Connectors
J5, J6 front side Right and Left Connectors
J9 front side Option Connector
J12 front side Pulse & Direction Connector
J15 front side Ethernet Connector
J16 front side CANbus Connector
J17 front side Serial Connector
J19 front side Reserved
J20 front side Reserved
J21 front side Power Connector
Item Setting Description
Resistor packs
RS1, RS2, RS3
Installed; this is the default setting of resistor
packs RS1 - RS3.
If differential connections are being used, leave these
resistor packs installed.
Removed If single-ended encoder connections are being used,
remove the resistor packs.
Axis
Set for DC Brush, Brushless DC,
or Microstepping Set for Pulse & Direction
1 1 on, 5 off 1 off, 5 on
2 2 on, 6 off 2 off, 6 on
3 3 on, 7 off 3 off, 7 on
4 4 on, 8 off 4 off, 8 on
Power to the card should be turned off when changing the state of the SW1 switches, and care should be taken
not to set both switch pairs on (for example both 1 and 5 on, or both 2 and 6 on etc.) or damage may occur to
the board.
Label Located Description

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Prodigy/CME PC/104 User’s Guide 17
1
Figure 1-3:
Switch settings
1.9 Connection Summary
1.9.1 Motor Connections
The following sections summarize the recommended connections for various motor types. DC brush, brushless DC,
microstepping, and step (pulse & direction) motors may be connected to the same card, so motor type is allowed to
be different on a per-axis basis.
DC Brush Motors
The following table summarizes connections to the Prodigy/CME PC/104 cards when DC brush motors are used.
Between one and four axes may be connected, depending on the specific Prodigy card and application requirements.
All connections are made through GP Connector, J6 locatable on the card using Figure 1-1 on page 15.
See Chapter4, Electrical Reference, on page69 for a detailed list of connections.
Signal Category Signal Description
Encoder input signals: (per axis) A quadrature Channel input
B quadrature channel input
Index pulse channel input
Amplifier output signals:
(per axis, if PWM sign, magnitude used)
PWM direction
PWM magnitude
Amplifier output signals:
(per axis, if PWM 50/50 used)
PWM magnitude
Amplifier output signals:
(per axis, if DAC output used)
DAC out
Other control signals:
(optional per axis)
Home signal input
Positive limit switch input
Negative limit switch input
AxisIn input
AxisOut output
Miscellaneous signals: Digital GND, AmpEnable,+5V (for encoder power)
ON
1
2
3
4
5
6
7
8
SW1

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18 Prodigy/CME PC/104 User’s Guide
1
Brushless DC Motors
The following table summarizes connections to the Prodigy/CME PC/104 cards when brushless DC motors are used.
Between one and four axes may be connected, depending on the specific Prodigy card and application requirements.
Connections are made through GP Connector, J6 and Option Connector, J5. Both of these connectors are locatable
on the card using Figure 1-1 on page 15.
See Chapter4, Electrical Reference, on page69 for a detailed list of connections. See Section4.2.5, “Option Connector,”
on page76 for detailed information regarding the Option Connector.
Step Motors
The following table summarizes connections to the Prodigy/CME PC/104 cards when pulse & direction interface
step motors are used. Between one and four axes may be connected, depending on the specific Prodigy card and
application requirements. Unless differential pulse & direction output is desired, all connections are made through
connector GP Connector, J6. This connector is locatable on the card using Figure 1-1 on page 15.
See Chapter4, Electrical Reference, on page69 for a detailed list of connections.
Microstepping Motors
The following table summarizes connections to the Prodigy/CME PC/104 cards when microstepping-interface step
motors are used. Between one and four axes may be connected, depending on the specific Prodigy card and
application requirements. All connections are made through the GP Connector, J6, and Option Connector, J5. Both
of these connectors are locatable on the card using Figure 1-1 on page 15.
Signal Category Signal Description
Encoder input signals: (per axis) A quadrature channel input
B quadrature channel input
Index pulse channel input
Amplifier output signals:
(per axis, if PWM 50/50 used)
PWM magnitude (phase A)
PWM magnitude (phase B)
PWM magnitude (phase C)
Amplifier output signals:
(per axis, if DAC output used)
DAC out (phase A)
DAC out (phase B)
Hall inputs:
(Option Con)
Hall (phase A)
Hall (phase B)
Hall (phase C)
Other control signals:
(optional per axis)
Home signal channel input
Positive limit switch input
Negative limit switch input
AxisIn input
AxisOut output
Miscellaneous signals: Digital GND, AmpEnable,+5V (for encoder power)
Signal Category Signal Description
Encoder input signals: (optional per
axis)
A quadrature channel input
B quadrature channel input
Index pulse channel input
Amplifier output signals: Pulse
Direction
Other control signals:
(optional per axis)
AtRest signal output
Home signal channel input
Positive limit switch input
Negative limit switch input
AxisIn input
AxisOut output
Miscellaneous signals: Digital GND, AmpEnable, +5V (for encoder power)

