502913 - Orbit3 System manual
Contents
1. 21 8 2 2 Grounding with non DIN rail installations sees 27 82 3 Orbit Cables eie se diri er e e bres ee cea E CAREY Nee UE 22 8 2 4 Power Supply Interface Modules 23 8 2 5 PSIM Schematic ard Pin o t erret 24 9 ORBIT CONTROLLER INSTALLATION AND 25 9 1 CONTROLLER TYPES la ta dai a 25 9 2 INSTALLING THE ORBIT amp 3 SUPPORT PACK FOR WINDOWS OSPW 25 9 3 ORBIT PCI CARD INSTALLATION AND USER GUIDE 26 93 1 Hardware Installation dl a d nt ti CE THEME TU SE ai atei ai 26 9 4 PC104 CONTROLLER 29 9 5 USB CONTROLLER coaie ea aa nainte aa i ceai diana igienei 30 9 5 1 Hardware Installation eee nana AE 30 9522 Usine TEE ETE 21 DG PRS 2S AW e 32 6 a taiata de agata tat aaa aaa ULLA I MIN erect ree errr ae sal data 32 oe eoi metus oa dale ua patina eta 9 7 RSA fem c aa i a a Ca i Sc Gl in a Ca ai al 36 9 8 ETHERNET CONTROLLER scenic a toi gat cl RR 37 9 9 SETTING UP2. Orbit3 Channel A Channel of an Orbit Controller that is capable of supporting a Network of Modules Channels are numbered either Channel 1 or Channel 2 Note Channel 2 only exists depending on the type of Orbit Controller Digital Probe A special case of Orbit product where a linear measurement probe usually a gauging probe is permanently attached to an Orbit Module This module is known as the Probe Interface Electronics PIE TCON A 3 way connector housed in a case which allows an Orbit Measurement System to be easily installed The TCONs are connected together to form the backbone of a network and Orbit Modules plugged into the TCONS See MECHANICAL INSTALLATION for more details Orbit System Manual Issue 1 7 of 44 Orbit 3 Support pack for Windows9 A suite of software COM drivers and DLL s which allow the user to interface to the Orbit Measurement System using modern development systems in most common software languages 5 2 TERMS ASSOCIATED WITH ORBIT MEASUREMENT MODES Orbit Measurement Mode The method by which the Orbit Measurement System takes measurement data from the Orbit Network group of modules There are three modes of measurement Standard Mode Buffered Mode and Dynamic Mode Refer to the Orbi3 Measurement System Software Manual for further details of the measurement modes and how to use them Standard Measurement Mode Orbit Modules are communicated with on an individual basis Each modul
3. Orbit System Manual Issue 1 31 of 44 9 6 52321 Hardware Installation Unlike the PCI network card and the USB module the RS2321M does not require the Orbit amp 3 Support Pack for Windows to be installed for basic operation If using the RS2321M with the COM or DLL then install the Orbit 3 Support Pack for Windows The RS232 module needs to be used with a PSIM which provides its power It must be placed after the PSIM in the TCON backbone The RS232 module plugs directly into the PC serial port RS232 PIN ALLOCATIONS PC or PLC Serial Port ON 6 7 8 9 NYA o 1 2 3 4 5 X A RS232 MODULE MUST BE SECOND T ODULE No Connection MUST BE FIRST a i M 2 Rx from RS2321M MORE ORBIT MODULES MAY BE CONNECTED HERE 13 Tx to RS2321M GND DSR linked to DTR RTS to RS2321M 8 CTS on RS232IM ini The RS232 module provides a bridge between the PC PLC and the Orbit Measurement System The RS232IM receives a command header string and an Orbit Command string from a PC or PLC It then sends the Orbit Command string to the Orbit network at 187 5kBaud The Orbit Measurement System the processes the command and responds to the RS2321M the 52321 adds a header sends the data back to the PC or PLC DTR linked to DSR 9 6 1 Operation Command orders must be in accordance with the standard Orbit Protocol Please refer to the Orbit Soft
4. 6 orbit Support Pack for Windows Setup or Windows f je amp Orbit Install Complete olortron 5 Welcome to The Install Wizard has successfully installed Orbit Support Pack For Windows Click Finish to exit the wi m f Solartron Metrology s he wizard e Ogy Orbit 3 Measurement System A reboot is required before use ULTRA PRECISION TECHNOLOGIES RS232 and ISA Controllers need to After installing the Orbit 3 Support Pack for Windows the following components will be loaded e Orbit Com Library which provides a language independent interface to the Orbit Measurement System e A dynamic link library Orbit IF dll that provides an interface between 32 bit application and the Orbit Network via an Orbit Controller Orbit3 PCI Network card USB Controller RSS232 Controller e Orbit Registration Program OrbitRegistration exe which allows you to register a RS232 device or Orbit ISA network card Orbit System Manual Issue 1 25 of 44 Orbit ComTest demonstrator program using COM e Orbit3 Demonstrator Program e Code examples 9 3 ORBIT PCI CARD INSTALLATION AND USER GUIDE PC System Requirements e PC with a Pentium Processor running at 7OOMHz or above with 128MB or more of RAM PCI Slots each card will require one PCI slot This is NOT PCI EXPRESS Microsoft Windows 32 Bit operating system 64 bit operating systems are not supported Microsoft Windows xXP Win
5. Orbit Voltage Error 4 5V or gt 5 5 Slow Flash The Orbit voltage is outside of 0 8 secs on 0 2 specification and the modules return secs off an error code they do continue to communicate unless the voltage becomes so low that they stop Hardware Fault On The modules return an error code The red LED s which indicate a fault condition will stay active as long as the fault exists they are not cleared by a reset or cycling the power unless the fault is cleared 6 3 2 HOT SWAP ERROR INDICATION STATUS BLUE EI Not Present fuc second second The Red LED will either fast flash if there is a Hot Swap error or stay on following an OrbitSetAddr command if there is a Hot Swap hardware error 6 3 3 EIM ERROR INDICATION The EIM is a special case and does not have the Orbit Voltage Warning indication All other error conditions are reported Orbit System Manual Issue 1 14 of 44 7 1 MECHANICAL INSTALLATION Orbit Modules comprise of an electronic module sensors are either hard wired into the electronics module or a cable is provided for connection to external elements The electronics modules are formed into an easy mechanical system using T connectors ICONS for rapid installation and simple maintenance The Orbit Electronics Module comprises a plastic molding with a nine way D Type connector two recesses for connection to a and two diagnostic LED indicators The TCON contains t
