MACHINE CONTROLLER

INTRODUCTION

CHAPTER 6 MACHINE CONTROLLER

INTRODUCTION
The machine control electronics enclosure houses the MultiMove and Dual
Stepper driver cards for the machine stepper and servo motors, the Multiplexer
card used to route signals to and from nonalignment dependent axes and all the
interfaces used in upline and down line communication.
Signals are routed either through one of the five breakout boards PCB A-E to
the relevant device or directly wired to the device. Where breakout boards are
used, the signal paths can be followed for test purposes.
Central to the control function is the NextMove card, this is housed in the PC
enclosure, it is used as the primary machine controller leaving the PC microproc-
essor free to perform general operating system and peripheral control tasks.
Purpose Collectively, this module provides all machine control. Feedback from a variety
of sensors is communicated to the software control program and enables activa-
tion of output devices such as motor brakes, solenoids and position fixing
actuators and motors.

Elements The chief components of machine control are listed below:

• NextMove Controller Card

• Servo/Stepper Drive Cards
• MultiMove Cards
• Multiplexer and Supplies Monitor Card
• Control Enclosure Backplane
• Connector Panel
CAUTION
ANTI-STATIC HANDLING. Standard precautions must be adhered to
when handling electronic cards and configuring and inserting into the
enclosures.

Chapter Issue 5 Apr 02 Technical Reference Manual 6.1

6.2

ELECTRICAL SCHEMATIC

ELECTRICAL SCHEMATIC
MACHINE CONTROLLER
Machine
Controller MIU
MultiMove Lane A/
Backplane or
Lane B
FMI Pod
MultiMove MultiMove
Slot X13 Totem O/P’s M 24Vdc Motors
16 Input/Output
8 Totem
Sensors
Beacon
Table Brake
Solenoids
Clamps
Figure 6-1 Control Enclosure Schematic

MultiMove
Machine PC
Slot X12
16 Input/Output
8 Totem
Technical Reference Manual

NextMove
PC Card CAN BUS
Single 24 Inputs 100
Board ISA BUS 12 Outputs Servo Demand Servo/ Stepper
Computer Dual Port RAM
Backplane
Machine Control
MUX Axis Home Encoder
Program Store M Home
(512K RAM) Servo Motors
Encoders
Servo Drive
Cards
Step 3
Dir 1
24V Stepper Motors
Dual/Single
Stepper Drive Coarse Fine
M
NextMove Paste Disp, Rear Sqy Cards Home Home
Step Front Sqy, Moving Rail
Breakout Dir MUX/Supplies
MonitorCard
MUX Homes
Y, X Forward, X Rear
Chapter Issue 5 Apr 02

Stepper Motor Drive Servo Motor Drive 24Vdc Motor Drive

NOTE Paste Dispenser X Forward Actuator Rising Table Paste Dispenser Tilt
The NextMove card is housed in the machine PC enclosure. Rear Squeegee X Rear Actuator Camera X Carriage Screen Cleaner
The NextMove provides the machine controller functions Front Squeegee Y Actuator Print Carriage Transport Belt Front
and direct control of some aspects of running the machine, Moving Rail Camera Y Carriage Transport Belt Rear
it is described in this chapter.
 MACHINE CONTROLLER
ELECTRONICS ENCLOSURE

ELECTRONICS ENCLOSURE

MultiMove Backplane NextMove Breakout

MultiMove
MMX12 (IN 8-F)

MMX11 (IN 8-F)

M19SK04

M19SK05
M19SK01
MIU ‘A’

M19SK28

M19SK40
M19SK34
M19PL24
M19SK22
MMX12 (IN 0-7)

M19SK29

M19SK35
A

M19SK41
MMX11 (IN 0-7)

12
X
M19SK06
M19SK03
M19SK02

M19SK07
MMX13
MIU ‘B’

M19SK42
M19SK30

M19SK36
M19SK23 M19SK25

M19SK31
M19SK19

M19SK43
M19SK13

M19SK37
M19SK08 M19SK14
M19SK27

M19SK15
M19SK09 M19SK20
M19SK32

M19SK44
M19SK38
M
19
SK
12
M19SK16
M19SK10 19
M
SK
11
M19SK26

1
M19SK17 X
M19SK21

M19SK45
M19SK39
M19SK33

8
M19SK12 MODEL X
M19SK11
BATCH NO
BATCH
M19SK18
CENTRE 6
X

4
X

Rear Connector Panel

2
X

(Next Move Breakout and

MultiMove Backplane at Rear)

X11A X12A X13A

MUX SUPPLIES MONITOR

DUAL STEPPER DRIVE

DUAL STEPPER DRIVE

MULTIMOVE X11A(24V SW) - IF FITTED

SERVO AMP

MULTIMOVE X12A(24V SW)

SERVO AMP

MULTIMOVE X13A(24V US)

Control Enclosure
X1 X3 X5 X7 X9

X11B X12B X13B

DUAL STEPPER DRIVE

DUAL STEPPER DRIVE

MULTIMOVE X11B(24V SW) - IF FITTED

MULTIMOVE X13B(24V US)

SERVO AMP

SERVO AMP

MULTIMOVE X12B(24V SW)

X2 X4 X6 X8 X10

M19 Backplane
(Viewed from Front of Enclosure)

Card Rack

Figure 6-2 Electronics Enclosure Layout

NOTE
1. The Electronics Enclosure is housed in the machine in a slider mechanism,
the enclosure can be pulled forward and hinged down for ease of access.
2. The Rear Connector Panel can be folded down for access to the M19
backplane.

CAUTION
ANTI-STATIC HANDLING. Standard precautions must be adhered to
when handling electronic cards and configuring and inserting into the
enclosures.

Chapter Issue 5 Apr 02 Technical Reference Manual 6.3

MACHINE CONTROLLER
ELECTRONICS ENCLOSURE

Card Placement
Designation Card Function Axis
(Slot)
X1 MUX Supplies Stepper motor drives, axis home signals
Monitor and supplies monitor function
X2 Spare Spare
X3 Dual Stepper Stepper drive to the X fwd and X rear 4, 5
alignment actuator motors
X4 Dual Stepper Stepper drive to the rear squeegee and 7 MUX-1
the moving rail motors
X5 Dual Stepper Stepper drive to the Y alignment actua- 6, 7 MUX-1
tor and the front squeegee motors
X6 Single Stepper Single Stepper drive to the paste dis- 7 MUX-1
(see Note) penser motor
X7 Servo Drive Rising table servo motor 0
X8 Servo Drive Camera X servo motor 2
X9 Servo Drive Print carriage servo motor 1
X10 Servo Drive Camera Y servo motor 3
X11 MultiMove Spare
(switched)
X12 MultiMove Control of inputs/outputs
(switched)
X13 MultiMove Control of inputs/outputs
(unswitched)

NOTE
Dual Stepper Card (X6) is configured to drive a single stepper motor.

