^1 HARDWARE REFERENCE MANUAL ^2 Turbo PMAC2 Realtime Express Controller ^3 Programmable Multi-Axis Controller ^4 9xx-603862-1xx ^5 October 14, 2013 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.
Copyright Information © 2013 Delta Tau Data Systems, Inc. All rights reserved. This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses are unauthorized without written permission of Delta Tau Data Systems, Inc. Information contained in this manual may be updated from time-to-time due to product improvements, etc., and may not conform in every respect to former issues. To report errors or inconsistencies, call or email: Delta Tau Data Systems, Inc.
REVISION HISTORY REV. DESCRIPTION DATE CHG APPVD 04/03/07 CP S. SATTARI 1 NEW MANUAL CREATION 2 CLEARED FOR RELEASE 12/07/07 CP S.SATTARI 3 REVISED GENERAL PURPOSE IO CONNECTOR ADDED MULTIPLEXED IO PORT INFO ADDED PANASONIC PROGRAM SETUP INFO ADDED PARAMETER PASSING INFO ON REALTIME EXPRESS NETWORK 01/29/09 CP S.SATTARI 4 CORRECTION IN J5 PIN-OUT TABLE UPDATED WIRING FOR HANDWHEEL PORT IMAGE 5 ADDED SUPPORT FOR A5N NETWORK DRIVES 02/15/10 10/14/13 CP SS S.SATTARI S.
Turbo PMAC2 Realtime Express Controller Table of Contents INTRODUCTION .................................................................................................................................. 1 Overview .............................................................................................................................................. 1 Compatibility ........................................................................................................................................
Turbo PMAC2 Realtime Express Controller INTRODUCTION Overview The Turbo PMAC2 Realtime Express Controller is a member of the Turbo PMAC family of boards optimized for interface to the system through Panasonic’s Realtime Express Network. It can command up to 32 axes through Realtime Express Network. This controller is also capable of communicating and control of MACRO drives and IO modules if ordered with the MACRO option.
Turbo PMAC2 Realtime Express Controller Configuration Base Version The base version of the Turbo PMAC2 Realtime Express Controller provides: 80 MHz DSP56303 CPU 128k x 24 SRAM compiled/assembled program memory 128k x 24 SRAM user data memory 1M x 8 flash memory for user backup & firmware 32k x 16 bank of dual-ported RAM Latest released firmware version RS-232 serial interface, USB 2.
Turbo PMAC2 Realtime Express Controller Option 5: CPU and Memory Configurations Different versions of Option 5 provide different CPU speeds and main memory sizes. Only one Option 5xx may be selected for the board. The CPU is a DSP563xx IC as component U1. The CPU is available in two speed options: 80MHz CPU is a DSP56303 (Option 5C0), 240 MHz CPU is a DSP56321 (Option 5F3). The Maximum frequency of operation is indicated with a sticker on the CPU in U1.
Turbo PMAC2 Realtime Express Controller Part Number Definition Based on the different options of Turbo PMAC 2 Realtime Express Controller, there will be a single line part number which is used for ordering and identification. The part number is assigned based on the following chart: A B C D E F G H J K L Turbo PMAC2 Realtime Express 9 A B C0 - Opt. 5C0 80MHz DSP563xx CPU 256Kx24 SRAM 1Mx8 flash* (Standard) C3 - Opt. 5C3 80MHz DSP563xx CPU 1024Kx24 SRAM 4Mx8 flash* F3 - Opt.
Turbo PMAC2 Realtime Express Controller HARDWARE SETUP Receiving and Unpacking Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the Turbo PMAC2 Realtime Express Controller is received, do the following immediately. 1. Inspect the condition of the shipping container and report any damage immediately to the commercial carrier that delivered the controller. 2. Remove the controller from the shipping container and remove all packing materials.
Turbo PMAC2 Realtime Express Controller The controller is mounted to the back panel with four M4 screws and internal-tooth lock washers. It is important that the teeth break through any anodization on the controller’s mounting gears to provide a good electrically conductive path in as many places as possible. Mount the controller on the back panel so there is airflow at both the top and bottom areas of the controller (at least three inches).
