Application and Configuration of ADLINK DIN-812M Adapter Board

Application and Configuration of ADLINK DIN-812M Adapter Board

In industrial automation motion control systems, reliable connection between high-performance motion control cards and servo drivers or stepper motor drivers is the foundation for stable system operation. DIN-812M is a 2-axis interface adapter board designed specifically for ADLINK motion control cards. It provides standardized signal routing and convenient wiring terminals, supporting Mitsubishi J2S series servo amplifiers and universal stepper motor drivers, greatly simplifying system integration work. This article will provide you with a complete DIN-812M application guide from the perspectives of hardware architecture, interface definition, jumper configuration, typical applications, and troubleshooting.

Product positioning and hardware overview

DIN-812M is a passive adapter board (passive backplane), whose core function is to convert the CN2 interface (usually 100 pin SCSI) of the motion control card into an industrial terminal for easy on-site wiring. It supports up to 2 motion axes, each axis providing two interface options:

CNA #/CNB # (# represents axis numbers 1-2): A 20 pin dedicated interface designed specifically for Mitsubishi J2S series servo drives (with CNA and CNB connectors), including all signals such as pulse commands, encoder feedback, enable, alarm, emergency stop, etc.

SJ #: A 10 pin simple interface provided for stepper motor drivers or other brand servo drivers, including pulse, direction, enable, alarm, and+5V/+24V power output.

Important warning: CNA/CNB and SJ on the same axis are directly short circuited inside the PCB (signal lines are connected in parallel). It is strictly prohibited to use two interfaces at the same time, otherwise it may cause signal conflicts and hardware damage.

In addition, each axis is equipped with an IOIF # (mechanical I/O interface) for connecting limit switches (positive limit PEL, negative limit MEL), origin signal ORG, deceleration signal (PSD/MSD), and external emergency stop signal Ext.EMG. The board also provides a variety of isolated digital inputs/outputs (IOIF3~IOIF6), totaling 16 DI and 16 DO, all of which support isolation and can be directly connected to on-site sensors and actuators.

The board is powered through the CN2 interface of the motion control card (no external power supply is required), but the digital input/output on IOIF requires external power supply (+24V) for DI-COM and DO-COM, which is configured by jumper J3.

Interface Definition and Signal Explanation

1. CNA #/CNB # Mitsubishi servo interface (20 pins each)

This is the core interface of DIN-812M, used to connect Mitsubishi J2S series servo drives (such as MR-J2S-A/B models). Use two 20 pin 1:1 flat cables for connection (special cables need to be purchased from ADLINK or distributors). The following is the analysis of key signals:

CNA connector (instruction and encoder signal)

Key points of the signal name direction function description project

OUT+, OUT - differential output of pulse signals for position control mode, combined with DIR direction signal to form servo pulse commands.

DIR+, DIR - The differential output of the output direction signal determines the direction of motor rotation.

EA+, EA -, EB+, EB - input encoders A/B differential input receive encoder signals returned by servo drives for position closed-loop.

EZ+, EZ - Input encoder Z-phase (zero point) input for origin reset.

Clear the position deviation counter in the servo drive by resetting the ERC output error counter.

The INP input positioning signal is valid after the servo reaches the command position, and is used to confirm that it is in place.

The RDY input servo ready signal indicates that the driver has been powered on and there are no faults.

+24VO output isolation+24V output provided by the motion card, which can supply power to external sensors.

IGND - Ground reference for all isolated signals.

CNB connector (control and status signal)

Signal Name Direction Function Description

Servo ON outputs a servo enable signal, and a high level excites the motor.

EMG outputs an internal emergency stop signal (which can be connected to an external Ext. EMG via jumper).

ALM input servo alarm signal, valid in case of malfunction.

+24VO output isolation+24V output.

IGND - Isolation Zone.

EMG jumper configuration (J1~J2): DIN-812M provides two emergency stop operation modes:

1-2 Short circuit (default): The EMG signal is directly short circuited to GND (internal emergency stop disabled), and the Ext.EMG pin of IOIF is invalid.

2-3 Short circuit: The Ext.EMG pin of IOIF is connected to the EMG input of the driver, and the user can pull the Ext.EMG low (to GND) through an external switch to trigger an emergency stop.

Please choose the appropriate mode based on security requirements. J1 corresponds to the first axis, J2 corresponds to the second axis.

2. SJ # stepper/universal interface (10 pins)

For stepper motor drivers or other brands of servos, DIN-812M provides simplified interfaces, with signal definitions as follows (please refer to the PCI-8132 user manual for detailed wiring):

OUT+, OUT -: Pulse signal differential output (same as CNA's OUT signal).

DIR+, DIR -: Differential output of directional signals.

EZ+: Encoder Z-phase input (used for closed-loop or origin signals).

+5VO: Provides a+5V power supply to power the optocoupler input of the stepper driver.

+24VO: Provides+24V power supply.

SVON: Enable output.

ALM: Driver alarm input.

IGND: Quarantine location.

Note: The CNA/CNB signals of SJ and the corresponding axis are in parallel and cannot be connected to external devices simultaneously.

3. IOIF1~IOIF2 mechanical I/O interfaces (12 pins each)

This is a key interface for connecting safety related sensors such as on-site limit, origin, deceleration, and emergency stop:

PEL: Positive direction limit - prohibits forward movement when triggered.

MEL: Negative direction limit.

ORG: Origin signal.

PSD: Forward deceleration signal, used to reduce speed before approaching the limit.

MSD: Negative deceleration signal.

Ext.EMG: External emergency stop input, to be used in conjunction with J1/J2 jumper wires.

+24VO and IGND: Provide isolated power supply for sensors (provided by the sports card).

