InStep IV User Manual
Contents
1. Tables InStep Command Summary Command Without Data With Data Data Range Default A Returns Advance Value Sets Label Advance 0 to 65535 330 dec B Returns Batch Count Sets Batch Count 0 to 65535 0 C Returns Total Count Sets Total Count 0 to 99 N A D Returns Coder Delay Sets Coder Delay 0 to FFFF E Returns Enable Status Sets Enable On or Off Oor 1 0 e Returns EOR Setpoint Sets EOR Setpoint 0 to 255 3 F Returns Forward Label Value Sets Forward Label Count 0 to FF 10 dec f Returns reason for disable Returns lt BELL gt lt CR gt 0 to FF N A G Manual Dispense Go Returns lt BELL gt lt CR gt N A N A H Returns Batch Preset Value Sets Batch Preset 0 to FFFFFF 0 I Returns Input Port Status Returns lt BELL gt lt CR gt 0 to FF N A J Returns Jig Delay Sets Jig Delay 0 to 65535 0 j Returns Jig Hold Delay Sets Jig Hold Delay 0 to 65535 0 K Returns Air Blast Time Sets Air Blast Time 0 to 8191 0 L Returns Length Measure Sets Length Measure On or 0 1 or 2 0 Status Off or sets mislab value l Returns Average Length Returns lt BELL gt lt CR gt 0 to FFFF N A M Returns Master Speed Returns lt BELL gt lt CR gt 0 to 1FFFFF N A N Returns Missing Label Status Sets Missing Label Length 0 to 65535 16 lt 3 20 0 to 8 5 O Returns Output Port Status Sets Output Port Bits 0 to FF N A P Returns Label Position Value Sets Label Position 0 to 65535 0 Q Manual Stop Dispense Quit Returns lt BELL gt lt C2. 1 Flash Disabled via serial command EO 01 2 Flashes Disabled due to missing label fault 02 3 Flashes Disabled due to fault input being turned on 04 4 Flashes Disabled due to printer error being indicated 08 5 Flashes Insufficient advance to allow for deceleration and speed 10 compensation Increase advance value or run slower 6 Flashes Disabled due to Servo Stepper Error 20 7 Flashes Disabled due to End of Reel Detected 40 8 Flashes Disabled due to Orientation Error 80 Note The LED flashing feature is yet to be implemented At present the LED simply indicates the enabled status use the f command query to determine cause As of 15 06 the value returned by the f command has two bytes the lower byte remains as above The upper byte is as follows Bit 0 indicates that the t command value is insufficient rather than the A value when the lower code is 10 Bit 1 is dispense too long when lower byte is 02 Bit 2 is four simulations in a row when lower byte is 02 Note that versions prior to 5 06C return the two bytes in the incorrect order Page 21 of 31 InStep IV User Manual doc Industronics Hardware Modifications In order to provide for special installations there are certain hardware modifications identified by a letter in the Options field of the device s label They are described here The InStepIV is also available in the Plus version as with the older InStep This enclosure has 24 termina
3. 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 These pins are not fitted unless option G is ordered J32 1 to 2 jumpered J33 1 to 2 jumpered J34 This jumper when installed connects IN6 to OUT7 for a bussed fault line to use between multiple units Ensure J6 is set to match output IC if this jumper is fitted J34 is actually pins 1 amp 2 of P6 Rev 1 PCB s have this linked via a track on the rear Installed Page 17 of 31 InStep IV User Manual doc Industronics J36 Used to route additional signals to Rev 1 Exp Board only Not Fitted J37 When set 1 2 routes signal TCMP through the output driver and _ If option G 1 to 2 on to terminal 3 for use as an NPN STEP output If fitted 2 3 the otherwise 2 to 3 PB7 signal is connected to produce OUTS8 on term 3 J38 Rev 1 PCB s only and is wrongly marked J34 near R11 Jumpered 1 to 2 by a Routes pin 3 of J21 to J23 to either OUTA 1 to 2 or track on rear of PCB INB STEPA 2 to 3 Page 18 of 31 InStep IV User Manual doc InStepIV Terminal Descriptions Industronics Terminal Terminal Description Comment Number Name 1 24V Connect a 12 to 28 volt power supply to this terminal to provide the InStep module with power 2 OV This is the 0 volt reference terminal for the
4. P amp R when used in orient jig mode Also fixes another issue that has been around for a while where if you end a orient jig sequence that fails to find the mark with a manual dispense the next sequence is not done correctly None Page 27 of 31 InStep IV User Manual doc Industronics Version I5 05A 09 02 2010 Changes Fixes Additions Based on I5 04S and 15 05 Changes acceleration curves to all linear profiles and expands the range available to 14 This version adds all of the 15 05 changes on top of version 15 04S Also changes the reaction to a drive fault Previously the drive was only disabled at the end of the label move now it is stopped and disabled instantly which aids in resetting some drives Adds the advance fix from version I5 04J None Version I5 05B 23 02 2010 Changes Fixes Additions Based on I5 05A Changes the default acceleration curve selected from 3 to 4 This more closely approximates the default curve of 3 in the older setup None None Version I5 05C 26 02 2010 Changes Fixes Additions Based on I5 05B Changes the speed compensation table selected when J29 is fitted Prior to this version installing J29 selected a table optimised for a SIG servodrive with a 2 1 belt drive to the nip roller Now the selected table is set up for the same 400W Mitsubishi servomotor as without J29 but direct drive to the nip roller rather than 2 1 belt drive None None Version I5
5. Range 0 to 9FF hexadecimal in command as address 0 to FF returned as data The range for address is limited by the MPU GT16 47F GT16A 87F Default N A Description This command is for debugging purposes only and requires an intimate knowledge of the firmware to interpret the responses Y Synchronisation Ratio Function Sets or queries the sync ratio Range 0 to 255 decimal in command 0 to FF in response Default 128 decimal 80 hex or 100 Description This command sets the sync ratio between the master encoder and the output pulse rate FF is 50 10 is 800 Refer to table for correct value A value of 0 causes the master encoder to be ignored and the set speed value to take effect Z Internal Port Function Returns a value indicating the internal port status or can force output bits Range 0 to FF Default N A Description Returns two hex digits representing the status of the 8 bit internal port refer to the port assignment table for individual bit functions and states A value can be written to the port in order to force the state of the output bits on that port the input bits remain unaffected Write RAM Function Writes the specified data into the specified RAM location Range 0 to 9FF hexadecimal in command as address 0 to FF returned as data The range for address is limited by the MPU GT16 47F GT16A 87F Default N A Description This command has a special data format there are two data fields separated by
6. Special version for tagger infeed Fixes None Additions None Version I5 03y 26 10 2006 Changes Special version for first J3 type tagger Use normal version with w80 command now This one had forced output frequency input frequency Fixes None Additions None Version X 5 00FK 26 10 2006 Changes Special version for taggers with J3 servos Has assemble time switch for feeder or knife Fixes None Additions None Version 15 03 15 11 2006 Changes Changed bit 7 of the w command to make output frequency equal to input frequency normally is double This bit was for End of Reel mode in a Servotron Missing Label now changes type above 127 rather than above 63 Fixes Red LED now correct if enable at power on selected on option port Additions None Version I5 03T 28 11 2006 Changes Has two speed dispense for labels longer than pitch Built on top of I5 03A For 333 s Fixes Removed redundant timer 2 interrupt service routine and vector Needs doing in others Additions None Version 15 048 19 12 2006 Changes New version of loop controller for single loop WebMaster For Cerebos machine Fixes None Additions None Version 15 02B 21 12 2006 Changes Print signal activates on both labels of two label set This is built on I5 02A and is for WebMaster with barcode checking to confirm front back set over the join Fixes None Additions None Page 24 of 31 InStep IV User Manual doc Indu
7. This is the time between the last two encoder pulses so when the encoder has a stopped a value will still be indicated The returned value is actually 6 digits of hexadecimal the first digit indicates whether of not the master is considered as stopped or not 1 stopped and so value is invalid 0 running and value following is valid The second digit is used internally to detect a stopped condition It will normally show 8 except at extremely low encoder rates N Missing Label Length Function Range Default Description Sets or queries distance required to trip on missing label fault 0 to 65 535 decimal in command 0 to FFFF hexadecimal in response lt I5 05Y is 48 12 288 steps IS OSY amp 15 06 is 64 and gt 15 06 is 80 20480 steps or 620mm at 33p mm or 1 024m 20p mm The missing label function can work in either of two ways If the value entered here is less than 128 63 prior to 15 03 the missing label function works as before except that the number of steps is set differently The number of steps at which the labeller will stop is 256 times the value set here So a value of 16 gives the same as the old default value of 5 256 x 16 4096 This gives a much more precise way to set the trip point If the value is greater than 127 the no gap skip style of missing label is implemented This allows the labeller to skip past missing labels or blocked label gaps as if they never happened Since I5 05J and L not K a