X1 X3 X5 X7 X9

X2 X4 X6 X8 X10 X11 X12 X13

Card Rack (Front)

Figure 6-3 Card Designations

6.4 Technical Reference Manual Chapter Issue 5 Apr 02

Chapter Issue 5 Apr 02

NextMove Connections
EXTERNAL CONNECTIONS
MultiMoves NextMove
Relay
Software E-Stop in slots X12 and X13 M19PL15
NextMove Breakout
M19SK12 M19SK11
M19SK18 CAN 2
CAN 3
2 2 CAN 1 50

2
M19SK16
Figure 6-4 NextMove External Connections

3 NextMove 100 Way Connector

Technical Reference Manual

PL16 DIG IN 0 - 23 50
M19SK10 M19SK08
PL31 M19PL17
M19SK09 NextMove Breakout
Servo Stepper

M19SK19 M19SK20 M19SK14 M19SK13

25 25 25

EXTERNAL CONNECTIONS
MACHINE CONTROLLER
8PL32 10PL06 8PL18 10PL05
PCB B Breakout PCB A Breakout
Print Camera Rising Camera
Carriage X Table Y
Encoder Encoder Encoder Encoder

Vacuum Tooling Board Position Hall Effect and

Table Brake Sensors Through Beam
Paste Disp. Sol Lane A/B Opto Switches
6.5
MACHINE CONTROLLER
NEXTMOVE CARD

NEXTMOVE CARD
The NextMove card is a PC bus motion controller that utilizes a Digital Signal
Processor for executing the C instruction language set (The motion control
program). The card controls all motion and input/output for the machine,
leaving the main machine processor free to run the MMI and provide peripheral
interface.
The card sits on the ISA bus of the PC in slot ISA 10 and has the control program
downloaded to it during system boot-up. This program directly controls the
main axes and I/O lines of the machine and indirectly controls the two Multi-
Move cards via a Controller Area Network (CAN).
NextMove controls; four servo axes with 12 DAC demand outputs and incre-
mental encoder feedback; four stepper motor axes, three of which are utilized to
provide precision alignment the fourth output is multiplexed giving serial con-
trol of a further five motors.
There are several digital or analog input/output signals that are used in the
control function which are routed through and controlled by the NextMove card.

4 Servo
Amp Demands 4 NextMove
4 Axes of
Closed Loop
Motion Controller
4 Incremental Servo Control
Encoders 4
ISA/ PCI Communication
Bus Interface via
4 Step and PISA Bus
Direction Signals
to Control 4 Axes of
4 Stepper
Stepper Drives
Motors
3 Direct, 1 Via MUX

32 Bit Digital
Signal Processor
System
12 Digital Outputs CAN Bus Industrial Control
12 12
Opto-isolated Network Local Area Network
Digital
Drive Enable Relay Outputs

24 Digital Inputs
Opto-isolated 24 24 512K RAM
Hardware Position Digital (Motion Control
Inputs Program Storage)
Latch and Fast
Serial High Speed Card to
Interrupt Input
Ports Card Data Transfer

4 x 12 Bit 4
Differential 4 Analog
Analog Inputs Inputs

Figure 6-5 NextMove Card Overview

6.6 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
NEXTMOVE CARD

NextMove Card Configuration

The NextMove card bit switch and jumper settings are shown below:

Figure 6-6 NextMove Card Set Up

Chapter Issue 5 Apr 02 Technical Reference Manual 6.7

MACHINE CONTROLLER
NEXTMOVE CARD

Safety Features The NextMove card incorporates many safety features:

• A Limit Error signal is generated at the end of travel limits.

• The maximum permissible following error, before cutting power to the
motors, can be pre-set.
• A Control Stop input is used to bring all axes to a controlled stop.
• An External Error input is used to bring all axes to a quick stop, ie E Stop.
• The system watchdog (Jumper L) resets the processor in the event of a
major operating firmware malfunction.
Change-over Relay A change-over relay which is energized under software control is included on
the NextMove card to provide a volt free contact, it is used to provide the
software controlled E Stop. The relay is controlled by a latch which is cleared
during reset of the card. Reset occurs on power down, watchdog error or under
control of the PC. Reset is indicated by all three LEDs being illuminated at the
same time.

6.8 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
NEXTMOVE CARD

NextMove Block Diagram

PC
Single Board Computer

ISA BUS

Motion Control Dual Port RAM

‘C’ Program Storage NextMove
512K RAM

NextMove Breakout

MUX Control Axis Homes

Servo Demand

CAN
Servo Drive MultiMove X12 MultiMove X13

MultiMove Backplane
Axis 0 - 3

MIU
or Upline/Downline Sensors
FMI Pod
MUX/Monitor I/O

Servo Motor Digital Switches, Interlocks, Error

Encoders Sensors

Figure 6-7 NextMove Block Diagram

CAUTION
ANTI-STATIC HANDLING. Standard precautions must be adhered to
when handling electronic cards and configuring and inserting into the
enclosures.

Chapter Issue 5 Apr 02 Technical Reference Manual 6.9

MACHINE CONTROLLER
NEXTMOVE CARD

Analog to Digital Analog inputs are fed to MAX 180 devices, an eight channel, twelve bit
Converter multiplexed analog to digital converter. The NextMove card is capable of
operating with either a bipolar input voltage or a unipolar input voltage and
selection of this feature is made under software control.

+V

+Signal In
Digital MAX 180 Analog In
Out
Out ADC
-Signal In

-V

NextMove Differential
NextMove Card Sensor
Breakout Amplifier

Figure 6-8 Sample ADC Circuit

Digital Inputs The digital inputs are selected as opto-isolated NPN circuits. The signal must
be present for a minimum of 1ms (one software scan) for the input to be accepted
by the application program.
An example of a digital input is shown below:

Hall Effect (Home) Switch NextMove Digital Input

Control V+ 12V V+ (User)

Circuit
12V 2K
Signal 0V

0V

Opto-Isolator
0V

Figure 6-9 Digital Input Sample

6.10 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
NEXTMOVE CARD

Digital Outputs The twelve digital outputs are opto-isolated open collector type arranged as a
bank of eight and a bank of four. The bank of eight are NPN Darlington pairs,
the bank of four are FET’s which supply the servo enable control of the servo
drive cards and the stepper MUX control signals.
An example of a servo enable control digital output is shown below:

NextMove Card
12V
User V+
Enable In Enable Out
Link **
Z LED LED
ENABLE
IC

FET * * For the bank of 8, an NPN Darlington Pair is used instead

of an FET.
** For the bank of 8, Link Z is replaced with Link X, which is Load
not fitted enabling the voltage at the collector to be
different than 12V.
User Gnd

+10V Demand
44V 44V
AC2 AC1
NextMove
-10V

Servo 0 Demand +VE +VE

Encoder
Servo 0 Demand -VE
Servo Drive M
Dig O/P Servo 0 Enable
(FET)
Servo 0 Error -VE
Dig I/P
Servo 0
Input

Com
U 37
ULN 2803
1
U 38
ZYXW

FET
Daughterboard

Part of NextMove Card

Figure 6-10 Digital Output Sample

Chapter Issue 5 Apr 02 Technical Reference Manual 6.11

MACHINE CONTROLLER
NEXTMOVE CARD

Servo Loop The servo motor demands are ±10V outputs buffered by operational amplifiers
(Analog Outputs) which are not opto-isolated. The voltage outputs are arranged in four groups.
These are routed to their respective servo drive cards to drive individual motors.
An example of the servo loop connection is shown below:

