029 ST200 2008 Rev2 Eng

TECHNICAL 031_ST200_2008_ENG
Società soggetta alla direzione e al DOCUMENTATION

coordinamento della FINMAGNETI S.p.A. con
sede in Lainate (MI) – Via Nerviano, 31 ST200 Pag. 1 / 90
ST200
Rev. 10
(with auto-diagnostic features)
Technical documentation
Rev. Description Date Drawn Verify

2 General revision 05/02/2008 M. Lazzaroni, A. Prati, M. Ingrao Roberto Faranda
REVISION HISTORY
N° Rev. Date Reason of the review Notes
0 03/01/2006 Emission First emission of the document
1 – Software release Pag. 4
2 – Table 1 fixing Pag. 26
1 29/09/2006
3 – Changing of “12 – Tables management”. Da pag. 27 a pag. 31
4 – New Layout ST200-K board. Pag. 8, 10, 23 e 32
2 05/02/2008 General revision -
DOCUMENT IN ELECTRONIC FORMAT

Original issue: 031_ST200_2008_ENG.doc of 05/02/2008 - R&S
Issue for use: 031_ST200_2008_ENG.PDF of 05/02/2008 - server

SUMMARY
1. FEATURES ............................................................................................................................................................. 7
REFERENCES SOFTWARE ................................................................................................................................................ 7
DESCRIPTION .................................................................................................................................................................. 8
2. ST200-L BOARD LAYOUT – COMPONENT SIDE .......................................................................................... 9
3. ST200-L BOARD LAYOUT – BOTTOM VIEW ............................................................................................... 10
4. ST200-K BOARD LAYOUT – COMPONENT SIDE........................................................................................ 11
5. SCHEMATIC OF ST200-L BOARD .................................................................................................................. 12
6. SCHEMATIC OF ST200-K BOARD .................................................................................................................. 13
7. HOW TO CONFIGURE THE SYSTEM ............................................................................................................ 14
8. TURNING ON THE SYSTEM (COMMON FOR ALL VERSIONS) ............................................................. 22
SETUP PROCEDURE (FIRST TIME TURN ON OR RECONFIGURATION OF THE SYSTEM) ....................................................... 22
PROCEDURE OF STANDARD ACTIVATION ...................................................................................................................... 23
9. HOW TO USE THE DIP-SWITCH (FOR ALL VERSIONS) .......................................................................... 26
ST200-KM BOARD (MASTER) – PAD 1 OPEN ....................................................................................................... 26
ST200-L BOARD (LOGIC BOARD) .......................................................................................................................... 29
ST200-KE BOARD (CH-ENABLE) – PAD 1 CLOSED ............................................................................................. 30
ST200-KE BOARD (WITH SOFTWARE CH_ENABLE_SPECIAL) – PAD 1 CLOSED ............................................... 32
10. THE CURRENT CONTROL .............................................................................................................................. 33
11. THE CONNECTION SYSTEM........................................................................................................................... 39
12. QUALIFICATIONS ............................................................................................................................................. 41
INPUT ENABLE .............................................................................................................................................................. 41
OUTPUT ENABLE .......................................................................................................................................................... 42
HARDWARE KEY .......................................................................................................................................................... 43
13. MANAGING THE TABLES................................................................................................................................ 44
MILLING MACHINE VERSION ........................................................................................................................................ 45
GRINDING MACHINE VERSION ...................................................................................................................................... 45
MAGNETIZATION TABLE STORAGE PROCEDURE ............................................................................................................ 45
14. JUMPER MEANING ........................................................................................................................................... 48
ST200-K BOARD JUMPER.............................................................................................................................................. 48
JUMPER OF THE ST200-L BOARD .................................................................................................................................. 49
15. THE KEYBOARDS OF THE ST200 COMMAND ........................................................................................... 51
KEYBOARD WITHOUT MAGNETIZATION LEVELS (3 PUSH BUTTON) – SOFTWARE: K10_UNI ................................... 51
KEYBOARDS WITH TWO MAGNETIZATION LEVELS (5 PUSH BUTTON) – SOFTWARE: K10_UNI ................................ 53
KEYBOARD WITH 7 MAGNETIZATION LEVEL (5 PUSH BUTTON) – SOFTWARE: K10_UNI ......................................... 55
CH-ENABLE KEYBOARD – SOFTWARE: K10_UNI........................................................................................................ 57
CH-ENABLE KEYBOARD – SOFTWARE: CH10-ENABLE-SPECIAL............................................................................ 59
KEYBOARDS DIMENSIONS ............................................................................................................................................. 59
16. SYSTEM OPERATIONS IN STANDARD CONFIGURATION ..................................................................... 60
17. INSTRUMENTAL CHECK................................................................................................................................. 62
SUPPLY CIRCUIT............................................................................................................................................................ 64
VOLTAGE RANGE ADMITTED FOR THE MICROCONTROLLER PIC18F4520 ..................................................................... 65
ZERO-CROSS CIRCUIT. .................................................................................................................................................. 66
18. COMPATIBILITY WITH THE PREVIOUS VERSION AND HARDWARE CHANGES .......................... 67
COMPATIBILITY WITH THE PREVIOUS VERSIONS. .......................................................................................................... 67
HARDWARE MODIFICATION. ......................................................................................................................................... 67
19. AUTO-DIAGNOSIS SYSTEM ............................................................................................................................ 68
20. PLC INTERFACE ................................................................................................................................................ 69
INPUT SIGNAL AT THE µCONTROLLER OF THE PLC INTERFACE .................................................................................... 69
OUTPUT SIGNAL AT THE µCONTROLLER PINS OF THE PLC INTERFACE ......................................................................... 70
SCHEMATIC .................................................................................................................................................................. 71
PLC INTERFACE BOARD LAYOUT – TOP VIEW ............................................................................................................... 72
PLC INTERFACE BOARD LAYOUT – BOTTOM VIEW ........................................................................................................ 73
FEATURES ..................................................................................................................................................................... 74
REFERENCES SOFTWARE .............................................................................................................................................. 74
OPERATIONS ................................................................................................................................................................. 74
LUMINOUS SIGNALS (LED) ........................................................................................................................................... 75
OPERATIONS OF THE SYSTEM IN BASE CONFIGURATION ................................................................................................ 79
USE OF THE DIP-SWITCH IN PLC INTERFACE. ............................................................................................................... 79
THE CONNECTION SYSTEM ............................................................................................................................................ 79
DB37 ............................................................................................................................................................................ 81
21. KOSMEK RELEASE ........................................................................................................................................... 83
SCHEMATIC FOR KOSMEK KEYBOARD ....................................................................................................................... 83
REFERENCES SOFTWARE .............................................................................................................................................. 84
FRONT PANEL OF KOSMEK KEYBOARD ...................................................................................................................... 84
DB37 FOR KOSMEK ................................................................................................................................................... 86
FUNCTION ..................................................................................................................................................................... 87

LIST OF FIGURE
FIG. 1– FILE: ST200-7L.MAX DIRECTORY: ...\PROGETTI2007\ST200LREV7\... ............................................................ 9

FIG. 2 – FILE: ST200-7L.MAX DIRECTORY: ...\PROGETTI2007\ST200LREV7\... ......................................................... 10
FIG. 3 – FILE: ST200-5K-1.MAX DIRECTORY: ..\PROGETTI2006\... .............................................................................. 11
FIG. 4 – SCHEMATIC OF THE ST200-L BOARD.................................................................................................................... 12
FIG. 5 – SCHEMATIC OF THE ST200-K BOARD. .................................................................................................................. 13
FIG. 6 – CONFIGURATION PADS, JUMPERS AND DIP-SWITCHES FOR ST200-KM BOARD. .................................................. 14
FIG. 7 – POSITION OFF OF THE PIN 8 - SW1. ..................................................................................................................... 22
FIG. 8 – POSITION OFF OF THE PIN 8 - SW1. ..................................................................................................................... 24
FIG. 9 – FIRST 5 POSITION ON SW1. .................................................................................................................................. 26
FIG. 10– CURRENT MEASUREMENT CIRCUIT. ..................................................................................................................... 33
FIG. 11 – WHERE TO MEASURE THE DISCHARGE CURRENT ON THE BOARD. ....................................................................... 34
FIG. 12 – SIGNAL MEASURED AT IMAG: THE PULSES THAT OVERCOME THE MIN THRESHOLD ARE VALID IF AT THE SAME
TIME THEY NOT OVERCOMES THE MAX THRESHOLD ON THE IMAX TEST POINT REPORTED IN FIG. 14. .................. 37
FIG. 13 – SIGNAL MEASURED AT IDEMAG LABEL: THE PULSES THAT OVERCOMES THE MIN THRESHOLD ARE VALID IF AT
THE SAME TIME THEY NOT OVERCOMES THE MAX THRESHOLD ON THE IMAX TEST POINT. ................................... 37
FIG. 14 – SIGNAL MEASURED AT IMAX TEST POINT: THE SYSTEM GOES NOT IN ALARM STATE IF THE PULSES NOT OVER
THE MAX THRESHOLD. ............................................................................................................................................ 38
FIG. 15 – THE CONNECTION SYSTEM AVAILABLE OF THE ST200-K BOARD........................................................................ 39
FIG. 16 – THE CONNECTION SYSTEM AVAILABLE OF THE ST200-L BOARD. ....................................................................... 40
FIG. 17 – SECTION FO THE SCHEMATIC FOR MANAGING ENABLES. .................................................................................... 41
FIG. 18 – JMP3 POSITION. .................................................................................................................................................. 44
FIG. 19 – JUMPER JMP3 OF THE ST200-K BOARD. ............................................................................................................ 48
FIG. 20 – JUMPER OF THE ST200-L BOARD. ....................................................................................................................... 49
FIG. 21 – JMP SUPPLY VOLTAGE SELECTION. .................................................................................................................... 50
FIG. 22 – IMAGE OF THE KEYBOARD WITHOUT MAGNETIZATION LEVELS. .......................................................................... 51
FIG. 23 – IMAGE OF KEYBOARD WITH TWO MAGNETIZATION LEVELS. ............................................................................... 53
FIG. 24 – IMMAGINE PULSANTIERA A 7 LIVELLI. ................................................................................................................ 55
FIG. 25 – IMAGE OF THE CH-ENABLE KEYBOARD.............................................................................................................. 57
FIG. 26 – MEASURING POINT. ............................................................................................................................................ 62
FIG. 27 – MEASURING POINT. ............................................................................................................................................ 63
FIG. 28 – SUPPLY CIRCUIT OF THE ST200-L BOARD........................................................................................................... 64
FIG. 29 – VOLTAGE RANGE OF THE CORRECT OPERATION OF THE PIC18F4520 (GRAPHIC FROM THE DATA SHEET OF THE
MICROCHIP MICROCONTROLLER)............................................................................................................................. 65
FIG. 30 – ZERO-CROSS CIRCUIT. ....................................................................................................................................... 66
FIG. 31 – THE ZERO-CROSS SIGNAL. .................................................................................................................................. 66
FIG. 32 – SCHEMATIC OF THE PLC INTERFACE. ................................................................................................................. 71
FIG. 33 – PLC INTERFACE BOARD LAYOUT – TOP VIEW. .................................................................................................... 72
FIG. 34 – PLC INTERFACE BOARD LAYOUT – BOTTOM VIEW.............................................................................................. 73
FIG. 35 – FRONT PANEL OF THE PLC INTERFACE IN 130 X 80 RELEASE. ............................................................................. 75
FIG. 36 – SCHEMATIC OF THE FRONT PANEL. ..................................................................................................................... 76
FIG. 37 – LAYOUT OF THE DB37 CONNECTOR. .................................................................................................................. 81
FIG. 38 – SCHEMATIC OF KOSMEK KEYBOARD. .............................................................................................................. 83
FIG. 39 – FRONT PANEL FOR KOSMEK KEYBOARD. ......................................................................................................... 84
FIG. 40 – LAYOUT OF DB37 CONNECTOR FOR KOSMEK ..................................................................................................... 86
FIG. 41 – SINGLE POLE COIL FLUX MEASUREMENT CIRCUIT. .............................................................................................. 87