8. module When the printer is enabled by the Coder Delay D command with an odd value this input must be on otherwise the InStep is disabled and the bussed fault output is turned on If an even value is used in D the input must be off for printer OK The printer fault input is only checked just after the label dispense is completed This allows it to possibly serve as an actual print confirmation input from a contrast scanner for instance or just a simple printer fault signal monitor See jumper J4 for input polarity selection On a standard InStep J21 controls which terminal this signal is connected to to 2 is terminal 8 2 to 3 is terminal 12 INS Servodrive OK This input is connected to the OK or fault output of the servo stepper drive See Option2 command for input polarity setting It stops and disables labelling when changes to the selected faulty state As of V5 04F this input is only checked when labelling is enabled As of V5 05A when faulty the drive pulses are stopped and the drive enable is dropped immediately Previously it was only done at the end of the dispense cycle J22 controls which terminal this signal is connected to 1 to 2 is terminal 8 2 to 3 is terminal 12 IN6 Disable Bussed Fault In This input disables the labelling when on It is normally used in the bussed mode where jumper J34 on InStep or J60 on the Expansion Board is installed When several units are connected together via their IN6 or OUT7 termin
9. sent senders address flag Previously was a common flag for send and receive Assists when used in multi master mode Only relevant when checksums are enabled which causes sender address to be added to communications None None Page 28 of 31 InStep IV User Manual doc Industronics Version I5 05G 12 12 2010 Changes Fixes Additions None Based on I5 05F Fixed problem with debounce delay of gap enable Now works like product sensor input only delays if required and rechecks gap sensor status before re enabling This has the effect that if the gap sensor is set to the wrong polarity it will never enable at higher speeds with normal labels narrow gaps None Version I5 05H 26 01 2011 Changes Fixes Additions None Fixes a problem where a false gap trigger would cause a missing label now it resets and retries Based on I5 05G Add a gate function to the Gap sensor This is activated by bit 0 of the w command When activated input two must be on before the gap signal is accepted Version I5 05J 16 02 2011 Changes Fixes Additions Based on I5 05H Stops label sequence from starting by the product scanner while the master is stopped Also does auto teach of the missing label setting Changed default F command value to 107 to match new decel introduced in I5 05A Also change default advance A to 330 to allow for all of speed compensation and decel None None Version I5 05K 5 03
10. 05T 18 03 2010 Special Changes Fixes Additions Based on I5 05C Special two speed dispense version made for Parmalat rotary Adds functionality from I5 03T to the current version with new accel etc None None Version I5 05D 06 04 2010 Changes Fixes Additions Based on I5 05C Since 13 07 when in two label mode no deceleration was performed at the end of dispense of the first label and no acceleration was performed at the beginning of the second label This was done to allow small gaps between the two labels and overcome the different amount of deceleration done at different speeds This is a problem when a stepper drive is utilised and so this version re introduces deceleration and acceleration between the two labels with its inherent side effects None None Version I5 05E 24 06 2010 Changes Fixes Additions None None Based on I5 05D Adds Blanking Mode This mode is selected by setting J to 1 and setting the desired blanking length in the j command The blanking length starts at the end of the label dispense and delays the enabling of the product sensor until this length is finished Also when this mode is selected the product sensor is re confirmed to be on at the completion of the product delay This prevents false triggers especially ones made while the machine is paused Version I5 05F 4 08 2010 Changes Fixes Additions Based on I5 05E Changes to a separate
11. Additions M command response now has stopped status in first digit returned Version I5 04F 16 04 2008 including B C E D was a special Changes B Changed servo error so only tested when enabled allows polarity to be set without error C Changed bussed fault in to like before 3 12B to allow reset while fault still present F stops faults bussed fault in and printer error from occurring when head is disabled Prevents unnecessary messages on second commander keypad and also stops head form being enabled when these faults are reset Fixes E Fixes an old problem where there was no manual dispense while waiting for jig closure with no jig control mode Additions None Version 15 04G 26 09 2008 Changes Based on I5 04F Set or manual dispense speed rescaled to allow a higher maximum speed to be specified by the S command 9999 now is equal to 32 was 110 Default speed same as before as it is set in hexadecimal Fixes None Additions None Version 15 04H 9 12 2008 Changes Based on I5 04G Changed method of bailing out of an orientation jig operation where the colour scanner fails to detect the mark Was just header found just send a now need to send at least the semicolon followed by the actual address of this module Fixes None Additions Added orientation error like on Servotron Mainly for when used with the Commander keypad Requires bit 1 of the w command to be set to work Causes a disable and
12. I5 04L Changes the orient cycle part of the code Introducing the counter polling from the Commander keypad caused issues with full orientation jig mode The counter polling would release the jig and cancel the cycle Now the colour sensor detection is done with interrupts to avoid these problems Now the only ways to cancel a jig cycle where the colour sensor does not detect a mark are force open the jig cause orientation error by re triggering the product sensor or sending the EO command Also the G command will release a label and complete the jig cycle Changes response to a further semicolon received before the previous line is handled Now the line received bit is cleared to start completely over None Version 15 04P 25 05 2009 Changes Fixes Additions None A problem where if the checksum happens to equal then it is taken as the header and not as the checksum This has been an issue in all checksum versions to date Based on I5 04N Adds a field for the senders address in the communication protocol Version 15 04R 23 07 2009 Changes Fixes Additions None Based on I5 04P Fixes a major problem when version I5 04P is in non checksum mode Problem was that only every second command query is received It worked correctly if in checksum mode e g Commander systems None Version 15 048 24 09 2009 Changes Fixes Additions None Based on I5 04R Fixes a problem in version I5 04N
13. Port DIP Switch Function returns a value indicating the option port status Range No value allowed Default N A Description Returns two hex digits representing the status of the 8 bit option port refer to the port assignment tables for the jumper functions A value of 00 is all off Also used to load a new setting Bit 0 corresponds to J24 w Option Port 2 Function Sets or queries the Option port status Range 00 to FF Default 00 Description Two hex digits representing the status of the 8 bit option2 port A value of 00 is all off Bit 7 Output frequency equals input frequency 0 is normal Out In x 2 Double Bit 6 End of Reel Mode When on selects reel turning detection type and when off selects reel diameter low or no web type detection Set to 0 if no end of reel sensor is fitted Bit 5 Use Checksum When set it is necessary to send a two s complement checksum byte after the lt CR gt byte Responses will then include this byte also Bit 4 Acknowledge mode lt ACK gt and lt NAK gt sent expected Bit 3 Stepper Boost When on changes the servo enable output function to a stepper drive boost Bit 2 Servo OK input polarity 0 is Off OK 1 is On OK Bit 1 Orientation Error Enable Page 10 of 31 InStep IV User Manual doc Industronics Bit 0 Gap Sensor Gate Mode I5 05H was Fixed Pull Mode prior to this X Examine RAM Function Returns the value stored at the specified RAM address
