ESC629 2-Channel DC Servo Motor Interface Board User's Manual
Contents
1. 21 8255 01 12 1 Oak 22 ESC629 4 RTD Finland Oy User s Manual CHAPTER 5 BOARD OPERATION AND PROGRAMMING 23 Defining the memory Map cnt new eaten ea al ates 24 LM629 Instruction Set 0 27 User Command Set reprint from National Semiconductor 5 3 3 7 7 711 29 What is 1 17 090 29 Interrupt 1 111 090 29 8259 Programmable interrupt Controller cceeeeeeeseeeeeeeeeeeeeeeeeeeee 29 Interrupt mask register IMR ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeseseneaeeeeeeeeees 29 End Of Interrupt EOI Command 2222222222200eeeeoenennnnnnnnnne 30 What exactly happens when an interrupt OCCUIS 2 222 2 2 444 30 Using interrupts in your program 22442eeeeeeeeooennnnnnnnnnnnnennnnn 30 Writing an interrupt service routine ISR 2222 22eeeeeeeeennnennn 30 Saving the startup IMR and interrupt 66 222 32 Common Interrupt 22. 9 Factory Configured jumper settings 9990oeeeeeeeeneeennnnnnnne 10 Base Address JUIMPETS 2232922 11 Interrupt 6 n 13 CHAPTER 3 BOARD INSTALLATION 14 Board 21 h 14 External V O CONMECH ONS oa a eae 7777 7 15 Motor control port I O connector Motor interface connectors Incremental encoder connectors General purpose digital I O header connector pinout CHAPTER 4 HARDWARE DESCRIPTION teeee 19 The LM629 servo controller chips 222 2900eeeeeeeeeeeenonnnnnnennnnnnne 20 H bridges for motion 91 1161 20 Incremental encoder inputs 2222 299 6 21 Motor control POI 2
3. 33 CHAPTER 6 ESC629 50 34 CHAPTER 7 RETURN POLICY amp 36 ESC629 5 RTD Finland Oy User s Manual LIST OF ILLUSTRATIONS AND TABLES ILLUSTRATIONS Fig 2 1 ESC629 Board layout showing jumper locations Fig 2 2 Base address jumpers Fig 2 3 Interrupt jumpers Fig 3 1 ESC629 integrated with a PC 104 RTD cpuModule stack Fig 3 2 Motor interface terminal block Fig 3 3 Incremental encoder terminal blocks Fig 4 1 ESC629 Block diagram Fig 4 2 Typical motor control scheme Fig 4 3 Onboard 12V supply connection solder blob Fig 5 1 8255 Control byte bit definition TABLES Table 2 1 Table 2 2 Table 3 1a Table 3 1b Table 3 2 Table 5 1 Table 5 2 ESC629 Factory configured jumper settings Base Address jumper settings of ESC629 Motor control port pinout of the ESC629 Motor control port pinout description 50 pin connector pinout ESC629 I O map LM629 Instruction set 6 RTD Finland Oy User s Manual Chapter 1 INTRODUCTION This user s manual describes the operation of the ESC629 Embedded Servo Controller board Features Some of the key features of the E
4. Function init_irq_handlers Inputs Nothing Returns Nothing Purpose Set the pointers in the interrupt table to point to our functions i e setup for ISR s void init_irq_handlers void _disable old_IRQ1_handler _dos_getvect IRQ1_VECTOR 8 _dos_setvect IRQ1_VECTOR 8 new_IRQ1_handler Gi_old_mask inp 0x21 outp 0x21 Gi_old_mask amp 1 lt lt IRQ1_VECTOR _enable 7 e Function Restore do this before exiting program Inputs Nothing Returns Nothing Purpose Restore interrupt vector table 2 void restore void Restore the old vectors _disable _dos_setvect IRQ1_VECTOR 8 old_IRQ1_handler outp 0x21 Gi_old_mask _enable ESC629 34 RTD Finland Oy User s Manual Chapter 6 ESC629 SPECIFICATIONS Host Interface 0 mapped occupies 16 bytes of space Jumper selectable base address with 4 jumpers 8 bit data bus 16 bit AT bus connector Jumper selectable interrupts both XT and AT 5 7 10 11 12 Servo controllers and H bridge 8255 Digital I O Connectors ESC629 LM629 servo controllers e Position range 1 073 741 824 to 1 073 741 823 counts e Velocity range 0 to 1 073 741 823 2 EXP 16 counts sample i e 0 to 16368 counts per sample with 1 2 EXP16 counts sample resolution e Acceleration ra
5. 2 7 Channel 2 Sign signal from LM629 chip TTL MAGN 2 TTL Channel 2 PWM output signal from LM629 chip TTL 1 16 1 Channel 1 direction TTL DIR1 gt DIR1 FORWARD DIR1 TTL 0 6 1 direction TTL DIR1 lt DIR1 FORWARD DIR2 TTL Chamel 2 direction TTL DIR2 gt DIR2 FORWARD DIR2 TTL Channel 2 direction TTL DIR2 lt DIR2 FORWARD Table 3 1b Motor control port pinout description Motor interface connectors The figure 3 2 below illustrates the logical connection of the DC servo motors to the ESC629 The Motor should be connected to the DC motor terminal for correct loop operation Connect Motor to the negative terminal of the motor Note that the maximum supply voltage is 60V It is very important that the nominal motor voltage is not exceeded MOTOR1 V MOTOR GND MOTOR MOTOR2 V MOTOR2 GND MOTOR2 Fig 3 2 Motor interface terminal block ESC629 17 RTD Finland Oy User s Manual Incremental encoder connectors The figure 3 3 below illustrates the screw terminal blocks used to connect the incremental encoders of the DC servo motors to the ESC629 5 is the connector for Channel 1 and J6 for Channel 2 The 5V is supplied by the PC 104 bus Both of these outputs are independently fused with 2A fuses located under the terminal blocks
6. Sf H BRIDGES MOTOR LOW o8 GND 2A T osc EE i ae or 1 2 BRIDGE DRIVERS 12V SUPPLY J4 O p EN g Ol g on g LM629 Motion PWM DIR CH 12 gt Control Chip HBRIDGE R LCH I2 E J3 Z 8255 z 4 PPI Chip z gt ADDRESS d CONROL A DECODER EPLD Chip N Fig 4 1 ESC629 Block Diagram ESC629 20 RTD Finland Oy User s Manual The LM629 servo controller chips The LM629 chips are dedicated motion control processors designated for use with a variety of applica tions using DC Servo motors These parts perform the complete real time computational tasks of complex digital motion control Included in the chips are three following blocks 1 a 32 bit command position sequencer 2 a 32 bit position feedback processor and 3 a 16 bit programmable PID filter Figure 4 2 below illustrates the setup for a LM629 based motor control system The clock frequency of the controllers is 4MHz This must be taken into account in all timing calculations 3MHz ESC629 boards are also available upon special request control lines position velocity profile generator direction digital PID filter ie magnitude 16 bits PWM H bridge quadrature decoder DC motor 3 quadrature incremental encoder ANO1 Fig 4 2 Typical motor control scheme Main features of the LM629 include 32 bit position velocity and acceleration registers Programmable PID filter with 16 bit coeffi