+10V Demand
44V 44V
AC2 AC1
NextMove
-10V

Servo 0 Demand +VE +VE

Encoder
Servo 0 Demand -VE
Servo Drive M
Dig O/P Servo 0 Enable
(FET)
Servo 0 Error -VE
Dig I/P

Servo 0
Input

Servo Loop Block Diagram

Figure 6-11 Typical Servo Loop Connection

6.12 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
NEXTMOVE CARD

Stepper Motor The stepper motor demand outputs are digital output drivers which are opto-
Outputs isolated. The outputs are arranged in four groups for the three positional axis
drives and the fourth output is used in the multiplexer drive circuit.
Their functions are as follows:

• STEP Step pulses to the stepper drive cards

• DIR Direction of rotation to stepper drive cards.
• BOOST Not used
The outputs are routed to their respective stepper drive cards or via the multi-
plexer card to drive the individual motors.
An example of the digital output for the stepper motor system is shown below:

NextMove Card

V+ 12V

STEP
STEP
Single/Dual
Gnd Stepper
Stepper Drive
STEP AXIS V+ 12V Motor

DIR
DIR

Gnd

Figure 6-12 Stepper Drive Signals

Chapter Issue 5 Apr 02 Technical Reference Manual 6.13

MACHINE CONTROLLER
NEXTMOVE CARD

NextMove The NextMove card passes signals through the 100 way breakout backplane
Breakout known as the NextMove Breakout. The breakout is situated on the rear connec-
tor panel as shown below. DEK provide a breakout service tool which plugs into
either M19PL15 or M19PL17 it enables monitoring of the 100 Way connector
M19SK16 which has all the encoder, analog and digital signals directed to it.

Figure 6-13 NextMove Breakout Backplane

6.14 Technical Reference Manual Chapter Issue 5 Apr 02
 MACHINE CONTROLLER
NEXTMOVE CARD

Service Tool The NextMove breakout service tool has screw terminals to enable easy connec-
tion of test equipment to the 50 way breakout connectors M19PL15 and
M19PL17. This tool is used to enable all the signals available on the breakout
board sockets to be accessed for monitoring. Plug M19PL15 connects to all of
the odd numbered pins (1 through to 99) in connector M19SK16 whilst plug
M19PL17 connects to the even numbered pins of M19SK16.

Rear Connector Panel

M19SK28

M19SK40
M19SK34
M19PL24
M19SK22

M19SK29

M19SK35

M19SK41
M19SK42
M19SK30

M19SK36
M19SK23 M19SK25

M19SK31
M19SK19

M19SK43
M19SK13

M19SK37
M19SK08 M19SK14

M19SK27
M19SK15
M19SK09 M19SK20

M19SK16

M19SK32

M19SK44
M19SK38
M19SK10

M19SK17

M19SK26
M19SK21

M19SK45
M19SK39
M19SK33
M19SK11 M19SK12 MODEL
BATCH NO
M19SK18 BATCH
CENTRE

50 way IDC Connector

50 way IDC Connector

NOTE
To monitor the signals on
the 100 Way NextMove
Connector M19SK16
connect the Service Tool
to either M19PL15 or
M19PL17 using the
interface ribbon cable.
Service Tool

Figure 6-14 NextMove Breakout Service Tool

Chapter Issue 5 Apr 02 Technical Reference Manual 6.15

MACHINE CONTROLLER
NEXTMOVE CARD

NextMove Breakout Inputs and Outputs

Connector M19PL15 Connector M19SK16 Connector M19PL17

PIN 1 ANALOG GND PIN 1 ¦ PIN 2 PIN 2 ADC0
PIN 2 ADC1 PIN 3 ¦ PIN 4 PIN 1 ADC2
PIN 3 ADC3 PIN 5 ¦ PIN 6 PIN 4 ADC4
PIN 4 ADC5 PIN 7 ¦ PIN 8 PIN 3 ADC6
PIN 5 ADC7 PIN 9 ¦ PIN 10 PIN 6 DAC0
PIN 6 DAC1 PIN 11 ¦ PIN 12 PIN 5 DAC2
PIN 7 DAC3 PIN 13 ¦ PIN 14 PIN 8 ANALOG GND
PIN 8 DOP0 PIN 15 ¦ PIN 16 PIN 7 DOP1
PIN 9 DOP2 PIN 17 ¦ PIN 18 PIN10 DOP3
PIN 10 DOP4 PIN 19 ¦ PIN 20 PIN 9 DOP5
PIN 11 DOP6 PIN 21 ¦ PIN 22 PIN 12 DOP7
PIN 12 DOP8 PIN 23 ¦ PIN 24 PIN 11 DOP9
PIN 13 DOP10 PIN 25 ¦ PIN 26 PIN 14 DOP11
PIN 14 USER V+ PIN 27 ¦ PIN 28 PIN 13 USR GND
PIN 15 CAN WIRE+ PIN 29 ¦ PIN 30 PIN 16 CAN WIRE-
PIN 16 !EXT.INT.U PIN 31 ¦ PIN 32 PIN 15 ENCO.1
PIN 17 ENCO!! PIN 33 ¦ PIN 34 PIN 18 ENCO.B
PIN 18 ENCO!B PIN 35 ¦ PIN 36 PIN 17 ENCO.A
PIN19 ENCO!A PIN 37 ¦ PIN 38 PIN 20 ENC1.1
PIN 20 ENCO1!! PIN 39 ¦ PIN 40 PIN 19 ENC1.B
PIN 21 ENC.1 !B PIN 41 ¦ PIN 42 PIN 22 ENC1.A
PIN 22 ENC1 !A PIN 43 ¦ PIN 44 PIN 21 ENC2.1
PIN 23 ENC2!! PIN 45 ¦ PIN 46 PIN 24 ENC2.B
PIN 24 ENC2 !B PIN 47 ¦ PIN 48 PIN 23 ENC2.A
PIN 25 ENC2 !A PIN 49 ¦ PIN 50 PIN 26 ENC3.1
PIN 26 ENC3!! PIN 51 ¦ PIN 52 PIN 25 ENC3.B
PIN 27 ENC3 !B PIN 53 ¦ PIN 54 PIN 28 ENC3.A
PIN 28 ENC3 !A PIN 55 ¦ PIN 56 PIN 27 USR V+
PIN 29 PULSE 0 PIN 57 ¦ PIN 58 PIN 30 DIR 0
PIN 30 BOOST 0 PIN 59 ¦ PIN 60 PIN 29 PULSE 1
PIN 31 DIR 1 PIN 61 ¦ PIN 62 PIN 32 BOOST 0
PIN 32 PULSE 2 PIN 63 ¦ PIN 64 PIN 31 DIR 2
PIN 33 BOOST 2 PIN 65 ¦ PIN 66 PIN 34 PULSE 3
PIN 34 DIR 3 PIN 67 ¦ PIN 68 PIN BOOST 3
PIN 35 USER GND PIN 69 ¦ PIN 70 PIN 36 DIG.IN.0
PIN 36 DIG.IN.1 PIN 71 ¦ PIN 72 PIN 35 DIG.IN.2

