^1 HARDWARE REFERENCE MANUAL
^2
Brick Motion Controller
^3 Programmable Servo Amplifier
^4 5xx-603869-xUxx
^5 May 2, 2007
Single Source Machine Control
Power // Flexibility // Ease of Use
21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com
After removing the power source from the equipment, wait at least 10 minutes before touching or
disconnecting sections of the equipment that normally carry electrical charges (e.g., capacitors, contacts,
screw connections). To be safe, measure the electrical contact points with a meter before touching the
equipment.
The following text formats are used in this manual to indicate a potential for personal injury or equipment
damage. Read the safety notices in this manual before attempting installation, operation, or maintenance
to avoid serious bodily injury, damage to the equipment, or operational difficulty.
WARNING:
A Warning identifies hazards that could result in personal injury or death. It
precedes the discussion of interest.
Caution:
A Caution identifies hazards that could result in equipment damage. It precedes
the discussion of interest
Note:
A Note identifies information critical to the user’s understanding or use of the
equipment. It follows the discussion of interest.
REVISION HISTORY
REV.
DESCRIPTION
DATE
CHG
APPVD
1
MANUAL CREATION
05/02/07
CP
S. MILICI
Brick Motion Controller Hardware Reference Manual
Table of Contents
125................................................................................................................................................................................. I
RECEIVING AND UNPACKING.............................................................................................................................5
X9-10: Analog I/O Ch5 (X9) and Ch6 (X10), (Optional) ....................................................................................9
X11-12: Analog I/O Ch7 (X11) and Ch8 (X12), (Optional) ................................................................................9
X13: USB 2.0 Connector ...................................................................................................................................10
X14: RJ45, Ethernet Connector.........................................................................................................................10
TB1: Power Connector.......................................................................................................................................11
S1: Re-Initialization on Reset Control...............................................................................................................11
S2: Firmware Reload Enable ............................................................................................................................11
J6: General Purpose I/O....................................................................................................................................17
J7: Extra General Purpose I/O (Optional).........................................................................................................19
Suggested M-Variable Addressing for the optional General Purpose I/O (J7)..................................................20
J8: Extra General Purpose I/O (Optional)........................................................................................................21
Signal Format.....................................................................................................................................................24
Hardware Setup..................................................................................................................................................24
Setting up the Analog Inputs (optional)..............................................................................................................26
DB- Connector Spacing Specifications...................................................................................................................35
Type of Cable for Encoder Wiring..........................................................................................................................36
Table of Contents
i
Brick Motion Controller Hardware Reference Manual
X15: Watchdog ..................................................................................................................................................38
J6 and J7: General Purpose I/O........................................................................................................................38
J4: Limit Inputs for Axis 1-4..............................................................................................................................40
J5: Limit Inputs for Axis 5-8..............................................................................................................................41
Dimensional Layout and Connector location.....................................................................................................42
ii
Table of Contents
Brick Motion Controller Hardware Reference Manual
INTRODUCTION
The Brick Motion Controller is a fully scaleable automation controller utilizing
the intelligence and capability of its embedded Turbo PMAC2. With the ability
to store programs locally and built-in PLC execution, it is programmable for
virtually any kind of automation application. This allows for complete machine
motion and logic control.
This product has 4 or 8 (optional) axes of analog +/-10V filtered-PWM (12-bit
resolution) or pulse and direction outputs as standard. Options are available for
dual true-DAC analog outputs at 18-bit resolution or Direct-PWM with current
loop. Feedback with quadrature incremental encoders is standard. Options for
sinusoidal, resolver or serial encoders are available.
The Brick Motion Controller provides a standard I/O capability of 16 inputs
and 8 outputs at 12-24volts fully protected and isolated with separate commons
for each bank of 8 inputs. Outputs are rated for 1 ampere each and are thermal-
fuse protected. Outputs can be current sinking or sourcing depending on use of
common emitter or common collector connections. Additional I/O is an option
(up to 64 inputs and 32 outputs). Also an option for up to four 16 bit analog
inputs is available.
Brick Motion
Controller
The Brick Motion Controller’s functionality doesn’t stop there, but also includes features such as
extensible I/O via ModBus TCP master, or ModBus TCP slave for third party HMI hardware. Our PC-
based HMI package connected through USB 2.0 or Ethernet makes the Brick Motion Controller a
powerful single-source solution.
Brick Motion Controller Features
The Brick Motion Controller is capable of controlling up to eight axes with direct-PWM commands.
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Motorola DSP 56k digital signal processor
Turbo PMAC2 CPU (for kinematics, open servo, NC applications)
Fully Configurable via USB2.0 and/or Ethernet TCP/IP (100 Base-T)
Operation from a PC
Stand-alone operation
Linear and circular interpolation
256 motion programs capacity
64 asynchronous PLC program capability
Rotating buffer for large programs
36-bit position range (± 64 billion counts)
Adjustable S-curve acceleration and deceleration
Cubic trajectory calculations, splines
Set and change parameters in real time
Torque, Velocity and Position control standard
Small footprint saves space
Full rated temperature cooling standard (no need for additional fans)
16 inputs (expandable to 32 with option) fully-protected and isolated with separate commons for
two banks of eight
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Eight thermal-fuse protected outputs (expandable to 16 with option) rated for 0.5A @ 24VDC
each (Flexible outputs allow for sinking or sourcing of current depending on whether the common
emitter or common collector is used.)
Introduction
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Brick Motion Controller Hardware Reference Manual
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Primary encoder for each axis with TTL differential/single-ended inputs with A, B quadrature
channels and C index channel, 10 MHz cycle rate, and digital Hall-effect inputs
Five flags per axis using DB-25: HOME, PLIM, MLIM and USER inputs; EQU compare
Optional analog inputs and outputs, ± 5VDC
Optional two PWM outputs.
Optional Dual Port RAM (Required for NC)
Optional Modbus Protocol
Optional Sinusoidal encoder feedback
Optional Resolver feedback
Optional EnDat, Hiperface interfaces.
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Introduction
Brick Motion Controller Hardware Reference Manual
SPECIFICATIONS
Part Number
Brick Controller
Model Number Definition
Axis 1-4 Output Options
F: Filtered-PWM analog output on Channels1-4, 12-bit resolution(default)
D: Dual true-DAC analog outputs on Channels1-4, 18-bit resolution
CPU Options - Turbo PMAC 2 Processor
C0 : 80Mhz, 8Kx24 Internal, 256Kx24SRAM, 1MB Flash (Default)
F3: 240Mhz, 192Kx24 Internal, 1Mx24SRAM, 4MB Flash
Digital I/O Option
0: Digital I/O 16 inputs and 8 outputs, 0.5A, 24VDC (default)
1: Expanded digital I/O additional16 inputs and 8 outputs, 0.5A, 24VDC
2: Expanded digital I/O additional32 inputs and 16 outputs, 0.5A, 24VDC
Analog I/O Options
0: No Options(default)
3: Two 16-bit analog inputs
4: Four 16-bit analog inputs
Number of Axes
4: Four Axes (Default)
8: Eight Axes
BC4 - C0 - F00 - 000 – (0000)
MACRO and Special Feedback Options (See Note)
Axis 5-8 Feedback Options , apply only to BC4 controller
Number and Type of Special Feedback Channels
Note: For Other Feedback Options See “Special Feedback Options”
00: No added encoders or flags, 12-24V flags on Channels1-4 (default)
02: Four added encoders(Channels5-8), four added flag sets, 12-24V flags all channels
05: No added encoders or flags, 5V flags on Channels1-4
BC X - XX - XXX - XXX - XXXX
00: No Special Feedback Channels
4A: 4 Sinusoidal Encoder Feedback Channels
4B: 4 Resolver Feedback Channels
07: Four added encoders(Channels5-8), four added flag sets, 5V flags all channels
4C: 4 Serial Encoder Feedback Channels
Axis 5-8 Options, apply only to BC8 controller
Note: Letter must be same as previous letter
F2: Filtered-PWM analog output on Channels5-8, 12-bit resolution, 12-24V flags all channels
D2: Dual true-DAC analog outputs on Channels5-8, 18-bit resolution, 12-24V flags all channels
F7: Filtered-PWM analog output on Channels5-8, 12-bit resolution, 5V flags all channels
D7: Dual true-DAC analog outputs on Channels5-8, 18-bit resolution, 5V flags all channels
4D: 4 Sinusoidal Encoder and Serial Encoder Feedback Channels
8A: 8 Sinusoidal Encoder Feedback Channels
8B: 8 Resolver Feedback Channels
8C: 8 Serial Encoder Feedback Channels
8D: 8 Sinusoidal Encoder and Serial Encoder Feedback Channels
Serial Encoder Protocols
BC X - XX - XXX - XXX - XXXX
0: No Serial Encoder Protocol(for previous digit= 0, A, or B)
1: SSI
2: Yaskawa Sigma II
3: EnDat
Communication Options
Note: To use PMAC-NC software, DPRAM is required
0: No Options, Default
D: DPRAM option, size 32K x 16-bit wide (required for NC software)
M: ModBus Ethernet Communication Protocol(Software) option
S: DPRAM and Modbus Options Combined
R: RS232 port on 9-pin D-sub Connector
E: DPRAM & RS232 Options Combined
Note: If this portion of the model number is
4: HiperFace
present at all, an add-in board with RS-232
5: Tamagawa
comms port, 2 channel "handwheel" port and8
relay outputs for the amplifie-renable signals will
be provided, regardless of the values in this
portion of the model numbe.rAdditional circuits
are provided as specified by the codes her.e
MACRO Ring Interface
BC X - XX - XXX - XXX - XXXX
0: No MACRO Interface
1: RJ45 MACRO Interface
2: Fiber Optic MACRO Interface
N: RS232 & ModBus Options Combined
T: Modbus, DPRAM & RS232 Combined
Brick Motion Controller Options
CPU Options
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Option C0 – 80MHz Turbo CPU with 8Kx24 internal memory, 1Mx24 256Kx24 SRAM, 1Mx8 flash
memory
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Option F3 – 240MHz Turbo CPU with 192Kx24 internal memory, 1Mx24 SRAM, 4Mx8 flash memory
Axis 1-4 Output Options
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Filtered-PWM analog output on Channels 1-4, 12-bit resolution (default)
Dual true-DAC analog outputs on Channels 1-4, 18-bit resolution
Secondary Encoder Options
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Four secondary encoder inputs, and flags 12-24V.
Four secondary encoder inputs, and flags 5V.
