Pmd Pmdx-132 User manual

PMDX-132

4-Axis Breakout/Motherboard

for Gecko Stepper Motor Drivers

User’s Manual

Document Revision: 1.0

Date: 17 April 2008

PCB Revision: PCB-466A

Serial Numbers: 23410 and above

PMDX Web: http://www.pmdx.com

9704-D Gunston Cove Rd Phone: +1 (703) 372-2975

Lorton, VA 22079-2366 USA FAX: +1 (703) 372-2977

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

Table of Contents

1.0 Overview....................................................................................................................................3

1.1 Important Safety Information...........................................................................................................................3

1.2 Warranty Summary.............................................................................................................................................3

1.3 Features..................................................................................................................................................................4

1.4 Updates to this Manual......................................................................................................................................4

2.0 Quick Setup Guide ...................................................................................................................4

2.1 Package Contents................................................................................................................................................4

2.2 Assembly steps.....................................................................................................................................................4

2.3 Example Limit Switch Wiring...........................................................................................................................5

2.4 Example Configuration with Daisy-Chained PMDX-122..........................................................................6

3.0 Functional Description and Block Diagrams........................................................................8

3.1 Data Bus.................................................................................................................................................................8

3.2 Control Outputs..................................................................................................................................................8

3.3 Relay Outputs.......................................................................................................................................................9

3.4 Status Inputs........................................................................................................................................................10

3.5 Fault, E-Stop and Motor Disable....................................................................................................................10

3.5.1 Fault Input..................................................................................................................................................11

3.5.2 E-Stop Input...............................................................................................................................................12

3.5.3 Motor Disable Input................................................................................................................................12

3.6 Charge Pump (watchdog)................................................................................................................................12

4.0 Connectors..............................................................................................................................13

4.1 DC (Motor) Power Supply (J1)......................................................................................................................14

4.2 AC Power Supply (J2).......................................................................................................................................14

4.3 Relay Contact Connectors (J3 & J4).............................................................................................................15

4.4 Unregulated Power and Daisy-Chain Output (J5)....................................................................................15

4.5 PC Parallel Port (J6 & J7).................................................................................................................................15

4.6 Status Input Connector (J8)............................................................................................................................17

4.7 Control Output Connector (J9)....................................................................................................................17

4.8 Fault, E-Stop and Motor Disable Connector (J10)....................................................................................18

4.9 Motor Driver Connectors (J11 through J22).............................................................................................18

4.9.1 Disable Signal.............................................................................................................................................19

4.9.2 Step & Direction Signals.........................................................................................................................19

4.9.3 +5V Common...........................................................................................................................................19

4.9.4 Rset Signals.................................................................................................................................................19

4.10 PMDX Expansion Connector (J23)...............................................................................................................19

5.0 Jumpers....................................................................................................................................19

5.1 Output Enable (JP1)..........................................................................................................................................20

5.2 Pin 17 Mode (JP2)..............................................................................................................................................20

5.3 Relay Mode (JP3 and JP4)................................................................................................................................21

5.4 Gecko Step & Direction Common (JP5, JP6, JP7 and JP8)....................................................................21

6.0 Mechanical Specifications......................................................................................................22

7.0 Electrical and Environmental Specifications......................................................................23

Appendix A – Warranty....................................................................................................................24

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

1.0 Overview

This document describes the configuration and operation of the PMDX-132 4-Axis

Breakout/Motherboard. The PMDX-132 interfaces between the parallel port of an IBM-PC style

computer and up to four Gecko stepper driver modules, models G201, G202, G210, G212 and G203V.

This document pertains to the following versions of the PMDX-132:

Circuit Board Revision: PCB-466A (marked on the bottom of the board)

Serial Number Range: 23410 and above

Note that Geckodrive, Inc., the maker of the Gecko stepper motor drives, does not manufacture, sell, or

nor provide technical support for the PMDX-132.

