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 realtime 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 labelling, 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 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 - ♀ -------- 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. For N/C (X) wires, be sure to isolate them from each other to prevent shorts. Either cut them to different lengths as shown below, and tape or heat shrink them to protect them from each other: Wires to Drive Terminals ___________ / \ || || || || || || || || Unused wires || || || || _________ || || || || / \ ...||.||.||.||................. . || || || || . . || || || || || . . || || || || || . . || || || || || || . . || || || || || || . <-- heat shrink wrap . || || || || || || || . . || || || || || || || . . || || || || || || || || . . _||_||_||_||___||_||_||_||_ . .| |. .| |. .|...........................|. | | | RJ-45 | | CABLE | | | Ensure there's enough difference in the wire lengths so that there's no way for their cut ends to touch each other, as the conductors at the cuts are still live. Or, cut the wires close to the cable shield, splay them apart, and put a large blob of liquid electrical tape over them to isolate them. When wiring the Centent or Gecko's, be EXTRA careful with the unused +5V signal wire (WHT/BRN). You don't want that shorting out to ANYTHING, or the entire computer's 5V supply will shut down, causing the machine to reboot (if you're lucky) or blow its internal fuse or worse. So BE CAREFUL with that. When wiring to the screw clamp terminals, I advise tining the wires (if they're stranded) before inserting them, to prevent wire fraying and shorts from stray pieces of stranded wire. Use heat shrink to prevent wire fatigue at the screw terminal points, and use nylon tie downs to also prevent wire motion at the screw terminals. ♀ -------- a800card.doc ------- SUPERIOR ELECTRIC 6 WIRE SLO-SYN INTERNAL WIRING DIAGRAM Centent and Anaheim terminals shown To rotate the motor, energize coils sequentially in the following order: P1, P2, P3, P4... I know it looks wrong, but that's how it works. ANAHEIM **CENTENT** **CENTENT** ANAHEIM (LO) (HI) (LO) (HI) P1 6 6 RED ------O O------- G/W 3 x P4 > < > P1 P4 < > < P1&P3 x 5 BLK ------O O------- WHT x 3 P2&P4 > < > P3 P2 < > < P3 5 x R/W ------O O------- GRN 4 4 P2 SUPERIOR ELECTRIC 8 WIRE SLO-SYN INTERNAL WIRING DIAGRAM Centent and Anaheim terminals shown ANAHEIM **CENTENT** **CENTENT** ANAHEIM (LO) (HI) (LO) (HI) P1 6 6 G/W ------O O------- R/W 4 4 P4 > < > P1 P4 < > < P1&P3 (ORN) 5 B/W ------O O------- WHT (BLK) 3 P2&P4 P1&P3 5 5 GRN ------O O------- BLK (WHT) 4 P2&P4 > < > P3 P2 < > < P3 (B/W) 6 ORN ------O O------- RED 3 3 P2 ♀ -------- connector.doc ------- *************** SUPERIOR ELECTRIC ************************ *************** 6 WIRE MOTOR CONNECTOR PINOUT ************************ AMPHENOL (MILITARY STYLE) CONNECTOR WIRING Superior Electric, Astrosyn, Anaheim, Rapidsyn BACK OF MALE N O T C H RED | | BLK o |_| o WHT o o o WHT/GRN N.C. o o WHT/RED GRN 6 PIN NYLON (MEDIUM DUTY) RADIO SHACK CONNECTOR Superior Electric, Astrosyn, Anaheim, Rapidsyn BACK OF MALE ________________ / | / GRN WHT | | | | / | \ | | | G/W BLK | | | | / | \ | | \ WHT RED | \_______________| Back of Male *************** SUPERIOR ELECTRIC ************************ *************** 8 WIRE MOTOR CONNECTOR PINOUT ************************ AMPHENOL (MILITARY STYLE) CONNECTOR WIRING Superior Electric, Astrosyn, Anaheim, Rapidsyn BACK OF 8 WIRE MALE BACK OF 6 WIRE MALE N O T C H N O T C H G/W | | B/W & ORN RED | | BLK o |_| o o |_| o BLK & WHT o o o R/W WHT o o o WHT/GRN N.C. N.C. o o o o GRN RED WHT/RED GRN *************** CENTENT MOTOR DRIVE ******************** *************** 8 WIRE MOTOR CONNECTOR PINOUT ******************** AMPHENOL (MILITARY STYLE) CONNECTOR WIRING Superior Electric, Astrosyn, Anaheim, Rapidsyn Centent terminals shown BACK OF FEMALE SERIES (LOW POWER) PARALLEL (HIGH POWER) N O T C H N O T C H x | | 5 6 | | 5 o |_| o o |_| o 3 o o o x x o o o 3 N.C. N.C. o o o o 4 6 4 x 6 PIN NYLON (MEDIUM DUTY) RADIO SHACK CONNECTOR BACK OF FEMALE CONNECTORS Centent Terminals Shown FULL WINDING (LO POWER) HALF WINDING (HI POWER) ________________ ________________ | \ | \ | 4 5 \ | 4 X \ | | | | \ | \ | / | / | | | | | | 3 X | | X 5 | | | | | \ | \ | / | / | | | | | | X 6 / | 3 6 / |______________/ |______________/ Back of Female Back Of Female ♀ -------- centent.doc ------- CENTENT MOTOR WIRING -------------------- These pinouts are straight out of the Centent CNO143 manual. Quothe the Centent docs: "One motor winding connects to T3 and T4, while the other winding connects to T5 and T6. The step motor drive will operate 4, 6, and 8 wire motors. The 6 and 8 wwire motors may be wired in either a series (low power) or parallel (hi power) configuration. For 8 wire motors, follow the manufacturer's hookup diagrams for series or parallel operation." (See below) In the following table, T3, T4, T5 and T6 refer to the numbered terminals on the drive. Colors indicate the wire colors that come off the motor shown. *** SERIES WIRING - CNO-143 *** Manufacturer T3 T4 T5 T6 ----------------- ------- ------- ------- ------- Superior Electric GRN/WHT GRN RED RED/WHT Rapidsyn GRN/WHT GRN RED RED/WHT IMC GRN/WHT GRN RED RED/WHT Sigma YEL RED BLK ORN Oriental Motor BLU RED BLK GRN Portescap YEL/WHT RED ORN/WHT BRN Bodine YEL RED BRN ORN Digital Motor YEL RED BLK ORN Warner RED YEL ORN BRN Japan Servo YEL GRN BLU RED *** PARALLEL WIRING - CNO-143 *** Manufacturer T3 T4 T5 T6 ----------------- ------- ------- ------- ------- Superior Electric WHT GRN RED BLK Rapidsyn WHT GRN RED BLK IMC WHT GRN RED BLK Sigma RED/YEL RED ORN/BLK ORN Oriental Motor BLU WHT YEL GRN Portescap RED/WHT RED ORN/WHT ORN Bodine RED/WHT RED ORN/WHT ORN Digital Motor RED/WHT RED BLK BLK/WHT Warner RED WHT ORN BLK Japan Servo WHT GRN BLU WHT ♀ FIELD WIRING NOTES ------------------ These are actual wiring diagrams I've used in the field. These are NOT from the Centent docs; use at own risk. Although these work, double check manufacturer's recommended wiring; see SLOSYN(DOCS) man page ('man slosyn') for info. *** SERIES (LO POWER) *** *** CENTENT CNO-143 WIRING *** Superior Ele. Centent Superior Ele. 8 wire motor CNO-143 6 wire motor ------------ ------- ------------ wht/grn 3 wht/grn grn 4 grn red 5 red wht/red 6 wht/red (*) wht & blk NOT CONNECTED blk (*) wht/blk & orn NOT CONNECTED wht *** PARALLEL (HI POWER) *** *** CENTENT CNO-143 WIRING *** Superior Ele. Centent Superior Ele. 8 wire motor CNO-143 6 wire motor ------------ ------- ------------ (*) wht/blk & orn 3 wht grn 4 grn red 5 red (*) wht & blk 6 blk wht/grn x wht/grn wht/red x wht/red (*) 8 WIRE NOTE: With 8 wire connections, WHT and BLK