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Prodigy-PC/104 User`s Guide

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1. J5 J6 l QuadAl Quadrature A encoder input axis 1 l QuadA3 Quadrature A encoder input axis 3 2 QuadAl Quadrature A encoder input axis 2 QuadA3 Quadrature A encoder input axis 3 3 QuadBI Quadrature B encoder input axis 3 QuadB3 Quadrature B encoder input axis 3 4 QuadBI Quadrature B encoder input axis 4 QuadB3 Quadrature B encoder input axis 3 5 Index 1 Index input axis 1 5 Index3 Index input axis 3 6 Indexl Index input axis 6 Index3 Index input axis 3 7 Vcc 5V 7 Vcc 5V 8 GND Ground 8 GND Ground 9 PosLim Pos direction limit switch input axis 9 PosLim3 Pos direction limit switch input axis 3 0 NegLim Neg direction limit switch input axis 1 10 NegLim3 Neg direction limit switch input axis 3 l Homel Home input axis I Home3 Home input axis 3 2 GND Ground 12 GND Ground 3 AxisOut AxisOut output axis 13 AxisOut3 AxisOut output axis 3 4 PWMMaglA PWM magnitude output axis 1 14 PWMMag3A PWM magnitude output axis 3 5 PWMSign 1A PWM sign output axis 1 15 PWMSign3A PWM sign output axis 3 6 AxisIn Axisln input axis 16 AxisIn3 AxisIn input axis 3 7 DACIA Analog mtr cmd output axis 10V 17 DAC3A Analog mtr cmd output axis 3 10V 8 AGND Ground for analog motor command 18 AGND Ground for analog motor command 9 QuadA2 Quadrature A encoder input axis 2 19 QuadA4 Quadrature A encoder input axis 4 20 QuadA2 Quadrature
2. Prodigy Motor PC 104 Amplifier Input Output Connection Connection Connection Method Name Name Axis 1 Axis2 Axis3 Axis 4 DAC DACI 4A Refl or VI Option 38 Option 39 Option 40 Option 41 DACI 4B Ref2 or V2 Option 42 Option 43 Option 44 Option 45 AGND Ref or GND Option 37 Option 46 Option 37 Option 46 PWM PWMMag1 4A PWM magnitude Option _ Option 6 Option Option 16 sign magnitude PWMSign 4A PWM direction Option 4 Option 9 Option 14 Option 19 PWMMasg1 4B PWM magnitude Option 2 Option 7 Option 12 Option 17 PWMSign 4B PWM direction Option 3 Option 8 Option 13 Option 18 GND Ground Option 5 Option 10 Option 15 Option 20 Names of amplifier connections vary Common names are shown 3 3 4 Step Pulse amp Direction Motor Connections Prodigy Motor PC 104 Amplifier Input Output Connection Connection Connection Method Name Name Axis 1 Axis2 Axis3 Axis 4 Pulse amp direction Pulsel 4 Pulse or step J5 14 J5 31 J6 14 J6 31 single ended Direction l 4 Direction J5 15 J5 32 J6 15 J6 32 GND Ground J5 12 J5 26 J6 12 J6 26 Pulse amp direction Pulsel 4 Pulse or step Jl2 13 J12 9 J12 17 J12 3 differential Pulse 4 Pulse or step jl2 14 12 10 J12 18 J12 4 Direction 4 Direction J12 5 J12 15 J12 11 J12 7 Direction l 4 Direction J12 6 J12 16 J12 12 J12 8 GND Ground J12 1 J12 2 J12 19 J12 20 Pulse amp direction AtRest l 4 At Rest J5 17 J5 34 J6 17 J6 34 Names of a
3. 2 3 5 CAN Communications The Prodigy PC 104 Motion Card offers a CAN port All functions of the card can be commanded through this port of it can be used to monitor certain operations even while the PC 104 bus is used to command motion sequences The CAN port may be operated at various baud rates from 1 200 to 1 000 000 The Magellan commands SetCANMode and GetCANMode are used to set CAN communication parameters A complete description of the CAN connector and its usage modes are provided in the Magellan Motion Processor Users Guide A complete description of Magellan com mands can be found in the Magellan Motion Processor Programmers Command Reference After a reset or at power up the board sets the CAN default parameters to 20 000 bps and node ID to 0 To alter these parameters the user may set new CAN parameters using the SetCanMode command while communicating at the default parameters and then switch to the new communications parameters The Prodigy PC 104 Motion Card will integrate with a CAN 2 0B network It will coexist but not communicate with other CAN 2 0B nodes on that network The CAN functionality receives commands sends responses and optional sends asynchronous event notifications Connections amp associated signals A special 2 pin connector is used to connect to the CAN port See Section 3 2 9 CAN Connector for a detailed signal description of the CAN connector 2 3 6 Watchdog Timer To enhance the ove
4. Connector Functionality GP Con x2 Provides connections to an external amplifier and motor elements Option Con For brushless DC and microstepping motors the Option Con connector provides additional con nections to external amplifier and motor components Serial The Serial connector allows the Prodigy PC 104 Motion Card to be controlled via a serial port or to enable monitoring over a separate serial port Sync I O x2 The Sync I O connectors synchronize additional boards within the same system CAN The CAN connector allows for integration with a CAN 2 0B network P amp D Con The pulse amp direction differential output connector Extension Con The extension connector allows the DC 1000 card to be installed on the Prodigy PC 104 Motion Card Syne I O is not available on the 8255 xxx series motion boards 3 2 1 GP Con The GP Con connector J5 and J6 in Figure 3 1 connects to various motion peripherals such as encoders amplifiers etc The GP Con is comprised of two standard 50 pin ribbon cable headers See Section 3 2 12 Connector Parts Ref erence for more information 40 Prodigy PC 104 Motion Card User s Guide Prodigy PC 104 Electrical Reference 7 3N 3 2 2 GP Con Using DC Brush Motors Pin Connection Description Pin Connection Description
5. Motor Type Value Commutation Brushless DC 0 3 phase Brushless DC 2 phase Microstepping 2 3 phase Microstepping 3 2 phase Step pulse amp direction 4 None DC brush 7 None 1 11 2 Step 2 Set the Output Mode The Prodigy PC 104 Motion Card must be told what type of motor output mode to use PWM Sign Magnitude PWM 50 50 or parallel DAC This can be set using the command SetOutputMode Axisl mode I Sets the output mode for axis See the Magellan Motion Processor Programmer s Command Reference for additional information Prodigy PC 104 Motion Card User s Guide 19 4 Installation 1 11 3 Step 3 Initialize the Commutation NOTE This section applies to brushless DC motors only For the motor to be properly controlled the Prodigy PC 104 Motion Card must select and possibly initialize the com mutation phasing If Hall based commutation will be used then no initialization is necessary Simply specify this to the Prodigy PC 104 Motion Card using the command SetCommutationMode Axisl Sets the commutation mode to Hall for Axis No other commands are necessary and you may proceed to step 4 If commutating using a sinusoidal technique the commutation phasing must be initialized There are two ways this can be done either by using Hall based or by algorithmic methods See the Magellan Motion Processor Users Guide for more information Each of these two phase initialization methods requires a separate sequence as dem
6. Mechanical Dimensions 3 1 User Settable Components Figures 3 1 and 3 2 illustrate the locations of the principal components of the Prodigy PC 104 Motion Cards The im portant uset accessible components of the board are listed in the following table Component Function Resistor packs RSI RS2 and RS3 Sets the encoder termination JPI and JP2 jumpers Selects pulse amp direction step or DC brush and brushless DC mode for each axis SWI DIP switch Sets base I O address Figure 3 1 Components and layout front of board Option XILINX FPGA Extension Con PC 104 Con Prodigy PC 104 Motion Card User s Guide 37 Prodigy PC 104 Electrical Reference Figure 3 2 Components and layout back of board gt Sync 1 0 PC 104 Con 3 1 1 Encoder Connections and Resistor Packs The RS1 RS2 and RS3 resistor packs labeled RS 1 3 in Figure 3 1 are installed on the Prodigy PC 104 Motion Card by default Encoder inputs may be connected differentially with two wires for QuadA QuadB and Index signals or with just one wire per signal If differential connections are being employed resistor packs RS1 RS2 and RS3 should remain installed If single ended encoders are used remove all three resistor packs and connect encoder signals to the positive encoder input only The negative input may remain unconnected Encoder connections are detailed in the fol lowing tables Encoder connections when using
7. SSI interface 46 standard memory buffer access 31 Step Pulse amp Direction Motor Connections 48 storage temperature 48 supply voltage limits 48 sync I O 45 sync I O cable 45 sync I O connectors 45 sync I O pinouts 45 synchronization of multiple boards 45 synchronizing multiple boards 45 Synchronous Serial Interface 46 53 T trace buffer 31 Trajectory Move 21 transmission speed 53 two phase initialization methods 19 type of motors supported 9 U under voltage detection circuit 29 undesired motion 18 User Settable Components 37 Vv virtual trace 32 W watchdog function 28 watchdog timer event 30 WritelO 24 WriteIO command 25 64 Prodigy PC 104 Motion Card User s Guide For additional information or for technical assistance please contact PMD at 978 266 1210 You may also e mail your request to support pmdcorp com Visit our website at http www pmdcorp com gt PM D Performance Motion Devices 80 Central Street Boxborough MA 01719 Prodigy PC 104 Motion Card User s Guide 65
8. axis 3 3 QuadBI Quadrature B encoder input axis 3 QuadB3 Quadrature B encoder input axis 3 4 QuadBI Quadrature B encoder input axis 4 QuadB3 Quadrature B encoder input axis 3 5 Index 1 Index input axis 1 5 Index3 Index input axis 3 6 Indexl Index input axis 6 Index3 Index input axis 3 7 Vcc 5V 7 Vcc 5V 8 GND Ground 8 GND Ground 9 PosLim Pos direction limit switch input axis 9 PosLim3 Pos direction limit switch input axis 3 0 NegLim Neg direction limit switch input axis 1 10 NegLim3 Neg direction limit switch input axis 3 l Homel Home input axis I Home3 Home input axis 3 2 GND Ground 12 GND Ground 3 AxisOut AxisOut output axis 13 AxisOut3 AxisOut output axis 3 4 Pulse Pulse output axis 14 Pulse3 Pulse output axis 3 5 Direction Direction output axis 15 Direction3 Direction output axis 3 6 AxisIn Axisln input axis 16 AxisIn3 AxisIn input axis 3 7 AtRest Atrest indicator output axis 17 AtRest3 Atrest indicator output axis 3 8 GND Ground 18 GND Ground 9 QuadA2 Quadrature A encoder input axis 2 19 QuadA4 Quadrature A encoder input axis 4 20 QuadA2 Quadrature A encoder input axis 2 20 QuadA4 Quadrature A encoder input axis 4 2l QuadB2 Quadrature B encoder input axis 2 2l QuadB4 Quadrature B encoder input axis 4 22 QuadB2 Quadrature B encoder input axis 2 22 QuadB4 Quadrature B encoder input axis 4 23 Index2 Index input axis 2
9. 2 installed 3 JP1 3 installed JP2 3 installed 4 JP1 4 installed JP2 4 installed Prodigy PC 104 Motion Card User s Guide Installation amp Figure 1 3 JP2 Example of pulse amp direction jumper settings JP1 1 JP2 1 JP1 A NOTE Use caution when setting motor jumpers Be sure that the jumper settings are valid for the specified motor type 1 8 3 DIP Switch Settings The Prodigy PC 104 is equipped with DIP switches labeled SW1 in Figure 1 2 for ISA bus mode and base address settings These switches along with their functionality and settings are detailed in the following table Item ISA bus mode SW1 PC 104 base address jumpers SW1 Setting SI I S1 2 10 hex S1 3 20 hex S1 4 40 hex S1 5 80 hex S1 6 100 hex S1 7 200 hex S1 8 400 hex Description SI I on 16 bit ISA bus mode default SI I off 8 bit ISA bus mode When the board is in 8 bit ISA bus mode the data transfer scheme is the same as the motion processor s 8 16 bit mode The motion pro cessor transfers instructions and data as full 16 bit words using an 8 bit data path Words are transferred in two successive bytes the high order byte of each word is transferred first in all cases Switch S sets the board address on the PC 104 bus The selected board address is the additive value of the switch settings indicated in the Settings column Moving the switch to the off position
10. 23 Index4 Index input axis 4 24 Index2 Index input axis 2 24 Index4 Index input axis 4 25 Vcc 5V 25 Vcc 5V 26 GND Ground 26 GND Ground 27 PosLim2 Pos direction limit switch input axis 2 27 PosLim4 Pos direction limit switch input axis 4 28 NegLim2 Neg direction limit switch input axis 2 28 NegLim4 Neg direction limit switch input axis 4 29 Home2 Home input axis 2 29 Home4 Home input axis 4 30 AxisOut2 AxisOut output axis 2 30 AxisOut4 AxisOut output axis 4 31 Pulse2 Pulse output axis 2 31 Pulse4 Pulse output axis 4 32 Direction2 Direction output axis 2 32 Direction4 Direction output axis 4 33 AxisIn2 Axisln input axis 2 33 AxisIn4 AxisIn input axis 4 34 AtRest2 Atrest indicator output axis 2 34 AtRest4 Atrest indicator output axis 4 35 GND Ground 35 GND Ground 36 DigitallnO General purpose digital input 0 36 Digitalln4 General purpose digital input 4 37 Digitalln General purpose digital input 37 Digitalln5 General purpose digital input 5 38 Digitalln2 General purpose digital input 2 38 Digitalln General purpose digital input 6 39 Digitalln3 General purpose digital input 3 39 Digitalln7 General purpose digital input 7 40 AmpEnable Amplifier enable signal axis 40 AmpEnable3 Amplifier enable signal axis 3 4l DigitalOutO General purpose digital output 0 4l DigitalOut4 General purpose digital output 4 42 DigitalOut General purpose digital output 42 DigitalOut5 General purpose digital output 5 43
11. 41 23 DigitalOut4 J6 42 21 DigitalOut5 J6 43 19 DigitalOut J6 44 17 DigitalOut7 J5 40 15 AmpEnable J5 45 13 AmpEnable2 J6 40 II AmpEnable3 J6 45 09 AmpEnable4 J5 13 07 AxisOut J5 30 05 AxisOut2 J6 13 03 AxisOut3 J6 30 0l AxisOut4 All even numbered pins GND Prodigy PC 104 Motion Card User s Guide Interconnect Module ran 4 2 DC 1000 SSI Option Board The DC 1000 is an optional expansion board for the Prodigy PC 104 Motion Card The DC 1000 is a Synchronous Serial Interface SSI for absolute encoders and connects to the Prodigy PC 104 Motion Card s extension connector J1 see Figure 4 1 The data of the absolute encoders is read through the DC 1000 interface and is then transmitted to the Prodigy PC 104 s motion controllers The electronics of the absolute encoder converts the parallel format data into serial format data and transmits this data to the DC 1000 The DC 1000 converts the incoming data into a 16 bit data word from Gray code to binary code and transmits the data to the Prodigy PC 104 Motion Card The DC 1000 can accept connections of up to four axes and the data of each axis can be programmed for a read rate of up to 20 kHz Some of the major features of the DC 1000 are as follows e Up to four axes can be read e Resolution can be programmed for 10 12 13 or 25 bits e Compatible with single and multi turn absolute encoders e Programmable frequencies of 1 1 MHz 550 kHz 275 kHz and 137 5 kHz e Default ju
12. A encoder input axis 2 20 QuadA4 Quadrature A encoder input axis 4 2l QuadB2 Quadrature B encoder input axis 2 2l QuadB4 Quadrature B encoder input axis 4 22 QuadB2 Quadrature B encoder input axis 2 22 QuadB4 Quadrature B encoder input axis 4 23 Index2 Index input axis 2 23 Index4 Index input axis 4 24 Index2 Index input axis 2 24 Index4 Index input axis 4 25 Vcc 5V 25 Vcc 5V 26 GND Ground 26 GND Ground 27 PosLim2 Pos direction limit switch input axis 2 27 PosLim4 Pos direction limit switch input axis 4 28 NegLim2 Neg direction limit switch input axis 2 28 NegLim4 Neg direction limit switch input axis 4 29 Home2 Home input axis 2 29 Home4 Home input axis 4 30 AxisOut2 AxisOut output axis 2 30 AxisOut4 AxisOut output axis 4 31 PWMMag2A PWM magnitude output axis 2 31 PWMMag4A PWM magnitude output axis 4 32 PWMSign2A PWM sign output axis 2 32 PWMSign4A PWM sign output axis 4 33 AxisIn2 Axisln input axis 2 33 AxisIn4 AxisIn input axis 4 34 DAC2A Analog mtr cmd output axis 2 10V 34 DAC4A Analog mtr cmd output axis 4 10V 35 AGND Ground for analog motor command 35 AGND Ground for analog motor command 36 DigitallnO General purpose digital input 0 36 Digitalln4 General purpose digital input 4 37 Digitalln General purpose digital input 37 Digitalln5 General purpose digital input 5 38 Digitalln2 General purpose digital input 2 38 Digitalln General purpose digital input 6 39 Digitall