1.1 Important Safety Information

The PMDX-132 is intended for integration by the purchaser into industrial control systems. It is solely

the purchaser's responsibility to assure that the system is configured in a manner consistent with

applicable safety requirements. Practical Micro Design, Inc. does not control how this board is integrated

into the purchaser's system and cannot be responsible for guaranteeing the safety of your system.

The PMDX-132 is not guaranteed to be fail-safe. The system into which the PMDX-132 is installed should

provide fail-safe protection and emergency stop capability.

The PMDX-132 contains circuitry that may be connected to dangerous voltages. Care must be taken that

user cannot come in contact with these voltages. An enclosure that allows for modest ventilation, but

prevents intrusion by operator’s hands and foreign objects, especially conductive byproducts of machining

operations, should be utilized with this board. Interlock switches on power circuits should remove

power when the enclosure is opened.

Automated machine tools, into which the PMDX-132 may be integrated, can cause injury. Precautions

should be taken to assure that operators are trained in their proper operation and safety procedures, and

that they are protected from moving parts that may be under remote control and may move

unexpectedly.

This product may not be used in life support or other critical safety applications.

1.2 Warranty Summary

The PMDX-132 is warranted against failure due to defective parts or workmanship for 90 days from the

date of sale. Refer to Appendix A for complete warranty details.

If you have an item requiring service, please see the support page on the PMDX web site

(http://www.pmdx.com) for return instructions.

The purchaser must pay shipping to return the unit to PMDX. We will ship the repaired unit back to you

via ground transportation at our expense. Repairs are normally completed within 10 business days. See

Appendix A for our complete warranty details.

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

1.3 Features

The PMDX-132 has the following features:

PC Parallel Port:

•Buffers signals to/from the PC parallel port

•Allows use of all 8 data bits, 4 control outputs

and 5 status inputs

•Centronics cable connector uses standard PC

printer cable

•Ribbon header for optional cable to 25-pin

“D” connector or devices with compatible

ribbon connectors such as the SmoothStepper

Status Inputs:

•5 each status inputs w/pull-up resistors

•Status signals are isolated and buffered

•LED indicators for each input

Control Outputs:

•4 each general purpose digital outputs

•2 outputs may also drive relays with N.O and

N.C. terminals

•Outputs are isolated and buffered

•LED indicator for each output

Gecko Stepper Driver Interface:

•4 axes of step and direction

•Driver fault sensing

•Buffers signals to drive step & direction inputs

•Selectable +5V or GND step/dir common

•Wire clamp terminals for the current set

resistors

Power Supply Input:

•120 or 240 VAC input for logic supply

•Separate DC supply input for motor drivers

Special Features:

•Pluggable wire clamp terminal strips for I/O

connections from parallel port status and

control signals

•Support for “charge pump”

•Auxiliary +5V supply output

•Power output for optional fan

•Daisy-chain status signal for sharing

E-Stop/Charge Pump with PMDX-122 boards

1.4 Updates to this Manual

Check the PMDX web site for revisions or updates to this manual (http://www.pmdx.com). The latest

revision of this manual is available on the PMDX-132 page (follow the links from the main page).

2.0 Quick Setup Guide

2.1 Package Contents

Each PMDX-132 ships with the following items:

1 each PMDX-132 circuit board

4 each 4-position plug-on terminal strips (use on the Geckodrive modules, not on the

PMDX-132)

6 each Nylon standoffs, 1-1/4” with 4-40 thread (use to mount the PMDX-132 and Geckodrive

assembly to a heat sink plate)

Note that the PMDX-132 ships without plug-on terminal strips for its connectors (J3, J4, J8, J9 and J10).

You will be re-using the terminal strips from the Gecko stepper driver modules for the PMDX-132

connectors as described below.

2.2 Assembly steps

1. Remove the pluggable terminal strips from each of the Gecko stepper driver modules (these should

be 2 sections of 6-pins each)

2. Install the 6-position terminal strips onto the PMDX-132 connectors J3/J4, J8, J9 and J10. Note that

the connectors J3 and J4 are combined into a single 6-position terminal strip.

