AES BeBoPr++ User Manual

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SER

ANUAL

Author:

Bas Laarhoven

Version:

1.4.9

Date:

April 09, 2014

Table of Contents

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Summary of Contents for AES BeBoPr++

Page 2: Disclaimer, Warranties And Liability
BeBoPr++ User Manual Disclaimer, Warranties and Liability Disclaimer UNLESS OTHERWISE MUTUALLY AGREED TO BY THE PARTIES IN WRITING, LICENSOR OFFERS THE PRODUCT AS-IS AND MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND CONCERNING THE PRODUCT, EXPRESS, IMPLIED, STATUTORY OR OTHERWISE, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF TITLE, MERCHANTIBILITY, FITNESS FOR A PARTICULAR PURPOSE, NONINFRINGEMENT, OR THE ABSENCE OF LATENT OR OTHER DEFECTS, ACCURACY, OR THE PRESENCE OF ABSENCE OF ERRORS, WHETHER OR NOT DISCOVERABLE.
Page 3: Table Of Contents
BeBoPr++ User Manual Table Of Contents Disclaimer, Warranties and Liability...............2 Disclaimer....................2 Warranties ....................2 Limitation on Liability..................2 Table Of Contents....................3 Introduction....................5 Getting Started....................6 The Third Generation..................7 What has changed..................7 What did not change..................10 BeBoPr++ Features..................11 Generic I/O view..................11 3D printer specific I/O view................12 NC router specific I/O view................13 Software......................14 Linux operating system.................14...
Page 4 BeBoPr++ User Manual Switches......................33 Fuses......................34 Jumpers......................35 I2C and Emergency Stop...................36 Emergency Stop Input...................36 I2C Bus.....................36 Specifications (preliminary)................37 Connectors....................38 Mating Connectors..................40 I/O connectors:..................40 Power connectors:..................41 Troubleshooting.....................42 References....................43 Board dimensions...................44 version 1.4.9 (09/04/14) page 4...
Page 5: Introduction
BeBoPr++ User Manual Introduction The BeBoPr++ is the third generation of BeBoPr boards. It integrates the original/classic BeBoPr and the Bridge that was necessary to use the BeBoPr with the BeagleBone Black. By integrating the Bridge, the BeBoPr++ stays compatible with both the original BeagleBone and the BeagleBone Black.
Page 6: Getting Started
BeBoPr++ User Manual Getting Started Although the BeBoPr may seem to have an overwhelming number of connectors, one can start with only a power supply and a BeagleBone attached. This way some of the functionality can be tested to get familiar with the board and before integrating it into the final configuration. Step 1 - First get a BeagleBone that has been working before, so that you don't run into USB or networking configuration issues.
Page 7: The Third Generation
BeBoPr++ User Manual The Third Generation This chapter summarizes the differences between the original BeBoPr and the BeBoPr++. It contains useful information for users that already own a BeBoPr or are otherwise familiar with the BeBoPr specifications. Illustration 1 - BeBoPr++ R1 prototype What has changed Board layout The BeBoPr++ has gotten a complete new board layout.
Page 8 BeBoPr++ User Manual port, HDMI connector and uSD card slot while mounted on the BeBoPr. This feature was propagated into the design of the BeBoPr++. Extended pin-header connectors create a similar gap between BeBoPr++ and BeagleBone. Wide input power range The step down converter has been re-designed to operate from a DC supply voltage in the range from 12 to 24 Volts.
Page 9 BeBoPr++ User Manual Improved PWM outputs The PWM output stages have been redesigned to generate less heat in the output switches (FETs) and allow up to 32 kHz PWM switching frequency without significant losses. The TO220 FETs have been replaced by SMD parts with lower R .
Page 10: What Did Not Change
