Installation & Maintenance
TMC470
Marking System Controller
This document contains installation and maintenance information
for the Telesis® TMC470 Marking System Controller.
Document No. 34701F
Telesis Technologies, Inc.
28181 River Drive
P.O. Box 1000
Circleville, Ohio 43113
TMC470 Installation & Maintenance
Foreword
Telesis Technologies, Inc. (hereinafter referred to as Telesis) reserves the right to change the information and
specifications contained in this document without prior notice. The reader should consult Telesis to determine whether
such changes have been made.
In no event shall Telesis be liable for any incidental, indirect, special, or consequential damages whatsoever, including but
not limited to lost profits, arising out of, or relating to this document or the information it contains, even if Telesis has
been advised, has knowledge, or should have knowledge of the possibility of such damages.
Telesis expressly warrants the equipment it manufactures as set forth in the Standard Terms and Conditions of Sale.
Telesis makes no other warranties, expressed or implied, including and without limitation, warranties as to
merchantability or fitness for a particular purpose.
The information contained in this document is confidential and is proprietary to Telesis or its licensors.
Trademarks
Telesis and Merlin are registered trademarks of Telesis Technologies, Inc. in the United States and/or other countries.
NEMA is the registered trademark and service mark of the National Electrical Manufacturers Association.
© 2008 – 2011 Telesis Technologies, Incorporated – All Rights Reserved
34701F
i
TMC470 Installation & Maintenance
License Agreement for Telesis Software
IMPORTANT: THE SUBJECT PROGRAMS ARE LICENSED BY TELESIS TECHNOLOGIES, INC. TO
END-USERS FOR THEIR USE ONLY ON THE TERMS BELOW. ACCEPTING AND USING THESE
PROGRAMS INDICATES YOUR ACCEPTANCE OF THESE TERMS. THIS IS A LEGAL AGREEMENT
BETWEEN YOU, THE END USER, AND TELESIS TECHNOLOGIES, INC.
1) GRANT OF LICENSE. Telesis Technologies, Inc. (Telesis) agrees to grant to you a non-exclusive license to use the Telesis
software/firmware program (the program) subject to the terms and conditions of this license agreement.
2) DEFINITION OF TERMS. The term software refers to a computer program stored on electronic media that must be loaded
into computer memory to be executed. The term firmware refers to a computer program stored in semiconductor memory
(ROM, PROM, EPROM, EEPROM, NVRAM, etc.) that is an integral part of the computer memory. Together, these forms of
computer programs are referred to as the program.
3) COPYRIGHT. The program(s) and documentation is owned by Telesis and is protected by United States copyright laws
and international treaty provisions. The program(s) contain trade secrets and proprietary property of Telesis. You may
make one copy of the program(s) solely for backup or archival purposes provided that the copy clearly displays the Telesis
copyright notice. Additional copies may be made when authorized to do so in writing by Telesis. In addition to any other
right of Telesis, Telesis has the right to terminate this license if the terms of the license are violated.
4) RESTRICTION ON USE AND TRANSFER. The single-processor version(s) of the program(s) and documentation are to be
used on one computer or embedded system at any one time. The multi-processor version(s) of the program(s) and
documentation may be used over a network provided that the number of computers accessing the network simultaneously
shall not exceed the number authorized by Telesis or for which you paid the corresponding multi-processor fee. You may
not distribute the programs or documentation to a third party. You may transfer the license and complete package
(retaining nothing) if the transferee agrees to the terms of this License Agreement. Neither the program(s) nor the
documentation may be changed or translated without express written permission of Telesis. You may not reverse engineer,
decompile or disassemble the program(s).
5) WARRANTY for the subject program(s) is covered under the Telesis Standard Terms and Conditions of Sale.
6) TERM. The license is effective until terminated. It will be terminated if you fail to comply with any term or condition of
this License Agreement. You may terminate this License Agreement at any time. In the event of termination, you agree to
destroy the program(s) and documentation together with all copies and related material.
7) YOUR USE OF THIS PROGRAM(S) acknowledges that you have read this License Agreement and agree to its terms. This
agreement is complete and supersedes any other agreement that may have related to the subject matter of this
agreement.
ii
34701F
TMC470 Installation & Maintenance
Safety Summary
The following safety precautions should be observed at all times.
¡
The controller uses high voltage power supplies. Accordingly, there is some danger when working with, and near,
marking machines.
¡
Never use the equipment in any manner or for any purpose other than that for which it was designed.
Warnings, Cautions, and Notes may be placed throughout this document to alert you to important information. These
messages have the following significance.
Warnings contain information that is essential to the personal safety of the user.
Cautions contain information that is essential to avoid damage to the equipment.
Notes call attention to information of special importance at specific points within the text.
The following Warnings and Cautions are contained in this document.
WARNING
Turn all power OFF when performing maintenance on the controller.
Ensure that all equipment energy sources are turned off or disconnected and that the
switches are either locked or tagged while equipment is cleaned or serviced.
The controller contains a lithium battery. Improper disposal of lithium batteries may
cause an explosion. Always dispose of the lithium battery in a proper manner.
CAUTION
Do not block vents on the bottom of the controller.
The TMC470 is not a sealed unit. Protect it from potentially damaging conditions and
contaminants. Ensure the marking system is electrically isolated from any devices that
may generate extreme electromagnetic interference (EMI).
If your equipment arrives during cold weather, allow the components to warm up for
several hours before opening the containers. Exposing the equipment to room
temperatures may cause condensation in the units.
The controller is shipped with electrostatic covers installed on the back panel
connectors. Leave the covers installed on those connectors that will not be used. This
will help to prevent electrostatic discharge (ESD) problems.
Never connect or disconnect the Marker cable or the Auxiliary Axis cable while controller
power is ON. Damage to the equipment will occur.
Do not press on the LCD display nor apply heavy pressure to the keyboard.
Be extremely careful not to scratch the LCD display or the membrane keyboard.
Do not apply liquids directly to the controller. Apply liquid to cleaning cloth instead.
Application of excessive liquid may enter the case and damage internal components.
Mounting brackets incorrectly on the underside of the controller will block air flow and may
damage the controller or cause the unit to shutdown abnormally.
