PIO-100(DOCS) Optical Printer Control System PIO-100(DOCS)
NAME
pio-100 - OPCS parallel port I/O interface board
DESCRIPTION
The OPCS parallel port interface board (PIO-100) was designed to
simplify wiring between the computer parallel port and the various
digital sensors on the printer, using standard RJ-45 patch cables
to route the signals to each sensor. The board also optically
isolates the computer and the optical printer's digital sensors,
namely home sensors, buckle/viewer switches, deenergize options,
tension motors, etc.
There are several revisions of this board:
REV 3/Feb 2010: First use by Disney (YCM printers), used by others
See: http://seriss.com/opcs/docs/parallel-port-interface/rev3
REV 6/Jan 2021: First use by Mike Ferriter, Andy Kaiser,
Bruce Heller, Carl Spencer, etc.
See: http://seriss.com/opcs/pio-100/
REV 6 "PIO-100" Parallel I/O Board - Jan 2021
=============================================
This board has a webpage with schematics, wiring diagrams, PCB layouts,
photos, and other useful information here:
http://seriss.com/opcs/pio-100/
As of this writing (Aug 2021), REV 6 is the latest revision of this board.
This board was branded with the model number "PIO-100", to differentiate
it from the other OPCS boards (A800, SD-800, etc).
At the top, a parallel port connector is connected to the computer's
parallel port via a DB-25 ribbon cable. On the right side, a single
12V power connector. Derives 5V with an onboard 7805 used for the
computer interface.
While this board is optically isolated for the signals, there is a
common ground between the 12V and 5V supplies.
Along the bottom are 16 RJ-45 connectors arranged in two-tier
connector blocks. These fan out to the optical printer's sensors
and motor controls as individual RJ-45 patch cables, one per
device. These devices can be 12V home sensors (or 'optical sensors'),
tension motor control relays (SSR's), buckle/viewer switches,
motor enable/disable controls, etc.
The REV 6 board looks like this:
PARALLEL PORT
_______________
____________________________|_______________|__________________________
| _ _ | | _____ |
| | | | | |_______________| | | |
| | | | | _____ _____ |7805 | |
| |_| | | |_____| |_____| | | |
| |_| |_____| |
| ||| |
| _________ _________ _________ _________ _________ __|
| |_________| |_________| |_________| |_________| |_________| -| | 12V
| +|__| POW
| |
| ||..||..||..||..||.. |
| ||..||..||..||..||.. |
| NPN PNP |
| |
| ______________________________ ______________________________ |
| | TENS TENS TENS OUT | | IN IN IN IN | |
| | (2) (3) (4) (5) | | (10) (11) (12) (13) | |
| |______________________________| |______________________________| |
| | OUT OUT OUT OUT | | IN | |
| | (6) (7) (8) (9) | | (15) X X X | |
|__|______________________________|__|______________________________|___|
\____________________________/ \____________________________/
Eight RJ-45 Eight RJ-45
Connectors Connectors
(Two Tiers) (Two Tiers)
Regarding the labels on the RJ-45 connectors,
the numbers in parenthesis are the parallel port pin#s:
> Outputs (from the computer) are pins 2 thru 9.
> Inputs (to the computer) are pins 10 thru 13, and 15.
TENSION OUTPUTS
---------------
At the bottom left, there are three 'TENSION' outputs intended to control
the SSR relays for tension motors, one RJ-45 output cable per pair of
feed/takeup motors, one pair for each film movement, which is typically:
TENS(2) -- Aerial Projector (feed/takeup)
TENS(3) -- Main Projector (feed/takeup)
TENS(4) -- Camera (feed/takeup)
Changing a bit on one of these outputs inverts the state of the
feed/takeup so that only one of the two tension motor relays is on,
and the other off. In the OPCS software's setup file, OPCSDEFS.OPC,
the TENSION(OPCSDEFS) command is used to configure this for each
channel that supports tension motors.
When the channel is running forward, the TAKEUP motor is energized,
and FEED is disabled. Typically a small high power low ohm rating
resistor lies across each SSR relay's output, allows a small amount
of 110VAC to run the tension motor as a "holding current" when the
relay is off. When the relay is on, full 110 VAC drives the tension
motor. Actual voltage to the motors are usually tunable with a variac
the camera operator can set.
### TENSION(2,3,4) OUTPUTS ###
### RJ-45 PINOUTS ###
PIN# DESCRIPTION COLOR
1 GND WHT/ORN
2 TAKEUP(-) ORN
3 GND WHT/GRN
4 TAKEUP(+) BLU
5 GND WHT/BLU
6 FEED(-) GRN
7 GND WHT/BRN
8 FEED(+) BRN
GENERIC OUTPUTS
---------------
Since the first three output pins of the parallel port are used for
tension motors, the remaining five pins are generic optically isolated
12V outputs that can be used for various purposes. Often these are
used to deenergize channels, allowing the software to unlock motor(s)
on command, allowing the operator to freewheel the motor, then the
software can re-home the motor on completion.