are tied together, but are not connected to the drive. Also, WHT/BLK and ORN are similarly tied together. The following tables are for Superior Electric motors, and pretty much re-iterate the Centent docs, albeit clearer to my eyes: FULL WINDING (LO POWER) HALF WIRING (HI POWER) __________________________ __________________________ | | CENTENT | MOTOR | | | CENTENT | MOTOR | | | DRIVE | WIRE | | | DRIVE | WIRE | | PHASE | TERMINAL | COLOR | | PHASE | TERMINAL | COLOR | |-------|----------|-------| |-------|----------|-------| | "A" | 3 |GRN/WHT| | "A" | 3 | WHT | | "B" | 4 | GRN | | "B" | 4 | GRN | | "C" | 5 |RED/WHT| | "C" | 5 | BLK | | "D" | 6 | RED | | "D" | 6 | RED | |_______|__________|_______| |_______|__________|_______| ♀ -------- gecko.doc ------- GECKO MOTOR WIRING -------------------- Excerpts from Gecko 201 manual and other sources for actual wire colors. Motors rated phase current: 0.3 AMP - 7 AMP. Power supply voltage should be between 4x and 20x the motor rated voltage. The current set resistor may be 1/4W, 5%. Current set resistor goes across T11 and T12. Values: _______________________________________________________ | HEATSINK OPTIONAL | HEATSINK REQUIRED | |----------------------------|--------------------------| | MOTOR RESISTOR | MOTOR RESISTOR | | CURRENT VALUE | CURRENT VALUE | | ------- -------- | ------- -------- | | 1.0 AMP 7.8K | 4.0 AMP 62.7K | | 1.5 AMP 12.8K | 4.5 AMP 84.6K | | 2.0 AMP 18.8K | 5.0 AMP 117.5K | | 2.5 AMP 26.1K | 5.5 AMP 172.3K | | 3.0 AMP 35.2K | 6.0 AMP 282.0K | | 3.5 AMP 47.0K | 6.5 AMP 611.0K | | | 7.0 AMP OPEN | |____________________________|__________________________| _____________________________________________________________________ | Gecko 201 Terminal Arrangement | |---------------------------------------------------------------------| | Terminal# | Description | |-----------|---------------------------------------------------------| | T1 | Supply Ground | | T2 | Supply Power (+) (+18VDC to +80VDC) | | T3 | Phase A | | T4 | Phase B | | T5 | Phase C | | T6 | Phase D | | T7 | Disable windings (when connected to ground T12) | | T8 | Direction (ground-going signal relative to +5V common) | | T9 | Step (ground-going signal relative to +5V common) | | T10 | +5V Common | | T11 | Current set resistor | | T12 | Current set resistor (ground) | |___________|_________________________________________________________| Use heat sinks for current settings above 3 amps. Drive should be heatsinked to a piece of aluminum, preferably with fins and a fan to increase heat dissipation and surface area. GECKO OPTION JUMPERS -------------------- 1 2 3 4 .------------. > Jumper pins 2 and 6 for STANDBY ENABLED | o o o o | > Jumper pins 1 and 5 for STANDBY DISABLED | o o o o | > Leave all pins open for LOW CURRENT RANGE `------------' > Jumper pins 3 and 7 for SIZE 42 MOTOR 5 6 7 8 > Jumper pins 4 and 8 for MID-BAND DISABLED > Jumper pins 7 and 8 for NORMAL (DEFAULT) ♀ GECKO COMPUTER CONNECTIONS -------------------------- On the Kuper cards and A800 boards, connect STEPS to T9, DIRECTION to T8, and +5v from card (pin 20) to T10, e.g. Kuper RTMC/A800 Pin Gecko Drive Terminals ------------------- --------------------- 1 (no connection) 2 (A-Step) T9 for channel A 3 (B-Step) T9 for channel B 4 (C-Step) T9 for channel C : : : etc etc etc : : : 20 (+5VDC) T10 on ALL GECKO DRIVES 21 (A-Dir) T8 for channel A 22 (B-Dir) T8 