Download The system consists roughly of three parts:

WinCapp Function Generator PCB Card
Technical manual
Revision 4
March 22, 2000
TCD Teknologi ApS
Genuavej 44
DK-2300 Kbh. S
DENMARK
e-mail: [email protected]
Internet: www.tcd.dk
Phone & Fax: +45 32 97 32 87
This package contains:
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This manual.
1 WinCapp Function Generator board.
1 Function Test Board with LED's and connector.
1 10-pin to 9-pin D-type adapter for AT null modem cable.
1 AT null modem cable for RS232-C comms.
1 diskette with WinCapp software.
1 diskette with system update software.
What is WinCapp? ............................................................................................................................................ 3
Hardware ........................................................................................................................................................... 3
Connectors: ................................................................................................................................................. 3
Jumpers ....................................................................................................................................................... 3
LED indicators ............................................................................................................................................. 5
Charge measuring feedback ....................................................................................................................... 5
Other devices .............................................................................................................................................. 5
Incorporating in a standard power supply.................................................................................................... 5
Interface considerations. ............................................................................................................................. 6
Software ............................................................................................................................................................. 7
Installation diskette ...................................................................................................................................... 7
Setting up the IN_ file .................................................................................................................................. 7
System Update .................................................................................................................................................. 8
Bipolar configuration .................................................................................................................................... 8
Other Configurations ................................................................................................................................... 8
Quick start ......................................................................................................................................................... 8
Appendix............................................................................................................................................................ 9
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2
What is WinCapp?
WinCapp is a system developed by TCD Teknologi ApS, Denmark. It can be used in a number of
electrochemical processes and pulse plating and anodizing in particular.
The WinCapp System consists of:
 PC Software: Application for Win 3.1 / Win95 / Win98. (Win2000 from Oct. 2001).
 Hardware: A WinCapp Function Generator (WFG) which is normally incorporated into a large power
supply and thereby enhancing it. It communicates with the PC software through a PC serial port.
WinCapp handles two-electrodes and, to some extent, three-electrodes systems. This manual describes twoelectrodes systems only.
Bipolar and unipolar power supplies are supported. Bipolar supplies are widely used with pulse plating and
unipolar supplies are more common at anodizing processes. The board is shipped with bipolar configuration.
If unipolar configuration is required, refer to the System Update section.
Hardware
The WFG only needs power 0 and +5 V to work. The WFG board is controlled by a microcomputer with a
Flash memory so code can be changed and upgraded for customer specific configurations at their location.
An optically isolated serial communication port (RS232-C) works as the PC-interface. A dual 12-bit Digital-toAnalog Converter generates analog signals for controlling the output of a large power supply. Please see
appendix for diagrams.
Connectors:
The WFG has three connectors: J1 (main), J2 (optional LED indicators) and J4 (PC Communication):
Unmentioned pins have no connection. All signal lines to and from WFG (except J4) must be buffered.
Jumpers
J1
pin
31
30
29
28
27
26
25
24
23
22
21
19
13
12
11
4
3
2
1
J2
pin
2
4
6
8
10
J4
pin
7
9
3
5
7
9
Line
Range
i/o
Description
p1.0
p1.1
p1.2
p1.3
p1.4
p1.5
p1.6
p1.7
int0
int1
t0
res
DAC1
DAC2
AGND
-15 V
+15 V
Vcc
DGND
RxD
TxD
DTR
0
CMOS/TTL
CMOS/TTL
CMOS/TTL
CMOS/TTL
CMOS/TTL
CMOS/TTL
CMOS/TTL
CMOS/TTL
CMOS/TTL
CMOS
CMOS
CMOS/TTL
±5 V analog
±5 V analog
0 V analog
-15 V analog
+15 V analog
+5V
0V
±12V
±12V
±12V
Common
o
o
o
o
i/o
Remote Control LED: 0=On; 1=Off
Voltage Reg. LED: 0=On; 1=Off
Current Reg. LED: 0=On; 1=Off
Output On LED: 0=On; 1=Off
User available: 0=On; 1= Off
reserved
reserved
reserved
reserved
Charge counter: Count 1C on 1-0 transition
0=Cathodic count (Qc); 1=Anodic count (Qa)
0=Run; 1=Reset
Potential controlling analog signal
Current controlling analog signal
analog ground
analog power supply (5 mA out max)
analog power supply (5 mA out max)
+5VDC (±5%) main power supply
Ground for main power supply
Serial Receive
Serial Transmit
Serial Data Terminal Ready
Serial GND
i
i
i/o
o
o
o
o
i
i
i
o
o
Table 1. Connectors
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3
JP1 & JP6:
Determines whether to run code internally in the CPU or externally from a ROM device placed in the IC3socket.