Digital I/O Option
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Digital I/O 16 inputs and 8 outputs, 0.5A, 24VDC (default)
Expanded digital I/O additional 16 inputs and 8 outputs, 0.5A, 24VDC
Expanded digital I/O additional 32 inputs and 16 outputs, 0.5A, 24VDC
Specifications
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Brick Motion Controller Hardware Reference Manual
Analog I/O Options
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Two 16-bit analog inputs
Four 16-bit analog inputs
Communication Options
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DPRAM option, size 32K x 16-bit wide (required for use with NC software)
ModBus Ethernet Communication Protocol (Software) option
DPRAM and Modbus options combined
RS232 port on 9-pin D-sub connector
DPRAM & RS232 options combined
Modbus & DPRAM options combined
Modbus, DPRAM & RS232 options combined
MACRO and Special Feedback Options
Number and Type of Special Feedback Channels
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No Special Feedback Channels
4 Sinusoidal Encoder Feedback Channels
4 Resolver Feedback Channels
4 Serial Encoder Feedback Channels
4 Sinusoidal Encoder and Serial Encoder Feedback Channels
8 Sinusoidal Encoder Feedback Channels
8 Resolver Feedback Channels
8 Serial Encoder Feedback Channels
8 Sinusoidal Encoder and Serial Encoder Feedback Channels
Serial Encoder Protocols
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No Serial Encoder Protocol (for previous digit = 0, A, or B)
SSI Serial Absolute Encoder Interface
Yaskawa Sigma II Serial Absolute Encoder Interface
EnDat Serial Absolute Encoder Interface
HiperFace Serial Absolute Encoder Interface
Tamagawa Serial Absolute Encoder Interface
MACRO Ring Interface
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RJ45 MACRO Interface
Fiber Optic MACRO Interface
4
Specifications
Brick Motion Controller Hardware Reference Manual
RECEIVING AND UNPACKING
Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the
Brick Motion Controller is received, there are several steps that should be performed immediately:
1. Observe the condition of the shipping container and report any damage immediately to the
commercial carrier that delivered the drive.
2. Remove the control from the shipping container and remove all packing materials. Check all
shipping material for connector kits, documentation, diskettes, CD ROM, or other small pieces of
equipment. Be aware that some connector kits and other equipment pieces may be quite small and
can be accidentally discarded if care is not used when unpacking the equipment. The container and
packing materials may be retained for future shipment.
3. Verify that the part number of the unit received is the same as the part number listed on the purchase
order.
4. Inspect the unit for external physical damage that may have been sustained during shipment and
report any damage immediately to the commercial carrier that delivered the drive.
5. Electronic components in this product are design-hardened to reduce static sensitivity. However, use
proper procedures when handling the equipment.
6. If the Brick Motion Controller is to be stored for several weeks before use, be sure that it is stored in a
location that conforms to published storage humidity and temperature specifications stated in this
manual.
Use of Equipment
The Brick Motion Controller is a Turbo PMAC2 controller. So parallel with this manual the user needs to
use the Turbo Software Reference Manual and the Turbo User Manual. Always download the latest
manual revision from the Delta Tau website: www.deltatau.com
Note:
If Ethernet communications are used, Delta Tau Systems strongly recommends the
use of RJ45 CAT5e or better shielded cable.
Newer network cards have the Auto-MDIX feature that eliminates the need for
crossover cabling by performing an internal crossover when a straight cable is
detected during the auto-negotiation process.
For older network cards, one end of the link must perform media dependent
interface (MDI) crossover (MDIX), so that the transmitter on one end of the data
link is connected to the receiver on the other end of the data link (a crossover/patch
cable is typically used). If an RJ45 hub is used, then a regular straight cable should
be implemented.
Maximum length for Ethernet cable should not exceed 100m (330ft).
Specifications
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Brick Motion Controller Hardware Reference Manual
6
Specifications
Brick Motion Controller Hardware Reference Manual
SYSTEM WIRING
WARNING:
Installation of electrical control equipment is subject to many regulations including
national, state, local, and industry guidelines and rules. General recommendations
can be stated but it is important that the installation be carried out in accordance
with all regulations pertaining to the installation.
Noise Problems
When problems do occur often it points to electrical noise as the source of the problem. When this
occurs, turn to controlling high-frequency current paths. If the grounding instructions do not work, insert
chokes in the motor phases. These chokes can be as simple as several wraps of the individual motor leads
through a ferrite ring core (such as Micrometals T400-26D). This adds high-frequency impedance to the
outgoing motor cable thereby making it harder for high-frequency noise to leave the control cabinet area.
Care should be taken to be certain that the core’s temperature is in a reasonable range after installing such
devices.
Wiring Earth-Ground
Panel wiring requires that a central earth-ground location be installed at one part of the panel. This
electrical ground connection allows for each device within the enclosure to have a separate wire brought
back to the central wire location. Usually, the ground connection is a copper plate directly bonded to the
back panel or a copper strip with multiple screw locations. The Brick Motion Controller is brought to the
earth-ground via the fourth pin on the J1 connector, located at the bottom of the unit through a heavy
gauge, multi-strand conductor to the central earth-ground location.
Earth Grounding Paths
High-frequency noises from the PWM controlled power stage will find a path back to the drive. It is best
that the path for the high-frequency noises be controlled by careful installation practices. The major
failure in problematic installations is the failure to recognize that wire conductors have impedances at
high frequencies. What reads 0 Ohms on a DVM may be hundreds of Ohms at 30MHz. Consider the
following during installation planning:
1. Star point all ground connections. Each device wired to earth ground should have its own conductor
brought directly back to the central earth ground plate.
2. Use unpainted back panels. This allows a wide area of contact for all metallic surfaces reducing high
frequency impedances.
3. Conductors made up of many strands of fine conducts outperform solid or conductors with few
strands at high frequencies.
4. Motor cable shields should be bounded to the back panel using 360-degree clamps at the point they
enter or exit the panel.
5. Motor shields are best grounded at both ends of the cable. Again, connectors using 360-degree shield
clamps are superior to connector designs transporting the shield through a single pin. Always use
metal shells.
6. Running motor armature cables with any other cable in a tray or conduit should be avoided. These
cables can radiate high frequency noise and couple into other circuits.
System Wiring
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Brick Motion Controller Hardware Reference Manual
Connectors
X1-X8: Encoder Input (1 to 8)
The main encoder input channels for the Brick Motion Controller support only differential quadrature
feedback. 5V supply to power the encoder is provided.
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4-axis drives with no Option 01 or Option 02 have only X1 to X4, for a total of four encoders
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Option 01 adds two extra S. encoders: X5 and X6, for a total of six encoders
Option 02 adds two more S. encoders on top of Option 01: X7 and X8 for a total of eight encoder
feedbacks.
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6-axis drives with no Option 02 have only X1 to X6, for a total of six encoders
Option 02 adds two extra S. encoders: X7 and X8 for a total of eight encoder feedbacks.
8-axis drives have a default of eight encoders (X1 to X8) and there are no additional encoder options.
8
7
6
5
4
3
2
1
X1-X8 Encoder Input (1-8)
(Female DB-15 Connector)
15
14
13
12
11
10
9
Pin
#
Symbol
Function Notes
CHAn+
Input
Axis n Encoder A+
Axis n Encoder B+
1
CHBn+
Input
2
CHCn+
Input
Axis n Encoder Index+
Encoder Power 5V
3
ENCPWRn
CHUn+ / DIRn+
CHWn+ / PULn+
2.5V
Output
In/Out
In/Out
Output
Input
4
Axis n U Commutation+ / If set for Steppers, axis #n Direction output +
Axis n W Commutation+ / If set for Steppers, axis #n Pulse output +
2.5V Reference power
5
6
7
Stepper Enable #n
CHAn-
Short pin 8 to pin 4 (5V) to enable stepper output for channel #n*
Axis n Encoder A-
8
Input
9
CHBn-
Input
Axis n Encoder B-
10
11
12
13
14
15
CHCn-
Input
Axis n Encoder Index-
GND
Common
In/Out
In/Out
Output
Common GND
CHVn+ / DIRn-
CHTn+ / PULn-
ResOut#n
Axis n V Commutation+ / If set for Steppers, axis #n Direction output -
Axis n T Commutation+/ If set for Steppers, axis #n Pulse output -
Resolver excitation output for channel #n
Because the same pinouts are used for all encoders, n stands for encoder number 1 to 8: n=1 / axis 1, n=2 / axis 2, etc.
For spacing specifications between the DB- connectors, see Appendix A of this manual.
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System Wiring
Brick Motion Controller Hardware Reference Manual
X9-10: Analog I/O Ch5 (X9) and Ch6 (X10), (Optional)
X9/10 (Female DB-9 Connector)
Pin #
Symbol
AGND
ADC5/6+
Function
Notes
1
2
3
4
5
6
7
8
9
Common
Input
16-bit Analog Input, channel 5/6+ *
ADC5/6-
Input
16-bit Analog Input, channel 5/6+ *
For spacing specifications between the DB- connectors, see Appendix A of this manual.
X11-12: Analog I/O Ch7 (X11) and Ch8 (X12), (Optional)
X11/12 (Female DB-9 Connector)
Pin #
Symbol
AGND
ADC7/8+
Function
Notes
1
2
3
4
5
6
7
8
9
Common
Input
12-bit Analog Input, channel 7/8+ *
ADC7/8-
Input
12-bit Analog Input, channel 7/8+ *
For spacing specifications between the DB- connectors, see Appendix A of this manual.
System Wiring
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Brick Motion Controller Hardware Reference Manual
X13: USB 2.0 Connector
This connector is used in conjunction with USB A-B cable, which can be purchased from any local
computer store and is provided when Option 1A is ordered. The A connector is connected to a PC or Hub
device; the B connector plugs into the J9-USB port.
X14: RJ45, Ethernet Connector
This connector is used for Ethernet communications from the Geo PMAC Drive to a PC.
Note:
Delta Tau Systems strongly recommends the use of RJ45 CAT5e or better shielded
cable.
Newer network cards have the Auto-MDIX feature that eliminates the need for
crossover cabling by performing an internal crossover when a straight cable is
detected during the auto-negotiation process.
For older network cards, one end of the link must perform media dependent interface
(MDI) crossover (MDIX), so that the transmitter on one end of the data link is
connected to the receiver on the other end of the data link (a crossover/patch cable is
typically used). If an RJ45 hub is used, then a regular straight cable must be
implemented.
Maximum length for Ethernet cable should not exceed 100m (330ft).
X15: Watchdog
The X15 connector allows the user to send an output from the Brick Motion Controller to the machine if a
watchdog condition has occurred at the Drive. This is an important safety feature because the Geo is
totally disabled when it is in watchdog condition and this output will allow the other machine’s
hardware/logic to bring the drive to a safe condition.
1
2
3
Watchdog (X15)
TB-5: 016-PL0F05-38P
(Phoenix 3-pin Terminal Block)
Pin #
Symbol
N.O.
N.C.
Function
Output
Output
Input
Notes
1
2
3
Normally open contact
Normally closed contact
Watchdog common
COM
3-pin terminal block connector at the front.
Part Type: FRONT-MC 1, 5/3-ST-3.81 p/n: 1850673
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System Wiring
Brick Motion Controller Hardware Reference Manual
TB1: Power Connector
The TB1 connector at the bottom panel allows the user to supply 24V DC power for the Brick Controller.
1
2
3
Watchdog (TB1)
TB-5: 016-PL0F05-38P
(Phoenix 3-pin Terminal Block)
Pin #
Symbol
+24VDC
Chassis GND
+24V return
Function
Input
Input
Notes
1
2
3
Input
S1: Re-Initialization on Reset Control
Hold switch in during power cycle for PMAC re-initialization.
S2: Firmware Reload Enable
Hold switch in during power cycle for PMAC firmware reload.