LIST OF TABLE
TABLE 1 – TABLE USEFUL WHEN A ST-200K BOARD IS AVAILABLE AND IT IS NECESSARY TO KNOWN THE ACTUAL
CONFIGURATION (FOR TECHNICAL SUPPORT, FAULT ANALYSIS ETC.) ....................................................................... 16
TABLE 2 - TABLE USEFUL WHEN IT IS NECESSARY TO CONFIGURE ST-200K BOARD IN COMPLIANCE WITH A WANTED
CONFIGURATION (USEFUL FOR EXAMPLE DURING DESIGN). PLEASE NOTE THAT THE TABLE IS DIVIDED IN MORE THAN
ONE SHEET. .............................................................................................................................................................. 18
TABLE 3 – FIRST 5 POSITION OF THE SW1 AND RELATED CODE OF THE NUMBER OF BOARD PRESENTS. ............................. 26
TABLE 4 – 5 PUSH BUTTON KEYBOARD (2 LEVELS) .......................................................................................................... 27
TABLE 5 – 5 PUSH BUTTON KEYBOARD (7 LEVELS) .......................................................................................................... 28
TABLE 6 – 3 PUSH BUTTON KEYBOARD ............................................................................................................................ 28
TABLE 7 – POSITION 6 AND 7 OF THE DIP SWITCH SW1 OF THE ST200-L LOGICAL BOARD. .............................................. 29
TABLE 8 – POSITION 6 E 7 OF THE DIP SWITCH SW PRESENT ON THE CH-ENABLE ST200-KE BOARD. ............................. 30
TABLE 9 – CONFIGURATION TABLE FOR CH-ENABLE BOARD. ........................................................................................... 31
TABLE 10 – POSITION 6 AND 7 OF THE DIP SWITCH SW1 ON THE ST200-KE BOARD CH-ENABLE SPECIAL. .................... 32
TABLE 11 - EXTERNAL QUALIFICATION RELÉ STATE ACCORDING TO THE SYSTEM STATE. ................................................. 42
TABLE 12 - MAIN FEATURES OF THE EXTERNAL QUALIFICATION RELÉ. ............................................................................. 43
TABLE 13 – SELECTING THE TABLE ACCORDING TO THE JUMPERS. .................................................................................... 44
TABLE 14 – TABLES SELECTION. ....................................................................................................................................... 50
TABLE 15 – TABLE FOR SUPPLY VOLTAGE SELECTION. ...................................................................................................... 50
TABLE 16 – CONFIGURATION TABLE FOR THE KEYBOARD WITHOUT MAGNETIZATION LEVELS (3 PUSH BUTTON). ....... 51
TABLE 17 – LUMINOUS SIGNAL ON KEYBOARD WITHOUT MAGNETIZATION LEVELS (3 PUSH BUTTON). ........................ 52
TABLE 18 – CONFIGURATION TABLE OF HTE KEYBOARD WITH 2 MAGNETIZATION LEVELS (5 TASTI). ............................. 54
TABLE 19 – LUMINOUS SIGNAL ON KEYBOARD WITH TWO MAGNETIZATION LEVELS (5 PUSH BUTTON). ...................... 54
TABLE 20 – CONFIGURATION TABLE FOR THE KEYBOARD WITH 7 MAGNETIZATION LEVELS (5 PUSH BUTTON). ........... 56
TABLE 21 – LUMINOUS SIGNAL FOR THE KEYBOARD WITH 7 MAGNETIZATION LEVELS. .................................................... 56
TABLE 22 – CONFIGURATION TABLE FOR THE CH-ENABLE KEYBOARD. ........................................................................... 57
TABLE 23 – POSITION 6 AND 7 OF THE DIP SWITCH SW1 ON THE ST200-KE CH-ENABLE SPECIAL BOARD. .................... 59
TABLE 24 – INPUT SIGNALS AT THE µC PINS OF THE PLC INTERFACE. ............................................................................... 69
TABLE 25 – OUTPUT SIGNAL AT THE µCONTROLLORE PINS OF THE PLC INTERFACE. ........................................................ 70
TABLE 26 – CH-ENABLE CONFIGURATION. ....................................................................................................................... 75
TABLE 27 – LUMINOUS SIGNALING MEANING OF THE PLC INTERFACE. ............................................................................. 77
TABLE 28 – LUMINOUS SIGNAL PRESENTS ON THE PLC INTERFACE. ................................................................................. 77
TABLE 29 – LED MEANING OF THE OUTPUT (AS PRESENTS ON THE FRONT PANEL – TWO RAW ON THE LEFT) .................... 78
TABLE 30 – LED MEANING OF THE INPUT (AS PRESENTS ON THE FRONT PANEL – ON THE RIGHT)...................................... 78
TABLE 31 – LED’S MEANING ON PLC KEYBOARD WHEN USING IN CH-ENABLE MODE. .................................................... 79
TABLE 32 – CORRESPONDENCE BETWEEN LEVEL/BINARY CODE. ....................................................................................... 82
TABLE 33 – LED MEANINGS. ............................................................................................................................................. 85
TABLE 34 – CONNECTOR PIN-OUT ON KOSMEK KEYBOARD VS SIGNAL ON PLC BOARD. ................................................. 85
TABLE 35 – CHUCKS SELECTION........................................................................................................................................ 88
TABLE 36 – NUMBER OF LOGIC BOARD CONNECTED: POSITIONS FROM 1 TO 5 OF DIP-SWITCH SW1. ................................ 89
TABLE 37 – NUMBER OF LOGIC BOARD WORKING SIMULTANEOUSLY: POSITION 6 AND 7 OF DIP-SWITCH SW1. ............... 89
TABLE 38 – TYPE OF OPERATION: STANDARD / SETUP. ..................................................................................................... 89

1. FEATURES
Model of microcontroller used: ............................................................... PIC18F4520 (Microchip)

Quartz frequency: .................................................................................................................. 10 MHz
Job voltage: ..................................................................................................... 230 V – 400 V – 460 V
Job frequency: ..................................................................................................................... 50 – 60Hz
Discharge formality: ........................................................................................................... Impulsive
References Software
1. L10_400_X for board from 1 to 4 discharges for voltage from 200V up to 400V for both 50
and 60 Hz of industrial frequency; Letter X (e.g. 1, 2 …etc) indicates different table settings.
2. L10_480_X for board from 1 to 4 discharges for 460V and 480V for both 50 and 60 Hz of
industrial frequency; Letter X (e.g. 1, 2 …etc) indicates different table settings.
3. K10_UNI for keyboard available in two different version: master and CH-Enable. In
particular, with this software the following configurations are available:
o Master Keyboard with 7 levels of partial magnetization (+ Full Mag) – For further
information an details please ref. to chapter 15 in section Keyboard with 7
magnetization level (5 PUSH BUTTON) – Software: K10_UNI.
o Master Keyboard with 2 levels of partial magnetization (+ Full Mag) – For further
information an details please ref. to chapter 15 in section Keyboards with two
magnetization levels (5 PUSH BUTTON) – Software: K10_UNI.
o Master Keyboard with only full magnetization (Full Mag) – For further information
an details please ref. to chapter 15 in section Keyboard without magnetization
levels (3 PUSH BUTTON).
o Keyboard used as CH-Enable – For further information a details please ref. to
chapter 15 in sectione CH-Enable.
4. M10_PLC for PLC Master Interface. This software supports only the keyboards with 7
levels of partial magnetization.
5. CH10_PLC: this software is used when the selection of the channels through PLC is
necessary.

6. CH10_ENABLE_SPECIAL: this software is used when it is necessary to manage channel in

a different way as used in the standard release. In particular It is possible to select the
discharge as indicated in section CH-Enable Keyboard – Software: CH10-ENABLE-
SPECIAL.
Description
The ST200 system is a multi-board system:
ST200-L: Logical board, for the SCR command
ST200-K:
o ST200-KM: Keyboard in Master version;
o ST200-KE: Keyboard in CH-Enable version.
The ST200-K boards differ only from the jumper and PAD configuration. The programmed
software is unchanged.
The system ST200 can be shaped as follows:
a Master ST200-KM board and n logical ST200-L boards with a number of discharges that
are fixed and equal to 1, 2, 3 or 4 (the maximum value of n is 32);
a Master ST200-KM board, n logical ST200-L boards, n CH-Enable ST200-KE boards and
up to 4 n selectable discharges (the maximum value of n is 32).
The ST200 system is used both to realize demagnetization systems (Grinding machine) and
inversion systems (Milling Machine).
It is possible to manage up to a maximum of 4 discharge channels for every ST200-L logical board.
The system has a current transducer for the measurement of the discharges current both during the
magnetization and the demagnetization phase. Such sensor is mounted on logical ST200-L board.
The communication among all boards happens through a serial RS485 line common to all the
boards. The communication resistance has to be 60Ω when measured through the pin 1 and pin 2
pin of the JP3 connector.

2. ST200-L BOARD LAYOUT – COMPONENT SIDE
1
P2
TOT SING
D23
SW2
JP3
SW1
1
C60
R71
1
FCS IN
R67
R44
R69
Sing JP4Tot
P3
INTERFACE
J1
C40 C38
JP7
R701
D11 D16
R68 Q13
3
SING
Q2 CH4 CH3 CH2 CH1
FCS
R15
K4
1
C61
DISCHARGE
Q5
X1
Q12 R47
Q8
D7
1
C28
C29
TOT R19 C3
R39
Q6 C1
R18
DL1
JMP6
+
C2
R46
USERPROG
C12
C11
JMP4
Q7 ALARM
U11
JMP1
D18
L2
JMP3
C4
C31
+5V
R56
C25
+
Q10
+
JP5
C5
R58
R55
1 P4
M_B M_A
U4
R35
+12V
R36 1
U14
1
Q11
U2
WP6
P1
U13
R37
R80
C24
C6 C18
IMax
U7
WP5
Z/C
U10
IDEM
R31
R38
R57
R30
C20
R24
D13
U9
C32
IMAG
VFW
+
L1
R42 R43
C30
D8 ISO1
+
D17
+
B1
F4
F3
D12 -
C35
R32
D10
+
U6
15V 0V 15V 0V
1
K2
T1
D19
460V 400V 230V 200V 0

K3
POWER
200V230V
400V460V
JMP10
JMP7
JMP8
JMP9
JP6
Fig. 1– File: ST200-7L.MAX Directory: ...\Progetti2007\ST200Lrev7\...

3. ST200-L BOARD LAYOUT – BOTTOM VIEW
Fig. 2 – File: ST200-7L.MAX Directory: ...\Progetti2007\ST200Lrev7\...

4. ST200-K BOARD LAYOUT – COMPONENT SIDE
3K3
33K
R7
R6
10MHz
4K7
4K7
100
100
100
100
Fig. 3 – File: ST200-5K-1.MAX Directory: ..\Progetti2006\...

5. SCHEMATIC OF ST200-L BOARD
3 2
1 3
4 8
8 4
1
3 2
2 7 4
1
5
1
1 3
3 2 2 1 2 1
2 21 1
7 4
1
5
8 4
8 4
1 3
2 1 2 1
2 1 2 1
2 1
3 3 2
2 1
2 1 2 1 2 1 2 1
3 2
2 3 2 3 2 3 2 3
INPUT
+ 1 2
ON/OFF
5
FB NC2
4 3
GND
6
NC1
2
C27 100nF
Gnd
2
R14 10k
RC7/RX NC
1 33 1 2
RD4/PSP4 RC0
2 32
RD5/PSP5 OSC2
3 31
RD6/PSP6 OSC1
4 30
RD7/PSP7 VSS
5 29
VSS VDD
6 28
VDD RE2
7 27
RB0 RE1
8 26
RB1 RE0
9 25
RB2 RA5
10 24 8 7
RB3* RA4
11 23
14 1
5
1
7 4
3 2
1 2
3 1
3 2
R54 10k
R53 10k
R52 10k
R51 10k
R50 10k
R49 10k
R48 10k 2 2 2 2
R29 10k
Fig. 4 – Schematic of the ST200-L board.

6. SCHEMATIC OF ST200-K BOARD
Fig. 5 – Schematic of the ST200-K board.

7. HOW TO CONFIGURE THE SYSTEM

On ST200-K board the following configuration devices are implemented:
• 3 PAD labeled PAD1, PAD2 and, finally, PAD3;
• 1 traditional jumper (labeled JMP3),
• 1 Dip-Switch with 8 position (SW1) where only the final 3 position are available due to the
fact that the first 5 position are reserved for the board address selection.
Using this device is possible change the system configuration. For further details please see Fig. 6 .
PAD2
JMP3
SW1- pos 7
PAD3 ON
PAD1
Fig. 6 – Configuration Pads, Jumpers and Dip-Switches for ST200-KM board.
The system configuration is indicated in the following by means two different tables:
• Table 1 useful when a ST-200K board is available and it is necessary to understand the
actual configuration (this table is useful during the fault analysis, services etc.);
• Table 2 useful when a ST-200K board need to be configured as wanted (this table is useful
during system design, system realization etc).
Single configuration will be further discussed in the following when the different keyboard will be
shown.

The function of the available PAD are the following:
PAD 1: For Master or Ch_Enable selection

PAD 2: It discriminates between channel selected using a CH_Enable board or channel selected
using an ad hoc configuration of the Dip-Switch 1 mounted on ST200-L board.
PAD 3: Change the output enable setting. Two different choice are available: Output Enable
available when the system is at level 8 of magnetization (PAD3 open) or Output Enable available
when the system is at level 1 of magnetization (PAD3 closed).
When the PAD configuration is changed a new setup procedure is necessary to acquire the new
PAD configuration.
JMP3 allows to program the board in the following manner:
JMP3 in user position Standard use

JMP3 in prog position Programming state (it is possible the download of a new program)
The meaning of the latest 3 position of SW1 is:
SW1 – Position 6 non used in master keyboard. In Ch-Enable keyboard is used with SW1 –
Position 7 to fix the discharge number.
SW1 – Position 7 On master keyboard is used to set the system as system with 2 level (named
even system without level) or with 7 level. In Ch_Enable board is used with SW1 – Position 6 to fix
the discharge number.
SW1 – Position 8 On master board is used during set-up procedure. Please see the dedicated
section for further details. In CH_Enbale board is used to set how to select or deselect the channel
during stand-by.
In the following Table 1 and Table 2, N.I. means “Not important”, i.e. the state is not read from
the system.

