InStep Plus Hardware Manual (Instep with Expansion Board) For Main board Rev 1 and Expansion board Rev 0

Transcription

1 Design, Application and Service of Electronics in Industry InStep Plus Hardware Manual (Instep with Expansion Board) For Main board Rev 1 and Expansion board Rev 0 (To be used in conjunction with the appropriate Software Manual) 22 September, Wanganui Road Kirrawee NSW Australia 2232 Phone: (02) Fax: Mobile: dpayne@oz .com.au WWW:

2 Overview The InStep control module is intended to be used in conjunction with a stepper drive and motor or a servodrive with step input and a servomotor. It provides stop/start registration control of processes such as self adhesive labelling, overprinting etc. This operation can be speed syncronised with another operation such as the product conveyor or printing machine. It is housed in a DIN rail mountable enclosure. The enclosure can be opened by operating four small catches to enable the user to configure the unit via several jumpers located inside. This allows very diversified applications while maintaining the same hardware minimising the need for several units to be kept for spares. The enclosure has 24 screw terminals and one modular RJ12 phone type connector. This connector is for serial communications to PLC s, touch screens, computers and other user interfaces. The unit provides for RS485 communications in half duplex operation over 2 pair cables. Up to 8 units may be daisy chained or multidropped from the one cable to allow 1 user interface to control several axes of motion. The 24 terminals on the base unit provide for 3 dedicated inputs, up to 10 general purpose inputs, 1 dedicated output and up to 8 general purpose outputs. The dedicated I/O are: PRODSENS - For product sensor input to start the indexing operation. GAPSENS - A label gap sensor or registration mark sensor input. ENC - An encoder input to provide a master speed to slave the indexing speed to. STEP - An output to connect to the drive to provide the step information. The general purpose I/O s function will vary depending on the firmware installed. All inputs are independently jumperable to change their polarity for use with either sinking (NPN) or sourcing (PNP) input devices. The outputs can be changed for sinking or sourcing type but all must be the same type. A green LED is fitted beside the serial connector to indicate that the internal 5V supply is functional. In order to minimise the amount of firmware versions two of the input terminals have jumpers which can select 1 of 3 available input signals and two of the output terminals can be jumpered to one or more of 4 available output signals. Also there are 8 jumpers to select various options. Three of these will usually be used to select the units address on the multidrop network. The expansion card adds several functions to the main InStep module and these are catagorised here as options. Some options preclude the use of others and are shown below. The rightmost terminal in each of the four rows of terminals on the standard module provided for two selectable inputs and two selectable outputs. This was done because there are insufficient terminals on the standard housing. These terminals do not exist on the expanded version and so jumpers J17 to J23 serve no purpose here. With the additional terminals available on the expanded version each of these selectable I/O is brought out to its own terminal. Because of this just the addition of the bare board with terminals only fitted provides one additional input and two additional outputs. Page 2 of 7

3 The available options are: 0. No options fitted. (provides terminals for additional I/O implemented on main board) 1. RS-232 interface. 2. IDC type front mounted header for RS-232 interface connection. 3. EEPROM for non-volatile storage of settings and for storing a number of sets of settings. 4. Step output frequency doubler for higher speed applications. 5. Two additional inputs. 6. A further two additional inputs. 7. One additional output. (Selectable for NPN or PNP seperately from other outputs) The following combinations are not possible: The RS-232 communications and the second two extra inputs. The EEPROM and the additional output. The step output frequency doubler and the additional output. If J61 is used to provide a ground terminal for the RS-232 on the OUT8 terminal, the additional output cannot be used. The option number is generated by combining the numbers of the options fitted. i.e. RS-232, EEPROM and two additional inputs is option number 135. Wiring Power A power supply of between 12 and 28 volts DC is required to be connected to terminals 1 and 2. The total power requirement is 100mA plus input and output currents. Inputs All input are required to either sink or source between 5 and 12mA at between 12 and 28 volts DC. Refer to jumper description table to select polarity of inputs. Outputs All outputs can sink or source up to 100mA each at the same voltage as supplied to the power supply terminals. Refer to configuration section for changing polarity. Serial Communications The serial communications connector is wired with the transmit and receive reversed from that of a normal InStep unit. This because with the RS-232 option installed this unit becomes the master on the buss. This allows the use of a straight through one for one connected cable to the next unit. Configuration Configuration consists of selecting the appropriate jumpers for your application and installing the appropriate output driver IC in position IC9. The jumpers are fully explained in the jumper description table. The unit is normally supplied with an NPN output driver IC, however it can be ordered with a PNP type or changed in the field. The correct IC for NPN outputs is ULN2803A and for PNP outputs is UDN2981A. Be sure to set jumpers J9 and J10 correctly to match the installed IC or damage will result! Page 3 of 7