6. PSIM AND 1 CHANNEL OF ORBIT MODULES FOUR PSIMS POWERING 100 ORBIT MODULES No more than 32 odules per PSIM PCI CARD MOUNTED IN PC PC WITH PCI NETWORK CONTROLLER PSIMS AND 1 CHANNEL OF 100 ORBIT MODULES PCI CARD No more than 32 Modules per PSIM PC WITH PCI NETWORK CONTROLLER 2 CHANNELS OF ORBIT MODULES 8 PSIMS 200 MODULES Orbit System Manual Issue 1 40 of 44 10 3 USBIM NETWORKS USB INTERFACE E lt 5 Modules USB PORT MODULE BASIC PC WITH USB NETWORK CONTROLLER AND 1 CHANNEL OF UP to 4 ORBIT MODULES USBIM FIRST MODULE IN STACK T lt 32 Modules PC WITH USB NETWORK CONTROLLER PSIM AND 1 CHANNEL OF ORBIT MODULES NOTE USB MUST BE FIRST MODULE IN STACK 11 COMMUNICATING WITH AN ORBIT NETWORK Refer to the Orbit Software Manual included with the OSPW CD Orbit System Manual Issue 1 41 of 44 12 ORBIT ACCESSORIES Part Number Description 806127 Orbit cables specifically designed to ensure good system performance Available in various lengths 804067 3 Screwlock kit supplied with cables 971000 3 TCON connector 209501 Orbit3 Earth and Mounting Bracket used to mechanically lock the TCONS together in environments subject to vibration and to produce a good earth to chassis at the TCON backbone 802968 Terminator Connector used to provide a matched impedance and to be connected at the end of the TCON backbone Orbit System Manual Issue 1 42
7. ORBITS HOT SWAP nn nai s d da nina ni di ni di oi 13 6 3 DIAGNOS TIC Ss nisi cani na ni aie in ji fe tu lt n a a iati 14 6 3 GENERAT STATUS ceea ra aia aa s e ia SERIE cab a Doe EEEE e od aaa 14 6 3 2 HOT SWAP ERROR INDICATION saca scan nn asa do ana eaae be catena 14 6 3 3 EIM ERROR INDICATION sis ne ttn da oaia e apoasa iaca da d aaa d una sana oana 14 7 MECHANICAL INSTALLATION anas nk aan aan a tm rami Ra GR ia aa ambii 15 7 1 BASIC TCON CONNECTION circ acarieni ana ia pug ci ea aaa i dud aia 15 7 2 BASIC MODULE TO TCON MOUNTING 16 7 3 DIN RAIL MOUNTING citi cum citea Dim tns Seven tai di i 1 Orbit System Manual Issue 1 3 of 44 7 4 MODULE or PIE to 17 7 5 OPTIONAL SCREW MOUNTING DIN RAIL 18 7 6 REMOVAL OF DIN RAIL FITTING OF 18 8 ELECTRICAL INSTAELATION cue sax eMe D 19 8 1 OPERATING VOLTAGE AND 2 1 1 19 8 1 1 CHECKING ORBIT VOETAGES uote UR UR Eo REOR NE E au e da E tat d 20 8 2 GROUNDING CABLES AND POWER 21 8 2 1 Grounding with DIN rail
8. computer user manual for any special instructions Find an empty PCI slot and remove the slots blanking plate Insert the Orbit 3 Network card If you are intending to use more than one PCI card for Dynamic operation then fit the Multicard Link Cable to the PCI Network cards you wish to link before refitting the case of the computer Each Link cable can link up to 4 PCI cards If you are linking less leave the remaining connectors disconnected Each PCI card has two 2 way Molex connectors on the edge opposite the Orbit connectors as you look at this edge the connector on the right is the Master connector and the one on the left nearest the 10 way header is the target connector Use the link cable to connect one PCI card nearest the PSU as the master and connect the remaining as targets Replace the computer s cover and turn the power on Windows will detect the Orbit 3 Network Card s and automatically install the driver software Note the Network Card Firmware detects whether the cards are linked Master or target automatically no Software settings are required Orbit System Manual Issue 1 27 of 44 The Orbit Measurement System up to 6 PCI cards Each card must be set up as defined below Card Number Card Channel Network Number 1 1 0 2 1 2 1 2 2 9 3 1 4 2 5 4 1 6 2 7 5 1 8 2 9 6 1 10 2 11 Any number of networks can be allocated but
9. the networks must be numbered in sequence Orbit System Manual Issue 1 28 of 44 94 PC104 CONTROLLER CARD The Orbit PC104 Network Card provides an Orbit network capability to any PC with a PC104 bus The card s operation is the same as the Orbit PCI MK2 Network Card for details of this see the relevant User Manual 502566 PC104 Configuration Links The units are shipped with the links in the default positions of INT A GNT 0 PCLK O REQ 0 IDSEL 0 It is up to the user to configure the links for their specific system GNT lt m T PCLK CONFIGURATION LINKS Orbit System Manual Issue 1 29 of 44 9 5 USB CONTROLLER PC System Requirements e See Section PCI card e PC will require a USB Port Carton Contents Orbit USB Interface Module e 9 Way Terminator Plug used to terminate end of TCON backbone Earthing and Mounting Bracket 9 5 1 Hardware Installation 1 Before using and connecting the USB controller install the Orbit 3 Support Pack for Windows 2 Insert the USB plug into any USB Type A socket on the PC 3 The PC will recognize the USBIM and on some operating systems report it has been connected If the PC shows a message similar to the following please follow the instructions Found New Hardware Wizard Welcome to the Found New Hardware Wizard Windows will search for current and updated software by looking on your computer on the hardware insta