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

3. For each Gecko stepper driver module, determine the step/direction common reference required:

•Models G201 and G202 without the G901 step multiplier board require a +5V common.

•Models G210 and G212, and the G201 or G202 with the G901 step multiplier board installed can

be configured for either +5V or GND. Look at the “Input Option Header” jumpers and record

the setting.

•Model G203V requires a GND common reference.

4. Take the results from step (3) above and configure the four PMDX-132 jumpers JP5, JP6, JP7 and JP8

to supply to correct common reference to each Gecko drive. See section 5.4 for more information.

5. For each Gecko stepper driver module, plug the 4-pin terminal strip (supplied with the PMDX-132)

onto the Gecko module’s “Phase A” through “Phase D” terminals.

6. Connect each motor to the 4-pin terminal strips on the Gecko stepper driver module

7. Plug each Gecko stepper driver module onto the connectors on the bottom of the PMDX-132.

8. For each Gecko stepper driver module, install the motor current set resistor in the corresponding 2-

pin terminal strip on the PMDX-132. When looking at the PMDX-132/Geckodrive assembly from

the edge as shown in Figure 1, this would be the green 2-pin terminal strip above and to the right of

each Geckodrive module.

9. Install either (a) an emergency stop switch, or (b) a jumper wire from “E-Stop” to “GND” on

connector J10. See section 3.5.2 for more information.

10. The resulting assembly should look similar to Figure 1.

Figure 1– Sample PMDX-132 and Geckodrive Assembly

2.3 Example Limit Switch Wiring

Mechanical switches, in either “normally open” or “normally closed” configurations, or optical interrupter

switches can be used to provide input signals to the PMDX-132. These switches can act as limit switches,

home indicators or other status information. Since the PMDX-132 provides pull-up resistors on the

status inputs (see section 3.4), mechanical switches can be wired directly to the signal pins on J8 and

ground. Note that the examples below show the signals connected to “pin 11” input. The input signals

may be connected to any of the signal pins on J8.

Normally Closed Switches

The left-hand drawing in Figure 2shows an example of “normally closed” mechanical switches. The

switches are wired in series so that the “normal” case is ground (logic low) going into pin 11 of the PC’s

parallel port. When one or more of the switches open, the pull-up resistor on the PMDX-132 provides a

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

logic high into pin 11 on the PC’s parallel port. Any number of “normally closed” switches may be

connected in series to a single input terminal on the PMDX-132.

Figure 2– Example Switch and Optical Interruptor Configurations

Normally Open Switches

The center drawing in Figure 2shows an example of “normally open” mechanical switches. The switches

are wired in parallel so that the “normal” case is +5V (logic high) going into pin 11 of the PC’s parallel

port (due to the pull-up resistor on the PMDX-132). When one or more of the switches close, a logic

low appears on pin 11 on the PC’s parallel port. Any number of “normally open” switches may be

paralleled onto a single input terminal on the PMDX-132.

Optical Interrupter

The right-hand drawing in Figure 2shows an example of an optical interrupter. This example uses the

“+5V Aux Out” from the PMDX-132 to power the sensor. The output signal is connected as an “open

collector” output between the PMDX-132 input pin and ground. When light from the LED strikes the

sensor, the sensor conducts giving a logic low on pin 11 of the PC’s parallel port. When the LED is

“interrupted”, the transistor stops conducting and the PMDX-132’s pull-up resistor gives a logic high on

pin 11. The same basic operation applies to the “reflective” version of sensor, i.e. when the light from the

LED reflects and strikes the sensor, the sensor outputs a logic “low”.

2.4 Example Configuration with Daisy-Chained PMDX-122

The PMDX-132 can be connected to a PMDX-122 in a daisy-chain configuration. This allows the

PMDX-132’s charge pump, E-Stop and Fault circuitry to enable and disable the PMDX-122’s signals. This

configuration also allows the PMDX-122’s E-Stop input to be used as a general-purpose input.