When installing the controller into a TMC470N enclosure, be careful to not damage the
rubber grommets when removing them from the cabinet seal module.
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TMC470 Installation & Maintenance
Table of Contents
TOPIC
PAGE
Foreword .....................................................................................................................................................
i
Trademarks .................................................................................................................................................
i
License Agreement for Telesis Software...........................................................................................................
ii
Safety Summary ..........................................................................................................................................
iii
List of Illustrations ........................................................................................................................................
vi
List of Tables ...............................................................................................................................................
vi
Section 1 – Installation
1.1
Overview.......................................................................................................................................
1-1
1.2
Description ...................................................................................................................................
1-1
1.3
Specifications................................................................................................................................
1-2
1.4
Unpacking the Equipment .............................................................................................................
1-3
1.5
Installation Requirements ............................................................................................................
1-4
Installation Procedures .................................................................................................................
1-6
1.6.1
1-6
1.6
1.7
1.8
iv
Site Preparation ..................................................................................................................
1.6.2
Standard Table-top Installation .............................................................................................
1-7
1.6.3
Optional Wall-mounted Installation ........................................................................................
1-7
1.6.4
Optional Panel-mounted Installation ......................................................................................
Attaching the Mounting Brackets ........................................................................................
Installing the Bezel Gaskets ...............................................................................................
Attaching the Mounting Bezel .............................................................................................
Attaching the Controller ....................................................................................................
1-8
1-8
1-9
1-10
1-12
1.6.5
Optional TMC470N NEMA Enclosure Installation .......................................................................
1-13
Data and Electrical Connections ....................................................................................................
1-16
1.7.1
Marker Connection...............................................................................................................
1-17
1.7.2
Power Connection ................................................................................................................
1-17
1.7.3
Auxiliary Axis Connection .....................................................................................................
1-18
1.7.4
TTL Connection ...................................................................................................................
1-19
1.7.5
Comm 1 / Comm 2 Connections ............................................................................................
RS232 Interface ...............................................................................................................
RS485 Interface ...............................................................................................................
Programmable Protocol .....................................................................................................
Extended Protocol ............................................................................................................
1-20
1-21
1-22
1-24
1-24
1.7.6
Remote I/O Connection ........................................................................................................
VDC Input Connections .....................................................................................................
VDC Output Connections ...................................................................................................
Remote I/O Signal Timing .................................................................................................
Remote Pattern Selection ..................................................................................................
1-25
1-26
1-27
1-28
1-29
1.7.7
Ethernet/Merlin Connection...................................................................................................
1-30
1.7.8
TMC420N NEMA Enclosure – Cabinet Seal ...............................................................................
1-32
Controller Checkout ......................................................................................................................
1-32
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TMC470 Installation & Maintenance
Table of Contents
TOPIC
PAGE
Section 2 – Maintenance
2.1
Overview ......................................................................................................................................
2-1
2.2
Maintenance Precautions ..............................................................................................................
2-1
2.3
Cleaning Procedures .....................................................................................................................
2-1
2.4
Troubleshooting............................................................................................................................
2-2
2.5
Testing Procedures .......................................................................................................................
2-3
2.5.1
Comm 1 and Comm 2 Port Testing ........................................................................................
2-3
2.5.2
I/O Port Testing ..................................................................................................................
2-4
2.5.3
TTL Port Testing ..................................................................................................................
2-5
2.5.4
Marker Port Testing .............................................................................................................
2-6
2.5.5
Auxiliary Axis Port Testing ....................................................................................................
2-7
2.6
Replacement Procedures ..............................................................................................................
2-8
2.7
Reference Data .............................................................................................................................
2-10
2.7.1
Replacement Parts ..............................................................................................................
2-10
2.7.2
Ordering Parts ....................................................................................................................
2-11
Appendix A
ASCII Character Cross Reference
Standard ASCII Characters .......................................................................................................................
A-1
Extended ASCII Characters .......................................................................................................................
A-2
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TMC470 Installation & Maintenance
List of Illustrations
FIGURE
PAGE
1-1
TMC470 Controller Back Panel .............................................................................................................
1-2
TMC470 Table-top or Wall-Mounted Installation Drawing ........................................................................
1-1
1-5
1-3
Power Entry Module – Fuse Configurations ............................................................................................
1-6
1-4
Proper Wall-mount Bracket Orientation ................................................................................................
1-7
1-5
Mounting Bracket Orientation ..............................................................................................................
1-8
1-6
Gasket Orientation.............................................................................................................................
1-9
1-7
Mounting Bracket Orientation ..............................................................................................................
1-10
1-8
Panel (or Enclosure) Mounting Surface .................................................................................................
1-10
1-9
TMC470 Panel-mounted Installation Drawing ........................................................................................
1-11
1-10
Controller Orientation and Hardware Locations ......................................................................................
1-12
1-11
TMC470N NEMA Enclosure ..................................................................................................................
1-13
1-12
TMC470N NEMA Enclosure Installation Drawing .....................................................................................
1-15
1-13
TTL Connections ................................................................................................................................
1-19
1-14
RS232 Cable Diagrams .......................................................................................................................
1-21
1-15
RS485 Connections for Networked Markers ...........................................................................................
1-23
1-16
VDC Input Connections ......................................................................................................................
1-26
1-17
VDC Output Connections ....................................................................................................................
1-27
1-18
Input/Output Signals – Timing Diagram ...............................................................................................
1-28
2-1
Power Entry Module / Fuse Holder Assembly .........................................................................................
2-8
List of Tables
TABLE
PAGE
1-1
Optional TMC470 Panel Mount Kit (63150) ............................................................................................
1-8
1-2
Comm 1 Port – Pin Assignments ..........................................................................................................
1-20
1-3
Comm 2 Port – Pin Assignments ..........................................................................................................
1-20
1-4
I/O Port – Pin Assignments ................................................................................................................
1-25
1-5
Reserved Pattern Names for Remote Pattern Selection ...........................................................................
1-29
1-6
Ethernet Port – Pin Assignments ..........................................................................................................
1-30
2-1
Troubleshooting ................................................................................................................................
2-2
2-2
Comm Port Connectors.......................................................................................................................