10. AN ORBIT MEASURMENT 5 37 10 EXAMPLES OF ORBIT 5 4 4 442 022 0 38 10 1 SIMPLE PCI CARD NETWORKS 38 10 2 PCI CARD WITELPSIM oie anc aia a nete que as Ek eras ebria ia 39 10 3 USBIM NETWORKS CINE AK OUR ARE DIA C UE cU ai oul aaa 40 11 COMMUNICATING WITH AN ORBIT NETWORK eene enne nnns 40 Orbit System Manual Issue 1 4 of 44 12 ORBIT ACCESSORIES iii a iii ia ot aut dai 41 13 REVISION HISTORY omite ci ice iai d i iai 43 3 3 1 INTRODUCTION SCOPE The Orbit 3 Measurement System is a modular measurement system that be put together quickly easily and is cost effective It allows different types of sensors to be easily mixed and integrated on a single network independent of sensor technology In addition to linear probes and linear displacement transducers third party sensors can easily be integrated this combined with programmable input and output modules for interfacing to external equipment makes the Orbit 3 Measurement System a flexible solution for measurement applications Typically an Orbit amp 3 Measurement System will consist of four elements Measurements Modules with T Connectors Measurement System controllers po
11. LiveUp See information about your computer system Customize the Start Menu and the taskbar suc Change user account settings and passwords ft Manage Information Cards used to log on and t Configure the Windows Firewall Set up or add to a wireless network for your hc gt The following System Propeties screen will appear Orbit System Manual Issue 1 34 of 44 System Properties System Restore Automatic Updates Computer Name Hardware System Microsoft Windows XP Professional Version 2002 Service Pack 2 Registered to Nick Deadman 76487 0EM 0011903 00102 Manufactured and supported by Dell Latitude D430 Intel R 2 CPU U7600 amp 1 20GHz 790 MHz 1 88 GB of RAM Physical Address Extension Select Hardware System Properties System Restore oma Remote General Computer Name Advanced Device Manager The Device Manager lists all the hardware devices installed on your computer Use the Device Managerto change the properties of any device Driver Signing lets you make sure that installed drivers are compatible with Windows Windows Update lets you set up how Windows connects to Windows Update for drivers Driver Signing Windows Update Hardware Profiles Hardware profiles provide way for you to set up and store different hardware configurations Hardware Profiles Select Device Manager the following screen will
12. SeralData RS485 3 SerialData RS485 4 850 7 6 O 8 80 4 Orbit System Manual Issue 1 19 of 44 8 1 1 ORBIT VOLTAGES If the status LEDs indicate a low operating RED LED INDICATES voltage this can be VOLTAGE OUT OF LIMIT caused by e Insufficient power supply PC for example cannot supply enough current if using VOLTAGE AT THIS POINT gt 4 75V PCI card MEASURED AT FURTHEST POINT t FROM POWER SOURCE Cable lengths too long Use of poor lt quality cables x recommend using cables designed to for Orbit VE NOMINAL 5V PINS 6 amp 7 Insufficient PSIM VE 0V PINS 5 amp 9 PSIM derating not being followed if ambient temperature is high P 8 9 N y To check the Orbit Voltage measure the voltage at the end of the TCON stack furthest from the power source for the stack which is indicating an Orbit Voltage problem Orbit System Manual Issue 1 20 of 44 8 2 GROUNDING CABLES AND POWER SUPPLIES It is advisable to provide a good ground point for an Orbit installation Grounding of the Orbit3 product can be achieved using two methods Grounding the system back to the primary power source or grounding the TCON stack using a special grounding bracket The grounding bracket can be fitted to either end of the TCON backbone using the screw lock connections on the
13. TCON Note With Orbit3 there is no connection between the mounting screws on the TCON and the system ground This has been done to allow alternative grounding schemes Previous versions of Orbit had metal TCONS and cases which forced earthing via the case The Digital Probes have their body connected to the cable screen Therefore all parts of the system should be at ground potential 8 2 1 Grounding with DIN rail installations For DIN rail mounted applications the bracket provides a means of locking the stack in place on the DIN rail in applications where their may be vibration and or a local ground point is required See below for assembly Orbit System Manual Issue 1 21 of 44 8 2 2 Grounding with non DIN rail installations For non DIN rail mounted applications the bracket provides a means of locking the stack in place on a surface in applications where there may be vibration and or a local ground point is required See below for assembly 8 2 3 Orbit Cables Special Cables which are specifically made to reduce voltage drop and to provide adequate screening for compliance with the directives are recommended A terminator is supplied with each controller this should be placed at the end of the network For accessories see ORBIT ACCESSORIES Orbit System Manual Issue 1 22 of 44 8 2 4 Power Supply Interface Modules PSIMS Power Supply Modules PSIM are recommended for larger installations an
