WIRING(DOCS) Optical Printer Control System WIRING(DOCS)
NAME
wiring - all the wiring documentation in one document
-------- kuper.doc -------
KUPER CONTROL RTMC16 CARD CONNECTOR 'P2'
(DB37S - 37 pin connector)
--------------------------------
1 - (*) 20 - +5VDC
2 - STEP A 21 - DIR A DB37S (37 pin connector)
3 - STEP B 22 - DIR B
4 - STEP C 23 - DIR C
5 - STEP D 24 - DIR D
6 - STEP E 25 - DIR E
7 - STEP F 26 - DIR F (*) = Jumper Select GND or +5 with JP5:
8 - STEP G 27 - DIR G +5VDC - Short pins 1 & 2 on JP5
9 - STEP H 28 - DIR H GND - Short pins 2 & 3 on JP
10 - STEP I 29 - DIR I
11 - STEP J 30 - DIR J
12 - STEP K 31 - DIR K NOTE: All outputs are OPEN COLLECTOR
13 - STEP L 32 - DIR L TTL. Maximum +5 current draw
14 - STEP M 33 - DIR M should not exceed 400 milliamps.
15 - STEP N 34 - DIR N
16 - STEP O 35 - DIR O
17 - STEP P 36 - DIR P
18 - (*) 37 - +5VDC
19 - (*)
KUPER CONTROL CARD IRQ JUMPER SETTINGS (JP3)
Selects the IRQ used for feeding velocities
--------------------------------
JP3 has a single jumper on one set of pins to set the IRQ;
from left to right, pins set IRQ 2 thru 7, with 5 being the default:
_
JP3 | |
o o o |o| o o
o o o |o| o o
| | | |_| | |
| | | | | |
| | | | | |__ IRQ7
| | | | |_____ IRQ6
| | | |________ IRQ5 <-- DEFAULT
| | |___________ IRQ4
| |______________ IRQ3
|_________________ IRQ2
KUPER CONTROL CARD SWITCH SETTINGS 'JP4'
Selects the KuperBase address value
(Jumpers A3-A9)
--------------------------------
This is the default configuration for 0300h:
JP4
_ _ _ _ _
| || || || || |
|o||o||o||o||o| o o
|o||o||o||o||o| o o
|_||_||_||_||_|
A3 A4 A5 A6 A7 A8 A9
Here's the table of the JP4 jumper variations from the
RTMC16 manual, shown in "most likely to work" order:
KuperBase
Address A3 A4 A5 A6 A7 A8 A9
------------------------------
0300 1 1 1 1 1 0 0
0320 1 1 0 1 1 0 0
0320 0 1 0 1 1 0 0
0330 1 0 0 1 1 0 0
0340 1 1 1 0 1 0 0
0280 1 1 1 1 0 1 0
02a0 1 1 0 1 0 1 0
0308 0 1 1 1 1 0 0
0310 1 0 1 1 1 0 0
0318 0 0 1 1 1 0 0
NOTE: 0 = off 1 = on
Factory setting is 0300, and there is usually no need
to modify this setting unless other boards in the machine
are conflicting with this address. Same for the IRQ setting.
KUPER LOGIC CONNECTOR [R1]
Inputs are tied high to +5
PIN NAME PORT MASK (hex)
-------------------------------------------
1 GND GND GND
2 out 0 0x306 01
3 out 1 0x306 02
4 out 2 0x306 04
5 out 3 0x306 08
6 out 4 0x306 10
7 out 5 0x306 20
8 out 6 0x306 40
9 out 7 0x306 80
10-12 ??? ??? ??
13 +5 +5 +5
14 GND GND GND
15 in 0 0x306 01
16 in 1 0x306 02
17 in 2 0x306 04
18 in 3 0x306 08
19 in 4 0x306 10
20 in 5 0x306 20
21 in 6 0x306 40
22 in 7 0x306 80
23-24 ??? ??? ??
25 +5 +5 +5
KUPER "INDUSTRIAL" CARD
The Kuper Controls "Industrial Card" is a 'half slot ISA' card,
a variation on the RTMC-48. So for OPCS, install the "RTMC48.COM"
driver.
The "H1" 40 pin connector (upper-left) is the steps/direction.
The "H2" 40 pin connector (upper-right) is the "logic" connector.
For OPCS, only the "H1" connector should be used.