BeBoPr++ User Manual What did not change Dimensions The board dimensions and mounting hole pattern have remained the same. Connectors All connectors have remained the same and are compatible with the original BeBoPr connectors † . The locations on the board haven't changed either, making the BeBoPr++ a plug- in replacement for BeBoPr+ boards or BeBoPr-with-Bridge combinations.
Page 11: Bebopr++ Features
BeBoPr++ User Manual BeBoPr++ Features Although designed as 3D printer controller, the BeBoPr++ can be used for many other applications. This chapter describes the interfaces in a generic way first, followed by mapping these features on 3D printer hardware. Generic I/O view Analogue inputs (3x) Three analogue inputs accept a 0 - 3.6 Volt input range.
Page 12: 3D Printer Specific I/O View
BeBoPr++ User Manual source. Choose between a cheap ATX power supply, a simple laptop 18-20 Volt adapter, an adjustable lab bench supply, an industrial 24 Volt supply or whatever is available and can deliver sufficient power for your application. 3D printer specific I/O view Stepper outputs The BeBoPr has no integrated stepper drivers, but offers four sockets that accept Pololu, StepStick or other compatible modules.
Page 13: Nc Router Specific I/O View
BeBoPr++ User Manual Warning: Some of the components can get very hot, too hot to touch! If in doubt, use a moistened finger before probing a package † Never ever leave your system unattended when playing with these kinds of high currents! The intention is to generate heat, but sometimes the heat will appear at an unexpected location: An oxidized connector, a connector screw not tightened properly, a bad solder joint.
Page 14: Software
BeBoPr++ User Manual Software The BeBoPr++ can be used with all BeagleBone versions. The classic (white) and the BeagleBone Black are both hardware compatible with the BeBoPr++. The BeBoPr++ cape's on-board EEPROM holds configuration information for both the 3.2 kernel (I/O multiplexer settings) and the device tree based 3.8 kernels. The board identifies itself as 'cape-bebopr-brdg'.
Page 15: Linuxcnc
BeBoPr++ User Manual motor control without needing extra hardware or highly specialized real-time code. LinuxCNC LinuxCNC has been around for a long time. Originally Intel X86 only, was developed to control mills, lathes and routers. Since the port to the BeagleBone, its also being used for 3D printers.
Page 16: The Cape
BeBoPr++ User Manual The Cape Illustration 2: - BeBoPr features on an early prototype Power The on-board switching step-down converter creates the 5 Volts DC required for the BeagleBone, BeBoPr and (external) digital inputs. Configuration EEPROM The BeBoPr uses an on-board EEPROM to identify itself to the BeagleBone. version 1.4.9 (09/04/14) page 16...
Page 17: Daughter Modules
BeBoPr++ User Manual For 3.2 kernels (used by the original BeagleBone), the pinmux configuration is read from the EEPROM during kernel start-up. All inputs and outputs are configured accordingly (this requires kernel 3.2.16 or later). The 3.8 kernels used by the BeagleBone Black have a different way to set the pinmux configuration.
Page 18 BeBoPr++ User Manual surface. Spacers with a minimum height of 4 mm are needed to prevent shorting pins on the bottom side of the cape. Although BeagleBone and its capes are designed to form a stack of undetermined height, there can only be a single BeBoPr and a single BeagleBone in the stack. The BeagleBone is always the first board of a stack, and the BeBoPr cape is always the last, because neither board has stack-through connectors.
Page 19: Connections
BeBoPr++ User Manual Connections Power Connections J18 – Stepper driver power. Connect a 12-24 Volt DC (+/- 10%) regulated power supply. Can be left unconnected if no Pololu-like stepper drivers modules are used. J20 – Board power. Connect a 12-24 Volt DC regulated power supply. This is the supply for the BeagleBone and the high-power PWM outputs.
Page 20: Stepper Motor Connections
BeBoPr++ User Manual WARNING: Do not exceed the maximum specified current for these connectors. WARNING: Do not connect power to the DC INPUT (P5) jack on the BeagleBone once mounted on the BeBoPr. This will most likely damage the BeBoPr and/or the supply connected to the DC INPUT.
