Anaheim Stepper PCL601 Users Guide

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#L010153September 2005
PCL601
Programmable Step Motor Controller
User’s Guide
910 East Orangefair Lane, Anaheim, CA 92801
e-mail: [email protected](714) 992-6990  fax: (714) 992-0471
website: www.anaheimautomation.com
ANAHEIM AUTOMATION, INC. 
						

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#L010153September 2005
Table of Contents
Section 1: Introduction .......................................................................................................................... 3
Description ............................................................................................................................................... 3
Methods of Communication ..................................................................................................................... 4
Baud Rate ................................................................................................................................................ 4
RS232 Protocol - SW1 in RS232 position ................................................................................................ 4
RS485 Protocol - SW1 in RS485  position ............................................................................................... 4
Terminating Resistor ................................................................................................................................ 5
Axis Selection ........................................................................................................................................... 5
Status LED ............................................................................................................................................... 5
Interfacing With A Driver .......................................................................................................................... 5
Technical Support .................................................................................................................................... 5
Electrical Specifications ........................................................................................................................... 6
Ordering Information ................................................................................................................................ 6
Dimensions/Switch Locations .................................................................................................................. 7
Wiring Diagrams ....................................................................................................................................... 7
Terminal Descriptions .............................................................................................................................. 8
Connector Descriptions ............................................................................................................................ 8
Slide Switch Descriptions ......................................................................................................................... 8
Section 2: Functions .............................................................................................................................. 9
Section 3: SMC60WIN Software .......................................................................................................... 13
File Menu ............................................................................................................................................... 14
Setup Menu ............................................................................................................................................ 14
Setup - Axis Menu .................................................................................................................................. 14
Program Menu ....................................................................................................................................... 15
Program - Autostart Program Menu ....................................................................................................... 15
Edit Menu ............................................................................................................................................... 15
Help Menu .............................................................................................................................................. 16
“The Unit is Connected” / “The Unit is NOT Connected” ....................................................................... 16
Toolbar ................................................................................................................................................... 17
Tab Sheets ............................................................................................................................................. 17
Add/Change/Insert Commands .............................................................................................................. 22
Calculator ............................................................................................................................................... 27
Section 4: Direct Talk Mode ................................................................................................................ 28
Section 5: Troubleshooting ................................................................................................................ 38
Error Codes ............................................................................................................................................ 39
Section 6: Tutorial ................................................................................................................................ 40
Appendix 1: ASCII Table for Direct Mode .............................................................................................. 45
Appendix 2: Firmware Revisions ............................................................................................................ 45 
						

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#L010153September 2005
Section 1: Introduction
The PCL601 is a single-axis step motor controller containing 2 Kbytes of nonvolatile stored programming
space and quadrature encoder feedback. The user can write the program and then have the PCL601
autostart the program on power up. It provides flexible, independent control of stepper motors from com-
puters, or any machine controller with a serial port. It is also capable of standalone operation, making it an
embedded machine controller. The easy to use Windows software, SMC60WIN, can be used to directly
control motion and to program the PCL601. The PCL601 also has the ability for real time functions. “Direct
Mode” is used to directly control motion for Real Time Movements through serial communication.
The PCL601 has 40 commands, which are easy-to-remember for direct movement of a stepper motor.
The PCL601 communicates via either an RS232 or RS485 bidirectional serial data bus. Up to 99 PCL601’s
can be networked from one communications port on your PC or PLC, utilizing the RS485 communications
protocol. Special functions of the PCL601 include 8 programmable open collector outputs and 6 TTL,
CMOS and 24V compatible inputs, a quadrature encoder input with the ability to autocorrect, an analog
input to control either maximum speed or absolute position, registration mark indexing during a slew
command, an output that will trigger during an index command at an absolute position, and a thumbwheel
input for indexing a motor. The PCL601 can be powered with DC (5VDC or 8 -24VDC) or AC (8-16VAC)
voltages and uses only 2 watts at 24VDC and only a 1/2 watt at 5VDC (with no connections to terminal
blocks).