6.16 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
NEXTMOVE CARD

Connector M19PL15 Connector M19SK16 Connector M19PL17

PIN 37 DIG.IN.3 PIN 73 ¦ PIN 74 PIN 38 DIG.IN.4
PIN 38 DIG.IN.5 PIN 75 ¦ PIN 76 PIN 37 DIG.IN.6
PIN 39 DIG.IN.7 PIN 77 ¦ PIN 78 PIN 40 DIG.IN.8
PIN 40 DIG.IN.9 PIN 79 ¦ PIN 80 PIN 39 DIG.IN.10
PIN 41 DIG.IN.11 PIN 81 ¦ PIN 82 PIN 42 DIG.IN.12
PIN 42 DIG.IN.13 PIN 83 ¦ PIN 84 PIN 41 DIG.IN.14
PIN 43 DIG.IN.15 PIN 85 ¦ PIN 86 PIN 44 DIG.IN.16
PIN 44 DIG.IN.17 PIN 87 ¦ PIN 88 PIN 43 DIG.IN.18
PIN 45 DIG.IN.19 PIN 89 ¦ PIN 90 PIN 46 DIG.IN.20
PIN 46 DIG.IN.21 PIN 91 ¦ PIN 92 PIN 45 DIG.IN.22
PIN 47 DIG.IN.23 PIN 93 ¦ PIN 94 PIN 48 GND
PIN 48 +5V O/P PIN 95 ¦ PIN 96 PIN 47 GND
PIN 49 +5V O/P PIN 97 ¦ PIN 98 PIN 50 RELAY COM
PIN 50 RELAY N/C PIN 99 ¦ PIN 100 PIN 49 RELAY NO

M19PL15 M19SK16 M19PL17

01 01 02 01

50 99 100 50

Refer to Drawing 155502 Sh 01 for detail

Figure 6-15 Sample of Next Move Breakout Wiring

Chapter Issue 5 Apr 02 Technical Reference Manual 6.17

MACHINE CONTROLLER
CAN BUS

CAN BUS
The Controller Area Network (CAN) is a bus system for machine motion
control. A transceiver for the 1Mbaud rate CAN serial link is fitted to the
NextMove card to enable communication with the two MultiMove cards. The
CAN is a 2-wire data link designed for transmission of small data packets for
fast update of axis position information.
The CAN is presented on two shielded RJ - 45 sockets.

1 8

Figure 6-16 CAN Bus Connector

Signal Function RJ-45 Pin

CAN+ CAN Data Signal 1
CAN- CAN Data Signal 2
CAN V+ Power to the CAN Nodes 5
GND Chassis Connection 4
Chassis Screen Pin
N/C No Connection 3,6,7,8
Chassis 360 Degree Cable Screen Shell

6.18 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
MULTIMOVE

MULTIMOVE Two MultiMove cards fitted in slots X12 and X13, control the outputs and
inputs for the upline and downline machine interface (MIU), data collection
from and to machine sensors and provide drive to the 24V motors, screen
clamps, air valves and solenoid devices. The cards are controlled by the
Controller Area Network (CAN) with provision for a third card if required. X12
is 24Vdc switched X13 is 24Vdc unswitched, this card remains on during an
emergency stop to enable control of certain functions eg, board stop and board
clamp release etc.
Card Features The MultiMove cards each have the following features:

• Eight 2A source-sink (totem) drivers for PWM control.

• Eight 2A source drivers. Sixteen opto-isolated digital inputs with LED
status indication.
• Remote operation via a 1Mbit/s serial communication link (CAN BUS).
• Error indication of faults on output circuits.
• Isolation of µ processor circuit from power drivers.
ON 1 2 3 4 5 6

RJ - 45 CAN Connectors
Bit Switches
(Note the different
JP11
configurations)
IN 0
IN 1
MultiMove X13 IN 2
IN 3
IN 4
ON 1 2 3 4 5 6

IN 5
IN 6 U219 U217 U223 U221
IN 7
DIG I/P STATUS SOURCE OUTPUT DRIVERS
IC 8
Yellow LEDs (ALONG HEAT SINK)
IN 8
IN 9
IN A MICROPROCESSOR
IN B U220 U218 U224 U222
MultiMove X12 IN C
IN D U200 U202 U204 U206
IN E
IN F IC 10
TP 20 (green) +5V TOTEM OUTPUT DRIVERS
(yellow) CAN
EEPROM
TP 16 (red) ERR
U201 U203 U205 U207
TP 17
TPX20
TP 18 GND U208 U210 U212 U214
TPX17
TP 19 VPOWR
TPX16
VCC TPX18 TOTEM OUTPUT DRIVERS
Early Test Points VISOL

TPX19 TPX15 U209 U211 U213 U215

Test GNDISOL SWPWR
Point Voltage
LED Green LED - +5V Power is being supplied to the microprocessor.
TPX20 0V Microprocessor
Indications
TPX16 5V Yellow LED - LED lights momentarily to indicate that the
TPX17 24V microprocessor is being addressed via the CAN.
TPX18 5V Power
TPX19 0V Red LED - LED flashes at 1Hz rate. Communications over the
TPX15 24V SW CAN have failed or an error has been detected on
an output channel.

Figure 6-17 MultiMove Card Layout

Chapter Issue 5 Apr 02 Technical Reference Manual 6.19

MACHINE CONTROLLER
MULTIMOVE

MultiMove Block The MultiMove cards are controlled via the CAN network by the NextMove
Diagram cards.

Single Board Computer

ISA BUS Machine

Software I/P

Upline/Downline
See Machine
Note 1 JP1
NextMove

24V US MIU
24V _SW
Controller Area Network
Peripheral I/O Control NextMove Breakout +12V_US
5V LOGIC

CAN

MultiMove X12
MultiMove X13

16 I/P’s 8 O/P’s 8 O/P’s

IN0 to INF Totem 0 Source 0 16 I/P’s 8 O/P’s 8 O/P’s
to Totem 7 to Source 7
SK12A SK12B SK13A SK13B
Source 0

P8
Rising Table Brake

Figure 6-18 MultiMove Interface

NOTE
1. JP1 is a link to DIG IN 9 and it is fitted to the MultiMove Backplane. The
machine software interrogates this function and determines the correct machine
software to run. This link should not be removed.
2. See the MultiMove tables for a complete listing of the MultiMove inputs and
outputs.

CAUTION
ANTI-STATIC HANDLING. Standard precautions must be adhered to
when handling electronic cards and configuring and inserting into the
enclosures.

6.20 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
MULTIMOVE

Universal Drivers The universal drivers described below form the basis for both the totem and
source drive outputs.
The PBD 3548/1 device is a source driver which has an output stage that is
switched on or off according to the voltage at its input. A high input signal
switches the transistor off, if the input is left open then it is detected as a low
signal.
The PBD 3545/1 is a sink driver and it also has an output stage that is switched
on or off according to the voltage at its input. A low input signal switches the
transistor off, if the input is left open then it is detected as a high signal.

Totem Drivers The totem driver uses a pair of devices in a source/sink (totem pole) arrange-
ment. This configuration is used to drive the 24V motors using pulse width
modulated (PWM) techniques. To drive a motor in both directions ie, a transport
belt, a dual driver arrangement of the type shown below is used.