14. View See Also Windows Update 9 Help and Support Click System Name P internet Options a Keyboard 3 Modem Diagnostic Tool 1 Mouse Network Connections Phone and Modem Options 3 Power Options Printers and Faxes PA Program Updates Q QuickTime Regional and Language Options Scanners and Cameras E Scheduled Tasks Security Center X SigmaTel Audio Sounds and Audio Devices a Speech 9 Symantec LiveUpdate System il Taskbar and Start Menu 8 User Accounts windows CardSpace Windows Firewall lt 4 Wireless Network Setup Wizard lt v Go Comments Configure your Internet display and connection Java TM Control Panel Customize your keyboard settings such as the Diagnose the modem hardware and software p Customize your mouse settings such as the bu Connects to other computers networks and th Configure your telephone dialing rules and moc Configure energy saving settings for your comp Shows installed printers and fax printers and hi InstallShield Update Manager checks for update Configures QuickTime software and hardware Customize settings for the display of languages Add remove and configure scanners and cam Schedule computer tasks to run automatically View your current security status and access in Controls SigmaTel Audio Settings Change the sound scheme for your computer Change settings for text to speech and for spec This applet allows you to configure your
15. appear Orbit System Manual Issue 1 35 of 44 Device Manager File Action View Help e amp R Disk drives Display adapters lt 3 DVD CD ROM drives amp Human Interface Devices IDE ATA ATAFI controllers amp e IEEE 1394 Bus host controllers gt Keyboards Mice and other pointing devices H Modems 9 Monitors 50 Multi port serial adapters 88 Network adapters PCMCIA adapters 7 Processors Secure Digital host controllers X Smart card readers m Sound video and game controllers 11 curtam desicec 19 1 j Expand the Ports COM and LTT heading to expose the COM ports 5 Device Manager File Action View Help e R Monitors 1 30 Multi port serial adapters 9 88 Network adapters PCMCIA adapters iY Ports COM amp LPT 7 BT Port COM10 9 BT Port COM11 BT Port COM12 7 BT Port COM13 BT Port COM14 7 BT Port COM20 7 BT Port COM21 BT Port COM22 BT Port COM6 7 BT Port 7 Communications Port COM1 7 Digi One SP Port 1 COM2 Digi One SP 2 Port 1 COM4 Drintar Dart reri The COM ports can now be edited and re alloated Select a Port and click to open the Port The select the Port Settings Tab Orbit System Manual Issue 1 36 of 44 TruePort Serial Port COM8 Proper 2 General P
16. d for applications where the stack is greater than 3m from the PSIMs are the preferred option for providing a quiet supply for the Orbit bus They must always be used with the RS232 controller and Ethernet controller However the USB controller can provide power for up to four Orbit modules providing that the PC is capable of providing sufficient USB power IEC INPUT MAINS 90 230V PSIM USE TO POWER ORBIT MODULES FROM LOCAL MAINS SUPPLY NN VDC SUPPLY PSIM 5V USE TO POWER ORBIT MODULES FROM LOCAL 5V DC SUPPLY 10 30 VDC SUPPLY PSIM DC USE TO POWER ORBIT MODULES FROM LOCAL DC SUPPLY The PSIM will only provide power to modules that follow the PSIM Typical configurations are shown in the Section EXAMPLES OF ORBIT NETWORKS The PSIM power connections are shown in the diagram below Note The USB controller must go before the PSIM Orbit System Manual Issue 1 23 of 44 8 2 5 PSIM Schematic and Pin out From External Power Supply PLUG Side SOCKET Side 5 V from Orbit Network 5 V to Orbit no pins on connector Network OV 0v RS485 lt a 5485 The 5 V power supply line from the network is isolated at the PSIM All modules after the PSIM are powered from the external power supply connected the PSIM O V is common When installing a PSIM the following points should be considered e The AC Power block may be mounted in any direction e The AC power block shoul
17. d not be exposed to fluids or excessive dust e Cooling of the AC power block is by convection so allow some air flow around the unit e When installing the DC PSIM in large Networks it is advisable to fit a TCON between the previous Orbit Module and the PSIM to allow for cooling In hot environments fit a TCON either side to allow air flow around the DC PSIM e The PSIM output current requires to be thermally derated from above 40 C by 50 up to its maximum working temperature of 60 C See the Orbit Dimensional Drawings supplied with the OSPW for dimensional and mounting data for the PSIM products Orbit System Manual Issue 1 24 of 44 9 ORBIT CONTROLLER INSTALLATION AND USE 9 1 CONTROLLER TYPES See Controllers Overview 9 2 INSTALLING THE ORBIT 3 SUPPORT PACK FOR WINDOWS OSPW The OSPW must be installed before connecting or fitting any of the Orbit Controllers To install the OSPW you must be an administrator on the PC Also ensure the PC s power saving mode is not set to enter Standby If this occurs and then the system re awakes the Orbit Controller will not respond To install the software insert the Orbit 3 Measurement System and Documentation CD into the appropriate drive The CD should run automatically if it doesn t run the file index hta Select the option Install Orbit3 Support Pack for Windows follow the instructions on the screen until the Install Shield Wizard Completed Window is displayed
18. ditioning module that is fitted to the DP is called a PIE module Analogue Input A module that can take in 3 party sensors with either Module AIM voltage of current outputs E g pressure load cells A Special variant is available for a PT100 temperature sensor Encoder Input A module that can take in a square wave signal from a Module EIM rotary encoder or line scale This allows angular position to be easily brought into the Orbit3 measurement system for profiling The EIM can also act as a pseudo controller for Dynamic measurement applications Module DIOM outputs for control functions Module such as a Vernier Caliper Digital Displacement A displacement sensor hard wired to an Orbit3 Conditioning Module allowing Displacement sensors to be easily networked and data collected from them PSIM Power Supply Interface Module used to power the Orbit3 Network For further information of the Orbit Modules refer to the Orbit Modules Documentation supplied on the OSPW CD Orbit System Manual Issue 1 11 of 44 5 5 OVERVIEW ORBITE3 CONTROLLERS The Orbit3 Measurement System Controller Products which are suitable for different applications as summarized below Controller Description Measurement Orbit Bus Type Modes Speed Supported Baud Rate PCI Card PCI card that fits inside a Dynamic 9600 Baud and can control two Orbit Buffered 187 5kBaud Measurement channels 6 Normal 1 5MBaud cards can be installed in o