Figure 3shows a typical daisy-chain configuration. This requires two parallel ports in the PC: one for the

PMDX-132 and a second one for the PMDX-122. The PMDX-132 provides power to the PMDX-122 via

the unregulated “fan power” output on connector J5. The PMDX-122 is shown connected to two optical

encoders, with the data bus direction set to “input to PC”. This is just one example of how the daisy-

chained PMDX-122 can be used. Other uses include having the data bus drive Opto-22 relays. Make sure

to set the PMDX-122’s jumpers according to your configuration.

GND

pin11

+5V

AUX

pin12

pin13

pin15

Three "normally closed"

switches in series.

GND

pin11

+5V

AUX

pin12

pin13

pin15

Three "normally open"

switches in parallel.

GND

pin11

+5V

AUX

pin12

pin13

pin15

Optical Interrupter

(slotted or reflective)

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

Figure 3– PMDX-132 with Daisy-Chained PMDX-122

PHASE A

PHASE B

GND

OPTICAL

ENCODER

+5V

JP6

JP4 JP5 JP2

JP1 JP3

GND

+5V

pin 2-9 COM

not EStop/fault

Outputs Enabled

CP-OK & not EStop/fault

pin 2-9 enable

out

DIR

always

normal

pin17out

"OK"

E-Stop Mode

normal

signal only

pin2 pin3 COM pin4 pin5 COM pin8 pin9 COMpin6 pin7 COM

RLY

COM

N/C

N/O

J1 J2 J3 J4 J7

J10

GND

pin11

+5V

AUX

OUT

pin12

pin13

pin15

fault

E-Stop

GND

PWR

Alt In

pin17

pin16

pin14

+5V AUX OUT

J12

J11

PHASE A

PHASE B

GND

OPTICAL

ENCODER

+5V

PMDX-122

(on 2nd parallel port)

E-Stop is a

general purpose

digital input

Data bus direction is

"input to PC" for this example.

Set JP1, JP2 and JP5 according

to your configuration.

fan

pwr

chain PC side

ground

J5J6

PMDX-132

(on 1st parallel port)

Outputs Enabled

CP-OK

not EStop

JP1

pin 17 mode

CP-OK

normal

JP2

JP4

off

pin 8

pin 14 off

pin 9

pin 1

relay mode

JP3

J4 J3J8J9J10

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

3.0 Functional Description and Block Diagrams

3.1 Data Bus

The PC parallel port contains an 8-bit data bus. The PMDX-132 buffers the data bus signals between the

PC and the Gecko stepper drivers. The data bus signals are used as step and direction controls to the

stepper drivers as shown in Table 7on page 16. The output buffers may be disabled via the Fault, E-Stop,

or Motor Disable inputs, as well the Gecko stepper driver’s “Error” output and, optionally, the charge

pump circuit. See sections 3.5 and 3.6 for more information.

Figure 4– Block diagram of data bus (step and direction) signals

3.2 Control Outputs

The control signals are isolated and buffered by the PMDX-132. Each control signal output has a 10K

ohm pull-down resistor paralleled with an LED. The pull-down resistor provides a default “logic low”

when the output buffer is disabled (due to E-Stop, fault, etc.). The LED lights when the output is driven

or pulled high. Two of the control signals (pin 1and pin 14) may also drive the two relays. See section 3.3

for more information.

