ADLINK PCI-8132 Motion Control Card Installation, Programming, and Debugging Guide

ADLINK PCI-8132 Two Axis Motion Control Card Installation, Programming, and Debugging Guide

In the upgrading and transformation of automation equipment, the motion control card serves as the core execution unit, and its selection, wiring, and programming directly determine the system performance. The PCI-8132 launched by ADLINK is a two axis servo/stepper motion control card based on a 32-bit PCI bus. It uses a dedicated ASIC (PCL5023) to achieve complex motion control such as trapezoidal/S-shaped acceleration and deceleration, two axis linear/arc interpolation, zeroing, and handwheel following. The maximum output frequency is 2.4Mpps, and it supports incremental encoder feedback, 16 isolated digital I/O, and hardware position comparison trigger output. Although this model has gradually been discontinued, it is still widely deployed in a large number of in use devices. Mastering its installation, signal definition, motion mode programming, and interrupt/comparison function applications is of great practical significance for maintenance engineers and system integrators. This article is based on the official user manual, providing a set of system operation instructions from hardware installation, I/O connection, motion mode, function library calling to typical servo wiring.

Product Overview and Open Box Inspection

PCI-8132 is a half size PCI card suitable for industrial PCs. Its main features include:

2-axis stepper/directional pulse output, maximum 2.4Mpps, supports OUT/DIR or CW/CCW modes.

28 bit encoder feedback counter per axis (range 0~268435455 or ± 134217728).

Mechanical sensor interfaces such as origin (ORG), positive and negative limit (PEL/MEL), deceleration point (PSD/MSD), etc.

Servo drive interface: Alarm (ALM), In Place (INP), Deviation Counter Reset (ERC), Servo Enable (SVON), Drive Ready (RDY).

16 channels of optoelectronic isolated digital output (current injection), 16 channels of isolated digital input (5-24V).

Handwheel pulse input (PA/PB, supports 1 ×/2 ×/4 × AB phase or CW/CCW).

The synchronous start/stop signal (STA/STP) supports simultaneous start and stop of multiple cards and axes.

On board hardware position comparator, capable of generating trigger pulses (CMP1/CMP2) for visual aerial photography or shearing.

Provide Motion Creator Windows debugging tool, as well as C/C++/VB function library under DOS/Windows 95/98/NT/2000/XP, supporting up to 12 cards (24 axes).

The unboxing includes a PCI-8132 card, user manual, ADLINK CD, and a+24V power input cable (CN1). Please confirm electrostatic protection before installation to avoid damaging sensitive components.

Hardware installation and jumper switch setting

1. PCI slot and plug and play

PCI-8132 supports plug and play, and the system BIOS automatically assigns I/O base addresses and IRQs without the need for manual settings. Simply insert it into any PCI slot and secure the baffle. If there is a startup exception or interrupt conflict, it is usually caused by an ISA device resource conflict, and the PCI/ISA resource allocation in the BIOS needs to be checked.

2. External power supply (CN1)

A+24V external power supply must be provided for isolating the I/O circuit power supply. CN1 is a 2-pin terminal block:

1 pin: EXGND

2 legs: EX+24V (± 5%, 500mA max)

The onboard voltage regulator generates+5V for internal and external output use (such as encoder power supply). It is recommended to use AWG22~28 wires for wiring, with a bare length of 10mm.

3. Pulse output type jumper (J1~J4)

The OUT and DIR signals of each axis can be selected through jumper to drive differential lines (default) or output with open collector:

J1 (OUT1), J2 (DIR1), J3 (OUT2), J4 (DIR2): Short circuit 1-2 is differential, 2-3 is open circuit.

When the output is open circuit, OUT - and DIR - are signal lines, with a current not exceeding 20mA. An external resistor should be connected to EX+5V (capacity 500mA).

4. Type of limit switch and comparison of output polarity (S1)

S1 DIP switch:

Bit1/2: EL (PEL/MEL) switch types corresponding to axis 1 and axis 2 respectively, OFF (default)=normally open (contact A), ON=normally closed (contact B).

Bit3/4: Set the effective levels of CMP1 and CMP2 trigger outputs respectively, OFF (default)=output high level (100 μ s pulse) when the comparison condition is met, ON=low level effective.

It is necessary to set the limit signal correctly according to the actual switch type on site, otherwise the limit signal will not be triggered properly.

Detailed explanation and wiring points of main connector CN2 signal

CN2 is a 100 pin SCSI connector that integrates all axis I/O and digital I/O. The following are the key signal groups and their wiring precautions.

1. Pulse output (OUT ±, DIR ±)

Differential output can be directly connected to servo drives that support differential input, such as Panasonic and Yaskawa. If the driver is an optocoupler receiver, open circuit mode can be selected and a current limiting resistor can be connected in series. The default OUT/DIR mode (pulse+direction) can also be changed to CW/CCW dual pulse mode through software.

2. Encoder feedback (EA ±, EB ±, EZ ±)

Differential input requires a voltage of ≥ 3.5V and a driving capability of ≥ 6mA. It can be connected to the frequency division output of an encoder or driver. For encoders with open collector output, an external pull-up resistor is required (not added at+5V, 1.8k Ω for+12V, 4.3k Ω for+24V), and ensure common ground.