System Wiring
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Brick Motion Controller Hardware Reference Manual
J4 Limit Inputs (1-4 Axis)
The Brick Motion Controller limit and flag circuits give the flexibility to wire in standard 12V to 24V limits
and flags or wire in 5V level limits and flags on a channel basis. The default is set for the standard 12V to
24V inputs, but if the resistor pack is added to the circuit, the card can read 5V inputs.
J4 Limit Inputs
1
9
8
7
6
5
4
3
2
13
12
11
10
(Female DB-25
Connector)
25
24
23
22
21
20
19
18
17
16
15
14
Pin #
1
2
3
4
5
6
7
Symbol
USER1
MLIM1
FL_RT1
USER2
MLIM2
FL_RT2
USER3
MLIM3
FL_RT3
USER4
MLIM4
FL_RT4
GND
Function
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Description
User Flag 1
Negative Limit 1
Flag Return 1
User Flag 2
Negative Limit 2
Flag Return 2
User Flag 3
Negative Limit 3
Flag Return 3
User Flag 4
Negative Limit 4
Flag Return
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Common
PLIM1
Input
Input
Output
Input
Input
Output
Input
Input
Output
Input
Input
Output
Positive Limit 1
Home Flag 1
Compare Output, EQU 1, signal is TTL (5V) level
Positive Limit 2
Home Flag 2
Compare Output, EQU 2, signal is TTL (5V) level
Positive Limit 3
Home Flag 3
Compare Output, EQU 3, signal is TTL (5V) level
Positive Limit 4
Home Flag 4
Compare Output, EQU 4, signal is TTL (5V) level
HOME1
BEQU1
PLIM2
HOME2
BEQU2
PLIM3
HOME3
BEQU3
PLIM4
HOME4
BEQU4
If RP39 (limits 1), RP43 (limits 2), RP47 (limits 3) and RP51 (limits 4) are installed to the unit, the voltage
level of the flags can be lowered to 5V. User needs to specify these when ordering the unit.
RP39, RP43, RP47 and RP51 for 5V flags: 1Kohm Sip, 8-pin, four independent Resistors
RP39, RP43, RP47 and RP51 for 12-24Vflags: Empty bank (Default)
See Appendix B for Schematic
12
System Wiring
Brick Motion Controller Hardware Reference Manual
J5 Limit Inputs (5-8 Axis)
The Brick Motion Controller limit and flag circuits give the flexibility to wire in standard 12V to 24V
limits and flags or wire in 5V level limits and flags on a channel basis. The default is set for the standard
12V to 24V inputs, but if the resistor pack is added to the circuit, the card can read 5V inputs.
Note:
J5 comes only with the 8-axis configuration.
J5 Limit Inputs
1
9
8
7
6
5
4
3
2
13
12
11
10
(Female DB-25
Connector)
25
24
23
22
21
20
19
18
17
16
15
14
Pin #
1
2
3
4
5
6
7
Symbol
USER5
MLIM5
FL_RT5
USER6
MLIM6
FL_RT6
USER7
MLIM7
FL_RT7
USER8
MLIM8
FL_RT8
GND
Function
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Description
User Flag 5
Negative Limit 5
Flag Return 5
User Flag 6
Negative Limit 6
Flag Return 6
User Flag 7
Negative Limit 7
Flag Return 7
User Flag 8
Negative Limit 8
Flag Return 8
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Common
PLIM5
Input
Input
Output
Input
Input
Output
Input
Input
Output
Input
Input
Output
Positive Limit 5
Home Flag 5
Compare Output, EQU 5, signal is TTL (5V) level
Positive Limit 6
Home Flag 6
Compare Output, EQU 6, signal is TTL (5V) level
Positive Limit 7
Home Flag 7
Compare Output, EQU 7, signal is TTL (5V) level
Positive Limit 8
Home Flag 8
Compare Output, EQU 8, signal is TTL (5V) level
HOME5
BEQU5
PLIM6
HOME6
BEQU6
PLIM7
HOME7
BEQU7
PLIM8
HOME8
BEQU8
If J5 is present and RP89 (limits 5), RP93 (limits 6), RP97 (limits 7) and RP101 (limits 8) are installed to the
unit, the voltage level of the flags can be lowered to 5V. User needs to specify these when ordering the unit.
RP89, RP93, RP97 and RP101 for 5V flags: 1Kohm Sip, 8-pin, four independent Resistors
RP89, RP93, RP97 and RP101 for 12-24Vflags: Empty bank. (Default)
SSee Appendix B for Schematic
Limit and Flag Circuit Wiring
The Brick Motion Controller allows the use of sinking or sourcing position limits and flags to the
controller. The opto-isolator IC used is a PS2705-4NEC-ND quad phototransistor output type. This IC
allows the current to flow from return to flag (sinking) or from flag to return (sourcing).
System Wiring
13
Brick Motion Controller Hardware Reference Manual
A sample of the positive limit circuit is shown below. The 4.7K resistor packs used will allow 12-24V
flag inputs. If 0-5V flags are used, then a 1KΩ resistor pack (RP) can be placed in:
Flags 1-4: RP39 (channel 1), RP43 (channel 2), RP 47 (channel 3), RP51 (channel 4)
Flags 5-8: RP89 (channel 5), RP93 (channel 6), RP 97 (channel 7), and RP 101 (channel 8).
If these resistor packs are not added, all flags (±Limits, Home, and User) will be referenced from 12-24V.
Sample J4/J5, Flags Wiring Diagrams
Return
24V
Sinking
Separate
Supply
24V
Flag
Flag Supply
12-24VDC
Flag Supply
12-24VDC
Sourcing
Separate
Supply
Flag
0V
0V
Return
24V Supply
0V 24V
24V Supply
0V 24V
GBL_Sinking Flags
GBL_Sourcing Flags
USER 1
USER
1
1
2
3
4
5
6
7
8
1
2
Pos.Limit 1
Neg.Limit 1
Pos.Limit 1
Neg.Limit 1
14
14
15
16
17
Home 1
FLG_RTN1
15
16
17
Home 1
3
4
5
FLG_RTN1
EQU 1
EQU 1
USER 2
USER
2
Pos.Limit 2
Neg.Limit 2
Pos.Limit 2
Neg.Limit 2
Home 2
18
19
20
21
22
23
24
25
18
19
20
21
22
23
24
Home 2
6
7
8
FLG_RTN2
FLG_RTN2
FLG_RTN3
EQU 2
EQU 2
USER 3
USER 3
Pos.Limit 3
Pos.Limit 3
Neg.Limit 3
Home 3
Neg.Limit 3
Home 3
9
9
FLG_RTN3
EQU 3
EQU 3
10
10
USER 4
USER 4
Pos.Limit 4
Neg.Limit 4
Pos.Limit 4
Neg.Limit 4
11
11
Home 4
FLG_RTN4
Home 4
EQU 4
12
13
12
13
FLG_RTN4
EQU 4
25
GND
GND
J4 and J5 pinout is the same; J4 is for axis 1-4 and J5 for 5-8.
For the Flags, sinking and sourcing may be mixed depending on the FLG_RTNn input (n=1-8
depending on the channel).
14
System Wiring
Brick Motion Controller Hardware Reference Manual
AMP1-AMP8: Amplifier connections (1 to 8)
AMP1-AMP8 Amplifier connections
8
7
6
5
4
3
2
1
(1-8)
15
14
13
12
11
10
9
(Female DB-15 Connector)
Pin
#
Symbol
DACnA+
DACnB+
AE_NCn+
AE_NOn+
AFAULTn-
N.C.
Function Notes
Output
Output
Output
Output
Input
DAC A output channel n +
DAC B output channel n +
1
2
Amplifier Enable Relay Normally Open channel n +
Amplifier Enable Relay Normally Closed channel n
Amplifier Fault channel n -
No connection
3
4
5
6
N.C.
No connection
7
AGND
Common
Output
Output
Common
Input
Analog Ground
8
DACnA -
DACnB -
AE_COMn
AFAULTn+
N.C.
DAC A output channel n -
DAC B output channel n -
Amplifier Enable Relay Common channel n
Amplifier Fault channel n +
No connection
9
10
11
12
13
14
15
AGND
Common
Analog Ground
N.C.
No connection
Because the same pinouts are used for all amplifiers, n stands for amplifier number 1 to 8: n=1 / axis 1, n=2 / axis 2,
etc.
System Wiring
15
Brick Motion Controller Hardware Reference Manual
Amplifier Fault / Amplifier Enable diagrams
16
System Wiring
Brick Motion Controller Hardware Reference Manual
J6: General Purpose I/O
General purpose I/O is available on the Brick Motion Controller. All I/O is electrically isolated from the
drive. Inputs can be configured for sinking or sourcing applications. All Inputs are 12-24VDC. All
Outputs are 24V nominal operation, 0.5A maximum current. Outputs are robust against ESD and
overload.
J6 General Purpose I/O
19
18
17
16
15
14
13
12
10
9
8
7
6
5
4
3
2
11
(Female DB-37 Connector)
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
Pin #
1
2
3
4
5
6
7
8
Symbol
GPIN01
GPIN03
GPIN05
GPIN07
GPIN09
GPIN11
GPIN13
GPIN15
IN_COM 01-08
N.C
Function
Input
Input
Input
Input
Input
Input
Description
Input 1
Input 3
Input 5
Input 7
Input 9
Input 11
Input 13
Input 15
Input 01 to 08 Common
Not Connected
Input
Input
Input
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
COM_EMT
GP01-
Input
Output
Output
Output
Output
Output
Output
Output
Output
Input
Input
Input
Input
Input
Input
Input
Input
Input
Common Emitter *
Sourcing Output 1 **
Sourcing Output 2 **
Sourcing Output 3 **
Sourcing Output 4 **
Sourcing Output 5 **
Sourcing Output 6 **
Sourcing Output 7 **
Sourcing Output 8 **
Input 2
Input 4
Input 6
Input 8
Input 10
Input 12
Input 14
Input 16
Input 09 to 16 Common
Common Collector **
Sinking Output 1 *
Sinking Output 2 *
Sinking Output 3 *
Sinking Output 4 *
Sinking Output 5 *
Sinking Output 6 *
Sinking Output 7 *
Sinking Output 8 *
GP02-
GP03-
GP04-
GP05-
GP06-
GP07-
GP08-
GPIN02
GPIN04
GPIN06
GPIN08
GPIN10
GPIN12
GPIN14
GPIN16
IN_COM_09-16
COM_COL
GP01+
Input
Output
Output
Output
Output
Output
Output
Output
Output
GP02+
GP03+
GP04+
GP05+
GP06+
GP07+
GP08+
*For sinking outputs, connect the COM_EMT (pin11) line to the Analog Ground of the Power supply and the outputs to
the individual plus output lines, e.g. GPO1+
**For sourcing outputs, connect the COM_COL (pin29) line to 12-24V and the outputs to the individual minus output
lines, e.g., GPO1-
Do not mix topologies, i.e., all sinking or all sourcing outputs. If the common emitter is used, the common collector
should be unconnected. Conversely, if the common collector is used, the common emitter should be unconnected.