Description
The PCL601 step motor controller provides independent programming of acceleration/deceleration, base
speed (start up speed), max speed (running speed), jog speed, and the number of steps to be taken in
both relative and absolute positioning modes. On absolute positioning moves, the PCL601 automatically
determines the proper direction to go and the number of steps to take. The relative positioning will move
a number of steps in the direction that the user defines. The PCL601 also has specific functions such as
index-on-the-fly, which during a slew move will move a predefined number of steps after an input has
been triggered. Output-on-the-fly, which will trigger an output on for 50uS during an indexing move at an
absolute position and repeat triggering the output on after a given number of steps. An analog input can
be used to set either the maximum speed or goto an absolute position based between the upper and lower
programmable limits. A seven decade thumbwheel switch can be read for relative indexing. The PCL601
also has a high level programming command set that includes: branching, looping, conditional statements,
time delays, text strings, and I/O which the user can use in the programming mode to fully control all
machine functionality.
A home input, a set of bidirectional hard and soft limit switch inputs and bidirectional jog inputs are provided
for each axis. These features are generally required in most machine control designs. 6 testable TTL,
CMOS and 24V compatible inputs and 8 programmable open-collector outputs are provided per axis. The
I/O may be used for monitoring and controlling machine operation and/or interaxis coordination. The I/O
are accessible independent of the busy state of the axis controls.
The PCL601 has a built-in programmable reset circuit. Reset is automatic on power-up, or by pressing the
external reset button. A CD, provided when you purchase the unit, contains this user’s manual, along with
the SMC60WIN software and PCL601 program examples. The software allows you to write and change
programs that are to be stored in the PCL601 for autostart use, and also upload the program that is stored
in the PCL601 itself for editing and viewing. The software also allows you to save the programs onto your
computer hard drive, and easily retrieve them when needed. 
						

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Methods of Communication
There are two methods for sending commands to the PCL601. One is to directly talk to the PCL601 by
using Direct Talk Mode. This is usually used with a computer or PLC (Programmable Logic Controller),
where the computer or PLC gives the PCL601 serial commands to off-load its processor. For example: A
PLC can utilize its outputs to toggle the PCL601’s inputs and gain control of variable speeds, variable
programs, variable distances, etc. Simply using the PCL601 as the intelligent pulse generator, a PLC can
remove some of the tasks that were not meant for ladder logic or any PLC processing time.
The second way to give commands to the PCL601 is to use the software program SMC60WIN to either
manually control, or to write and send programs. This method is used when the PCL601 is the main
controller. For example: A PCL601 can replace simple motion control and replace I/O functional when
minimal quantities of I/O are required to control specific machinery. Simple motion profiles that can operate
with 6 or less inputs and 8 or less outputs can utilize a PCL601 controller.
Baud Rate
A term used frequently in serial data communications, a “baud” is defined as the reciprocal of the shortest
pulse duration in a data word signal, including start,  stop, and parity bits. This is often taken to mean the
same as “bits per second”, a term that expresses only the number of “data” bits per second. Very often,
the parity bit is included as an information or data bit. The PCL601 accepts a baud rate of 38400 only .
RS232 Protocol - SW1 in RS232 position
The PCL601 is a DCE device, therefore it will transmit on pin 2 and receive on pin3 of the DB9 RS-232
connector . The RS232 serial communication mode is single ended. This means that for each signal there
is one wire, and a common ground reference used by all the signals. The PCL601 does not use handshaking,
thus the CTS and RTS lines are internally connected, and the CD, DTR and DSR lines are internally
connected inside the PCL601. The signal line maintains levels of +5VDC to +15VDC and -5VDC to -
15VDC. For a valid logic level in the controller, the voltage must be at least +/-3 volts. RS232 works at
distances of up to 50 feet maximum. RS232 is susceptible to electrical noise, and should not be used
in noisy areas. Always use the shortest cable connection possible. NOTE: Keep controller wiring
separated from motor cable/wiring.
RS485 Protocol - SW1 in RS485  position
The RS485 protocol mode is as follows; On board receivers will remain in active mode indefinitely.