Vcc +24V

PBD 3548\1 ON
(PWM)
OFF Medium speed
CH 0
I/P from S/W Period ON
Time
PBD 3545\1
ON

OFF High speed

M Period ON
Vcc +24V
Time

ON
PBD 3548\1
-1 OFF Slow speed
(PWM)
CH 1
I/P from S/W Period

PBD 3545\1 Bi-directional

ON
Time
Speed Control
eg. Belts

NOTE
PWM CH1 is the inverse of PWM CH0

Figure 6-19 Bipolar (Totem) as a PWM Driver

Chapter Issue 5 Apr 02 Technical Reference Manual 6.21

MACHINE CONTROLLER
MULTIMOVE

Eight Totem outputs are derived from the devices shown below.

Totem 1 Totem 3
Totem 0 Totem 2

U200 U202 U204 U206 PBD 3548/1

U201 U203 U205 U207 PBD 3545/1

MultiMove Card
Totem 1 Totem 3
Totem 0 Totem 2

Totem 5 Totem 7
Totem 4 Totem 6

U208 U210 U212 U214 PBD 3548/1

U209 U211 U213 U215 PBD 3545/1

Totem 4 Totem 6
Totem 5 Totem 7

V Isol V Power

4K7 4K7 4K7 4K7

U200
2 IN 4
V+
1 ERR
5
3 GND OUT

PBD 3548/1
Totem 0

U201
5 IN 2
OUT
4
ERR
1 3
V+ GND

PBD 3545/1

Gnd Isol

Figure 6-20 Typical Totem Drive Schematic

6.22 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
MULTIMOVE

Source Drivers

Source 0 Source 4
Source 2 Source 6

U219 U217 U223 U221 PBD3548/1

U220 U218 U224 U222 PBD3548/1

Source 3 Source 7
Source 1 Source 5

V Isol
MultiMove Card
V Power

4K7

2
IN 4
V+
1
ERR
5 Source 0
OUT
3
GND

* 4K7

Device Type 3548/1 Only Shown.

Gnd Isol
*Tied low, input is from
tristate logic device Vcc 24V
which may float during
power ON/reset.
ON/OFF
eg. Clamps

Load
Source 0

Figure 6-21 Typical Source Driver Schematic

Chapter Issue 5 Apr 02 Technical Reference Manual 6.23

MACHINE CONTROLLER
MULTIMOVE

MultiMove Input and Ouputs

Signal Inputs MultiMove X13 Function Destination Device

IN0 Switch - Jog Right 14PL08 8SW2
IN1 Switch - Jog Left 14PL08 8SW1
IN2
IN3 Power On Monitor PCB C - CPL1 PSU
IN4 Switch - Cover Interlock PCB C - CSK6 9SW1
IN5 Switch - Cleaner Home PCB C - CSK5 8SE10
IN6 Sensor - Paper Low 8PL71
IN7 Sensor - Solvent Low 8PL73
IN8
IN9
INA MIU Lane B Read Status M19SK02 N/C
INB MIU Downline Ready M19SK02 N/C
INC MIU Upline Ready M19SK02 N/C
IND MIU Lane A Read Status M19SK01 FMI Lane A
INE MIU Downline Ready M19SK01 FMI Lane A
INF MIU Upline Ready M19SK01 FMI Lane A

Source O/P MultiMove X13 Function Destination Device

0 N/C Solenoid Bank #1
1 Cleaner Squeegee Solenoid Bank #1 16SOL08
2 Cleaner Vac Valve Solenoid Bank #1 16SOL09
3 Solenoid - Board Clamp Solenoid Bank #1 16SOL10
4 Solenoid - Board Stop Solenoid Bank #1 16SOL14
5 N/C Solenoid Bank #1
6 N/C Solenoid Bank #1
7 N/C Solenoid Bank #1

Totem O/P’s MultiMove X13 Function Destination Device

0 N/C
1 Lamp - Beacon, Green 14PL07 Beacon
2 Lamp - Beacon, Amber 14PL07 Beacon
3 Lamp - Beacon, Red 14PL07 Beacon
4 Buzzer
6 Solenoid - Cleaner Home Clamp Rt/Lft PCB D DSK12 8SOL19/20
(Linked at PCB D DSK12)
7 Solenoid - Chase Clamp Rt/Lft (Linked P1 & P2/P3 & P4 13SOL01/02
at PCB D DSK13/14)

6.24 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
MULTIMOVE

Signal Inputs MultiMove X12 Function Destination Device

IN0 Switch - Air Pressure PCB D SK9 8SE11
IN1 Sensor - Screen Present SK01 13SE07
IN2 Lid Bolt Extended PCB D SK7 9SW8
IN3 Sensor - Paste Cartridge Empty PCB E EPL6 9SE15
IN4 Switch - Paste Cartridge Horizontal 9PL45 9SE13
IN5 Switch - Paste Cartridge Vertical 9PL44 9SE14
IN6 Switch - ProFlow Cassette Low M18PL01 M18SE01
IN7 Switch - ProFlow Cassette Fitted M18PL01
IN8 SPARE M19SK04
IN9 SPARE M19SK04
INA SPARE M19SK04
INB SPARE M19SK04
INC SPARE M19SK04
IND SPARE M19SK04
INE SPARE M19SK04
INF SPARE M19SK04

Source MultiMove X12 Function Destination Device

Outputs
0 Solenoid - Table Brake 8PL09 8SOL02
1 Solenoid - External/Vacuum Filtration PCB B BSK8
2 Solenoid - Vacuum Tooling (Option) BPL9 8SOL24
3 N/C
4 N/C
5 Lid Bolt Solenoid Bank 16SOL04
6 Solenoid - Paste Dispenser Solenoid Bank 16SOL05
7 Solenoid - Solvent Tank Pressure Solenoid Bank 16SOL06

Totem MultiMove X12 Function Destination Device

Ouputs
0 Belt Motor #01+ (Front Rail) 8SK21 8M03
1 Belt Motor #01- (Front Rail) 8SK21 8M03
2 Belt Motor #04+ (Rear Rail) 8SK23 8M04
3 Belt Motor #04- (Rear Rail) 8SK23 8M03
4 Cartridge Tilt Motor+ 9PL48 9M9
5 Cartridge Tilt Motor- 9PL48 9M9
6 Solenoid - Solvent Valve 8PL76 8SOL25
7 Paper Feed Motor 8PL72 8M5

Chapter Issue 5 Apr 02 Technical Reference Manual 6.25

MACHINE CONTROLLER
SERVO DRIVE CARD

SERVO DRIVE CARD

Four torque amplifier cards are used as servo drive cards by the machine
controller, to drive the rising table, the camera X axis, the camera Y axis and the
print carriage axis motors. The axes for these motors are designated Axis 0 to
Axis 3. The servo motors are connected to the servo/stepper backplane and Axis
0 connects to SK7, Axis 1 to SK9, Axis 2 to SK8 and Axis 3 to SK10. Two types
of servo drive card may be fitted, as shown below and over the page.