Turbo PMAC2 Realtime Express Controller System Wiring 8 Inputs / 8 Outputs TTL Level (typically used to create multiplexed I/O with accessory boards) 8 Sinking/Sourcing Digital Inputs 4 Sourcing/Sinking Digital Outputs Watchdog relay contacts 1 Sinking/Sourcing Input 25 23 21 19 17 15 13 11 9 7 5 3 1 26 24 22 20 18 16 14 12 10 8 6 4 2 13 12 25 J10 JTHW 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 Handwheel DAC output ADC Input Pulse and Direction 1 14 8 7
Turbo PMAC2 Realtime Express Controller Push-button Switches There are two push-button switches located at the bottom of the unit next to the 24V power supply input. These buttons are accessible for reinitializing the board back to factory default settings and loading new firmware revisions. FW LOAD switch The FW LOAD switch is used to download new firmware to the controller. In order to use this switch, you need to hold the switch pressed while powering up the system.
Turbo PMAC2 Realtime Express Controller Pin # 1 2 3 4 5 6 Symbol VCC DD+ GND SHELL SHELL Function N.C. DATADATA+ Ground Shield Shield Ethernet / Modbus Connection, J2 This connector is used for Ethernet communications from the Turbo PMAC2 Eth Ultralite to a PC or into an Ethernet network. The default IP address for all Delta Tau products with Ethernet communication capability is 192.6.94.5 which can be changed later with the proper software provided by Delta Tau.
Turbo PMAC2 Realtime Express Controller Fieldbus Setup Connector, J3 This connector is a 10-pin female flat cable connector that is directly connected to the Fieldbus communication device installed in the system based on order options. Use SyCon program to set up the communication module. SyCon is a universal Fieldbus configuration tool developed by Hilscher Corporation used to configure the PMAC Gateway. Delta Tau has licensed SyConas part of the PMAC Gateway product.
Turbo PMAC2 Realtime Express Controller Hardware Setup 11
Turbo PMAC2 Realtime Express Controller CANopen Pin # 1 2 3 4 5 6 7 8 9 J4 DB9 Female Symbol N.C. CAN_L CAN_GND N.C. N.C. N.C. CAN_H N.C. N.C 5 4 9 3 8 2 7 1 6 Function CAN_L Bus line ISO 11898 CAN Ground CAN_H Bus line ISO 11898 DeviceNet J4 DB9 Female Pin # Symbol 1 V+ 2 CAN_H 3 V4 N.C. 5 SHELL 6 CAN_H 7 N.C. 8 N.C.
Turbo PMAC2 Realtime Express Controller General Purpose I/O Connection, J5 The 25 pin D-Sub connector located on top of the controller provides 8 optically isolated inputs, 4 optically isolated outputs, and a controller watchdog output with both normally closed and normally open contacts. The connector also has an extra input which can be used as either sinking or sourcing input regardless of the other inputs setup.
Turbo PMAC2 Realtime Express Controller Inputs wiring There are 8 inputs on the I/O connector, which can be used as sinking or sourcing inputs.
Turbo PMAC2 Realtime Express Controller To write to the outputs you need to define these M variables: M52->Y:$078402,2 M53->Y:$078402,3 M54->Y:$078402,4 M55->Y:$078402,5 ; ; ; ; M60->X:$078402,0,8 M61->Y:$078406,0,8 M62->X:$078406,0,8 ; Direction control for DAT0 to DAT7 ; Data type control DAT0 to DAT7 ; Data inversion control M60=$FF M61=$FF M62=$0 DAT2 DAT3 DAT4 DAT5 Line; Line; Line; Line; J2 J2 J2 J2 Pin Pin Pin Pin 6 7 8 9 or or or or 19 20 21 22 ;Setting the Direction control to 1, meani
Turbo PMAC2 Realtime Express Controller Auxiliary Connector, J8 The 15-pin DB style female connector contains connections for handwheel quadrature input, two ADC inputs, one DAC output and one pulse and direction output. Please check the software setup and connector pin out sections for more information on how to use each of these features.
Turbo PMAC2 Realtime Express Controller You can access the position of the handwheel. You can also use the same address ($3501) as a master address for any of the motors (Ixx05) Analog-to-Digital Connections (Option 12 required) There are two analog-to-digital circuits on J8 which can have 12-bit or 16-bit resolution based on the requested options. The signal can be either differential or single-ended.
Turbo PMAC2 Realtime Express Controller To write into the DAC output: I6816=0 M1005->Y:$78414,8,16,S ;set the channel output type to PWM output By changing the value of M1005 in a range of ±I6800, you can have ±10VDC output on your DAC output. Note: Please note that the DAC output is a filtered PWM signal and is limited by the max phase settings which cannot be changed because of Realtime Express network requirements.