2-3
2-3
I/O Port Connector ............................................................................................................................
2-4
2-4
TTL Port Connector ............................................................................................................................
2-5
2-5
Marker Port Connector .......................................................................................................................
2-6
2-6
Optional Auxiliary Axis Port Connector ..................................................................................................
2-7
2-7
Controller Power Inlet Fuses ...............................................................................................................
2-9
2-8
Spare Parts .......................................................................................................................................
2-10
vi
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TMC470 Installation & Maintenance
Section 1
Installation
1.1 OVERVIEW
This section documents the installation of the TMC470 controller. The controller may be used with a variety of Telesis
marking heads. Installation of the controller is almost identical for all systems. Where variations do exist, they will be clearly
identified within the text to inform you of the differences.
1.2 DESCRIPTION
The TMC470 controller contains an integrated keyboard and display. It runs the marking system software and generates
commands that control the marker. The marking system software is an easy-to-use program that is pre-installed in the
controller. Refer to the TMC470 Controller Operation Manual for details on using the software.
The TMC470 may be installed in any of the following configurations:
•
•
•
•
Standard controller placed on a table top
Standard controller with optional kit, mounted on a wall or exterior panel
Standard controller with optional kit, mounted in a customer-supplied panel or enclosure
Standard controller mounted in an optional Telesis TMC470N NEMA® enclosure.
The back panel provides various ports for connections to facility power, the marking head, and optional, remote
input/output devices. See Figure 1-1.
Figure 1-1. TMC470 Controller Back Panel
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TMC470 Installation & Maintenance
1.3 SPECIFICATIONS
The controller design and specifications are subject to change without prior notice.
Integrated Keyboard.............. Standard keyboard plus special function keys
Integrated Display ................. Eight-line liquid crystal display (LCD)
Rating .................................. NEMA 1 (I.P. 30) – table-top and wall-mounted configuration
NEMA 12 (I.P. 65) – panel-mounted configuration (customer-supplied panel or enclosure)
NEMA 12 (I.P. 65) – enclosure-mounted configuration (Telesis TMC470N enclosure)
Dimensions (H x W x D) ......... Table-top Configuration:
2.95 x 13.71 x 7.71 in. (74.9 x 348.2 x 195.8 mm) controller only
4.25 x 14.62 x 12.00 in. (108.0 x 371.4 x 304.8 mm) surrounding envelope
Wall-mounted Configuration:
7.71 x 14.62 x 3.29 in. (195.8 x 371.4 x 83.5 mm) controller & brackets
12.00 x 14.62 x 4.25 in. (304.8 x 371.4 x 108.0 mm) surrounding envelope
Panel-mounted Configuration:
8.53 x 14.53 x 3.17 in. (216.53 x 368.9 x 80.6 mm) controller, bezel & brackets
12.43 x 15.51 x 4.00 in. (315.6 x 394.0 x 101.5 mm) surrounding envelope
Enclosure-mounted Configuration:
11.82 x 19.00 x 16.00 in. (300.32 x 482.45 x 406.28 mm) TMC470N NEMA enclosure
14.00 x 23.00 x 22.00 in. (355.60 x 584.20 x 558.80 mm) surrounding envelope
Weight ................................. 3.69
3.90
5.52
28.1
lb.
lb.
lb.
lb.
(1.68 kg) controller only
(1.77 kg) controller and wall-mounting hardware
(2.51 kg) controller and panel-mounting hardware
(12.77 kg) controller, enclosure, and mounting hardware
Power Requirements .............. 95 to 250 VAC, 2 amps, 50-60 Hz, single phase
Communications ................... TTL, Discrete I/O, RS232, RS485 (multi-drop network), TCP/IP, USB (data backup/transfer)
Input Signals ........................ Twelve (12) total, optically isolated; 8 dedicated, 1 programmable, 3 available
(customer-supplied)
10 VDC (minimum voltage)
30 VDC (maximum voltage)
12 to 24 VDC (nominal voltage)
2.3 mA @ 12VDC; 4.9 mA @ 24VDC (nominal current)
Output Signals ...................... Six (6) total; 4 dedicated, 2 available
0.25 amps (maximum current)
0.50 ohms (maximum On resistance)
40 VDC (maximum line voltage)
12 to 24 VDC (nominal line voltage)
Operating Temperature .......... 32° to 122°F (0° to 50°C), non-condensing
Cooling ................................ Internal, thermostatically-controlled fan
Humidity .............................. 10% to 80%
Shock .................................. 30G/4ms half sine-wave (operating)
75G/11ms half sine-wave (non-operating)
Vibration .............................. 0.67G (5-500 Hz) random RMS (operating)
1.04G (2-200 Hz) random RMS (non-operating)
Storage and Handling Requirements
¡
Do not drop the containers.
Shock .................................. 75G/11ms half sine-wave
Vibration .............................. 1.04G (2-200 Hz) random RMS
¡
Store all containers in a dry, heated, non-condensing environment.
Temperature......................... -4° to 158°F (-20° to 70°C)
Humidity .............................. 5% to 95%
¡
1-2
Store all containers away from splashing or sprayed moisture.
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TMC470 Installation & Maintenance
1.4 UNPACKING THE EQUIPMENT
This section provides guidelines for receiving and unpacking the controller equipment.
CAUTION
If your equipment arrives during cold weather, allow the components to warm
up for several hours before opening the containers. Exposing the equipment to
room temperatures may cause condensation in the units.
When your controller arrives, check the shipping cartons for damaged corners, holes through the cardboard, or any other
signs of damage. Ask the delivery service to note any damage to the containers on the delivery receipt. Save all packing
materials in case you need to return any components.
Accounting for Equipment
Check the materials against the packing list. Note any discrepancies to your delivery service and request that they note the
discrepancies on the delivery receipt. The controller equipment consists of:
•
•
•
•
•
•
•
Controller
Controller Power Cable *
Connector Kit (spare fuses, mating I/O connectors & connector pins)
Optional Wall Mounting Kit, Part No. 42477 (brackets and attaching hardware)
Optional Panel Mounting Kit, Part No. 63150 (bezel, brackets, and attaching hardware)
Optional TMC470N NEMA Enclosure, Part No. 66738 (enclosure, bezel, brackets, and attaching hardware)
Additional components may be included with the controller.
