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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: 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 Page 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 Page 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. Page 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. Page 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. Page 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. Page 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. Page 8 Appendix Figure 3. WFG diagram. Page 9 Figure 4. LED board diagram. Figure 5. LED borad mounting. Page 10