Table 1 – Table useful when a ST-200K board is available and it is necessary to known the actual configuration
(for technical support, fault analysis etc.)
Keyboard JMP3 PAD1 PAD2 PAD3 SW6 SW7 SW8 Type Configuration
It allows the board programming. Both
prog
PAD and SW1 state are not considered.
• Master with 2 levels
• The channel are selectable using a CH-
5 PUSH BUTTON KEYBOARD (2 LEVELS)
Open OFF Enable board

• Output Enable is activate when FullMag
is present
Open
Closed OFF Enable board
• Output Enable is activate when the first
MASTER
ON
level of partial magnetization is present
user Open
• The channel are selcted by the Dip-
Closed OFF Switch 1 presents on the ST200-L board.
is present
Closed
• The channel are selected by the Dip-
prog
Open ON Enable board

is present
Open
Closed ON Enable board
MASTER
ON
user Open
Open ON Switch 1 presents on the ST200-L board.
is present
Closed
Closed ON Switch 1 presents on the ST200-L board.

Table 1 – Cont.
prog
• Master without magnetization levels
3 PUSH BUTTON
Open OFF • The channel are selectable using a CH-

KEYBOARD
Open Enable board

MASTER
Closed OFF ON
is present
user Open
Open OFF • The channel are selected by the Dip-
Closed Switch 1 presents on the ST200-L board.
• Output Enable in corrispondenza del
Closed OFF FullMag
prog
• Ch-enable The deselection of the
N.I. OFF OFF
• 1 discharge discharge is allowed
CH-ENABLE
N.I. when the system is in

• Ch-enable
N.I. OFF ON stand by only if in
MASTER
ON • 2 discharges
DEMAG state without
user Closed • Ch-enable
N.I. ON OFF alarm and the selection
• 3 discharges of the discharge is
N.I. • Ch-enable allowed only if there
N.I. ON ON • 4 discharges are not alarms
(preferred selection).
• Ch-enable
N.I. OFF OFF
• 1 discharges
N.I. Both selection and
CH-ENABLE
• Ch-enable
MASTER
N.I. OFF ON detection of the

• 2 discharges
user Closed OFF discharge is always
• Ch-enable permitted when in
N.I. ON OFF
• 3 discharges stand-by.
N.I.
• Ch-enable
N.I. ON ON
• 4 discharges

Table 2 - Table useful when it is necessary to configure ST-200K board in compliance with a wanted
configuration (useful for example during design). Please note that the table is divided in more than one sheet.
It allows the board
programming. Both
prog N.I. N.I. N.I. N.I. N.I. N.I.
PAD and SW1 state
are not considered.
• The channel are selectable
using a CH-Enable board user Open Open Open N.I. OFF ON
• Output Enable is activate
when FullMag is present

using a CH-Enable board
• Output Enable is activate user Open Open Closed N.I. OFF ON
when the first level of
partial magnetization is
present
MASTER
• The channel are selected
by the Dip-Switch 1
presents on the ST200-L user Open Closed Open N.I. OFF ON
board.
by the Dip-Switch 1
presents on the ST200-L
board. user Open Closed Closed N.I. OFF ON
present

Table 2 – Cont.
It allows the board
programming. Both
PAD and SW1 state
are not considered.
using a CH-Enable board user Open Open Open N.I. ON ON

• Output Enable is activate user Open Open Closed N.I. ON ON
present
MASTER
by the Dip-Switch 1
presents on the ST200-L user Open Closed Open N.I. ON ON
board.
by the Dip-Switch 1
board. user Open Closed Closed N.I. ON ON
present

Table 2 – Cont.
It allows the board
programming. Both
PAD and SW1 state
are not considered.
• Master without
magnetization levels user Open Open Open N.I. OFF ON
3 PUSH BUTTON JEYBOARD

when FullMag is present user Open Open Closed N.I. OFF ON
• the channel are selected by
the Dip-Switch 1 presents
MASTER
on the ST200-L board.
• Master without
magnetization levels user Open Closed Open N.I. OFF ON
by the Dip-Switch 1
board.re
• Output Enable in user Open Closed Closed N.I. OFF ON
corrispondenza del
FullMag
It allows the board
programming. Both
PAD and SW1 state
are not considered.
CH-ENABLE • Ch-enable
user Closed N.I. N.I. OFF OFF ON
The deselection of the • 1 discharge
CH-ENABLE
discharge is allowed when • Ch-enable

the system is in stand-by user Closed N.I. N.I. OFF ON ON
• 2 discharges
only if in DEMAG state • Ch-enable
without alarm and the user Closed N.I. N.I. ON OFF ON
• 3 discharges
selection of the discharge is
• Ch-enable
allowed only if there are not user Closed N.I. N.I. ON ON ON
alarms (preferred selection). • 4 discharges
• Ch-enable
user Closed N.I. N.I. OFF OFF OFF
• 1 discharge
CH-ENABLE
CH-ENABLE. • Ch-enable
user Closed N.I. N.I. OFF ON OFF
Both selection and detection • 2 discharges
of the discharge is always • Ch-enable
user Closed N.I. N.I. ON OFF OFF
permitted when in stand-by. • 3 discharges
• Ch-enable
user Closed N.I. N.I. ON ON OFF
• 4 discharges

The ST200 System can work, as previously described, both as Milling Machine version and
Grinding Machine version; it is sufficient to shape correctly the configuration Dip-Switch 1 on the
logical board to get a Milling Machine or a Grinding Machine.
See the specific paragraph for the correct use of the Dip-Switch which is located on the boards.
WARNING
Mixed CH-Enable configurations are not possible. In particular, either all the logical boards have
the relative CH-Enable board or none of the logical boards have the CH-Enable board. On the
contrary, mixed discharge configurations are possible. In particular some logical boards can be
configured according to the grinding or the Milling Machine type.

8. TURNING ON THE SYSTEM (COMMON FOR ALL VERSIONS)

While lighting the system can perform two different Setup procedures according to the Dip-Switch
setting placed on the ST200-KM board. In particular the configuration procedure that is performed
during the lighting is:
o setting the pin in the position OFF, the Setup procedure (for the first lighting or the system
reconfiguration);
o setting the pin on ON, the standard activation procedure (for all the other cases).
Setup procedure (first time turn on or reconfiguration of the system)

In order to activate this procedure, move the selector 8 of the Dip-Switch 1 on the ST200-KM board
in position OFF.
OFF
Fig. 7 – Position OFF of the Pin 8 - SW1.
1. when the system is turned on all the cycle LEDs on the keyboard Master checked by the ST200-
KM board are activated and, if present, also the ones on the CH-Enable keyboard checked by the
ST200-KE board. The other luminous signaling are out;
2. the number of logical ST200-L boards of the system is determined through the reading of the
Dip-Switch on the ST200-KM board. See the specific paragraph for the correct configuration of
the Dip-Switch;
3. the probable ST200-L (logical) boards and the probable ST200-KE (CH-Enable) boards of the
system are singularly checked by the ST200-KM board. Such interrogation is necessary to know
if the n board is present in the system and if the number of logic and CH-Enable boards in the
system corresponds to the boards number set by the system. If this boards number is different
from those planned by the Dip-Switch in the ST200-KM board the system goes in an alarm state.
The system is therefore able to acknowledge the presence of a number of logical and CH-Enable
boards different from those planned by the Dip-Switch. The boards can be also be configured
with non sequential addresses. When the master board doesn't receive any answer from a
particular address, then after a prefixed time it will check the board with the following address.
The process stops when the master board finishes checking all the manageable boards equal to
32, the esteemed time for this operation is equal to about 40 seconds;
4. when the process of interrogation is finished, then it is memorized in the Master board what and
how many ST200-L (logical) boards compose the system. Also the logical and CH-Enable
boards memorize their code of activation that cannot be modified anymore if a new interrogation
is not developed (Setup procedure). When the number of ST200-L boards in the system doesn't
correspond to the number planned on the ST200-KM board then the system produces a signaling
of alarm configuration (see point 6);
5. when the interrogation of the ST200-L boards is finished, then all the cycle LEDs on the
different keyboards are extinguished and the system is idle;
6. if the system reveals a condition of configuration alarm, then all the alarm, cycle, mag and
demag leds on the Master keyboard are activated according to a flashing way while the cycle
leds of the other CH-Enable keyboards are extinguished and the system is idle. (for the setting of
the Dip-Switch 1 see the relative paragraph).
Eventually alarms presents on the ST200-L board are now erased.
The configuration of the whole system will require a fixed waiting time which is also independent
from number of logical boards of the system. The end of the procedure is signaled correctly by the
turning off of all LEDs. The time can be esteemed equal to about 40 seconds.
At the end of the setup procedure the state of the Dip-Switch and the PAD is memorized on every
board.
Procedure of Standard activation

In order to activate this procedure move the selector 8 of the Dip-Switch 1 on the ST200-KM board
in position ON. This selector must be always in this position during the ordinary functioning.

ON
Fig. 8 – Position OFF of the Pin 8 - SW1.
1. when the system is turned on all the cycle LED on the keyboard Master checked by the ST200-
KM board are activated and, if present, also the ones on the CH-Enable keyboard checked by the
ST200-KE boards. The other luminous signaling are out;
2. the number of ST200-L (logical) boards is recovered from the EEPROM of the microcontroller
on the ST200-KM board and if present also the number of ST200-KE (CH-Enable) boards
connected in the system and their address. It is important to remember that the Master board
knows previously if it has to manage logical boards with or without CH-Enable boards according
to the PAD configuration. (See therefore the relative paragraph). In order to reset the number of
present boards it is necessary to perform the procedure " Setup procedure (first time turn on
or reconfiguration of the system)" (see therefore the previous paragraph);
3. the code of the last cycle correctly performed, the possible alarms and the level of selected
magnetization are recovered from the EEPROM memory of the microcontroller on the ST200-
KM board;
4. it is required to ST200-L boards to determine the frequency of the supply voltage;
5. if every board answers with the same frequency value (50Hz or 60Hz), the state of every logic
board is required;
6. when the interrogation of the ST200-L and ST200-KE boards is finished, all cycle leds on the
different keyboards checked by the ST200-KM and ST200-KE boards are extinguished and all
leds that represent the state of the system are activated. If the ST200-KE (CH-Enable) keyboards
are present, then all leds that represent the state of each channel are activated;
7. now the operator can begin to work.

This procedure requires from the operator a waiting time which depends on the number of the
present logical boards. The end of the procedure is signaled by the turning off of all cycle leds and
by the lighting of the leds of state. It can be esteemed a time equal to about 1 second when the board
(ST200-L and ST200-KE) is connected.
Warning! When the system turns on, then every board checks the PAD and Dip-Switches condition.
If the configuration is changed in comparison to the last memorized configuration, the system
reveals a configuration alarm activating the alarm, cycle, mag and demag leds on the Master
keyboard according to a flashing way and the command is idle. In order to eliminate the alarm it is
possible:
o To turn off the system and turn it on again according to the " Setup procedure (first time
turn on or reconfiguration of the system)" in order to reset the system according to the
new necessities;
o To turn off the system, to reset the PAD and the Dip-Switches configuration of every board
according to the previous state and to turn on the system again.
Even when the system turns on for the first time without having performed the " Setup procedure
(first time turn on or reconfiguration of the system)", the system reveals a configuration alarm.

9. HOW TO USE THE DIP-SWITCH (FOR ALL VERSIONS)

ST200-KM BOARD (MASTER) – PAD 1 OPEN
The Dip-Switch 1 on the ST200-KM board points out to the board itself how many ST200-L
(logical) boards are in the system.
ON
OFF
Fig. 9 – First 5 position on SW1.

For such operation only the first five positions (from 1 to 5) are used. In order to establish the
correct number of connected ST200-L boards, the following binary numeration system is
considered. Therefore it is possible to connect up to 32 ST200-L boards and 32 ST200-KE boards.
See the following table for the correct system configuration.
Table 3 – First 5 position of the SW1 and related code of the number of board presents.
№ boards Binary code № boards Binary code № boards Binary code

1 00001 12 01100 23 10111
2 00010 13 01101 24 11000
3 00011 14 01110 25 11001
4 00100 15 01111 26 11010
5 00101 16 10000 27 11011
6 00110 17 10001 28 11100
7 00111 18 10010 29 11101
8 01000 19 10011 30 11110
9 01001 20 10100 31 11111
10 01010 21 10101 32 00000
11 01011 22 10110
Example: 4 logic board (ON = “1”; OFF = “0”)
Bit 1 Bit 5
00100

In order to determine the board address it is necessary to know that when the Switch is on the
position ON the relative address bit has value 1; likewise when it is on the position OFF the relative
address bit has value 0.
The configuration of PADs, Jumper and Dip-Switch is reported in the following tables:
• Table 4 – 5 Push Button Keyboard (2 levels)
• Table 5 – 5 Push Button Keyboard (2 levels)
• Table 6 – 3 Push Button Keyboard.
Table 4 – 5 Push Button Keyboard (2 levels)

prog

is present
Open
MASTER
ON
user Open
Open OFF Switch 1 presents on the ST200-L board.
is present
Closed

Table 5 – 5 Push Button Keyboard (7 levels)

prog

is present
Open
MASTER
ON
user Aperto
• The channels are selected by the Dip-
is present
Closed
Table 6 – 3 Push Button Keyboard

prog
3 PUSH BUTTON

KEYBOARD
Open Enable board

MASTER
Closed OFF ON
is present
user Open
Closed Open OFF Switch 1 presents on the ST200-L board.
FullMag
The eighth position of the Dip-Switch (8) is used for pointing out to ST200-KM board which
configuration procedure must be performed during the start – up of the system:
o Switch ON Procedure of Standard activation;

o Switch OFF Setup procedure (first time turn on or reconfiguration of the system).