Specific information for optional equipment may be provided in a separate installation manual.
Specific information for custom equipment may be provided in a custom addendum.
* A power cable is provided with the TMC470 controller for connection to a 115 VAC 60 Hz power source.
Inspecting for Damage
Place the components on a table and inspect each one for damage. Report any damage to your delivery service
immediately.
¡
Ensure the controller case is not cracked or otherwise damaged.
¡
Ensure the integrated display is not cracked, scratched, or damaged.
¡
Ensure the connectors and connector pins (on the back of the controller) are not bent or broken.
¡
Optional TMC470N NEMA enclosure:
Ensure the toggle switch on side of enclosure is not damaged.
Ensure the rubber cabinets seals in the cable access window on the back panel are intact and are not torn, damaged
or missing.
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TMC470 Installation & Maintenance
1.5 INSTALLATION REQUIREMENTS
The following items are required for proper installation of the controller.
NOTICE
It is the responsibility of the installing agency to ensure the
installation requirements are correctly implemented.
•
A dedicated, 10-amp, clean, conditioned-power, branch circuit must be provided for the marking system.
•
The controller should be visible from the marking head. Most standard marker cables are approximately 4m (13 ft.).
•
An electrical lockout switch must be installed if the controller is not visible from the marking head.
•
An emergency stop (E-STOP) switch must be installed if the controller cannot be easily reached from the marking
head. The switch must interrupt inlet power to the controller.
•
Systems that will use 230 VAC require a controller power cable that matches the source power outlet.
The cable must be supplied by the customer.
•
Power for remote I/O signals be supplied by the customer and must comply with I/O signal limitations.
Refer to Specifications for details.
•
Data cables to connect the controller with a remote I/O device or host computer must be supplied by the customer
and must comply with cable requirements. Refer to Data and Electrical Connections for details.
•
The controller should not be exposed to sprays, solvents, chemicals, or other contaminants.
•
Do not place the controller in an area where flammable mists or fumes are present.
•
Allow enough space around the controller to permit adequate ventilation and to facilitate access to the interface panel
for electrical connections. See Figure 1-2 for unit dimensions and surrounding clear space envelope.
•
Do not block the vents on the sides of the controller.
•
Contaminants. The vented TMC470 is rated NEMA 1 (IP30) and contains a thermostatically-controlled, variable speed
fan. Accordingly, in environments where solid and/or liquid contaminants are present, the possibility exists that these
contaminants can be drawn into the TMC470 controller and possibly result in failure of a number of electronic
components. For that reason, in these types of environments, the controller must be located in a sealed industrial
enclosure. To facilitate such installations, Telesis offers optional kits for panel-mounting and enclosure-mounting.
•
EMI Susceptibility. Although the system has been found to be in compliance with pertinent susceptibility standards,
care should be taken when installing near welders and other extreme generators of electromagnetic interference
(EMI). Particular care should be taken to ensure welder currents are not injected through the marking head chassis.
The marking head chassis is connected to the electrical service earth ground through the marking head cable. The
marking head should be electrically isolated from all surfaces which could become part of a welder current path.
1-4
34701F
TMC470 Installation & Maintenance
Figure 1-2. TMC470 Table-top or Wall-Mounted Installation Drawing
34701F
1-5
TMC470 Installation & Maintenance
1.6 INSTALLATION PROCEDURES
The TMC470 controller may be installed as a table-top unit, a wall-mounted unit, a panel-mounted unit, or an enclosuremounted unit. Refer to the appropriate procedures below for details.
1.6.1 Site Preparation
¡
Before beginning installation, refer to Installation Requirements and ensure all conditions for installation are satisfied.
¡
Ensure the marking head is installed before proceeding.
Refer to the marking head Installation/Maintenance Manual for guidelines and procedures.
CAUTION
The TMC470 is not a sealed unit. Protect it from potentially damaging conditions
and contaminants. Ensure the marking system is electrically isolated from any
devices that may generate extreme electromagnetic interference (EMI).
¡
Select an appropriate location for the controller. Keep these points in mind when choosing a location.
Ensure the controller will not be exposed to sprays, solvents, chemicals, moisture, dust, or other contaminants.
The marking head should be visible from the controller. Ensure the distance between the controller and the marking
head does not exceed the available cable length.
Allow enough space around the controller to permit adequate ventilation and to facilitate access to the back panel
for electrical connections. See Figure 1-2 for details.
Do not block the vents on the bottom of the controller.
¡
Position the controller power switch (power entry
module on back panel of controller) to OFF (O).
¡
Verify the controller fuse arrangement is correctly
configured for the facility power (115 or 230 VAC).
Remove the power supply cord from the power
entry module on the controller back panel.
Insert a very small, flat-tip screwdriver into the slot on the top of the power entry module cover.
See Figure 1-3. Gently pry the cover open.
Figure 1-3. Power Entry Module – Fuse Configurations
1-6
34701F
TMC470 Installation & Maintenance
1.6.1 Site Preparation (continued)
Pull the fuse holder out of the power entry module.
Verify the fuse arrangement is c0rrectly configured for the facility power (115 or 230 VAC).
115 VAC systems
•
•
•
Ensure the metal clip is installed on one side of the fuse holder. See Figure 1-3.
Ensure one fuse is installed in the fuse holder on the side opposite the clip
Ensure the metal clip is oriented toward the top.
230 VAC systems
•
•
•
Ensure the metal clip has been removed from the fuse holder. See Figure 1-3.
Ensure two fuses are installed in the fuse holder, one on each side.
Ensure the fuses are installed in the inward-most position in the fuse holder (at the end where the clip would
normally be installed). The fuses must be positioned away from the exposed end of the fuse holder.
Slide the fuse holder into the power entry module.
Close the power entry module cover.
¡
Proceed to Standard Table-top Installation, Optional Wall-mounted Installation, Optional Panel-mounted Installation, or
Optional TMC470N NEMA Enclosure Installation, as applicable.
1.6.2 Standard Table-top Installation
¡
Ensure Site Preparation is complete.
¡
Place the controller on a solid, sufficiently sturdy base.