4 Mounting The InStep module can be mounted on 35mm DIN rail and should be mounted with terminals 1 to 6 uppermost and the rail clip at the bottom. If the InStep module is dissassembled to facilitate the changing of jumpers etc, it should be reassembled so that terminals 19 to 24 are at the rail clip end of the housing. If the module must be mounted on a vertically mounted DIN rail it should be mounted with terminal 1 lowermost. This would place the side label uppermost. Spare Parts Spare jumpers, output driver IC s and serial port plugs are available from or the following suppliers: Farnell Electronic Components Pty Ltd. Phone (02) ULN2803A $2.91 ea UDN2981A $6.90 ea Jumpers $3.37 Strip of 10 Comms Plugs $1.98 ea Crimp Tool $ ea Die Set $98.34 ea RS Components Pty Ltd. Phone (02) UDN2981A $6.03 ea Jumpers $5.05 for 5 (min) Jaycar Electronics. Phone (02) Jumpers HM-3240 $1.60 Pack of 10 Comms Plugs PP-1432 $3.95 Pack of 5 Crimp Tool TH-1932 $17.95 ea Page 4 of 7

5 InStep Main Card Jumper Descriptions Jumper Description Default J1 to J8 These three point jumpers select the polarity of the signal required 1 to 2 jumpered to operate the inputs. Jump 1 to 2 for sinking (NPN) type input devices. Jump 2 to 3 for sourcing (PNP) type input devices. J1 to J6 correspond to input 1 to 6 respectively. J7 is for the product sensor input. J8 is for the label sensor input. J9 and J10 These jumpers are set to match the type of output driver IC 1 to 2 jumpered installed in position IC9. Jump both 1 to 2 for NPN type IC (ULN2803A) Jump both 2 to 3 for PNP type IC (UDN2981A) Note: jumpers must be set correctly or damage will result! J11 and J12 These jumpers are not used. Refer J56 and J57 on expansion card. N/A J13 and J14 J13 connects signal TXA to RXA on the serial port connector. Jumpers off J14 connects signal TXB to RXB on the serial port connector. If RS-232 option fitted these jumpers must be off. J15 and J16 These jumpers connect a resistive termination network to the Both jumpered receive lines of the serial port connector. These are both jumpered to connect the termination network. When the RS-232 option is fitted this unit becomes the master and as such should have the termination network connected. J17 to J23 These jumpers are not used as all the signals are brought out to N/A seperate terminals. J24 to J31 These jumpers select various software options. These options may change with the software version. Refer to separate table for usage Refer to option port table. J32 and J33 These jumpers are set to match the polarity of the output of the master encoder connected to terminal 15. Jumper J32 and J33 1 to 2 for NPN output encoders. Jumper J33 2 to 3 and J32/1 to J33/1 for PNP output encoders. J34 This jumper is not used. Refer to J60 on expansion card. N/A J32, 1 to 2 jumpered J33, 1 to 2 jumpered Page 5 of 7