Damping VR 5 Fuse FS1

AUX Gain VR 1 250V
20A
TACHO Gain VR 2
Offset VR 3
Gain VR 4

Heat Sink

JP 1 LD 4
a
b Edge
Connector

Disable yellow
Error red
Power green

POTENTIOMETERS d b z
All potentiometers on the card are pre-set at the factory and MUST NOT be adjusted. 2
4
6
LEDs 8
10
DISABLE - This LED illuminates when the NextMove card removes the Enable signal
12
from the I/P, ie it echoes the state of the Enable I/P on Pin 2z.
14
16
ERROR - Over Temperature - The temperature of the heatsink has become excessive
due to an enclosure ventilation problem or if the card has been operating at
a high current for too long. 20
22
Over Current - The output current exceeds 25A - 30A.
24
POWER - Illuminates to indicate that the system power (40V ac) is applied to the card. 26
This is the only indication during normal operation.
28
30

JUMPER JP 1 32

Position a -A ground on the Enable is required to disable the card - an open

circuit or voltage on the enable input enables the card. End View on
Edge Connector
Position b -A ground on the Enable is required to enable the card - an open
circuit or voltage on the disable input disables the card. Indicates pins used

Figure 6-22 Type 1 Servo Drive Card Layout (Part No. 114025)

6.26 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
SERVO DRIVE CARD

Fuse F1, 250V, 20A

F1

Disable
PWR On
Bad PWR
Over Temp
Over Curr

Edge
Connector

d b z
LEDs 2
4
Disable - This LED illuminates when the NextMove card removes the Enable signal from the I/P, 6
ie it echoes the state of the Enable I/P on Pin 2z.
8
10
Power On - This LEd illuminates to indicate that the system power (40V ac) is applied to the card. 12
This is the only indication during normal operation. 14
16
Bad Power - This LED illuminates when the cards dc supply rail, (nominal 60Vdc) has exceeded the
threshold of 91Vdc. 20
22

Over Temperature - This LED illuminates when the temperature of the heatsink has become excessive, 24
o
(over 75 C) due to an enclosure ventilation problem or if the card has been operating 26
at a high current for too long.
28
30
Over Current - This LED illuminates when the output current exceeds 20A on any individual cycle. 32

Bad Power
Over Temperature These three LED's flashing together indicates a catastrophic over current failure. End View on
Edge Connector
Over Current
Indicates pins used

Figure 6-23 Type 2 Servo Drive Card Layout (Part No. 153073)

Chapter Issue 5 Apr 02 Technical Reference Manual 6.27

MACHINE CONTROLLER
SERVO DRIVE CARD

Servo Drive Card 44Vac is applied to the servo amplifier from the mains isolating transformer.
Block Diagram This input is rectified on each card and is used to power the motor output stage.
The servo motors are voltage surge protected by a thermal trip device connected
to the system reset circuit in the power supply. The machine software generates
a profile of the correct servo demand voltage to achieve the speed that the motor
is required to rotate. Servo demand signals are applied directly to the servo drive
card from the NextMove card, the derived output is a 25kHz PWM drive signal.
An encoder that is directly attached to the motor feeds back a series of pulses to
the NextMove card to complete the servo loop. If the pulses returned are in error,
an error signal is generated

Mains
Transformer

44V ac

Error
NextMove
Card Encoder
Enable
Servo Drive Card Motor +VE

25kHz PWM
+10V +VE +62V
Output Motor
to Motor -62V
Demand

-10V -VE Motor -VE

Encoder Out

Figure 6-24 Servo Drive Card Schematic

NOTE
Each servo drive card has an enable input on pin 2z which must be pulled low
for the card to operate. If this input is disconnected or if there is a voltage on
the line, then the card is disabled

CAUTION
ANTI-STATIC HANDLING. Standard precautions must be adhered to
when handling electronic cards and configuring and inserting into the
enclosures.

6.28 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
SERVO DRIVE CARD

Signals and Pins The following shows servo drive card edge connector pins for all cards used on
the machine:

Pin Signal Description Edge Connector

2d Demand +V ±10V with respect to 4d from the NextMove Card.
Torque proportional to demand voltage (max
demand = 10V, Zero demand = 0V)
d b z
4d Demand - V Tied to GND
2
6d GND 4
6
2z Master Enable Input, must be grounded to enable card
8
12b Error Output Normally high, goes low in error condition 10
12
20 AC1 44V ac input from transformer tapping
14
22 AC2 16

24 Motor +ve Output to motor, ±62V Pulse Width Modulated 20

(PWM) 22
26 Motor -ve
NOTE 24
The connectors for the output are plug-in types, 26
the wiring diagram does not show this connection
28
28 GND 0V 30

32

Indicates connections used

NOTE
Axis 1 also has an input at pin 14d from the MultiMove card and an output at
pins 14b and 14z (0V) to provide the rising table brake function.

Chapter Issue 5 Apr 02 Technical Reference Manual 6.29

MACHINE CONTROLLER
STEPPER MULTIPLEX CARD

STEPPER MULTIPLEX CARD

Multiplexer The Stepper Multiplexer is used to control the stepper motors and their sensors
Description which do not need to be controlled in conjunction with each other ie, not for
alignment purposes. A decoder on the multiplexer board converts the three input
control (CTRL 0-2), the drive signal (MUX Axis Step) and the axis direction
control (MUX Axis Dir) into Step and Direction outputs that are used by the
Dual Stepper Drivers. The axes controlled are; the front and rear squeegees; the
moving rail and the paste dispenser. When the axes are driven to their respective
home position switches, they indicate to the multiplexer board that the axis has
reached home, a single MUX Axis Home signal is fed back to the NextMove
controller. All signals can be monitored on LEDs MUX0 to MUX4, in this way
the single home signal can be deduced for the relevant axis used.
The multiplexer can be thought of as a fully programmable switch where the
controlling inputs CTRL 0-2 determine the logical output state of eight internal
switches in the multiplexer. Only five of these switched outputs are utilized in
this application. Two signals are provided by the NextMove card - Step and
Direction (Dir). By combining (multiplexing) these signals it is possible to
sequentially switch the relevant axis (as determined in machine software) to
enable it to be driven to position. The dual stepper cards condition the signals to
achieve optimum drive results.

6.30 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
STEPPER MULTIPLEX CARD

Electrical Block Diagram

Alignment (XF, XR, Y)[to alignment Dual Stepper Cards]

2
NextMove Stepper Multiplexer MUX 0-4 Step Dual N/A
2
4 Output Drives Monitor Stepper Home
2 Dir

2 MUX Axis Dir

Step Dual Home
3 CTRL 0-2 Stepper
Multiplexer Dir Home
NextMove I/O
Home
MUX Axis
Home
MUX Axis Paste Car Home
Step Rail Home
Multiplexer Control MUX 0-4 Rear Sq Home
Truth Table Front Sq Home
CTRL
Bit Description O/P
210
000 Front Squeegee MUX 0
001 Rear Squeegee MUX 1
010 Moving Rail MUX 2
011 Paste Carriage MUX 3
100 Unused MUX 4

TP
Supplies Monitor
AC1
AC2
AC1 24V US MMX13 24V Fans
AC2 24V Stepper
24V Fans 24V USR 24 SW MMX12
+ 12V USR 24 SW MMX11
24V Stepper 24 US MMX13
5V LOGIC +12 USR
24V SW MMX13 -12V USR 5V LOGIC
-12 USR
24VSW MMX11 0V US
0V US
NOTE
MMXxx Denotes the MultiMove Axis

Figure 6-25 Stepper Multiplexer/Supplies Monitor Block Diagram

In addition to the multiplexer function this card also has a set of indicator LEDs
and test points (TP), available on the front panel for supplies voltage monitoring.
CAUTION
POTENTIAL MACHINE DAMAGE. The links fitted to this card control
the drive sequence and step modes for each axis. If the link positions are
changed, the axis can be driven out of sequence and may cause damage to
the machine. The correct link fittings are factory set and should not be
changed.