7. Fig 3 3 Incremental encoder terminal blocks General purpose digital I O header connector pinout ESC629 18 RTD Finland Oy User s Manual The Table 3 2 below illustrates the pinout of the 50 pin header connector that is used for general purpose digital I O 5V is available in pin 49 is fused with a 2A fuse This fuse is located in the proximity of the XT PC 104 connector on the solder side PIN number Signal Description PIN Number Signal Description 2 PC1 4 GND P2 16 GND P3 18 GND 11 2505 7 7 GND 13 P6 114 GND 15 P7 116 GND 19 PB1 120 GND 21 PB2 122 GND 23 PBS 7124 GND 27 PB5 128 GND 29 PB6 30 GND 31 PBZ 2 GND 35 PAL 7 786 GND 37 PA 138 GND 39 PA3 140 GND 43 PA 144 GND 45 PA 146 GND 47 PA7 148 GND 49 5V Fused 2A 150 GND Table 3 2 50 pin connector pinout ESC629 19 RTD Finland Oy User s Manual Chapter 4 HARDWARE DESCRIPTION This chapter describes in detail the major features of the ESC629 The LM629 Servo controller chips e H bridges for motor control e Incremental encoder inputs e Motor control port e 8255 based digital I O e Interrupts z CHA v we fi 0 pa 919 Be ee BS wo Oe NOTE Channel 2 is identical aig az aN MOTOR VS lt 60V 60V MOSFET MOTOR HIGH
8. Input signals are inverted in this stage This must be taken into account when making sensor channel connections The input impedance of the encoder inputs lines are 4 7K Motor control port The header J4 carries all the necessary signals required to interface to an external power stage Avail able in this connector are power 8 bit PWM and sign as well as direct 1 2 bridge control signals The power in this connector is selected to be either 12V or 5V The selection is made using the solder ESC629 22 RTD Finland Oy User s Manual blob B1 located on the solder side of the board next to the 50 pin connector This output is protected with a 2A fuse 8255 based digital I O ESC629 The 8255 programmable peripheral interface PPI is used for digital I O functions This high per formance TTL CMOS compatible chip has 24 digital I O lines divided into two groups of 12 lines each All the 24 digital I O lines are pulled down with 10K Ohm resistor Group A Port A 8 lines and Port C upper 4 lines Group B Port B 8 lines and Port C lower 4 lines Port A Port B and Port C are available in the 50 pin expansion connector These Ports can be utilized using any of the three operating modes as described below Mode 0 Basic I O this lets you use simple input output functions for a port Data is written to or read from the specified port Mode 1 Strobed input output Lets you transfer data I O from port A in conjunction
9. Understanding the sequence of events when an interrupt is triggered is necessary to correctly write interrupt handlers When an interrupt request line is driven high by a peripheral device such as the ESC629 the interrupt controller checks to see if interrupts are enabled for that IRQ It then checks to see if other interrupts are active or requested and determines which interrupt has priority The inter rupt controller then interrupts the processor The current code segment CS instruction pointer IP and flags are pushed onto the system stack and a new set if CS and IP are loaded from the lowest 1024 bytes of memory This table is referred to as the interrupt vector table and each entry to this table is called an interrupt vector Once the new CS and IP are loaded from the interrupt vector table the processor starts to execute code from the new Code Segment CS and from the new Instruction Pointer IP When the interrupt routine is completed the old CS and IP is popped from the system stack and the program execution continues from the point where interruption occurred Using Interrupts in your Program Adding interrupt support to your program is not as difficult as it may seem especially when program ming under DOS The following discussion will cover programming under DOS Note that even the smallest mistake in your interrupt program may cause the computer to hang up and will only restart after a reboot This can be frustrating and time
10. 777 ESC629 2 Channel DC Servo Motor Interface Board User s Manual Hardware Release 2 0 2 2 RTD FINLAND Oy User s Manual ESC626 2 CHANNEL DC SERVO MOTOR INTERFACE BOARD USER S MANUAL REAL TIME DEVICES FINLAND OY LEPOLANTIE 14 FIN 00660 HELSINKI Phone 358 9 346 4538 FAX 358 9 346 4539 E Mail sales rtdfinland fi Website www rtdfinland fi ESC629 2 RTD Finland Oy User s Manual Revision History 14 04 1999 Release 1 0 05 06 1999 Updated figures and specifications 10 07 2001 Corrected text and formatting 03 06 2003 Corrected text and formatting IMPORTANT Although the information contained herein has been carefully verified RTD Finland Oy assumes no responsibility for any errors that may oc cur for any damage to property or persons resulting from improper use of this manual or from the related software RTD Finland Oy also reserves the right to alter the contents of this manual as well as fea tures and specifications of this product at any time without prior no tice Notice We have attempted to verify all information in this manual as of the publication date Information in this manual may change without prior notice from RTD Finland Oy Published by Real Time Devices Finland Oy Lepolantie 14 FIN 00660 Helsinki Finland Copyright 1999 2003 Real Time Devices Finland Oy All rights reserved Printed in Finland PC XT PC AT are registered trademarks of IBM Corporation PC