13. DigitalOut2 General purpose digital output 2 43 DigitalOut6 General purpose digital output 6 44 DigitalOut3 General purpose digital output 3 44 DigitalOut7 General purpose digital output 7 45 AmpEnable2 Amplifier enable signal axis 2 45 AmpEnable4 Amplifier enable signal axis 4 46 Reset Hardware reset input 46 AnalogGND Gnd for general purpose analog inputs 47 Analog General purpose analog input 47 Analog5 General purpose analog input 5 48 Analog2 General purpose analog input 2 48 Analog General purpose analog input 6 49 Analog3 General purpose analog input 3 49 Analog7 General purpose analog input 7 50 Analog4 General purpose analog input 4 50 Analog8 General purpose analog input 8 Prodigy PC 104 Motion Card User s Guide 43 738 Prodigy PC 104 Electrical Reference 3 2 5 Option Con Connector 44 When the Prodigy PC 104 Motion Card is used with either brushless DC or microstepping motors the Option Con connector labeled J9 in Figure 3 1 provides additional signals for multi phase motor output and input of signals such as Hall sensors The Option Con is a single standard 50 pin ribbon cable header See Section 3 2 12 Connector Parts Reference for more information 3 2 6 PC 104 Option Con Using Multiple Motor Types PR8258xxx only Pin Connection Description Pin Connection Description l PWMMaglA Phase A PWM magnitude output axis 1 26 Hall
14. Kp followed by an Update command can be specified just a Kd fol lowed by Update etc When exercising the motor use extreme caution It is the responsibility of the user to observe safety precautions at all times 1 11 6 Step 6 Check Encoder Direction NOTE This Section applies to DC brush and brushless DC motors only The next step is to ensure that the sense of direction between the PID output and the encoder is synchronized A positive PID output should induce a direction of torque in the motor corresponding to positive encoder incrementation In other words a positive motor torque which creates motion should cause a positive encoder displacement This condition can be tested immediately after completing Step 5 This is because the system will respond to a position error once the filter parameters have been set If the motor runs away after setting the filter parameters then the encoder direction does not correspond to the motor torque direction If the motor remains stationary manually rotate Prodigy PC 104 Motion Card User s Guide 21 4 Installation the motor to induce a position error If the motor runs away then the encoder direction does not correspond to the motor torque direction The simple solution for this is to use the C Motion command SetSignalSense 0x0001 to invert the direction of the encoder If the motor does not run away but remains servoed then no action is necessary 1 11 7 Ste
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 PWM magnitude phase A per axis if PWM sign magnitude used PWM magnitude phase B PWM direction phase A PWM direction phase B Amplifier output signals PWM magnitude phase A per axis if PWM 50 50 used PWM magnitude phase B Amplifier output signals DAC out phase A per axis if DAC output used DAC out phase B Other control signals Home signal channel input optional per axis Positive limit switch inputs Negative limit switch inputs AxisIn input AxisOut output Miscellaneous signals Digital GND AmpEnable 5V for encoder power 1 10 Applying Power Once you have installed the Prodigy PC 104 Motion Card in your PC and have made the necessary connections to your external amplifiers and motor encoders hardware installation is complete and the board is ready for operation Upon power up the board will be in a reset condition In this condition no motor output will be applied Therefore the motors should remain stationary If the motors do move or jump power down the board and check the amplifier and encoder connections If anomalous behavior is still observed call PMD for application assistance Complete PMD contact information is listed on the last page of this manual If the PR8258x20 is being used there may be a situ
16. adds that value to the final base address For example to select a base address of 340 hex the following DIP switch settings would be selected 1 2 on S1 3 on S1 4 off SI 5 on S1 6 off SI 7 off 1 8 on The user specified board address must match the address expected by the software In addition this address must not be used by any other boards From the specified base address 6 addresses are used by the board For example if 300 hex is selected then locations 300 30F will be used by the board and cannot be used by other boards on the bus NOTES I The default base address is 300 hex 2 The recom mended base address range for PCs is 200 3F0 Prodigy PC 104 Motion Card User s Guide 15 4 Installation 16 1 8 4 IRQ Jumper Settings The Prodigy PC 104 is equipped with IRQ jumpers labeled JP4 in Figure 1 1 These jumpers along with their func tionality and settings are detailed in the following table Item Location IRQ Description IRQ selection JP4 1 IRQ3 Selects the specific IRQ signal to be active on the PC 104 bus The JP4 JP4 2 IRQ5 jumper block has eight positions with JP4 1 on the left nearest the JP4 3 IRQ7 mounting hole Only one IRQ may be selected and that IRQ must be JP4 4 IRQIO available on the system If not using the IRQ functionality leave all loca JP4 5 IRQI I tions unjumpered The IRQ if connected is activated by the motion JP4 6 IRQI2 processor under various host programma
17. bus can be configured as an 8 bit or 16 bit interface Ihe ISA bus mode is set with DIP switches as detailed in Section 1 8 3 DIP Switch Settings Prodigy PC 104 occupies a block of 16 contiguous addresses in I O space Memory space is not used The base I O address is set with DIP switches as detailed in Section 1 8 3 DIP Switch Settings The following table outlines the func tion of each address offset within the address block Address Offset Register Name Type Function 0 Data Write Read These two locations implement the parallel interface to the 2 Command Status Write Read motion processor Refer to the Host Communications sec tion of the Magellan Motion Processor User s Guide for more information 4 not used 6 Hard Reset Write only Writing to this location will cause a Hard reset of the Prodigy board 8 not used A DPRAM Address Pointer Write Read These three locations are used to implement direct high C DPRAM Data Write Read speed read and write of the onboard dual port RAM over E DPRAM Config Write Read the ISA bus Prodigy PC 104 Motion Card User s Guide 35 Operation This page intentionally left blank 36 Prodigy PC 104 Motion Card User s Guide 3 Prodigy PC 104 Electrical Reference PN In This Chapter User Settable Components Connectors Connections Summary Motor Amplifiers Command Summary Board Specific Functions Environmental and Electrical Ratings
18. conditioning Pulse amp direction signal conditioning Digital signal conditioning Digital I O Amplifier Enable converter Home Axis In Axis Out Limits Hall sensors Quad A B Index Analog in Pulse amp Direction differential output Pulse amp Direction single ended output PWM out Digital I O Amplifier Enable em DAC out Figure 2 1 Prodigy PC 104 internal block diagram 23 2 Operation 24 2 1 Board Function Overview The Prodigy PC 104 Motion Card s resources can be broken down into three overall categories Magellan Motion Processor functions These are programmable functions which reside in the Magellan Motion Processor chipset Included are profile generation DC brush and brushless DC loop closure microstep generation and much more These functions are accessed through the Magellan API commands which allows for sophisticated control of the board s overall behavior Board specific functions These are programmable functions which are controlled by the Magellan Motion Proces sor using the ReadlO and WritelO commands but which reside in various portions of the board circuitry These func tions include general purpose digital I O and other board specific capabilities Signal processing amp hardware functions A substantial portion of the board provides signal conditioning and oth er functions associated with non programmable signal related processing 2 2 Magel
19. differential encoder input Signal J5 amp J6 Pin Connections QuadAn J5 1 J5 19 J6 1 J6 19 QuadAn J5 2 J5 20 J6 2 J6 20 QuadBn J5 3 J5 21 J6 3 J6 21 QuadBn J5 4 J5 22 J6 4 J6 22 Indexn J5 5 J5 23 J6 5 J6 23 Indexn J5 6 J5 24 J6 6 J6 24 Vcc J5 7 J5 25 J6 7 J6 25 GND J5 8 J5 26 J6 8 J6 26 38 Prodigy PC 104 Motion Card User s Guide Prodigy PC 104 Electrical Reference amp gt Encoder connections when using single ended encoder input Signal J5 amp J6 Pin Connections QuadAn J5 1 J5 19 J6 1 J6 19 QuadBn J5 3 J5 21 J6 3 J6 21 Indexn J5 5 J5 23 J6 5 J6 23 Vcc J5 7 J5 25 J6 7 J6 25 GND J5 8 J5 26 J6 8 J6 26 The Prodigy PC 104 Motion Card has minimal jumper settings most settings are software configurable To prepare the board for installation the following user specified resistor pack options should be observed Item Setting Description Resistor packs Installed this is the default setting of resistor f differential connections are being used leave the RSI RS2 RS3 packs RSI RS3 resistor packs installed Removed If single ended encoder connections are being used remove the resistor packs 3 1 2 Motor Jumpers Various possibilities exist for setting up the Prodigy PC 104 Motion Card for use with either DC brush brushless DC with or without on board commutation microstepping or step pulse amp direction motors The default mode at power on is for DC brush
20. direction interface step motors are used Between one and four axes may be connected depending on the specific Prodigy board and application requirements Except for differential pulse amp direction output all connections are made through connec tor GP Con the primary 50 pin connectors labeled J5 and J6 in Figure 1 1 For a detailed list of connections see Chapter 3 Prodigy PC 104 Electrical Reference Signal Category Signal Description Encoder input signals per axis A quadrature channel input B quadrature channel input Index pulse channel input Amplifier output signals Pulse Direction Other control signals AtRest signal output 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 1 9 4 Microstepping Motors The following table summarizes connections to the Prodigy PC 104 Motion Card when microstepping interface step motors are used Between one and four axes may be connected depending on the specific Prodigy board and appli cation requirements All connections are made through the connectors GP Con the primary 50 pin connectors la beled J5 and J6 in Figure 1 1 and Option Con which is labeled J9 For a detailed list of connections see Chapter 3 Prodigy PC 104 Electrical Reference Prodigy PC 104 Motion Card User s Guide 17 4 Installation
21. extra work during each cycle Most applications should disable trace capture once the motion application has been debugged It is also possible to access the on board memory independent of the trace function which allows it to be used for generic storage The remaining on board memory available for trace must be calculated accordingly See the Trace Capture section of the Magellan Motion Pro cessor Users Guide for more information on these subjects Prodigy PC 104 Motion Card User s Guide 31 2 Operation 32 The Prodigy PC 104 Motion Card has 40 KBytes of on board dual ported memory DPRAM which is interfaced to the motion processor as well as the PC 104 decode circuitry allowing two paths of communication In many applica tions the Magellan Motion Processor can be used to store and access all trace data This method of operation is de scribed in the Magellan Motion Processor Users Guide Alternatively for moving large amounts of data the host computer can directly interface to the DPRAM so that the memory can be used in a real time circular buffer mode In this con figuration the motion processor stores data to the DPRAM and the host processor reads the data using the PC 104 interface instead of using motion processor commands The PC 104 interface offers a much higher read and write rate than is available through the motion processor This allows an almost unlimited amount of virtual trace storage space as the host computer s
22. motor on all axes The jumpers JP1 and JP2 consist of four jumper blocks each relating to axis 1 2 3 or 4 The following table describes the correct jumper settings for each motor type See Figure 3 1 for JP1 and JP2 locations In the following table the individual jumpers are numbered from left to right on each jumper block with each jumper number preceded by its jumper block JP1 1 is the jumper farthest to the left on JP1 JP1 2 is second from the left and so on An example of jumper settings is shown in Figure 3 3 Note that the motor type selection determines the default out put mode See the Magellan Motion Processor Users Guide for more information Axis Pulse amp Direction DC Brush Brushless DC JPI I installed JP2 I installed 2 JP 1 2 installed JP2 2 installed 3 JP1 3 installed JP2 3 installed 4 JP 1 4 installed JP2 4 installed NOTE Use caution when setting motor jumpers Be sure that the jumper settings are valid for the specified motor type Figure 3 3 JP1 JP2 Example of pulse amp g H R i toa of direction jumper A A settings JP1 1 JP2 1 Prodigy PC 104 Motion Card User s Guide 39 738 Prodigy PC 104 Electrical Reference 3 2 Connectors There are nine user accessible connectors on the Prodigy PC 104 Motion Card See page 14 for the specific locations of the connectors on the board The connectors and their functions are outlined in the following table
23. mounted on Prodigy PC 104 Option PC 104 Con 4 2 5 DC 1000 Software Commands The DC 1000 may be operated in mixed mode Any or all of the four axes may be configured in any combination of incremental or absolute modes The following commands are required to configure the absolute encoder mode for the DC 1000 SetEncoderSource Axis n mode Sets the mode to 0 incremental or1 absolute for Axis n Setting the mode to absolute parallel deactivates the incremental mode and setting to incremental deactivates the ab solute parallel mode SetEncoderModulus Axis n modulus Sets the modulus 0 to 65535 for Axis n Modulus settings are required for single turn absolute encoders in order to capture the full position when the encoder exceeds a full turn The Prodigy PC 104 Motion Card will accumulate the full 32 bits for the position The modulus must always be one half of the encoder s resolution Assuming an encoder with 12 bits 4 096 the resulting modulus to be programmed would be 2 048 One more command is required to program the SSI clock and resolution on the DC 1000 SetSSIRegister Axis n resolution frequency This function sets the resolution and clock frequency for Axis n Resolution can be set to one of 4 values 10 bits 12 bits 13 bist or 25 bits The frequency can also be set to one of 4 values 1 1 MHz default 550 kHz 275 kHz or 137 5 kHz Each axis can be programmed independently ee the Magella