ST200-L BOARD (LOGIC BOARD)
On the ST200-L (logical) board the Dip-Switch is used to determine the identification address of
the board and for the selection of the cycle typology which is to perform during the Demag
procedure.
The first 5 positions identify the board number. See the previous table for the correct system
configuration.
Warning: every ST200-L board must have a proper univocal address in the system: therefore
it is not possible to have more ST200-L boards with the same address.
The sixth and the seventh position of the Dip-Switch (6 and 7) define the number of discharges that
the command must perform if the ST200-KE (CH-Enable) board is not present. The number of
discharges is indicated in the following table.
Table 7 – Position 6 and 7 of the Dip Switch SW1 of the ST200-L logical board.
№ discharges Dip-Switch 6 Dip-Switch 7

4 ON ON
3 ON OFF
2 OFF ON
1 OFF OFF
Warning: shape the Dip-Switch 6 and 7 of the ST200-L board in the position ON and ON if
command ST200 is realized with the CH-Enable.
The eighth position of the Dip-Switch (8) allows to set the typology of the Demag cycle:
o setting the Switch on ON the system performs a Demag inversion cycle (Milling Machine);
o setting the Switch on OFF the system performs a Demag demagnetization (Grinding
Machine).

ST200-KE BOARD (CH-ENABLE) – PAD 1 CLOSED
The Dip-Switch on the ST200-KE (CH-Enable) board is used to determine the identification
address of the board.
Even in this case, as for the ST200-L board, the first 5 positions identify the board number. See the
Table 3 for the correct system configuration.
WARNING
Each ST200-KE (CH-Enable) board requires a
ST200-L (Logical) board. The address of the ST200-KE (CH-Enable) board must be the same
to the address of the corresponding ST200-L (Logical) board.
The sixth and the seventh position of the Dip-Switch (6 and 7) define the number of discharges that
the ST200-KE board must manage. The number of discharges corresponds to what reported in the
following table.
Table 8 – Position 6 e 7 of the Dip Switch SW present on the Ch-Enable ST200-KE board.
№ discharges Dip-Switch 6 Dip-Switch 7

4 ON ON
3 ON OFF
2 OFF ON
1 OFF OFF
The eighth position of the Dip-Switch (8) allows to set the logic of operation of the ST200-KE (CH-
Enable) board:
o setting the Switch on ON position, the system deselects only the Demag discharges out of
the cycle without alarms and selects them only if there are no alarms (recommended
solution);
o setting the Switch on OFF position, the system deselects/selects the discharges out of the
cycle in every condition.
For sake of simplicity the configuration table is also here reported.

Table 9 – Configuration table for CH-Enable board.
prog
N.I. OFF OFF
CH-ENABLE

• Ch-enable
N.I. OFF ON stand-by only if in
MASTER
ON • 2 discharges
DEMAG state without
• 3 discharges
of the discharge is
• Ch-enable
N.I. OFF OFF
• 1 discharge
CH-ENABLE
• Ch-enable
MASTER
• 2 discharges
N.I. ON OFF
N.I.
• Ch-enable
N.I. ON ON
• 4 discharges

ST200-KE BOARD (with software CH_ENABLE_SPECIAL) – PAD 1 CLOSED
The Dip-Switch presents on ST200-KE board (CH-Enable) is used to assign the identification
address of the board.
The position 6 and 7 of this Dip-Switch (6 and 7) are used during the definition of the discharges
and the number of channel as reported in the following table.
Table 10 – Position 6 and 7 of the Dip Switch SW1 on the ST200-KE board CH-Enable Special.
N° of
№ of the Dip- Dip-
available Note
discharge Switch 6 Switch 7
selection
Ch1 and Ch2 only are available: selecting CH1 first
2+2 2 ON ON and second discharges are selected, selecting CH2
third and fourth discharges are selected,
Only CH1 channel is managed; others channels
4 1 ON OFF are not managed.
4 discharges are operated.
Only CH1 channel is managed and the other
3 1 OFF ON channels are not managed.
3 discharges are operated.
2 1 OFF OFF channels are not managed.
2 discharge are operated
See table 9 to configure a board.

10. THE CURRENT CONTROL

Fig. 10 shows the circuit used for current measurement.
U17B
D25
5
2 1 7 +
6
-
MBRS140 1458 R78 3K3
R79 1k8
VCC R76 3K3 R77 1k8

2
VF
R75 1k8
D26 U17A
8
MBRS140
D24
3 R74 3K3 VF
1
1IMAX 2 1 1 + U16B
2 U16A
8
WP11 - 5
MBRS140 1458 7 + 3
4
6 1 +
- 2
-VF -
1458 R72 4k7
1458
4
1 3
-VF
R73 470 P4 50k C10 100nF
2
VF VF
1
1
C7 1uF
VCC
3
C8 100nF M_A M_B U6
2
+V
U5A 1 OUT
8
D8 R20 3k3
WP8
MBRS140 3 R22 -V
1IMAG 1 + VAC 4644x100 SK N2
10
2 1
2
2 R21 3K09 1%
- VCC -VF
C13 1458
4
1
D9 100nF C14 100nF
MBRS140 -VF
D10 R80 2
WP9
1
MBRS140 5 10
1IDEMAG 7 + P1 ELIMINARE P1
21
6 100
-
3
C15 C16 D12 C17 1458 U5B R23 3k24 1%
1uF 100nFMBRS140 100nF
1
Fig. 10– Current measurement circuit.
The cycle current can be measured placing a probe on the following test point:
IMAG WP8 test point
IDEMAG WP9 test point
IMAX WP11 test point
It is not necessary to regulate Trimmer labeled P4 if the value is a 50kΩ (board is shipped correctly
configured so no regulation is necessary).
The system works as reported in this section.
In particular:
o On IMAX channel the current pulse must not exceed the MAX threshold;
o On IMAG cannel the current pulse must exceed the MIN threshold during MAG cycle and the
current pulse must not exceed the MIN threshold during DEMAG cycle;
o On IDEMAG cannel the current pulse must exceed the MIN threshold during DEMAG cycle
and the current pulse must not exceed the MIN threshold during MAG cycle;
The ST200-L board is endowed with a current sensor (U6) whose function is to check the discharge
current both when the system functions and when the system is idle (attended command).
1
P2
TOT SING
D23
SW2
JP3
1
R71
R67
R44
R69
Sing JP4Tot
P3
J1
C40 C38
R701
R68 Q13
3
SING
CH4 CH3 CH2 CH1
FCS
R15
K4
1
C61
DISCHARGE
X1
Trimmer P4 Q8
1
C29
TOT
R39
R18
DL1
JMP6
+
R46
USERPROG
C12
C11
JMP4
U11
JMP1
D18
L2
JMP3
C31
+5V
R56
C25
+
JP5
R58
R55
M_B M_A
U4
R35
+12V
IMAX (WP11)
U14
1
U2
P1
U13
R37
C24
IMax
U7
Z/C
IDEM
U10
R31
R57
R30
R24
U9
C32
IMAG
VFW
L1
LM7812 (U10)
C30
IDEMAG (WP9)
+
D17
B1
F4
F3
IMAG (WP8)
C35
R32
+
U6
1
K2
T1
Sensore di corrente (U6)

D19
K3
POWER
200V230V
400V460V
JMP10
JMP7
JMP8
JMP9
JP6
Fig. 11 – Where to measure the discharge current on the board.
It is now given the detailed on how the current measurement is performed.

The measure of the current is carried out by means of both three signal and three thresholds. The
used signals are the following:
o IMAG
o IDEMAG
o IMAX
The utilized threshold are the following:
o ZERO Threshold setted at 500 mV;
o MIN Threshold setted at 700 mV;
o MAX Threshold setted at 4,7 V.
It is possible to see the current value from the system putting the probes of the oscilloscope in the
following way:
o On the test point labeled IMAG (WP8) when it is necessary the measure of the magnetization
current;
o On the test point labeled IDEMAG (WP9) when it is necessary the measure of the
demagnetization current;
o On the test point labeled IMAX (WP11) when it is necessary the measure of the maximum
current;
The reference of the oscilloscope must be connected to the frame of the tension regulator LM7812
(U10).
The current sensor returns a voltage which is proportional to the current previously revealed. The
microcontroller acquires such voltage and compares it with the software planned thresholds.
When the system is in standby no current must circulate. Nevertheless the microcontroller keeps on
reading the current even when it is in stand-by. In such case if the current read by the sensor
overcomes the ZERO threshold, then the ST200-L board produces an alarm and it is not more
possible to perform any cycle; when the current stops circulating out of the cycle, the alarm ends
and it is possible to perform the desired activation cycles again.
During the Mag and inversion Demag cycle every discharge impulse is checked as follows:
o the pulse is valid and is counted therefore if:
• The IMAG signal read on WP8 test point overcome the MIN threshold
• The IMAX read on WP11test point not overcome the MAX threshold
o if the current pulse doesn't overcome the MIN threshold, the pulse is repeated. The system is set
in order to produce a maximum number of impulses equal to the constant NUMBER (fixed at 5);
when such value is reached or a double of NUMBER pulses are generated, the system stops the
cycle and activate an alarm signaling;
o if the signal at IMAX read at WP11 overcome the MAX threshold, the system stops the cycle
and produces an alarm condition is setted;
o if an opposite polarity current circulates, then the system stops the cycle and produces an alarm
condition. The current is defined of “opposite polarity” when it overcomes the ZERO threshold
in the non correct test point. For example, if the system is performing a MAG cycle and the
microcontroller reads a value pulse which overcome the ZERO threshold on the IDEMAG input,
an alarm condition would be produced.
If ST200-L board is set to perform a demagnetization Demag, the verification of the impulses above
described happens only for the first two sequences of pulses (two first packets); for the next packets
the verification only involves the followings controls:
o the pulse of current is valid and therefore is counted if the signal IMAX measured at WP11
test point not overcome the threshold MAX and it is not presents a current with opposite
polarity;
o if the pulse of current signal IMAX measured at WP11 test point overcome the threshold
MAX then the system stops the cycle and produces an alarm condition;
o if an opposite polarity current circulates, then the system stops the cycle and produces an
alarm condition. The current is considered “of polarity” when it overcomes the ZERO
threshold in the non correct test point. For example, if the system is performing a MAG
cycle and the microcontroller reads a value impulse which overcome the ZERO threshold on
the IDEMAG input, an alarm condition would be produced on the door that has to read the
DEMAG current.
Some examples are reported in the following.

Fig. 12 – Signal measured at IMAG: the pulses that overcome the MIN threshold are valid if at the same time
they not overcomes the MAX threshold on the IMAX test point reported in Fig. 14.
Fig. 13 – Signal measured at IDEMAG label: the pulses that overcomes the MIN threshold are valid if at the
same time they not overcomes the MAX threshold on the IMAX test point.

ALARM Vcc = + 5V
MAX ALARM
Reading on IMAX
THRESHOLD (WP11)
SI
SI
Fig. 14 – Signal measured at IMAX test point: the system goes not in alarm state if the pulses not over the MAX
threshold.
The current pulses can be measured through an oscilloscope placing on the IMAG (WP8),
IDEMAG (WP9) and IMAX (WP11) tests point.
The current is checked also during an impulse and the next one. In such case no current must
circulate in the chuck. Therefore in case of current different from zero the system reveals an alarm
immediately.

11. THE CONNECTION SYSTEM

The boards are connected in parallel on the same bus through a RS-485 net. The use of this system
of connection allows to connect in parallel 32 ST200-L and ST200-KE boards.
Since all the signals are in parallel it is not necessary to connect the different boards following a
precise order because every exit signal from a board is an entry one according to all the other
system boards.
The connectors that are able to develop the serial connection are indicated below.
JP1
JP3
3K3
33K
R7
R6
10MHz
4K7
4K7
100
100
100
100
Fig. 15 – The connection system available of the ST200-K board.

SW1
C60 1
FCS IN
INTERFACE
D11 D16 JP7
Q2
Q5
JP3
Q12 R47 D7
C28
Q6 C1 R19 C3
C2
Q7 ALARM
C4
Q10
C5 +
1 P4
R36 1
Q11 JP7
R80 WP6
C6 C18
WP5
R38
C20
D13
ISO1 R42 R43

D8
+
D12 -
D10
15V 0V 15V 0V
460V 400V 230V 200V 0
Fig. 16 – The connection system available of the ST200-L board.

12. QUALIFICATIONS
Input Enable
The ST200 command is endowed with an entry qualification coming from a hardware key which is
given with the system. Without such qualification (then with a lacking qualification hardware key)
it is not possible to perform any activation cycle and if a cycle is required the system goes in alarm
state.
This qualification acts on the ST200-L board, through a logical circuit, in parallel to the POWER
ENABLE signal generated by the microcontroller, without which it is not possible to activate the
spools of the power relé used for the supply voltage cut to the SCR (K2 and K3) blocks. The circuit
that realizes it is the following:
INPUT_ENABLE
coming from the
connector for flat JP7
POWER ENABLE
coming from the
microcontroller U2
Cycle voltage VFW
Fig. 17 – Section fo the schematic for managing Enables.