19. dowsGVista or Windows 7 Earlier versions generally work but are not supported Carton Content Orbit PCI network Card e Cable 2m with 9 way D Types connectors Connects Orbit Network Card to TCON stack e 2earthing and mounting brackets 9 Way Terminator Plug used to terminate end of network cable 9 3 1 Hardware Installation The Orbit Su Network Card ort Pack for Windows must be installed before fitting the Orbit PCI Before handling the Orbit PCI Network Card read the following information A Static Electricity The Orbit Network card contains components that can be damaged by static electricity To reduce the risk of damage to the card keep it in its conductive plastic packaging until it is required When fitting the card handle it by its free edges and do not touch the card edge connector High Voltages Before opening the cabinet of the computer switch off the power and disconnect the power supply lead from the mains supply Do not operate with the cover removed The Orbit 3 Network Card is designed to be installed into a PCI slot on the computer motherboard Follow the steps below Orbit System Manual Issue 1 26 of 44 The Orbit Network Card is designed to be installed into a PCI slot on the computer motherboard Follow the steps below 1 Before fitting the card install the Orbit 3 Support Pack for Windows Turn off power remove lead and remove the cover Refer to the
20. e is asked for its measurement data by the controller as required This mode is suited to measuring static parts where the measurement is not related to other parameters Buffered Measurement Mode Orbit Modules those with buffered capability are told by the controller to take a series of measurements and store them in internal module memory This data is then extracted in one block by the controller when the required measurements have been taken Dynamic Measurement Mode Orbit Modules take a measuring on receipt of a common synchronization pulse sent to the modules from the controller Each module in turn sends its data back to the controller within a specific time frame This process continues until the required number of measuring have been taken Dynamic Mode Data Time Frame 2565 time window in which the modules that are performing a Dynamic Measurement return their data This time frame defines the data rate and number of modules that can perform a dynamic measurement Orbit System Manual Issue 1 8 of 44 5 3 Dynamic Mode Reading Rates The table below explains the reading rate and module relationships Reading Rate Number of Modules Term used to describe Readings second 3906 8 4k Mode 1953 16 2k Mode 976 31 1k Mode Dynamic Synchronization Pulse Pulse sent from a Dynamic capable Orbit Controller which tell the Orbit Modules to take a reading This pulse is either generated by an Orb
21. fied in this document under individual or other property modules Symbols in this manual Caution Low Voltage This equipment operates below the SELV and is therefore outside the scope of the Low Voltage Directive Indicates cautionary or other Service and Repair information CAUTION This equipment contains no user serviceable parts Return to supplier for all service and repair All of the Orbit 3 Products CE marked and comply with EN50081 1 Electrical Emissions and EN50081 2 Electrical Immunity Orbit System Manual Issue 1 6 of 44 5 5 1 GLOSSARY TERMS AND BASIC SYSTEM INFORMATION TERMS ASSOCIATED WITH THE ORBIT3 MEASURMENT SYSTEM HARDWARE Orbit Measurement System A system of Orbit controllers modules cables and interface software that are connected together to form a Measuring System Orbit Module An Orbit Module which can be connected to the Orbit system as part of a Network Channel Orbit modules perform various measurement and interfaces to the external world Orbit Controller Orbit hardware which controls a network of Orbit modules and is used for communicating with the modules The controller provides the link between the Orbit Network and a PC or PLC Orbit Network Term used to describe a group of Orbit Modules connected to one channel of an Orbit Controller Networks are numbered within a measurement system from 0 to 11 A network may consist of a mixture of different Orbit Modules
22. hree nine way D Type connectors for connection to other TCONS and to an Orbit Electronics Module TCONS are plugged together to form a backbone for the Orbit Electronics Modules The TCONS are designed to be DIN Rail mounted however the DIN Rail mount may be removed to allow the modules to be mounted via screws through the base or using feet BASIC TCON CONNECTION TCONS PUSH TOGETHER FORM A MECHANICAL AND ELECTRICAL BACKBONE Orbit System Manual Issue 1 15 of 44 7 2 BASIC MODULE TO TCON MOUNTING MODULES PLUG INTO TCON BACKBONE CONTROLLER CONNECTS TO END OF TCON BACKBONE Please see the Orbit3 Sales Dimensional Drawings supplied on the OSPW for precise dimensions of the Orbit Modules and TCONS Detailed mounting guidelines are shown in the remainder of this section Orbit System Manual Issue 1 16 of 44 7 3 DIN RAIL MOUNTING 1 Push Clip Down 3 To Lock Lift Clip to Release 1 MOUNT ON DIN RAIL RELEASE FROM DIN RAII 7 4 MODULE OR PIE TO TCON MOUNTING 100 NOM A 30 NOM 2 19mm PITCH Note The 19mm pitch also applies to fitting an Orbit3 TCON to an Orbit2 TCON Note The Orbit2 TCON to Orbit2 TCON pitch is 17 8mm Orbit System Manual Issue 1 17 of 44 7 5 OPTIONAL SCREW MOUNTING DIN RAIL REMOVED 8 5x 90 Max Sc