System Wiring
17
Brick Motion Controller Hardware Reference Manual
Suggested M-Variable Addressing for the General Purpose I/O (J6)
Suggested M-var. #
M0->
Address
Y:$78800,0,1
Y:$78800,1,1
Y:$78800,2,1
Y:$78800,3,1
Y:$78800,4,1
Y:$78800,5,1
Y:$78800,6,1
Y:$78800,7,1
Y:$78801,0,1
Y:$78801,1,1
Y:$78801,2,1
Y:$78801,3,1
Y:$78801,4,1
Y:$78801,5,1
Y:$78801,6,1
Y:$78801,7,1
Y:$078802,0,1
Y:$078802,1,1
Y:$078802,2,1
Y:$078802,3,1
Y:$078802,4,1
Y:$078802,5,1
Y:$078802,6,1
Y:$078802,7,1
Notes
Input 1 Data Line, J6 Pin 1
Input 2 Data Line, J6 Pin 20
Input 3 Data Line, J6 Pin 2
Input 4 Data Line, J6 Pin 21
Input 5 Data Line, J6 Pin 3
Input 6 Data Line, J6 Pin 22
Input 7 Data Line, J6 Pin 4
Input 8 Data Line, J6 Pin 23
Input 9 Data Line, J6 Pin 5
Input 10 Data Line, J6 Pin 24
Input 11 Data Line, J6 Pin 6
Input 12 Data Line, J6 Pin 25
Input 13 Data Line, J6 Pin 7
Input 14 Data Line, J6 Pin 26
Input 15 Data Line, J6 Pin 8
Input 16 Data Line, J6 Pin 27
Output 1 Data Line
Output 2 Data Line
Output 3 Data Line
Output 4 Data Line
Output 5 Data Line
Output 6 Data Line
Output 7 Data Line
Output 8 Data Line
M1->
M2->
M3->
M4->
M5->
M6->
M7->
M8->
M9->
M10->
M11->
M12->
M13->
M14->
M15->
M32->
M33->
M34->
M35->
M36->
M37->
M38->
M39->
12
13
14
15
16
17
18
19
30
31
32
33
34
35
36
37
Do not mix topologies, i.e., all sinking or all sourcing outputs. If the common emitter is used, the
common collector should be unconnected. Conversely, if the common collector is used, the common
emitter should be unconnected.
18
System Wiring
Brick Motion Controller Hardware Reference Manual
J7: Extra General Purpose I/O (Optional)
General purpose I/O is available on the Brick Motion Controller. All I/O is electrically isolated from the
drive. Inputs can be configured for sinking or sourcing applications. All Inputs are 12-24VDC. All
Outputs are 24V nominal operation, 0.5A maximum current. Outputs are robust against ESD and
overload.
J7 General Purpose I/O
19
18
17
16
15
14
13
12
10
9
8
7
6
5
4
3
2
11
(Female DB-37
Connector)
Symbol
GPIN17
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
Pin #
1
2
3
4
5
6
7
8
Function
Input
Input
Input
Input
Input
Input
Input
Input
Input
Description
Input 17
Input 19
Input 21
Input 23
Input 25
Input 27
Input 29
Input 31
GPIN19
GPIN21
GPIN23
GPIN25
GPIN27
GPIN29
GPIN31
9
IN_COM 17-24
N.C
Input 17 to 24 Common
Not Connected
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
COM_EMT
GPO9-
GPO10-
GPO11-
GPO12-
GPO13-
GPO14-
GPO15-
GPO16-
GPIN18
GPIN20
GPIN22
GPIN24
GPIN26
GPIN28
GPIN30
GPIN32
Input
Output
Output
Output
Output
Output
Output
Output
Output
Input
Input
Input
Input
Input
Input
Input
Input
Input
Common Emitter **
Sourcing Output 9 **
Sourcing Output 10 **
Sourcing Output 11**
Sourcing Output 12 **
Sourcing Output 13 **
Sourcing Output 14 **
Sourcing Output 15 **
Sourcing Output 16 **
Input 18
Input 20
Input 22
Input 24
Input 26
Input 28
Input 30
Input 32
Input 25 to 32 Common
Common Collector *
Sinking Output 9 *
Sinking Output 10 *
Sinking Output 11 *
Sinking Output 12 *
Sinking Output 13 *
Sinking Output 14 *
Sinking Output 15 *
Sinking Output 16 *
IN_COM_25-32
COM_COL
GPO9+
Input
Output
Output
Output
Output
Output
Output
Output
Output
GPO10+
GPO11+
GPO12+
GPO13+
GPO14+
GPO15+
GPO16+
*For sinking outputs, connect the COM_EMT (pin11) line to the Analog GND of the Power supply and the
outputs to the individual plus output lines, e.g. GPO9+
**For sourcing outputs, connect the COM_COL (pin29) line to 12-24V and the outputs to the individual
minus output lines, e.g., GPO9-
Do not mix topologies, i.e., all sinking or all sourcing outputs. If the common emitter is used, the common
collector should be unconnected. Conversely, if the common collector is used, the common emitter should be
unconnected.
System Wiring
19
Brick Motion Controller Hardware Reference Manual
Suggested M-Variable Addressing for the optional General Purpose I/O (J7)
Suggested M-var. #
M40->
M41->
M42->
M43->
M44->
M45->
M46->
M47->
M48->
M49->
M50->
M51->
M52->
M53->
M54->
M55->
M56->
M57->
M58->
M59->
M60->
M61->
M62->
M63->
Address
Y:$78803,0,1
Y:$78803,1,1
Y:$78803,2,1
Y:$78803,3,1
Y:$78803,4,1
Y:$78803,5,1
Y:$78803,6,1
Y:$78803,7,1
Y:$78804,0,1
Y:$78804,1,1
Y:$78804,2,1
Y:$78804,3,1
Y:$78804,4,1
Y:$78804,5,1
Y:$78804,6,1
Y:$78804,7,1
Y:$078805,0,1
Y:$078805,1,1
Y:$078805,2,1
Y:$078805,3,1
Y:$078805,4,1
Y:$078805,5,1
Y:$078805,6,1
Y:$078805,7,1
Notes
Input 17 Data Line, J7 Pin 1
Input 18 Data Line, J7 Pin 20
Input 19 Data Line, J7 Pin 2
Input 20 Data Line, J7 Pin 21
Input 21 Data Line, J7 Pin 3
Input 22 Data Line, J7 Pin 22
Input 23 Data Line, J7 Pin 4
Input 24 Data Line, J7 Pin 23
Input 25 Data Line, J7 Pin 5
Input 26 Data Line, J7 Pin 24
Input 27 Data Line, J7 Pin 6
Input 28 Data Line, J7 Pin 25
Input 29 Data Line, J7 Pin 7
Input 30 Data Line, J7 Pin 26
Input 31 Data Line, J7 Pin 8
Input 32 Data Line, J7 Pin 27
Output 9 Data Line
Output 10 Data Line
Output 11 Data Line
Output 12 Data Line
Output 13 Data Line
Output 14 Data Line
Output 15 Data Line
Output 16 Data Line
12
13
14
15
16
17
18
19
30
31
32
33
34
35
36
37
Do not mix topologies, i.e., all sinking or all sourcing outputs. If the common emitter is used, the
common collector should be unconnected. Conversely, if the common collector is used, the common
emitter should be unconnected.
20
System Wiring
Brick Motion Controller Hardware Reference Manual
J8: Extra General Purpose I/O (Optional)
General purpose I/O is available on the Brick Motion Controller. All I/O is electrically isolated from the
drive. Inputs can be configured for sinking or sourcing applications. All Inputs are 12-24VDC. All
Outputs are 24V nominal operation, 0.5A maximum current. Outputs are robust against ESD and
overload.
J8 General Purpose I/O
19
18
17
16
15
14
13
12
10
9
8
7
6
5
4
3
2
11
(Female DB-37 Connector)
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
Pin #
1
2
3
4
5
6
7
8
Symbol
GPIN33
GPIN35
GPIN37
GPIN39
GPIN41
GPIN43
GPIN45
GPIN47
IN_COM 33-40
N.C
Function
Input
Input
Input
Input
Input
Input
Input
Input
Input
Description
Input 33
Input 35
Input 37
Input 39
Input 41
Input 43
Input 45
Input 47
9
Input 33 to 40 Common
Not Connected
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
COM_EMT
GP17-
Input
Output
Output
Output
Output
Output
Output
Output
Output
Input
Input
Input
Input
Input
Input
Input
Input
Input
Common Emitter *
Sourcing Output 17 **
Sourcing Output 18 **
Sourcing Output 19 **
Sourcing Output 20 **
Sourcing Output 21 **
Sourcing Output 22 **
Sourcing Output 23 **
Sourcing Output 24 **
Input 34
Input 36
Input 38
Input 40
Input 42
Input 44
Input 46
Input 48
Input 41 to 48 Common
Common Collector **
Sinking Output 17 *
Sinking Output 18 *
Sinking Output 19 *
Sinking Output 20 *
Sinking Output 21 *
Sinking Output 22 *
Sinking Output 23 *
Sinking Output 24 *
GP18-
GP19-
GP20-
GP21-
GP22-
GP23-
GP24-
GPIN34
GPIN36
GPIN38
GPIN40
GPIN42
GPIN44
GPIN46
GPIN48
IN_COM_41-48
COM_COL
GP17+
Input
Output
Output
Output
Output
Output
Output
Output
Output
GP18+
GP19+
GP20+
GP05+
GP22+
GP23+
GP24+
*For sinking outputs, connect the COM_EMT (pin11) line to the Analog Ground of the Power supply and the outputs to
the individual plus output lines, e.g. GPO1+
**For sourcing outputs, connect the COM_COL (pin29) line to 12-24V and the outputs to the individual minus output
lines, e.g., GPO1-
Do not mix topologies, i.e., all sinking or all sourcing outputs. If the common emitter is used, the common collector
should be unconnected. Conversely, if the common collector is used, the common emitter should be unconnected.
System Wiring
21
Brick Motion Controller Hardware Reference Manual
Suggested M-Variable Addressing for the General Purpose I/O (J8)
Suggested M-var. #
M64->
M65->
M66->
M67->
M68->
M69->
M70->
M71->
M72->
M73->
M74->
M75->
M76->
M77->
M78->
M79->
M80->
M81->
M82->
M83->
M84->
M85->
M86->
M87->
Address
Y:$78A00,0,1
Y:$78A00,1,1
Y:$78A00,2,1
Y:$78A00,3,1
Y:$78A00,4,1
Y:$78A00,5,1
Y:$78A00,6,1
Y:$78A00,7,1
Y:$78A01,0,1
Y:$78A01,1,1
Y:$78A01,2,1
Y:$78A01,3,1
Y:$78A01,4,1
Y:$78A01,5,1
Y:$78A01,6,1
Y:$78A01,7,1
Y:$078A02,0,1
Y:$078A02,1,1
Y:$078A02,2,1
Y:$078A02,3,1
Y:$078A02,4,1
Y:$078A02,5,1
Y:$078A02,6,1
Y:$078A02,7,1
Notes
Input 33 Data Line, J6 Pin 1
Input 34 Data Line, J6 Pin 20
Input 35 Data Line, J6 Pin 2
Input 36 Data Line, J6 Pin 21
Input 37 Data Line, J6 Pin 3
Input 38 Data Line, J6 Pin 22
Input 39 Data Line, J6 Pin 4
Input 40 Data Line, J6 Pin 23
Input 41 Data Line, J6 Pin 5
Input 42 Data Line, J6 Pin 24
Input 43 Data Line, J6 Pin 6
Input 44 Data Line, J6 Pin 25
Input 45 Data Line, J6 Pin 7
Input 46 Data Line, J6 Pin 26
Input 47 Data Line, J6 Pin 8
Input 48 Data Line, J6 Pin 27
Output 17 Data Line
Output 18 Data Line
Output 19 Data Line
Output 20 Data Line
Output 21 Data Line
Output 22 Data Line
Output 23 Data Line
Output 24 Data Line
12
13
14
15
16
17
18
19
30
31
32
33
34
35
36
37
Do not mix topologies, i.e., all sinking or all sourcing outputs. If the common emitter is used, the
common collector should be unconnected. Conversely, if the common collector is used, the common
emitter should be unconnected.