Generic output control can be done via the 'home' command as configured
in the HOMEDEFS.HOM file, using either the 'setbit' or 'clrbit' commands.
Similar commands in the OPCSDEFS.OPC file and/or OPCS run scripts
can be used to change the parallel port's bits via command control,
e.g.
ldefs -c setbit 0378 8 0 -- set parallel port pin #5 (bitmask 0x08)
ldefs -c clrbit 0378 8 0 -- clear parallel port pin #5 (bitmask 0x08)
### OUT(5,6,7,8,9) OUTPUTS ###
### RJ-45 PINOUTS ###
PIN# DESCRIPTION COLOR
1 GND WHT/ORN
2 GND ORN
3 GND WHT/GRN
4 N/C BLU
5 GND WHT/BLU
6 OUTPUT GRN <-- LOW=GND HI=+12V
7 GND WHT/BRN
8 +12 BRN
GENERIC INPUTS
--------------
The generic inputs IN(10) thru IN(13) and IN(15) can be used for either
home sensors, buckle/viewer switches, etc. These respond to voltages
typically 12V (for "on") or pulled to Ground (for off).
+12 and Ground signals are provided on each RJ-45 port to be used for
driving the home sensor's internal circuits and for 12v/Gnd reference.
Home sensors are typically configured for the 'home' command using the
HOMEDEFS.HOM file's 'homeport' command, which procedures in that file
can then use to test the home sensor to conditionally run motors.
Buckle and Viewer switches can also be used to drive these inputs.
Schematics are available on the website, and also are printed on the
board's silk screen for reference, along with simple wiring diagrams.
### IN(10,11,12,13,15) ###
### RJ-45 PINOUTS ###
PIN# DESCRIPTION COLOR
1 GND WHT/ORN
2 GND ORN
3 GND WHT/GRN
4 N/C BLU
5 GND WHT/BLU
6 IN GRN
7 GND WHT/BRN
8 +12 BRN
INPUT JUMPERS
-------------
To support both NPN and PNP home sensors, a jumper block is provided
on the board to allow either type to be supported. The default is NPN,
which is the most common sensor type. It is advised you standardize
on only one type of sensor for all sensors, so they can be easily
reassigned without having to change the jumpers.
WARNING: BE SURE THE BOARD'S 12V POWER IS REMOVED BEFORE CHANGING JUMPERS.
If you must change the jumpers while the board is "hot", remove
*both jumpers completely* before replacing to the new positions.
AVOID changing one jumper at a time, as that can short the 12V
power supply during mid-change.
CAVEATS
-------
The RJ-45 connectors labeled "X" are unused for I/O, but can be used
for access to +12V and GND from the board for various purposes (such
as 12V power lights, etc)
On the REV 6 board, there are a TWO MINOR ERRORS that will be fixed
in future revisions (probably REV 6A and up):
> Many of the little diagrams on the silk screen are wrong.
White labels are affixed over these problem diagrams to make
corrections. All REV 6 boards in the field should already have
these white 'fix labels' on them.
> Two of the outputs, OUT(8) and OUT(9), do not match the normal wiring
pattern of the other connectors. It's advised you do not use OUT(8)
and OUT(9) on the REV 6 board, for consistency.
REV 3 "Parallel Port Interface Board" - Feb 2010
================================================
This board has a webpage with schematics, wiring diagrams, PCB layouts,
photos, and other useful information here:
http://seriss.com/opcs/docs/parallel-port-interface/rev3/
The REV 3 board uses separate +5V and +12V power, to ensure complete
isolation. But it is possible to use a single dual +5v/+12v power supply
and share the signal ground.
At the top, a parallel port connector is connected to the computer's
parallel port via a ribbon cable. On the sides, power connectors for
the input +12V and +5V. Along the bottom, RJ-45 connectors are used
to fan out to the optical printer's sensors and motor controls; home
sensors, tension motors, buckle/viewer switches, motor enable/disable
controls, etc. It looks like this:
PARALLEL PORT
____________
__________________________________________|____________|______________________
| _ | | _ |
| | | +5/+12 |____________| +5/+12 | | |
| | | POW CHAIN _____ _____ POW | | |
| |_| OUTPUT |_____| |_____| |_| |
| _______ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ |
| |_______| |_||_||_||_||_||_||_||_||_||_||_||_||_||_||_| |
| ______ ______ |
| |______| |______| |
| |
|______________________________________ _______________________________________|
|PWR PWR PWR IN IN IN IN IN | TEN TEN TEN OUT OUT OUT OUT OUT|
| 1 2 3 15 13 12 11 10 | 9 8 7 6 5 4 3 2 |
|______________________________________|_______________________________________|
\___________/ \____________________/ \___________/ \_____________________/
RJ-45 RJ-45 RJ-45 RJ-45
Power Inputs from Buckle, Tension Outputs for
Outputs Viewer, Home sensors Motor various uses
Outputs
For the most part, the buckle/viewer sensors are configured by the
BUCKLE(OPCSDEFS) and VIEWER(OPCSDEFS) commands in the OPCSDEFS.OPC
file to define the port and bit mask values corresponding to the
RJ-45 ports used for those features.