24. the commutation section of the Magellan Motion Processor Users Guide for more information When the operating mode is set to 3 the motor is not under closed loop position control Be aware that the motor may spin rapidly after a motor command value is applied To begin use small values and then gradually increase the values i Contact PMD for additional information on the Phase Initialization application note 20 Prodigy PC 104 Motion Card User s Guide Installation amp 1 11 4 Step 4 Check Commutation NOTE This section applies to brushless DC motors only After phase initialization has been completed we recommend checking the smoothness of the motor rotation in open loop mode to verify that the motor phasing initialization and commutation is correct For this verification use the following command sequence SetOperatingMode Axisl 3 mode 3 disables the positon loop of Axis SetMotorCommand Axisl xxxx I xxxx is the motor command Update Axis updates the buffered parameters and starts the move The motor command value represents the fraction of 32 767 where 32 767 is equivalent to total power which will be applied to the motor For example a value of 1000 sends roughly 3 1000 32 767 of the total power to the motor After executing this command sequence the motor should spin smoothly in the specified direction The motor command is a signed number and the sign controls the rotation direction
25. value of 0 indicates that it is disabled meaning that the voltage being output by the DAC is forced to 0 0 volts To enable or disable the DAC enable function the WritelO command is used The change mask bit located at bit 15 must be loaded with a 1 Bit 8 must be loaded with a value of 0 to disable or a value of 1 to enable output The powerup default value for DAC Output Enable is disabled In addition the DAC Output Enable is disabled upon a hard reset which is a reset via the PC 104 bus or via the external Reset signal See Section 2 3 8 Reset for more information Examples WritelO Address 0x8080 write 0x8080 to I O Address to enable all DACs WritelO Address 0x8000 write 0x8000 to I O Address to disable all DACs Related commands In addition to the low level ReadlO and WritelO commands the following utility commands are also supported in C Motion and VB Motion SetDACOutputEnable and GetDACOutputEnable These utility commands provide a simpler in terface by handling the bit shifting See the Magellan Motion Processor Programmer s Command Reference for more information Connections amp associated signals DAC output enable is an internal function of the board Thus there are no signals directly associated with this function 2 3 4 Serial Communications The Prodigy PC 104 Motion Card offers an asynchronous serial communications port All functions of the card can be commanded through this port or it can be us
26. 1000 is an interconnect module which assists in the set up and configuration of the Prodigy PC 104 Motion Card and also provides complete options for external connections All wiring to and from the Prodigy PC 104 Motion Card the amplifiers power supplies IOs and encoder feedback may easily be connected to this central point 160 0 6 3 a Figure 4 1 IM 1000 location of components 108 0 4 3 JP5 JP1 JP2 JP3 JP4 AE 7 Screw terminals KEY mm lt a inch 145 0 57 4 0 0 157 diameter Connector Description Fl Amp fuse for power supply F2 Amp fuse for power supply Jl 100 position connector J3 OPTO22 connector J4 50 position connector J5 50 position connector SI External hardware reset button Screw terminals 3 100 terminal connection blocks for connecting to one 100 position or two 50 position cables 51 Prodigy PC 104 Motion Card User s Guide amp Interconnect Module 52 The enclosure of the board is a standard Phoenix DIN rail mounting system Alternatively the enclosure may be re moved and the board mounted to other systems via the 3 5 mm mounting holes located on the corners of the board The pinout descriptions that follow provide a detailed illustration of the IM 1000 s connections Please observe the differences between the DC brush and
27. 125 01 L DV Samtec IDSD 25 S J7 CAN Molex 53261 0271 Molex 51021 0200 J9 Option Con Samtec TSM 125 01 L DV Samtec IDSD 25 S J12 Pulse amp Direction Con Samtec TSM 110 01 L DV Samtec IDSD 10 S Prodigy PC 104 Motion Card User s Guide Prodigy PC 104 Electrical Reference 7 3N 3 3 Connections Summary Motor Amplifiers The Prodigy PC 104 Motion Card supports four methods of output to motor amplifiers as described in the following table Motor Output Method Signal Output DAC Analog signals from the onboard D A converters PWM sign magnitude Pulse width modulated signals with separate magnitude and sign signals per output phase PWM 50 50 Pulse width modulated square wave signals with a single PWM signal per output phase Pulse amp Direction One signal representing stepping information and a signal representing direction In addition each motor axis may have one two or three output phases associated with it For DC brush motors the number of phases is one For multi phase motors such as brushless DC or microstepping motors the number of phas es can be two or three depending on the output waveform programmed into the Prodigy PC 104 Motion Card For more information see the Magellan Motion Processor Users Guide The following tables provide convenient summaries of amplifier connections for common configurations of motor output method and motor type These outputs should be connected from the designated connec
28. 15 Board type This nibble encodes the board type and has one of the following values 0 ISA Bus PCI Bus 2 CompactPCI 3 PC 104 4 MIPS 5 RS232 6 CAN Example To read the Card ID the command ReadIO is used Assuming the value returned is 0x3805 this can be interpreted as Prodigy PC 104 Motion Card board generation 8 board revision 5 0 Related commands In addition to the low level ReadlO command a ReadCardID utility command is also supported by C Motion and VB Motion This utility command returns the Card ID in the format described above See the Magellan Motion Processor Programmer s Command Reference for more information Connections amp associated signals The Card ID is an internal function of the board There are no signals directly associated with this function 2 3 11 Memory Configuration Trace capture is a powerful feature of the Prodigy PC 104 Motion Card which allows various Magellan Motion Pro cessor parameters and registers to be continuously captured and stored to an external memory buffer The captured data may later be downloaded by the host using standard memory buffer access commands Data traces are useful for optimizing DC brush and brushless DC performance verifying trajectory behavior capturing sensor data or to assist with any type of monitoring where a precise time based record of the system s behavior is required Maintaining the trace buffer requires the motion processor to perform
29. 2 2l QuadB4 Quadrature B encoder input axis 4 22 QuadB2 Quadrature B encoder input axis 2 22 QuadB4 Quadrature B encoder input axis 4 23 Index2 Index input axis 2 23 Index4 Index input axis 4 24 Index2 Index input axis 2 24 Index4 Index input axis 4 25 Vcc 5V 25 Vcc 5V 26 GND Ground 26 GND Ground 27 PosLim2 Pos direction limit switch input axis 2 27 PosLim4 Pos direction limit switch input axis 4 28 NegLim2 Neg direction limit switch input axis 2 28 NegLim4 Neg direction limit switch input axis 4 29 Home2 Home input axis 2 29 Home4 Home input axis 4 30 AxisOut2 AxisOut output axis 2 30 AxisOut4 AxisOut output axis 4 31 n c No connection 31 n c No connection 32 n c No connection 32 n c No connection 33 Axisln2 Axisln input axis 2 33 Axisln4 Axisln input axis 4 34 DAC2A Phase A analog mtr cmd output axis 2 10V 34 DAC4A Phase A analog mtr cmd output axis 4 10V 35 AGND Ground for analog motor command 35 AGND Ground for analog motor command 36 Digitalln0 General purpose digital input 0 36 Digitalln4 General purpose digital input 4 37 Digitalln I General purpose digital input 37 Digitalln5 General purpose digital input 5 38 Digitalln2 General purpose digital input 2 38 Digitalln General purpose digital input 6 39 Digitalln3 General purpose digital input 3 39 Digitalln7 General purpose digital input 7 40 AmpEnable Amplifier enable signal axis 40 AmpEnable3 Amplifier ena
30. 2B Phase B Hall sensor input axis 2 2 PWMMag1B Phase B PWM magnitude output axis 1 27 Hall2C Phase C Hall sensor input axis 2 3 PWMMaglIC Phase C PWM magnitude output axis 28 GND Ground PWMSign 1B Phase B PWM sign output axis 4 PWMSignIlA Phase A PWM sign output axis 29 Hall3A Phase A Hall sensor input axis 3 5 GND Ground 30 Hall3B Phase B Hall sensor input axis 3 6 PWMMag2A Phase A PWM magnitude output axis 2 31 Hall3C Phase C Hall sensor input axis 3 7 PWMMag2B Phase B PWM magnitude output axis 2 32 GND Ground 8 PWMMag2C Phase C PWM magnitude output axis 2 33 Hall4A Phase A Hall sensor input axis 4 PWMSign2B Phase B PWM sign output axis 2 9 PWMSign2A Phase A PWM sign output axis 2 34 Hall4B Phase B Hall sensor input axis 4 10 GND Ground 35 Hall4C Phase C Hall sensor input axis 4 I PWMMag3A Phase A PWM magnitude output axis 3 36 GND Ground 12 PWMMag3B Phase B PWM magnitude output axis 3 37 AGND Ground for analog motor command 13 PWMMag3C Phase C PWM magnitude output axis 3 38 DACIA Phase A analog mtr cmd output axis 1 PWMSign3B Phase B PWM sign output axis 3 10V 14 PWMSign3A Phase A PWM sign output axis 3 39 DAC2A Phase A analog mtr cmd output axis 2 10V 15 GND Ground 40 DAC3A Phase A analog mtr cmd output axis 3 10V 16 PWMMag4A Phase A PWM magnitude output axis 4 4l DAC4A Phase A analog mtr cmd output axis 4 10V 17 PWMMag4B Phase B PWM magnitude output axis 4 42 DACIB Phas
31. Chapter 4 Interconnect Module 3 2 11 Pulse and Direction Differential Output Connector This connector labeled J12 in Figure 3 1 provides pulse and direction outputs using line drivers Using this connector with pulse and direction step drivers will provide a higher immunity to noise reducing the chance of mispositioning The pins and their associated signals are described in the following table Pin Pin Number Signal Number Signal GND Il axis 3 direction 2 GND 12 axis 3 direction 3 axis 4 pulse 13 axis pulse 4 axis 4 pulse 14 axis pulse 5 axis direction 15 axis 2 direction 6 axis direction 16 axis 2 direction 7 axis 4 direction 17 axis 3 pulse 8 axis 4 direction 18 axis 3 pulse 9 axis 2 pulse 19 GND 10 axis 2 pulse 20 GND 3 2 12 Connector Parts Reference PMD recommends using only the PMD supplied cable assemblies These assemblies are guaranteed to remain below the maximum height so as to allow stacking of multiple Prodigy PC 104 Motion Cards Using normal IDC connectors will result in exceeding the maximum height permitted by PC 104 specifications The following table is supplied as a reference only Label Description Header Part Number Connector Mate Jl Extension Con Samtec TMM 123 01 L D SM J2 Serial Molex 53261 0571 Molex 51021 0500 J3 J4 Sync I O Molex 53261 0271 Molex 51021 0200 J5 J6 GP Con Samtec TSM
32. Gray code 53 H Hall sensors 44 Hall based initialization command sequence 19 Hard reset 29 hardware configuration 11 Home 32 I IDC connectors 46 IM 1000 51 incremental mode 57 Index 33 index capture 24 Installation 12 Installation Sequence 11 Interconnect module 51 IRQ selection 15 ISO 11898 standard 45 J jumper 14 39 L Limits 32 M Magellan instruction set 24 Magellan Motion Processor part numbers 9 memory available for trace 31 Prodigy PC 104 Motion Card User s Guide 61 a Index Memory configuration 31 Microstepping 10 Microstepping Cards 42 Microstepping Motor Connections 48 Microstepping Motor connections 17 Modulus settings 57 motion processor reset 29 motor amplifier output methods 47 motor axis 47 Motor Jumpers 39 motor output method 47 motor types 10 multi phase motor output 44 multi phase motors 47 multi turn encoders 53 N negative direction limit input 32 noise immunity 46 number of axes supported 9 O on board memory 31 Operating temperature 48 operating temperature 48 optical encoders 53 Option Con Connector 44 option con connector 40 OPTO 22 connector 52 OPTO22 connector 51 output phases 47 output waveform 47 P Parallel encoder input adaptor 11 parallel input connector 46 parallel format data 53 PC 104 back diagram 13 PC 104 connectors 12 PC 104 decode circuitry 32 PC 104 front diagram 12 peripherals 40 phasing initialization 20 Phoenix DIN rail m
33. Processor Programmers Command Reference for more information Prodigy PC 104 Motion Card User s Guide 2 Operation Connections amp associated signals The general purpose I O are direct digital inputs and outputs There are no associated connections required for these signals to function properly however one or more of the digital grounds must be connected Digital inputs are pulled up through 4 7 kOhm resistors to 5V The power up default value for all general purpose digital outputs is low For a complete description of the pinout connections to and from the board see Chapter 3 Prodigy PC 104 Elec trical Reference 2 3 2 Amplifier Enable The signals AmpEnable l 4 provide four digial outputs which may be used as amplifier enable signals They can also be used as general purpose digital ouputs Similar to the general purpose digital inputs and outputs see Section 2 3 1 General Purpose Digital 1 O these signals are not directly affected by the Prodigy PC 104 Motion Card s behav ior However they can be read or written through the Prodigy PC 104 Motion Card s ReadlO and WritelO commands ReadIO and WriteIO commands These outputs are read using the ReadlO command and written to using the WritelO command using an address of 1 as shown in the following table TOU Address Location Signals 0 3 Amplifier enable outputs 0 3 4 6 Unused 7 DAC enable status 1 enabled 0 disabled 8 11 Ch
34. Prodigy PC 104 Motion Card User s Guide gt PM D Performance Motion Devices Inc 80 Central Street Boxborough MA 01719 Revision 1 3 August 2007 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 ot 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 2007 by Performance Motion Devices Inc Prodigy Magellan ION Magellan ION Pro Motion C Motion and VB Motion are trademarks of Performance Motion Devices Inc Prodigy PC 104 Motion Card User s Guide 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 pr
35. When a positive motor command is given the motor should rotate in the positive increasing encoder counts direction If the motor spins either roughly in the wrong direction or if it moves a short distance and then stops abruptly there may be a problem with the commutation Check the wiring and re test Once the motor is spinning smoothly in both directions under open loop control re enable closed loop DC brush and brushless DC control by executing the command SetOperatingMode Axis 0x33 mode 0x33 enables the trajectory generator position loop and motor output 1 11 5 Step 5 Set Filter Parameters For motion to occur some amount of feedback gain must be specified Initially use a proportional gain with a very low value between 1 and 25 Later integral or derivative gains may be added as well as feedforward gains if desired The following sequence shows how to set the P I and D terms of the filter and how to update them thus making them active SetPositionLoop Axis Param0 xxxx ParamO selects Kp and xxxx is the desired proportional gain SetPositionLoop Axis Param3 yyyy Param3 selects Kd and yyyy is the desired derivative gain SetPositionLoop Axis Param zzzz Param selects Ki and zzzz is the desired integral gain SetPositionLoop Axis Param2 aaaa Param2 selects llimit and aaaa is the desired integration limit value Update Axis make the values active It is not necessary to specify all three gains Just