Output Enable
The ST200-L board has inside a monostable double contact relay which is used for the external
qualification and is denominated K4 (Finder model 30.22.7.005); its contacts are placed again out
of the system through the connector for flat JP7. This output enable is also present at the rear panel
of the system through an “hardware key” (see the following section).
The relay closing is commanded by the ST200-KM board when:
• at least one of the magnetic chuck connected to the commands is in Full-Mag without alarm
and if PAD3 is closed.
• At least one of the magnetic chuck is in Full-Mag without alarm and the PAD3 is open
Viceversa, the relay is open when:
o all the discharges are in DEMAG state, or

o an alarm state is present on the system.
When a magnetization or demagnetization cycle starts ST200-KM board send a parallel command
to every connected ST200-L board to open the relay. After this operation the ST200-L board
receives the command cycle.
In case the system consists of several ST200-L boards, the relé closing is activate at the end of the
cycle without the alarm of at least one of the connected magnetic plans in Pick-Up.
Table 11 - External qualification relé state according to the system state.
System configuration Relays configuration (PAD3 open) Relays configuration (PAD3 closed)
Full-Mag Closed Closed
Demag Open Open
Livelli Open Closed
Ciclo Open Open
Allarme Open Open

Table 12 - Main features of the external qualification relé.
Contacts features Commutable current

Max current:
@ 30 VDC 2A
@ 110 VAC 0.3 A
A 24VDC voltage is recommended.

Some software changes must be performed for external qualification operations different from what
has been described and they must be defined previously.
Hardware Key
In the ST200 system is presents a “hardware key”: This key has to be connected to the rear panel of
the system. The connector pin-out is depicted in the following figure. Without this key the system is
not able to perform any command.
By means this key the abolition is obtained with a short circuit between pin 6 and 7. Using pins 1, 2,
3, and 4 is possible to realize a RS-485 communication bus with optional external systems.
Finally, on pin 8 and 9 is available an external habilitation. This habilitation is realized with a relay
(see the following section).
DB9 connector for the machine interface:

external hardware key
Vista frontale
pin n° 1 485 “B”

pin n° 2 485 “A”
pin n° 3 Vcc
pin n° 4 Ground
pin n° 5 Alarm
pin n° 6 VF
pin n° 7 Input Enable
pin n° 8 Output Enable (COM)
pin n° 9 Output Enable (NO)
13. MANAGING THE TABLES

The JMP3 and JMP4 jumpers are present on the ST200-L board through which it is possible to
select one of the 4 tables implemented in the software according to the job frequency of the
command.
SW1
C60 1
FCS IN
INTERFACE
D11 D16 JP7
Q2
Q5
Q12 R47 D7
C28
Q6 C1 R19
JMP4 C3
C2
Q7 ALARM
C4
Q10
C5 +
1 P4
R36
Q11
1 JMP3
R80 WP6
C6 C18
WP5
R38
C20
D13
ISO1 R42 R43

D8
+
D12 -
D10
15V 0V 15V 0V
460V 400V 230V 200V 0
Fig. 18 – JMP3 position.

Table 13 – Selecting the table according to the jumpers.
JMP3 JMP4 Table number

Open Open 1
Open Closed 2
Closed Open 3
Chiuso Chiuso 4

Milling Machine version

When the selected board changes, it is possible to vary the number and the primer angle of the
impulses both for the magnetization and demagnetization phase.
Actually, the 4 tables are identical and it is necessary to select the table 1 (JMP3 and 4 open).
Grinding Machine version

When the selected board changes, it is possible to change the number and the primer angle of the
pulses for the magnetization procedure. In order to vary the number value and the primer angle of
the impulses for the magnetization procedure it is necessary to program the command through a
different software for ST200-L board.
For the demagnetization procedure it is possible to vary for every packet the primer angle and the
number of impulses.
Up to now 4 different software versions are available for ST200-L board. Up to now, four different
versions of software are available for the ST200-L logic board. These version are different in order
to match both the magnetic chuck used and the industrial voltage applied.
Magnetization table storage procedure
On the logic board, it is possible to select the desired demagnetization and magnetization table
using jumper JMP3 and JMP4.
The selection of the demagnetization table is not bound to the selection of the magnetization table
and vice versa: ST200L board can memorize the code of the magnetization table that is desired to
use and to leave free to use the four tables available for the demagnetization. In this way the system
executes always the same table of magnetization while it is possible to choose the demagnetization
table managing jumper JMP3 and JMP4.
Memorization of the magnetization table

Selected the magnetization table through jumper JMP3 and JMP4 it is necessary to complete the
following points:
1. execute a Full-Mag cycle;
2. move from its position switch number 8 of the 8 positions dip-switch present on ST200L
board;
3. wait for some seconds;

4. bring back in its original position the position 8 of the switch previous moved.
With this procedure, the system executes always the same table of magnetization independently
from the position of jumper JMP3 and JMP4 for the selection of the demagnetization table.
The procedure of memorization of the table must be executed within 10 s from the end of the Full-
Mag cycle.
How to erase a memorized table of magnetization levels.

1. execute a Demag cycle;
2. move from the initial position the switch number 8 of the 8 positions dip-switch
present on ST200L board;
3. wait for some seconds;
4. bring back in its original position the switch previous moved.
Even in this case the procedure of memorization of the table must be executed within 10 s from the
end of the Demag cycle.
Example of memorization
This procedure must be carried out only after to have verified that the configuration of the system is
not the wanted one. The procedure allows the change of the tables.
The system must be found initially in DEMAG. At the end of the DEMAG cycle move the Dip
Switch 8 from OFF position to ON position and after a pair of second again in OFF position. This
operation must be completed within 10s from the term of the cycle. It is now possible to set the
correct Mag table.
For this purpose it is necessary to select a configuration for jumper 3 and 4. It is necessary then
execute a partial magnetization level cycle in order to check the magnetic induction within the
desired air gap.

If the obtained values are not satisfactory it is necessary change the configuration of Jumper 3 and 4
until an adequate table is found. To this point it is necessary to execute a Full-Mag cycle that goes
to good aim. After this cycle it is necessary to move the Dip Switch 8 from position OFF to position
ON and after a pair of second newly in position OFF. This operation must be completed within 10s.
It has been now memorized the chosen table and the position of Jumper 3 and 4 comes ignored as
far as the selection of the MAG. It is now possible to select the DEMAG table. For this act on
Jumper 3 and 4 in order to select the wished DEMAG table and execute a demagnetization cycle. It
is necessary to repeat this operation until the correct table has been found. Once found the correct
DEMAG table no operation are required; in fact the software continuously read the configuration of
the Jumpers. Please note that, a change of the configuration of Jumper 3 and 4 is monitored from
the software and the table is changed as requested. This function is very different if compared with
the MAG table. The MAG table is in fact memorized, the DEMAG table is setted by the jumpers.
In order to change the DEMAG table it is, therefore, sufficient to change the position of Jumper 3
and 4. In order to change the MAG table it is instead necessary to repeat the aforementioned
procedure.

14. JUMPER MEANING
ST200-K board jumper

In this figure the positions of the Jumper are indicated.
JMP3
Fig. 19 – Jumper JMP3 of the ST200-K board.
JMP3 placed on "user" it allows the board to be operational, while placed on "prog" it allows
the planning of the microcontroller.

Jumper of the ST200-L board

In this figure the positions of the jumpers are indicated.
JMP6
JMP1
JMP4
JMP3
JMP8 JMP9 JMP10
JMP7
Fig. 20 – Jumper of the ST200-L board.

JMP1 if positioned on “user” allows the standard function of the board; if positioned on
prog position allows the download of the software.
JMP3 e JMP4 permits the table selection as depicted in the following table:
Table 14 – Tables selection.
JMP3 JMP4 Table number

Open Open 1
Open Closed 2
Closed Open 3
Closed Closed 4
JMP6 not used
JMP7, 8, 9 e 10 they are three position jumper used for voltage selection as depicted on PCB
and in Fig. 21
Fig. 21 – JMP supply voltage selection.
Table 15 – Table for supply voltage selection.
Supply voltage 200 V 230 V 400V 460 V

JMP7 2-3 1-2 2-3 1-2
JMP8 2-3 1-2 2–3 1-2
JMP9 2-3 2-3 1–2 1-2
JMP10 2-3 2-3 1–2 1-2

15. THE KEYBOARDS OF THE ST200 COMMAND

Keyboard without magnetization levels (3 PUSH BUTTON) – Software: K10_UNI
4
5 2 6
1 3
Fig. 22 – Image of the keyboard without magnetization levels.

1. Button FULL-MAG (green)
2. Button ENABLE (yellow)
3. Button DEMAG (white)
4. Wait led (yellow)
5. Total Mag led (green)
6. Demag led (white)
7. Alarm led (red)
In the following the configuration table for this keyboard is reported:
Table 16 – Configuration table for the keyboard without magnetization levels (3 PUSH BUTTON).
prog
3 PUSH BUTTON

KEYBOARD
Open Enable board

MASTER
Closed OFF ON
is present
user Open
Closed Open OFF Switch 1 presents on the ST200-L board.
FullMag

This keyboard typology implements the Milling and Grinding machine functionalities without the
possibility to manage any partial magnetization level. The yellow button (ENABLE) must be used
with the FULL-MAG button or with the DEMAG button to call the job cycle (pressed button time
500ms). For the meaning of the luminous signaling consult the Table 17.
Table 17 – Luminous signal on keyboard without magnetization levels (3 PUSH BUTTON).
System state MAG led DEMAG led Cycle led Alarm led
Full-Mag Fixed on Off Off Off

Demag Off Fixed on Off Off
Cycle Off Off Fixed on Off
Alarm Off Off Off Fixed on
Communication In compliance with In compliance with
Off Lamps
alarm the actual state the actual state

Keyboards with two magnetization levels (5 PUSH BUTTON) – Software: K10_UNI
6
7 8
4
1 5
3 2
Fig. 23 – Image of keyboard with two magnetization levels.
1. Button FULL-MAG (green)

2. Button MAG Lev 1 (green)
3. Button MAG Lev2 (green)
7. Full or partial Mag led (green)
9. Alarm led (red)
This keyboard typology implements the Milling and Grinding functionalities with the possibility to
manage two partial magnetization levels and the Full-Mag.
The yellow button (ENABLE) must be used with the MAG magnetization button or with the
DEMAG demagnetization button to call the job cycle desired (pressed button time 500ms).
The configuration table is reported in the following.

Table 18 – Configuration table of hte keyboard with 2 magnetization levels (5 TASTI).
prog

is present
Open
MASTER
ON
user Open
is present
Closed
For the meaning of the luminous signaling consult the following Table 19.
Table 19 – Luminous signal on keyboard with two magnetization levels (5 PUSH BUTTON).
Full-Mag Fixed On Off Off Off

Demag Off Fixed On Off Off
Mag Lev 1 Flashing Off Off Off
Mag Lev 2 Flashing Off Off Off
Cycle Off Off Fixed On Off
Current Alarm Off Off Off Fixed On
Communication According to the According to the
Off Flashing
Alarm actual state actual state

Keyboard with 7 magnetization level (5 PUSH BUTTON) – Software: K10_UNI

7 6
2
1 4
10
5
3
8 9
Fig. 24 – Immagine pulsantiera a 7 livelli.
1. Button MAG (green)

4. Button of level increase for the MAG cycle (blue) (pressed buttons time 250ms)
5. Button of level decrease for the MAG cycle (blue) (pressed buttons time 250ms)
7. Total or partial Mag led (green)
9. Alarm led (red)
10. Magnetization level led (yellow)
This keyboard typology implements the Milling and Grinding functionalities with the possibility to
manage seven magnetization levels and the Full-Mag.
The yellow button (ENABLE) must be used with the MAG button or with the DEMAG button to
call the job cycle desired (pressed button time 500ms); the buttons + and – can utilized to increase
or decrease the magnetization level that has to be performed.
The configuration table is reported in the following:

Table 20 – Configuration table for the keyboard with 7 magnetization levels (5 PUSH BUTTON).
prog

is present
Open
MASTER
ON
user Open
is present
Closed
For the meaning of the luminous signaling consult the Table 21.
Table 21 – Luminous signal for the keyboard with 7 magnetization levels.
Full-Mag Fixed On Off Off Off

Demag Off Fixed On Off Off
Level 1-7 Lighting On Off Off Off
Cycle Off Off Fixed On Off
Current Alarm Off Off Off Fixed On
Communication According to the According to the
Off Lighting On
Alarm actual state actual state

CH-Enable Keyboard – Software: K10_UNI

5 6
13
1 2
9 10
3 4
12
7 8
11 14
Fig. 25 – Image of the CH-Enable keyboard.
1. Button CH-Enable 1 8. CH-Enable 4 state led (green)

2. Button CH-Enable 2 9. CH-Enable 1 selection led (yellow)
5. CH-Enable 1 state led (green) 12. CH-Enable 4 selection led (yellow)
6. CH-Enable 2 state led (green) 13. Cycle led (yellow)
7. CH-Enable 3 state led (green) 14. Alarm led (red)
The configuration table is reported in the following:
Table 22 – Configuration table for the CH-Enable keyboard.

prog
N.I. OFF OFF
CH-ENABLE

• Ch-enable
N.I. OFF ON standby only if in
MASTER
ON • 2 discharges
DEMAG state without
• 3 discharges of the discharge is
• Ch-enable
N.I. OFF OFF
• 1 discharge
CH-ENABLE
• Ch-enable
MASTER

• 2 discharges
N.I. ON OFF
N.I.
• Ch-enable
N.I. ON ON
• 4 discharges

This keyboard typology is in the commands where it is possible to select the channel on which to
perform the magnetization/demagnetization cycle and it is used with the ST200-KM board (CH-
Enable).
It can be used both on Milling and Grinding machine.
In order to select the desired channel it is sufficient to press the respective button for 250ms around;
when the channel is selected the respective selection Led will be on.
In order to remove the selection it is sufficient to press again the button for 250ms around; when the
channel is not selected the respective selection led will be off.
The state Leds will be off when the relative magnetic plan is in Demag, on (non lighting) when in
Full-Mag and flashing when in a partial magnetization state.
The cycle Leds are on (no flashing) when the system is in cycle while they are off when the system
is not in cycle.
The alarm Leds are on (no flashing) in any alarm condition (not including the communication
alarm).
The ST200-KE board is configured for a certain number of selectable channels, therefore it is not
possible to select a number channels in excess because in the ST200-KE board the command of
channel selection is idle.