Turbo PMAC2 Realtime Express Controller 24 VDC Power Supply Input, J9 An external 24VDC power supply is required to power the Turbo PMAC2 Eth Ultralite. The 24V is wired into connector J9. The polarity of this connection is extremely important. Carefully follow the instructions in the wiring diagram. This connection can be made using 16 AWG wire directly from a protected power supply.
Turbo PMAC2 Realtime Express Controller • Option C provides the MACRO-ring RJ-45 electrical interface connectors. The key components on the board are CN3 and CN4. MACRO RJ45 Connector CN3 and CN4 Front View Pin # 1 Symbol DATA+ 2 DATA- 3 4 5 6 7 8 Unused Unused Unused Unused Unused Unused Hardware Setup OUT Function Differential MACRO Signal. CN4: DATA+ input. CN3: DATA+ output. Differential MACRO Signal. CN4: DATA- input. CN3: DATA- output. Unused terminated pin. See schematic below.
Turbo PMAC2 Realtime Express Controller Realtime Express Connector These connectors are used to establish the Realtime Express Ring between the controller and Panasonic’s A4N/A5N drives.
Turbo PMAC2 Realtime Express Controller Thumbwheel Multiplexer Port (JTHW Port), J10 The Thumbwheel Multiplexer Port, or Multiplexer Port, on the JTHW connector has eight input lines and eight output lines. The output lines can be used to multiplex large numbers of inputs and outputs on the port, and Delta Tau provides accessory boards and software structures (special Mvariable definitions) to capitalize on this feature.
Turbo PMAC2 Realtime Express Controller How to use THW Port with Acc-34: 1. 2. 3. 4. Set i29=$78400 save $$$ Follow the setup for Acc-34 How to use THW Port as general purpose IO (8 Input and 8 Output): 1. WX:$78400, $FF00 ;IO Direction Control 2. WY:$78404, $FFFF ;IO Data Type Control 3.
Turbo PMAC2 Realtime Express Controller SOFTWARE SETUP Host Communications To communicate with Turbo PMAC2 Realtime Express Controller from your host computer, you can use any of the provided communication ports. The choice only affects the speed at which you will be talking to the controller. You can communicate with the controller over the Serial communication or Ethernet ports without any special software.
Turbo PMAC2 Realtime Express Controller A window will appear, stating it cannot verify the compatibility of the driver with Windows XP. Click on Continue Anyway button and the driver will be installed on your computer. You should then be able to see the device in the Windows Device Manager. Once you have established the connection between the controller and the computer, start your software by clicking on Pewin32PRO2 icon either from your desktop or from the Start menu.
Turbo PMAC2 Realtime Express Controller Click Insert. Select the communication port from the list. All the available Serial ports (COM1, COM2, …) and Delta Tau USB products are present on this list. When trying to communicate through an Ethernet port and the IP address for the PMAC is not in the list, click New: Select the Ethernet (Eth) option and click OK. Enter the IP address of the controller. The Default IP address for all Delta Tau Products is 192.6.94.5 .
Turbo PMAC2 Realtime Express Controller To check the communications, click Test. If communication is established, you will see the following confirmation window: In case of Ethernet Communication, the Pcommserver will report the result of PING command to the network driver chip on the controller before trying to communicate to the controller CPU. Once the communication is established, you can use any of the windows and tools provided by the Pewin32PRO2 software and accompanied tools.
Turbo PMAC2 Realtime Express Controller Realtime Express Network Setup – Step by Step Although the software package needed for Realtime Express setup includes several files, you only need to modify one file in order to set up the controller. The file to modify based upon the settings of your network is called “PANADLWD.PMC” First, establish communication with the controller through the PEWIN32PRO2 software. From the File menu, then select Open File and open “PANADLWD.PMC”.
Turbo PMAC2 Realtime Express Controller Update Period (ms) Com. Period (ms) Servo Freq. (kHz) Phase Freq. (kHz) MAXPHASE MAXPHASE_TO_PHASE_DIV PHASE_TO_SERVO_DIV CLK_DIV_SAVE_M 1.000 1.000 0.500 0.167 0.167 1.000 0.500 0.500 0.167 0.083 1.000 1.000 2.000 6.000 6.000 1.000 2.000 2.000 6.000 12.
Turbo PMAC2 Realtime Express Controller I124,PanasonicMtrs,100=$800000 5. Absolute Position Capture: (Starting at line 102) By default, these variables read the absolute position of the motor from the A4N/A5N drives. If you don’t have an absolute encoder, it’s still acceptable to keep these values since they will return a zero on power up. The user has to comment out the I-variables for motors which are not on the Realtime Express network. In this example, only the first four motors are being used.