22
System Wiring
Brick Motion Controller Hardware Reference Manual
Sample J6/J7, I/O Wiring Diagrams
GBL
GBL
Sourcing 01-16 Inputs
Sourcing 01-08 Outputs
Sinking 01-16 Inputs
Sinking 01-08 Outputs
24V Supply
0V 24V
24V Supply
0V 24V
GPIN01
GPIN02
GPIN03
GPIN01
GPIN02
GPIN03
GPIN04
GPIN05
GPIN06
GPIN07
GPIN08
GPIN09
GPIN10
GPIN11
GPIN12
GPIN13
20
21
20
21
22
2
3
2
3
Inputs
01-08
Inputs
01-08
GPIN04
GPIN05
GPIN06
GPIN07
GPIN08
GPIN09
GPIN10
GPIN11
GPIN12
GPIN13
22
23
4
5
4
5
23
24
24
6
7
8
6
7
Inputs
09-16
Inputs
09-16
25
26
25
26
GPIN14
GPIN14
8
GPIN15
GPIN15
GPIN16
27
28
29
GPIN16
27
28
29
9
9
IN_COM_01-08
IN_COM_09-16
IN_COM_01-08
IN_COM_09-16
10
10
COM_COL
11
12
11
12
13
COM_EMT
GPO1+
30
31
30
31
Output 01
Output 02
Output 03
Output 04
Output 05
Output 06
Output 07
Output 08
Output 01
Output 02
Output 03
Output 04
Output 05
Output 06
Output 07
Output 08
GPO1-
GPO2-
GPO2+
GPO3+
GPO4+
GPO5+
GPO6+
GPO7+
GPO8+
13
14
15
16
32
33
34
32
33
34
14
15
16
GPO3-
GPO4-
GPO5-
GPO6-
GPO7-
GPO8-
35
36
35
36
17
18
17
18
19
37
37
19
GBL
GBL
24V Supply
0V 24V
Sourcing 01-08 Inputs
Sinking 09-16 Inputs
Sinking 01-08 Inputs
Sourcing 09-16 Inputs
24V Supply
0V 24V
2
20
GPIN01
GPIN02
GPIN03
GPIN04
GPIN05
GPIN06
GPIN07
GPIN08
GPIN09
GPIN10
GPIN11
GPIN12
GPIN13
GPIN01
GPIN02
GPIN03
GPIN04
GPIN05
GPIN06
GPIN07
GPIN08
GPIN09
GPIN10
GPIN11
GPIN12
GPIN13
20
2
3
Inputs
01-08
21
22
Inputs
01-08
21
22
3
4
5
4
5
23
23
24
24
6
7
6
7
Inputs
09-16
Inputs
09-16
25
26
25
26
GPIN14
8
GPIN14
8
GPIN15
GPIN16
GPIN15
GPIN16
27
28
29
27
28
29
9
9
IN_COM_01-08
IN_COM_01-08
IN_COM_09-16
10
IN_COM_09-16
10
11
12
11
12
30
31
30
31
13
14
15
16
13
14
15
16
32
33
34
32
33
34
35
36
35
36
17
18
17
18
37
37
19
19
J6 and J7 pinout is the same, J6 is default I/O. J7 (Inputs 17-32 and Outputs 9-16) is installed only when
Digital I/O Option1 is ordered. J8 (Inputs 33-48 and Outputs 17-24) is installed only when Digital I/O
Option2 is ordered.
System Wiring
23
Brick Motion Controller Hardware Reference Manual
Setting up Quadrature Encoders
Digital quadrature encoders are the most common position sensors used with Geo Drives. Interface
circuitry for these encoders comes standard on board-level Turbo PMAC controllers, UMAC axis-
interface boards, Geo drives, and QMAC control boxes.
Signal Format
Quadrature encoders provide two digital signals that are a function of the position of the encoder, each
nominally with 50% duty cycle, and nominally one-quarter cycle apart. This format provides four distinct
states per cycle of the signal, or per line of the encoder. The phase difference of the two signals permits the
decoding electronics to discern the direction of travel, which would not be possible with a single signal.
Typically, these signals are at 5V TTL/CMOS levels, whether single-ended or differential. The input
circuits are powered by the main 5V supply for the controller, but they can accept up to +/-12V between
the signals of each differential pair, and +/-12V between a signal and the GND voltage reference.
Differential encoder signals can enhance noise immunity by providing common-mode noise rejection.
Modern design standards virtually mandate their use for industrial systems, especially in the presence of
PWM power amplifiers, which generate a great deal of electromagnetic interference.
Hardware Setup
The Geo Drive accepts inputs from up to eight digital encoders
and provides encoder position data to the motion processor. X1
is encoder 1 connector and X2 is encoder 2 and respectively up
to X8. The differential format provides a means of using
twisted pair wiring that allows for better noise immunity when
wired into machinery.
CHAn+
CHAn-
CHBn+
CHBn-
CHCn+
1
2
3
4
5
9
10
Geo Drives encoder interface circuitry employs differential line
receivers. The wiring diagram on the right shows an example
of how to connect the Geo drive to a quadrature encoder.
CHCn-
11
12
13
14
ENCPWRn
GND
Shield
Function
CHAn+
CHAn-
CHBn+
CHBn-
CHCn+
CHCn-
ENCPWR
GND
Pin #
1
9
2
10
3
11
4
6
7
8
15
12
Encoder Decode
Value
Description
Clockwise decode
Counter clockwise decode
3
7
I7mn0
m = 0 for axis 1-4 (n = 1-4) and m = 1 for axis 5 – 8 (n = 1-4)
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System Wiring
Brick Motion Controller Hardware Reference Manual
Encoder Loss Setup
The Brick Motion Controller has encoder-loss detection circuitry for each encoder input. Designed for
use with encoders with differential line-driver outputs, the circuitry monitors each input pair with an
exclusive-or (XOR) gate. If the encoder is working properly and connected to the Brick Motion
Controller, the two inputs of the pair should be in opposite logical states – one high and one low –
yielding a true output from the XOR gate.
Note
A single-ended encoder cannot be used on the channel Encoder-Loss Errors
For the Brick Motion Controller Controller Encoder-loss detection bits come in the locations shown in the
table below.
Channel#
Address
Y:$78807,0,1
Y:$78807,1,1
Y:$78807,2,1
Y:$78807,3,1
Y:$78807,4,1
Y:$78807,5,1
Y:$78807,6,1
Y:$78807,7,1
Description
Encoder #1
Encoder #1 Loss Input Signal
Encoder #2 Loss Input Signal
Encoder #3 Loss Input Signal
Encoder #4 Loss Input Signal
Encoder #5 Loss Input Signal
Encoder #6 Loss Input Signal
Encoder #7 Loss Input Signal
Encoder #8 Loss Input Signal
Encoder #2
Encoder #3
Encoder #4
Encoder #5
Encoder #6
Encoder #7
Encoder #8
As of this writing, there is no automatic action taken on detection of encoder loss. Users who want to
take action on detecting encoder loss should write a PLC program to look for a change in the encoder loss
bit and take the appropriate action. Generally, the only appropriate response is to kill (open loop, zero
output, disabled) the motor with lost encoder feedback; other motors may be killed or aborted as well.
This next example program reacts to a detection of encoder loss. This is a more serious condition than a
count error, so a “kill” command is issued when the loss is detected. The example is for a single axis only,
but is easy to duplicate for multiple axes.
; Substitutions and definitions
#define Mtr1OpenLoop
Mtr1OpenLoop->Y:$0000B0,18,1
#define Enc1LossIn
Enc1LossIn->Y:$078807,0,1
#define Mtr1EncLossStatus
#define Lost
M138 ; Motor status bit
; Standard definition
M180 ; Input loss-detection bit
; Brick Motion Controller Ch1 loss bit
P180 ; Internal latched status
0
1
; Low-true fault here
; High is encoder present
#define OK
; Program (PLC) to check for and react to encoder loss
OPEN PLC 18 CLEAR
; Logic to disable and set fault status
IF (Mtr1OpenLoop=0 AND Enc1LossIn=Lost) ; Closed loop, no enc
CMD^K
Mtr1EncLossStatus=1
; Kill all motors
; Indicate encoder loss
ENDIF
; Logic to clear fault status
IF (Mtr1OpenLoop=1 AND Enc1LossIn=OK AND Mtr1EncLossStatus=0)
Mtr1EncLossStatus=0 ; Indicate valid encoder signal
ENDIF
CLOSE
System Wiring
25
Brick Motion Controller Hardware Reference Manual
For more details about Encoder Loss look into the Turbo USERs Manual chapter: Making Your
Application Safe.
Setting up the Analog Inputs (optional)
The Brick Motion Controller can be ordered with two or four 16-bit hi-resolution analog to digital
converters.
The Brick Motion Controller uses the Burr Brown ADS8361. See Appendix B for partial Schematics
When selected for bipolar mode, differential inputs allow the user to apply input voltages to ±5 volts
(10Vp-p).
To read the A/D data, the user needs to set the ADC strobe word for the second gate array to I7106 =
$1FFFFF. Also, the user needs to create M-variable definitions that point to the ADC inputs (M-variables
that are used are suggested ones) for channels 5 to 8.
Bipolar
The data received is a signed 16-bit number scaled from –5V to +5V (-32768cts to 32767cts).
M5061->Y:$78105,8,116,s ;ch5 A-D channel
M5062->Y:$7810D,8,16,s ;ch6 A-D channel
M5063->Y:$78115,8,16,s ;ch7 A-D channel
M5064->Y:$7811D,8,16,s ;ch8 A-D channel
Filtered DAC Outputs Configuration (optional)
The Brick Motion Controller analog +/-10V outputs are produced by filtering a PWM signal. This
technique has been used for some time now by some other DeltaTau products (PMAC2A-PC/104) and
many of our competitors. Although this technique does not contain the same levels of performance as a
true Digital to Analog converter (DAC), for most servo applications it is more than adequate. Passing the
PWM signal through a 10KHz low pass filter creates the +/-10V signal output. The duty cycle of the
PWM signal is what generates the magnitude the voltage output. The frequency of the PWM signal
determines the magnitude and frequency of ripple on that +/-10V signal. As you lower the PWM
frequency and subsequently increase your output resolution, you increase the magnitude of the ripple as
well as slow down the frequency of the ripple as well. Depending on the system, this ripple can effect
performance at different levels.