CH-Enable Keyboard – Software: CH10-ENABLE-SPECIAL

The keyboard with CH-ENABLE-SPECIAL software is used when a different managing of the
channel from the standard one is necessary
The position 6 and 7 of the Dip-Switch SW1 (6 and 7) are used to configure both the number of the
discharges and the number of the available channels as reported in the following Table 23.
Table 23 – Position 6 and 7 of the Dip Switch SW1 on the ST200-KE CH-Enable Special board.
N° of
№ of the Dip- Dip-
available Note
discharge Switch 6 Switch 7
selection
Ch1 and Ch2 only are available: selecting CH1 first
2+2 2 ON ON and second discharges are selected, selecting CH2
third and fourth discharges are selected,
Only CH1 channel is managed; others channels
4 1 ON OFF
are not managed. 4 discharges are operated.
3 1 OFF ON channels are not managed. 3 discharges are
operated.
2 1 OFF OFF
channels are not managed. 2 discharges are operated
For a complete configuration please refer to the table reported in the previous section.
Obviously, the meaning of the position 6 and 7 of the SW are changed as aforementioned reported.
Keyboards dimensions
The keyboards on ST200 command have all the same dimensions: 120mm × 60mm (at first the
keyboards dimension was 130mm × 80mm). The remote keyboards of the ST200 command are on a
plastic container of 130mm × 80mm.
The possible keyboards have the following dimensions: 120mm x 60mm, 120mm x 80mm,
130mm × 60mm and 130mm × 80mm.

16. SYSTEM OPERATIONS IN STANDARD CONFIGURATION
Single Master Keyboard with n Logic board with 1, 2, 3 or 4 fixed discharges

In this configuration the ST200 system consists of a ST200-KM board and e n ST200-L boards
(logical). Therefore there isn’t any ST200-KE board (CH-Enable).
The ST200-KM board has the PAD1 opened and the PAD2 closed. According to this configuration
the ST200-KM board calls the cycle without specifying the discharges and every ST200-L board
(logical), reading the pin 6 e 7 of the Dip-Switch 1 determines how many discharges must be
performed.
The system is commanded by the ST200-KM board; when the buttons state has been defined, the
ST200-KM board orders the activation of the cycle of every single ST200-L board, sending a signal
on the communication bus that consists of a series of data/information.
After having received the data from the ST200-KM board, the ST200-L board performs the single
cycle developing the current control for every discharge impulse.
The ST200-KM board, after having sent the command to the ST200-L board and attended about a
second of time, begins questioning the ST200-L board that doesn't answer until the end of the cycle.
At the end of the cycle the ST200-KM board receives the new state of the magnetic plans (Mag,
Demag, magnetization level, Alarm, etc.) from the ST200-L board.
If this cycle doesn’t end in 30 seconds, from the beginning of the questioning of the ST200-L
board by the ST200-KM one, the system goes in alarm stopping the command that has to be
extinguished and activated again in order to function.
The ST200-KM board, after having received the state of the first ST200-L board, commands the
following one according to the procedure previously described. At the end of the cycle the ST200-
KM board knows the new state of all boards and therefore actives the new visual signaling on the
corresponding keyboard removing the cycle signal.
If at least one of the magnetic plans connected to the commands is in Full-Mag and any alarm is not
present, then the closing of the qualification relé of every single board is commanded (with PDA3
open) or if at least a sector is not in DEMAG state (PAD3 closed).
A ST200-KM board, n ST200-L boards and n ST200-KE boards

In this configuration the ST200 system consists of a ST200-KM board, n ST200-L boards (logical)
and n ST200-KE boards (CH-Enable).
The system is commanded by the keyboard connected to the ST200-KM board as in the previous
example except for the presence of the ST200-KE boards.
The ST200-KM board has the PAD1 and PAD2 opened. According to this configuration the ST200-
KM board sends the command to the first ST200-L board after having questioned the relative
ST200-KE board and having checked that one channel at least has been selected (on the contrary
the ST200-L board would not perform any cycle).
WARNING: In this configuration the pins 6 and 7 of the Dip-Switch 1 of the ST200-L board
must be both on ON otherwise the ST200-L board sends the system in configuration alarm.
After having received the data from the ST200-KM board, the ST200-L board performs the
requested cycle checking the current control for every impulse of the selected discharge.
The ST200-KM board, after having sent the command to the ST200-L board and attended about one
second of time, begins questioning the ST200-L board which doesn't answer until the end of the
cycle. At the end of the cycle the ST200-KM board receives the new state of the magnetic plans
(Mag, Demag, magnetization level, Alarm, etc.) from the ST200-L board.
If this cycle doesn’t end in 30 seconds, from the beginning of the questioning of the ST200-L
board by the ST200-KM one, the system goes in alarm stopping the command that has to be
extinguished and activated again in order to function.
The ST200-KM board, after having received the new state from the first ST200-L board forwards it
to the relative ST200-KE board (CH-Enable). When the message exchange among the boards is
finished, then the ST200-KM board commands the following ST200-L board according to the
procedure just described. At the end of the cycle the ST200-KM board knows the new state of all
boards, therefore actives the new visual signaling on the corresponding keyboard removing the
cycle signal.
Even on the CH-Enable keyboard that is checked by the ST200-KE board the state of every single
magnetic plan is represented.
If at least one of the magnetic plans connected to the commands is in Full-Mag and any alarm is not
present, then the closing of the qualification relé of every single board is commanded (with PAD3
open) or otherwise if at least a sector is not in DEMAG state (PAD3 closed).
17. INSTRUMENTAL CHECK

For the instrumental check see the following figures for the probes positioning.
Place HERE the probe of the

oscilloscope for the single coil Place HERE the probe of the
FLUX measurement oscilloscope for the GROUND
(ST200 System – Pressa) verification (Carcass)
Place here the probe of the digital
multimeter (ohmmeter) Place HERE the probe of
M_A = RED PROBE the oscilloscope for the
M_B = BLACK PROBE VCC verification (+5V)
for trimmer resi stance
measurement Place HERE the probe of
the oscilloscope for the
IMAX verification
Place HERE the probe of
Place HERE the probe of +12V(VF) voltage
the oscilloscope for the verification
IDEMAG verification
Place HERE the probe of the

oscilloscope for the ZERO-
CROSS verification
Place HERE the probe of
Place HERE the probe of VFW verification
IMAG verification
Fig. 26 – Measuring point.

Voltage VF (+12V) Voltage VCC (+5V) Ground VFW

IMAG IDEMAG Zero – Cross Point for the P1 Measure with a multimeter.
IMAX
Fig. 27 – Measuring point.
Supply circuit
The circuital zone that realizes the supply circuit of the ST200-L board is represented in the Fig. 28.
The voltages on the board are the following ones:
1. VCC = +5V
2. VF = +12V
3. –VF = -12V
MBRS140
D21
2 1
C24
L1 68uH/1.2A 100uF/25V
+
HEAT SINK
B1 VF
1
DF04S 8 1
7 NC FB 2 C23
U10
6 OUT SGND 3 100nF
LM7812
3 4 1 3 5 NC ON/OFF 4
- + Vin Vout VIN GND -VF
Gnd
C27
U9 LM2574-12 VCC
+ + 1 WP4
C35 C26 C28
2
4
100nF
1000uF/50V 220nF C31 10nF/50V
470uF/35V 1
FB
7 CB
VIN
ON/OFF
F3 500mA L2
C25 + 8 47uH/1.2A
GND
NC1
NC2
VSW
1
220uF/35V
F4 500mA U11 + C29
2
6
3
5
LM2675 D20 100uF/25V
MBRS360
2
Fig. 28 – Supply circuit of the ST200-L board.
The instrumental verification can be realized, through the aid of an oscilloscope, placing the ground
reference (crocodile) on the carcass of the voltage regulator U10 (LM7812) and the probe on the
following points:
1. WP4 = supply voltage of the microcontroller and the ST200-K boards equal to 5V. This
voltage should not go down under the 4.6V for the correct functioning of the system. The
minimum voltage value must be guaranteed both in stand by and during the cycles. It is
important to note that when the voltage below under 4.5 V the watchdog reset system
prevents the microcontroller to operate in non correct condition.
2. WP6 = supply voltage for the generation of the cycle voltage (only used on ST200-L board)
equal to +12V;
3. U5 pin 4 = negative supply voltage used for the circuit of the current sensor equal to .12V.

Voltage range admitted for the Microcontroller PIC18F4520
In Fig. 29 the range of supply voltage that guarantee the correct operations of the micro controller is
reported. The voltage supervisor reset system (watchdog) turn off the microcontroller when the
voltage goes under 4.5 V. In this way a safety range of about 0.3 voltage is guarantee.
Fig. 29 – Voltage range of the correct operation of the PIC18F4520 (Graphic from the data sheet of the
Microchip microcontroller).

Zero-Cross circuit.
The circuit that realizes the Zero-Cross is the following one:
HIGH ISOLATION ZONE
VCC
C30 + C18
100uF/16V 220nF
R24 2k2
VF R25
1k
2 6 R42 470k 1W[2512] ZERO CROSS 1 WP5
14
Vin +V
8
3 7 230VAC
Ctrl COM
7
1 8 ISO1
Ref -V R43 3 CNY 65
U14 + 6
10k 1W[2512]
7
RECOM RS1212D 2
- TL061CD
U7
4
1
5
C32 + C20
100uF/16V 220nF
Fig. 30 – Zero-Cross Circuit.
The instrumental check can be realized, through the aid of an oscilloscope, placing the ground
reference on the carcass of the voltage regulator U10 (LM7812) and the probe on the point Z/C. The
signal must be a square wave whose ampleness is equal to 5V and a period of 20ms in case the net
voltage frequency is 50Hz, while the period is of 16.67ms in case the net frequency is equal to 60Hz
(see Fig. 31).
10 ms
Standard
5V
Values
Measured
values
20 ms
These values would verified both in stand-by and during the cycle.
Fig. 31 – The Zero-Cross signal.
Many system incorrect operations (for ex. Demag with residual, unjustified alarms, Mag not in
saturation etc.) can be caused by a Zero-Cross signal which is not symmetrical or noise.

18. COMPATIBILITY WITH THE PREVIOUS VERSION AND HARDWARE CHANGES

In this section the following aspects are discussed:
I. The compatibility of the latest version of the board (revision 7) with the previous revisions. If the
compatibility is not completed the operation necessary to recover the compatibility are shown.
II. The hardware changes introduced in the latest version that lead to important difference with the
previous versions of the boards. At this purpose it is good practices to verify even the
modification of the present documentation as indicated at page 2 in the REVISION HISTORY
section. In fact, the change on the documentation are due to the hardware or software
modification.
Compatibility with the previous versions.

If the revision 7 board is used in substitution of a revision 6 or previous the following operations are
necessary:
- When a previous version keyboard is removed and a new version keyboard is used it is necessary
change even the logical board. This is due to an incompatibility caused from the software.
- The cable insert in the current sensor must be inserted at the contrary as respect the previous
direction.
Hardware modification.
The following modification are presented:
1 Both the main transformer and the voltage configuration jumpers are changed (starting from
release 5);
2 The zero – cross circuit is changed: however, this modification it does not involve problem
concerning managing, configuration and compatibility with other revision (starting from release
5);
3 Starting form release 6 the circuit for both single and total coil flux measurement is changed. The
circuit for total coil flux measurement is not actually used and the component are not present on
the board. As a results of that:
3.1 Starting from release 6 the jumper JMP6 were added and it is used for the drift regulation
of the single coil integrator;
3.2 Starting from release 6 is changed the connector used for programming the board.
4. A diagnostic system is now present. Please see the Auto-diagnosis System section.
19. AUTO-DIAGNOSIS SYSTEM
It is possible connect the TECNOMAGNETE diagnostic system in order to find eventually present
fault situation.
Please see TECNOMAGNETE diagnostic system documentation.

20. PLC INTERFACE
Input signal at the µController of the PLC Interface
The signals in the following reported are the input signal at the µC pins. It would be noted that
when PLC interface is installed the standard keyboard are not installed.
Table 24 – Input signals at the µC pins of the PLC interface.