¡
Proceed to Data and Electrical Connections.
1.6.3 Optional Wall-mounted Installation
¡
Ensure Site Preparation is complete.
¡
Locate the optional wall mounting kit # 42477.
¡
Carefully, lay the controller face down on a
surface that will not damage the display
screen.
¡
Remove the foam cushions from the
controller’s four corner footpads to expose the
mounting holes.
¡
Orient each bracket over its set of mounting
holes with the larger flange down (closer to
the controller) and the smaller flange outward
(toward the edge of the controller).
See Figure 1-4.
¡
Attach each bracket with two #6 self-tapping
screws (provided). Tighten securely.
¡
Drill the mounting surface for attaching the brackets. See Figure 1-2 for hole locations and dimensions.
¡
Attach the controller/bracket assembly to mounting surface with four M4 pan head screws (provided) or with suitable,
customer-supplied hardware. Tighten securely.
¡
Proceed to Data and Electrical Connections.
Figure 1-4. Proper Wall-mount Bracket Orientation
34701F
1-7
TMC470 Installation & Maintenance
1.6.4 Optional Panel-mounted Installation
The optional panel-mount kit (63150) is designed to mount the TMC470 Controller to a customer-supplied panel or a
customer-supplied enclosure. Additionally, the kit is used to mount the controller into a Telesis TMC470N NEMA enclosure.
The panel-mount kit contains the following components. Please locate and identify these parts before installing the
equipment.
Table 1-1. Optional TMC470 Panel Mount Kit (63150)
Part No.
Description
Qty.
63151
Bezel, TMC470
1
63149
Gasket, TMC470, Face to Bezel, Inner
1
63148
Gasket, TMC470, Bezel to Mounting Surface
1
63866
Bar Clamping, Middle, TMC470 Enclosure
1
63867
Rod, Threaded, M3x3"
6
24153
Nut, Hex Kepsnut, M3 (Tooth Washer)
12
62933
Bracket, Mounting, TMC470
2
14634
Screw, Pan Head, Phillips, M3-0.50 x 8mm
10
17637
Screw, Pan Head, Phillips, B Self Tap, #6 X 3/8"
4
Attaching the Mounting Brackets
¡
Carefully, lay the controller face down on a
surface that will not damage the display
screen.
¡
Remove the foam cushions from the
controller’s four corner footpads to expose the
mounting holes. See Figure 1-5.
CAUTION
Mounting the brackets incorrectly
will block air flow and may
damage the controller or cause
the unit to shutdown abnormally.
¡
Orient each bracket over its set of mounting
holes with the larger flange facing inward
(over the footpads) and the smaller flange
outward (toward the edge of the controller).
See Figure 1-5.
¡
Attach each bracket using two #6 x 3/8" selftapping screws. Tighten securely.
¡
Proceed to Installing the Bezel Gaskets.
Figure 1-5. Mounting Bracket Orientation
1-8
34701F
TMC470 Installation & Maintenance
Installing the Bezel Gaskets
¡
Locate two gaskets provided with the mounting kit.
¡
The Bezel-to-Mounting Surface gasket (63148) has pre-punched holes. It is to be applied to the back side of the bezel
along the perimeter. See Figure 1-6.
Apply as follows:
•
•
•
•
¡
Remove the paper cover to expose the adhesive.
Orient the adhesive side of gasket toward the bezel.
Align the gasket holes with the holes along the perimeter of the bezel.
Press gasket evenly around the bezel perimeter.
The Face-to-Bezel gasket (63149) has no holes. It is to be applied to the recessed area on the back side of the bezel.
See Figure 1-6.
Apply as follows:
•
•
¡
Center the gasket over the bezel opening with the wider edge of the gasket toward the top of the bezel.
The gasket should extend approximately 1/8 inch beyond the entire inside edge of the bezel opening.
Proceed to Attaching the Mounting Bezel.
Figure 1-6. Gasket Orientation
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Attaching the Mounting Bezel
NOTICE
The following step is not necessary if using the Telesis-supplied TMC470N Enclosure.
The cutout and mounting holes are already provided in the TMC470N Enclosure.
¡
Prepare the customer-supplied panel or customer-supplied enclosure for controller installation.
•
•
•
¡
See Figure 1-9 for dimensions and locations.
Cut out an area in the panel (or enclosure) for controller insertion.
Drill mounting holes around the perimeter of the cutout.
Access the backside of the mounting panel (or
the inside of the enclosure).
Note: If using the Telesis TMC470N
enclosure, you may need to loosen
the two quick-lock screws on the
front side of the lid to open it.
¡
Orient the bezel on the front side of the panel
(or enclosure) with the wider edge toward the
top. See Figure 1-7.
Figure 1-7. Mounting Bracket Orientation
¡
From the back side of the panel (or
enclosure), attach the bezel using ten M3 pan
head screws. See Figure 1-8 for screws
locations. Torque to 10 in-lb (1.12 N-m)
max.
¡
Locate the six remaining mounting holes
drilled in the panel (or enclosure).
¡
From the back side of the panel (or
enclosure), install one threaded rod in each
remaining mounting hole until it bottoms out
in the bezel.
¡
Secure each threaded rod with a locking hex
nut. Torque to 10 in-lb (1.12 N-m) max.
¡
Proceed to Attaching the Controller.
Figure 1-8. Panel (or Enclosure) Mounting Surface
1-10
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TMC470 Installation & Maintenance
Figure 1-9. TMC470 Panel-mounted Installation Drawing
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TMC470 Installation & Maintenance
Attaching the Controller
¡
Access the backside of the mounting panel (or the inside of the enclosure).
Note: If using the Telesis TMC470N enclosure, you may need to loosen the two quick-lock screws on the front side
of the lid to open it.
¡
Orient the controller on the backside of the panel (or inside if the enclosure) as follows. See Figure 1-10.
•
•
controller display/keyboard facing outward
controller connectors toward the top of panel or enclosure.
Note: If using the Telesis TMC470N enclosure, orient the controllers toward the hinged edge of the enclosure lid.
¡
Align the holes in the mounting flanges with the four threaded rods near the corners of the mounting bezel.