Installation
Prodigy/CME PC/104 User’s Guide 19
1
See Chapter4, Electrical Reference, on page69 for a detailed list of connections.
1.9.2 Communication Connections
While the Prodigy/CME PC/104 card can communicate to a host controller using Ethernet, CANbus, and one of two
serial modes (RS-232 and RS-485), in this first-time installation we will set up the card for Ethernet communications.
To set up the card for operation in other communication modes, see Chapter2, Operation, on page31 and the Pro-
Motion User’s Guide.
Because the Ethernet address for the card will need to be configured, we will first connect the RS-232 serial port, and
then the Ethernet port on the card. During initialization, we will then use Pro-Motion to change the IP address that
the card expects Ethernet communications on.
If the standard PMD accessory cables are used, Cable-4301-01.R should be plugged into the Prodigy/CME PC/104
card 10-pin J17 serial connector, and the base of the “Y” of the dual serial cable (PMD p/n Cable-4355-01.R) should
be connected to Cable-4301-01.R. The opposite end of the serial cable marked “Port1” should be connected to your
computer's 9 pin serial port. If your computer does not have a dedicated serial port, a standard USB to serial converter
should be used. Figure 1-4 shows a typical serial port connection.
Figure 1-4:
Serial Port
Connection
The Ethernet connection will not be made until serial communications are established. See Section1.11.2, “Changing
the Ethernet Parameters of the Prodigy/CME PC/104 Card,” on page24 for detailed instructions on when to
physically make the Ethernet connection. When Ethernet is ready to connect, use PMD’s Cable-4505-01.R, and plug
one end of the connector into J15, and the other end into Cable-RJ45-02.R. Then, plug the other end of this cable into
your computer’s Ethernet port. Figure 1-5 on page 20 shows the complete serial and Ethernet connection setup.
Signal Category Signal Description
Encoder input signals: (optional per axis) A quadrature channel input
B quadrature channel input
Index pulse channel input
Amplifier output signals:
(per axis, if PWM sign, magnitude used)
PWM magnitude (phase A)
PWM magnitude (phase B)
PWM direction (phase A)
PWM direction (phase B)
Amplifier output signals:
(per axis, if PWM 50/50 used)
PWM magnitude (phase A)
PWM magnitude (phase B)
Amplifier output signals:
(per axis, if DAC output used)
DAC out (phase A)
DAC out (phase B)
Other control signals:
(optional per axis)
Home signal channel input
Positive limit switch input
Negative limit switch input
AxisIn input
AxisOut output
Miscellaneous signals: Digital GND, AmpEnable,+5V (for encoder power)
Port 1
Port 2
unused
Serial Port Serial Port
Prodigy/CME
Host PC
Cable-4301-01.R Cable-4355-01.R

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20 Prodigy/CME PC/104 User’s Guide
1
The communication connections are locatable on the card using Figure 1-1 on page 15.
Figure 1-5:
Serial and
Ethernet
Connection
1.9.3 Power Connections
There are a few options for providing power to the Prodigy/CME PC/104 card. For first time system verification,
however, the convenient AC wall adapter power supply and cable set contained in PMD accessory p/n PW-2001-KIT-
01.R will be used. Plug the AC wall adapter into any AC outlet, and connect the power plug to J21 on the card. This
connector is locatable on the card using Figure 1-1 on page 15. Outside of the US & Canada, one of the AC adapter
plugs included with the power supply will be needed depending on the plug type used with your AC service.
In addition to the power supply and connections for the Prodigy/CME PC/104 card, the motor amplifiers also need
to have power provided to them. Consult the technical manual for the amplifiers you are using for more information.
While it is possible for the motor power to be the same as the card power (which is 5V), it is much more likely that
the power provided to the amplifiers will be at a higher voltage, and therefore be provided by a different power supply.
1.10 Applying Power
Once you have made your motion hardware, communication, and power connections, hardware installation is
complete and the card is ready for operation. When power is applied, the card will be in a reset condition. In this
condition, no motor output will be applied. Therefore, the motors should remain stationary. If the motors move or
jump, power down the card and check the amplifier and encoder connections. If anomalous behavior is still observed,
call PMD for assistance. Complete PMD contact information is listed on the last page of this manual.
When using a Prodigy/CME PC/104 card there are some combinations of motor output signal and amplifier type
where undesired motion may occur when the card is powered up. In particular, if the connected amplifier is a
PWM 50/50 amplifier, the motor will receive 100% power because the Prodigy/CME PC/104 card defaults to a
different PWM signal encoding, PWM sign/magnitude, on reset. To avoid this situation, use AmpEnable as an en-
able/disable signal for the amplifier, and set the motor type for each axis before enabling the amplifier. See Chap-
ter2, Operation, on page31 for more information on this function.
Port 1
Port 2
unused
Ethernet Port
Serial Port
Ethernet Port
Serial Port
Prodigy/CME
Host PC
Cable-4301-01.R Cable-4355-01.R
Cable-4505-01.R Cable-RJ45-02.R