11. port is used to access the 8255 control byte The functionality of these bits is described briefly in the following page in figure 5 1 ESC629 26 RTD Finland Oy User s Manual 8255 Mode Definition Bit Set Reset Feature Control Word Control Word D7 D6 D5 D4 D3 D2 D1 D0 D7 D6 D5 04 030201 00 GROUP 2 Port C low 1 Input 0 Output Bit Set Rst 1 Set 0 Reset ort a Bit Select Mode Select 0 Mode 0 1 Mode 1 Bit set rst fla GROUP 1 Bit Set Reset 9 Port C high 1 Input 0 Output Port A 1 Input 0 Output Mode Select 00 Mode 0 01 Mode 1 IX Mode 2 Mode set flag Active Mode Definitlon S Fig 5 1 8255 Control byte bit definitions ESC629 27 RTD Finland Oy User s Manual LM629 Instruction set A complete list of instructions accepted by the LM629 chip is described below in table 5 2 Instruction Type Description HEX Reset LM629 00 DFH Define Home 02 ISIP Set Index Position 03 Interrupt on Error 1B Stop on Error 1A Set Breakpoint Absolute 20 Set Breakpoint Relative 21 Mask Interrupts 1C Reset Interrupts 1D Load Filter Parameters 1E Update Filter 04 Load Trajectory 1F Start Motion 01 Read Status Byte None Read Signals Register 00 RDIP Report Read Index Position 09 Rea
12. 104 is a registered trademark of PC 104 Consortium The Real Time Devices Logo is a registered trademark of Real Time Devices utilityModule is a trademark of Real Time Devices All other trademarks appearing in this document are the property of their respective owners ESC629 3 RTD Finland Oy User s Manual TABLE OF CONTENTS LIST OF ILLUSTRATIONS AND TABLEG 0 cccceeeeseseeseeeeeees 6 CHAPTER 1 INTRODUCTION 7 EatUr S 3 3 50 0 7 Moom OONO ETS a stat a le att 7 1 0 3 333313 313 1 1111 7 1 3 3 3 33 7 Connector description 8 1 9 8 What comes with your board 22222 990eeeeoeeeeeeenonnnnnnnnnnnnnnnnnnnn 8 BO ard Kele aseeto ler 522 8 Application software and drivers Hardware accessories Using 2 23 3 3 3 2 3 3 3 8 When you need help as creas 0 0 0 8 CHAPTER 2 BOARD
13. 29 chips include a tunable PID filter Trajectory control unit and position counter These parts perform the intensive real time computational task required in high performance digital motion control Motor drive stage ESC629 A powerful onboard H bridge is used to interface directly to motors Overvoltage and transient protec tion diodes ensure reliable operation in industrial environments The H bridges are capable of driving either 24V or alternatively 48V DC motors The current drive capability is rated to 10A peak using the onboard terminal blocks The ESC629 features a 12V supply with a 500mA output that can be used to drive small 12V motors directly from the board In this case you do not need an external power supply for the motors This onboard power supply is over current limited 7 RTD Finland Oy User s Manual Mechanical description The ESC629 is designed on a PC 104 form factor An easy mechanical interface to both PC 104 and EUROCARD systems can be achieved Stack your ESC629 directly on a PC 104 compatible com puter using the onboard mounting holes Connector description There are two 4 position terminal blocks on the left side of the module to directly interfacing to DC motors The incremental encoders connect to the ESC629 using small screw terminal blocks The general purpose 50 pin digital I O interface connector is located on the right hand side of the board The 10 pin motor control port header located on the
14. M629 chips With the PS bit you may select whether you are addressing the chip with commands or data This bit must be set before access to the chip is performed to ensure correct interpretation of the data ESC629 25 RTD Finland Oy User s Manual written to the addresses BA 1 and BA 2 See the software disk for more examples on the usage of this bit 0 gt DATA 1 gt COMMAND BA 3 Reserved for factory testing purposes BA 4 PPI Port A 1 8 Read Write This port is used to access the 8255 Port A bits Instructions on how to access port A is described in greater detail in the software that is included in the shipment For an exhaustive explanation of the op eration of the 8255 PPI chip please consult the data sheet available from Intel or NEC BA 5 PPI Port B 1 8 Read Write This port is used to access the 8255 Port B bits Instructions on how to access port A is described in greater detail in the software that is included in the shipment For an exhaustive explanation of the operation of the 8255 PPI chip please consult the data sheet available from Intel or NEC BA 6 PPI Port C 1 8 Read Write This port is used to access the 8255 Port C bits Instructions on how to access port A is described in greater detail in the software that is included in the shipment For an exhaustive explanation of the op eration of the 8255 PPI chip please consult the data sheet available from Intel or NEC BA 7 PPI Control byte 1 8 Read Write This
15. OCARD installations is possible This chapter gives step by step instructions on how to install the ESC629 into your system After completing the installation it is recommended that you use the diagnostic and test software to fully verify that your board is working Board Installation Keep your board in the antistatic bag until you are ready to install it into your system When removing it from the bag hold the board at the edges and do not touch the components or connectors Please handle the board in an antistatic environment and use a grounded workbench for testing and han dling of your hardware Before installing the board in your computer check the jumper settings Chap ter 2 reviews the factory settings and how to alter them If any alterations are needed please refer to the appropriate instructions in this chapter Do however note that incompatible settings can result in unpredictable board operation and erratic response General installation guidelines Turn OFF the power to your computer and all devices connected to the ESC629 Touch the grounded metal housing of your computer to discharge any antistatic build up and then remove the board from its antistatic bag Hold the board by the edges and install it in an enclosure or place it on the table on an antistatic sur face Connect your motors to the available terminal blocks Connect the incremental encoders to the correct screw terminal blocks Connect the 50 pin digital I O co