14. a comma The data in front of the comma is the address to write to and the data after the comma is the data to be written This command is for debugging purposes only and requires an intimate knowledge of the firmware to use it successfully Inputs All inputs are selectable for NPN 1 to 2 or PNP 2 to 3 input devices The function of each input follows PRODSENS Product Sensor This input initiates the labelling sequence It starts with a transition from off to on of this input See jumper J7 for input polarity selection Terminal 9 on a standard InStep GAPSENS Gap Sensor This is the registration input It is normally connected to a fork sensor that detects the gap between the labels on the backing paper The label advance starts counting with an off to on transition of this input See jumper J8 for input polarity selection Terminal 10 on a standard InStep Master Encoder This is where the encoder for the product speed is connected The encoder is usually coupled to the conveyor turret or vacuum belt of the machine The pulses per rev of the Page 11 of 31 InStep IV User Manual doc Industronics encoder and its gearing to the conveyor belt should be selected so that the rate is the same as the step rate of the motor It is best to be on the low side of one to one if this cannot be achieved The encoder should have a 5V differential output If the G option is fitted the encoder should have a 24 volt NPN PNP output Terminal 11
15. address selection table 3 J26 Address Bit Three Refer address selection table 4 J27 Coder Type Select On Moving Type 5 J28 Enable State On Power Up Select On Enabled at power up 6 J29 Select Direct coupled motor or 2 1 belt On Direct Off 2 1 belt drive drive Prior to 5 05C was SIG Was on for SIG Also On is 20 pulses per millimetre Off is 33 7 J30 Speed Compensation Factor On Apply for Servodrives 8 J31 Product Sensor Gate On Gate sig Req d on IN2 Input Port Assignment Input Description Terminal Notes Number Number 1 Colour Sensor 5 Orient Mode Only 2 Jig In Sensor Prod Gate 6 Orient Mode J31 w command 3 End of Reel Proximity 7 Refer to the e amp w commands 4 Printer OK 8 12 Terminal 12 only available with Opt G 5 Servo OK 8 12 Used in Commander systems J22 1 2 6 Disable Bussed Fault In 8 12 Linked to Output 7 by J34 7 Product Sensor 9 Product detection Sensor 8 Gap Sensor 10 Label Gap Sensor Output Port Assignment Output Description Terminal Notes Number Number 1 Coder 13 Refer to Note 1 2 Servo Enable 14 3 Missing Label 15 On Missing label Fault 4 Jig Solenoid 16 4 5 Air Blast 16 4 6 Air Assist 16 4 T Bussed Fault Out 16 4 8 Out 8 3 No signal assigned yet 1 When moving type coder is selected and enabled via the D command the output will come on just after the acceleration has completed and turn off just after the label stops The opposite will occur when this jumper
16. after the Jig Solenoid is turned on The sense of the Jig In Sensor Input has been changed so that off jig in This was done to allow the use of a more standard N O proximity sensor in the orient jig mechanism Because the Product Gate and Jig In share the same input it is not practical to have both enabled at the same time However this is not normally a limitation as gating is usually only used on a rotary type machine where an orientation jig cannot be fitted The Spin Up Delay is used to ensure the product is spinning smoothly in the jig before the Colour Sensor Prod 2 is enabled This prevents false triggers from the Colour Sensor Sending at least a semicolon followed by the address over serial port while waiting for the colour sensor input to be activated will cause the sequence to reset without dispensing This was changed in version I5 04N now you need to send either the disable command EO or the manual dispense command G to release a jig waiting for the colour sensor to operate Additionally you may force open the jig or re activate the product sensor to cause an orientation error as before Page 20 of 31 InStep IV User Manual doc Industronics Serial Communication Sockets Pin Descriptions Option G only Pin Pin Description Comment Number Name 1 GND 0 volt or ground 2 TXA Transmit positive side Transceive positive side if J13 installed 3 TXB Transmit negative side Transceive negative si
17. delay Changed default missing label from 16 to 48 to maintain old actual length Fixes Fixed a problem with FIXED command Corrected incorrect polarity in signals to read option port Fixed problem with stopped detection caused by now frequency out is 2 times input Additions Rough version of speed compensation table added for 700W J3A servo Uses old MR C jumper setting Is roughly suitable for 400W J3A as well Version 15 02A 02 09 2006 See I5 01A Changes TXENA change and missing label change as per 15 01 Fixes None Additions Speed compensation table as per 15 01 Version 15 02 25 09 2006 Changes Changed default values for set speed and advance Set speed changed to 120 hex and advance changed to 190 decimal Fixes None Additions None Page 23 of 31 InStep IV User Manual doc Industronics Version 15 038 28 09 2006 Special version for WebMaster Splice Loop control based on 15 0285 Changes None Fixes None Additions Added special purpose output to signal head loop In Step that the dancer arm is too high and it should stop Implemented on output 6 Air Assist but linked across to OUT8 so signal exits on terminal 3 Version 15 03H 28 09 2006 Special version for WebMaster head loop control based on I5 02H Changes None Fixes None Additions Added special purpose input to stop movement when it is on Implemented on Product Sensor input Terminal 9 Version X 5 00i 21 10 2006 Changes
18. is off Page 15 of 31 InStep IV User Manual doc Internal Port Assignment Industronics Bit Description Notes Number 0 PCO Connector EXP2 Pin 5 1 PCI Connector EXP1 Pin 10 2 PC2 Connector EXP1 Pin 8 3 PC3 Connector J36 Pin 1 4 Red LED 0 LED On 5 Option Port Load Output 1 Load enabled 6 RS 485 Receive Enable Output 0 Receiver enabled 7 Not on MCU Synchronisation Value Table Sync Percent Value in Dec Value in Hex Sync Percent Value in Dec Value in Hex 50 255 FF 160 80 50 60 213 D5 170 75 4B 70 183 B7 180 71 47 80 160 AO 190 67 43 90 142 8E 200 64 40 100 128 80 250 51 33 110 116 74 300 42 2A 120 106 6A 400 32 20 130 98 62 600 21 15 140 91 5B 800 16 10 150 85 55 To calculate the value to use with the Y command use the following formula Y value 12800 Sync in percent Address Selection Table Bit3 Bit2 Bit1 Address J26 J25 J24 Off Off On 1 Off On Off 2 Off On On 3 On Off Off 4 On Off On 5 On On Off 6 On On On 7 Off Off Off 8 Page 16 of 31 InStep IV User Manual doc InStep Jumper Descriptions Industronics Jumper Description Default J1 to J8 These three point jumpers select the polarity of the signal required to operate the inputs Jump 1 to 2 for sinking NPN type input devices Jump 2 to 3 for sourc
19. is stopped the label will be dispensed at the set speed rate H Batch Preset Not implemented yet Function Sets or queries the batch preset value Range 0 to FFFFFF hexadecimal Default 0 or off Description This command sets the count at which the batch counter will activate the output and reset the counter Page 5 of 31 InStep IV User Manual doc Industronics I Input Port Status Function Returns a value indicating the status of the input port Range No value allowed Default N A Description This command returns two hex digits representing the status of the 8 bit input port A value of 00 is all off Refer to the port assignment tables for the function of each input J Jig Delay Blanking Mode Function Sets or queries the jig delay or blanking mode Range 0 to 65 535 decimal in command 0 to FFFF hexadecimal in response Default 0 or off Description This command sets the steps between product detection and activating the jig solenoid output A value greater than zero enables Jig Control Mode If you select this mode you must select a mode with the U command as well As of version 5 05E setting this command to enables blanking mode rather than Jig Control mode See j command below j Jig Hold Delay Blanking Length Function Sets or queries the jig hold delay Range 0 to 65 535 decimal in command 0 to FFFF hexadecimal in response Default 0 or off Description In Jig Control Mode this command sets the l
20. sets fault output if product sensor is reactivated while jig is closed Version 15 04T 2 03 2009 Special Changes None Fixes None Additions Based on I5 04H Adds two speed dispense mode like older I5 03T Old version was always on two speed This one needs to be turned on with t and H commands Version 15 04J 23 03 2009 Changes None Fixes Based on I5 04H Fixes problem where there is actually one more advance pulse done than specified Additions None Page 26 of 31 InStep IV User Manual doc Industronics Version 15 05 23 03 2009 Changes Fixes Additions Based on I5 04H Changes handling of H register where it is always assumed to be dirty Changes the way acceleration and deceleration works to provide for more gentle curves to aid in very high speed machines Incomplete Not released None None Version 15 04K 23 03 2009 Special Changes Fixes Additions Based on I5 04H Changes where in the cycle the position delay starts when in straightening jig mode The delay starts together with the Jig Delay This was done as an experiment for the Paradise Beach machine None None Version I5 04L 30 03 2009 Changes Fixes Additions None None Based on I5 04H Adds a label counter that counts to 99 and add back in the C command to set the counter value Fails in conjunction with orientation jig mode Version I5 04N 30 04 2009 Changes Fixes Additions Based on