36. all and configure the Prodigy PCI motion board iv Prodigy PC 104 Motion Card 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 ot 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 2007 by Performance Motion Devices Inc Prodigy Magellan ION Magellan ION Pro Motion C Motion and VB Motion are trademarks of Performance Motion Devices Inc Prodigy PC 104 Motion Card User s Guide 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 advi
37. ange mask for bits 0 3 amplifier enable outputs change 0 don t change 12 14 Unused 15 Change mask for DAC enable 1 change 0 don t change To read the status of the amplifier enable outputs the command ReadlO is used at address 1 The values currently being output will appear in bits 0 3 To write values to the amplifier enable output signals the WritelO command is used with an address of 1 The change mask bits corresponding to the signals which will be changed must be loaded at bits 8 11 and the value s to be loaded must be loaded in bits 0 3 Examples WritelO Address 0x0505 II write 0x0505 to I O Address to enable Amplifiers amp 3 WritelO Address 0x0400 I write 0x0400 to I O Address to disable Amplifier 3 WritelO Address 0x0100 write 0x0100 to I O Address to disable Amplifier Related commands In addition to the low level ReadlO and WritelO commands the following utility commands are also supported in C Motion and VB Motion SetAmplifierEnable and GetAmplifierEnable These utility commands provide a simpler inter face by handling the bit shifting See the Magellan Motion Processor Programmers Command Reference for more information Connections amp associated signals AmpEnable 4 are direct digital outputs There are no associated connections required for these signals to function properly however one or more of the digital grounds must be connected The power up default value for all a
38. ard for installation the following user specified resistor pack options should be checked Item Setting Description Resistor packs Installed this is the default setting of resistor If differential connections are being used leave these RSI RS2 RS3 packs RSI RS3 resistor packs installed Removed If single ended encoder connections are being used remove the resistor packs 1 8 2 Motor Jumper Settings Various possibilities exist for setting up the Prodigy PC 104 Motion Card for use with either DC brush brushless DC with or without on board commutation microstepping or step pulse amp direction motors The default mode at power on is for DC brush motor on all axes The jumpers JP1 and JP2 consist of four jumper blocks each relating to axis 1 2 3 or 4 The following table describes the correct jumper settings for each motor type See Figure 1 1 for JP1 and JP2 locations In the following table the individual jumpers are numbered from left to right on each jumper block with each jumper number preceded by its jumper block JP1 1 is the jumper farthest to the left on JP1 JP1 2 is second from the left and so on An example of jumper settings is shown in Figure 1 3 Note that the motor type selection determines the default out put mode See the Magellan Motion Processor Users Guide for more information Axis Pulse amp Direction DC Brush Brushless DC _ JPI I installed JP2 1 installed 2 JP1 2 installed JP2
39. ards 3 2 9 CAN Connector The Prodigy PC 104 Motion Card s controller area network CAN transceivers are designed for use with CAN control lers or with equivalent devices They are intended for use in applications employing the CAN serial communication phys ical layer in accordance with the ISO 11898 standard The transceiver provides differential transmit and differential receive capability to from a CAN controller at speeds up to 1 Mbps The Prodigy PC 104 Motion Card will integrate with a CAN 2 0B network It will coexist but not communicate with other CAN 2 0B nodes on that network The CAN functionality receives commands sends responses and optional sends asynchronous event notifications Prodigy PC 104 Motion Card User s Guide 45 738 Prodigy PC 104 Electrical Reference 46 The pinouts for the CAN connector are as follows Pin Number Signal CANH 2 CANL The CAN connector is located on the back of the board and is labeled J7 in Figure 3 2 3 2 10 Extension Connector This is a 46 pin connector labeled J1 in Figure 3 1 which connects the DC 1000 expansion board to the Prodigy PC 104 The DC 1000 is a a Synchronous Serial Interface SSI for absolute encoders and connects to the Prodigy PC 104 Motion Card s parallel input connector The DC 1000 its functionality and installation instructions are fully detailed in
40. arranty or endorsement thereof Prodigy PC 104 Motion Card User s Guide E 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 alphabetically for quick reference 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 Other Documents Magellan Motion Processor Electrical Specifications Booklets containing physical and electrical characteristics timing diagrams pinouts and pin descriptions of each series MC58000 Series for DC brush brushless DC Microstepping and Pulse amp Direction motion processors MC55000 Series for Pulse amp Direction motion processors Magellan Motion Processor Developer s Kit Manual How to install and configure the DK58000 series and DK55000 series developer s kit PC board ION Digital Drive User s Manual How to install and configure ION Digital Drives Prodigy PCI Motion Card User s Guide How to install and configure the Prodigy PCI motion board iv Prodigy PC 104 Moti
41. ask Axis Profile Il specify that an update of profile parameters only II is to occur Update Axis Double buffered registers are copied into II the active registers thereby initiating the move Prodigy PC 104 Motion Card User s Guide Operation 2 3 Board Specific Functions Board specific functions are those functions which are mapped through the Prodigy PC 104 Motion Card s ReadlO and WritelO facility but are implemented in the board circuitry Board specific functions are detailed in this document rather than the Magellan Motion Processor Users Guide or the Magellan Motion Processor Programmers Command Reference 2 3 1 General Purpose Digital I O In addition to numerous special purpose digital signals which are input or output to the board such as AxisIn AxisOut Home QuadA etc the Prodigy PC 104 Motion Cards support eight general purpose inputs and eight general purpose outputs These signals provide a convenient way of accessing additional general purpose digital I O Although access to these sig nals occurs through the Prodigy PC 104 Motion Card s ReadlO and WritelO commands the signals present at these var ious connections do not directly affect the Prodigy PC 104 Motion Card s behavior the Prodigy PC 104 Motion Card simply passes them through The general purpose digital I O voltage range is 0 5V ReadIO and WriteIO commands The eight inputs and eight outputs are read using the ReadlO co
42. ated signals For analog voltages to be read correctly in addition to the analog signal itself AnalogGND analog ground must be connected Prodigy PC 104 Motion Card User s Guide 33 2 Operation 2 4 4 Pulse and Direction For pulse amp direction applications these signals provide a stream of pulse and direction data and are compatible with a wide variety of off the shelf step motor amplifiers These signals are generated by the Magellan Motion Processor and are named Pulse 4 and Direction l 4 The default value at power up and reset for all pulse and direction output signals is pulse signal is high direction signal is low Connections amp associated signals Both single ended and differential line driver versions of these signals are output from the Prodigy PC 104 Card There are no associated connections required for these signals to function properly however one or more of the dig ital grounds must be connected For a complete description of the pinout connections to and from the board see Chapter 3 Prodigy PC 104 Electrical Reference 2 4 5 PWM Out For DC brush brushless DC or microstepping motors these signals provide PWM pulse width modulated motor command signals when the motor output mode is set to PWMSignMagnitude or PWM5050Magnitude The number of signals per axis varies depending on factors such as the motor type the number of phases of the motor and the motor drive method sign magnitude or 50 50 S
43. ation where undesired motion may occur when the processor is powered up In particular if the connected amplifier is a PVM 50 50 amplifier the motor will receive 100 power because the PR8258x20 Prodigy PC 104 Motion Card defaults to PWM sign magnitude on reset To avoid this situation use AmpEnable as an enable disable signal for the amplifier and set the motor type for each axis before enabling the amplifier See Section 2 3 2 Amplifier Enable 1 11 First Time System Verification The best way to setup and configure the Prodigy PC 104 motion system is to run the Axis Wizard in Pro Motion The Axis Wizard performs a step by step software configuration and verification of each function for each axis Refer to the Pro Motion Users Guide for complete information on the Pro Motion applicaton and its Axis Wizard You may also want to refer to the Magellan Motion Processor User s Guide to familiarize yourself with operation of the board s motion processor The following sections are provided as a summary for users who are developing applications using C Motion or VB Motion They show the minimum set of steps required to get an axis up and running The Axis Wizard in Pro Motion performs a more exhaustive list of software configuration steps incuding limit switch configuration index capture etc 18 Prodigy PC 104 Motion Card User s Guide Installation amp Since the configuration steps differ depending on motor type the follow
44. ble conditions JP4 7 IRQI4 JP4 8 IRQI5 1 9 Connection Summary for Prodigy PC 104 Motion Cards The following sections summarize the recommended connections for various motor types Generally the motor type to be installed is specified by the type of Prodigy PC 104 Motion Card see table on page 9 However with the PR8258x20 boards DC brush brushless DC microstepping and step pulse amp direction motors may be connected to the same board 1 9 1 DC Brush Motors The following table summarizes connections to the Prodigy PC 104 Motion Card when DC brush motors are used Between one and four axes may be connected depending on the specific Prodigy board and application requirements All connections are made through connector GP Con the two 50 pin connectors labeled J5 and J6 in Figure 1 1 For a detailed list of connections see Chapter 3 Prodigy PC 104 Electrical Reference Signal Category Signal Description Encoder input signals per axis A quadrature Channel input B quadrature channel input Index pulse channel input Amplifier output signals PWM direction per axis if PWM sign magnitude used PWM magnitude Amplifier output signals PWM magnitude per axis if PWM 50 50 used Amplifier output signals DAC out per axis if DAC output used Other control signals Home signal input optional per axis Limit switch inputs AxisIn input AxisOut output Miscellaneous signals Digital GND AmpEnable 5V
45. ble signal axis 3 4l DigitalOutO General purpose digital output 0 4l DigitalOut4 General purpose digital output 4 42 DigitalOut General purpose digital output 42 DigitalOut5 General purpose digital output 5 43 DigitalOut2 General purpose digital output 2 43 DigitalOut General purpose digital output 6 44 DigitalOut3 General purpose digital output 3 44 DigitalOut7 General purpose digital output 7 45 AmpEnable2 Amplifier enable signal axis 2 45 AmpEnable4 Amplifier enable signal axis 4 46 Reset Hardware reset input 46 AnalogGND Gnd for general purpose analog inputs 47 Analog General purpose analog input 47 Analog5 General purpose analog input 5 48 Analog2 General purpose analog input 2 48 Analog6 General purpose analog input 6 49 Analog3 General purpose analog input 3 49 Analog7 General purpose analog input 7 50 Analog4 General purpose analog input 4 50 Analog8 General purpose analog input 8 42 Prodigy PC 104 Motion Card User s Guide Prodigy PC 104 Electrical Reference 7 3N 3 2 4 GP Con Using Step Pulse amp Direction Motors Pin Connection Description Pin Connection Description J5 J6 l QuadAl Quadrature A encoder input axis 1 l QuadA3 Quadrature A encoder input axis 3 2 QuadAl Quadrature A encoder input axis 2 QuadA3 Quadrature A encoder input
46. brushless DC and stepping motor versions The screw terminal numbers cor respond to the pinout description for the Prodigy PC 104 Motion Card in the following way PC 104 IM 1000 crew Terminals J5 J4 1 50 J6 J5 51 100 The following table lists the functions of the remaining screw terminals Screw Terminals Function 101 103 5V from JI through Amp fuse F2 102 104 105 GND 106 External power in 107 GND 108 Unused The Prodigy PC 104 Motion Card supplies 5V DC from the computer to pins J5 7 J5 25 J6 7 and J6 25 through a 1 Amp fuse to power encoders When the jumpers JP1 JP2 JP3 and JP4 are installed 1 2 this 5V is passed on to screw terminals 7 25 57 and 75 respectively Alternatively it is also possible to use an external power supply in the range of 5 12 VDC for the encoders To do this intall jumpers JP1 JP2 JP3 and JP4 on pins 2 3 and connect the external power to screw terminal 106 and its ground to 107 This external power will be limited to 1 Amp by fuse F1 Connections to J3 the OPTO 22 connector are as follows J5 J6 J3 Description 49 5V if JP5 jumper is installed J5 36 47 DigitallnO J5 37 45 Digitalln J5 38 43 Digitalln2 J5 39 4l Digitalln3 J6 36 39 Digitalln4 J6 37 37 Digitalln5 J6 38 35 Digitalln6 J6 39 33 Digitalln7 J5 41 31 DigitalOutO J5 42 29 DigitalOut J5 43 27 DigitalOut2 J5 44 25 DigitalOut3 J6
47. ctor table shows the relationship between board part numbers Prodigy PC 104 Motion Card P N Ma gellan Motion Processor part numbers contained on the board Magellan P N the number of axes supported and the type of motors supported In the motor type column in the following table all motor types refers to DC brush brush less DC microstepping and step pulse amp direction motors Prodigy PC 1 04 Number of Motion Card P N Magellan P N Axes Motor Type PR8258120 MC58120 All motor types PR8258220 MC58220 2 All motor types PR8258320 MC58320 3 All motor types PR8258420 MC58420 4 All motor types PR8255120 MC55120 Step pulse amp direction only PR8255220 MC55220 2 Step pulse amp direction only PR8255320 MC55320 3 Step pulse amp direction only PR8255420 MC55420 4 Step pulse amp direction only Prodigy PC 104 Motion Card User s Guide 9 4 Installation 10 1 2 Prodigy PC 104 Motion Card Motor Types DC Brush output is a single phase motor command either in PWM pulse width modulated or analog 10V out put format They are intended to control DC brush motors or brushless DC motors using an amplifier which per forms commutation Brushless DC provides 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 ampli fiers a