JP1
JP6
Operation
Internal ROM
(Default)
External ROM in IC3
Table 2. JP1 & JP6 settings.
JP4:
CPU Reset.
JP4
Operation
Normal Operation
(Default)
CPU Reset
Table 3. JP4 settings.
JP2 & JP3:
Sets analog output voltage signal range. JP2 sets DAC1 (potential) and JP3 sets DAC2 (current).
JP2
JP3
DAC Output
Voltage Range
0 to 5 V
0 to 10 V
-5 to 5 V
Table 4. JP2 & JP3 settings.
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4
JP5:
Connects analog and digital ground. In some systems it is necessary to separate AGND and DGND due to
noise on digital power lines. If JP5 is open, J1 pin 11 must be connected to DGND somewhere in the
equipment.
JP5
Operation
AGND floats
AGND=DGND
(Default)
Table 5. JP5 settings.
LED indicators
Sometimes it is convenient to have Light Emitting Diodes (LED’s) show the power supply status. The LED
lines can be taken from J1 or J2. The LED test board in this package fits on J2. LED’s can be labeled as
suggested in Table 1Error! Reference source not found.. Some of the LED signal lines are also used by
the Power Supply. If another LED board or the like is used, the signal lines must be buffered.
Charge measuring feedback
It is possible for the WFG to keep track of anodic and cathodic charge flow, and give this information to the
PC-software. A small charge sampler board must be developed though. The board must provide two signal
lines to the WFG (J1 pin 21 and 22) in order to make it count. See Table 1. This feature enables functions of
charge f(q) in the PC-software. To utilize this feature the On-Chip code must be changed. See the System
Update section for detailes.
Other devices
WFG can control and be controlled from other devices, so tasks like controlling a crane and checking water
levels can be implemented. These features are limited by the amounts of digital inputs/outputs available on
J1. The only available i/o is J1 pin 27, but if some of the LED indicator lines and/or the charge counter are not
used, they can be used as i/o’s (this requires on-chip software update, see section System Update). As
default, J1 pin 27 is used as a digital output.
Incorporating in a standard power supply
Consider a standard power supply with two potentiometers on the front panel: One for setting the voltage and
one for the current. Since the parameters are mutually dependent, normally only one of them is actually
regulated. Hence, the potentiometers set the limit values for the voltage and current parameters. If the
potentiometers’ end pins are connected to 0 V and 5 V, then their middle pins provide voltages in this range,
acting as controlling signals for the regulator. 0 V in corresponds to 0 V or 0 A out, and 5 V in corresponds to
the maximum voltage or current the power supply can provide. The WFG can also make these controlling
signals, so by inserting analog selectors or small two-position relays on the regulator control lines, the WFG
can select whether the controlling signals come from the front panel potentiometers (local control) or from the
WFG analog outputs (remote control), see Figure 1.
The analog selectors and the potentiometers are optional since we can choose to work in remote mode only.
If the power supply is unipolar, the WFG analog outputs are best set to the range 0 to 5 V, just like the
potentiometers. If it is bipolar (default), the best output range is -5 to 5 V corresponding to the maximum
anodic (reverse) and cathodic (forward) voltage or current, the power supply can provide. The WFG can also
control an optional output relay, which can set the power supply into ‘idle’ state, where the outputs are
unconnected. This is useful when working with high voltages and during power up, where the outputs might
be indeterminate.
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5
Figure 1. Connecting WFG to a standard power supply.
Interface considerations.
When interfacing with other equipment, please consider the following:
Digital lines: All digital 5V range signal lines to and from the WFG must be buffered. CMOS buffers are
preferred.
RS232-C: Interface is optically isolated and buffered. Please use the AT null modem cable included in this
package only or ensure compatibility is using another cable.
Analog lines: Outputs are filtered on-board to eliminate noise pickup and digital to analog glitch impulses.
Filter is shown if fig. 2. Outputs are also overvoltage protected from transient peaks, not continuous
overvoltage.
100
Input
1 nF
Output
Figure 2. Analog noise filter.