Both the resolution and the frequency of the Filtered PWM outputs are configured in software on the
Brick Motion Controller through the variable I7m00. This I7m00 variable also effects the phase and
servo interrupts. Therefore as we change I7m00 we will also have to change I7m01 (phase clock
divider), I7m02 (servo clock divider), and I10 (servo interrupt time). These four variables are all related
and must be understood before adjusting parameters. I7mn6 (m=1, n=1-4) needs to be set for PWM
output.
When the analog I/O option is ordered the Brick Motion Controller comes with 2 or 4 analog (+/10VDC)
output signals. These analog output signals are filtered PWM signals, 12-bit analog outputs. These
outputs can be either single-ended or differential. For a single-ended analog output use the DACn+ side
of the signal and leave the DACn- floating; do not ground it. For a differential command output, connect
the positive side of the DACn+, and the negative side DACn-.
To limit the range of each signal to ±5V, use parameter Ixx69. Any analog output not used for dedicated
servo purposes may be utilized as a general-purpose analog output. Usually this is done by defining an
M-variable to the digital-to-analog-converter register (suggested M-variable definitions M502, M602,
26
System Wiring
Brick Motion Controller Hardware Reference Manual
etc.), then writing values to the M-variable. The analog outputs are intended to drive high-impedance
inputs with no significant current draw. The 220Ω output resistors will keep the current draw lower than
50 mA in all cases and prevent damage to the output circuitry, but any current draw above 10 mA can
result in noticeable signal distortion.
The following I-variables must be set properly to use the digital-to-analog (filtered DAC) outputs:
I7000 = 1001
I7001 = 5
I7002 = 3
I7003 = 1746
I7100 = 1001
I7103 = 1746
I70n6 = 0
; PWM frequency 29.4kHz, PWM 1-4
; Phase Clock 9.8kHz
; Servo frequency 2.45kHz
; ADC frequency
; PWM frequency 29.4kHz, PWM 5-8
; ADC frequency
; Output mode: PWM
Ixx69 = 1001
; DAC limit 10Vdc
; Servo interrupt time
I10
= 3421867
n = channel number from 1 to 8
xx = motor number from 1 to 8
Parameters to Set up Global Hardware Signals
I7000 determines the frequency of the MaxPhase clock signal from which the actual phase clock
signal is derived. It also determines the PWM cycle frequency for Channels 1 to 4. This variable
is set according to the equation:
I7000 = INT[117,964.8/(4*PWMFreq(KHz)) - 1]
The Clipper Board filtered PWM circuits were optimized for about 30KHz. The minimum
frequency I7000 should be set to is 1088 (calculated as 27.06856KHz)
I7001 determines how the actual phase clock is generated from the MaxPhase clock, using the
equation:
PhaseFreq(kHz) = MaxPhaseFreq(kHz)/(I7001+1)
I7001 is an integer value with a range of 0 to 15, permitting a division range of 1 to 16. Typically,
the phase clock frequency is in the range of 8 kHz to 12 kHz. About 9 KHz is standard, set I7001
= 5.
I7002 determines how the servo clock is generated from the phase clock, using the equation:
ServoFreq(KHz) = PhaseFreq(KHz)/(I7002+1)
I7002 is an integer value with a range of 0 to 15, permitting a division range of 1 to 16. On the
servo update, which occurs once per servo clock cycle, PMAC updates commanded position
(interpolates) and closes the position/velocity servo loop for all active motors, whether or not
commutation and/or a digital current loop is closed. Typical servo clock frequencies are 1 to 4
kHz. The PMAC standard is about 2 KHz, set I902 = 3.
I10 tells the Clipper Board interpolation routines how much time there is between servo clock
cycles. It must be changed any time I7000, I7001, or I7002 is changed. I10 can be set according
to the formula:
I10 = (2*I7000+3)(I7001+1)(I7002+1)*640/9
I10 should be set to 3421867.
I7003 determines the frequency of four hardware clock signals used for machine interface channels 1-4;
This can be left at the default value (I7003=*) unless the on board Option-12 ADCs are used. The four
System Wiring
27
Brick Motion Controller Hardware Reference Manual
hardware clock signals are SCLK (encoder sample clock), PFM_CLK (pulse frequency modulator clock),
DAC_CLK (digital-to-analog converter clock), and ADC_CLK (analog-to-digital converter clock).
Parameters to Set Up Per-Channel Hardware Signals
I70n6 is the output mode; “n” is the output channel number (i.e. for channel 1 the variable to set would be
I7016, I7026 for channel 2 etc.). On Pmac1 there is only one output and one output mode, DAC output.
On PMAC2 boards, each channel has 3 outputs, and there are 4 output modes. Since this is board was
designed to output filtered PWM signals we want to configure at least the first output as PWM. Therefore
the default value of 0 is the choice. For information on this variable, consult the Turbo Software
Reference Manual.
Ixx69 is the motor output command limit. The analog outputs on PMAC1 style boards and some PMAC2
accessories are 16-bit or 18-bit DACs, which map a numerical range of -32,768 to +32,767 into a voltage
range of -10V to +10V relative to analog ground (AGND). For our purposes of a filtered PWM output
this value still represents the maximum voltage output; however the ratio is slightly different. With a true
DAC, Ixx69=32767 allows a maximum voltage of 10V output. With the filtered PWM circuit, Ixx69 is a
function of I7000. A 10V signal in the output register is no longer 32767 as was in PMAC1, a 10V signal
is corresponds to a value equal to I7000. Anything over I7000 will just rail the DAC at 10V. For
example:
Desired Maximum Output Value = 6V
Ixx69 = 6/10 * I7000
Desired Maximum Output Value = 10V
Ixx69= I7000 + 10 ; add a little headroom to assure a full
10V
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System Wiring
Brick Motion Controller Hardware Reference Manual
Setting up for Pulse and Direction Output
The following section shows how to quickly setup the key variables for a stepper motor (PFM) system.
The step and direction outputs are RS422 compatible and are capable of being connected in either
differential mode or single ended configurations for 5V input drivers.
Below are two examples for wiring the Brick Motion Controller to the stepper Amplifier. The user needs
to write pin 8 to pin 4 so as to enable the Stepper output and the AENA.
GBL_Stepper output wiring X1-X8,
quadrature encoder feedback,
Amplifier Enable lines are used
GBL_Stepper output wiring X1-X8,
no encoder feedback
Amplifier Enable lines are used
CHAn+
1
2
3
4
5
1
2
3
4
5
CHAn-
9
9
CHBn+
CHBn-
10
10
ENCPWR
AENAn+/index +
AENAn-/index -
Shield
AENAn+
AENAn-
11
11
12
13
14
GND
GND
DIRn+
DIRn-
PULn+
PULn-
12
DIRn+
Stepper
Amplifier
Stepper
Amplifier
DIRn-
PULn+
PULn-
13
14
15
6
7
8
6
7
8
Shield
15
Short pin 8 to pin 4 to enable Stepper Output
Short pin 8 to pin 4 to enable Stepper Output
(For Older version Brick Motion Controllers: Jumpers E21(E31) throughE24( E34) must be jumpered in the inside of the unit for
PFM outputs and E25(35) through E28(38) must be jumpered for amplifier enable outputs. Pin 8 was not connected to anything)
Software Setup
After having the hardware ready for steppers the user needs to set the software for Pulse and direction
output as well. There are several I-variables that must be set up properly for proper operation of the Pulse
and direction output in a Brick Motion Controller system. It is recommended for the user to also look into
the Turbo Software reference and the Turbo Users manual. The most important ones are analyzed
below and we can separate them into two categories:
Multi-Channel Servo IC I-Variables
I7m00: Servo IC m MaxPhase/PWM Frequency Control
Typically, this will be set to the same value as the variable that controls the system clocks: I7000
(channels 1-4) I7100 (channels 5-8). If a different PWM frequency is desired, then the following
constraint should be observed in setting this variable:
2* PWMFreq( kHz )
= { Integer }
PhaseFreq
I7m03: Servo IC m Hardware Clock Frequency Control
The hardware clock frequencies for the Servo IC should be set according to the devices attached to it.
There is no reason that these frequencies have to be the same between ICs. There is seldom a reason to
change this value from the default. At default this value will be 2258, which is to a PFM clock of
approximately 10 MHz, (which is about 10 times greater than normally needed). Therefore, this value is
not normally changed. Refer to the Turbo Software Reference manual for changing these variables.
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29
Brick Motion Controller Hardware Reference Manual
I7m04: PFM Pulse Width Control
The pulse width is specified in PFM clock cycles and has a range of 1 to 255 cycles. The default value is
15. Since the default value of PFM clock is actually set to 9.8304 MHz, the default output pulse width
will be 15/9,830400 = 1.5258 µS. Note that when the PFM clock values are changed, the PFM pulse
width values must be evaluated for proper stepper drive operation.
The user of a typical stepper drive should not need to modify these control variables. However, PFM
pulse width should be increased if the stepper drive’s input cannot handle the speed of the pulse output.
This often occurs with slow opto-couplers used on stepper drive inputs.
Single-Channel I-Variables
Each Servo IC has four channels n, numbered 1 to 4. For the first (standard) Servo IC on the Brick Motion
Controller, the channel numbers 1 – 4 on the Servo IC are the same as the channel numbers 1 – 4 on the
board. For the second (optional) Servo IC on the Brick Motion Controller, the channel numbers 1 – 4 on
the Servo IC correspond to board channel numbers 5 – 8. The most important variables are:
I7mn0: Servo IC m Channel n Encoder Decode Control
Typically, I7mn0 is set to 3 or 7 for x4 quadrature decode, depending on which way is up. If the channel
is used for open-loop stepper drive, I7mn0 is set to 8 to accept internal pulse-and-direction.
Caution:
If I7mn0 and I7mn8 are not matched properly, motor runaway will occur.
I7mn6: Servo IC m Channel n Output Mode Select
I7mn6 determines whether the A and B outputs are DAC or PWM, and whether the C output is PFM
(pulse-and-direction) or PWM. Typically, it is set to 0, either for 3-phase PWM, or to 3 for DACs and
PFM.
Set the output mode for the Brick Motion Controller for Pulse Frequency Modulation output (PFM),
I7mn6 equal to 2.
I7mn8: Servo IC m Channel n PFM Direction Signal Invert Control
The polarity of the direction output is controlled by this I-variable. This output establishes an active low
or high output.
This I-variable works in conjunction with I7mn0. To operate correctly with the Brick Motion Controller,
if I7mn0 is set to 0, then I7mn8 is set to 0. If I7mn0 is set to 4, then I7mn8 is set to 1.
Caution:
If I7mn0 and I7mn8 are not matched properly, motor runaway will occur.
The Brick Motion Controller applies its gain formulas the same way it does for a classic servo system.
The basic difference with a stepper system is that most of the times, the typical encoder feedback
interface is handled using electronic circuitry rather than a physical encoder.
When the stepper output interface is selected, it allows the use of an electronic encoder feedback or a
physical encoder feedback. When used with an actual physical encoder, the axis should be tuned as if it
were a typical servomotor.
The process of tuning the simulated feedback loop is identical to tuning a servomotor with the exception
that some of the parameters become more predictable.