48. d party s products or services does not constitute PMD s approval warranty or endorsement thereof Prodigy PC 104 Motion Card User s Guide A 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 alphabetically for quick reference 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 Other Documents Magellan Motion Processor Electrical Specifications Booklets containing physical and electrical characteristics timing diagrams pinouts and pin descriptions of each series MC58000 Series for DC brush brushless DC Microstepping and Pulse amp Direction motion processors MC55000 Series for Pulse amp Direction motion processors Magellan Motion Processor Developer s Kit Manual How to install and configure the DK58000 series and DK55000 series developer s kit PC board ION Digital Drive User s Manual How to install and configure ION Digital Drives Prodigy PCI Motion Card User s Guide How to inst
49. e B analog mtr cmd output axis 1 10V 18 PWMMag4C Phase C PWM magnitude output axis 4 43 DAC2B Phase B analog mtr cmd output axis 2 PWMSign4B Phase B PWM sign output axis 4 10V 19 PWMSign4A Phase A PWM sign output axis 4 44 DAC3B Phase B analog mtr cmd output axis 3 10V 20 GND Ground 45 DAC4B Phase B analog mtr cmd output axis 4 10V 2l Halll A Phase A Hall sensor input axis 1 46 AGND Ground for analog motor command 22 Hall B Phase B Hall sensor input axis 47 GND Ground 23 Halll C Phase C Hall sensor input axis 1 48 GND Ground 24 GND Ground 49 Vcc 5V 25 Hall2A Phase A Hall sensor input axis 2 50 Vec 5V 3 2 7 Serial Connector The following table gives the pinout for the 5 position Molex 1 25 mm header used for serial communications Pin Connection Description l SrlEnable Serial enable used only for RS422 485 2 SrlXmt Serial transmit output 3 SriRcv Serial receive input 4 GND Ground 5 Vcc 3 3V Prodigy PC 104 Motion Card User s Guide Prodigy PC 104 Electrical Reference amp For more information on communicating to the Magellan Motion Processor via the serial port see the Magellan Motion Processor Users Guide 3 2 8 Sync I O Connector The two Sync I O connectors located on the back of the Prodigy PC 104 Motion Card J3 and J4 in Figure 3 2 allow for the synchronization of multiple Prodigy PC 104 Motion Cards within a single system This configuration enables operation
50. e cece cece cnet ene e nee enenenennees 35 3 Prodigy PC 104 Electrical Reference ceeeeeecees e 37 3 1 User Settable Components 0 ccc e cece cnet ene e tent eneneees 37 3 2 CONNMECUOMS a5 s ea ass hed Sa eae estos ulna eee se acaelgwiaa ele ase a8 40 3 3 Connections Summary Motor Amplifiers cece cece eee eee 47 3 4 Environmental and Electrical Ratings 0c eee ee cece ence eee ees 48 3 5 Mechanical Dimensions eee e eee e cece ence e eee ene eneees 49 3 6 User I O Memory Map cece ccc cece cece ce enn ee ee ERA 49 4 Interconnect Module cece ccc ce es cccsccccccccccces 51 4 1 IM 1000 Interconnect Module cece e cece cence eee een en ees 51 4 2 DC 1000 SSI Option Board cece cece cece cece nee e tee enenenes 53 Index eee0 ak bere ar bela deere a alate E E aw tress bets ox 4 6 59 Prodigy PC 104 Motion Card User s Guide v y Table of Contents This page intentionally left blank vi Prodigy PC 104 Motion Card User s Guide ey O List of Figures l 1 Prodigy PC 104 Motion Card front view 0 cece ccc eee eet eee eee 13 1 2 Prodigy PC 104 Motion Card back view 0 cee cece cence teens 13 1 3 Example of pulse amp direction jumper settings 0 cee cece eee ee eee I5 2 Prodigy PC 104 internal block diagram 1 1 eee eee eee ene 23 3 1 Components and layout front of board 2 cece ee
51. e eee nee 37 3 2 Components and layout back of board cece nes 38 3 3 Example of pulse amp direction jumper settings 0 cece eee eee eee ee 39 3 4 Sync I O connector to three boards ee eee eee eee eee neces 45 3 5 Prodigy PC 104 mechanical dimensions 2 0 cece eee e eee eee eee eens 49 4 IM 1000 location of components 0 cece cece etn eee en eee 5I 4 2 DC 1000 location of components 0 cece eee eee ett eee eee eee 54 4 3 DC 1000 mounted on Prodigy PC 104 ee ccc cece ee 57 Prodigy PC 104 Motion Card User s Guide vii A List of Figures This page intentionally left blank viii Prodigy PC 104 Motion Card User s Guide 1 Installation In This Chapter Prodigy PC 104 Motion Card Types Prodigy PC 104 Motor Types Software Accessory Products Installation Sequence Recommended Hardware Software Installation Preparing the Board for Installation Board Components Connection Summary for Prodigy PC 104 Motion Cards Applying Power First Time System Verification vvvvvvvvvvvyv 1 1 Prodigy PC 104 Motion Card Types The Prodigy PC 104 Motion Cards are high performance PC 104 bus boards which provide motion control for DC brush brushless DC microstepping and step pulse amp direction motors These boards are based on PMD Magellan Motion Processors which perform motion command interpretation and many other real time functions The following product sele
52. e optional and are connected depending on the nature of the application These signals are named Home 4 Axisin l 4 AxisOut 4 PosLim l 4 positive direction limit input NegLim l 4 negative di rection limit input and Halll A 4C 12 signals in all Connections amp associated signals These signals are single ended digital inputs to the board with the exception of AxisOut which is a single ended output There are no associated connections required for these signals to function properly however one or more of the dig ital grounds must be connected The input signals are pulled up through 4 7 kOhm resistors to 5V The default power up value for all AxisOut signals is high For a complete description of the pinout connections to and from the board see Chapter 3 Prodigy PC 104 Electrical Reference Prodigy PC 104 Motion Card User s Guide Operation A 2 4 2 QuadA QuadB Index These signals provide position feedback to the motion controller which is used to track motor position For DC brush and brushless DC motors they are required for proper operation For microstepping or step pulse amp direction mo tors they are optional The encoder processing circuitry provides a multi stage digital filter of the QuadA QuadB and Index signals for each axis This provides additional protection against erroneous noise spikes thus improving reliability and motion integrity These signals are named QuadAl through QuadB4 16 s
53. e watchdog timer is an internal function of the board There are no signals directly associated with this function 2 3 7 Undervoltage Monitor To enhance reliability under a variety of electrical conditions an undervoltage detection circuit has been included This citcuit triggers a hard reset when the voltage has dropped to an unsafe level Resetting the Prodigy PC 104 Motion Card will have the result of setting all motor command outputs to zero thus allowing the motors to come to a safe stop An undervoltage condition is detected when the 3 3V internal supply on the board drops below 95 of its rated value To determine if a reset was caused by an undervoltage condition see Section 2 3 9 Reset Monitor Connections amp associated signals The undervoltage detector is an internal function of the board There are no signals directly associated with this function 2 3 8 Reset Although a reset occurs automatically during power up it is sometimes desirable to reset the Prodigy PC 104 Mo tion Card explicitly through a user initiated command or action There are several methods by which the Prodigy PC 104 Motion Card may be reset The methods are summarized in the following table Type of Method Reset Description External reset Hard reset When the external signal Reset on GP Con is brought low a hard reset occurs which resets all of the board s circuitry and the Magellan Motion Processor Reset through the Magel
54. ec If the axis is not moving or if the axis jumps rapidly in one direction or the other there may be a problem with the motor connections or software settings Re check and review the board setup procedures as well as the exerciser parameter settings If problems still exist after re checking the system contact PMD for applications assistance PMD contact info is located on the final page of this manual Whichever profile values you use be sure that they are safe for your system 22 Prodigy PC 104 Motion Card User s Guide 2 Operation A In This Chapter Board Function Overview Magellan Motion Processor Functions Board Specific Functions Signal Processing and Hardware Functions The Prodigy PC 104 Motion Cards are high performance PC 104 bus boards which provide motion control for DC brush brushless DC pulse amp direction and microstepping motors These boards are based on Magellan Motion Processors which perform motion command interpretation and other real time functions The overall board functions are divided among a number of modules as illustrated in the following diagram CAN Xmt Rev Serial Xmt Rev Sync Dual port Trace amp profile RAM storage Magellan Motion Processor Undervoltage monitor PC 104 decode PC 104 Bus Watchdog timer External Reset Prodigy PC 104 Motion Card User s Guide Digital signal conditioning Quadrature signal conditioning Analog
55. ed to monitor operations even while the PC 104 bus is used to com mand motion sequences Prodigy PC 104 Motion Card User s Guide 27 2 Operation The serial port can be operated at various baud rates from 1 200 to 460 800 and in varying configurations of stop start and parity codes In addition two serial protocols are supported point to point and multi drop idle line mode The Magellan commands SetSerialPortMode and GetSerialPortMode are used to set and read the serial port communication parameters A complete description of the serial port and its usage modes are provided in the Ma gellan Motion Processor Users Guide A complete description of Magellan commands can be found in the Magellan Mo tion Processor Programmer s Command Reference Also see Section 3 2 7 Serial Connector After a reset or at power up the board sets the communication parameters to 57 600 baud no parity one stop bit and point to point mode To alter these parameters new serial port parameters should be set using the SetSerialPortMode command while communicating at the default parameters and then switch to the new communications parameters Connections amp associated signals A special 5 pin connector is used to connect to the serial port A convenient cable with this connector installed may also be ordered See Section 1 4 Accessory Products and Section 3 2 7 Serial Connector for a detailed signal description of the serial connector
56. ee Chapter 3 Prodigy PC 104 Electrical Reference for complete con nection tables for various motor configurations These signals are named PWMMag A 4C 12 signals and PWMSign A 4B 8 signals Connections amp associated signals These signals are generated by the Magellan Motion Processor There are no associated connections required for these signals to function properly however one or more of the digital grounds must be connected For a com plete description of the pinout connections to and from the board see Chapter 3 Prodigy PC 104 Electrical Reference 2 4 6 DAC Out For DC brush brushless DC or microstepping motors this is the analog motor command when the motor output mode is set to DAC digital to analog converter These signals are named DACIA DAC4B 8 signals and vary between 10V and 10V The number of signals per axis depends upon the motor type See Section 3 4 Environmental and Electrical Ratings and the Magellan Motion Processor Users Guide for more information Connections amp associated signals For analog voltages to be output correctly AGND motor command ground must be connected For a complete descrip tion of the pinout connections to and from the board see Chapter 3 Prodigy PC 104 Electrical Reference 34 Prodigy PC 104 Motion Card User s Guide Operation 2 5 ISA Bus Address Map The Prodigy PC 104 Motion Card has a 16 bit ISA bus for parallel communications The ISA
57. ended Hardware To install a Prodigy PC 104 Motion Card the following hardware is recommended 1 The recommended platform is an Intel or compatible processor Pentium or better at least one PC 104 connector 30 MB of available disk space 32MB of available RAM and a CD ROM drive The supported PC operating systems are Windows 9X ME NT 2000 XP 2 One to four pulse and direction PWM or analog input amplifiers The type of amplifier depends on the type of motor being used 3 One to four step motors or DC brush and 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 4 Additional connectors as required to connect the Prodigy PC 104 Motion Card to the amplifiers and the motors Two 50 pin header type connectors will be required and the PR82582x0 boards will require an additional 50 pin connector See Section 3 3 Connections Summary Motor Amplifiers for more information on setting up these connections Prodigy PC 104 Motion Card User s Guide 11 4 Installation 1 7 Software Installation Locate the CD ROMs containing the Pro Motion C Motion and VB Motion software These CDs contain software to exercise the Prodigy board and source code enabling you to develop your own motion applications All software applications are designed to work with W
58. ers At power on or after a reset the system clock will be set to 1 1 MHz and the default system resolution will be deter mined by the settings of the DIP switches Additional parameters are defined in the following tables Switches 0 1 Resolution 00 10 bits Ol 12 bits 10 13 bits 1I 25 bits Prodigy PC 104 Motion Card User s Guide 55 amp Interconnect Module For the DIP switches ON 1 OFF 0 Default settings are all DIP switches set to OFF 0 The DIP switches are labeled SW1 in Figure 4 2 DIP Switches Axis 1 2 X axis 3 4 Y axis 5 6 Z axis 7 8 W axis NOTE These values may be overwritten by software 4 2 4 Installing the DC 1000 The DC 1000 attaches directly to the Prodigy PC 104 Motion Card with the component sides of both boards facing each other The DC 1000 s parallel input socket DC1 connects to the Prodigy PC 104 board s Extension Con connector J1 see Figure 1 1 1 To mount the DC 1000 to the Prodigy PC 104 remove the Prodigy PC 104 Motion Card from the com puter if installed Orient the card as shown in Figure 4 3 with the Option Con connector J9 on the left 2 Position the DC 1000 s parallel connector socket DC1 over the Prodigy PC 104 board s Extension Con Ensure that the top edge of the mating connectors are aligned The DC1 connector socket is shorter than the Prodigy PC 104 board s Extension Con and when the top edges of both are properly aligned th
59. escribed in the Pro Motion User s Guide C Motion provides a convenient set of callable routines comprising all of the code required for controlling the Prodigy PC 104 Motion Card C Motion includes the following features E Axis virtualization E The ability to communicate to multiple Prodigy PC 104 Motion Cards E Can be easily linked to any C C application VB Motion provides a complete set of methods and properties for developing applications in Visual Basic and other Active X enabled programs All the features of C Motion are also available in VB Motion C Motion and VB Motion are documented in the Magellan Motion Processor Programmer s Command Reference Prodigy PC 104 Motion Card User s Guide Installation amp 1 4 Accessory Products The Prodigy PC 104 Motion Cards can be enhanced with the addition of any or all of the following list of hardware accessory products Component Part Number Description Cable 2003 50 pin ribbon cable DC 1000 Parallel encoder input adaptor This daughter board module allows parallel word and other encoders which use the SSI interface format to be directly connected IM 1000 Breakout interconnect module that provides convenient jack screw type terminators for the 100 pin cable Used with cable 1003 or cable 1006 Cable 4003 3 foot long RS232 cable that connects to the serial connector This cable allows serial RS232 communication to the PC 104 board Only used if serial port com