21. to J18 1 to 2 equals OUTS J20 J19 1 to 2 equals OUT6 Polarity depends on IC9 J20 1 to 2 equals OUT7 Buss Connector Descriptions Terminal Terminal Description Number Name 1 Enc A Master Encoder Input RS 485 channel A 2 Enc A Master Encoder Input RS 485 channel A 3 OV 0 volts reference 4 485A RS 485 communications A side 5 485B RS 485 communications B side Note Buss connector not accessible with option G Pin is at top nearest screw terminal to 4 Page 19 of 31 InStep IV User Manual doc Industronics InStep Labelling Modes and Sequence Chart Step No Step Comments 1 Product Input On All modes except Jig Only Orient and Man Dispense 2 Product Gate Input On Only if selected on option port InStep I J31 or InStep II bit 7 3 Jig Delay Jig Control Mode Only Jig Delay gt 0 4 Jig Solenoid Output On Jig Control Mode Only Jig Delay gt 0 5 Jig In Input Off Jig In Jig modes only Jig Only Orient Mode starts here S U D gt 0 6 Spin Up Delay Orient jig mode only Spin Up Delay gt 1 7 Colour Sensor Prod 2 Input Orient jig mode only Spin Up Delay gt 1 8 Label Position Delay All modes except manual release 9 Air Blast Output On Air Blast Mode Only Man Dispense starts here AB Time gt 0 10 Air Blast Time Air Blast Mode Only Air Blast Time gt 0 11 Air Blast Output Off Air Blast Mode Only Air Blas
22. 2011 Changes Fixes Additions None Fixes faulty speed compensation on first label of a two label set which has existed for a long time Fixed problem where two label mode does not work in conjunction with jig control mode which has existed since I5 05D Based on I5 05H Add a rewind enable output in place of missing label fault output when communication checksums are enabled This output will disable instantly on EO always where the servo enable may remain on until the current dispense is complete Version I5 05L 29 03 2011 be careful of special versions with different values of HWIDTH Changes Fixes Additions Based on I5 05J amp K combined Removed the L2 command and associated code as this is replaced by the auto teaching method A change was made internally HWIDTH that makes high speed operation more stable and less prone to the drive stuttering under certain conditions unfortunately this also reduces the maximum speed achievable Fixes speed compensation on first label of two label set Fixed a problem where the decel value forward was not applied to the advance value Adds the changes made in J version to the K version Version I15 05W 29 03 2011 Special Changes Fixes Additions Based on I5 05L Adds the Webmaster specific changes from 15 04W on top of I5 05L and then applies some special customisations for the Hidec Webmaster If used elsewhere then these customisations should probably be r
23. Enable This output is turned on when a missing label has been detected It is reset by sending the E1 command As of I5 05K this output changes function to Rewind Inverter Enable if checksums are enabled in the w command Terminal 15 on a standard InStep OUT4 Jig Solenoid This output connects to the solenoid that controls jig closure J17 controls which terminal this signal is connected to 1 to 2 is terminal 16 2 to 3 is terminal 4 OUTS Air Blast This output is turned on when an air blast time is entered with the K command at the end of the product delay and before the servo starts to move J18 controls which terminal this signal is connected to 1 to 2 is terminal 16 2 to 3 is terminal 4 OUT6 Air Assist This output is turned on at the start of the servo moving and off at the beginning of decel J19 controls which terminal this signal is connected to to 2 is terminal 16 2 to 3 is terminal 4 OUT7 Bussed Fault Out This output is turned on when there is a fault Please refer to the table for all the faults Fault code 02 and greater will turn the output on The enable command clears the faults This output can be tied to input 6 with J34 on a standard InStep to implement the bussed fault mode J20 controls which terminal this signal is connected to 1 to 2 is terminal 16 2 to 3 is terminal 4 Page 13 of 31 InStep IV User Manual doc Industronics
24. R gt N A N A q Manual Instant Stop Returns lt BELL gt lt CR gt N A N A R Returns Selected Ramp Selects Acceleration Ramp 0 to 13 4 S Returns Set Speed Sets Set Speed 0 to 9999 9743 d T Returns Two Label Spacing Sets Two Label Spacing 0 to 65535 0 Value t Returns Two Label 1 Label Sets Two Label 1 Label 0 to 65535 330 dec Advance Advance U Returns Spin Up Delay Value Sets Spin Up Delay 0 to 65535 0 u Returns Option Port 3 Status Sets Option3 Port 00 to FF 0 V Returns Firmware Version Returns lt BELL gt lt CR gt A0 00 to N A Z9 99Z v Returns Serial Number Returns lt BELL gt lt CR gt A000000 to N A Z999999 W Returns Option Port Status Returns lt BELL gt lt CR gt 0 to FF N A w Returns Option2 Status Sets Option2 Port 0 to FF 0 X Returns lt BELL gt lt CR gt Returns RAM value 0 to 9FF N A Y Returns Sync Ratio Sets Sync Ratio 0 to 255 128 dec Z Returns Internal Port Status Sets Internal Port Output 0 to FF N A Bits Returns lt BELL gt lt CR gt Write data to RAM location 0 0 to 9FF FF N A Any Other Returns lt BELL gt lt CR gt Returns lt BELL gt lt CR gt Page 14 of 31 InStep IV User Manual doc Industronics Option Port Assignment Option Jumper Description Notes Number Number 1 J24 Address Bit One Refer address selection table 2 J25 Address Bit Two Refer
25. alculations of speed compensation exceeding advance setting are required to trigger a fault Previously it was one leading to false trips at low advance and stationary master encoder jitter Additions None Version I5 06U 30 10 2012 Special Changes Based on I5 06B Old I5 05U mods applied to I5 06B is special quiet zone for orient jig mode Fixes None Additions None Version I5 06C 03 05 2013 Changes None Fixes Based on I5 06B Fix problem with two label first advance tripping on too small a value and fix incorrect response to f command The bytes were returned in the wrong order since 15 06 Additions None Version I5 06D 22 03 2014 Changes None Fixes None Additions Based on I5 06C Lowercase r command added Page 31 of 31
26. als all units will be disabled when a fault occurs on any one unit See J6 for input polarity selection On a standard InStep J23 controls which terminal this signal is connected to to 2 is terminal 8 2 to 3 is terminal 12 Note IN6 and OUT7 polarities must be the same and on InStep J20 and J23 must be set correctly to bring them out to terminals Page 12 of 31 InStep IV User Manual doc Industronics Outputs All outputs are selectable for NPN or PNP however they must all be one or the other Selection is made by changing IC9 For NPN use ULN2801A No PNP option at present Jumpers J9 and J10 must be set to suit STEP Step Signal This differential output is used to drive the pulse input of the stepper or servo drive Terminal 11 is A and terminal 12 is A If jumper J37 is set 1 to 2 the STEP signal is available as an open collector NPN signal on terminal 3 If using the differential output to the drive J37 should be set 2 to 3 OUT1 Coder This output is the start trigger for a date coder etc Jumper J27 selects whether the coder is of the type that prints while the web is stationary e g hot stamp or moving e g ink jet Terminal 13 on a standard InStep OUT2 Servo Enable This output is used to enable disable a servo stepper drive when a fault occurs or it is commanded so May also be used to enable disable web winder drives as well Terminal 14 on a standard InStep OUTS3 Missing Label Labeller Fault Rewind Inverter
27. ange is 1 to 8 ASCII e 0 is the senders address in ASCII This field is optional and is selected along with the checksum e P is the command All messages from the master have this field All responses from the InStep modules do not have this field Refer to the InStep Command Summary for more details e 2AB is the value Whether this field exists and its width depends on the command All responses from the InStep modules have this field e lt CR gt is the message terminator All messages are terminated by a carriage return OD hex character e CHK is a message checksum It is the two s complement of the preceding bytes This field is optional but must will be present if it is selected at bit 5 of OPTION2 Some commands are queries only and so no value field is allowed Some command values are in decimal ASCII others are in hexadecimal ASCII All response values are in hexadecimal ASCII All hex digits A to F must be in upper case Leading zeroes are not required in commands but are tolerated Leading zeroes are always returned to the width of the value field Space and Line Feed characters in commands are ignored Responses are always directed to address zero By setting bit 4 of OPTION2 commands that do not expect a response and successful setting type commands can be made to return an lt ACK gt character Out of range data or invalid commands will result in a lt NAK gt When this is not set or prior to 15 04 the only respo