On the H1 connector, pin #1 is at the lower-left of the connector
(component side facing you).
This card has 3 jumper blocks, whose "factory" settings are:
JP1: o-o o -- sets voltage for pin #1 (OPCS: dont care)
JP2: o o o o o -- sets samples-per-second(?) (default: 120/sec)
| | |
o o o o o
JP3: o o o o o o -- sets the IRQ (default IRQ 5)
|
o o o o o o
..where '-' is a horizontal jumper, and '|' is a vertical jumper.
KUPER PORT MONITOR PROGRAM
The OPCS software comes with kuper.exe, a program that monitors
the real time status of the Kuper logic port. Run 'kuper.exe'.
This tool can be downloaded from http://seriss.com/opcs/ftp/
-------- a800card.doc -------
OPCS A800 CARD
==============
This card controls 8 axes and is a half sized IBM PC ISA card.
For complete info on this card, see: http://seriss.com/opcs/a800
*** A800 ***
_________________________________________________
| _____ __________ __________ A800 |
||16Mhz| | CPU2 | | CPU1 | REV-A1 |
||Xtal | |__________| |__________| ____|_
||_____| ____ 74HCT04 | | |
| | | ______ | | |
| |8255| |______| | | |
| | | ______ | | | DB-37
| BASE | | |______| | | | Connector
| ______ ADDR | | ______ | | |
| |______| :: IRQ | | |______| | | |
| _______ :: :: | | | | |
| |_______| :: :: |____| |____|_|
| :: :: |
|_________________________ ___|
|...................|
||||||||||||||||||||
DB-37 Connector (similar to Kuper):
PIN# SIGNAL PIN SIGNAL
--------------------------------
1 - N/C 20 - +5VDC
2 - STEP A 21 - DIR A
3 - STEP B 22 - DIR B
4 - STEP C 23 - DIR C
5 - STEP D 24 - DIR D
6 - STEP E 25 - DIR E
7 - STEP F 26 - DIR F (*) = JP3 configures DB37 Pin#19:
8 - STEP G 27 - DIR G "+5" - Makes Pin #19 +5 VDC
9 - STEP H 28 - DIR H "GND" - Makes Pin #19 GND (default)
10 - N/C 29 - N/C
11 - N/C 30 - N/C
12 - N/C 31 - N/C NOTE: When fitted with 74LS07 chips,
13 - N/C 32 - N/C outputs are OPEN COLLECTOR TTL.
14 - N/C 33 - N/C
15 - N/C 34 - N/C When those chips are replaced with
16 - N/C 35 - N/C 74ALS1034N, outputs swing a full
17 - N/C 36 - N/C +5/GND and are CMOS/TTL compatible.
18 - N/C 37 - N/C
19 - GND(*)
BASE ADDRESS (JP1)
==================
Closeup of the 'BASE ADDRESS' jumpers (JP1), which sets the base
address of the 8255 chip's I/O port registers:
___________
| BASE ADDR |
|___________|
| |
| 200 o o |
| 240 o o |
| 280 o o |
| 2C0 o o |
| 300 o o <-- Default jumper for 300 across these two pins
| 340 o o |
| 380 o o |
| 3C0 o o |
|___________|
JP1
A800 Base Address Jumpers
Always defer to the board's labeling (if any), as the board
designs may have changed since this document's writing (May 2020).
DEFAULTS:
This board has labels for the BASE ADDRESS and IRQs:
"300" is the default base address (5th pair of pins from top jumpered).
"IRQ5" is the default IRQ (4th pair of pins from top jumpered).
DB-37 OUTPUT SIGNALS
====================
The STEPS output are normally high (+5) during idle,
and fall low (GND) to pulse the motor a single step.
The outputs for DIR (direction) are logic hi (+5) for forward,
and logic low (GND) for reverse.
The output signals can either be CMOS hi/low levels, or can be
"open collector" (where logic 'hi' is 'open', and logic low is gnd).
Which it is depends on the chips installed in the three chip positions
to the left of the DB-37 connector on the A800 board:
74HCT04 -- CMOS high/low levels (default)
74LS07 -- Open Collector
For controlling the modern DM542 and FMD27400 motor drivers,
the 74HCT04 chips are recommended in these positions.
For Centent and Gecko drives, traditionally 74LS07 chips were used,
but will probably also work with the 74HCT04's.