Siganl at the µC Type
Gate Pin Value Meaning
pin (Analog/Digital)
RX RC7 1 Digital 0/1 Receiving serial comunication signal
SET_PROG/BIT7 RD6 4 Digital 0/1 Setup mode at the system start-up
0 None priority alarm
ALARM RB0 8 Digital
1 Priority alarm at the input
BIT0 RA0 19 Digital 0/1 Number of logical board. Most significant bit
BIT1 RA1 20 Digital 0/1 Number of logical board.
BIT4 RA4 23 Digital 0/1 Number of logical board. Least significant bit
BIT5 RA5 24 Digital 0/1 Level of the Output Enable. Most significant bit
BIT6 RE0 25 Digital 0/1 Level of the Output Enable. Least significant bit
PLC_ABILIT RE1 26 Digital 0/1 PLC habilitation
Push button for decrease the Pick-Up – logic level
1
presents when the push button is not pushed
LEVEL-_SW RC0 32 Digital
Push button for decrease the Pick-Up – logic level
0
presents when the push button is pushed
Push button for increment the Pick-Up – logic level
1
presents when the push button is not pushed
LEVEL+_SW RC1 35 Digital
Push button for increment the Pick-Up – logic level
0
presents when the push button is pushed
1 Demag push button – Push button not pushed
DEMAG_SW RC2 36 Digital
0 Demag push button – Push button pushed
1 Mag push button – Push button not pushed
MAG_SW RC3 37 Digital
0 Mag push button – Push button pushed

Output signal at the µController pins of the PLC interface
For the correct interpretation please see even the section Luminous signals (LED) in the following
reported.
Table 25 – Output signal at the µControllore pins of the PLC interface.

Type
Signal Gate Pin Value
(Analog/Digital)
0
CYCLE_LED RD4 2 Digital
1
0
ALARM_LED RD5 3 Digital
1
0
LD15 RD7 5 Digital
1
0
LEV2 RB1 9 Digital
1
0
LEV3 RB2 10 Digital
1
0
LEV4 RB3 11 Digital
1
0
LEV5 RB4 14 Digital
1
0
LEV6 RB5 15 Digital
1
0
LEV7 RB6 16 Digital
1
0
LEV8 RB7 17 Digital
1
0
LD14 RE2 27 Digital
1
0
RD0 (LD3) RD0 38 Digital
1
0
RD1 (LD5) RD1 39 Digital
1
0
DEMAG_LED RD2 40 Digital
1
0
MAG_LED RD3 41 Digital
1
0
LEV1 RC4 42 Digital
1
0
D_ENABLE RC5 43 Digital
1
TX RC6 44 Digital 0/1

Schematic
Fig. 32 – Schematic of the PLC interface.

PLC Interface board layout – top view
ISO4 ISO6 ISO8 ISO10 ISO13
R58
R54
R22 R24 R28
R39
R43
R56
R52
R37
R41
R51
R20
R19
R36
R21
R53
ISO9 ISO5
R38
R25
RP1
R40
R55
R50
RP2
R65
R48
R63
JP3
R35
R34
R17
U3
R42
R14
R57
R47
R11
R32
R62
ISO18 ISO16
R8
R33
C4
R18
R44
R59
ISO11 ISO15 ISO17 ISO12 ISO14ISO7 ISO3
U2
R23
JP4
C5
R64
R49
R30
C11
R2
C14
R26
R46
R61
D2
R31
U7
R29
R60
R45
R27
D1
WP1
R66
Fig. 33 – PLC Interface board layout – top view.

PLC Interface board layout – bottom view
J1
JMP2
POWER ON
+
Fig. 34 – PLC Interface board layout – bottom view.

Features
Model of microcontroller used: ............................................................... PIC18F4520 (Microchip)

Quartz frequency: .................................................................................................................. 10 MHz
Job voltage: ................................................................................................................................. 230 V
Job frequency: ..................................................................................................................... 50 – 60Hz
Discharge formality: ................................................................................................... Not applicable
References Software
M_PLC.c Standard version of the software for PLC interface used as a master board.
CH_PLC.c Software for PLC interface used as Ch_Enable version (this release is actually not
available)
Operations
The board is able to performs two different function: it is able to replace both a ST200-KM board as
a master of the system and to replace a ST200-KE board working, in this case, as a interface
between the external system and the ST-200 for channel selection.
To second of the aforementioned cases the board could be used replacing the following two
different boards:
o ST200-KM: Keyboard working as Master of the system: in this situation the system is not
more managed by the tradition master board but by the PLC board.
o ST200-KE: Keyboard working as a CH-Enable board: in this situation the channel are not
more selected by the Keyboard acting as CH-Enable but by the PLC interface. The CH-
ENABLE are reported at the input of the board by means the JP4 connectors in the
following reported. In particular the four CH-Enable are managed in the following manner:

Table 26 – CH-Enable configuration.

CH Logical level necessary at the iunpt of the Input voltage necessary at the input at the input of
ENABLE JP4 connector for the channel selection the JP4 connector for the channel selection
CH1 1 + 24V
CH2 1 + 24V
CH3 1 + 24V
CH4 1 + 24V
Luminous signals (LED)

In the following the picture (not in scale) of the two different version of the panel of the PLC
interface are reported
The board can be supplied in 130 x 80 mm version or in 120 × 60 mm version.
In Fig. 35 the picture of the front panel of the PLC interface is shown.
Fig. 35 – Front panel of the PLC interface in 130 x 80 release.

Rev. 5 4 3 2 1
2
sede in Lainate (MI) – Via Nerviano, 31
Società soggetta alla direzione e al

SW1
MAG_SW
SW3 SW2
DEMAG_SW
General revision
Description
D +Vopto D
+Vopto
Q1 LD1 Yellow R1 2k2
R3 2k2 Yellow LD3 Q9 Q2 LD2 Yellow R2 2k2

Fig. 36 – Schematic of the front panel.

05/02/2008

C C
DOCUMENTATION
Date
R16 2k2 Yellow LD16 Q16 I1 LD17 Green R17 2k2
TECHNICAL
I2 LD18 Yellow R18 2k2
VCC
ST200
SW1 = Mag SW [Verde]
M. Lazzaroni, A. Prati, M. Ingrao

SW2 = Demag SW [Bianco]
SW3 = Safe SW [Giallo] JP2
2 1
VCC
JP2 = PIN STRIP IN FILA DOPPIA DEMAG_SW 4 3 I4
I3 6 5 I6
B B
14 x 2 PASSO 2,54 mm FEMMINA I2 8 7 I5
Drawn
I1 10 9 Q13
12 11 Q12
MAG_SW 14 13 Q4
Q9 16 15 Q5
Q8 18 17 Q11
Q7 20 19 Q3
Q6 22 21 Q10
031_ST200_2008_ENG
Q14 24 23 Q2
Q15 26 25 Q1
Q16 28 27
+Vopto
Pag. 76 / 90
HEADER 12X2
Roberto Faranda
A A
Verify
Title
Schema Circuitale Pulsantiera a Membrana
Size Document Number Rev
A KEYBOARD 0.0
Date: Wednesday, April 18, 2007 Sheet 1 of 1

5 4 3 2 1
The luminous signaling have the brought reported in Table 27. The LED is turned on when the
relative signal Q goes to low level.
Table 27 – Luminous signaling meaning of the PLC interface.

Nets as reported on the schematic Display
N° Output of the µC Output LED N° Level
LEV3 LEV2 LEV1 LEVEL3 LEVEL2 LEVEL1 Q1/LD1 Q2/LD2 Q3/LD4
0 0 0 0 1 1 1 0 0 0 8
1 0 0 1 1 1 0 0 0 1 7
2 0 1 0 1 0 1 0 1 0 6
3 0 1 1 1 0 0 0 1 1 5
4 1 0 0 0 1 1 1 0 0 4
5 1 0 1 0 1 0 1 0 1 3
6 1 1 0 0 0 1 1 1 0 2
7 1 1 1 0 0 0 1 1 1 1
It is presents the following luminous signals:
Table 28 – Luminous signal presents on the PLC interface.
Output Signal at the µC µC pin

Function
signal level
N° Name
The ALARM LED (corresponding at Q11) is turned on when the
ALARM ALARM_LED signal ALARM_LED in output from the µC is at the low logic level 3 RD5
(0V)
The DEMAG LED (corresponding at Q10) is turned on when the
DEMAG DEMAG_LED signal DEMAG_LED in output from the µC is at the low logic level 40 RD2
(0V)
LD3 RD0 Not Used 38 RD0
LD5 RD1 Not Used 39 RD1
LEVEL1 LEV1 42 RC4
LEVEL2 LEV2 Level selection (as aforementioned reported) 9 RB1
LEVEL3 LEV3 10 RB2
LEVEL4 LEV4 Not Used 11 RB3
The MAG LED is turned on when the signal MAG_LED in output
from the µC is at the low logic level
MAG MAG_LED 41 RD3
When in pick-up the MAG LED is lumping and the MAG_LED
signal is a square wave signal
OUT1 LD14 Not Used 27 RE2
OUT2 LD15 Not Used 5 RD7
WAIT CYCLE_LED Cycle LED: it is turned on during the cycle 2 RD4

MASTER MODE
Table 29 – LED meaning of the output (as presents on the front panel – two raw on the left)
Keyboard PLC interface
Output LED
JP2 JP3 µC line Pin Meaning
LED identifier
1 LD1 Q1 LD8 LEV1 42 Level 1 (3 bit binary code)
4 LD6 Q4 LD13 LEV4 11 Not used
9 LD3 Q9 LD2 MAG_LED 41 MAG LED is turn on when in MAG state.
In Pick-Up state the MAG LED is flushing
10 LD5 Q10 LD4 DEMAG_LED 40 DEMAG LED is turn on when in DEMAG
state.
11 LD7 Q11 LD0 ALARM_LED 3 ALARM LED is turn on when an alarm is
present.
12 LD9 Q12 LD5 RD1 39 Not used
13 LD11 Q13 LD1 CYCLE_LED 2 Cycle LED: turned on during the cycle
14 LD13 Q14 _LD14_ LD14 27 Not used
15 LD15 Q15 _LD15_ LD15 5 Not used
16 LD16 Q16 LD3 RD0 38 Not used
Table 30 – LED meaning of the input (as presents on the front panel – on the right)
Keyboard PLC interface
Input LED
JP2 JP3 µC line Pin Meaning
LED identifier
Input Enable to use in place of the
1 LD17 I1 ENABLE_EXT - -
habilitation key hardware
2 LD18 I2 PLC_ABILIT_LED PLC_ABILIT 26 Not used
3 LD19 I3 SW_MAG MAG_SW 37 MAG push button
4 LD20 I4 SW_DEMAG DEMAG_SW 36 DEMAG push button
Decrease the magnetization level.
5 LD21 I5 SW_LEVEL- LEVEL-_SW 32 To every pressure of the push-button the
level comes decremented of one.
Increase the magnetization level.
6 LD22 I6 SW_LEVEL+ LEVE,+_SW 35 To every pressure of the push-button the
level comes increased of one.

CH-ENABLE MODE
Table 31 – LED’s meaning on PLC keyboard when using in CH-Enable mode.
Front panel keyboard PLC interface keyboard
Id LED identifier JP2 JP3 µC nets Pin Meaning
1 LD3 Q9 LD2 MAG_LED 41 Ch-Enable 1: MAG state for CH1
2 LD2 Q2 LD6 LEV2 9 Ch-Enable 2: MAG state for CH2
3 LD5 Q10 LD4 DEMAG_LED 40 Ch-Enable 3: MAG state for CH3
4 LD1 Q1 LD8 LEV1 42 Ch-Enable 4: MAG state for CH4
5 LD10 Q6 LD10 LEV6 15 CH1 selected

Operations of the system in base configuration

Three connector are present on the board: a 10 pin flat connector (connected to DB9 connector) for
the interface with the logic board ST200-4L, a 28 pin connector for the connection to synoptic and,
finally, a DB37 connector used for the connection with the PLC.
Both inputs to the microcontroller (coming from the external PLC) and the transistor outputs, are
opt insulated.
The signal named Input Enable of the ST200-4L board, is managed by the PLC through the K17
relay presents on this interface board; when the K17 relay is disabled, it is not possible to activate
the discharge cycle: this is due to the fact that the power relay (T9A) are not able to be activate. On
the contrary, when the K17 relay is closed the discharge cycle for magnetization and
demagnetization is normally executable
The choice of the cycle, the level to be selected, and all other necessary information are transmitted
using the RS-485 bus.
Use of the Dip-Switch in PLC interface.

The Dip-Switch SW1 on the ST200TR-PLC board show the same meant of the one presents on the
Master board. For more detail please refer to the ST200-KM BOARD (MASTER) section.
The connection system

The boards are interfaced by means the same RS-485 bus. The use of this connection system
permits a connection up to 32 ST200-L boards. To each ST200-L board is possible to connect a
ST200-KE board.

All the generated signal on the RS-485 bus are paralleled. Thus, it is not necessary to connect the
boards one of each other following a prior defined order. In fact, all the output signals are received
to all the boards following a define order: any signal in output to a board is reported in input to all
other boards.
The connection is realized using a DB9 connector.
The external interface with the PLC is, instead, realized by means a DB37 connector. Through this
connector the following signals are received: the activation command (MAG and DEMAG), the
push button signal used to increment or decrement the magnetization level (Level + e Level -), both
the state and level signals, and, finally, the supply voltage.
The schematic pin-out of the aforementioned connector are shown in the following two sections.