28. becomes the A input Without G the master encode is connected to the buss connector usually via a HeadUnit The HeadUnit also allows for the correct scaling of the encoders pulse rate IN1 Colour Sensor Product Sensor 2 This input only functions in Orientation Mode It triggers the labelling cycle just as the normal product scanner does however only after the orient part of the cycle is complete See jumper J1 for input polarity selection Terminal 5 on a standard InStep IN2 Jig In Sensor Product Gate Gap Sensor Gate This input is usually a proximity detector mounted on the orientation jig to indicate when the jig is closed It initiates the spin up delay in orient jig mode If option port jumper J31 is installed this input becomes the product sensor gate input In this mode this input must be on before a product detection will start the dispense cycle If bit 0 of w command is set this input becomes a gate signal for the gap sensor gt I5 05H See jumper J2 for input polarity selection Terminal 6 on a standard InStep IN3 End of Reel This input is either connected to a sensor that detects a low diameter of labels on the unwind reel or one that pulses as the unwind reel turns Refer to the description of e End of Reel Setpoint menu See jumper J3 for input polarity selection Terminal 7 on a standard InStep IN4 Printer OK This input is connected to the printer OK fault output of the printer controlled by the InStep
29. de if J14 installed 4 RXA Receive positive side Same as pin 2 if J13 installed 5 RXB Receive negative side Same as pin 3 if J14 installed 6 GND 0 volt or ground Note Both serial communication sockets are wired together pin for pin Two are provided to aid daisy chaining multiple units together Pin 1 is the leftmost when looking at a plug with the cable leading away from you and the contacts facing down When viewing the sockets pin is the one nearest terminals 9 to 12 Servodrive Connections InStep InStep Signal Mitsu J3 A Mitsu J3 A Signal Terminal Description CN1 Signal CN1 Terminal SERVENA 14 Servo Enable SON 15 Step A 11 Step positive side PP 10 Step A 12 Step negative side PG 11 24V 1 Power in positive DICOM 20 21 OV 2 0 volt or ground DOCOM 46 47 ServoOK 8 J22 1 2 Servo Healthy ALM 48 Note The correct pulse multiplier in the Mitsubishi J3 servodrive is 109 for direct drives and 131 for 2 1 drives This is often implemented in the servodrive as PA06 PA07 10900 100 or 131 1 Direct drives with version I5 05C to P used 65 53 1 implemented as 6553 100 The speed compensation tables are optimised for these values only Refer to jumper J29 to select which table is in use Red LED Flash Codes Red LED Status Description P Command Off Servo Enabled with no faults present 00 On Servo Disabled and never been enabled since power on FF
30. e to do deceleration and or speed compensation a fault is generated and the labeller is disabled Previously the deceleration or speed compensation was trimmed back to allow it to fit within the advance This causesd speed dependant errors in the stopping position Fixed a problem where if the gapskip value is set and a real label trailing edge is not seen during the dispense and the gap sensor goes off during the deceleration phase of the dispense the labeller would lock up and not dispense without creating an error None Page 30 of 31 InStep IV User Manual doc Industronics Version I5 05Y 20 06 2012 Changes Based on I5 05V Change default mislab from 48 to 63 Fixes None Additions None Version 15 05d 20 06 2012 Special Changes Based on I5 05Y Old 500d mods applied to 15 05Y still for TetraPak turner Fixes None Additions None Version 15 05t 01 08 2012 Special Changes Based on I5 05Y Old I5 04T mods applied to 15 05Y still for two speed dispense Fixes None Additions None Version 15 06 05 08 2012 Changes Response to f command changed to two bytes to narrow fault down further Fixes Based on I5 05Y Fixes problem when gap comes in during deceleration phase Additions None Version I5 06A 27 09 2012 Changes Based on 15 06 Change default mislab from 63 to 80 Fixes None Additions None Version I5 06B 23 10 2012 Changes None Fixes Based on I5 06A Three consecutive c
31. ed to either sink or source between 5 and 12mA at between 12 and 28 volts DC Unless option G is ordered the master encoder input is five volt differential RS 422 RS485 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 Unless option G is ordered the STEP output is five volt differential RS 422 RS485 Refer to configuration section for changing polarity Note that at this time only NPN outputs are available As of Hardware Revision 1 PNP is now optional again Serial Communications The serial communications via the bus connector is two wire half duplex mode only If the G option is ordered the serial communications is via two RJ 12 connectors and can be full duplex 4 wire or half duplex two wire type Option G not available on Rev 1 PCB s Rev 1 provides for one RJ45 socket to be optionally fitted for comms and power Page 2 of 31 InStep IV User Manual doc Industronics 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 ULN2801A Rev 0 and ULN2803 for Rev 1 PNP for R
32. emoved None None Version 15 05M 17 05 2011 Changes Fixes Additions Based on I5 05L Fixed pull mode selection that was taken from Option 2 bit 0 in version 15 05H is reinstated at the new Option Port 3 None Adds the u command for Option Port 3 Page 29 of 31 InStep IV User Manual doc Industronics Version I5 05X 18 03 2011 Special Changes Fixes Additions Based on I5 05L Removes the special customisations from I5 05W So it is L with Webmaster mods can use for any Webmaster None None Version I5 05N 10 06 2011 Changes Fixes Additions None Based on I5 05M Filters the fault inputs to avoid false triggers leading to disabling of labelling This problem has only occurred very spasmodically and this modification has not been confirmed to be effective in preventing this issue None Version I5 05P 29 06 2011 Changes Fixes Additions None None Based on I5 05N When the N command is set to 0 the auto teaching of the missing label length is disabled At any value other than 0 the auto teaching is always active Version 15 05Q 08 08 2011 Changes Fixes Additions Based on I5 05P Because of the changes made in version 5 05L the speed compensation table for a direct drive 400W Mitsubishi drive has now been altered to suit a drive scaling of 20 pulses mm Prior to this all 15 xx versions were designed for a resolution of 33 pulses mm This now all
33. ength between the dispense stopping and the deactivation of the jig solenoid It is up to the operator to ensure correct product spacing You must ensure the product is released before the following product is detected by the product sensor or that product will be ignored In Blanking Mode this setting sets the length that the product sensor is ignored for after the label stops In addition when blanking mode is set the product sensor is re confirmed to be on at the completion of the product delay If only this product sensor confirmation is required simply set a very short blanking length Blanking is useful when the trailing edge of the product has a possible second trigger point because of a hole or handle etc The product sensor re confirmation is very good for preventing false dispenses caused by product sensor activation while the machine is stopped This setting is only used when in Jig Control Mode or Blanking Mode which is enabled by the J command above so you can leave the value in here always K Air Blast Time Function Sets or queries the air blast time Range 0 to 255 decimal in command 0 to FF in response Default 0 or off Description This command sets the air blast time in milliseconds The air blast is for machines with an air box attachment The air blast time occurs after the product delay and before the label starts to move Page 6 of 31 InStep IV User Manual doc Industronics L Length Measuring Function Range De
34. ep IV User Manual doc Industronics 13 200 r High Page Register Read Function Returns the value stored at the specified High Page Register address Value in command is an index added to 1800 hexadecimal Range 0 to A hexadecimal in command as index no data is latched SRS 0 to FF returned as data Default N A Description This command is for debugging purposes only and requires an intimate knowledge of the MPU hardware to interpret the responses S Set Speed Function Sets or queries the set speed Range 0 to 9999 in command 0 to FFFF hexadecimal in response Default 120 hex As of I5 05Q default is now 200 hex Or equivalent to 9537 Description This command sets the speed of dispensing when no master encoder is used Sync ratio of zero must be set for this value to take effect Also this value will be used if a manual dispense is done with the master stopped A value in the 9000 s is typical with a larger number being a faster speed Now as of I5 05S the default set speed depends on J29 If on the default is 200hex S9537 or when off it is 120hex S9761 also the scaling was changed slightly The returned value is not scaled T Two Label Spacing Function Range Default Description Sets or queries the two label spacing value 0 to 65 535 in command 0 to FFFF in response 0 or off This command sets the number of steps to pause between the first and second label of a set A value of 0 turns this functio