16. OSED Table 2 2 Base Address Jumper settings of the ESC629 BRE BASE ADDRESS Fig 2 2 Base address jumpers illustrating address 300H 13 A5 A6 A7 A8 0 0 0 0 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 0 1 0 1 0 0 1 1 0 1 1 1 0 of 8 4 1 0 0 1 0 1 0 1 1 1 0 1 0 0 1 1 1 0 1 1 0 1 1 1 1 1 1 1 RTD Finland Oy User s Manual Interrupt Channels Factory setting IRQ5 IRQ11 The header connectors shown in Figure 2 3 below lets you connect the LM629 servo controller inter rupt outputs to one of the interrupt channels available on the host XT AT bus If your board has no AT extension interrupts 10 15 are not available Both servo controllers must use different interrupts and therefore two headers are available IRQ1 marks the Channel 1 interrupt and IRQ2 marks the inter rupt for Channel 2 IRC O 102 11 8 19 2 9 7 0 5 Fig 2 3 Interrupt jumpers Note The ESC629 does not support interrupt sharing This feature is sometimes regarded as a part of the PC 104 special features After extensive software and hardware tests we have found that error free interrupt performance can not be guaranteed when sharing interrupts ESC629 14 RTD Finland Oy User s Manual Chapter 3 BOARD INSTALLATION The ESC629 DC servo motor interface board is very easy to connect to your industrial distributed con trol system Direct interface to PC 104 as well as EUR
17. SC629 include Two independent Servo Motor controller channels Onboard full H bridges with 10A drive capability with additional cooling 6A drive capability with the standard heat sink Direct motor interfaces using onboard terminal blocks 2 Independent LM629 PWM output servo motor controllers 2 Protected and filtered incremental encoder inputs Control port interfacing to external power driver stage 24 user accessible programmable TTL level digital I O 8255 compatible 5V only operation onboard 12V supply 1A for external devices Supports direct drive of 12V motors from onboard power supply PC 104 compliant CE approved design The following paragraphs briefly describe the major features of the ESC629 A more detailed discus sion is included in chapter 4 Hardware description and in Chapter 5 Board operation and program ming The board setup is described in Chapter 2 Board Settings A full description of the LM629 servo controllers is included in Chapter 5 Board operation and programming Motion controllers The ESC629 DC servo motor interface is implemented using two LM629 controller chips This versa tile chip offers powerful features that will enable complex positioning tasks with minimal host interven tion The ESC629 channels can be programmed to operate totally independently offering a complete subsystem for 2 axis motion control using standard DC motors with encoder feedback often called servo motors The LM6
18. SC629 is CE certified in the IDAN Enclosure System ESC629 36 RTD Finland Oy User s Manual Chapter 7 RETURN POLICY AND WARRANTY Return Policy If the module requires repair you may return it to us by following the procedure listed below Caution Failure to follow this return procedure will almost always delay repair Please help us expedite your repair by following this procedure 1 Read the limited warranty which follows 2 Contact the factory and request a Returned Merchandise Authorization RMA number 3 On a sheet of paper write the name phone number and fax number of a technically competent person who can answer questions about the problem 4 On the paper write a detailed description of the problem with the product Answer the following ques tions Did the product ever work in your application What other devices were connected to the product How was power supplied to the product What features did and did not work What was being done when the product failed What were environmental conditions when the product failed 5 Indicate the method we should use to ship the product back to you We will return warranty repairs by UPS Ground at our expense Warranty repairs may be returned by a faster service at your expense e Non warranty repairs will be returned by UPS Ground or the method you select and will be billed to you 6 Clearly specify the address to which we should return the product
19. ait until the one in progress has been completed The priority level of the interrupt is determined by the number of the IRQ as follows IRQO has the highest priority whilst IRQ15 has the lowest Many of the IRQ s are used by the standard system resources IRQO is dedicated to the internal timer IRQ1 is dedicated to the keyboard input IRQ3 for the serial port COM2 and IRQ4 for the serial port COM1 Often interrupts 5 and 7 are free for the user 8259 Programmable Interrupt Controller The chip responsible for handling interrupt requests in a PC is the 8259 Interrupt Controller To use interrupts you will need to know how to read and set the 8259 s internal interrupt mask register IMR and how to send the end of interrupt EOI command to acknowledge the 8259 interrupt controller Interrupt Mask Register IMR Each bit in the interrupt mask register IMR contains the mask status of the interrupt line If a bit is set equal to 1 then the corresponding IRQ is masked and it will not generate an interrupt If a bit is cleared equal to 0 then the corresponding IRQ is not masked and it can then generate an interrupt The interrupt mask register is programmed through port 21h 30 RTD Finland Oy User s Manual ESC629 End of Interrupt EOI Command After an interrupt service routine is complete the 8259 Interrupt Controller must be acknowledged by writing the value 20h to port 20h What exactly happens when an interrupt occurs
20. al ESC629 Base Address jumpers Factory setting 300h The most common cause of failure when you are first setting up your module is address contention Some of your computer s I O space is already occupied by other internal I O devices or expansion boards When the board attempts to use it s own reserved I O addresses which are being already used by another peripheral device erratic performance may occur and the data read from the board may be corrupted To avoid this problem make sure you set up the base address first using the eight jumpers marked BASE It allows you to choose from 16 different I O addresses in your computer s I O map Should the factory installed setting of 300h be unusable for your system configuration you may change this setting to another using the options illustrated in Table 2 2 overleaf The table shows the switch settings and their corresponding values in hexadecimal values Ensure that you verify the correct lo cation of the base address jumpers When the jumper is removed it corresponds to a logical 0 connecting the jumper to a 1 When you set the base address of the module record the setting in side the back cover of this manual directly after the Appendices 12 RTD Finland Oy User s Manual ESC629 BASE ADDRESS JUMPER SETTINGS OF THE ESC629 200 220 240 260 280 2A0 2C0 2E0 300 320 340 360 380 3A0 3C0 3E0 0 JUMPER OFF BASE ADDRESS HEX 1 JUMPER CL