60. for encoder power 1 9 2 Brushless DC Motors The following table summarizes connections to the Prodigy PC 104 Motion Card when brushless DC motors are used Between one and four axes may be connected depending on the specific Prodigy board and application requirements All connections are made through GP Con the two 50 pin connectors labeled J5 and J6 in Figure 1 1 and Option Con which is labeled J9 For a detailed list of connections see Chapter 3 Prodigy PC 104 Electrical Reference For detailed information regarding the Option Con see Section 3 2 5 Option Con Connector Prodigy PC 104 Motion Card User s Guide Installation amp Signal Category Signal Description Encoder input signals per axis A quadrature channel input B quadrature channel input Index pulse channel input Amplifier output signals PWM magnitude phase A per axis if PWM 50 50 used PWM magnitude phase B PWM magnitude phase C Amplifier output signals DAC out phase A per axis if DAC output used DAC out phase B Hall inputs Hall phase A Option Con Hall phase B Hall phase C Other control signals Home signal channel input optional per axis Positive limit switch input Negative limit switch input AxisIn input AxisOut output Miscellaneous signals Digital GND AmpEnable 5V for encoder power 1 9 3 Step Motors The following table summarizes connections to the Prodigy PC 104 Motion Card when pulse amp
61. he bottom Figure 1 2 shows the bottom or back side of the PC 104 board The components and connectors for both sides of the board are detailed on page 14 12 Prodigy PC 104 Motion Card User s Guide Installation Figure 1 1 Prodigy PC 104 Motion Card front view Option XILINX FPGA Extension Con PC 104 Con Figure 1 2 Prodigy PC 104 Motion Card back view gt Sync O PC 104 Con Prodigy PC 104 Motion Card User s Guide 13 gt Installation 14 Front of Board Components The following table describes the components on the front of the board as shown in Figure 1 1 and their functionality Label Description RSI RS3 Resistor packs PI P2 PC 104 connectors Jl Extension connector J5 Right GP Con connector J6 Left GP Con connector J9 Option Con connector J12 Pulse amp direction differential output connector JPI JP2 Motor type jumpers JP3 Reserved JP4 Interrupt IRQ selection jumpers Back of Board Components The following table describes the components on the back of the board as shown in Figure 1 2 and their functionality Label Description PI P2 PC 104 connectors SWI DIP switch block for base I O address selection J2 Serial connector J3 J4 Sync I O connectors J7 CAN connector 1 8 1 Resistor Pack Settings The Prodigy PC 104 Motion Card has minimal jumper settings most settings are software configurable To prepare the bo
62. ignals and IndexI through Index4 8 signals Connections amp associated signals These signals can be connected in one of two ways Single ended means that only one wire per signal is used while differential means two wires encode each signal labeled and Differential transmission is generally recommended for the highest level of reliability because it provides greater noise immunity than a single ended connection scheme If single ended connections are used only the signal is connected and the signal should be left floating For example in connecting to the A quadrature input QuadAl connects to the signal and QuadAl remains floating If differential connections are used both the and signals are used Differential or single ended termination must be selected through resistor pack installation For details see the table in Section 1 8 Preparing the Board for Installation Note that all quadrature and index connections should be in either single ended or differential mode It is not possible to mix on a signal by signal basis When using the system with differential connections the polarity of the differential signal can be reversed by swapping the and connections This may be useful for altering the motor and or encoder direc tion however this same function can also be accomplished through commands to the Prodigy PC 104 Motion Card See the Magellan Motion Processor Users Guide for more information Associated con
63. indows 9X ME NT 2000 XP If autorun is enabled the installation process will begin when the CD ROM is inserted If autorun is not enabled go to Start gt Run and in the Open textbox type D setup exe where D is the drive letter of your computer s CD ROM drive Follow the on screen prompts to complete the installation process Upon completion of the installation process the following components will be installed 1 Pro Motion an application for communicating to and exercising the installed board Refer to the Pro Motion Users Guide for operating instructions 2 C Motion source code which may be used for developing motion applications in C C based on the Magellan Motion Processor 3 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 4 PDF versions of the Prodigy PC 104 Motion Card Users Guide Magellan Motion Processor Programmer s Command Reference and Magellan Motion Processor Users 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 Board for Installation Figure 1 1 shows the location of the resistor packs RS1 RS2 RS3 along with other components such as jumpers and connectors The front or top side of the board is shown with the main PC PC 104 connectors at t
64. ing table provides an overview listing each step by number These steps are then detailed in subsequent sections Perform only the setup step sequences for the board motor type installed in your system Motor Type DC brush id ct 0 x tr Operation Set motor type Set output mode Set filter parameters Check encoder direction Make a trajectory move Set motor type Set output mode Initialize commutation Check commutation Set filter parameters Check encoder direction Make a trajectory move Set motor type Set output mode Set the Motor Command Make a trajectory move Set motor type Make a trajectory move Brushless DC Microstepping Step pulse amp direction MO ONN HOB UABRWN ODUN It is assumed that each axis of your system will be verified one at a time The Steps below are for Axis 1 To verify other axes use a new axis number and verify each axis accordingly 1 11 1 Step 1 Set the Motor Type The Prodigy PC 104 Motion Card must be told which type of motor will be driven by which axis To do this use the command SetMotorType Axisl type II Sets the motor type for axis The operation sets the number of phases for commutation on the axis as well as internally configuring the motion IC for the motor type See the Magellan Motion Processor Programmers Command Reference for additional information The following table lists the number of phases to be commutated
65. ion Card and the correct position will be stored The direction of motion will also be correctly detected Prodigy PC 104 Motion Card User s Guide 53 amp Interconnect Module Figure 4 2 DC 1000 location of components 54 4 2 1 DC 1000 Specifications e Dimensions 2 75 inches x 2 25 inches e 40 position mating connector for the Prodigy PC 104 Motion Card e 2stand offs with screws for mounting to Prodigy PC 104 Motion Card e Encoder mating connector for 5V DC or 12V DC from PC power supply e Jumper for selecting 5V or 12V supply voltage for the encoders e 26 position IDC connector and mating stub IDC ribbon cable e DIP switches for setting encoder resolution for each axis e Four position registers one for each axis maintain absolute positions e All positions may be read by the Prodigy PC 104 Motion Card at any time e Four read and write registers one for each axis for programmatically setting resolution and clock speed e Resolution and clock speed settings can be different for every axis The following diagram illustrates the location of the DC 1000 s main components and connectors The component side of the board is shown KEY mm inch z oe The names and descriptions of the main components of the DC 1000 are detailed in the following table Label Name Description DCI Parallel connector This socket connects to the parallel input connec
66. is l QuadA3 Quadrature A encoder input axis 3 2 QuadAl Quadrature A encoder input axis 2 QuadA3 Quadrature A encoder input axis 3 3 QuadBI Quadrature B encoder input axis 3 QuadB3 Quadrature B encoder input axis 3 4 QuadBI Quadrature B encoder input axis 4 QuadB3 Quadrature B encoder input axis 3 5 Index 1 Index input axis 1 5 Index3 Index input axis 3 6 Index Index input axis 1 6 Index3 Index input axis 3 7 Vcc 5V 7 Vcc 5V 8 GND Ground 8 GND Ground 9 PosLim Pos direction limit switch input axis 9 PosLim3 Pos direction limit switch input axis 3 10 NegLim Neg direction limit switch input axis 10 NegLim3 Neg direction limit switch input axis 3 I Homel Home input axis I Home3 Home input axis 3 12 GND Ground 12 GND Ground 13 AxisOut AxisOut output axis 13 AxisOut3 AxisOut output axis 3 14 n c No connection 14 n c No connection I5 n c No connection I5 n c No connection 16 AxisIn Axisln input axis 16 AxisIn3 AxisIn input axis 3 17 DACIA Phase A analog mtr cmd output axis 1 10V 17 DAC3A Phase A analog mtr cmd output axis 3 10V 18 AGND Ground for analog motor command 18 AGND Ground for analog motor command 19 QuadA2 Quadrature A encoder input axis 2 19 QuadA4 Quadrature A encoder input axis 4 20 QuadA2 Quadrature A encoder input axis 2 20 QuadA4 Quadrature A encoder input axis 4 2l QuadB2 Quadrature B encoder input axis
67. lan Motion Processor Functions The Magellan Motion Processor block pictured in Figure 2 1 consists of two ICs a CP command processor chip and an IO input output chip A summary list of the functions provided by the Magellan Motion Processor is as follows Profile generation Motor output signal generation PWM and analog Quadrature encoder counting and index capture DC brush and brushless DC loop closure Breakpoint processing AxisIn and AxisOut signal processing Trace Motion error detection tracking windows and at settled indicator Limit switches Access to the Magellan Motion Processor on the Prodigy PC 104 Motion Card occurs through the PC 104 bus the serial port or the CAN port Two manuals describe how the Magellan Motion Processor operates and how it is pro grammed the Magellan Motion Processor Users Guide and the Magellan Motion Processor Programmers Command Reference The Magellan instruction set is very flexible and powerful The following example which would be used to set up and execute a simple trapezoidal profile illustrates just a small part of the overall command set SetProfileMode Axis trapezoidal II set profile mode to trapezoidal for axis SetPosition Axis 12345 II load a destination position for axis SetVelocity Axis 223344 II load a velocity for axis SetAcceleration Axis 1000 load an acceleration for axis SetDeceleration Axis l 2000 load a deceleration for axis SetUpdateM
68. lan Soft reset Sending the Reset command to the Prodigy PC 104 Motion Card Motion Processor causes a soft reset of the Magellan Motion Processor only Reset through PC 104 bus Hard reset The HardReset command uses the PC 104 bus to perform a hard reset which resets all of the board s circuitry and the Magellan Motion Processor After a reset occurs the Prodigy PC 104 Motion Card and other related output signals will be driven to known states depending on the type of reset performed These are summarized in the following table Signal Name Soft Reset Hard Reset _ AxisOut 4 High High PWMMaglA 4C Low Low PWMSign A 4B Low Low DACIA DAC4B No change 0 0 volts DigitalOut0 7 No change Low AmpEnable l 4 No change Low DAC On Off No change Off Watchdog Timer No change Disabled Prodigy PC 104 Motion Card User s Guide 29 2 Operation Related commands A HardReset utility command is provided in C Motion and VB Motion This utility command uses the PC 104 inter face to force a Hard reset of the entire board See the Magellan Motion Processor Programmers Command Reference for more information on this command Connections amp associated signals The reset feature has an external signal input Reset associated with it This active low signal is located on the GP Con It is pulled up through a 4 7 kOhm resistor to 5 V 2 3 9 Reset Monitor In addition to resets which are explicitly requested by the u
69. memory or hard drive is used to store the data For both the host computer and the Magellan Motion Processor the 40 KBytes of DPRAM memory is accessed from offset 0 to offset 10 240 where the offset is calculated in 4 byte 32 bit dwords The number of dwords read or written can be 0 to 10 240 but must never be greater than 10 240 offset_in_dwords The following commands are used by the host to read and write directly to the DPRAM ReadDPRAM WriteDPRAM By using these commands blocks of 32 bit data can be read or written to the DPRAM While a trace is in progress the location to which the motion processor is currently writing may be determined by using the motion processor command GetBufferWritelndex Only data behind the current write index location should be read These commands are documented in the Magellan Motion Processor Programmer s Command Reference 2 4 Signal Processing and Hardware Functions These functions are implemented in hardware and are not directly user programmable The following sections are or ganized into related groups of signals and provide information which may be helpful when connecting the motion system 2 4 1 Home Axisin AxisOut Limits Hall Sensors These signals are conditioned by the board and then input or output directly to the Magellan Motion Processor The Magellan Motion Processor Users Guide explains the functions provided in connection with these various signals Most of the signals ar
70. mmand and WritelO command with an I O address of 0 This is illustrated in the following table along with the bit locations of the input and output signals 1 0 Bit Address Location Signals 0 0 7 DigitalOut0 7 8 15 Digitalln0 7 To read the eight general purpose digital I Os a ReadlO command is performed at address offset 0 The 16 bit read word returns the current output values set using the WritelO command in bits 0 7 while bits 8 15 hold the digital values corresponding to the signal levels at the connector for those inputs To write new signal values to the eight dig ital outputs a WritelO command to address offset 0 is sent and the values on bits 0 7 will be output to the signal connections The value of bits 8 15 are ignored Example To write the value OxAA to bits 0 7 the command WritelO is used Assuming that the signal pattern 0x55 is present on the eight input connections then if the command ReadlO is used the value returned will be 0x55AA The upper eight bits reflect the present value of the input signals while the lower eight bits reflect the 8 bit value being output Related commands In addition to the low level ReadlO and WritelO commands the following utility commands are also supported in C Motion and VB Motion WriteDigitalOutput ReadDigitallnput and ReadDigitalOutput These utility commands provide a simpler interface by handling the high byte low byte shifting See the Magellan Motion