Transmitters must be turned off when the unit is not sending data, to prevent the line from sending and
receiving data at the same time. Therefore when the PC is transmitting data its driver will be turned on and
each of the units connected will have their drivers off. If they are requested to send data back to the PC,
the selected unit will turn it’s driver on to send the data and then turn it off after it has completed transmission.
Note: The above protocol is done internally between the converter and the PCL601. The RS485 method
of communication allows increased noise immunity and increased communication distance of up to 4000
feet without repeaters. RS485 repeaters allow an additional 4000 feet per repeater. The PCL601 is designed
for two wire configuration. The 2 wire configuration makes use of the tristate capabilities of RS485 to allow
a single pair of wires to share transmit and receive signals for half duplex communications. This “two wire”
configuration (note that an additional ground conductor must be used) reduces cabling cost. NOTE: Keep
control wiring separated from motor cable/wiring.
RS232 to RS485 for multiple units or cables longer than 50ft
The PCL601 can be connected to your PC serial port via a RS485 converter (model number: 485SD9TB
sold separately). This converter will convert the RS232 voltage signals to the compatible RS485 differential
signals. Only one converter box is needed per serial port. Contact the factory or use the website
www.anaheimautomation.com for RS485 converter information and sales. 
						

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Terminating Resistor
To eliminate noise on the transmission lines or  when using a 4000 ft. or longer cable, a terminating
resistor is suggested. If used, the termination resistor need only be added to the last (furthest from the
converter box) PCL601 in the network between pins A(-) and B(+) on the RS485 Terminal Block. The
value of this resistor should be 120 ohms.
Axis Selection
Each PCL601 is addressed using a programmable register allowing the PC to address up to 99 PCL601’s
from one port. The Default axis is “0”. To change the axis, use the SMC60WIN software or the “~” com-
mand. To verify or check the axis, use the SMC60WIN software or the “%” command. The axis designa-
tion is nonvolatile and will remain the same until changed by the user.
Status LED
When powered and operated properly, the status LED will be green.  When an error occurs, the LED will
change to RED, and an error code will be generated in the error code register.  To read and clear the error
with the software, click on the “Verify Parameters” button located in the “Motion Tab”. To read and clear
the error while in “Direct Mode”, use the error code “!” command. Once the error has been read and
cleared, the LED will return to green and the error code register will be cleared to 0. Refer to the table on
page 39 for a complete list of the error codes.
Interfacing With A Driver
The PCL601 controller was designed to control a step motor driver. For drivers with “Opto-isolated” in-
puts, the PCL601 needs to sink current through the driver’s input LED. To do this, connect the +5VDC to
the positive terminals of the inputs and connect the clock, direction and on/off outputs of the PCL601 to
the negative terminals of the corresponding inputs on the driver.  For a driver with “TTL/CMOS” inputs, the
PCL601 has a negative going clock that will sink the current from the driver’s inputs. Wire the clock,
direction and on/off outputs and 0VDC reference of the PCL601 to the corresponding inputs of the driver
respectively.  For a PCL601 controller purchased with an integrated driver and power supply (Driver
Pack), these connections are already internally made.
Technical Support
Everyone needs assistance on occasion. If you have problems using any of the equipment covered by
this manual, please read the manual to see if it will answer your  questions. Be sure to look in the Trouble-
shooting Section located near the back of this manual. If you need assistance beyond what this manual
can provide, you may call the factory direct for application assistance. If possible, have this manual in
hand. It is often helpful to have the controller connected to a computer with the software installed. 
						

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Electrical Specifications
Power Requirements With No Connections:
5VDC @ 100mA or
8VDC to 24VDC @ 90mA
Operating Temperature:
0 to 60 degrees C
Pulse Output Range:
1 to 50,000 Hz
10uS negative going pulse width
Inputs (TTL-CMOS):
Logic “0”: 0 to 0.8VDC
Logic “1”: 3.5 to 24VDC
Analog input 1: 0 to 5VDCOutputs (CLK,DIR,ON/OFF):
Open Drain Type
40VDC, 75mA
Baud Rate:
38400 Baud, Fixed
Data Format:
Half-Duplex, 1 start bit, 8 data bits,
no parity, 1 stop bit
Outputs (8 programmable):
Open Drain Type
40V, 100mA
Output1 active low time for output on the fly:
50uS
Note: For inductive loads, customers must connect a
clamping diode to protect from flyback voltage spikes.