21. basics just something that enables you to verify you have entered the ISR and executed it success fully For example set a flag in your ISR and in your main program check for the flag Note If you choose to write your ISR in in line Assembly you must push and pop regis ters correctly and exit the routine with the IRET instruction instead of the RET instruction There are a few precautions you must consider when writing ISR s The most important is do not use any DOS functions or functions that call DOS functions from an interrupt routine DOS is not re entrant that is a DOS function cannot call itself In typical programming this will not happen because of the way DOS is written But what about using interrupts Consider then the following situation in your program If DOS function X is being executed when an interrupt occurs and the inter rupt routine makes a call to the same DOS function X then function X is essentially being called while active Such cases will cause the computer to crash DOS does not support such operations The general rule is that do not call any functions that use the screen read keyboard input or any file I O routines These should not be used in ISR s The same problem of re entrancy also exists for many floating point emulators This effectively means that you should also avoid floating point mathematical operations in your ISR Note that the problem of reentrancy exists no matter what programming language you u
22. cients Programmable derivative sampling interval 8 bit and sign PWM output Internal trapezoidal velocity profile generator Velocity target position and filter parameters may be changed during motion Position and velocity modes of operations Real time programmable interrupts Quadrature encoder feedback with index pulse H bridges for motion control ESC629 The ESC629 features two independent H bridges that are used to drive the motors The H bridges are implemented using 4 high performance N channel MOSFETs These MOSFETs are configured in two full bridges Each of the two bridges consists of high side and low side MOSFETs Special full bridge driver chips are used to drive the MOSFET bridges These drivers can tolerate negative voltage tran sients as well as voltages up to 600V The propagation delay for the high and low side is also matched to ensure precise control of the bridge The maximum peak current of the H bridge is 25A 10A con tinuous with a voltage of 60V maximum with additional heat sinking or convection cooling with a fan unit such as the EFAN104 If you use the standard heat sink supplied with the ESC629 board you should not exceed 6A continuous current drive 21 RTD Finland Oy User s Manual A special low power low motor drive scheme is supported by the ESC629 In this case the motor power is derived from the onboard 12V supply Limitations exist in this mode of operation the maxi mum motor voltage is limited t
23. consuming Writing an Interrupt Service Routine ISR The first step in adding interrupts to your software is to write an interrupt service routine ISR This is the routine that will be executed automatically each time an interrupt request occurs for the specified IRQ An ISR is different from other sub routines or procedures First on entrance the processor reg isters must be pushed onto the stack_before anything else Second just before exiting the routine you must clear the interrupt on the ESC629 by issuing the RSTI instruction and reading the interrupt status register and finally write the EOC command to the interrupt controller When exiting the inter rupt routine the processor registers must be popped from the system stack and you must execute the IRE assembly instruction This instruction pops the CS IP and processor flags from the system stack These were pushed onto the stack when entering the ISR Most compilers allow you to identify a function as an interrupt type and will automatically add these instructions to your ISR with one exception most compilers do not automatically add the EOI com 31 RTD Finland Oy User s Manual mand to the function you must do it yourself Other than this and a few exceptions discussed below you can write your ISR as any code routine It can call other functions and procedures in your pro gram and it can access global data If you are writing your first ISR we recommend you stick to the
24. d Desired Position 08 Read Desired Position 0A Read Desired Velocit 07 Read Real Velocity 0B Read Integration Sum OD Table 5 2 LM629 Instruction Set These instructions are loaded to the LM629 chip while the PS bit is in COMMAND mode See previous sections for more details The board status register can be read at all times remember to set the PS bit in DATA mode when reading this register Attached on the next pages is description reprinted from National Semiconductor LM629 data sheet that describes the commands in detail AN 639 Application note walks you through all the important functions required to solve most motion con trol problems This application note is included on your software disk and it can be downloaded from www national com The diagnostic program diag629 exe has the same functions described in flow charts in AN 639 as C functions This diagnostics program shows you how to correctly use them together ESC629 28 RTD Finland Oy User s Manual User Commanda set reprinted from National Semiconductor datasheet ESC629 29 RTD Finland Oy User s Manual INTERRUPTS ESC629 What is an interrupt An interrupt is an event that causes the processor in your computer to temporarily halt its current process and execute another routine Upon completion of the new routine control is returned to the original routine at the point where its execution was interrupted Interrupts are a very fle