for channel B 23 (C-Dir) T8 for channel C : : : etc etc etc : : : GECKO MOTOR CONNECTIONS ----------------------- In the following table, T3, T4, T5 and T6 refer to the numbered terminals on the drive. Colors indicate the wire colors that come off the motor. NOTE: These are derived from Centent docs, which /should/ be compatible. From what I could find, Gecko doesn't provide diagrams showing wire colors, but they seem to be terminal compatible with the Centent drives (which does). ********* GECKO 201 - SERIES WIRING - 6 WIRE ********* Manufacturer T3 T4 T5 T6 ----------------- ------- ------- ------- ------- Superior Electric GRN/WHT GRN RED RED/WHT Rapidsyn GRN/WHT GRN RED RED/WHT IMC GRN/WHT GRN RED RED/WHT Sigma YEL RED BLK ORN Oriental Motor BLU RED BLK GRN Portescap YEL/WHT RED ORN/WHT BRN Bodine YEL RED BRN ORN Digital Motor YEL RED BLK ORN Warner RED YEL ORN BRN Japan Servo YEL GRN BLU RED ********* GECKO 201 - PARALLEL WIRING - 6 WIRE ********* Manufacturer T3 T4 T5 T6 ----------------- ------- ------- ------- ------- Superior Electric WHT GRN RED BLK Rapidsyn WHT GRN RED BLK IMC WHT GRN RED BLK Sigma RED/YEL RED ORN/BLK ORN Oriental Motor BLU WHT YEL GRN Portescap RED/WHT RED ORN/WHT ORN Bodine RED/WHT RED ORN/WHT ORN Digital Motor RED/WHT RED BLK BLK/WHT Warner RED WHT ORN BLK Japan Servo WHT GRN BLU WHT ♀ ***************** 4-WIRE MOTOR ***************** ***************** WIRING DIAGRAM ***************** The following diagram shows the motor wiring for a 4 wire stepper motor. (GECKO T3) (GECKO T4) WHT/BLK BLK o o | | ::::|:::::::::::::::::::::::|:::: :: | .-----. | :: :: | | | | :: :: `vvvvvvvv' `vvvvvvvv' :: /| :: :: / | :: PHASE A ::_________ / | :: :: | /___| :: ::_________| | :: PHASE B :: | :: :: ----- :: .^^^^^^^^. .^^^^^^^^. :: WIRES :: | | | | :: :: | `-----' | :: ::::|:::::::::::::::::::::::|:::: | | o o WHT/RED RED (GECKO T6) (GECKO T5) ♀ ***************** SUPERIOR ELECTRIC MOTOR ***************** ***************** 6-WIRE - SERIES ***************** ***************** WIRING DIAGRAM ***************** The following diagram shows the SERIES "low power" motor wiring for for a Superior Electric 6 wire motor. (GECKO T3) n/c (GECKO T4) GRN/WHT WHT GRN o o o | | | ::::|:::::::::::|:::::::::::|:::: :: | .--O--. | :: :: | | | | :: _ :: `vvvvvvvv' `vvvvvvvv' :: / \ :: :: | _ :: PHASE-A PHASE-B ::_________ |/ \ :: ::_________| | | :: PHASE-D PHASE-C :: \_/ :: :: ----- :: .^^^^^^^^. .^^^^^^^^. :: WIRES :: | | | | :: :: | `--O--' | :: ::::|:::::::::::|:::::::::::|:::: | | | o o o RED/WHT BLK RED (GECKO T6) n/c (GECKO T5) ***************** SUPERIOR ELECTRIC MOTOR ***************** ***************** 6-WIRE - PARALLEL ***************** PARALLEL "high power" wiring for a Superior Electric 6 wire motor. WHT .----------------------- GECKO T3 n/c | GRN/WHT | ,----------- GECKO T4 | | | GRN ::::|:::::::::::|:::::::::::|:::: :: | .--O--. | :: :: | | | | :: _ :: `vvvvvvvv' `vvvvvvvv' :: / \ :: :: | _ :: PHASE-A PHASE-B ::_________ |/ \ :: ::_________| | | :: PHASE-D PHASE-C :: \_/ :: :: ----- :: .^^^^^^^^. .^^^^^^^^. :: WIRES :: | | | | :: :: | `--O--' | :: ::::|:::::::::::|:::::::::::|:::: | | | RED RED/WHT | `----------- GECKO T5 n/c | `----------------------- GECKO T6 BLK ♀ ***************** SUPERIOR ELECTRIC MOTOR ***************** ***************** 8 WIRE - SERIES ***************** SERIES "low power" wiring for a Superior Electric 8 wire motor. Tie WHT/YEL + WHT/RED together, isolate. .