Encoder and Driver Output:
+5VDC Output, 50mA
r e b m u N t r a Pn o i t p i r c s e D
1 0 6 L C P.k c a b d e e f r e d o c n e h t i w r e l l o r t n o c r o t o m p e t s d e r u t a e F
1 0 6 5 7 D P D. y l p p u s r e w o p d n a e v i r d r a l o p i n u p m a 7 a s e r u t a e F - k c a P e v i r D / r e l l o r t n o C
1 0 6 0 1 N P D. y l p p u s r e w o p d n a e v i r d r a l o p i b p m a 0 1 a s e r u t a e F - k c a P e v i r D / r e l l o r t n o C
B T 9 D S 5 8 4.r e t r e v n o c 5 8 4 S R o t 2 3 2 S R
7 S W T. r e l l o r t n o c s e i r e s 0 6 C M S y n a h t i w e l b i t a p m o c h c t i w s l e e h w b m u h t n o i t i s o p n e v e S
6 - C F M 9 A A. r o t c e n n o c e l a m e f 9 B D e n o d n a e l a m 9 B D e n o h t i w e l b a c l a i r e s h g u o r h t t h g i a r t s t o o f 6
A 5 . 3 V 5 - A 2 . 1 V 4 2 M A S P) A 5 . 3 @ V 5 , A 2 . 1 @ V 4 2 ( . 1 0 6 L C P r o f y l p p u s r e w o P
Ordering Information
The table below lists a variety of products available from Anaheim Automation, Inc. These products include
those covered by this manual, along with supporting cables and devices. We are continually adding new
products to our line, so please consult Anaheim Automation, Inc. or its representatives for information on
the latest releases. 
						

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Dimensions/Switch Locations
Wiring Diagrams 
						

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Slide Switch Descriptions
r e b m u N h c t i w Sn o i t p i r c s e D
1 W S.5 8 4 S R r o 2 3 2 S R r e h t i e t c e l e s o t d e s u s i h c t i w s s i h T
2 W S. 6 d n a 5 s t u p n i r o l e e h w b m u h t e h t r e h t i e t c e l e s o t d e s u s i h c t i w s s i h T
Connector Descriptions
r e b m u N h c t i w Sn o i t p i r c s e D
1 P. 2 3 2 - S R d e l e b a l s i d n a n o i t a c i n u m m o c 2 3 2 - S R e h t r o f s i r o t c e n n o c s i h T
1 J. S W T d e l e b a l s i d n a e l u d o m l e e h w b m u h t e h t r o f s i r o t c e n n o c s i h T
Terminal Descriptions
n o i t i s o Pr e w o P - n o i t p i r c s e D
1tu p n I r e w o P C D V 4 2 - 8
2nr u t e R r e w o P d n u o r G
n o i t i s o P5 8 4 S R - n o i t p i r c s e D
1)- ( A
2)+ ( B
3d n u o r g d e t a l o s i n a s i s i h T - D N G I
y l n o 5 8 4 S R r o f
n o i t i s o Pr e d o c n E - n o i t p i r c s e D
1re d o c n e r o f y l p p u s C D V 5 +
2re d o c n e r o f l e n n a h c A
3re d o c n e r o f l e n n a h c B
4re d o c n e r o f n r u t e r d n u o r G
n o i t i s o Ps t u p t u O r e v i r D - n o i t p i r c s e D
1r e v i r d d e t a l o s i - o t p o r o f y l p p u S C D V 5 +
s t u p n i
2tu p t u o k c o l C
3tu p t u o n o i t c e r i D
4tu p t u o f f o / n o t n e r r u c r o t o M
5d e t a l o s i - o t p o n o n r o f e c n e r e f e r d n u o r G
s t u p n i r e v i r d
n o i t i s o Ps t u p n I - n o i t p i r c s e D
1tu p n i g o l a n A - 1 t u p n I
2tu p n i y l f e h t n o x e d n I - 2 t u p n I
33t u p n I
44t u p n I
56/ 5 N I n o i t i s o p n i 2 W S - 5 t u p n I
66/ 5 N I n o i t i s o p n i 2 W S - 6 t u p n I
7dn u o r G
n o i t i s o Ps t u p t u O - n o i t p i r c s e D
1tu p t u o y l f e h t n o t u p t u O - 1 t u p t u O
22t u p t u O
33t u p t u O
44t u p t u O
55t u p t u O
66t u p t u O
77t u p t u O
8tu p t u o r o r r e s e i r t e r r e d o c n E - 8 t u p t u O
n o i t i s o Ps t u p n I h c t i w S t i m i L - n o i t p i r c s e D
1ti m i L e m o H
2+g o J
3-g o J
4go J t s a F
5+t i m i L d r a H
6-t i m i L d r a H
7+t i m i L t f o S
8-t i m i L t f o S
9dn u o r G 
						