Turbo PMAC2 Realtime Express Controller I603=$326 I604=$326 Note that you have to place the /* sign one line after the last motor number used for the Panasonic network. 8. Panasonic TX Block and MacID Number of motor xx: (Starting at line 267) Ixx30 and Ixx31 must match the order block number and MacID of the ring even though the node might be an I/O node. Slave I/O nodes should be put in the Ixx30 and Ixx31 variables after the Servo nodes. There can be no GAPS in the Ixx30/31 variables.
Turbo PMAC2 Realtime Express Controller 10. Fatal Following Error Limit: (Starting at line 378) Although the PMAC can monitor and take action based upon the following error of each motor, Panasonic suggests that the drive will determine the fatal following error and this feature is not to be used in PMAC, hence the value is set to zero. However, if the user decides to use the PMAC’s following error monitor, this I-variable can be used. I111,PanasonicMtrs,100=0 11.
Turbo PMAC2 Realtime Express Controller Reset the controller by issuing a $$$*** command in the terminal window. 17. Download the configuration file. 18. Save the configuration to the PMAC: Save the configuration to the PMAC by issuing a “SAVE” command in the terminal window of PEWIN32PRO2. SAVE 19. Reset the controller: Reset the controller by issuing a “$$$” command in the terminal window. $$$ 20.
Turbo PMAC2 Realtime Express Controller RESERVED M & P VARIABLE FOR PANASONIC IMPLEMENTATION M8100 - M8191 P8191 Since these variables have been used in user-written servo, phase and PLCC1, writing into these variables or changing their definition can cause unexpected behavior in the system. UNAVAILABLE PMAC COMMANDS FOR PANASONIC IMPLEMENTATION Certain PMAC commands are not available on the Realtime Express Controller.
Turbo PMAC2 Realtime Express Controller I100 Motor 1 Activation Control should always be equal to 1. Meaning at least 1 drive/motor should be connected to the controller. This setting is done in the PANADWLD.PMC file. Ixx01 Motor xx Commutation Enable This should be 0 for all the motors except motor #1 for which the default value is 1 and should not be changed.
Turbo PMAC2 Realtime Express Controller I Variable Value I Variable Value I Variable Value I Variable Value I110 I210 I310 I410 I510 I610 I710 I810 $1D05 $1D0D $1D15 $1D1D $1D25 $1D2D $1D35 $1D3D I910 I1010 I1110 I1210 I1310 I1410 I1510 I1610 $1D45 $1D4D $1D55 $1D5D $1D65 $1D6D $1D75 $1D7D I1710 I1810 I1910 I2010 I2110 I2210 I2310 I2410 $1D85 $1D8D $1D95 $1D9D $1DA5 $1DAD $1DB5 $1DBD I2510 I2610 I2710 I2810 I2910 I3010 I3110 I3210 $1DC5 $1DCD $1DD5 $1DDD $1DE5 $1DED $1DF5 $1DFD Motor Safety
Turbo PMAC2 Realtime Express Controller Motor Motion I-Variables Ixx24 Motor xx Flag Mode Control (Is a PMAC 1 Type) Since the amp-fault is a low true on the Panasonic drives, you need to have bit 23 set to 1.
Turbo PMAC2 Realtime Express Controller Ixx32 Motor xx PID Velocity Feed forward Gain (USED FOR A DIFFERENT PURPOSE WITH PANASONIC) Fatal Following Error Limit Default Value When setting the Ixx11, make sure that you store the same value in Ixx32 as the default value of your following error.