35. ers off J17 to J20 These jumpers connect output signals OUT4 OUT5 OUT6 and OUT7 to either output terminal 16 OUTA or terminal 4 OUTB As there are insufficient terminals for all the signals available these jumpers allow the user to choose which signals are brought out to the terminals Jumpering to 2 brings the respective signal out on OUTA and jumpering 2 to 3 connects it to OUTB Beware of possible conflict with inputs if J38 is 2 to 3 J17 1 to 2 jumpered J20 2 to 3 jumpered J18 and J19 jumpers off J21 to J23 These jumpers connect input terminals 8 INA and 12 INB to either input signal IN4 IN5 or IN6 As there are insufficient terminals for all the signals available these jumpers allow the user to choose which signals are connected to the terminals Jumpering to 2 connects the respective signal to INA and jumpering 2 to 3 connects it to INB When differential STEP out is fitted normally is pin 3 of J21 to J23 is not fitted as this is used for differential output Rev is different J21 1 to 2 jumpered J22 jumper off J23 jumper off If used with commander then J22 only is jumpered 1 to 2 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 11
36. ev 1 only is UDN2985 Be sure to set jumpers J9 and J10 correctly to match the installed IC or damage will result Mounting The InStep module can be mounted on 35mm DIN rail and should be mounted with terminals 1 to 4 uppermost and the rail clip at the bottom If the InStep module is disassembled to facilitate the changing of jumpers etc it should be reassembled so that terminals 13 to 16 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 Serial Communications Up to 32 modules may be daisy chained together to allow one master device to communicate with all units using only one communication port The address of each unit is selected via the first three jumpers on the option port Commands are issued by the master device in the system and the modules either simply act on this command or respond if it was a query type command All messages to and from the InStep modules have the following field format Header Address Command Optional value Carriage return and an optional checksum e g 1 0 P2AB lt CR gt CHK Where e The semicolon character 3B hex is the header All messages on the network begin with this header character e 1 is the destination address on the network The PLC or computer etc is always address zero Jumpers on the Option Port set the address of the InStep units The valid r
37. fault Description Turns the length measuring function on or off 0 1 or 2 Two is invalid since I5 05L 0 or off This command turns the length measuring function on 1 or off 0 When turned on the number of steps to dispense the label is transmitted to the master device shortly after the label is dispensed Value returned is number of steps in hexadecimal From version 15 04 to 15 05K whilst length measuring mode is on the L2 command can be issued This will calculate the no gap skip missing label length and if successful turn length measuring off l Average Length Function Range Default Description Displays the average length in steps No value allowed 0000 hex This command can be used to determine whether the automatically calculated missing label length is in use and what the average dispense length is When the unit is first powered up the value will be zero Also it can be reset by a change to either the advance value A t or six consecutive labels have been dispensed that are all more than 99 counts different from the current value M Master Speed Function Range Default Description Queries the speed of the master encoder No value allowed N A This command allows the user to check the operation of the master encoder To convert the value returned into a rate in kHz divide the lowest 4 digits into 1250 decimal i e Speed kHz 1250 Value If value is 1F4 then 1250 500 2 5kHz Note
38. iIndustronics Design Application and Service of Electronics in Industry InStep IV User Manual For Version I 5 06D Relevant for hardware revision 0 and 1 13 March 2014 27 Wanganui Road Kirrawee NSW Australia 2232 Phone 02 9545 6181 Fax 61 29545 6181 Mobile 0419 267 889 Email info industronics biz WWW hitp Awww industronics biz A division of D H Enterprises Pty Limited A B N 72 087 000 995 InStep IV User Manual doc Industronics Overview The InStep IV 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 synchronised 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 two small catches to enable the user to configure the unit via several jumpers located inside This allows for diversified applications while maintaining the same hardware minimising the need for several units to be kept for spares The enclosure has 16 screw terminals and a five way bus connector on the bottom The bus has two connections for the RS 485 half duplex communications bus two connections for a differential master encoder input and one connection for ground Up to 32 units may be daisy chained or multi dropped to allow a user
39. ing PNP type input devices J1 to J6 correspond to input to 6 respectively J7 is for the product sensor input J8 is for the label sensor input 1 to 2 jumpered J9 and J10 These jumpers are set to match the type of output driver IC installed in position IC9 Jump both 1 to 2 for NPN type IC ULN2801A Rev 0 Jump both 2 to 3 for PNP type IC Not available on Rev 0 Note jumpers must be set correctly or damage will result 1 to 2 jumpered J11 and J12 These jumpers connect the transmit and receive signals between the RS 485 driver IC and the microcontroller They are always installed except when an option card connects to these pins 1 to 2 jumpered linked by a track on rear side J13 and J14 J13 connects signal TXA to RXA on the serial port connectors J14 connects signal TXB to RXB on the serial port connectors These are both jumpered for 2 wire half duplex RS485 comms and both off for 4 wire full duplex RS485 RS422 comms Rev 1 PCB s do not have this jumper it is permanently jumpered 1 to 2 jumpered J15 and J16 These jumpers connect a resistive termination network to the receive lines of the serial port connectors These are both jumpered to connect the termination network Note The termination network should only be connected in the last unit connected to the RS485 RS422 network Rev 1 PCB s do not have this jumper R11 to R13 must be soldered in to provide network termination now Jump
40. interface PLC to control several axes of motion It is also possible to order the module with the RJ 12 jacks for communications and 24V master encoder input so it becomes compatible with the older InStep I modules Option G Rev 0 only 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 The amount of I O available is in fact limited by the terminals fitted to this enclosure and an expansion board is available which will plug onto the existing board and then fit into a wider enclosure that has 24 terminals This provides more I O and many other options There is a green and a red LED on the front The green LED is to indicate that the internal 5V supply is functional and the red LED indicates status 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 unit s address on the multidrop network 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 requir
41. ls and its own options described by a number Please refer to the old InStep Plus manual for details on these options Option A Special Additional card that plugs onto EXP1 and EXP2 It provides scaling from 0 to 10V to 0 to 3 3V and buffering The signal leaves the option PCB through pin 9 of EXP1 which is PB7 or AD7 Because of this J37 can not be 2 3 Analogue signal comes in differently depending on whether the InStep is G or not 333 Orlando Webmaster uses G so here the analogue signal comes in on EXP2 8 or Term 12 INB and so J21 to J23 can t use 2 3 Later Webmasters Hidec use differential output so INB is taken for this purpose Therefore the input now comes in on J17 J18 pin3 or OUTB Term4 This now means no 2 3 on J17 to J20 Firmware is the same Option B This is a wire link from IN5 to IRQ done by linking IC8 16 to the via near MPU 11 This is for Webmaster splice loop for the head speed input as the KBI interrupts are more complex because of the two gap sensors Option C This is for new Tagger feeder and knife versions it links IN1 to IRQ by linking P8 EXP2 7 to nearest via This is because there are 3 interrupt sources on these which used to be prod gap on IRQ and IN1 on KBI Now prod gap is KBI and IN1 is IRQ Also for Tetra Pak belt feeder on rotary Option D This is for Webmaster splice InStep when differential out used not G Later in Webmaster development when only Hidec and Orlando and 333 s existed a li
42. n off Note that as of V 5 05D there is a minimum spacing caused by the deceleration acceleration between the two labels Prior to this version the first label stopped with no deceleration and the second started with no acceleration t Two Label Spacing Advance Function Range Default Description Sets or queries the two label spacing advance value 0 to 65 535 in command 0 to FFFF in response 300 12C hex This command sets the number of steps of advance for the first label of a two label set This is set the same as A if the labels are the same size in the set and often different if the labels are different lengths Note that labels of different lengths in a two label set causes confusion for the auto setting missing label as it does not measure the two labels separately This will be upgraded in the future U Spin Up Delay Function Range Default Description Sets or queries the spin up delay 0 to 65 535 in command 0 to FFFF in response 0 or off This command can enable one of two modes A value of 1 puts the InStep into Jig Only Mode In this mode the normal product sensor is ignored and the sequence is started by the Jig In input When a larger value is entered the Orient Jig Mode is turned on This command sets the number of steps to pause before the registration scanner is enabled This is to ensure the product is spinning in the jig at the correct speed In orient jig mode the normal product