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6
Software
Installation diskette
The WinCapp PC-software normally comes to the customer on a diskette along with the power supply. The
software is installed by running the SETUP.EXE file. All the files on the installation diskette are compressed,
except SETUP.EXE and WINCAPP.IN_. The contents of the latter must be changed to fit the power supply to
be sold. WINCAPP.IN_ will automatically be renamed to WINCAPP.INI when installed.
Setting up the IN_ file
Use any text editor to change the WINCAPP.IN_ file.
The text file, which is more or less self-explaining, could look like this:
[Rectifier]
Current=Yes=100A
Voltage=Yes=30V
OutputControls=No
InputControls=No
ReferenceVoltage=No=3000mV
IRCompensation=No
QControl=No
Idle=Yes
Local=Yes
Bipolar=No
AntiBurn=No
U_Unit=Volts
I_Unit=A
Uref_Unit=mV vs SHE
[I/O]
Out1=Tap water
In1= Water level at 5”
[Communication]
SerialPort=COM1
BaudRate=4800
Handshake=DTR/DSR
[System]
*** unit = [µs, ms, s, min] ****
MinimumTimeScale=100ms
*** unit = [mC, C, kC] ****
MinimumChargeScale=1000C
DataCollectors=No
; can power supply limit the current and what’s the max?
; can power supply limit the voltage and what’s the max?
; can WFG control external devices?
; can external devices control WFG?
; three-electrode systems option
; three-electrode systems option
; is function of charge supported?
; is output relay supported?
; is local control supported?
; is power supply bipolar?
; is anti-burning supported?
; the unit for the voltage
; the unit for the current
; three electrode systems option
; name of output device line
; name of input device line
; communication parameters. DON’T CHANGE!!!
; this might be changed by installation program
; set minimum time scale
; change if it’s a slow power supply
; set minimum charge scale
; is data collection implemented?
[Profiles]
Profile=
; costumer specific profiles are entered here
[Printer]
ColourPrinter=No
; copy colours to clipboard
Since the WinCapp software is developed to support many kinds of power supplies, many of the parameters
must often be disabled.
SETUP.EXE asks for the installation directory and the serial port to use. When the installation is completed,
the renamed WINCAPP.INI file can be changed at any time e.g. if the PC serial port is changed or a data
collector board is added or the like. However, it is important that the rectifier manufacturer sets up the
WINCAPP.IN_ file to fit the rectifier properly before sale.
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7
System Update
The WinCapp software is divided into two parts:
 The PC-software.
 The WFG firmware (programmed into a chip on the WFG board).
On the diskette there is a file called “Flash”. This is used to update the firmware on the WFG board by
transferring hex-code files to the In-Circuit memory. The diskette may also include firmware hex-code files for
different setups you requested. Flash and hex-code files can also be found on the Internet.
Regular version checks on WinCapp, Flash and hex-code software on the Internet is highly recommended.
Internet site: http://www.tcd.dk
Bipolar / unipolar configuration
The WFG controlling signals can be changed to [0; 5V], [0; 10V] or [-5; 5V] range. This is done with jumpers
JP2 and JP3, see Table 4. But also the WFG software has to be changed to accordingly.
Other Configurations
If the standard types 4 and 5 don’t cover your requirements, other types are available. TCD Teknologi ApS
will also make special customer type configurations free of charge as long as they include minor changes to
the existing types. Please ask.
Other configurations could involve usage of only one DAC to control either voltage or current and then use
the digital lines to select the parameter. Also additional digital lines for i/o-purposes might be considered.
Any requests concerning system configuration changes should be forwarded by e-mail to [email protected].
Quick start
1.
2.
3.
4.
Connect the small 10-pin to 9-pin D-type adapter to J4. (colored flat cable wire at pin 1)
Connect a serial null modem cable from the D-type connector to a PC serial port.
Connect the small LED board to J2 via a flat cable. (colored flat cable wire at pin 1)
Connect power to main connector on WFG board J1 like this:
Pin1 = GND
Pin2 = +5V (±5%)
(current consumption is max. 500 mA)
5. Switch on power to the PC.
6. From Windows run ‘SETUP.EXE’ on the installation diskette to install WinCapp.
7. Run WinCapp. Use the WinCapp help file if you are new to WinCapp.
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8
Appendix
Figure 3. WFG diagram.
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9
Figure 4. LED board diagram.
Figure 5. LED borad mounting.
Page 10