Turbo PMAC2 Realtime Express Controller Supplemental Motor Setup I-Variables I6800/I6850/I6900/I6950 MACRO IC MaxPhase/PWM Frequency Control (USED WITH SPECIFIC VALUE FOR PANASONIC) I6800= 7371 I6801/I6851/I6901/I6951 MACRO IC Phase Clock Frequency Control230 (USED WITH SPECIFIC VALUE FOR PANASONIC) I6801 = 3 I6802/I6852/I6902/I6952 MACRO IC Servo Clock Frequency Control230 (USED WITH SPECIFIC VALUE FOR PANASONIC) I6802 = 1 UNUSABLE PMAC I-VARIABLES FOR PANASONIC IMPLEMENTATION Ixx02 Motor xx Command Outp
Turbo PMAC2 Realtime Express Controller Ixx42 Motor xx Amplifier Flag Address (NOT USED FOR PANASONIC) Ixx43 Motor xx Overtravel-Limit Flag Address (NOT USED FOR PANASONIC) Ixx55 Motor xx Commutation Table Address Offset (NOT USED FOR PANASONIC) Ixx56 Motor xx Commutation Delay Compensation (NOT USED FOR PANASONIC) Ixx57 Motor xx Continuous Current Limit (NOT USED FOR PANASONIC) Ixx58 Motor xx Integrated Current Limit (NOT USED FOR PANASONIC) Ixx60 Motor xx Servo Cycle Period Extension Period (NOT USED FOR
Turbo PMAC2 Realtime Express Controller Motor Commutation Setup I-Variables Ixx70 Motor xx Number of Commutation Cycles (N) (NOT USED FOR PANASONIC) Ixx71 Motor xx Counts per N Commutation Cycles (NOT USED FOR PANASONIC) Ixx72 Motor xx Commutation Phase Angle (NOT USED FOR PANASONIC) Ixx73 Motor xx Phase Finding Output Value (NOT USED FOR PANASONIC) Ixx74 Motor xx Phase Finding Time (NOT USED FOR PANASONIC) Ixx75 Motor xx Phase Position Offset (NOT USED FOR PANASONIC) Ixx76 Motor xx Current-Loop Back-Path
Turbo PMAC2 Realtime Express Controller Further Motor I-Variables Ixx91 Motor xx Power-On Phase Position Format (NOT USED FOR PANASONIC) Ixx97 Motor xx Position Capture & Trigger Mode....197 (NOT USED FOR PANASONIC) I3300 to I4899 should not be used. Conversion Table I-Variables I8000 - I8191 Conversion Table Setup Lines Encoder conversion table is not being used by default settings. If the user needs to use it for any purpose, it is usable and will not cause any conflicts.
Turbo PMAC2 Realtime Express Controller Before Deactivating the Backlash Feature: 1. Make sure motor present backlash is zero. If not, set it to zero by changing the motor backlash size (Ixx86) to zero. 2. Wait until motor present backlash becomes zero. 3. Set motor backlash take-up rate (Ixx85) and motor backlash hysteresis (Ixx87) equal to zero. 4. Check the direction of the backlash by looking at bit 4 of the motor status word. If it is equal to 1, write a zero to it.
Turbo PMAC2 Realtime Express Controller 4. If reading or writing to a parameter, set PARAM_NUM (M8182) equal to the parameter number based on following table. If saving the values to EEPROM of the drive, set PARAM_NUM equal to zero. No.
Turbo PMAC2 Realtime Express Controller 5. If writing to a parameter, set PARAM_DATA (M8183) equal to the desired value, but if you are reading from drive or saving the values to EEPROM of the drive set PARAM_NUM equal to zero. M8183=$0 6. Set the PMC_STATE (M8123) equal to 6 (Parameter Read Mode). M8123=6 7. Wait until PMC_STATE (M8123) changes to 4 (Running Mode). 8. If you are reading a parameter, you can get the value from PARAM_DATA (M8183). Otherwise, the writing or saving is done.
Turbo PMAC2 Realtime Express Controller The first four bytes of data for each RX block includes various status bits: Address Y:$680XX Bits 0~4 Name Actual MAC-ID 5~6 Update Counter 7 C/R Y:$680XX 8~14 X:$680XX 15 0 Command Code Echo CMD Error In Position 2 Homing Complete 3 4 5 6 Torque Limited Warning Alarm Servo Ready 7 8,9,10 Servo Active Home, CCWL/CWL, CWL/CCWL 11 12 13 14 15 EX-IN1 EX-IN2 EX-IN3 EX-IN4/EX-SON EMG-STP X:$680XX Software Setup Description Returns the node address o
Turbo PMAC2 Realtime Express Controller Using Absolute Feedback With A4N/A5N Drives If you have Panasonic motors with absolute feedback, you need to set up the drive in order to use this feature. Here are the steps that you need to follow: As an example, we will assume motor 1 has the absolute encoder. By default, the drives are set to incremental mode. So we need to change the mode to absolute encoders by changing the drive’s parameter $0B to a value of $0.
Turbo PMAC2 Realtime Express Controller The following error codes are possible in each of the elements above Error Code 0 1 2 4 8 9 A B C Error Description No Error ERR_TIMEOUT ERR_NODE_SUM ERR_NODE_BLK ERR_MACID ERR_FLAG2 ERR_I59 ERR_CRC_PER ERR_E_STOP To clear the fault from the drive/network, M8123=5 command can be used.