71. mper settings can be overwritten with software commands e Update rates of up to 20 kHz for all four axes e Automatic recognition and addition of position overflow e Index search not required e Absolute position is read at power on e Incremental and absolute encoders can be mixed in any combination e Real time switching between incremental and absolute modes e Compatible with any absolute encoders which support the Synchronous Serial Interface SSI such as Haidenhein Stegmann Thalheim Unlike incremental encoders optical encoders always supply the exact absolute position At power on the encoder will report its exact position This precludes the need for the machine to locate a machine reference Absolute encoders are grouped into two categories single turn and multi turn Encoders with a resolution of up to 360 degrees are single turn encoders Those which can resolve several turns normally up to 4 096 are classified as multi turn encoders The key components of an absolute encoder consist of an optical code disk an opto electronic sensor system and pulse shaping circuitry and amplification The code discs of most absolute encoders generate position data in Gray code This differs from binary and BCD code as Gray code guarantees higher reliability for increased accuracy of data transmission The requirements for the transmission of absolute position data is one data line for each bit of information An encoder with 13 bits of resolu tion
72. mplifier enable signals is low disabled For a complete description of the pinout connections to and from the board see Chapter 3 Prodigy PC 104 Electrical Reference 26 Prodigy PC 104 Motion Card User s Guide Operation A 2 3 3 DAC Output Enable In addition to the amplifier enable outputs there is a dedicated board function which allows the DAC output signals to be shunted to 0 volts for safety purposes DAC disabled or allowed to be set by the Magellan Motion Processor DAC enabled This shunting occurs at a hardware level outside the motion processor itself and provides an addi tional safety layer to control the motor command ReadIO and WriteIO commands The status of the DAC output enable function can be read using the ReadlO command and the DAC output enable status can be set using the WritelO command with an address of as shown in the following table 1 0 Bit Address Location Signals 0 3 Amplifier enable outputs 0 3 4 6 Unused 7 DAC enable status 1 enabled 0 disabled 8 11 Change mask for bits 0 3 amplifier enable outputs 1 change 0 don t change 12 14 Unused 15 Change mask for DAC enable 1 change 0 don t change To read the status of the DAC output enable function ReadlO is used The value currently in use will appear in bit 7 A value of 1 indicates DAC output is enabled meaning that the voltage being output by the DACs is controlled by the motion processor A
73. mplifier connections vary Common names are shown 3 4 Environmental and Electrical Ratings Storage temperature 40 to 125 degrees C 40 F to 257 F Operating temperature 0 to 70 degrees C 32 F to 158 F Power requirements 4 8V to 5 25V operating range 0 6A no outputs on Supply voltage limits 0 3V to 7V Analog DAC output range 10 0V to 10 0V 3mA min axis short circuit protected Analog input range 0 to 3 3V 1 4 KOhm input impedance Digital I O voltage range OV to 5V TTL thresholds inputs pulled up to 5V through 4 7 kOhm resistors Digital outputs drive capacity DC output source or sink current 50mA CAN communications 2 0B compliant non isolated Mbps Serial communications 3 3V signaling unbuffered no transceiver Prodigy PC 104 Motion Card User s Guide Prodigy PC 104 Electrical Reference 3 5 Mechanical Dimensions no 7 42 112 0 z 2 Q a e 3 85 7 a 3 37 8 80 0 gt 3 15 When stacking Prodigy PC 104 cards with 0 6 spacers the Option Con mating connector on one card will inter fere with connectors J2 J3 J4 and J7 on the other For clearance additional 062 or 1 5 mm shim washers are required 3 6 User I O Memory Map The Magellan Motion Processor reserves the sector from address 1000h to 10FFh in peripheral space for use
74. munication is required For information on ordering these accessory products please contact your PMD representative 1 5 Installation Sequence 1 Before using the board the software must be installed Installation of the software is described in Section 1 7 Software Installation Conventions in this manual refer to a Windows based system with a PC 104 bus or with an ISA to PC 104 converter device Such converters are available from a number of vendors 2 Fora normal installation of a Prodigy PC 104 Motion Card you will need to configure the board for the specific motor hardware to which it will be connected Configuration of the Prodigy PC 104 Motion Cards is described in detail in Section 1 8 Preparing the Board for Installation 3 Next connect the system s motors encoders amplifiers and sensors to operate the motion hardware A description of the available connections and options for the Prodigy PC 104 Motion Card is found in Section 1 9 Connection Summary for Prodigy PC 104 Motion Cards 4 If installing the DC 1000 see Section 4 2 DC 1000 SSI Option Board 5 Once this hardware configuration is complete the final step to finish the installation is to perform a functional test of the finished system This procedure is described in Section 1 11 First Time System Verification Once these steps have been accomplished the installation is complete and the board is ready for operation 1 6 Recomm
75. n Motion Processor Programmers Command Reference for more information See the Magellan Motion P P sC dR fo infi ti Prodigy PC 104 Motion Card User s Guide 57 amp Interconnect Module This page intentionally left blank 58 Prodigy PC 104 Motion Card User s Guide FE Index Numerics 100 terminal connection blocks 51 26 position IDC connector 54 40 position mating connector 54 50 position connector 51 A absolute encoder 53 absolute mode 57 Accessory 11 address settings 15 Algorithmic based initialization command sequence 19 AmpEnable 18 amplifier connections 47 amplifier enable output signals 26 amplifier inputs 47 amplifiers 40 analog input range 48 analog output range 48 Applying Power 18 axis verification 18 AxisIn 32 AxisOut 32 B base address jumpers 15 BCD code 53 board component and connector locations 12 board part numbers 9 Breakout 11 Breakout interconnect module 11 Brushless DC 10 Brushless DC Motor Connections 47 Brushless DC Motor connections 16 brushless DC motors 16 C cable assemblies 46 CAN 2 0B network 28 45 CAN 2 0B nodes 28 45 CAN Connector 53 CAN connector 46 CAN serial communication physical layer 45 Card Function Overview 23 Card Specific Functions 23 Prodigy PC 104 Motion Card User s Guide 59 a Index change mask bits 26 Check Commutation 20 C Motion 10 12 C Motion features 10 commutation 20 components back of board 14 components front of b
76. n3 General purpose digital input 3 39 Digitalln7 General purpose digital input 7 40 AmpEnable Amplifier enable signal axis 40 AmpEnable3 Amplifier enable signal axis 3 4l DigitalOutO General purpose digital output 0 4l DigitalOut4 General purpose digital output 4 42 DigitalOut General purpose digital output 42 DigitalOut5 General purpose digital output 5 43 DigitalOut2 General purpose digital output 2 43 DigitalOut6 General purpose digital output 6 44 DigitalOut3 General purpose digital output 3 44 DigitalOut7 General purpose digital output 7 45 AmpEnable2 Amplifier enable signal axis 2 45 AmpEnable4 Amplifier enable signal axis 4 46 Reset Hardware reset input 46 AnalogGND Gnd for general purpose analog inputs 47 Analog General purpose analog input 47 Analog5 General purpose analog input 5 48 Analog2 General purpose analog input 2 48 Analog General purpose analog input 6 49 Analog3 General purpose analog input 3 49 Analog7 General purpose analog input 7 50 Analog4 General purpose analog input 4 50 Analog8 General purpose analog input 8 Prodigy PC 104 Motion Card User s Guide 41 738 Prodigy PC 104 Electrical Reference 3 2 3 GP Con Using Brushless DC or Mlicrostepping Motors Pin Connection Description Pin Connection Description J5 J6 l QuadAl Quadrature A encoder input ax
77. nd motors Microstepping output is multi phase analog 10V or PWM pulse width modulation waveforms They are de signed to control 2 or 3 phase step motors using amplifiers which accept this command format Pulse amp direction output is standard pulse amp direction signals and are intended to interface with amplifiers which accept this command format For complete information on motor output formats and other information see he Magellan Motion Processor Users Guide 1 3 Software Three major software packages are provided with the Prodigy PC 104 Motion Cards Pro Motion an interactive Windows based exerciser program C Motion a C language library and VB Motion a set of Active X objects C Motion and VB Motion are designed to simplify the development of motion applications for Prodigy PC 104 Motion Cards Pro Motion is a sophisticated easy to use exerciser program which allows all board parameters to be set and or viewed and allows all board features to be exercised Pro Motion features include E 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 board parameters Ability to save and load current settings Distance and time units conversion Mototr specific parameter setup Axis shuttle performs continuous back and forth motion between two positions Pro Motion is d
78. nections supported by the board are the 5V output signals These are provided as a convenience as they are generally connected to a corresponding input on the encoder to power its internal circuitry As was the case for the digital input signals one or more of the digital grounds must also be connected For a complete description of the pinout connections to and from the board see Chapter 3 Prodigy PC 104 Electrical Reference 2 4 3 Analog Input The Analog 8 signals provide general purpose input of up to eight analog signals The voltages present at these various connections do not directly affect the Prodigy PC 104 Motion Card s behavior However they can be read through the Prodigy PC 104 Motion Card thus providing a convenient way of importing analog signal levels which may be acted upon by the user s application code located on the host PC These signals are read using the Magellan command ReadAnalog For more information on reading the value of these analog inputs see the Magellan Motion Processor Users Guide The minimum allowed input voltage is 0 0V and the maximum allowed input voltage is 3 3V To determine the numerical value that will be read by the Prodigy PC 104 Motion Card given a specific voltage the following formula is used ReadValue AnalogVoltage 65 536 3 3V Conversely given a read value the voltage at the connection is calculated as AnalogVoltage ReadValue 3 3V 65 536 Connections amp associ
79. ned would be 0x8000 To reset the reset monitor word the command WritelO is sent to address 2 with a value of zero 0 Related commands In addition to the low level ReadlO and WritelO commands a GetResetCause utility command is also supported by C Motion and VB Motion This utility command returns the cause and also clears the reset condition See the Magellan Motion Processor Programmers Command Reference for more information Connections amp associated signals The Reset monitor is an internal function of the board There are no signals directly associated with this function 30 Prodigy PC 104 Motion Card User s Guide Operation 2 3 10 Card ID This feature allows the user to query the card for a Card ID This may be helpful for verifying the type of Prodigy Motion Card in situations where multiple cards of varying types are installed ReadIO and WriteIO Commands To read the Card ID the ReadlO command is used with an address of OxFE The encoding of the bits returned is de tailed in the following table Bit Address Location Signals OxFF 0 3 Major board revision This nibble encodes the major board revision This value can range from 0 to I5 4 7 Minor board revision This nibble encodes the minor board revision This value can range from 0 to I5 8 11 Board generation This nibble encodes the board generation This value can range from 8 to 15 0 to 7 are reserved for older motion board families 12
80. oard 14 Connection Summary 16 Connections 52 Connections Summary 47 connector functions 40 connector parts reference 46 connector pins 47 Connectors 40 connectors 40 controller area network transceivers 45 current write index 32 cycle period 45 D DAC 47 data cables length of 53 data traces 31 DC brush cards 10 DC Brush Motor Connections 47 DC Brush Motor connections 16 DC 1000 Connections 55 DC 1000 Default parameters 55 DC 1000 expansion board 46 DC 1000 expansion card 53 DC 1000 Specifications 54 DC 1000 installing 56 default mode at power on 14 39 default output mode 14 39 differential connections 38 differential encoder input 38 Differential encoding 33 differential mode 33 differential receive capability 45 differentialtransmit capability 45 Digital outputs drive capacity 48 DIP switches 15 DIP switches DC 1000 54 DPRAM 32 E encoder connections 38 encoder feedback 51 Encoder inputs 38 Encoder mating connector 54 60 Prodigy PC 104 Motion Card User s Guide Index N encoder resolutions 53 Encoder Settings 38 encoder signals 38 encoders 40 Environmental and Electrical Ratings 48 49 external connections 51 External hardware reset button 51 External reset 29 F First Time System Verification 18 First Time System Verification 18 For 10 functional test 11 G General Purpose Digital I O 25 general purpose inputs 25 general purpose outputs 25 GP Con 16 GP Con connector 40
81. oducts 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 understood 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 intellectual property right of PMD covering or relating to any combination machine or process in which such products or services might be or ate used PMD s publication of information regarding any thir
82. on Card User s Guide Table of Contents D Table of Contents List of Figures sssssssssssosssseseososcesecsosoessososoees vii T Installation e ccc ccc ccc ccc a e E E 9 1 1 Prodigy PC 104 Motion Card Types cece cece cece eee eee eeenes 9 1 2 Prodigy PC 104 Motion Card Motor Types e eee ee eee ee eee ee 10 1 3 SOWA ics sila ais He se A E E AT AEEA Nats dh Ladle oa bude tha codes 10 1 4 AccessOry Products 0 cece cece cece cece een ence ence en eneneenee 11 1 5 Installation SEQUENCE nes tai punine cece n TE EE E TARA E TS 11 1 6 Recommended Hardware ssssusssssssssesrrresessesreerrrrers 11 1 7 Software Installation cece cece cece cent ence e eee ence eneees 12 1 8 Preparing the Board for Installation s eee cece eee ee eens 12 1 9 Connection Summary for Prodigy PC 104 Motion Cards 16 1 10 Applying Power ccc cece cece cence eee ence eect een eneeeeeenes 18 1 11 First Time System Verification cece cence cence cnet een ees 18 2 Op rati n ssesressesisnisnesn sinari t r a e e sve 0a rE 23 2 1 Board Function Overview 0 cece eee e cect ene e eee e en eneenees 24 2 2 Magellan Motion Processor Functions e eee e eee e tence eee 24 2 3 Board Specific Functions 2 0 ccc ccc cece cece eee e eee eneneees 25 2 4 Signal Processing and Hardware Functions eceeeeeeeeees 32 2 5 ISA Bus Address Map eee ee