The home sensors are configured in the HOME(DOCS) program's
HOMEDEFS.HOM to define the port and bit mask values corresponding
to the RJ-45 ports used for those features.
The tension motor controls are configured with the TENSION(OPCSDEFS)
command in the OPCSDEFS.OPC file to define the port and bit mask
values corresponding to the RJ-45 ports used for those features,
and are wired specially with Crydom solid state relays to control
the AC tension motors.
Various other inputs/outputs can be controlled by these ports, such as
energizing/deenergizing certain motors via OPCS command control. An example
would be the LOAD and LINEUP commands, which might want to run the motors
small amounts, and deenergize the motors to allow manually loading film.
♀
PARALLEL CONNECTOR
The parallel conenctor on the OPCS parllel port interface board is
a femal DB-25 connector, which should be connected to one of the
computer's parallel ports.
PIN PORT MASK I/O RJ-45 DESCRIPTION
2 0x378 0x01 Out OUT(2) Generic output
3 0x378 0x02 Out OUT(3) Generic output
4 0x378 0x04 Out OUT(4) Generic output
5 0x378 0x08 Out OUT(5) Generic output
6 0x378 0x10 Out OUT(6) Generic output
7 0x378 0x20 Out OUT(7) Generic output
8 0x378 0x40 Out TEN(8) Camera Tension
9 0x378 0x80 Out TEN(9) Projector Tension
10 0x379 !0x40 In IN(10) Generic Input
11 0x379 !0x80 In IN(11) Generic Input
12 0x379 0x20 In IN(12) Generic Input
13 0x379 0x10 In IN(13) Generic Input
15 0x379 0x08 In IN(15) Generic Input
18-25 - - Gnd - Ground
RJ-45 CONNECTORS
----------------
INPUTS - IN(10-15)
------------------
The 5 generic inputs are realtime inputs that can be read by the
computer. The OPCS software can be configured to make use of these
inputs by specifying the corresponding port/mask via the OPCSDEFS.OPC
or HOMEDEFS.HOM files.
Typically generic inputs are used for either home sensors or
buckle/viewer switch sensing.
### IN(10) - IN(15) ###
### RJ-45 PINOUTS ###
PIN# DESCRIPTION COLOR
1 Chassis WHT/ORN
2 GND ORN
3 Chassis WHT/GRN
4 - BLU
5 Chassis WHT/BLU
6 IN GRN
7 Chassis WHT/BRN
8 +12 BRN
♀
OUTPUTS - OUT(2-7)
------------------
The 6 generic outputs can be controlled directly by commands in HOMEDEFS.HOM
or OPCSDEFS.OPC, e.g. the SETBIT, CLRBIT, and XORBIT commands.
Typically, generic outputs are used for de-energizing motors to allow
manual load/unload of film with the custom LOAD and LINEUP commands.
### OUT(2) - OUT(7) ###
### RJ-45 PINOUTS ###
PIN# DESCRIPTION COLOR
1 Chassis WHT/ORN
2 GND ORN
3 Chassis WHT/GRN
4 - BLU
5 Chassis WHT/BLU
6 OUT GRN
7 Chassis WHT/BRN
8 +12 BRN
TENSION OUTPUTS - TEN(8) AND TEN(9)
-----------------------------------
The tension motor outputs TEN(8) and TEN(9) can control the FEED and TAKEUP
motors for camera and projector.
When parallel port pin 8's bit changes from 0 to 1, the TEN(8) RJ-45
connector's FEED and TAKEUP outputs will change state, always being
the compliment of each other (ie. if FEED is 'on', TAKEUP will be 'off').
### TEN(8) AND TEN(9) ###
### RJ-45 PINOUTS ###
PIN# DESCRIPTION COLOR CRYDOM PIN#
1 Chassis WHT/ORN 4
2 -TAKEUP ORN -
3 Chassis WHT/GRN 3
4 +TAKEUP BLU -
5 Chassis WHT/BLU 4
6 -FEED GRN -
7 Chassis WHT/BRN 3
8 +FEED BRN -
POWER OUTPUTS - PWR(1) THRU PWR(3)
----------------------------------
PWR-1 through PWR-3 can be used to supply +12V power to the printer.
### PWR-1 THRU PWR-3 ###
### RJ-45 PINOUTS ###
PIN# DESCRIPTION COLOR CRYDOM PIN#
1 Chassis WHT/ORN 4
2 GND ORN -
3 Chassis WHT/GRN 3
4 - BLU -
5 Chassis WHT/BLU 4
6 - GRN -
7 Chassis WHT/BRN 3
8 +12 BRN -
AUTHOR
Greg Ercolano / Seriss Corporation 2009, 2021