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Section 2: Functions
Move Number of Steps: This  command causes the motion to start in the direction last specified. This
command will move the motor the number of steps given. (Range: 1 to 8388607)
Move to Position: The move to position command specifies the next absolute position to go to. The
PCL601 controller automatically sets the direction and number of steps needed to go to that position.
(Range: -8388607 to +8388607)
Slew: The slew command will accelerate the motor up to maximum speed and continue to run at that
speed until reaching a registration mark, hard limit switch, soft limit switch, receiving a “.” (stop hard) or
“,” (stop soft) command.
Set Position: The set position command sets the position register to a designated value. The number
will be the new absolute position of the motor. The default value is 0. (Range: -8388607 to +8388607)
Limit Switch Inputs: The limit switch inputs are internally pulled up by a resistor making them normally
+5 volts. To activate the input, the pin must be grounded to (0VDC). All limit switch inputs are internally
clamped to +5V, thus allowing voltages of upto +24VDC to be used.
Hard Limit Inputs: When a hard limit switch is encountered, the motion will stop immediately. The
position counter will also cease counting. Hard limits are intended as an emergency stop for your
system. It should not be used to do any positioning type functions. These limits are directional.
Soft Limit Inputs: These switches should be used exclusively for homing. Once positioned properly
with the appropriate parameters, it causes the motor to ramp down to the base speed before encoun-
tering the home limit switch. However, the soft limit switch will work for any type of motion command.
These limits are directional.
NOTE: Whenever a soft limit switch is activated, the motor will decelerate and run at base speed during
an indexing move, or stop during a slewing move. Be sure to come back past the soft limit switch to set
any origins, otherwise the motor will decelerate as it goes past the soft limit switch during normal
operation.
Home Limit Input: This switch is used to establish a position designated “home” or datum position
using the following: home to soft and home limit, or home to home limit. This limit is not directional.
Home to Soft, Home Limit (2 Switch Operation): This type of homing routine requires two grounding
type limit switches called home and soft. The first limit switch seen is the soft limit. This will decelerate
the motor down to base speed. The motor will then continue to run at base speed until it contacts the
home limit switch input causing the motor to stop. The home limit switch activates as a hard limit if a
soft limit is not sensed. The soft limit is directional, meaning that it will work in only one direction as
specified. The soft limit switch will work for any type of motion command. The home limit switch will
work only for the two home motion commands.
NOTE: There should be sufficient distance between the two limit switches, as to let the motor reach
base speed.
Home to Home Limit (1 Switch Operation): This type of homing differs in that only one limit switch is
needed. In this homing routine the motor moves toward the home limit switch. When the home limit
switch is contacted the motor will ramp down to base speed, reverse direction and continue at base
speed until the limit switch is released.  This is a good way to compensate for any backlash in a sys-
tem. It is also useful for minimizing the number of limit switches needed for homing.
NOTE: The home switch needs to be low during the entire deceleration and reversing time. 