While both chips work on all drives, analysis with an oscilloscope
monitoring the stepper drive inputs may reveal one chip is better
than the other for noise reduction. With 6' cables, 74HCT04 seems
the best choice.
Always defer to the board's silk screen labeling, as the board
designs may change since this document's writing (May 2020).
-------- pio-100.doc -------
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 parentheses 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 commands. An example
would be the LOAD command, which might run the motors by small amounts
to unseat the film, before deenergizing for manual adjustment.
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 real time 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 deenergizing 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 -
-------- sd-800.doc -------
NAME
sd-800 - OPCS 8 channel "stepper distribution" (SD) card
DESCRIPTION
The OPCS "Stepper Distribution" card (SD-800) was designed to
simplify wiring between the computer step pulse generator card
(e.g. RTMC16, RTMC48, Kuper Industrial, A800..) and the stepper
motor driver modules (Centent, Gecko, LeadShine, etc) by breaking
out the DB-37 connector into separate RJ-45 patch cables, one per
stepper drive channel.
This board really has no active features on it, other than a fanout
to simplify wiring. Optional pullup resistor networks can be used
if the application requires open collector outputs from the card
to be pulled up to +5V for the idle state to prevent noise.
As of this writing, there is only one version of the board, REV 0,
which looks like this:
DB-37 PORT
(To RTMC or A800 cards)
____________________
__________|____________________|_________
| | | |
| |____________________| |
| |
| |
| |
| |
| ______________________________ |
| | | |
| | A B C D | |
| |______________________________| |
| | | |
| | E F G H | |
|____|______________________________|_____|
\____________________________/
Eight RJ-45
Connectors
(Two Tiers)
Typically the female DB-37 connector on the board is connected
to the DB-37 connector on the ISA stepper pulse generator card
plugged into the the DOS computer using 6' male/male cable.
And separate RJ-45 patch cables are wired to the A/B/C/D..
ports at the bottom of the board, which run out to the individual
stepper drives (Centent, Gecko, LeadShine, etc).
The DB-37 follows Kuper's pinout; see 'man kuper' for more info.
The RJ-45 pinout diagram is on the board, but is basically:
RJ-45 WIRE CENTENT GECKO LEADSHINE
PIN# SIGNAL COLOR (*) DRIVE DRIVE DRIVE
---- ---------- -------- ----------- ----------- ------------
1 GND - N/C N/C N/C
2 GND - N/C N/C N/C
_ 3 GND - N/C N/C N/C
DIR | 4 DIRECTION BLU DIRECTION (8) DIR DIR-(DIR)
|_ 5 +5V WHT/BLU +5 VOLTS DC (10) COMMON DIR+(5V-24V)
_ 6 GND - N/C N/C N/C
STP | 7 +5V WHT/BRN N/C N/C PUL+(5V-24V)
|_ 8 STEPS BRN STEP PULSE (9) STEP PUL-(PUL)
(*) Premade RJ-45 patch cables for cat5 and cat5e usually have
the standard wire colors shown above. For the signals used,
the wiring colors are the same for 568A and 568B.
Basically only 4 of the 8 wires are used. In some cases only 3 wires
are used (Centent & Gecko).
Please note these signals are DIRECTLY FROM THE COMPUTER MOTHERBOARD,
so be very careful with them. Do not let them short to chassis ground
on the printer, or to each other.
RJ-45 CABLE TERMINATION
-----------------------
For unused (N/C) wires, be sure to isolate them from each other
to prevent shorts. Cut them short to the stripped insulation or
stagger the lengths of the unused wires to prevent the frayed
ends from shorting into each other.
Wrap the unused conductors with a small piece of heat shrink:
4 wires to
Drive Terminals
___________
/ \
▐▌ ▐▌ ▐▌ ▐▌ <-- tinned wire tips
▐▌ ▐▌ ▐▌ ▐▌
▒▒ ▒▒ ▒▒ ▒▒
▒▒ ▒▒ ▒▒ ▒▒ 4 unused wires
▒▒ ▒▒ ▒▒ ▒▒ _________
▒▒ ▒▒ ▒▒ ▒▒ / \
...▒▒.▒▒.▒▒.▒▒.................