23. it ISA Card Addresses 5232 Baud Rate Easy Setup Advanced COMIT COM2 None OrbitCard COM3 None COM4 None OrbitCarde COMS OrbitCard3 COME None COM None OrbitCard4 115200 Unregister All DK ul Cancel Orbit System Manual Issue 1 33 of 44 above screen will appear Select the port that you want to use and set up the RS2321M baud rate At present only 8 COM ports COM1 to 8 be registered Note that in WinXP an assigned port be reassigned a different port number if not already in use If all of the 8 COM ports are not available this means the computer has already alloatted them to other devices It can be possible to move some of these devices using the Windows Device Manager some cases when using serial port adapter e g USB to serial the adapter will be set to a high COM port number This will need to be moved to be in the range 1 to 8 Reassigning COM ports requires some understanding of the Computer Setup and is at the users risk If unsure seek help from your company IT department Re assign a COM Port Example for Windows XP To reassign a COM port go to the Windows Start Menu Click Start Control Panel and select SYSTEM Control Panel File Edit View Favorites Tools Help Q Bac Search Folders E Address D Control Panel Control Panel e Switch to Category
24. it3 controller or by another Orbit Module which is given authority to generate the synchronization pulses by the controller This is particularity useful when using the Encoder Input Modules allowing synchronized measurements between angular and linear measurement e g profiling See Orbit Software Manual for details on using the different Orbit3 Measurement Modes THE DIFFERENT ORBIT MEASURMENT SYSTEMS ORBIT1 2 AND ORBIT3 Orbit1 The original Orbit system which consisted of just Digital Probes and some controllers Orbit2 Introduced improved measurement capability higher speeds and other Orbit Modules Orbit3 Orbit2 compatible but with many improved features For details of compatibility between different products please refer to the Orbit Compatibility Roadmap section in the Orbit Software Manual Orbit System Manual Issue 1 9 of 44 Abbreviations DP _ DigitalProbe e g DP10 USBIM USB Interface Module a e ess 4K MODE Synchronised Measurement at 3096 readings per second 2K MODE Synchronised Measurement at 1953 readings per second Time Division Multiplexing 1K MODE Synchronised Measurement at 976 readings per second Orbit System Manual Issue 1 10 of 44 5 4 OVERVIEW OF ORBIT MODULES MODULE DESCRIPTION Digital Probe DP A Linear Measurement Probe hard wired to an Orbit 3 Conditioning Module which provides improved accuracy and a simple method of constructing a Gauging System The con
25. lated or non isolated from ground 6 2 ORBIT3 HOT SWAP Allows compatible models to be changed without the need to reconfigure the computer e TCON remembers the Probe address PLC users can now easily configure their system beforehand with a PC Diagnostic LEDs indicate HOT SWAP error Requires PCI Card MK3 OSPW Version 5 and Orbit3 compatible TCONS and Modules A feature of Orbit3 is the ability to change a module in a network without having to edit the network configuration table A faulty module can be replaced by another compatible module e g DP2 can be replaced by DP2 but not a DP10 the original identity and address are assumed by the new module This means that the operating software does not need to change since all module identities are effectively the same A compatible module is the same module type and stroke For example a 2mm Digital probe is only compatible with another 2mm Digital Probe Incompatible modules indicate this by flashing the red status LED Orbit System Manual Issue 1 13 of 44 6 3 DIAGNOSTICS 6 3 1 GENERAL STATUS INDICATION The Orbit modules have a blue and red LED which is used to indicate the Module status rr ae oa BLUE Off URN 1 Off Orbit network active Blink No faults with modules for each command Pan is transmitted Orbit Voltage Warning 4 7V Medium Flash The Orbit voltage is low but n 0 2 secs on 0 8 modules are still operating correctly secs off
26. llation CD or on the Windows Update Web site with pour permission Read our privacy policy Can Windows connect to Windows Update to search for software O Yes this time only O Yes now and every time connect a device No not this time Click Next to continue Select No not this time and click the next button Hardware Installation EN The software you are installing for this hardware OrbitUSBIM has not passed Windows Logo testing to verify its compatibility with Windows Tell me why this testing is important Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing Continue Anyway STOP Installation Click the Continue Anyway button Found New Hardware Wizard This wizard helps you install software for OrbitUSBIM If your hardware came with an installation CD SE or floppy disk insert it now What do you want the wizard to do Install the software automatically Recommended O Install from a list or specific location Advanced Click Next to continue lt Back Next gt Cancel Select Install the software automatically and click the next button Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard ha