						

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Jog Inputs: The jog switch inputs are internally pulled up by a resistor making them normally +5 volts.
To activate the input, the pin must be grounded to (0VDC). All jog switch inputs are internally clamped
to +5V, thus allowing voltages of upto +24VDC to be used. Jog is a manual function. The user can
select the direction and speed (fast or slow) by grounding the appropriate combinations of inputs. To
jog a motor, it is necessary to ground the jog input  for the direction desired. For fast jog, both the fast
input and jog input for the appropriate direction must be low at the same time. By grounding one of the
jog inputs, the user causes the motor to run at base speed.  When the fast input is grounded, the motor
will then accelerate to the programmed jog speed. The position register will keep track of the number of
steps that are taken during jogging. Once a +jog or a -jog function has been performed, the direction
register will retain the last direction of movement; that is, a subsequent go command will be in the same
direction as the last jog command.
Inputs: All inputs (except input 1) are internally pulled up by a resistor making them normally +5 volts.
To activate the input, the pin must be grounded to (0VDC). All inputs are internally clamped to +5V,
thus allowing voltages of upto +24VDC to be used. Six inputs are provided per axis.  The inputs are
TTL, CMOS and 24V compatible. The inputs may be used to initiate a machine cycle, for inter-axis
coordination (in stored program mode), for operator intervention, for sensing a machine condition such
as out of stock or wait for temperature to be reached, etc. A grounded input will read a “0” and an open
or high input will read as a “1”. Input 1 is a special input that is capable of reading an analog voltage
between 0 and +5VDC. Since this input does not have a pull-up resistor, biasing of this input is needed
if it is not used as an analog input. Inputs 5 and 6 are used together with the thumbwheel switch. To
use inputs 5 and 6, SW2 must be in the IN5/6 position. If SW2 is in the TWS position, then these two
inputs are not connected to the processor.
Analog Input: Input 1 can be configured to read an analog voltage to either set the absolute position of
the motor or to set the maximum speed of the motor.
To set the position, when told via the goto analog position command, the input will read a voltage
between 0 and +5VDC and based on the” upper and lower” limits of the function, a move will occur to a
calculated position between the two limits. The motor must finish the move before it can be told to read
the input again for the next position. For example, if the lower limit is set to 0 and the upper limit is set
to 5000 and the analog position is set at +2.0VDC, then the motor will move to position 2000. Changing
the lower limit to 1000 and the voltage to +3.2VDC, the motor will move to position 3560. See examples
below for calculations of the analog inputs. (Range of limits: 0 to 65535 and the lower limit < upper limit)
To set the max speed, when told via the set analog speed command the input will read a voltage
between 0 and +5VDC, and based on the “upper and lower” limits of the function, a max speed can be
obtained based on a calculated frequency between the two points. The speed however can not be
changed when the DPY50601 is busy (moving). See examples below for calculations of the analog
inputs. (Range of limits: 0 to 50000 and the lower limit < upper limit)
Analog  calculations. Example1: Example2:
(Upper-Lower) * (Voltage/5) = X (5000 - 0) * (2 / 5) = 2000 (5000 - 1000) * (3.2 / 5) = 2560
Lower + X = Position or Frequency 0 + 2000 = 2000 1000 + 2560 = 3560
Outputs: Eight outputs are provided per axis. Outputs may be used to operate relays, coolant valves,
air cylinders, or, with the correct interfacing, any electronically controlled device. The outputs can drive
all types of common peripheral power loads, including lamps, relays, solenoids, LED’s, printer heads,
and heaters. For inductive loads, it will be necessary to connect a clamping diode (refer to specification
section) from the output to the power source in order to provide adequate fly-back protection. The
outputs are current sinking, open collector darlingtons. They are capable of sinking up to 100mA per
output with voltages up to 40VDC. Turning an output on will pull the output pin to ground and turning an
output off will make the output pin open. Output 1 has a special function (output on the fly) that will
enable it to be triggered at a certain absolute position during a move. Output 8 has a special function
that will trigger when the encoder retries function fails.