6 InStep Expansion Card Jumper Descriptions Jumper Description Default J51 to J54 These three point jumpers select the polarity of the signal 1 to 2 jumpered required to operate the inputs. Jump 1 to 2 for sinking (NPN) type input devices. Jump 2 to 3 for sourcing (PNP) type input devices. J51 to J54 correspond to inputs 7 to 10 respectively. J55 This three point jumper selects the polarity of the output signal 1 to 2 jumpered OUT8. Jump 1 to 2 for sinking (NPN) output, 2 to 3 for sourcing (PNP) output. No jumper should be fitted if J61 is fitted. J56 and J57 These two jumpers control the RS-232 option. Both should be jumpered 2 to 3 to use the RS-232 interface. Both should be jumpered 1 to 2 to disable the RS-232 interface or if it is not fitted. 1 to 2 jumpered if option 1. 2 to 3 jumpered if no option 1. J58 J59 J60 J61 This jumper controls the duplex mode of the RS-485 transciever on the main card. J58 should be jumpered if the RS-232 interface is used. This three point jumper selects whether the additional output is used as general purpose output 8 or as the high speed step output. 1 to 2 jumpered is OUT8. 2 to 3 jumpered is high speed step output. This jumper replaces J34 on the main board. When jumpered it connects IN6 to OUT7 for a bussed fault. This jumper connects the OUT8 terminal to GND to provide a ground connection for the RS-232 interface. If jumpered, J55 must have NO jumper fitted! 1 to 2 if option 1 fitted. Off otherwise. 1 to 2 jumpered 1 to 2 jumpered. No jumper fitted. Page 6 of 7

7 Terminal Number Terminal Name InStep with Expansion Terminal Descriptions Option Req d Description 1 +24V None Connect a 12 to 28 volt power supply to this terminal to provide the InStep module with power. 2 0V None This is the 0 volt reference terminal for the power supply and the I/O terminals. 3 STEP None This is the step output that connects to the stepper or servo drive. Comment Polarity depends on IC9 4 OUT7 0 Output terminal number 7. Polarity depends on IC9. 5 OUT8 GND/HSTEP 7/4 Output terminal number 8 or comm port ground or high speed step output. Polarity depends on J55. Function depends on J59 and J61. 6 TXD/IN10 1/6 RS-232 transmit or input number 10. Depends on fitted options. 7 IN1 None Input terminal number one. J1 controls polarity. 8 IN2 None Input terminal number two. J2 controls polarity. 9 IN3 None Input terminal number three. J3 controls polarity. 10 IN4 0 Input terminal number four. J4 controls polarity. 11 IN5 0 Input terminal number five. J5 controls polarity. 12 RXD/IN9 1/6 RS-232 receive or input number 9. Depends on fitted options. 13 PRODSENS None This is the product sensor input terminal. J7 controls polarity 14 GAPSENS None This is the label gap sensor input terminal. J8 controls polarity 15 ENC None This is the master encoder input terminal. J32 and J33 control polarity 16 IN6 0 Input terminal number six. J6 controls polarity. 17 IN7 5 Input terminal number seven. J7 controls polarity. 18 IN8 5 Input terminal number eight. J8 controls polarity. 19 OUT1 None Output terminal number one. Polarity depends on IC9. 20 OUT2 None Output terminal number two. Polarity depends on IC9. 21 OUT3 None Output terminal number three. Polarity depends on IC9. 22 OUT4 0 Output terminal number four. Polarity depends on IC9. 23 OUT5 0 Output terminal number five. Polarity depends on IC9. 24 OUT6 0 Output terminal number six. Polarity depends on IC9. Pin Number Pin Name Serial Communication Socket Pin Descriptions Description Comment 1 GND 0 volt or ground 2 RXA Receive positive side Transceive positive side if J13 installed 3 RXB Receive negative side Transceive negative side if J14 installed 4 TXA Transmit positive side Same as pin 2 if J13 installed 5 TXB Transmit negative side Same as pin 3 if J14 installed 6 GND 0 volt or ground Note: This socket has transmit and receive terminals swapped to that of the standard InStep module. This is to allow direct connection to standard modules when the RS-232 option is fitted. Page 7 of 7