27. ne PC controlling up to 12 Orbit Measurement Channels PC104 Card PCI Card in PC104 Format Dynamic 9600 Baud Buffered 187 5kBaud Normal 1 5MBaud USB Connects to a USB port and Buffered 187 5kBaud Controller can control one Orbit Normal Measurement Channel RS232 Connects to a serial port Buffered 9600 Baud Interface can control one Orbit Normal 187 5kBaud Module Measurement Channel Ethernet Coming Soon Dynamic Module Buffered Normal RS485 Uses same commands as Buffered 9600 Baud Interface RS232 but RS485 levels for Normal 187 5kBaud Module use with PLCs The PCI Cards and RS2321M can control up to 100 modules on a single channel with Orbit3 Orbit 2 and lower can only accommodate 31 modules per channel Refer to the network examples EXAMPLES OF ORBIT NETWORKS Refer to the Orbit Measurement System Software Manual for further details of the controllers and how to use them Orbit System Manual Issue 1 12 of 44 6 NEW FEATURES WITH The Orbit3 system provides the following improvements over Orbit2 while still retaining backward compatibility 6 1 MECHANICS DIN Rail Mounting on all Modules as standard e Improved Sealing Improved locking between TCON PIE resulting in improved performance in high vibration applications New plastic construction is lighter by a third reducing the weight of the overall system significantly Optional Earthing arrangements enabling the TCON bus to be iso
28. ne with modules must be cabled to the controller Ensure that there is an adequate power source available O O O O Check the PC Power capability If using USB only 4 modules can be powered without a PSIM If using RS232 a PSIM must be used Evaluate the power requirements and use PSIMS Refer to the Section on Electrical installation and the Section on Orbit Networks e Consider Cable runs and cable lengths Orbit System Manual Issue 1 38 of 44 10 EXAMPLES ORBIT NETWORKS 10 1 SIMPLE PCI CARD NETWORKS NO PSIM One PCI Card Single Channel lt 10 Modules lt 10 Modules PCI CARD MOUNTED IN PC lt 10 Modules 5 Modules Multiple PCI Cards PCI CARD LINK PCI CARDS USING SOLARTRON CABLE FOR DYNAMIC APPLICATIONS ONLY PCI CARD MOUNTED IN PC s5 Modules MULTIPLE PC CARDS 6 MAX CAN BE INSTALLED IN ONE PC FOR DYNAMIC APPLICATIONS THE PCI CARDS MUST BE LINKED TOGETHER THE FIRST CARD IN THE NETWORK ACTS AS A MASTER NOTE PSIMs MAY BE REQUIRED DEPENDING ON THE AND ARE RECOMMENDED FOR MULTIPLE CARD NETWORS Orbit System Manual Issue 1 39 of 44 10 2 PCI CARD WITH PSIM PSIM FIRST MODULE IN STACK PCI CARD lt 32 Modules PC WITH PCI NETWORK CONTROLLER PSIM AND 1 CHANNEL OF ORBIT MODULES PSIM 1 PSIM 2 FIRST MODULE IN STACK lt 32 Modules lt 32 Modules MODULES MODULES POWER FROM POWER FROM PSIM 1 PSIM 2 PC WITH PCI NETWORK CONTROLLER
29. of 44 Orbit System Manual Issue 1 43 of 44 13 REVISION HISTORY REVISION DATE COMMENTS 1 22 02 10 Initial Issue Orbit System Manual Issue 1 44 of 44
30. ort Settings Driver Details Click the Advanced button Bts per second v Data bits 8 Panty None Stop bits 1 control None Advanced Restore Defaults Ek Cancel Advanced Settings for COM8 Use FIFO buffers requires 16550 compatible UART Select lower settings to connection problems Select higher settings for faster performance COM Port Number pesos Use the drop down menu at the bottom of the screen to change the COM Port 9 7 RS485IM The RS485 Interface Module RS485IM is functionally the same as the RS2321M the difference being the electrical signal levels used which are 5485 levels As with the RS2321M the RS485IM requires power from the Orbit Backbone hence a PSIM is always required The module is supplied with flying leads to enable connections to be made to terminal blocks Wire Colour Signal Direction Red Rx A To RS485IM Yellow Rx B White Tx A From RS485IM Blue Tx B Black OV Orbit System Manual Issue 1 37 of 44 9 8 ETHERNET CONTROLLER To be advised 9 9 SETTING UP AN ORBIT MEASURMENT SYSTEM This section gives some basic set up information it assumes that a controller has been successfully installed e The Orbit network must be connected before applying power to the PC or other power source e The TCON backbo
31. rew COUNTERSINK Insertion Depth 9mm M4 CAPTIVE NUTS a m 25 173 45 T 74 0 0 5 gt 87 0 MAX 48 0 7 6 REMOVAL OF DIN RAIL FITTING OF FEET a Place foot into recess and push down to locate 3 Orbit System Manual Issue 1 18 of 44 8 ELECTRICAL INSTALLATION 8 This section describes power requirements cables recommendations and grounding OPERATING VOLTAGE AND CURRENTS The Orbit Measurement system operates from DC input voltage of 4 75V to 5 25V It is essential that the correct operating voltage is maintained we recommend using special Orbit cables and PSIMs For advise on checking the Orbit Voltage refer to CHECKING ORBIT VOLTAGES The Modules take different amounts of power refer to the Orbit Modules Manual for specification of specific modules or use the Orbit Network Power Calculator Spreadsheet supplied on the OSPW CD This application allows Orbit networks to be simulated to calculate the number of PSIM modules needed and the effect of cable lengths The available Orbit Controllers have different power supply schemes as covered under the section on each controller All Orbit Modules are fitted with a 9 way D Type Connector with the Pin designation detailed below This connector provides the interface to the Orbit Network 1 Reseved 2
32. s finished installing the software for e OrbitUSBIM Click Finish to close the wizard Orbit System Manual Issue 1 30 of 44 9 5 2 Using the USB The Orbit USB Interface Module provides a simple interface between personal computers and the Orbit Network When the USBIM is initially powered up via PC power Windows will learn about its power requirements bus power 500mA max and assign the resources needed for it If the host is not capable of supplying the required power Windows will display not enough power message and stop the assignment of resources Once the resources have been assigned the USBIM can be used with the Orbit Support Pack for Windows to interface to all major programming languages It can not be used as a separate Virtual COM port it must be used with the Orbit COM or DLL The current drawn from the USBIM when controlling an Orbit Network depends on the number of Orbit modules and the type of Orbit Modules The USBIM limits the power drawn to a maximum of 500mA includes the USBIM power The USBIM continually monitors the Orbit Network Voltage and if this drops below 4 75V then the USBIM abandons the Orbit Transfer and reports an error code to the application See Orbit Software manual for further details Refer to the sections on Orbit Networks with USB Measuring Orbit Voltage and Diagnostics for further advice For further information refer to the Section Setting up an Orbit Measurement System