¡
Secure the controller using one M3 locking hex nut on each threaded rod. Torque to 10 in-lb (1.12 N-m) max.
¡
Position the clamping bar across the back of the controller and align the mounting holes with the two remaining
threaded rods. See Figure 1-10.
¡
Secure the clamping bar using one M3 locking hex nut on each threaded rod. Torque to 10 in-lb (1.12 N-m) max.
¡
Complete the TMC470 installation as follows:
If the controller is installed in a customer-supplied panel or a customer-supplied enclosure, proceed to Data and
Electrical Connections.
If the controller is installed in a Telesis TMC470N enclosure, proceed to Optional TMC470N NEMA Enclosure
Installation.
Figure 1-10. Controller Orientation and Hardware Locations
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TMC470 Installation & Maintenance
1.6.5 Optional TMC470N NEMA Enclosure Installation
The optional TMC470N NEMA Enclosure (66738) is designed to protect the TMC470 Controller in environments where solid
and/or liquid contaminants are present. This sealed, industrial enclosure inhibits these contaminants from being drawn into
the controller.
The controller is attached to a mounting bezel, which in turn is mounted to the enclosure. Two quick-lock screws allow the
enclosure lid to be opened to access the controller for maintenance and service. A cabinet seal module on the back side of
the enclosure allows cables to be routed to and from the controller without compromising the integrity of the enclosure.
Figure 1-11. TMC470N NEMA Enclosure
NOTICE
Typically, new marking systems that use a TMC470N NEMA enclosure are
shipped to the customer with the controller already installed in the enclosure.
However, if a TMC470N enclosure is being added to a customer’s existing
system, you must install the controller into the enclosure before proceeding.
¡
If the controller is already installed in the TMC470N enclosure, skip the next step.
¡
If the controller is not yet installed in the TMC470N enclosure, proceed as follows:
Refer to Panel-mounted Installation for instructions on mounting the controller in the enclosure.
After the controller is mounted, proceed with the following steps to install the enclosure.
¡
Ensure Site Preparation is complete.
¡
Position the toggle switch on the side of the enclosure to OFF (O).
¡
Loosen two hold-down screws that secure the enclosure lid. Open the lid to access the controller.
¡
Position the controller power switch (power entry module on back panel of controller) to OFF (O).
continued on next page…
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TMC470 Installation & Maintenance
Optional TMC470N NEMA Enclosure Installation (continued)
¡
Confirm the controller fuse arrangement is correctly configured for the facility power (115 or 230 VAC).
NOTICE
The power entry module may be configured for a line voltage of either 115 VAC
or 230 VAC. Systems using 115 VAC power require one fuse. Systems using 230
VAC require two fuses since both sides of the incoming voltage are not at
ground potential. Refer to Replacement Procedures for information on
controller fuses and configuring the power module.
¡
Inside the enclosure, locate the cabinet seal module near the bottom, center of the back panel.
Note: The cabinet seal module is where the interface cables will enter the enclosure. The module consists of several
rubber grommet blocks and an expansion plug that holds the grommets in place.
¡
In the cabinet seal module, loosen (but do not remove) the single hex nut in the expansion plug.
CAUTION
Be careful to not damage the rubber grommets when
removing them from the cabinet seal module.
¡
Working from the outside of the cabinet, press the rubber grommet blocks inward (into the enclosure) to remove them
from the cabinet seal module.
Note: Retain the rubber grommet blocks. They will be re-installed after all interface connections are made.
¡
Continue with procedures for Free-standing Configuration or Base-mount Configuration, as applicable.
Free-standing Configuration
¡
If the controller is to be used in a free-standing, table-top configuration, place the controller on a solid, sufficiently
sturdy base.
¡
Loosen two hold-down screws that secure the enclosure lid. Open the lid to access the controller.
¡
Proceed to Electrical and Data Connections.
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TMC470 Installation & Maintenance
Optional TMC470N NEMA Enclosure Installation (continued)
Enclosure Base-mount Configuration
As shipped, the enclosure is configured with footpads installed on the bottom of the unit. Optionally, you can re-configure
the enclosure so that the unit may be secured to the mounting surface.
¡
Carefully, turn the enclosure over to access the footpads on the bottom of the unit.
¡
Remove the four footpads from the enclosure.
¡
Locate the optional mounting kit (P/N 41192) supplied with the enclosure.
¡
Position one bracket at each footpad mounting location. Attach brackets with four screws (provided).
¡
Drill the mounting surface for attaching the brackets. See Figure 1-12 for hole dimensions.
¡
Attach the enclosure/controller assembly to the surface with suitable (customer-supplied) hardware.
¡
Loosen two hold-down screws that secure the enclosure lid. Open the lid to access the controller.
¡
Proceed to Electrical and Data Connections.
Figure 1-12. TMC470N NEMA Enclosure Installation Drawing
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1.7 DATA AND ELECTRICAL CONNECTIONS
CAUTION
The controller is shipped with electrostatic covers installed on the back panel
connectors. Leave the covers installed on those connectors that will not be used.
This will help to prevent electrostatic discharge (ESD) problems.
Never connect or disconnect the Marker cable or the Auxiliary Axis cable while
controller power is ON. Damage to the equipment will occur.
The back panel of the TMC470 controller provides the following ports for connections to facility power, the marking head,
and optional, remote input/output devices.
Required Connections:
• Power Entry Module
• Marker Port
Optional Connections:
• Auxiliary Axis Port
• TTL Port
• Comm 1 Port
• Comm 2 Port
• USB Port
• Ethernet Port
• I/O Port
Power Entry Module provides a standard power plug, with ground, to connect to facility power. TMC470 controllers
configured for 115 VAC 60 Hz power use a standard power cable (supplied with the controller). Systems configured for
230 VAC require a power cable that matches the source power outlet and must be must be supplied by the customer.
Refer to Power Connection for details.
Marker Port provides a DB37S connector for connecting the marking head using the marker cable (provided).
Refer to Marker Connection for details.
(optional) Auxiliary Axis Port is available only if the controller has the optional Auxiliary Axis board installed. This port
provides a DB37S connector for connecting optional auxiliary axis equipment. Optional axis components include the Z-axis
electromechanical tool post and the Theta-axis rotary drive unit. Refer to Auxiliary Axis Connection for details.