Page 21: Thermistor Connectors
BeBoPr++ User Manual If the BeBoPr controls external stepper drivers, the stepper motors connect directly to these drivers and the connectors J15, J16, J17 and J19 are not used. The stepper signals for the external drivers connect to J5. Thermistor connectors Designed for use with 100kΩ...
Page 22: Pwm Power Outputs
BeBoPr++ User Manual PWM Power Outputs Output stages The PWM outputs on the BeBoPr++ can be configured in software to operate at up to very high frequencies. 100 kHz PWM at 10 A is possible, but this will generate a lot of EMI and some dissipation in the FETs.
Page 23: Free-Wheeling Diodes
BeBoPr++ User Manual Illustration 6 - Temperature profile 10A PWM Free-wheeling diodes If an inductive load is installed, a free-wheeling diode should be used. A simple silicon rectifier diode of type 1N4007 or compatible will do in some situations, in other cases a fast recovery type will be better.
Page 24 BeBoPr++ User Manual Some example calculations to show the effect of large currents: The dissipation (power lost in the FET) roughly depends on three factors: The current through the FET, the switching frequency and the temperature of the FET. Using the FET to switch (mainly resistive) heaters for a 3D-printer does not require high speed switching.
Page 25: Analogue Inputs
BeBoPr++ User Manual Analogue inputs The AM335x processor has an integrated Analog to Digital Converter that can be used as touch screen controller and as general purpose ADC. This converter is called the TSCADC hereafter. Because of erratic behaviour of this converter †...
Page 26: Protection
BeBoPr++ User Manual Protection The pair of Schottky diodes (D2) in combination with the 470 Ohm resistor protect the ADC input against over-voltage caused by ESD or shorts to the supply. Scaling The PWR_THRM0 reference voltage is feeding a voltage divider that has the thermistor in the lower section and a 2k05 resistor in the upper part.
Page 27 BeBoPr++ User Manual 1,800 1,600 Vadc 1,400 1,200 1,000 0,800 0,600 0,400 0,200 0,000 -100 degrees Celcius Illustration 8: Epcos B57560G104F 100k thermistor transfer function With the component used on the BeBoPr, a 100k thermistor is probably the best choice. For each new thermistor a similar calculation will be necessary.
Page 28: Plug-In Stepper Drivers
BeBoPr++ User Manual Plug-in stepper drivers Before inserting the Pololu or StepStick driver modules in the sockets, the DIP switches should be set for the proper micro-stepping options. Refer to the stepper-module’s documentation for the proper settings. The numbers on the switches correspond with the MS input signals of the modules.
Page 29 BeBoPr++ User Manual Warning: This carrier board uses low-ESR ceramic capacitors, which makes it susceptible to destructive LC voltage spikes, especially when using power leads longer than a few inches. Under the right conditions, these spikes can exceed the 45 V maximum voltage rating for the DRV8825 and permanently damage the board, even when the motor supply voltage is as low as 12 V.
Page 30: I/O Enable
BeBoPr++ User Manual I/O enable To prevent I/O conflicts and glitches on (stepper or power) outputs during initialization, the inputs and outputs are isolated from the BeagleBone during start-up. Once the BeagleBone has booted it is the responsibility of the user (application) to initialize the outputs to safe values before enabling the I/O.
Page 31: Indicator Leds
BeBoPr++ User Manual Indicator LEDs Illustration 11: LEDs on the BeBoPr version 1.4.9 (09/04/14) page 31...
Page 32: Power Leds
BeBoPr++ User Manual Power LEDs Both power LEDs (see illustration 11) are green LEDs. The first, LED D19 in will light if the BeBoPr receives power via the board's power connector. The LED will not light if the fuse (F1 in illustration 12) is blown. Power LED D20 in Illustration 11) indicates that the BeagleBone is turned on.
Page 33: Switches