30
System Wiring
Brick Motion Controller Hardware Reference Manual
Ixx30: Motor xx Proportional Gain
To create a closed loop position response with a natural frequency of approximately 25 Hz and a damping
ratio of 1, use the following calculation:
660,000
Ixx30 =
Ixx08 * PFMCLK( MHz )
Example:
PFMCLK is set to default of 9.83 MHz, and Ixx08 is set to default of 96. Ixx30 = 660,000 / (96 * 9.83) =
700.
Ixx31 Motor x Derivative Gain
Derivative Gain is set to 0 because the motor system behaves like a velocity-loop servo drive. This
parameter sets the system damping which should be unnecessary.
Ixx32 Motor xx Velocity Feedforward Gain
Use the following equation to establish a value for Ixx32:
Ixx32 = 6660 * ServoFreq (kHz)
where ServoFreq (kHz) is the frequency of the servo interrupt as established by I7m00, I7m01, and
I7m02.
Example:
ServoFreq is set to default of 2.26 kHz (I7m00 = 6527, I7m01 = 0, I7m02 = 3). Ixx32 = 6660 * 2.26 =
15,050.
Note:
If Ixx30 were set differently from the above calculation, then Ixx32 would change
inversely. For instance, if Ixx30 were twice the above calculation, then Ixx32
would be half its calculation.
Ixx33 Motor xx Integral Gain
Typically, This I-variable should be set to 0. The digital electronic loop does not present offsets or
disturbances that need correction in the PMAC.
Ixx33 may be set to force zero steady-state errors, should they be present with electronic encoder
feedback.
Ixx34 Motor xx Integration Mode
The default value of 1 is sufficient for this, since usually Ixx33 is set to zero. When Ixx33 is set to 0, this
I-variable has no effect.
Ixx35 Motor xx Acceleration Feed-forward Gain
Start with this I-variable set to 0. Typically, this value does not need to be changed. However, Ixx35
might be adjusted to compensate for the small time delays created by the electronics when accelerating
the stepper. The effect of adjusting Ixx35 will be to reduce a slight following error during motor
acceleration.
Ixx36 - Ixx39 Motor xx Notch Filter Coefficients
These values should be set to their default value of 0. Since filter parameters adjust the way the gains
operate due to physical resonance of a system, there is no need to set these I-variables.
System Wiring
31
Brick Motion Controller Hardware Reference Manual
Example: User wants channels 5 to 8 to be used with stepper motors. First the user needs to wire the
Stepper drive, and so as to enable the Stepper output pin 8 needs to be shorted to pin 4 (+5V) for X5 to
X8. Assume for this example that all the stepper motors that will be used do not have encoders for
feedback.
For this example, the factory defaults for the other variables will allow the PFM outputs to be commanded
with a low true Amplifier Fault and ±Limits plugged in. If this is not the case, modify Ixx24.
For this type of system, make sure I7mn6 is set for PWM and PFM output mode.
I7116=2
I7126=2
I7136=2
I7146=2
;CH5A and CH5B outputs will be PWM and CH5C output will be PFM
;CH6A and CH6B outputs will be PWM and CH6C output will be PFM
;CH7A and CH7B outputs will be PWM and CH7C output will be PFM
;CH8A and CH8B outputs will be PWM and CH8C output will be PFM
I7110 = 8
I7120 = 8
I7130 = 8
I7140 = 8
;Simulated feedback for channel 5
;Simulated feedback for channel 6
;Simulated feedback for channel 7
;Simulated feedback for channel 8
I502=$078104
I602=$07810C
I702=$078114
I802=$07811C
;Command output to CH1A address (default address + 2) for
;Stepper
;Command output to CH2A address (default address + 2)
;for Stepper
;Command output to CH3C address (default address + 2)
;for Stepper
;Command output to CH4C address (default address +2)
;for Stepper
32
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Brick Motion Controller Hardware Reference Manual
Watchdog Timer
Brick Motion Controller has an on-board watchdog timer. This subsystem provides a fail-safe shutdown
to guard against software and hardware malfunction. To keep it from tripping the hardware circuit for the
watchdog timer requires that two basic conditions be met. First, it must see a DC voltage greater than
approximately 4.75V. If the supply voltage is below this value, the circuit’s relay will trip and the card
will shut down, Brick Motion Controller uses its own DC to DC converter to create 5V and +/-15V from
the user supplied 24VDC. This prevents corruption of registers due to insufficient voltage.
The second necessary condition is that the timer must see a square wave input (provided by the Turbo
PMAC software) of a frequency greater than approximately 25 Hz. In the foreground, the servo-interrupt
routine decrements a counter (as long as the counter is greater than zero), causing the least significant bit
of the timer to toggle. This bit is fed to the timer itself. At the end of each background cycle, the CPU
resets the counter value to a maximum value set by variable I40 (or to 4096 if I40 is set to the default of
0). If the card, for whatever reason, due either to hardware or software problems, cannot set and clear this
bit repeatedly at 25 Hz or greater, the timer will trip and the Turbo PMAC system will shut down.
Actions on Watchdog Timer Trip
When the timer trips due to either under-voltage or under-frequency, the system is latched into a reset
state, with a red LED indicating watchdog failure. The processor stops operating and will not
communicate. All Servo, MACRO, and I/O ICs are forced into their reset states, which force discrete
outputs off, and proportional outputs (DAC, PWM, PFM) to zero-level. In Turbo PMAC2 systems there
is a hard-contact relay with both normally open and normally closed contacts. In a system, these outputs
should be used to drop power to the amplifiers and other key circuitry if the card fails. Once the watchdog
timer has tripped, power to the Turbo PMAC must be cycled off and on, or the INIT/hardware reset line
must be taken low, then high, to restore normal functioning.
Diagnosing Cause of Watchdog Timer Trip
Because the watchdog timer is designed to trip on a variety of hardware and software failures, and the trip
makes it impossible to query the card, it can be difficult to determine the cause of the trip. The following
procedure is recommended to figure out the cause:
1. Reset the Turbo PMAC normally, just power cycle the cycle power. If it does not trip again
immediately, there is an intermittent software or hardware problem. Check for the following:
• Software events that overload the processor at times (e.g. additional servo-interrupt tasks, intensive
lookahead) or possible erroneous instruction (look for firmware or program checksum).
Review the Evaluating the Turbo PMAC’s Computational Load section of the Turbo USERS manual.
• 5V power-supply disturbances
• Loose connections
2. If there is an immediate watchdog timer trip in Step 1, power up with the re-initialization switch
pressed and hold in. If it does not trip now, there is a problem in the servo/phase task loading for the
frequency, or an immediate software problem on the board. Check for the following:
• Phase and servo clock frequencies vs. the number of motors used by Turbo PMAC. These
frequencies may need to be reduced.
• A PLC 0 or PLCC 0 program running immediately on power-up (I5 saved at 1 or 3) and taking too
much time.
• User-written servo or phase program not returning properly.
3. If there is an immediate watchdog timer trip in Step 2, check for hardware issues:
Troubleshooting
33
Brick Motion Controller Hardware Reference Manual
• Disconnect any accessories and cables other than the logic power and repeat to see if they are
causing the problem
• Check for adequate 24V power supply levels (check at the Brick Motion Controller connector side,
not at the supply)
• Inspect for hardware damage
4. If the watchdog insists after all the above, you should contact DeltaTau Inc. to get an RMA number,
and ship the drive for repairs.
34
Troubleshooting
Brick Motion Controller User Manual – Preliminary Documentation
APPENDIX A
DB- Connector Spacing Specifications
X1-8: DB-15 Connectors for encoder feedback
3.115±.05
1.541±.015
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
15
14
13
12
11
10
9
15
14
13
12
11
10
9
X9-12: DB-9 Connectors for Analog I/O
2.45±.05
1.213+.015
5
4
3
2
1
5
4
3
2
1
9
8
7
6
9
8
7
6
Screw Lock Size for all DB-connectors
.18
7
.235
DIA
.126
DIA
#4-40 FEMALE SCREWLOCK
QTY 2 per connector
Steel, Zinc Plated
LOCKWASHER
QTY 2 per connector
Clear Chromate
Appendix A
35
Brick Motion Controller Hardware Reference Manual
Type of Cable for Encoder Wiring
Low capacitance shielded twisted pair cable is ideal for wiring differential encoders. The better the shield
wires, the better the noise immunity to the external equipment wiring. Wiring practice for shielded cables
is not an exact science. Different applications will present different sources of noise, and experimentation
may be required to achieve the desired results. Therefore, the following recommendations are based upon
some experiences that we at Delta Tau Data Systems have acquired.
If possible, the best cabling to use is a double-shielded twisted pair cable. Typically, there are four pairs
used in a differential encoder’s wiring. The picture below shows how the wiring may be implemented for
a typical differential sinusoidal encoder using double shielded twisted pair cable.
SIN+
SIN-
SHIELD
COS+
COS-
SHIELD
INDEX+
INDEX-
SHIELD
ENC PWR
GND
SHIELD
OUTER
SHIELD
EXAMPLE OF DOUBLE SHIELDED
4 TWISTED PAIR CABLE
The shield wires should be tied to ground (Vcc return) at the interpolator end. It is acceptable to tie the
shield wires together if there are not enough terminals available. Keep the exposed wire lengths as close
as possible to the terminals on the interpolator.
Note:
It has been observed that there is an inconsistency in the shielding styles that are
used by different encoder manufacturers.
Be sure to check pre-wired encoders to ensure that the shield wires are not
connected at the encoder’s side. Shield wires should be connected only on one
side of the cable.
If the encoder has shield wires that are connected to the case ground of the
encoder, ensure that the encoder and motor cases are sufficiently grounded. Do
not connect the shield at the interpolator end.
If the encoder has pre-wired double shielded cable that has only the outer shield
connected at the encoder, then connect only the inner shield wires to the
interpolator. Be sure not to mix the shield interconnections.
One possible cable type for encoders is Belden 8164 or ALPHA 6318. This is a 4-pair individually
shielded cable that has an overall shield. This double-shielded cable has a relatively low capacitance and
is a 100Ω impedance cable.
Cables for single-ended encoders should be shielded for the best noise immunity. Single-ended encoder
types cannot take advantage of the differential noise immunity that comes with twisted pair cables.
36
Appendix A
Brick Motion Controller User Manual – Preliminary Documentation
Note:
If noise is a problem in the application, careful attention must be given to the
method of grounding that is used in the system. Amplifier and motor grounding
can play a significant role in how noise is generated in a machine.
Noise may be reduced in a motor-based system by the use of inductors placed
between the motor and the amplifier.
Appendix A
37
Brick Motion Controller Hardware Reference Manual
APPENDIX B
Schematics
X15: Watchdog
(JWDO)
TB2
DGND_PLANE
COM
1
2
3
U29
N.C.
K5
1
2
3
N.O.
