Parker EVM32-II Modular Expansion Base Plate

EVM32 Series I/O Expansion Board: Building a Flexible and Reliable Industrial I/O System for 6K Controllers

Product positioning and system composition

In modern motion control and automation systems, the number of I/O points on the controller itself often cannot meet the requirements of complex devices. To this end, Parker Hannifin has launched the EVM32 series I/O expansion board, specifically designed to work with 6K series motion controllers to achieve large-scale expansion of digital and analog input and output. The EVM32 substrate itself does not contain specific I/O circuits, but rather serves as a modular platform where users can insert different types of SIM boards (sub boards) according to their actual needs, allowing for flexible configuration of input and output types and quantities.

The standard supply scope for each EVM32 order includes the following components: an EVM32 substrate, a detachable ventilation cover, adhesive labels for identifying SIM configurations, and a 2-foot (0.61-meter) connecting cable. This cable can be used to directly connect the EVM32 substrate to the 6K controller, as well as for cascading expansion between multiple EVM32 units to achieve a decentralized I/O layout. The substrate adopts a metal shell and is equipped with a ventilation cover plate, which meets the needs of heat dissipation and protection.

Optional SIM card types and functions

The core of the EVM32 system lies in its modular SIM board design. Users can choose from the following SIM boards based on the on-site signal type and load requirements, with each SIM board providing 8 channels. All installation and replacement of SIM boards must be carried out with the substrate powered off to prevent electrical damage and ensure safe operation.

2.1 Digital input SIM board: SIM8-IN-EVM32

This board provides 8 digital input channels for receiving switch signals from external devices such as sensors, buttons, limit switches, encoder interfaces, etc. The input circuit is usually compatible with 24V DC logic level and has high anti-interference ability. It can be directly connected to industrial field proximity switches, photoelectric switches, etc. Each input status can be read in real-time through the internal registers of the 6K controller, suitable for applications such as status monitoring, position confirmation, start/stop instructions, etc.

2.2 Digital output SIM board: Four models meet different load requirements

The EVM32 system provides up to four digital output SIM boards to adapt to different load types and electrical environments:

SIM8-OUT-NPN (leakage type output): The 8-way output of this board adopts NPN transistor structure, with the common terminal connected to the positive power supply, and the output terminal pulled down to 0V (i.e. "low side switch") when conducting. Suitable for connecting DC relays, small solenoid valves or indicator lights, and the other end of the load needs to be connected to the positive pole. This output form is very common in Japanese PLCs and many industrial equipment.

SIM8-OUT-PNP (Source Output): Unlike NPN, PNP output boards adopt a source structure, and when conducting, the output terminal outputs a positive voltage (high side switch), with a common terminal connected to 0V. It is suitable for occasions that require high-level driving signals, such as certain safety relays or specific brand actuators. Users should choose NPN or PNP versions according to the wiring specifications of downstream devices to avoid signal mismatch.

SIM8-OUT-SSR (Solid State Relay Output): This board isolates 8 outputs through solid-state relays and can switch between AC or DC loads without mechanical contacts. Therefore, it has the advantages of spark free, long life, and high switching frequency. SSR output is particularly suitable for situations that require frequent on-off, such as pulse control, heater regulation, or high-speed counting output. Note: This board requires a 6K controller operating system version of 5.1 or higher to support.

SIM8-OUT-HCR (High Current Relay Output): This board uses high-capacity electromagnetic relays as output devices, and each contact can withstand greater current and surge capacity than SSR, making it suitable for directly driving high-power AC contactors, motor starters, or electromagnets. Due to being a mechanical contact, its switching frequency is relatively low, but the conduction resistance is extremely small and the heat generation is low. Similarly, this board requires 6K OS rev 5.1 or higher version.

The selection of the four types of digital output boards mentioned above directly determines the types of loads that the system can drive, current capacity, and durability. Engineers need to comprehensively consider load power, switching frequency, environmental requirements, and reliability indicators when designing.

2.3 Analog Input/Output SIM Board

For situations that require continuous process control, EVM32 provides analog I/O cards:

SIM8-AN-IN (8-channel analog input): This board provides 8 analog inputs, and each channel can accept ± 10V voltage signals. After analog-to-digital conversion, the input signal is read in digital form by the 6K controller for collecting pressure, flow rate, position feedback (from potentiometers or analog sensors), etc. Its typical resolution is 12 bits or higher, which can meet the needs of most industrial controls.

Analog output board (8 channels, ± 10V): referred to as the "Analog (+/-10V) output SIM board" in the document, it provides 8 analog output voltages with a range of ± 10V. This board is used to output control signals to frequency converters, proportional valves, servo drives, or other analog controlled devices. Through the motion program of the 6K controller or PLC logic, the output voltage can be changed in real time to achieve continuous adjustment. Similarly, this board requires support for 6K OS rev 5.1 or higher.