25. elp in determining your IRQ s bit After setting the bit write the new value to I O port 21h With the startup IMR saved and the interrupts temporarily disabled you can assign the interrupt vec tor to point to your ISR Again you can overwrite the appropriate entry in the vector table with a direct memory write but this is not recommended Instead use the DOS function 25h Set Interrupt Vector or if your compiler provides it the library routine for setting up interrupt vectors Remember that inter rupt vector 8 corresponds to IRQO vector 9 for IRQ1 etc If you need to program the source of your interrupts do that next For example if you are using transmitted or received messages as interrupt source program it to do that Finally clear the mask bit for your IRQ in the IMR This will enable your IRQ Common Interrupt mistakes Remember hardware interrupts are from 8 15 XT IRQ s are numbered 0 7 Forgetting to clear the IRQ mask bit in the IMR Forgetting to send the EOI command after ISR code Disables further inter rupts Example on Interrupt vector table setup in C code void far _interrupt new_IRQ1_handler void ISR function prototype 33 RTD Finland Oy User s Manual define IRQ1_VECTOR3 Name for IRQ void interrupt far old_IRQ1_dispatcher es ds di si bp sp bx dx cx ax ip cs flags Variable to store old IRQ_Vector void far _interrupt new_IRQ1_handler void
26. es beyond the control of REAL TIME DEVICES OR AS A RESULT OF SERVICE OR MODIFICATION BY ANYONE OTHER THAN REAL TIME DEVICES EXCEPT AS EXPRESSLY SET FORTH ABOVE NO OTHER WARRANTIES ARE EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND REAL TIME DEVICES EXPRESSLY DISCLAIMS ALL WARRANTIES NOT STATED HEREIN ALL IMPLIED WARRANTIES INCLUDING IMPLIED WARRANTIES FOR MECHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THE DURATION OF THIS WARRANTY IN THE EVENT THE PRODUCT IS NOT FREE FROM DEFECTS AS WARRANTED ABOVE THE PURCHASER S SOLE REMEDY SHALL BE REPAIR OR REPLACEMENT AS PROVIDED ABOVE UNDER NO CIRCUMSTANCES WILL REAL TIME DEVICES BE LIABLE TO THE PURCHASER OR ANY USER FOR ANY DAMAGES INCLUDING ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EXPENSES LOST PROFITS LOST SAVINGS OR OTHER DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE PRODUCT SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR CONSUMER PRODUCTS AND SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE ESC629 38 RTD Finland Oy
27. hip 2 Reads from chip Writes to chip Board control register Read control bits Write control bits Reserved Reserved Read digital inputs Write digital outputs Read digital inputs Write digital outputs Read digital inputs Write digital outputs Reserved Write to control byte BA Base Address 300h factory default BA 0 Servo chip channel 1 1 8 Read Write This is the address through which all communication is performed to the servo controller chip for chan nel 1 Data and commands are selected by one bit in the board control register bit 3 BA 2 BA 1 Servo chip channel 2 1 8 Read Write This is the address through which all communication is performed Data and commands are selected by one bit in the board control register bit 3 BA 2 BA 2 Board control register 1 4 Read Write The board control register is used to configure the operation of the ESC629 board The bit definitions are listed below e Bit0 0 after reset EN_RST this bit is used to block the host reset from resetting the servo control chips In some cases it may be desirable to inhibit a host reset for example from a watchdog timer to abort a trajectory 0 gt Enables host reset to reset servo chips 1 gt Disables host reset from resetting servo chips e Bit 1 0 after reset reserved for factory testing only e Bit 2 0 after reset reserved for factory testing only e Bit3 1 after reset PS this bit is important for all access to the L
28. n to fully utilize all the features on this board If you have any problems with installation or use of the board contact our Technical Support Department 358 9 346 4538 during European business hours Alternatively send a FAX to 358 9 346 4539 or Email to techsupport rtdfinland fi When sending FAX or Email requests please include the following information Your company s name and address your name your telephone number and a brief description of the problem ESC629 9 RTD Finland Oy User s Manual Chapter 2 BOARD SETTINGS The ESC629 DC servo motor interface board has jumper settings which can be changed to suit your ap plication and host computer memory configuration The factory settings are listed and shown in the dia gram in the beginning of this chapter ESC629 10 RTD Finland Oy User s Manual Factory Configured Jumper Settings Table 2 1 below illustrates the factory jumper setting for the ESC629 Figure 2 1 shows the board layout of the ESC629 and the locations of the jumpers The following paragraphs explain how to change the factory jumper settings to suit your specific application Table 2 1 Factory configured jumper settings Please check figure 2 1 below for detailed locations JUMPER NAME DESCRIPTION NUMBER OF JUMPERS FACTORY SETTING Base Addresses 300H Host interrupt Ch 1 Host interrupt Ch 2 Figure 2 1 ESC629 Board layout showing jumper locations ESC629 11 RTD Finland Oy User s Manu