: ▒▒ ▒▒ ▒▒ ▒▒ :
: ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ :
: ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ :
: ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ : <-- heat shrink wrap
: ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ ▒▒ :
:▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓:
:▓ ▓:
:▓ ▓:
:▓...........................▓:
▓ ▓
▓ RJ-45 ▓
▓ CABLE ▓ <-- RJ-45 outer insulation
▓ ▓
If heat shrink is not available, a blob of black liquid electrical
tape at the end of the cables outer insulation can be used instead:
4 wires to
Drive Terminals
___________
/ \
▐▌ ▐▌ ▐▌ ▐▌ <-- tinned wire tips
▐▌ ▐▌ ▐▌ ▐▌
▒▒ ▒▒ ▒▒ ▒▒
▒▒ ▒▒ ▒▒ ▒▒ 4 unused wires
▒▒ ▒▒ ▒▒ ▒▒ _________
▒▒ ▒▒ ▒▒ ▒▒ / \
::::▒▒:▒▒:▒▒:▒▒::::::::::::::::::
:::::▒▒:▒▒:▒▒:▒▒:::▒▒::::::::::::::
:::::▒▒:▒▒:▒▒:▒▒:::▒▒:▒▒:::::::::::
:::::▒▒:▒▒:▒▒:▒▒:::▒▒:▒▒:▒▒::::::::
::::::▒▒:▒▒:▒▒:▒▒:::▒▒:▒▒:▒▒:▒▒::::::
:::::▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓▓::::: <-- blob of "Liquid
:::::▓:::::::::::::::::::::::::::▓::::: Electrical Tape"
:::::▓:::::::::::::::::::::::::::▓:::::
::::▓:::::::::::::::::::::::::::▓::::
▓ ▓
▓ RJ-45 ▓
▓ CABLE ▓ <-- RJ-45 outer insulation
▓ ▓
Be sure the ends of the unused wires are well isolated from
the open air, and from each other during drying.
ISOLATE UNUSED RJ-45 CONDUCTORS
-------------------------------
Unused conductors on the SD-800 and SD-1600 are usually just the
chassis grounds, and are not critical to isolate from each other.
However, unused conductors on the PIO-800 Parallel Input/Output
boards are typically +5V and GND from the computer, and therefore
should be /carefully isolated/ from each other.
When wiring SD-800 and SD-1600 boards to the Centent or Gecko drives,
strip the two +5V signal wires and twist them together before tinning
with solder. Don't let one of the +5V signal wires hang loose,
because if it touches anything else, it will short the computer's
+5V supply, which at best reboots the machine, or at worst toasts
the computer's mother board.
STRIPPING RJ-45 CABLES
----------------------
When wiring to the screw clamp terminals, tin the wires (if they're
stranded) before inserting them, to prevent wire fraying and shorts
from stray pieces of stranded wire.
When tinning stranded wire, first twist the strands into a spiral,
then dip the twisted strands into some flux. This way when solder is
applied, the extra flux helps the solder wick down the conductors
beneath the insulation, stiffening the conductors beyond insulation's
edge, preventing flexion at the end of the wire.
Tinning will also cover over any nicks in the conductors that may
have occurred during wire stripping with solder, stiffening the nicks,
preventing fatigue:
BEFORE Solder Tinning
---------------------
████
████
████
████
████
██¡ <-- copper conductor "nicked"
████ during insulation stripping
▒▒▒▒▒▒▒▒▒▒
▒▒▒▒▒▒▒▒▒▒
▒▒▒▒▒▒▒▒▒▒ <-- single conductor
▒▒▒▒▒▒▒▒▒▒ insulation
▒▒▒▒▒▒▒▒▒▒
AFTER Solder Tinning
--------------------
████
████
████
████
████
████ <-- "nick" covered by solder
████
▒▒▒▒▒▒▒▒▒▒
▒▒▒▒▒▒▒▒▒▒ <-- solder wicked down wire
▒▒▒▒▒▒▒▒▒▒ below insulation edge
▒▒▒▒▒▒▒▒▒▒
▒▒▒▒▒▒▒▒▒▒
RJ-45 STRAIN RELIEF
-------------------
Don't let the cables hang by their screw terminals at motor drives
and/or termination at home sensors. Casual wire flexion will cause
wire fatigue, leading to breakage or intermittent signal dropouts.
Secure cables to the chassis or drive units by their insulation
within approx 6" of the wire termination point using zip ties or
nylon straps/cleats.
-------- sd-1600.doc -------