43. nk was added from OUT6 of splice InStep to PROD input of headloop InStep This caused a problem on non G type in that OUT6 could not come out of OUTB All other outputs are used up So this link between J37 2 and R9 6 was added to all to keep them the same Not actually required on G Comes out on OUTB with J19 2 3 Wire link is from InStep I splice to InStep 3 headloop b1 3 to b3 9 on Hidec which is non G B1 4 to b3 9 at 333 s Page 22 of 31 InStep IV User Manual doc Industronics InStep IV Version Update Summary Version 15 00 17 10 2005 Changes First released version None in use Fixes None Additions None Version 15 00D 25 06 2006 Changes None Fixes Has several 15 01 fixes as they were discovered here Additions Special version that has a direction output for a Tetra Pak machine Version I5 01A 06 07 2006 Special version for label head of WebMaster has pulse output for average web speed calculation Based on I5 00 and I 3 25A Changes First applied version Fixes None Additions None Version 15 02S 18 07 2006 Special version for WebMaster Splice Loop control based on 15 00 Changes First applied version Fixes None Additions None Version 15 02H 24 07 2006 Special version for WebMaster head loop control based on 15 00 Changes First applied version Fixes None Additions None Version 15 01 11 08 2006 Changes Changed TXENA to end of transmit delay now is Hi Z during
44. nse is the result of the query or a lt BEL gt to indicate an error Out of range characters in data will cause unpredictable results i e other than 0 to 9 and A to F A semicolon anywhere in the command string except the checksum position will clear the input buffer and start a new command query reception Previously the semicolon header was only scanned for after the previous string was terminated by a carriage return This meant that if a carriage return was garbled or lost the next string would be appended to the previous one and both then ignored as it would be an invalid Page 3 of 31 InStep IV User Manual doc Industronics string Also the backspace character 08 will delete the previous character sent This does not apply to the header or address characters Command Descriptions A Advance Function Sets the advance value or queries the current value Range 0 to 65 535 decimal in command 0 to FFFF hexadecimal in response Default 300 12C hex 330 14A hex I5 05J to I5 05P Was 180 B4 hex prior to 15 05J Description This command sets the number of steps to move after the gap sensor has activated If a value is entered that is less than the decel F command setting the stored value will be equal to the decel setting If the decel is adjusted this value must be entered again to adjust the entered advance value If the speed compensation is selected on the option port it is necessary to observe minimum values of ad
45. ote This is different from version I5 03T Changes None Fixes Based on 15 03 Has changes to eliminate false interrupts caused by noise This often shows up as labels being dispensed on power up down of machine s Estop circuit Additions None Version 15 03u 15 08 2007 Changes None Fixes Based on I5 03t Has changes to fix red LED status at power up Prior to this LED could power up off instead of on After initial enable it functioned OK Additions None Version I5 03v 24 09 2007 Changes Based on I5 03u Adds change shown at I5 02D above to the current standard version Fixes None Additions None Page 25 of 31 InStep IV User Manual doc Industronics Version 15 04 26 10 2007 Changes Changes made to allow new A version of the SO8GT16 MPU to be used All temporary variables now implemented on the stack All InStepII references removed Fixes None Additions Communications acknowledge and checksum added End of Reel detection added from Servotron Now if send G when stopped in sync mode will auto flip to set speed Version 15 04A 12 11 2007 Changes None Fixes Acknowledge of D and S command fixed Removed attempted acknowledge of E command when setting mode Fixed bug in j command that would erase w setting Fixed ACK from G command now sent at finish of label G is ignored if label moving in ACK mode Fixed an issue when changing from U1 to U gt 1
46. ows a much higher maximum web speed to be achieved The settings in the drive should be PA06 PA07 10900 100 The 2 1 speed compensation table is still for a motor with a 33 pulse mm resolution Prior to this version when the gap was simulated due to the missing label function the speed compensation was wrongly applied to the advance used This has been corrected in this version Now the raw advance value is used after the simulated gap position None Version I5 05S 26 02 2012 Changes Fixes Additions Based on I5 05Q Due to the change of HWIDTH back in version L the maximum speed was limited Version Q fixed this for 1 1 drive heads when the jumper J29 is installed this allows for approximately 75m min maximum with 20 pulses per millimetre This version adjusts HWIDTH back to 16 when J29 is not installed This allows 2 1 drives with 33 pulses per minute to still achieve high speeds for backwards compatibility Adjusts default manual dispense speed to compensate for 20p mm or 33p mm depending on J29 Adjust the scaling of the S command as high values generated rates that could not be achieved due to the changes to HWIDTH Added the lower case L command to display the average dispense length calculated by the missing label auto setting feature If the missing label has yet to be calculated the value 0000 is displayed Version I5 05V 28 05 2012 Changes Fixes Additions Based on I5 05S If there is insufficient advanc
47. power supply and the I O terminals 3 OUT8 This is a general purpose output as yet Polarity depends on IC9 G STEP unassigned If G option it is STEP output Refer to jumper J37 4 OUTB This is an output terminal J17 2 to 3 equals OUT4 Its function depends on jumpers J17 to J18 2 to 3 equals OUTS J20 J19 2 to 3 equals OUT6 Polarity depends on IC9 J20 2 to 3 equals OUT7 5 IN1 Product Sensor 2 input J1 controls polarity 6 IN2 Jig In Product Gate input J2 controls polarity 7 IN3 End of Reel input J3 controls polarity 8 INA This is an input terminal J21 1 to 2 equals IN4 Its function depends on jumpers J21 to J23 J22 1 to 2 equals INS J23 1 to 2 equals IN6 9 PRODSENS This is the product sensor input terminal J7 controls polarity 10 GAPSENS This is the label gap sensor input terminal J8 controls polarity 11 Step A This is the differential step output A J32 and J33 control G ENC If option G this is the master encoder polarity input terminal 12 Step A This is the differential step output A J21 2 to 3 equals IN4 G INB If option G is fitted it is INB J22 2 to 3 equals IN5 Its function depends on jumpers J21 to J23 2 to 3 equals IN6 J23 J21 23 pin 3 not fitted without G 13 OUTI Printer output Polarity depends on IC9 14 OUT2 Servo Enable Stepper Boost output Polarity depends on IC9 15 OUT3 Missing Label output Polarity depends on IC9 16 OUTA This is an output terminal J17 1 to 2 equals OUT4 Its function depends on jumpers J17
48. s the delay in steps between either the start of dispensing or the stopping and the print signal coming on depending on the type of batch coder selected At the moment 0 disables and any value enables with a small delay Any odd value causes checking for a printer OK signal at IN4 even values look for a printer faulty signal E Enable Function Enables the dispensing of labels Range Oorl Default Depends on state of J28 Refer to Option Port Table Description When set to 1 enables the dispensing of labels at the next product sensor activation or when set to 0 disables the dispensing of labels at the end of the currently dispensing label Also used to reset faults Page 4 of 31 InStep IV User Manual doc Industronics e End of Reel Setpoint Function Sets or queries the setpoint of the End of Reel counter Range 0 to FF Default 3 Description How the end of reel count functions is determined by bit 6 in Option2 With this bit on the setting here is the number of labels that can be dispensed in between operations of the end of reel sensor The sensor detects the movement of the label reel In this mode the number set here is usually quite low With the bit off it sets the number of labels that can be dispensed after the end of reel sensor activates The sensor detects that the label reel is low in diameter The setting is usually larger in order to allow the reel to become very close to finished before the head s