BeBoPr++ User Manual Switches Illustration 12: Fuses and switches The BeBoPr has two push button switches that connect directly to the BeagleBone. SW1 is used to control the BeagleBone's power state. Push this button for several seconds, until the BeagleBone turns off. Push it again to turn the BeagleBone on again. SW2 is used to (hard) reset the BeagleBone.
Page 34: Fuses
BeBoPr++ User Manual Fuses The BeBoPr has a thermal (PTC-type) fuse (F4) on-board that limits the current supplied to the switches or sensors be connected to J9-J14. In case of a short circuit, the current will be reduced to less than 300 mA and after removal of the short, operation will be back to normal.
Page 35: Jumpers
BeBoPr++ User Manual Jumpers On the back side of the board, several small configuration jumpers can be found. A soldering iron is required to apply some tin that shorts (closes) the jumper. Alternatively a bit of conductive glue can be used. Overview of the configuration jumpers and their purpose: JP1 - (default state: open) When closed this will write-protect the on-board EEPROM.
Page 36: I2C And Emergency Stop
BeBoPr++ User Manual I2C and Emergency Stop The BeBoPr++ has A new connector that was not on the older boards: J22. It can be seen on the cover photo, next to the two push buttons. This connector is divided in two parts and accepts either one single 6-pin mating part, or two separate connectors, one 4-pin part for the I2C bus and one 2-pin part for the emergency stop signal.
Page 37: Specifications (Preliminary)
BeBoPr++ User Manual Specifications (preliminary) Board Power input (J20): min. 10.8 Volt, max 26.4 Volt Stepper Power input (J18): max 35 Volt (see text) Board Power consumption via J20: BeBoPr only, no external connections: T.B.D. BeBoPr with BeagleBone and no external connections T.B.D.
Page 38: Connectors
BeBoPr++ User Manual Connectors For each connector the pins are numbered from 1 up-to the total number of pins present. All connectors have a square pad on the PCB layout. That pad identifies the first pin (nr. 1). The dual row connector J5 uses the normal header numbering scheme: an even row and an odd row.
Page 39 BeBoPr++ User Manual J6, J7, J8 Pin nr Direction analogue inputs Positive terminal GND - Negative terminal J9, J10, J11, J12, J13, J14 Pin nr Direction digital inputs +5 Volt supply (200 mA max over all connectors) Input, switch to GND J15, J16, J17, J19 Pin nr Direction...
Page 40: Mating Connectors
BeBoPr++ User Manual Mating Connectors The connectors used on the BeBoPr++ are the same types as on the BeBoPr and BeBoPr+ boards. On the BeBoPr++ connector J22 was added. This connector was split into two sections J22A (the I2C part) and J22B (the ESTOP part). This way a single 6 pin connector, or separate 4-pin and 2-pin connectors can be used for the wires.
Page 41: Power Connectors
BeBoPr++ User Manual Illustration 16 - HT-225D crimping tool Power connectors: Both power inputs on the BeBoPr (board power, stepper power) use the same type of connector: A 5.08 mm pitch plug that mates the pins on the BeBoPr. Illustration 17 - power connector Warning: Because the BeBoPr++ board has higher current ratings for the PWM outputs than the previous BeBoPr versions, a mating power connector with corresponding higher current rating was selected.
Page 42: Troubleshooting
BeBoPr++ User Manual Troubleshooting T.B.D. version 1.4.9 (09/04/14) page 42...
Page 43: References
BeBoPr++ User Manual References The main source of information is https://github.com/modmaker/BeBoPr. It contains the open source code for the Mendel 3D printer port. Make sure to read and watch the wiki pages at (https://github.com/modmaker/BeBoPr/wiki) for new information. These may contain more up-to-date information and other useful links. For on-line help and other links don't forget to visit and register at the BeBoPr forum: http://forum.bebopr.info.
Page 44: Board Dimensions
BeBoPr++ User Manual Board dimensions The sketch beneath shows the board dimensions and the positions of the four mounting holes † at the corners of the board. All dimensions are in mm. Illustration 18 - Board dimensions † The drawing above if from the original BeBoPr and BeBoPr+. The BeBoPr++ board has the same dimensions and identical mounting hole spacing.