Back to Basics: RS232 vs RS422 vs RS485

These are one of the fundamental communication standards out there for sending data between devices. RS stands for “Recommended Standard”. In its simple terms, RS 232 is used for point-to-point communication between 2 devices. You have RX, TX line and you share a GND line between the devices. Its main limitation is the speed of transmission and how immune it is to noise signals. They can do max 1Mbps and can extend the distance to around 15m.

RS422 was introduced to remove the shortcomings of RS232. It supports single-point to multiple-receiver connections. Meaning you can broadcast information. To improve noise immunity, they use a differential pair. So you have just 2 wires running between systems for a half-duplex connection and 4 wires if you want a full duplex. So effectively you have a higher bandwidth (Around 10Mbps) and you can have a longer cabling length of 1000m+. It uses twisted pair lines with a termination of 120 ohms.

RS485 is again an improvement over RS422 wherein electrical standards remain the same but it introduces the concept of multiple transmitters and receivers in a single line. For RS485, on the driver end, you need to have a minimal differential of 1.5V between lines whereas on the receiver end the differential is 200mV so you do have a large margin for longer transmission of signals. As usual, longer the distance, lower the speed of transmission you can achieve.

It is imperative to understand that, all the above three are electrical standards and not protocols(Protocols define how data is packed and sent) or connector types. It tells you the signal amplitudes, how it can be wired, termination resistance etc but not how to transmit data over it over a signalling scheme. These standards are still in use because it’s cheaper to implement for lower bandwidth wired data transmission between systems.

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Back to Basics: PCB Test Coupons

When making production-grade PCB Panels, for some specific PCBs we add something known as Test Coupons. These are structures which are created on a free area of a PCB panel to test a whole bunch of things. It is important to do that on a panel because ideally, you would want to test every panel which comes out from a production perspective(But it’s expensive). It’s imperative because these structures are put through the same manufacturing process as a regular PCB in the panel and any variation on these would affect the rest of the panel too.

So what are they for? There are different types of standard coupons used to test different things like what is the min drill size which comes out OK, how good is the alignment registration between layers for a large multi-layer board, what is the insulation resistance of the PCB materials used, how good is solderability of SMD pad, how is solder mask adhesion like, What about Via reliability for Blind, buried or filled vias etc. But one of the most important test patterns is to design a coupon to measure the impedance of a particular track on board. These structures once manufactured are used by them to measure the impedance with specialised equipment like a TDR(Will go over this some other day). They have specialised probe points which enable the reading of the impedance. It is very hard to do measurements in an actual PCB design. These impedance profiles help in defining the actual impedance for certain kinds of communication say a 90 Ohm differential for USB or a single-ended 50Ohm line for an antenna feed. By verifying the impedance of a PCB using test coupons, designers and manufacturers can improve the performance of high-speed digital and analog circuits, reduce signal degradation and improve signal integrity.

Coupons are typically test samples that include the most intricate features of your design that are prone to errors. By providing these samples to the manufacturer, you are allowing them to perform tests and avoid any potential errors during production. For more details read up on IPC 2221B:Appendix-A

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