WDO
WDO
NC7SZ08M5
(SOT23-5)
4
BWDO
4
9
5
TERMBLK 3
(.150 PITCH)
D18
MMBD301LT1
(SOT23)
10
8
1
12
DGND_PLANE
FBR12ND05
GND
J6 and J7: General Purpose I/O
Inputs
Opto Gnd Plane
U70
1
RP152
RP153
GPIN01
GPIN02
GPIN03
GPIN04
1
3
5
7
2
4
6
8
1
3
5
7
2
4
6
8
16
15
14
13
12
11
10
9
ACI1A
C1
E1
C2
E2
C3
E3
C4
E4
2
3
4
5
6
7
8
ACI1B
ACI2A
ACI2B
ACI3A
ACI3B
ACI4A
ACI4B
1.2KSIP8I
1.2KSIP8I
1
D34
2
1
D32
2
MMBZ5V6ALT1 MMBZ5V6ALT1 MMBZ5V6ALT1 MMBZ5V6ALT1
D51 D52 D53 D54
3
3
MMBZ33VALT1
1
MMBZ33VALT1
1
PS2705-4
RP154
2.2KSIP8I
3
D33
2
3
D31
2
C230
.1uf
C233
.1uf
MMBZ33VALT1
MMBZ33VALT1
U72
RP158
RP159
2
GPIN05
GPIN06
GPIN07
GPIN08
1
3
5
7
2
4
6
8
1
3
5
7
1
2
3
4
5
6
7
8
16
15
14
13
12
11
10
9
ACI1A
ACI1B
ACI2A
ACI2B
ACI3A
ACI3B
ACI4A
ACI4B
C1
E1
C2
E2
C3
E3
C4
E4
4
6
8
1.2KSIP8I
1.2KSIP8I
3
1
D38
2
1
D36
2
MMBZ5V6ALT1 MMBZ5V6ALT1 MMBZ5V6ALT1 MMBZ5V6ALT1
D55 D56 D57 D58
3
MMBZ33VALT1
1
MMBZ33VALT1
1
PS2705-4
RP160
2.2KSIP8I
3
D37
2
3
D35
2
C240
.1uf
C243
.1uf
IN_COM_01--08
MMBZ33VALT1
MMBZ33VALT1
Input Section
38
Appendix C
Brick Motion Controller User Manual – Preliminary Documentation
Outputs
COM_COL
D71
MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3
GPO1+
D72
D73
D74
D75
D76
D77
D78
Opto Gnd Plane
F1
RUE090
Raychem
30R090
1
Q5
NZT560A
(SOT-223)
Littelfuse
R80 2.2K
GPO1--
GPO2+
F2
U78
1
2
16
15
RUE090
Raychem
30R090
ANO1
C1
E1
1
Q6
NZT560A
(SOT-223)
CAT1
3
4
14
13
Littelfuse
ANO2
CAT2
C2
E2
R81 2.2K
GPO2--
GPO3+
F3
5
6
12
11
ANO3
CAT3
C3
E3
RUE090
Raychem
30R090
7
8
10
9
1
Q7
NZT560A
(SOT-223)
ANO4
CAT4
C4
E4
Littelfuse
R82 2.2K
GPO3--
GPO4+
PS2701-4
F4
RUE090
Raychem
30R090
1
Q8
NZT560A
(SOT-223)
Littelfuse
R83 2.2K
GPO4--
GPO5+
F5
RUE090
Raychem
30R090
1
Q9
NZT560A
(SOT-223)
Littelfuse
R84 2.2K
GPO5--
GPO6+
F6
U79
1
2
16
15
RUE090
Raychem
30R090
ANO1
CAT1
C1
E1
1
Q10
NZT560A
(SOT-223)
3
4
14
13
Littelfuse
ANO2
CAT2
C2
E2
R85 2.2K
GPO6--
GPO7+
F7
5
6
12
11
ANO3
CAT3
C3
E3
RUE090
Raychem
30R090
7
8
10
9
1
Q11
NZT560A
(SOT-223)
ANO4
CAT4
C4
E4
Littelfuse
R86 2.2K
GPO7--
GPO8+
PS2701-4
F8
RUE090
Raychem
30R090
1
Q12
NZT560A
(SOT-223)
Littelfuse
R87 2.2K
GPO8--
Opto Gnd Plane
D81
D82
D83
D84
D85
D86
D87
D88
MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3
COM_EMT
Appendix C
39
Brick Motion Controller Hardware Reference Manual
J4: Limit Inputs for Axis 1-4
U39
RP37
16
15
1
2
1
3
5
7
2
4
6
8
USER1
PLIM1
MLIM1
HOME1
FL_RT1
C1
E1
AC1
AC1
14
13
3
4
C2
E2
AC2
AC2
4.7KSIP8I
RP38
12
11
5
6
2
1
3
5
7
C3
E3
AC3
AC3
4
6
8
10
9
7
8
C4
E4
AC4
AC4
4.7KSIP8I
RP39
1
3
5
7
2
4
6
8
PS2705-4
x1KSIP8I
(IN SOCKET)
C160
.1
C162
.1
RP40
1
3
5
7
2
4
6
8
C161
.1
C163
.1
1KSIP8I
U40
RP41
16
15
1
2
1
3
5
7
2
4
6
8
USER2
PLIM2
MLIM2
HOME2
C1
E1
AC1
AC1
LIMITS 1,2,3,4
14
13
3
4
C2
E2
AC2
AC2
J10
FL_RT2
4.7KSIP8I
USER1
PLIM1
MLIM1
HOME1
FL_RT1
BEQU1
USER2
PLIM2
MLIM2
HOME2
FL_RT2
BEQU2
USER3
PLIM3
MLIM3
HOME3
FL_RT3
BEQU3
USER4
PLIM4
MLIM4
HOME4
FL_RT4
BEQU4
GND
USER1
PLIM1
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
RP42
12
11
5
6
2
1
3
5
7
C3
E3
AC3
AC3
4
6
8
MLIM1
HOME1
FL_RT1
BEQU1
USER2
PLIM2
MLIM2
HOME2
FL_RT2
BEQU2
USER3
PLIM3
MLIM3
HOME3
FL_RT3
BEQU3
USER4
PLIM4
MLIM4
HOME4
FL_RT4
BEQU4
10
9
7
8
C4
E4
AC4
AC4
4.7KSIP8I
RP43
1
3
5
7
2
4
6
8
PS2705-4
x1KSIP8I
(IN SOCKET)
C164
C166
.1
C165
.1
RP44
1
3
5
7
2
4
6
8
.1
21
9
C167
.1
22
10
23
11
24
12
25
13
1KSIP8I
U41
RP45
1
3
5
7
16
15
1
2
2
4
6
8
USER3
PLIM3
MLIM3
HOME3
FL_RT3
GND
C1
E1
AC1
AC1
DB25S
14
13
3
4
C2
E2
AC2
AC2
4.7KSIP8I
RP46
12
11
5
6
2
1
3
5
7
C3
E3
AC3
AC3
4
6
8
10
9
7
8
C4
E4
AC4
AC4
4.7KSIP8I
RP47
1
3
5
7
2
4
6
8
PS2705-4
x1KSIP8I
(IN SOCKET)
C168
C170
.1
C169
.1
RP48
1
3
5
7
2
4
6
8
.1
C171
.1
1KSIP8I
U42
RP49
16
15
1
2
1
3
5
7
2
4
6
8
USER4
PLIM4
MLIM4
HOME4
FL_RT4
C1
E1
AC1
AC1
14
13
3
4
C2
E2
AC2
AC2
4.7KSIP8I
RP50
12
11
5
6
2
1
3
5
7
C3
E3
AC3
AC3
4
6
8
10
9
7
8
C4
E4
AC4
AC4
4.7KSIP8I
RP51
1
3
5
7
2
4
6
8
PS2705-4
x1KSIP8I
(IN SOCKET)
C172
C174
.1
C173
.1
RP52
1
3
5
7
2
4
6
8
.1
C175
.1
1KSIP8I
40
Appendix C
Brick Motion Controller User Manual – Preliminary Documentation
J5: Limit Inputs for Axis 5-8
U59
RP87
16
15
1
2
1
3
5
7
2
4
6
8
USER5
PLIM5
MLIM5
HOME5
FL_RT5
C1
E1
AC1
AC1
14
13
3
4
C2
E2
AC2
AC2
4.7KSIP8I
RP88
12
11
5
6
2
1
3
5
7
C3
E3
AC3
AC3
4
6
8
10
9
7
8
C4
E4
AC4
AC4
4.7KSIP8I
RP89
1
3
5
7
2
4
6
8
PS2705-4
x1KSIP8I
(IN SOCKET)
C200
.1
C202
.1
RP90
1
3
5
7
2
4
6
8
C201
.1
C203
.1
1KSIP8I
U60
RP91
16
15
1
2
1
3
5
7
2
4
6
8
USER6
PLIM6
MLIM6
HOME6
FL_RT6
C1
E1
AC1
AC1
LIMITS 5,6,7,8
14
13
3
4
C2
E2
AC2
AC2
J20
4.7KSIP8I
USER5
PLIM5
MLIM5
HOME5
FL_RT5
BEQU5
USER6
PLIM6
MLIM6
HOME6
FL_RT6
BEQU6
USER7
PLIM7
MLIM7
HOME7
FL_RT7
BEQU7
USER8
PLIM8
MLIM8
HOME8
FL_RT8
BEQU8
GND
USER5
PLIM5
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
RP92
12
11
5
6
2
1
3
5
7
C3
E3
AC3
AC3
4
6
8
MLIM5
HOME5
FL_RT5
BEQU5
USER6
PLIM6
MLIM6
HOME6
FL_RT6
BEQU6
USER7
PLIM7
MLIM7
HOME7
FL_RT7
BEQU7
USER8
PLIM8
MLIM8
HOME8
FL_RT8
BEQU8
10
9
7
8
C4
E4
AC4
AC4
4.7KSIP8I
RP93
1
3
5
7
2
4
6
8
PS2705-4
x1KSIP8I
(IN SOCKET)
C204
C206
.1
C205
.1
RP94
1
3
5
7
2
4
6
8
.1
21
9
C207
.1
22
10
23
11
24
12
25
13
1KSIP8I
U61
RP95
1
3
5
7
16
15
1
2
2
4
6
8
USER7
PLIM7
MLIM7
HOME7
FL_RT7
GND
C1
E1
AC1
AC1
DB25S
14
13
3
4
C2
E2
AC2
AC2
4.7KSIP8I
RP96
12
11
5
6
2
1
3
5
7
C3
E3
AC3
AC3
4
6
8
10
9
7
8
C4
E4
AC4
AC4
4.7KSIP8I
RP97
1
3
5
7
2
4
6
8
PS2705-4
x1KSIP8I
(IN SOCKET)
C208
C210
.1
C209
.1
RP98
1
3
5
7
2
4
6
8
.1
C211
.1
1KSIP8I
U62
RP99
16
15
1
2
1
3
5
7
2
4
6
8
USER8
PLIM8
MLIM8
HOME8
FL_RT8
C1
E1
AC1
AC1
14
13
3
4
C2
E2
AC2
AC2
4.7KSIP8I
RP100
12
11
5
6
2
1
3
5
7
C3
E3
AC3
AC3
4
6
8
10
9
7
8
C4
E4
AC4
AC4
4.7KSIP8I
RP101
1
3
5
7
2
4
6
8
PS2705-4
x1KSIP8I
(IN SOCKET)
C212
C214
.1
C213
.1
RP102
1
3
5
7
2
4
6
8
.1
C215
.1
1KSIP8I
Appendix C
41
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