TTL Port provides a DB9S connector for connecting a remote push button device to start/stop print operations. Unless the
device is supplied by Telesis, the customer/installer must supply the mating connector, cabling, and switches.
Refer to TTL Connection for details.
Comm 1 Port provides a DB9P connector for connecting an RS232 device such as a host computer, remote terminal, or bar
code scanner. This port is used to transmit data, select patterns for printing, and control marker operation. Optionally, the
Comm 1 Port may be configured to support RS485 communications for networking multiple controllers to a single host.
Refer to Comm1 / Comm 2 Connections for details.
Comm 2 Port provides a DB9P connector for connecting an RS232 device such as a host computer, remote terminal, or bar
code scanner. This port is used to transmit data, select patterns for printing, and control marker operation.
Refer to Comm1 / Comm 2 Connections for details.
USB Port is provided for connecting a USB flash drive to backup or transfer data.
Ethernet Port provides a standard RJ45 connector for connecting a CAT5 cable from a TCP/IP network. This port may be
used to connect to a TCP/IP network. Refer to Ethernet Connection for details.
I/O Port provides a DB26P connector for connecting a remote I/O device such as a programmable logic controller (PLC). The
I/O device can remotely start or stop the marking cycle and may remotely select and load patterns. Output signals from the
marker may be transmitted to the I/O device to report system status. Refer to Remote I/O Connection for details.
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NOTICE
For TMC470N NEMA enclosure installations, route the electrical and data cables
through the cabinet seal module (on the back panel of the enclosure). The
rubber grommets will be installed in the cabinet seal module later in this
procedure after all electrical and data connections have been made.
1.7.1 Marker Connection
This is a required connection.
¡
Ensure the controller power switch (power entry module
on back panel of controller) is OFF (O).
¡
Connect the marker cable from the marking head to the
Marker Port [
] on the controller.
¡
Proceed with Power Connection.
1.7.2 Power Connection
This is a required connection.
The TMC470 may be configured for use with 115 VAC or
230 VAC power. Refer to the appropriate section below.
115 VAC Systems
For Table-top, Wall-mount, or Panel-mount Installations:
Ensure the controller power switch (power entry module on back panel of controller) is OFF (O).
Connect the controller power cable only to the receptacle in the power entry module.
Do not connect the power cable to facility power at this time.
Proceed with optional connections, as applicable.
If finished with all data and electrical connections, proceed to Controller Checkout.
For All TMC470N NEMA Enclosure Installations:
Obtain a power cable that has a compatible connector for the facility power outlet. The controller-end of the power
cable need not be terminated with a connector.
DO NOT CONNECT the power cable to facility power.
Connect the power cable ONLY to the terminal strip inside the enclosure, as follows:
Connect the HOT wire from the power cable to terminal strip connection L.
Connect the NEUTRAL wire from the power cable to terminal strip connection N.
Connect the GND wire from the power cable to terminal strip connection G.
Proceed with optional connections, as applicable.
If finished with all data and electrical connections, proceed to TMC470N NEMA Enclosure – Cabinet Seal.
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TMC470 Installation & Maintenance
230 VAC Systems
For Table-top, Wall-mount, or Panel-mount Installations:
Ensure the controller power switch (power entry module on back panel of controller) is OFF (O).
Obtain or fabricate a power cable that has compatible connectors for both the facility power outlet and the
receptacle in the controller power entry module.
Connect the power cable only to the receptacle in the controller power entry module.
Do not connect the power cable to facility power at this time.
Proceed with optional connections, as applicable.
If finished with all data and electrical connections, proceed to Controller Checkout.
For All TMC470N NEMA Enclosure Installations:
Obtain a power cable that has a compatible connector for the facility power outlet. The controller-end of the power
cable need not be terminated with a connector.
DO NOT CONNECT the power cable to facility power.
Connect the power cable ONLY to the terminal strip inside the enclosure, as follows:
Connect the L1 wire from the power cable to terminal strip connection L.
Connect the L2 wire from the power cable to terminal strip connection N.
Connect the GND wire from the power cable to terminal strip connection G.
Proceed with optional connections, as applicable.
If finished with all data and electrical connections, proceed to TMC470N NEMA Enclosure – Cabinet Seal.
1.7.3 Auxiliary Axis Connection
This is an optional connection.
Auxiliary axis components include the vertical (Z-axis) tool post and the rotational (Theta-axis) drive unit.
¡
Ensure the controller power switch (power entry module
on back panel of controller) is OFF (O).
¡
Refer to the Auxiliary Axis Installation Supplement
(supplied with the optional equipment) to install the
auxiliary axis components.
¡
Connect cable #25209 from the auxiliary axis
equipment to the Auxiliary Axis Port [
on the controller.
]
¡
Proceed with other optional connections, as applicable.
¡
If finished with all data and electrical connections:
For table-top, wall-mount, or panel-mount installations, proceed to Controller Checkout.
For all TMC470N NEMA enclosure installations, proceed to TMC470N NEMA Enclosure – Cabinet Seal.
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1.7.4 TTL Connection
This is an optional connection.
The TTL Port allows you to start and/or stop printing operations using a simple contact closure. Figure 1-13 shows a simple
contact closure circuit for remote START PRINT and STOP input signals.
¡
Obtain a Telesis-supplied TTL device.
or
¡
Fabricate an appropriate contact closure circuit for the TTL interface.
The customer/installer must supply the mating connector, switches, and cabling.
See Figure 1-13 for cable specifications, construction, and connections.
¡
Ensure the remote TTL device is OFF.
¡
Connect the data cable from the remote device to the
TTL Port [
] on the controller.
¡
Proceed with other optional connections, as applicable.
¡
If finished with all data and electrical connections:
For table-top, wall-mount, or panel-mount installations, proceed to Controller Checkout.
For all TMC470N NEMA enclosure installations, proceed to TMC470N NEMA Enclosure – Cabinet Seal.
Figure 1-13. TTL Connections
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1.7.5 Comm 1 / Comm 2 Connections
This is an optional connection.
The Comm 1 Port may be configured for use with an RS232 or RS485 device using Programmable or Extended Protocol.