Chapter Issue 5 Apr 02 Technical Reference Manual 6.31

MACHINE CONTROLLER
STEPPER MULTIPLEX CARD

Stepper Multiplexer Supplies Monitor Card

The card consists of a supplies monitor section and a multiplexer section. The
multiplexer can be subdivided into three sections the MUX monitor, the Stepper
Line Decoder and the Axis Home Encoder.
The supplies monitor section is labelled with the relevant monitor voltage and
green LEDs are used to indicate that voltages are present. Test points are also
provided so that the voltage of the supplies can be measured with respect to zero
volts.
The MUX monitor consists of 5 yellow LEDs which provide an indication of
the currently selected channel from the stepper line encoder section, this section
decodes the three input control lines to give eight sequential outputs as described
previously. The outputs from the decoder are fed to the dual stepper driver cards,
described later. In addition to this, the MUX axis step signal and the MUX axis
direction signals from the NextMove card are routed into the stepper line
encoder section to establish the step and direction commands on each of the dual
stepper drive cards.
The axis home encoder section enables the signals from the home axis switches
to be directed to the NextMove card, it can establish which axes have found their
home positions relevant to the control sequence.

Figure 6-26 Stepper MUX/Supplies Monitor

CAUTION
ANTI-STATIC HANDLING. Standard precautions must be adhered to
when handling electronic cards and configuring and inserting into the
enclosures.

6.32 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
DUAL STEPPER DRIVE

DUAL STEPPER DRIVE

The dual stepper drive card can be configured to drive either a single or two
stepper motors. For single axis control, the drive cards are not populated with
two device sets.
Stepper drive signal coding is generated by two on board OTP-EPROM 8-Bit
CMOS Micro-controllers (PIC16C54). The drive to each stepper motor phase
is provided by two H-Bridge motor driver devices (LMD 18245).
Circuit Protection The circuit is connected to the + 24V SW (Switched) and the + 24V US
(UnSwitched) supplies. The unswitched supply is protected by a diode-fuse
voltage transient suppressor circuit consisting of D2 and F1(0.5AT). The diode
operates over an extremely short time period, this enables the absorption of
voltage spikes without blowing the fuse. If a sustained current is experienced
the fuse exceeds its rated value and blows. The switched supply is similarly
protected by a diode-fuse circuit consisting of D1 and F2 (3.15AT)

Regulated Supply The +5V regulated voltage (VCC) is provided by the +24V US voltage at the
output of U7. This voltage in turn provides the CH1 and CH2 reference voltages
for the LMD 18245 DAC Ref, this output is used as a comparator voltage in the
device’s internal 4-Bit digital to analog converter.

Input Signals Two inputs, Dir1 and Dir 2 are the direction inputs and Step 1 and Step 2 are the
step signals to the stepper drive motors. These signals are opto coupled through
the input device U3 (TLP 521- 4) then routed to the respective micro controller
devices (PIC16C54) and test points TP1-4.

Chapter Issue 5 Apr 02 Technical Reference Manual 6.33

MACHINE CONTROLLER
DUAL STEPPER DRIVE

Output Signals Each micro controller is preprogrammed with a machine code that utilizes the
direction and step data from the multiplexer (MUX Dir/Step), to sequence the
stepper drive signals (RB0-7). These signals are fed to two LMD 18245 devices.
The LMD devices each form a bi-polar chopper amplifier stage providing single
phase drive to one half of the stepper motor (CHxA+ and CHxA-) or (CHxB+
and CHxB-) windings. Outputs RB0 and RB4 provide the direction data and are
utilized in the chopper circuit to switch the H-Bridge power switches and hence
the current direction in the phase winding. The LMD device compares the DAC
reference voltage mentioned previously with the output of the current sense
amplifier this is connected to the jumper links - JP3, 4, 5, 6, 9, 10, 11 and 12.
The links are all factory set to achieve either half step 1A/phase or half step 2A/
phase outputs. The actuators and the paste dispense stepper motors are rated at
1A/phase. The squeegee motors, the moving rail motors are rated at 2A/phase.

TP1 TP2 24VSW

or TP3 or TP4
Step/Dir I/P Buffer
H-Bridge
Chopper
Amplifier CHxA+
Dir
Microcontroller
RA0-RA1
CHxA-
RB0

RB1/2/3 { LMD 18245

Rotor
RB4 Dir

RB5/6/7 { H-Bridge CHxB+

Stepper
Motor

I
+5V Reference Sense CHxB-
Voltage
PIC16C54
DAC

NOTE LMD 18245

Both halves are identical.

Figure 6-27 Dual Stepper Block Diagram

6.34 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
DUAL STEPPER DRIVE

Stepper Drive Card

JP6 JP14
TP1 - Dir 1 JP5

TP2 - Step 1

TP3 - Dir 2

TP4 - Step 2
JP8

JP2
JP7

JP1
JP13
TP5 - 0V JP10
JP9
JP4 +5V
JP3 Regulator

Fuse F2-
3.15AT

JP11 JP12
Fuse F1 -
0.5AT

Dual Stepper Card Configuration Table

Jumper Links Slot X3 Slot X4 Slot X5 Slot X6

JP1
JP2
JP3 X
JP4 X
JP5 X
JP6 X
JP7
JP8
JP9 X X
JP10 X X
JP11 X X
JP12 X X
JP13
JP14
NOTE
X denotes jumper link fitted.

CAUTION
ANTI STATIC HANDLING. Standard precautions must be adhered to when handling
electronic cards and configuring and inserting cards into enclosures.

Figure 6-28 Dual Stepper Drive PCB

Chapter Issue 5 Apr 02 Technical Reference Manual 6.35

MACHINE CONTROLLER
DUAL STEPPER DRIVE

Stepper Drive Designations

Signal Function Destination Source

Motor 2A- Front Squeegee Stepper Motor 9M3 Stepper Drive X5
Motor 2A+ Front Squeegee Stepper Motor
Motor 2B- Front Squeegee Stepper Motor
Motor 2B+ Front Squeegee Stepper Motor
Front Sq. Home Switch - Home PCB E - ESK4 MUX PL1
Motor 1A+ Rear Squeegee Stepper Motor 9M4 Stepper Drive X4
Motor 1A- Rear Squeegee Stepper Motor
Motor 1B+ Rear Squeegee Stepper Motor
Motor 1B- Rear Squeegee Stepper Motor
Rear Sq. Home Switch - Home PCB E - ESK4 MUX PL1
Motor 1B- Y Actuator Stepper Motor Stepper Drive X5
Motor 1B+ Y Actuator Stepper Motor
Motor 1A- Y Actuator Stepper Motor
Motor 1A+ Y Actuator Stepper Motor
Y Actuator Home Switch - Home Coarse 9PL35 M19SK09
Y Actuator Home Switch - Home Fine
Motor 2A- Moving Rail Stepper Motor 8M2 Stepper Drive X4
Motor 2A+ Moving Rail Stepper Motor
Motor 2B+ Moving Rail Stepper Motor
Motor 2B- Moving Rail Stepper Motor
Mov. Rail Home Switch - Moving Rail Home 8SE6 MUX PL1
Motor 2B- X Rear Actuator Stepper Motor Stepper Drive X3
Motor 2B+ X Rear Actuator Stepper Motor
Motor 2A- X Rear Actuator Stepper Motor
Motor 2A+ X Rear Actuator Stepper Motor
X Rear Act. Home Switch - Home Coarse 9PL34 M19SK09
X Rear Act. Home Switch - Home Fine 9PL34 M19SK09
Motor 1B+ X Forward Actuator Stepper Stepper Drive X3
Motor
Motor 1B- X Forward Actuator Stepper
Motor
Motor 1A- X Forward Actuator Stepper
Motor
Motor 1A+ X Forward Actuator Stepper
Motor
X Fwd. Act. Home Switch - Home Coarse 9PL33 M19SK09
X Fwd. Act. Home Switch - Home Fine 9PL35 M19SK09