Enable

Dir

Step

+5V

PC Connector

Buffer

Common

Gecko #1

OK (isolated)

(from charge pump)

(Data0) pin 2

(Data1) pin 3

(Data2) pin 4

(Data3) pin 5

(Data4) pin 6

(Data5) pin 7

(Data6) pin 8

(Data7) pin 9

Dir

Step

Common

Dir

Step

Common

Dir

Step

Common

All referenced to PC ground

Gecko #2

Gecko #3

Gecko #4

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

Figure 5– Block diagram of control signals

3.3 Relay Outputs

Two of the control outputs on the PMDX-132 may drive the on-board relays in addition to being general-

purpose outputs (see section 3.2). PC parallel port pin 1 controls relay K1 via jumper JP3, and pin 14

controls relay K2 via jumper JP4. These two jumpers allow the relays to be disabled when the control

outputs are used as “logic only” outputs. The block diagram below shows the block diagram of one of the

relay circuits. The other circuit is identical but uses the second set of reference designators. See section

5.3 for more information on the jumper settings.

Each relay driver circuit has its own LED (in addition to the LED on the control output section as

described in section 3.2). The relay LED lights when the relay is energized (i.e. the “COM” terminal is

connected to the “N/O” terminal).

Figure 6– Block diagram of relay output signals

Each of the four

signals have their

own LED and

pull-down resistor

Enable

2.2K

JP2

PC Connector

Buffer

(~Strobe) pin 1

(~AutoFeed) pin 14

(~Init) pin 16

(~Selelct In) pin 17

Enable

Buffer

+5V

10K

Isolated Pin 17

(to charge pump)

OK (from

charge pump)

To JP3 (relay K1 control)

To JP4 (relay K2 control)

+5V

+5V Aux

pin 1

pin 14

pin 16

pin 17

GND

Equipment Ground

PC Ground

** **

10K

Each of the four

input signals have

their own pull-down

resistor Always

Enabled

N/C

COM

N/O

J3 or J4

K1 or K2

Relay

Driver

Disable

JP3 or JP4

Relay

Power

Relay K1 Control

Relay K2 Control

(from Control Signal

block diagram)

PMDX-132 User’s Manual PCB Revision: PCB-466A

Document Revision: 1.0 Serial Numbers: 23410 and above

3.4 Status Inputs

Four of the status signals are available as general-purpose inputs: pins 11, 12, 13 and 15. The fifth status

input on the PC parallel port (pin 10) is connected to the Fault and E-Stop circuitry. See section 3.5, for

more information on this signal. Figure 7shows a block diagram of the status input circuitry.

The “Status Input” LEDs are located next to connector J8, just above each of the pin number labels

(“pin 11”, “pin 12”, “pin 13” and “pin 15”). Each LED is “on” when the corresponding input signal is

driven low.

The status signals are isolated and buffered by the PMDX-132. Each status input has a 2.2K ohm pull-up

resistor in series with an LED. The pull-up resistor provides a default “logic high” when the input is not

connected, and also allows the input to be connected to open-collector drivers or mechanical switches to

ground. The LED lights when the input signal is driven low. The optical isolators further act as a low-pass

filter to remove high-frequency noise from the inputs.

NOTE – Due to logic inside the PC, some status inputs are inverted. This means that a logic

“high” output from the PMDX-132 to the PC’s parallel port is read as a “0” in the

status register. Please refer to technical documentation on the PC parallel port or

your control software for more information.

Figure 7– Block diagram of status signals

3.5 Fault, E-Stop and Motor Disable

The Fault, E-Stop and Motor Disable inputs, along with the Gecko stepper driver’s “Error” signals, provide

ways for external circuitry and the Gecko drivers to enable and disable the operation of the PMDX-132.

The following table summarizes the effects of these signals, as well as the charge pump (see section 3.6).

Figure 8shows a block diagram of the Fault, E-Stop and Motor Disable circuitry.

Each of these four signals have

their own LED and pull-up resistor

Enable

2.2K

PC Connector

Buffer

(~Ack) pin 10

(~Busy) pin 11

(Paper End) pin 12

(Select Out) pin 13

Enable

Buffer

10K

+5V

+5V Aux

pin 11

pin 12

pin 13

pin 15

GND

Equipment Ground

PC Ground

(~Error) pin 15

+5V

10K

EStop/Fault (isolated)

(from E-Stop and Fault circuit)

Always

Enabled Always

Enabled

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