Connecting cables and system expansion

The connection between the EVM32 substrate and the 6K controller or other EVM32 units is achieved through dedicated cables. The 2-foot (0.61-meter) cable included in the standard supply is suitable for short distance single machine connections or adjacent module cascading. For scenarios where I/O expansion units need to be placed in distant locations (such as on the other side of a large cabinet or a remote console), users can order a 100 foot (30.48 meter) cable separately. This cable can be used to connect the 6K controller to the first EVM32 unit, as well as for cascading between two EVM32 units to form a distributed I/O network. It should be noted that the total length of the cable is limited by the quality of the communication signal. It is recommended to refer to the maximum distance limit in the 6K controller manual during system design.

The cascading method is as follows: the 6K controller is connected to the input port of the EVM32 substrate through its dedicated expansion interface, and the output port of the first EVM32 substrate is then connected to the input port of the second EVM32 substrate through another cable, and so on. Each EVM32 substrate can accommodate up to a certain number of SIM boards (usually 8 slots, please refer to the 6K Addendum document for details). Through this daisy chain topology, a single 6K controller can manage hundreds of I/O points, making it ideal for complex automation devices that require a large amount of switch or analog monitoring.

Installation, labeling, and ESD protection

The EVM32 substrate is designed for installation inside the cabinet, and its detachable ventilation cover provides physical protection while allowing air circulation to dissipate the heat generated by the internal SIM board. Each EVM32 order comes with adhesive labels. After completing the SIM board configuration, users can label the I/O type and address corresponding to each slot on the label, and then paste the label on the surface of the cover plate. This detailed design greatly simplifies subsequent maintenance and troubleshooting work, allowing on-site engineers to quickly identify the function of each channel without consulting drawings.

Anti static warning: The document clearly indicates the "CAUTION" prompt: EVM32 SIM board is sensitive to static electricity, and appropriate ESD handling precautions must be followed during operation. This means that before touching the SIM board, a grounded wristband should be worn and operated on an anti-static workbench. In addition, before installing or removing the SIM board, the power supply to the EVM32 substrate must be cut off. This requirement is not only to prevent electric shock, but more importantly, to avoid transient current damage to sensitive electronic components on the board when inserting or removing the board while it is live.

Technical references and firmware requirements

For detailed specifications, installation steps, wiring diagrams, and programming information about EVM32, please refer to the 6K Controller Supplemental Manual (document number 88-017657-01). This supplementary manual provides register mapping for each SIM board, address allocation for input-output buffers, and example code on how to access these extended I/Os in the 6K motion program. Users should note that some SIM boards (such as SSR, HCR, and analog output boards) require the operating system version of the 6K controller to be no less than 5.1. Before ordering these boards, it is recommended to check the firmware version of the existing 6K controller and upgrade it if necessary to ensure compatibility.

Typical application scenarios

6.1 Automated assembly line

On a multi station assembly line, it is necessary to monitor dozens of proximity switches and buttons, while controlling cylinders, indicator lights, and buzzers. The I/O of a single 6K controller is often insufficient. By adding one or more EVM32 substrates and configuring SIM8-IN-EVM32 and SIM8-OUT-NPN (or PNP), it is easy to expand to dozens of input and output points, and each substrate can be installed near the workstation through a 2-foot cable, reducing long-distance wiring.

6.2 Process Control and Analog Adjustment

For equipment that requires adjustment of motor speed, valve opening, or heating power, SIM8-AN-IN can be used to collect ± 10V signals from sensors (such as pressure transmitters, thermocouple transmitters), and then send 0-10V control signals to frequency converters or proportional control valves through analog output boards. Due to the digital communication transmission between the EVM32 substrate and the 6K controller, the signal is not easily affected by interference like long-distance analog transmission, thereby improving the system's noise resistance.

6.3 High reliability switch application

When the load requires frequent switching (such as tens of times per second) or operates in flammable and explosive environments, SIM8-OUT-SSR solid-state relay board should be selected. Solid state relays have no mechanical contacts, do not generate sparks, and have a fast response speed and extremely long lifespan. For example, driving the cutter after color code detection in packaging machinery, or in LED light flicker testing, SSR output is an ideal choice.

6.4 High power load control

For direct control of high current AC contactors, motor brakes, or electromagnetic suction cups, it is recommended to use SIM8-OUT-HCR high current relay boards. Its contact capacity is much larger than that of ordinary solid-state relays, and it has a clear disconnect gap, making it safer. Although the switching life of mechanical relays is limited, their reliability and overload capacity advantages are obvious in situations where the switching frequency is not high (such as a few times per minute).

Brief explanation of installation steps

Although detailed steps need to refer to the 6K supplement manual, the back of the document provides basic instructions for inserting the SIM board into the substrate. The general process is as follows:

Ensure that all power supplies to the EVM32 substrate have been disconnected.

Wear an anti-static wristband and place the substrate on an anti-static pad.

Remove the ventilation cover plate from the substrate.

Insert the SIM board vertically into the corresponding slot according to the slot direction, ensuring that the connector is fully engaged.

Repeat the above steps to install all required SIM boards.

Use the accompanying label paper to record the SIM board type and I/O address for each slot, and then stick it on the outside of the cover plate.

Reinstall the ventilation cover.

Connect the cable to the 6K controller or the previous stage EVM32 unit.

Connect the power and confirm that each SIM board is correctly recognized through the software of the 6K controller.