29. nge 0 to 1 073 741 823 2 EXP 16 counts sample sample i e 0 to 16368 counts sample2 with 1 2 EXP16 counts sample resolution Motor drive output 8 bit PWM sign magnitude signals Operating Modes Position and Velocity e Feedback Device Quadrature signals index pulse TTL level signals Control Algorithm PID with programmable integration limit Sample Intervals Derivative term programmable from 2048 Fclk to 2048 2048 Fclk 256 to 65 536us Clock Frequency 4 MHz 8MHz also avialable upon request H bridge Max voltage 60V DC e Max cont current 10A 6A with supplied standard heat sink e Peak current 25A Output capacitors 220uF 63V for each channel e Protection 60V transient absorber diodes 1500W power dissipation TTL CMOS levels Number of lines 24 Drive capability 2mA Pull up Pull down 10K pull down on all 24 lines Motors cable connector Phoenix contact MSTB 2 5 4 ST 5 08 Motors PCB connector MSTB 2 5 4 G 5 08 Encoder feedback connectors MPT 0 5 5 2 54 Motor control port 10 pin headers TTL digital I O s Header connector 50 Pin Host bus XT AT PC 104 bus 35 RTD Finland Oy User s Manual Electrical Operating temperature ranges 0 to 70 C 40 to 85 0 Supply voltage 5V 8 Power consumption 2 0 W maximum with 12V output unloaded 12V power supply Max load 1A Mechanical PCB size 91 x96 mm MAX size 110 x 96 x 17 mm non stack through connectors CE The E
30. nnector flat ribbon cable to the board Make sure that the orienta tion of the cables is correct Installation integrated with a PC 104 module stack ESC629 Secure the four PC 104 installation holes with standoffs Connect the board to its peripherals using the appropriate connectors 15 RTD Finland Oy User s Manual 50 FIN EXPANSION CONNECTOR ESC629 RTD dataModule CMMG686G6X233 HR Fig 3 1 ESC629 integrated into a PC 104 RTD cpuModule stack External I O Connections Motor control port I O connector Tables 3 1 below show the connector layout of the ESC629 motor control port J4 This connector is located towards the top of the board Refer to this diagram when making signal connections PIN number Function Channel 1 Table 3 1a Motor control port pinout of the ESC629 5V is supplied by the PC 104 bus 12V is supplied by a DC DC converter The pinout of this connector to view is shown below 9 7 10 8 5 3 1 Sign_2 Sign_1 Mag_2 Mag_1 6 4 2 ESC629 16 RTD Finland Oy User s Manual The pins are logically deined as V Either 5V or 12V Positive supply selected by B2 on the solder side GND 7 5 ground 1 7 6 1 Sign signal from LM629 chip TTL 1 1 PWM output signal from LM629 chip TTL
31. o 12V and the aggregate motor current of channels 1 and 2 may not exceed 400mA The connection of the onboard 12V to the motor eliminates the need for an external motor supply This will reduce the wiring and power requirements of the overall system in low power motor applications You can connect the 12V onboard supply to the motor channels by closing the solder blobs B2 Diodes D7 and D6 will protect the DC DC converter against situations where an ex ternal motor power is connected to the board Figure 4 3 below illustrates the position of this jumper seen through the PCB from the component side cg A Q Fig 4 3 Onboard 12V supply connection solder blob The onboard bridge drivers are controlled by signals in the table 3 1b pins 6 10 These signals are not TTL level but 0 12V The signals can be used to drive an external bridge power element through the motor control port Incremental encoder inputs The feedback from DC servo motors is usually implemented using TTL level incremental encoders The ESC629 has terminal blocks onboard for direct connection to feedback encoders The incremental encoders are powered from 5V This output is protected against over voltages with a special transient absorber diode Encoder inputs CH_A CH_B and INDEX are protected against positive and negative voltage tran sients The encoder inputs are fed into a Schmidt trigger buffer that ensures reliable operation even under noisy environments
32. s interrupt has occurred Your program code should be here Read interrupt status registers Clear interrupt on ESC629 outp 0x20 0x20 Acknowledge the interrupt controller Saving the Startup Interrupt Mask Register IMR and interrupt vector The next step after writing the ISR is to save the start up state of the interrupt mask register and the original interrupt vector you are using The IMR is located in address 21h The interrupt vector you will be using is located in the interrupt vector table which is an array of pointers addresses and it is lo cate din the first 1024 bytes of the memory Segment 0 offset 0 You can read this value directly but it is a better practice to use DOS function 35h get interrupt vector to do this Most C compilers have a special function available for doing this The vectors for the hardware interrupts on the XT bus are vectors 8 15 where IRQO uses vector 8 and IRQ7 uses vector 15 Thus if your ESC629 is using IRQ5 it corresponds to vector number 13 Before you install your ISR temporarily mask out the IRQ you will be using This prevents the IRQ from requesting an interrupt while you are installing and initializing your ISR To mask the IRQ read the current IMR at I O port 21h and set the bit that corresponds to the IRQ The IMR is arranged so that bit 0 is for IRQO and bit 7 is for IRQ7 See the paragraph entitled Interrupt Mask Register IMR earlier in this discussion for h
33. se Even if you are writing your ISR in Assembly language DOS and many floating point emulators are not re entrant Of course there are ways to avoid this problem such as those which activate when your ISR is called Such solutions are however beyond the scope of this manual The second major concern when writing ISR s is to make them as short as possible in term of execu tion time Spending long times in interrupt service routines may mean that other important interrupts are not serviced Also if you spend too long in your ISR it may be called again before you have ex ited This will lead to your computer hanging up and will require a reboot Your ISR should have the following structure Push any processor registers used in your ISR Most C compiler do this automatically Put the body of your routine here Read interrupt status register of the LM629 chip on your ESC629 board Clear the interrupt bit by writing the RSTI instruction to the LM629 that caused the inter rupt Issue the EOI command to the 8259 by writing 20h to address 20h e Pop all registers Most C compilers do this automatically The following C example shows what the shell of your ISR should be like ESC629 Benen 1 1 Function new_IRQ_handler Inputs Nothing Returns Nothing Sets the interrupt flag for the EVENT void interrupt far new_IRQ_handler void 32 RTD Finland Oy User s Manual ESC629 IRQ_flag 1 Indicate to main proces