6.36 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
DUAL STEPPER DRIVE

Signal Function Destination Source

Motor 1B+ Paste Dispenser Motor Stepper Drive X6
Motor 1B- Paste Dispenser Motor
Motor 1A- Paste Dispenser Motor
Motor 1A+ Paste Dispenser Motor
Paste Disp Home Switch - Paste Disp Home M19SK27

Chapter Issue 5 Apr 02 Technical Reference Manual 6.37

MACHINE CONTROLLER
BREAKOUT BOARDS

BREAKOUT BOARDS
The five breakout boards, PCB’s A through to E are shown in the figure below:

NOTE
Items are located on the machine faces as indicated.

PCB D
Rear Right
of Base Frame
PCB A
Rear Left of
Base Casting

Rear of Machine

Cut-away
to show PCB

PCB B
Rear Left Corner of
Base Frame

Plan View of the Machine

Cut-away
to show PCB

PCB C PCB E
Front Left Front Right of
of Base Frame Print Carriage Assembly

Figure 6-29 Breakout Board Locations

6.38 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
BREAKOUT BOARDS

Breakout Board Signals

Breakout Pin No. Description +12V Pin 0V Pin

A SK3 2 Rising Table home 1,4,7 3,6,9
A SK3 8 Rising Table Interlock 1,4,7 3,6,9
A SK3 5 Rising Table Limit 1,4,7 3,6,9
A SK4 2 Rail Lifted Left 1,4,7,10 3,6,9,11,12
A SK4 5 Rail Lifted Right 1,4,7,10 3,6,9,11,12
A SK5 2 Camera X Home 1 3
A SK6 5 Camera Y Home 1,4 3,6
A SK6 2 Print Carriage Home 1,4 3,6
A SK7 7 X Forward Course Home 1,5,9 4,8,12
A SK7 6 X Forward Fine Home 1,5,9 4,8,12
A SK7 3 X Rear Course Home 1,5,9 4,8,12
A SK7 2 X Rear Fine Home 1,5,9 4,8,12
A SK7 11 Y Actuator Coarse Home 1,5,9 4,8,12
A SK7 10 Y Actuator Fine Home 1,5,9 4,8,12
B SK10 2 Not Used 6-10
B SK10 3 Lid Bolt 6-10
B SK10 11-12 Not Used 6-10
B SK10 4 Paste Dispense Solenoid 6-10
B SK10 1 Shuttle Anvil 6-10
B SK10 5 Solvent Tank Pressure 6-10
B SK3 2 Board at Left 1,4 3,6
B SK3 5 Board at Right 1,4 3,6
B SK4 2 Board at Left 1 3,6
B SK4 5 Board at Right 3,6
B SK5 2 Shuttle Sensor Left 3,6
B SK5 5 Shuttle Sensor Right 3,6
B SK6 2 Board at Stop 3,6
B SK6 5 Board Stop Extended 3,6
B SK7 1 Table Brake 2
B SK8 1 Cleaner Vacuum Power 2
B SK9 1 Vacuum Power 2
C SK10 1 Paste Roll Lamp Switch 6,7,8,9,10
C SK10 2 Paste Roll Lamp Switch 6,7,8,9,10
C SK4 5 Paper Low 3,6
C SK4 2 Solvent Low 3,6

Chapter Issue 5 Apr 02 Technical Reference Manual 6.39

MACHINE CONTROLLER
BREAKOUT BOARDS

Breakout Pin No. Description +12V Pin 0V Pin

C SK4 2 Cleaner Home 3
C SK5 1 Cover Interlock 6
C SK6 3 Not Used 6
C SK6 4 Jog Left 6
C SK6 5 Jog Right 6
C SK6 2 Power on Monitor 6
C SK7 2 Belt Motor #1- 6
C SK7 1 Belt Motor#1+ 6
C SK7 4 Belt Motor#4- 6
C SK7 3 Belt Motor#4+ 6
C SK8 2 Cart Tilt Motor- 4
C SK8 1 Cart Tilt Motor+ 4
C SK8 3 Paste Roll Lamp 24V 4
C SK9 3 Paper Feed Motor 2,4
C SK9 9 Solvent Pinch Valve 2,4
SK10 1 24v 24V 5
C SK10 1 Paste Roll Lamp Switch 5
D SK10 2 Not Used 5
D SK10 3 Not Used 5
D SK11 2 Amber Lamp 5
D SK11 4 Buzzer 5
D SK11 1 Green Lamp 5
D SK11 3 Red Lamp 5
D SK12 1 Cleaner Home Clamp, Left 2,4
D SK12 3 Cleaner Home Clamp, Right 2,4
D SK13 1 Chase Clamp, Left 2
D SK14 1 Chase Clamp, Right 2
D SK4 11 Cartridge Empty 1,2 3,12
D SK4 10 Cartridge Horizontal 1,2 3,12
D SK4 9 Cartridge Vertical 1,2 3,12
D SK4 4 Front Squeegee Home 1,2 3,12
D SK4 6 Paste Carriage Home 1,2 3,12
D SK4 8 ProFlow Cassette Low 1,2 3,12
D SK4 7 ProFlow Fitted 1,2 3,12
D SK4 5 Rear Squeegee Home 1,2 3,12
D SK5 2 Moving Rail Home 1 3
D SK6 2 Screen Drive home 1 3

6.40 Technical Reference Manual Chapter Issue 5 Apr 02

 MACHINE CONTROLLER
BREAKOUT BOARDS

Breakout Pin No. Description +12V Pin 0V Pin

D SK7 2 Lid Bolt Extended 1 3
D SK8 2 Screen Sensor 1,4 3,5,6
D SK9 2 Air Pressure 1 3
E SK2 5 ProFlow Cassette Low 1,4 3,6
E SK2 2 ProFlow Fitted 1,4 3,6
E SK3 6 Cartridge Horizontal 1,4 3
E SK3 2 Cartridge Vertical 1,4 2
E SK4 2 Front Squeegee Home 1,4 3,6
E SK4 5 Rear Squeegee Home/ProFlow Home 1,4 3,6
E SK5 2 Past Carriage Home 1 3
E SK6 2 Cartridge Empty 1 3

Chapter Issue 5 Apr 02 Technical Reference Manual 6.41

MACHINE CONTROLLER
BREAKOUT BOARDS

6.42 Technical Reference Manual Chapter Issue 5 Apr 02