4. IOIF3~IOIF6 isolated digital I/O interfaces (12 pins each)

DIN-812M provides a wide range of isolated digital inputs and outputs, suitable for connecting various field devices:

IOIF3~IOIF4: A total of 16 isolated digital outputs (DO0~DO15), each with an open collector output (requiring an external pull-up power supply to DO_CM).

IOIF5~IOIF6: There are a total of 16 isolated digital inputs (DI0~DI15) that require an external DI-COM power supply (+24V).

DI-COM/DO-COM: These are the external power input terminals for DI and DO, respectively. It is recommended to use+24VDC.

J3 jumper configuration (DI_CM polarity):

1-2 Short circuit: DI-COM is short circuited to GND (i.e. the input is low and active, source input).

2-3 Short circuit: DI-COM is short circuited to+24V (i.e. the input is a high-level active, leakage type input).

Please configure J3 correctly according to the type of sensor on site (NPN or PNP).

5. Quick wiring reference table

The manual provides a quick reference table to help users determine whether each interface needs to be wired under different configurations:

Configuration scenario CNA/CNB (Mitsubishi servo) SJ (stepper/non Mitsubishi) IOIF1-2 (mechanical I/O) IOIF3-6 (universal DI/DO)

Mitsubishi J2S servo (without external encoder) needs to be determined based on application requirements

Mitsubishi J2S servo (with external encoder) needs or not depending on application requirements

Non Mitsubishi servo does not need to be customized according to application requirements

Stepper motors do not need to be customized according to application requirements

Typical application scenarios and wiring guidance

1. Typical connection of Mitsubishi J2S servo system

Connect the CNA1/CNB1 of DIN-812M to the CN1A/CN1B (or CN2) port of the MR-J2S driver via two 20 pin flat cables. Be sure to use ADLINK original cables or self-made according to the pin definitions.

Connect the CN2 (usually 100 pin SCSI) of the motion control card to the CN2 input port of DIN-812M through a flat cable.

Configure J1/J2 jumpers according to security requirements (it is recommended to use 2-3 short circuits and enable external emergency stop).

Connect the limit and origin sensors to the PEL, MEL, and ORG terminals of IOIF1, ensuring that the sensor type (NPN/PNP) is compatible with the board.

Configure J3 jumper (DI_CM polarity) according to sensor type.

Connect the external+24V power supply to DI-COM and DO-COM (if DI/DO function is required).

After checking for accuracy, power on and the motion card should be able to enable servo and read encoder feedback normally after initialization.

2. Connection of stepper motor system

Connect the pulse+, pulse -, direction+, and direction - of the stepper driver to the OUT+, OUT -, DIR+, and DIR - of SJ1, respectively.

If the driver requires an enable signal, it can be connected to SVON; If alarm input is required, connect to ALM.

Use the+5VO of the board to power the optocoupler end of the driver (if the driver requires an external power supply).

Similarly connect the limit and origin to IOIF1.

Attention: SJ is connected in parallel with CNA/CNB signals. If stepping is used, CNA/CNB must be left vacant.

3. Typical applications of DI/DO isolation

Digital output (DO0~DO15): can drive relays, indicator lights, or PLC inputs. It is necessary to connect+24V to DO-COM, and the DO pin should have an open collector output (low level is valid).

Digital input (DI0~DI15): can connect buttons, sensors, limit switches, etc. J3 needs to be configured according to the sensor type (1-2 for NPN sensors and 2-3 for PNP sensors).

Common problems and troubleshooting

Problem 1: After the servo is enabled, the motor does not rotate and there is no alarm

Check whether the CNA/CNB cables are connected correctly, especially whether the differential lines of OUT+, OUT -, DIR+, and DIR - are connected incorrectly.

Check if the Servo ON signal has been set high (CNB pin 5).

Check if the servo parameters have been set to the correct command pulse input method (such as pulse+direction, CW/CCW, etc.).

Problem 2: Invalid triggering of limit or origin signal

Check whether the IOIF terminal is wired correctly and whether the PEL/MEL/ORG is connected to the output terminal of the sensor.

Check if the sensor type (NPN/PNP) matches the J3 configuration.

Check if+24VO is supplying power to the sensor normally.

Check if the motion control card software has enabled the limit function.

Problem 3: Emergency stop cannot be triggered

Check if the J1/J2 jumper position is 2-3 short circuited (with external EMG enabled).

Check if the Ext.EMG pin of IOIF is connected to an external emergency stop switch and can be pulled down to GND when the switch is activated.

Check if other safety devices (such as safety relays) are connected in series in the emergency stop circuit.

Question 4: DI/DO is unresponsive

Check if DI-COM/DO-COM has been connected to the+24V power supply.

Check if the J3 jumper position is correct (1-2 for NPN and 2-3 for PNP).

Inspection: DO is an open collector output, which requires an external pull-up resistor or a load of+24V to measure voltage changes.

Problem 5: Simultaneous use of CNA/CNB and SJ leads to abnormalities

Root cause: The two signals are short circuited, and a physical alternative must be chosen. If switching is necessary, it is recommended to use relays or jumper caps for selection, but the board does not provide them, so only one of the two can be chosen.

Maintenance and upkeep suggestions

Regularly check whether the wiring terminals are loose, especially for high current+24V and GND.

Avoid plugging or unplugging connectors while they are live to prevent damage to the optocoupler from static electricity or surges.

Keep the board clean to prevent short circuits caused by metal dust.

In case of lightning strikes or power fluctuations, it is recommended to add external surge protectors.

Regularly check if the emergency stop function is functioning properly to ensure the reliability of the safety circuit.