----------------------------------- GECKO T3 | .---. .----------- GECKO T4 | WHT | | WHT | YEL | YEL | | RED | RED o o o o _ :::::|:::::::::|:::|:::::::::|:::: / \ :: | | | | :: | | :: `vvvvvvvvv' `vvvvvvvvv' :: \_/ :: PHASE A PHASE B ::______ / \ :: ::______| | | :: PHASE D PHASE C :: | | :: .^^^^^^^^^. .^^^^^^^^^. :: \_/ :: | | | | :: ----- :::::|:::::::::|:::|:::::::::|:::: WIRES o o o o ORN | WHT | | WHT | BLK | ORN | | BLK | | `---' `----------- GECKO T5 `----------------------------------- GECKO T6 Tie WHT/ORN + WHT/BLK together, isolate. ***************** SUPERIOR ELECTRIC MOTOR ***************** ***************** 8 WIRE - PARALLEL ***************** PARALLEL "high power" wiring for a Superior Electric 8 wire motor. Tie YEL + WHT/RED together, connect to T3 Tie RED + WHT/YEL together, connect to T4 .-------------O===================== GECKO T3 | | | .---|---------O=========== GECKO T4 | | | | | WHT | | WHT | YEL | YEL | | RED | RED o o o o _ :::::|:::::::::|:::|:::::::::|:::: / \ :: | | | | :: | | :: `vvvvvvvvv' `vvvvvvvvv' :: \_/ :: PHASE A PHASE B ::______ / \ :: ::______| | | :: PHASE D PHASE C :: | | :: .^^^^^^^^^. .^^^^^^^^^. :: \_/ :: | | | | :: ----- :::::|:::::::::|:::|:::::::::|:::: WIRES o o o o ORN | WHT | | WHT | BLK | ORN | | BLK | | | | | | `---|---------O=========== GECKO T5 | | `-------------O===================== GECKO T6 Tie ORN + WHT/BLK together, connect to T5 Tie BLK + WHT/ORN together, connect to T6 ♀ -------- anaheim.doc ------- ======================================== = A N A H E I M A U T O M A T I O N = = C O N N E C T O R W I R I N G = = (2-AXIS & 6-AXIS DRIVER PACK WIRING) = ======================================== BACK OF FEMALE NYLON CONNECTOR __________ / | (PHASE2 & 4 COM) 11 | O O | 1 (PHASE 1) | / | \ (PHASE 4) 13 | O O | 3 (PHASE1 & 3 COM) | / | \ (PHASE 2) 12 | O O | 2 (PHASE 3) \_________| ======================================== = A N A H E I M A U T O M A T I O N = = C O N N E C T O R W I R I N G = = (4 AXIS DRIVER PACK ONLY!) = ======================================== BACK OF FEMALE NYLON CONNECTOR __________ / | (PHASE2 & 4 COM) 9 | O O | 1 (PHASE 1) | / | \ (PHASE 4) 11 | O O | 3 (PHASE1 & 3 COM) | / | \ (PHASE 2) 10 | O O | 2 (PHASE 3) \_________| ♀ -------- ciodio24.doc ------- --------------------------------------- CIO-DIO24 Male DB37 --------------------------------------- (LEFT ROW) (RIGHT ROW) Pin Description Pin Description --- ----------- --- ----------- 19 GND |\ 37 A0 18 +5 | \ 36 A1 17 GND | | 35 A2 16 +12 | | 34 A3 15 GND | | 33 A4 14 -12 | | 32 A5 13 GND | | 31 A6 12 -5 | | 30 A7 11 GND | | 29 B0 10 B0 | | 28 B1 9 B1 | | 27 B2 8 B2 | | 26 B3 7 B3 | | 25 B4 6 B4 | | 24 B5 5 B5 | | 23 B6 4 B6 | | 22 B7 3 B7 | | 21 GND 2 IR/ENA | / 20 +5 1 IR/IN |/ CIO-DIO24 DIP SWITCH (PORT BASE ADDRESS SET) -------------------------------------------- Default setting is '300' for the dip switches; 9 & 8 down. Switches are active when in the 'down' position. 9 8 7 6 5 4 3 2 1 .------------------------------. | _ _ _ _ _ _ _ | | | | [_][_][_][_][_][_][ ] | | | | | | | | | | | | | [_][_] | | | | | | | | |______________________________| | | | | | | | | | | | | | | | | | N/A | | | | | | | N/A | | | | | | +80 | | | | | +10 | | | | +20 | | | +40 | | +80 | +100 +200 ORIGIN If you encounter errors in this documentation, please send email to erco@seriss.com.