33. soloriron metrology ORBIT 3 SYSTEM MANUAL 502913 ULTRA PRECISION TECHNOLOGIES 1 1 DOCUMENTATION CROSS REFERENCE 502914 Orbit3 Modules Details on installation and electrical Manual requirements 502915 Orbit3 Software Details on programming and using the Manual Orbit System 502920 Orbit3 Catalogue Describes the Orbit system and provides details of the products including specifications and dimensions 502922 Digital Probe User Detailing the specific requirements for Leaflet using the Digital Probe such as mounting details 502923 Digital Mini Probe Detailing the specific requirements for User Leaflet using the Digital Mini Probe such as mounting details 502924 Digital Block Gauge Detailing the specific requirements for User Leaflet using the Digital Block Gauge such as mounting details 502925 Digital Lever Probe Detailing the specific requirements for User Leaflet using the Digital Lever Probe such as mounting details 502906 Digital Flexure Gauge Detailing the specific requirements for User Leaflet using the Digital Flexure Gauge such as mounting details 1 22 TRADEMARKS AND COPYRIGHTS Microsoft Windows xP Windows Vista Windows 7 Excel VBA and VB are registered trademarks or trademarks of Microsoft Corporation in the United States and or other countries Orbit is a registered trademark of Solartron Metrology Ltd 1 3 CONTACT INFORMATION For updated information
34. troubleshooting guide and to see our full range of products visit our website http www solartronmetrology com Orbit System Manual Issue 1 2 of 44 2 TABLE OF CONTENTS 1 1 DOCUMENTATION CROSS REFERENCE esses 2 1 2 TRADEMARKS AND 68 2 1 1 1 41 11 nnn nnn nnn nnne nn nnn 2 1 3 CONTACT INFORMATION ona riii a i DE ala 2 2 TABLE OF CONTEN Fo curias adc AME RUNI i ini CAE KM 3 3 INTRODUC DON M ROT 5 ME 5 3 2 NAVIGATE THIS DOCUMENT sii ea ia ien ia 0 ta an ri at 5 4 SAFETY SUMMARY n icri cinta oa di alel ie i ca iti tn 6 5 GLOSSARY OF TERMS AND BASIC SYSTEM 7 5 1 TERMS ASSOCIATED WITH THE MEASURMENT SYSTEM LAR DV ARS Evie a n Bl dana a dc i at 7 5 2 TERMS ASSOCIATED WITH ORBIT MEASUREMENT MODES 8 5 3 THE DIFFERENT ORBIT MEASURMENT SYSTEMS ORBIT1 ORBIT2 AND iip 9 5 4 OVERVIEW OF ORBIT MODULES n arunc erai maia ia iii ax a diana 11 5 5 OVERVIEW 8 2 4 12 6 NEW FEATURES WITH ORBIT3 i nana anti cea oa in ana Daia rain ii bi 13 Muze rule ea i ai m i ca i ia i ii A 13 6 2
35. ware manual for RS232 Commands Orbit System Manual Issue 1 32 of 44 RS232IM Default Baud Rates Standard RS2321M 9600 Baud on Power On Variant part No 911301 57 6 Baud on Power On Variant part No 911338 115 2 Baud on Power On 9 6 2 Orbit Registration This program is used to register Orbit RS2321Ms and the now obsolete Orbit ISA network cards Any RS2321Ms or Orbit ISA networks cards must be registered with this program in order to work with the Orbit DLL and COM software This is not applicable to the RS485 module which is designed primarily to interface with PLC s Note there is no need to register any USBIMs or PCI cards These are handled automatically via Plug amp Play in Windows Note that this registration option is included when installing the Orbit 3 Support Pack for Windows When Orbit connects the Orbit software will scan for any registered RS232IMs or ISA cards If a device is registered but not found a time out condition will eventually occur which may take some time Therefore to avoid this remember to unregister all unused RS232IMs or ISA cards If all need to be unregistered use the Unregister All button To register an RS2321M go to the Windows Start Menu Click Start Select All Programs Select Orbit Support pack for Windows Select Orbit registration Click Orbit registration to launch the registration program 1 Orbit Registration for ISA Cards Orb
36. wer supplies and cables All of which can be obtained from the same supplier thus guaranteeing compatibility and accelerating system integration This document addresses functionality mechanical installation electrical installation controllers and then proceeds to show examples of Measurement Systems The Orbit 3 Measurement System also includes a range of readouts for stand alone measurement systems these also can be used as a basic interface to a PLC 3 2 NAVIGATE THIS DOCUMENT This is a large document which is a useful reference when writing Orbit applications To aid navigating the document the following Navigation tip may be useful It is often necessary to jump to another item and then go back to where you jumped from This can be done in Adobe Reader by using the Previous Page View button ment Tools Window Help gt 10 204 E Find N Previous Page View Button Other PDF readers will have a similar Previous Page View option Orbit System Manual Issue 1 5 of 44 4 SAFETY SUMMARY WARNING statements Warnings and Cautions identify conditions or practices that could result in Warning Do not operate an explosive personal injury or loss of atmosphere life Warning this equipment is not intended for safety CAUTION statements critical applications identify conditions or practices that could result in Warning do not exceed maximum ratings as damage to the equipment speci
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