49. scanner is ignored and the cycle is initiated by a sensor connected to the Jig In input This initiates the spin up delay When this is complete the sensor connected Page 9 of 31 InStep IV User Manual doc Industronics to the Colour Sensor input is enabled When the colour sensor sees a leading edge the normal dispense sequence is started A value of 0 turns both jig modes off u Option Port 3 Function Sets or queries the Option3 port status Implemented in V 15 05M Range 00 to FF Default 00 Description Two hex digits representing the status of the 8 bit option3 port A value of 00 is all off Bit 0 Fixed Pull Mode Only bit 0 is used at this time Setting the other bits will have no effect V Version Function Queries the version number of the installed firmware Range No value allowed Default N A Description This command returns the installed firmware s version number in the following format A letter to indicate the type A major version number followed by a decimal point Two minor version digits to indicate revision level A space or letter to indicate special versions v Serial Number Function Queries the serial number of the device Range No value allowed Default N A Description This command returns the serial number in the following format A letter to indicate the number or versions this unit has had A is original The serial number in decimal in a fixed six digit format W Option
50. stronics Version I5 05S 15 01 2007 Changes New version of loop controller for single loop WebMaster For Coastal Springs machine This is really a continuation of development of 5 04S as first machine shipped before development finished Both machines are now 5 05S Fixes None Additions None Version 15 02C 12 03 2006 Changes Speeds up manual dispense over that of 5 02B on which this is based Same change as 5 02 to 5 03 Fixes None Additions None Version 15 068 20 04 2007 Changes None Fixes None Additions Added missing label type checking after end of reel detected Web only travels about 2 metres before faulting on missing label This is to handle dirty end of web sensors and false end of reel detection This is for single loop type Webmaster loop control only Version I5 07S 25 04 2007 Changes Changed master speed calculation to a moving average type This is to get faster startup of loop when web restarts after stopping also gives smoother operation This is for single loop type Webmaster loop control only Fixes None Additions None Version 15 02D 26 04 2007 Based on I5 02C Changes Sets missing label length to default when measuring turned on This is to allow longer labels than currently taught to be taught in Also gives a way to turn gap skip off This version is for WebMaster head only at this stage Supersedes I5 02C Fixes None Additions None Version 15 03t 07 08 2007 N
51. t Time gt 0 12 Air Assist Output On All modes 13 Acceleration All modes Except 2 label of two label set 14 Printer Output Off On Only if Printer enabled D gt 1 Off On selected on option port 15 Run in Sync or Set Speed All modes 16 Gap Sensor Input On All modes 17 Label Advance All modes Gets setting from t command on 1 label of 2 label 18 Air Assist Output Off All modes 19 Two Label Spacing Delay Two Label Mode Only Two Label Spacing gt 0 20 Back to step 9 on first pass Two Label Mode Only Two Label Spacing gt 0 21 Deceleration All modes Not done on 1 label of 2 label set 22 Knife Down On Up Off Knife Mode Only Option2 bit 4 on and Knife Down Time gt 0 23 Knife Down Time Knife Mode Only Option2 bit 4 on and Knife Down Time gt 0 24 Knife Up On Down Off Knife Mode Only Option2 bit 4 on and Knife Down Time gt 0 25 Jig Hold Delay Jig Control Mode Only Jig Delay gt 0 26 Jig Solenoid Output Off Jig Control Mode Only Jig Delay gt 0 27 Printer Output On Off Only if Printer enabled D gt 1 Off On selected on option port 28 Product Input Enabled Only if labelling still enabled E 1 2 If selected the Gate Input must be on at the instant of the product sensor coming on or the sequence will restart Therefore the timing is always controlled by the Product Sensor Input When using Jig Control Mode you must select either Jig Only or Orient Jig Mode as well If not the sequence will stall
52. tops In both modes the setting depends on the label length F Forward label Not implemented yet Temporary use implemented Function Allows the labeller to skip over a missing label to prevent one product not being labelled Number of Deceleration Steps during end of advance Range 0 to FF Default 0 or off prior to I5 05J was 10 15 05J to I5 05P was 107 I5 05Q and on is 100 Description The number of labels between the gap sensor and the peeler bar is set here When the missing label approaches the peeler bar a double length index is performed to skip over the missing label allowing all products to be labelled Temporarily used for number of deceleration steps Re enter advance after changing this value As of Ver 5 05 this decel setting is disabled You can still request the current setting Do not adjust this value f Fault Status Function Allows the query of the reason for the last disable Range 0 to 4FF Prior to 15 06 was 0 to FF Default N A Description Refer to the Red LED Flash Code table for the correlation between the value returned here and the reason for the disable G Manual Dispense Go Function Starts the label sequence independent of the product sensor Range No value allowed Default N A Description This command allows the operator to dispense a label without having to operate the product sensor Any product delay is bypassed and only one label is dispensed if in two label mode Also if the master
53. ts As a query it returns two hex digits representing the status of the 8 bit output port A value of 00 is all off Refer to the port assignment tables for the function of each output P Label Position Function Sets or queries the label position value Range 0 to 65 535 decimal in command 0 to FFFF hexadecimal in response Default 0 Description This command sets the delay in steps between the product sensor activation and the start of dispense effectively changing the position of the label on the product Q and q Stop Dispense Quit Function Used to stop the dispense of a label Range No value allowed Default N A Description This command stops the label dispense independent of the gap sensor Q simulates the gap sensor signal q causes instant deceleration and stop i e no advance R Ramp Select Function Sets or queries the acceleration ramp Range 0 to 13 Was 0 to 5 prior to V5 05A Default 4 Was 3 prior to V 5 05B Description This command selects 1 of 14 acceleration ramp profiles A value of 13 is the softest As of V5 05A the ramps are now linear whereas previously they had very high rates of acceleration towards the end of the curve The acceleration profiles are performed over the following number of steps Ramp Number Number of Steps 10 15 20 30 40 50 60 15 85 100 125 150 175 DlelolCle AlAIMAJ A wW rm elo Page 8 of 31 InSt
54. uto teach missing label is implemented This automatically sets this value As there is no way at the moment to switch off auto teach setting this value is not very useful A value of 0 here disables the missing label function and the motor will run works by simulating the label gaps presence at the number of counts specified here So the number entered here should be the label length minus the label advance setting If the actual gap occurs after the gap is simulated the actual gap position will override the simulated one to maintain correct registration If you change the advance Page 7 of 31 InStep IV User Manual doc Industronics after setting this value you should redo this setting to cater for the new advance value If the gap skip is done four times consecutively the labeller will disable and turn on the Missing Label and Bussed Fault Outputs Also refer to L command Note forever if no gap is seen 0 also stops auto teaching of this setting as of version I5 05P Care must be exercised when using low values of advance at high speed As the gap is ignored after the web starts to decelerate it is possible that no correction is done when the gap comes along after the gap has been simulated and deceleration has already started O Output Port Status Function Returns a value indicating the status of the output port Range 0 to FF hexadecimal Default N A Description This command allows the user to force the state of the output port bi
55. vance so that the compensation can function correctly The amount of compensation varies with the speed higher speed more compensation maybe up to 200 steps In addition to this there must be sufficient advance to do the deceleration which may be up to 100 steps depending on the speed At present it is necessary to re calculate re enter the label length if the advance is changed in gap skip mode As of I5 05L changing the advance value will reset the missing label length and restart the auto teaching function B Batch Count Not implemented yet Temporary use implemented Function Sets or queries the batch counter Sets fixed move length Range 0 to FFFFFF hexadecimal 0 to 65 535 dec in command 0 to FFFF hex in response Default 0 Description This command forces a value into the batch counter register Normally used to reset the count Sets the length in steps of the move done when the fixed move mode is activated C Total Count Function Sets or queries the total label counter Implemented in I5 04L Range 0 to 99 decimal Default 0 Description This command forces a value into the total counter register Normally used to reset the count Counter only counts to 99 then rolls over back to 0 It is up to the master controller to extend this count to a larger number by periodic polling D Coder Delay Partial implementation Function Sets or queries the coder delay Range 0 to FFFF Default 0 Description This command set
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