DB37
Fig. 37 – Layout of the DB37 connector.
Pin Name Dir Description

1 SW Mag MAG button
2 SW Demag DEMAG button
3 SW Level + MAG LEVEL increase
4 SW Level - MAG LEVEL decrease
5 Abilit PLC Input abilitation for PLC management
6 Input Enable Input Enable
7 n-c Not connected
8 n-c Not connected
9 n-c Not connected
10 Level 1 OUT-MAG level 1
18 COM Machine Enable Output COM
19 NO2 Machine Enable Output NO2
20 Wait Cycle signal - Output
21 Alarm Alarm signal - Output
22 Ld3 Not used
23 Ld5 Not used
24 Out2 Not used
25 Out1 Not used
26 n-c Not connected
27 n-c Not connected
28 Vext Common (MAG, DEMAG LEVEL+, LEVEL-)
29 Vext Power supply 24 VDC (Input)
30 Vext Power supply 24 VDC (Input)
31 Rif Common out
32 Rif 0 VDC ref
33 Rif 0 VDC ref
34 Mag Mag status - Output
35 Demag Demag status - Output
36 COM Machine Enable Output COM
37 NO2 Machine Enable Output NO2

Attention – The signaling concerning the 8 magnetization levels is realized in the following
way:
a. “A” release where the visualization of the 8 magnetization levels is obtained by

means a binary code. In this case only the first three levels are used. The following
table shows the utilized code:
Table 32 – Correspondence between level/binary code.

Magnetization level Output Level 3° (Level 3) Output Level 2° (Level 2) Output Level 1° (Level 1)
1 0 0 0
2 0 0 1
3 0 1 0
4 0 1 1
5 1 0 0
6 1 0 1
7 1 1 0
8 1 1 1
With “0” the output is not activated (0V), with “1” the output is activated (24 V).
Optionally, it is possible the following mode:
b. “B” release where in correspondences of each magnetization level the activation is

obtained (cfr. ST200KM board).
The PLC version is available only in the 7 level mode (+ FULL-Mag).

21.
2
Rev.
5 4 3 2 1
D D
JP2 +Vopto
2 1 Q1 LD1 Yellow R1 2k2
Description
VCC
4 3
General revision
Società soggetta alla direzione e al

I2 8 7
KOSMEK RELEASE
sede in Lainate (MI) – Via Nerviano, 31

12 11
14 13 Q4 Q4 LD6 Yellow R6 2k2

16 15 Q5
20 19 Q3
22 21
Schematic for KOSMEK Keyboard
24 23 Q2
26 25 Q1
C 28 27 C
+Vopto
Date
HEADER 12X2
05/02/2008
VCC
ST200
TECHNICAL
DOCUMENTATION
B B
I2 = POWER ON
Q1 = MCS
Drawn
Q2 = UCS PF ALARM
Fig. 38 – Schematic of KOSMEK Keyboard.

Q3 = UCS PM ALARM
Q4 = FCS PF ALARM
Q5 = FCS PM ALARM
M. Lazzaroni, A. Prati, M. Ingrao

A A
Title
SPECIAL KEYBOARD
Size Document Number Rev
Pag. 83 / 90
A KOSMEK 0.0
Date: Thursday, March 01, 2007 Sheet 1 of 1
Verify
5 4 3 2 1
031_ST200_2008_ENG
Roberto Faranda
References Software
Logica_kosmek.c Logic board;

Master_Kosmek.c Master Kosmek Keyboard.
Front panel of KOSMEK Keyboard
In the following the ad hoc front panel used for KOSMEK is reported.
Fig. 39 – Front panel for KOSMEK Keyboard.
LED meanings is discussed in the following.

Table 33 – LED meanings.

Sector LED name Color Meanings
When turned on it indicates that the communication net
POWER GREEN
works correctly and it is correctly configured.
GENERAL
Mold Change. When turned on the system is moved in “mold
MOLD CHANGE GREEN
change modality”.
MAGNET
RED UCS PF ALARM
MOVABLE SIDE ERROR
MOLD ERROR RED FCS PF ALARM
MAGNET
STATIONARY RED UCS PF ALARM
ERROR
SIDE
MOLD ERROR RED FCS PF ALARM
Table 34 shows the function of the LED present on the KOSMEK front panel and the PLC signal
board.
Table 34 – Connector pin-out on Kosmek Keyboard Vs Signal on PLC board.

PLC board KOSMEK Front panel
Connector Connector
µC
Optoisol JP3 JP2 LED Front panel Meanings
Pin Line Linea PIN Q PIN Q
RB1 LEV2 LEVEL2 LD6 23 Q2 9 LD2 MAGNET ERROR PM PM current alarm
RB2 LEV3 LEVEL3 LD7 19 Q3 8 LD4 MOLD ERROR PM PM flux alarm
RB3 LEV4 LEVEL4 LD13 13 Q4 7 LD6 MAGNET ERROR PF PF current alarm
RB4 LEV5 LEVEL5 LD9 15 Q5 6 LD8 MOLD ERROR PF PF flux alarm
Please note that during the cycle operation all luminous signal are turned off.
The system change the operation mode in case of different alarm. In particular:
o When a flux alarm is present (FCS) both flux alarm LED and current alarm LED of the
corresponding chuck are turned on.
o When a current alarm is present (UCS) only the current alarm LED of the corresponding chuck
is turned on.

DB37 for KOSMEK
Fig. 40 – Layout of Db37 connector for Kosmek
Pin Nome Dir. Description

1 OUTPUT ENABLE Out-Enable – normally open
2 COM_OUTPUT ENABLE Out-Enable - COM
3 NC - Not connected
6 MOLD_ERROR_PF Flux Safe System (FCS) error – PF (fixed chuck)
7 MAGNET_ERROR_PF Current Control System (CCS) error – PF (fixed chuck)
8 MOLD_ERROR_PM Flux Safe System (FCS) error – PM (moving chuck)
9 MAGNET_ERROR_PM Current Control System (CCS) error PM (moving chuck)
10 POWER_ON Turned on when network is available and correctly configured.
14 ENABLE_INPUT  Input enable from PLC (relay habilitation)
Mold Change, if not activate (logical level high) the system is not
15 MCS_INPUT 
operative
16 SW_DEMAG_PM  PM DEMAG button (moving chuck)
17 SW_MAG_PM  PM MAG button (moving chuck)
18 SW_DEMAG_PF  PF DEMAG button (fixed chuck)
19 SW_MAG_PF  PF MAG button (fixed chuck)
20 OUTPUT ENABLE Out-Enable (normally open)
21 COM_OUTPUT ENABLE Out-Enable (COM)
22 DEMAG_PF PF DEMAG state output
23 MAG_PF PF MAG state output
24 Rif COM output
25 Rif  Isolated 0V (ref from customer)
26 Rif  Isolated 0V (ref from customer)
27 Vext Common Mag, Demag, Level+, Level- push button
28 Vext  Isolated 24V (ref from customer)
29 Vext  Isolated 24V (ref from customer)
33 NC - Not connected to
34 DEMAG_PM PM DEMAG state output
35 MAG_PM PM MAG state output
36 ALARM Alarm output
37 CYCLE Cycle output

Function
In this version the system is able to measure the magnetic flux.
In the following the differences with the general release are reported.
1) Flux measurement
Magnetic flux is measured through an analog integration of the voltage of an exploring single pole
coil. Fig. 41 shows the circuit used for this measure.
IC LF351 (U8) works as an ideal integrator and it is resetted when necessary by the opto-transistor
ISO2 (TLP181).
Fig. 41 – Single pole coil flux measurement circuit.
Single coil voltage signal, opportunely integrated, is managed from the micro controller that
compare it with a threshold and, if the read value is less then such threshold, a flux alarm is
generated. The magnetic flux during the demagnetization cycle is not measured.
The experimental check of the magnetic flux level can be made on the label named FCS_SING,
verifying the value during a cycle of magnetization. The factory setting threshold for magnetic flux
is setted at 2.5V and this value is included in the software. If completely covered chuck is used the
voltage proportional to the magnetic flux must be equal to about 2.9V. This guarantees a force on
the chuck of 750Kg/pole approximately (80×80 mm pole).
The circuit for total coil flux measurement is not actually used
2) Drift calibration in circuit for flux measurement

For these operation it is necessary to connect an oscilloscope probe to the net labeled FCS_SING,
close JMP6 and operate on P2 trimmer (50 kΩ). The calibration is terminated when the signal
measured with the oscilloscope is stable (please set the oscilloscope in this configuration: horizontal
time base = 100 ms for division, vertical voltage base = 500 mV for division).
At the end of this operation please open the JMP6 jumper. The signals present on the oscilloscope
panel go to the zero.
Execute a magnetization cycle.
3) Chuck selection
Chuck are selected in compliance with the following table.
Table 35 – Chucks selection.

Dip Switch SW1 µC input state
Operation
Position # 6 Position #7 Bit 6 Bit 7
1 discharge for fixed chuck
ON ON 0 0 +
1 discharge for movable chuck
ON OFF 0 1 1 discharge for fixed chuck
2 discharges for fixed chucks
OFF ON 1 0 +
1 discharge for movable chuck
2 discharges for fixed chucks
OFF OFF 1 1 +
2 discharges for movable chucks
4) Kosmek PLC Interface

ST200-KM on board Dip-Switch would be configured as indicated in the following:
Number of logic board connected See Table 36

Number of Logic board working simultaneously See Table 37
Type of operation See Table 38

Table 36 – Number of logic board connected: positions from 1 to 5 of Dip-Switch SW1.
№ boards Binary code № boards Binary code № boards Binary code

1 00001 12 01100 23 10111
2 00010 13 01101 24 11000
3 00011 14 01110 25 11001
4 00100 15 01111 26 11010
5 00101 16 10000 27 11011
6 00110 17 10001 28 11100
7 00111 18 10010 29 11101
8 01000 19 10011 30 11110
9 01001 20 10100 31 11111
10 01010 21 10101 32 00000
11 01011 22 10110
Configuration example: 4 logic boards (ON = “1”; OFF = “0”)
Bit 1 Bit 5
00100
Table 37 – Number of Logic board working simultaneously: position 6 and 7 of Dip-Switch SW1.
Dip Switch SW1 Input state of µC
Type of operation
Pos 6 Pos 7 Bit 6 Bit 7
ON ON 0 0 4 logic board working simultaneously
ON OFF 0 1 3 logic board working simultaneously
OFF ON 1 0 2 logic board working simultaneously
OFF OFF 1 1 1 logic board
Table 38 – Type of operation: Standard / Setup.

Pos 8 of Dip-Switch Type of operation
ON Standard
OFF Setup

Blank page / End of document/ final page


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TECHNICAL 031_ST200_2008_ENG

Società soggetta alla direzione e al DOCUMENTATION

Rev. Description Date Drawn Verify

DOCUMENT IN ELECTRONIC FORMAT

Rev. Description Date Drawn Verify

Rev. Description Date Drawn Verify

FIG. 1– FILE: ST200-7L.MAX DIRECTORY: ...\PROGETTI2007\ST200LREV7\... ............................................................ 9

Rev. Description Date Drawn Verify

Rev. Description Date Drawn Verify

Model of microcontroller used: ............................................................... PIC18F4520 (Microchip)

Rev. Description Date Drawn Verify

6. CH10_ENABLE_SPECIAL: this software is used when it is necessary to manage channel in

Rev. Description Date Drawn Verify

2. ST200-L BOARD LAYOUT – COMPONENT SIDE

460V 400V 230V 200V 0

Fig. 1– File: ST200-7L.MAX Directory: ...\Progetti2007\ST200Lrev7\...

Rev. Description Date Drawn Verify

3. ST200-L BOARD LAYOUT – BOTTOM VIEW

Fig. 2 – File: ST200-7L.MAX Directory: ...\Progetti2007\ST200Lrev7\...

Rev. Description Date Drawn Verify

4. ST200-K BOARD LAYOUT – COMPONENT SIDE

Fig. 3 – File: ST200-5K-1.MAX Directory: ..\Progetti2006\...

Rev. Description Date Drawn Verify

5. SCHEMATIC OF ST200-L BOARD

Fig. 4 – Schematic of the ST200-L board.

Rev. Description Date Drawn Verify

6. SCHEMATIC OF ST200-K BOARD

Fig. 5 – Schematic of the ST200-K board.

7. HOW TO CONFIGURE THE SYSTEM

Fig. 6 – Configuration Pads, Jumpers and Dip-Switches for ST200-KM board.

Rev. Description Date Drawn Verify

The function of the available PAD are the following:

PAD 1: For Master or Ch_Enable selection

JMP3 allows to program the board in the following manner:

JMP3 in user position Standard use

The meaning of the latest 3 position of SW1 is:

Rev. Description Date Drawn Verify

Open OFF Enable board

Open ON Enable board

Rev. Description Date Drawn Verify

Open OFF • The channel are selectable using a CH-

Open Enable board

N.I. when the system is in

N.I. OFF ON detection of the

Rev. Description Date Drawn Verify

5 PUSH BUTTON KEYBOARD (2 LEVELS)

Rev. Description Date Drawn Verify

5 PUSH BUTTON KEYBOARD (7 LEVELS)

Rev. Description Date Drawn Verify

3 PUSH BUTTON JEYBOARD

discharge is allowed when • Ch-enable

Rev. Description Date Drawn Verify

Rev. Description Date Drawn Verify

8. TURNING ON THE SYSTEM (COMMON FOR ALL VERSIONS)

Setup procedure (first time turn on or reconfiguration of the system)

Fig. 7 – Position OFF of the Pin 8 - SW1.

Procedure of Standard activation

Rev. Description Date Drawn Verify

Fig. 8 – Position OFF of the Pin 8 - SW1.

Rev. Description Date Drawn Verify

Rev. Description Date Drawn Verify

9. HOW TO USE THE DIP-SWITCH (FOR ALL VERSIONS)

Fig. 9 – First 5 position on SW1.