34. top of the module can be used to interface to external power output stages What comes with your board Your ESC629 package contains the following items e ESC629 motor interface board User s manual Note Software and drivers are available from our website If any item is missing or damaged please call Real Time Devices Finland customer service at the following number 358 9 346 4538 Board accessories In addition to the items included in your ESC629 delivery several hardware accessories are avail able Contact your local distributor for more information and for advice on selecting the most appro priate accessories to support your control system These include the following Software drivers Hardware accessories including IDAN solid aluminum mounting frames for PC 104 Computers For more information on IDAN please visit our websites at the following internet addresses www rtdfinland fi or www rtd com Using this manual This manual is intended to help you install your new ESC629 card and get it working quickly whilst also providing enough detail about the board and it s functions so that you can obtain maximum use of it s features even in the most demanding applications The scope of this manual does not cover complex motion control programming and system design ESC629 8 RTD Finland Oy User s Manual When you need help This manual and all the example programs will provide you with enough informatio
35. when repaired 7 Enclose the paper with the product being returned 8 Carefully package the product to be returned using anti static packaging We will not be responsible for products damaged in transit for repair 7 Write the RMA number on the outside of the package 8 Ship the package to Real Time Devices Finland Oy Lepolantie 14 FIN 00660 Helsinki FINLAND ESC629 37 RTD Finland Oy User s Manual Limited Warranty Real Time Devices warrants the hardware and software products it manufactures and produces to be free from defects in materials and workmanship for one year following the date of shipment from REAL TIME DEVICES This warranty is limited to the original purchaser of product and is not transferable During the one year warranty period REAL TIME DEVICES will repair or replace at its option any defec tive products or parts at no additional charge provided that the product is returned shipping prepaid to REAL TIME DEVICES All replaced parts and products become the property of REAL TIME DEVICES Be fore returning any product for repair customers are required to contact the factory for an RMA number THIS LIMITED WARRANTY DOES NOT EXTEND TO ANY PRODUCTS WHICH HAVE BEEN DAMAGED AS A RESULT OF ACCIDENT MISUSE ABUSE such as use of incorrect input voltages improper or insufficient ventilation failure to follow the operating instructions that are provided by REAL TIME DEVICES acts of God or other contingenci
36. with strobed or handshake signals Mode 2 Strobed bi directional input output lets you communicate with an external device through the port A Handshaking is similar to mode 1 Available Port direction definitions Port A and B are defined to be Inputs or Outputs as ports the lower bits in Port C 0 3 and 4 7 may be set as Inputs or Outputs in groups All these modes are discussed in detail in the 8255 data sheet available from Intel In later sections of this manual an overview of the 8255 chip programming is included 23 RTD Finland Oy User s Manual Chapter 5 BOARD OPERATION AND PROGRAMMING ESC629 This chapter shows you how to program and use your ESC629 Included are a complete detailed description of the memory map and a detailed discussion of pro gramming operations to aid you in programming The full functionality of the LM629 is described in the attached data sheet reprint from national semiconductor 24 RTD Finland Oy User s Manual Defining the Memory Map The I O map of the ESC629 is shown in Table 5 1 below As shown the module occupies two ad dresses The Base Address designated as BA can be set using the jumpers as described in Chap ter 2 Board settings The following sections describe the register contents of each address used in the I O map Table 5 1 ESC629 I O Map Register Description Read Function Write Function Address in HEX Servo chip 1 Reads from chip Writes to chip Servo c
37. xible way of dealing with asynchronous events Keyboard activity is a good example your computer cannot predict when you might press a key and it would be a waste of proc essor time to do nothing whilst waiting for a keystroke to occur Thus the interrupt scheme is used and the processor proceeds with other tasks When a keystroke finally occurs the keyboard then terrupts the processor so that it can get the keyboard data It then places it into the memory and then returns to what it was doing before the interrupt occurred Other common devices that use inter rupts are A D boards network boards serial ports etc Your ESC629 can interrupt the main processor when a trajectory is completed motor is stopped or an error occurs in the motor control process A complete description of all the possible error condition interrupts is included in the documentation of the LM629 chip By using interrupts you can write pow erful code to interface to your motion control system Interrupt request lines To allow different peripheral devices to generate interrupts on the same computer the PC AT bus has interrupt request channels IRQ s A rising edge transition on one of these lines will be latched into the interrupt controller The interrupt controller checks to see if the interrupts are to be acknowl edged from that IRQ and if another interrupt is being processed it decides if the new request should supersede the one in progress or if it has to w
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