83. onstrated in the following examples Hall based initialization command sequence SetPhaseCounts Axis yyyy II yyyy is of encoder counts per electrical cycle SetPhaselnitializeMode Axis sets phase initialize mode Hall based for Axs InitializePhase Axis I Initiates the phase initialization sequence for Axis Algorithmic based initialization command sequence SetPhaseCounts Axis yyyy II yyyy is of encoder counts per electrical cycle SetPhaselnitializeMode Axis 0 I sets phase initialize mode 0 Algorithmic SetOperatingMode Axisl 3 disables the position loop required for algorithmic initialization SetPhaselnitializeTime Axis zzzz II zzzz is of motion processor cycles to initialize for SetMotorCommand Axis l wwww wwww is motor command InitializePhase Axis Initiates the phase initialization sequence for Axis To determine the values of yyyy zzzz and wwww please refer to the Magellan Motion Processor Users Guide and the Ma gellan Motion Processor Programmers Command Reference If your system has one or more of the following conditions present 1 one or more Hall signals must be inverted to commutate or initialize the commutation correctly or 2 the number of encoder counts per electrical cycle exceeds 32 767 then the preceding command sequences will need to be expanded For these systems you will need to use the SetSignalSense command along with the SetPhasePrescaleMode command Refer to
84. ounting system 52 Phoenix EN rail mounting system 52 polarity 33 positive direction limit input 32 power requirements 48 power up 18 product selector table 9 62 Prodigy PC 104 Motion Card User s Guide Index N profile generation 24 Pro Motion 10 12 Pro Motion features 10 Pulse amp direction 10 Pulse amp Direction Cards 43 pulse amp direction interface step motors 17 pulse and direction differential output connector 46 pulse and direction outputs 46 PWM 50 50 47 PWM sign magnitude 47 Q QuadA 33 QuadB 33 R ReadIO 24 ReadIO and WriteIO commands 27 ReadIO command 25 Recommended 11 recommended connections 16 Required Hardware 11 reset condition 18 30 reset monitor word 30 resistor pack options 39 Resistor Pack settings 38 Resistor packs 37 resistor packs 12 38 roll over 53 S screw terminal 52 serial communications 44 Serial Connector 44 serial port communication parameters 28 serial format data 53 servo loop closure 24 Set Filter Parameters 20 Set the Motor Command 21 SetCommutationMode 19 SetCommutationMode command 19 SetMotorType command 19 SetOutputMode 19 setup step sequences 18 shunting 27 signal conditioning 24 single ended connections 33 single ended encoder input 39 single ended encoders 38 Prodigy PC 104 Motion Card User s Guide 63 a Index single ended mode 33 single turn encoders 53 sinusoidal commutation 19 Soft reset 29 Software Commands DC 1000 57
85. p 7 Set the Motor Command NOTE this section applies to microstepping motors only In order for motion to occur the magnitude of the output must be set Refer to the Magellan Motion Processor Users Guide for more information A value between 0 and 32 767 represents an amplitude of 0 100 As a starting point a value of around 5000 should be satisfactory Here is the command sequence to use SetMotorCommand Axis xxxx sets the motor output level for Axis Update Axis execute the move 1 11 8 Step 8 Make a Trajectory Move To verify that the motor is being controlled properly set up and execute a short trapezoidal move For example a short distance of 5000 counts a low velocity of 10 000 and acceleration of 10 With a cycle time of 256usec these values correspond to roughly 596 counts sec and 2 4x10 counts sec respectively The command sequence to use is as follows SetProfileMode Axisl 0 sets the profile mode to trapezoidal for Axis SetPosition Axis 5000 5000 is the desired destination position SetVelocity Axis 10000 10 000 is the desired maximum velocity SetAcceleration Axis 10 10 is the desired acceleration SetDeceleration Axis 10 10 is the desired deceleration Update Axis execute the move After entering this sequence of commands the axis should move smoothly for about 15 seconds if the suggested values are used and the cycle time of the Prodigy PC 104 Motion Card is 256 1s
86. r defined I O devices The Prodigy PC 104 Motion Card uses this sector as shown in the following table Address Device Description 1000h General Purpose I O Includes the 8 digital inputs and 8 digital outputs 1001h Amplifier Enable register Also includes the DAC output enable 1002h Reset Monitor register See Section 2 3 9 1003h Reserved 1004h Watchdog register See Section 2 3 6 1005h Reserved Prodigy PC 104 Motion Card User s Guide Figure 3 5 Prodigy PC 104 mechanical dimensions 49 738 Prodigy PC 104 Electrical Reference 50 Address Device Description 1006h 100Fh Reserved 1010h 10IFh DC 1000 Includes the SSI clock resolution and absolute position registers 1020h 1OCFh None Available for use with custom peripherals over Extension Con 10DOh IODAh Reserved Used by Prodigy FPGA 10DBh Build register Build number of Prodigy FPGA 10DCh IODFh Reserved Used by Prodigy FPGA 10EOh OEFh None Available for use with custom peripherals over Extension Con 1OFOh OFDh Reserved OFEh Model type For compatibility with older Magellan Motion Card family 1OFFh Card ID See Section 2 3 10 See the Magellan Motion Processor Users Guide for more information on peripheral memory space Prodigy PC 104 Motion Card User s Guide 4 Interconnect Module A In This Chapter IM 1000 Interconnect Module DC 1000 SSI Option Board 4 1 IM 1000 Interconnect Module The IM
87. rall safety of the board a watchdog function has been included The watchdog will automatically trigger a hard reset if communication from the host should be lost Resetting the Prodigy PC 104 Motion Card will have the result of setting all motor command outputs to zero thus allowing the motors to come to a safe stop ReadIO and WriteI O commands To enable the watchdog timer the WritelO command is used to send a value of 0x5562 to address 4 Once enabled the watchdog timer will time out causing a hard reset if another write to address 4 with a value of 0x5562 is not re ceived within 104 milliseconds As long as a watchdog value is written to address 4 within the 104 millisecond interval no reset will occur and motion operations will proceed normally After powerup or any hard reset if no command is sent to the watchdog address then the watchdog will remain dis abled The watchdog is disabled by default at power up When the watchdog timer times out and triggers a hard reset it also disables itself 28 Prodigy PC 104 Motion Card User s Guide Operation A Related commands In addition to the low level ReadlO and WritelO commands the following utility command is also supported by C Motion and VB Motion SetWatchDog This utility command provides a simpler interface by automatically sending the value 0x5562 See the Magellan Motion Processor Programmer s Command Reference for more information Connections amp associated signals Th
88. ree sets of pins on the Extension Con will be visible at the bottom of the DC 1000 s connector when viewed from above the boards Before pressing the DC 1000 into place view the boards from the front in the same orientation as Figure 4 3 Verify that the two sets of mounting holes are in exact alignment 3 When this alignment is correct press firmly and evenly to seat the pins of the Prodigy PC 104 board s Ex tension connector into the sockets of the DC 1000 s parallel connector 4 Place the two standoffs between the boards so that they are aligned with the two mounting holes and insert the mounting screws through the mounting holes and standoffs 5 Once the boards are mated attach the supplied IDC cable to the encoder connector on the DC 1000 Pin 1 of the connector is located nearest the JP1 jumper and the cable s connector must be oriented so that the red striped wire of the IDC cable attaches to pin 1 The red marking on the cable will then be located on the left side of the boards 6 To connect DC power to the DC 1000 attach a small Molex plug from the computet s power supply to the 4 pin white connector on the DC 1000 labeled PC1 in Figure 4 2 These are the small power connectors which are used to connect a floppy drive 56 Prodigy PC 104 Motion Card User s Guide Interconnect Module ran The DC 1000 mounted to the front of the Prodigy PC 104 Motion Card is illustrated in the following figure Figure 4 3 DC 1000
89. ser as detailed in the previous section some reset conditions may occur automatically During normal operations the Prodigy PC 104 Motion Card is only reset during power up A reset serves the purpose of initializing values and bringing the Prodigy PC 104 Motion Card to a known and consistent state On occasion the Prodigy PC 104 Motion Card will be reset due to one of a few anomalous conditions ReadIO and WriteIO commands To determine the cause of a board reset special instructions to read the reset source have been provided The com mand ReadlO with an address of 2 should be used The following table details the encoding of this I O address word 1 O Bit Address Location Signals 2 0 11 Reserved 12 Hard Reset a value in this bit indicates a reset commanded over the bus 13 Undervoltage detection a value in this bit indicates a reset caused by undervoltage detection 14 External signal a value in this bit indicates a reset caused by the external Reset signal 15 Watchdog timeout a value in this bit indicates a reset caused by watchdog timeout Once a reset condition has occurred the reset status stored at address 2 described in the preceding table can be cleared by a WritelO command to address 2 with a value of zero 0 Example To determine that a reset has occurred and to determine the cause of the reset the command ReadlO is used Assum ing that a watchdog timer event has occurred the value retur
90. ses 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 understood 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 intellectual property right of PMD covering or relating to any combination machine or process in which such products or services might be or ate used PMD s publication of information regarding any third party s products or services does not constitute PMD s approval w
91. tor of the Prodigy PC 104 board DI D2 Mounting holes These holes 2 are in direct alignment with the mounting holes on the Prodigy PC 104 board and are used for the mounting screws and stand offs JPI Jumper This jumper selects either 5V or 12V supply voltage 5V DC is the default setting DC4 Encoder connector The encoders are connected to this pin block PCI Power connector Use this pin block to connect a small Molex connector for DC power SW DIP switches This block of DIP switches is used to set encoder resolution for each axis DC7 PLD This is the processor for the DC 1000 Prodigy PC 104 Motion Card User s Guide Interconnect Module ran 4 2 2 DC 1000 Connections The pinouts for connector DC4 are outlined in the following table IDC Pin No Description Axis 5 or 12 VDC to Encoder x 2 Clock I Xx 3 Clock l Xx 4 GND xX 5 DIN I x 6 DIN l x 7 5 or 12 VDC to Encoder Y 8 Clock 2 Y 9 Clock 2 Y 10 GND Y II DIN 2 Y 12 DIN 2 Y 13 No connection 14 No connection 15 5 or 12 VDC to Encoder Z 16 Clock 3 Z 17 Clock 3 Z 18 GND Z 19 DIN 3 Z 20 DIN 3 Z 2l 5 or 12 VDC to Encoder W 22 Clock 4 W 23 Clock 4 W 24 GND W 25 DIN 4 W 26 DIN 4 W The settings for the jumper labeled JP1 in Figure 4 2 are outlined in the following table Pins Jumpered Setting 1 2 12V DC 2 3 5V DC default 4 2 3 DC 1000 Default Paramet
92. tor pins to the appro priate amplifier inputs Note that the names of the pins will vary among amplifiers Common names are shown 3 3 1 DC Brush Motor Connections Prodigy Amplifier Motor PC 104 Input Output Connection Connection Connection Method Name Name Axis 1 Axis2 Axis3 Axis 4 DAC DACI 4A Ref or V J5 17 J5 34 J6 17 J6 34 AGND Ref or GND J5 18 J5 35 J6 18 J6 35 PWM PWMMagl 4A PWM magnitude J5 14 J5 31 J6 14 J6 31 sign magnitude PWMSignl 4A PWM direction J5 15 J5 32 J6 15 J6 32 GND Ground J5 8 J5 26 J6 8 J6 26 Names of amplifier connections vary Common names are shown 3 3 2 Brushless DC Motor Connections Prodigy Amplifier Motor PC 104 Input Output Connection Connection Connection Method Name Name Axis 1 Axis2 Axis3 Axis 4 DAC DACI 4A Refl or VI Option 38 Option 39 Option 40 Option 41 DACI 4B Ref2 or V2 Option 42 Option 43 Option 44 Option 45 AGND Ref or GND Option 37 Option 46 Option 37 Option 46 PWM 50 50 PWMMagl 4A PWM phase Option Option 6 Option I Option 16 PWMMag 4B PWM phase 2 Option 2 Option 7 Option 12 Option 17 PWMMagl 4C PWM phase 3 Option 3 Option 8 Option 13 Option 18 GND Ground Option 5 Option 10 Option 15 Option 20 Names of amplifier connections vary Common names are shown Prodigy PC 104 Motion Card User s Guide 47 738 Prodigy PC 104 Electrical Reference 3 3 3 Microstepping Motor Connections 48
93. within the same cycle period If multiple boards are installed yet not inter connected any additional boards would begin working after the first card master was initialized However none of the axes would be synchronized With Sync I O activated the servo loops of all slave boards are synchronized to the servo loop of the master board This allows for precise synchronization of all implemented axes To connect two or more Prodigy PC 104 Motion Cards for synchronization a Sync I O cable one cable for each set of two boards is required This cable may be connected to either of the two Sync I O connectors on the boards Both connectors function as either an input or output the two sync connectors are wired in parallel For more information on synchronizing multiple Prodigy PC 104 Motion Cards see the Magellan Motion Processor Users Guide Section 8 5 The Sync Pin Multiple Chip Synchronization The pinouts for the Sync I O connectors are defined in the following table Pin Number Signal Sync in or sync out pin depending on whether the card is master or slave 2 GND NOTE Sync I O is not available on the PR8 amp 255xx series boards Additionally if any axis is set for pulse direction the sync option cannot be used The following diagram shows three synchronized Prodigy PC 104 Motion Cards Note that the Sync I O connectors are located on the back of the board Figure 3 4 Sync I O connector to three bo
94. would therefore require 13 data lines an encoder with 25 bits of resolution would require 25 data lines A system with four encoders would require 100 4 x 25 data lines to transmit the data to the controller The SSI interface re quires only four data lines regardless of the encoder s resolution This is accomplished by converting the parallel data into serial data Each bit of the parallel data is the sent on the data lines synchronously to the clock lines The clock speed of the DC 1000 is programmable between 1 1 MHz and 137 5 kHz The clock speed depends on the length of the data cables between encoder and controller The DC 1000 converts the received Gray code to binary code serial data and stores it in parallel format in registers This data can then be read by the Prodigy PC 104 Motion Card For a system with four absolute encoders and a cable length of up to 50 meters the position of every encoder is read 20 000 times per second by the Prodigy PC 104 Motion Card This guarantees timely and accurate data The DC 1000 can be programmed for encoder resolutions of 10 12 13 and 25 bits The transmission speed may be programmed to accommodate cable lengths of greater than 300 meters and both sin gle turn encoders and multi turn encoders may be employed The Prodigy PC 104 Motion Card will capture the absolute position of single turn encoders for a full 32 bits When a roll over occurs it will be detected by the Prodigy PC 104 Mot

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