The Comm 2 Port may be used only with an RS232 device using only Programmable Protocol.
¡
Obtain or fabricate the appropriate data cable.
For connections to DTE devices (see Figure 1-14), use Telesis cable Part No. 20799 or obtain a standard PC-to-PC cable
with one DB9S connector and one suitable connector to mate with the host.
For connections to DCE devices or to RS485 devices, the customer/installer must supply the mating connectors and
cabling and must fabricate an appropriate data cable for the host interface.
See Figure 1-14 for RS232 cable specifications, construction, and connections.
See Figure 1-15 for RS485 cable specifications, construction, and connections.
¡
Ensure the host device is OFF.
¡
Connect the data cable from the host to the
] or Comm 2 Port [
],
Comm 1 [
as applicable.
¡
Proceed with other optional connections, as applicable.
¡
If finished with all data and electrical connections:
For table-top, wall-mount, or panel-mount installations, proceed to Controller Checkout.
For all TMC470N NEMA enclosure installations, proceed to TMC470N NEMA Enclosure – Cabinet Seal.
Table 1-2. Comm 1 Port – Pin Assignments
Table 1-3. Comm 2 Port – Pin Assignments
PIN
SIGNAL
1
X–
RS485 bi-directional data –
1
2
RXD
Receive Data (to controller)
2
RXD
Receive Data (to controller)
3
TXD
Transmit Data (from controller)
3
TXD
Transmit Data (from controller)
RS485 bi-directional data +
4
+5VDC
Signal Ground
5
GND
4
X+
5
GND
6*
T+
7
8
9*
X–
DESCRIPTION
PIN
SIGNAL
DESCRIPTION
not used
power for optional bar code scanner
Signal Ground
RS485 Terminator +
6
not used
( internal jumper to pin 8 ) **
7
( internal jumper to pin 8 ) **
( internal jumper to pin 7 ) **
8
( internal jumper to pin 7 ) **
RS485 bi-directional data –
9
not used
** Refer to RS485 Interface for important information on jumper installation and proper network termination.
** The TMC470 Controller does not use hardware handshaking.
It does, however, provide an internal jumper between pin 7 and pin 8 for RTS – CTS signals.
The marking system software allows you set parameters for the controller to communicate with the host interface. The
hardware type (RS232 or RS485) and the protocol for the marking system must match the serial device with which it is
communicating. To provide maximum flexibility, the system software offers Extended Protocol and Programmable Protocol.
Each interface option (RS232 and RS485) and each protocol are described later in this section.
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RS232 Interface
The RS232 interface is most often used with remote devices such as host computers, terminals, or bar code scanners.
•
•
Using the Comm 1 Port, the RS232 interface may use Extended Protocol or Programmable Protocol.
Using the Comm 2 Port, the RS232 interface may us only Programmable Protocol.
The Telesis protocols are briefly described later in this section and fully detailed in the TMC470 Controller Operation Manual.
The system supports XON/XOFF handshaking. When the system is unable to accept serial transmissions, it transmits the
XOFF character. When the serial port is available, XON is transmitted. Similarly, if the serial port receives an XOFF signal
while transmitting, the transmission is suspended until an XON is received.
Figure 1-14 shows connections to both DTE (data terminal equipment) and DCE (data circuit-terminating) devices.
Figure 1-14. RS232 Cable Diagrams
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TMC470 Installation & Maintenance
RS485 Interface
The TMC470 Controller provides a half Duplex RS485 interface. This interface is normally used when communicating over
long transmission distances or when several markers are networked. The RS485 interface is required in multi-drop network
applications.
NOTICE
Since RS485 communications transmit and receive signals on the same line, a
delay is required to manage the signal traffic. A delay allows time for the port
to switch from receive-mode to transmit-mode, and vice versa.
The TMC470 software provides a parameter to define the time delay. Refer to
the TMC470 Controller Operation Manual (see Host Communication Properties)
for details on setting the 485 RxÆTx Delay parameter. Set the parameter, as
required, to match the customer-supplied RS485 device. When using an RS485
interface, you must use the Comm 1 Port and Telesis Extended Protocol.
Some communications devices use RS422 and connect the transmit and receive
signals together. If these devices are used, the installer must ensure the
transmitter is turned OFF when the device is not transmitting.
When multiple markers are used in a multi-drop network, each one must be assigned a unique Station ID number. The
Station ID is used by the communications protocol to direct messages to a specific marker. Refer to the TMC470 Controller
Operation Manual for details on configuring the Station ID software parameter.
Figure 1-15 shows sample connections where several controllers are networked to a single host.
•
The Comm 1 Port mating connector must use a jumper across pins 6 and 9 on the Comm 1 Port mating connector.
The jumper places a 220 ohm resistance across the X+ and X– signals to ensure proper network termination.
•
If more than one controller is used, install only one jumper for the entire network of controllers. See Figure 1-15.
Specifically, jumper pins 6 and 9 on the Comm 1 Port mating connector on the last controller of the network.
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Figure 1-15. RS485 Connections for Networked Markers
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TMC470 Installation & Maintenance
Programmable Protocol
Programmable Protocol is used to communicate with devices where one-way communication is required, such as with bar
code scanners. It provides no error checking or acknowledgment of the transmitted data. The Programmable Protocol
parameters define which characters to extract from the data transmission and how to employ them during the marking
operation. Refer to the TMC470 Controller Operation Manual for details on using Programmable Protocol.
NOTICE
The host message may contain ASCII characters that define the Start,
Terminating, and Ignore characters within the transmitted data. To identify
these ASCII characters, you must specify their decimal equivalents when
setting up the following parameters. Refer to the ASCII Cross Reference table
in Appendix A to view decimal and hexadecimal equivalents of ASCII
characters.
Extended Protocol
Extended Protocol provides two-way communication with error checking. It is designed to provide secure communications
with an intelligent host device using pre-defined message formats, response formats, and message types. It also provides
hand-shaking to detect faults in the transmitted messages, effectively verifying that the data is properly received.
You must use Extended Protocol to communicate with an RS485 device. Extended Protocol also allows for multidrop communications so that the multiple markers may be networked through a host computer. All communications are
carried out in a master/slave relationship. Only the host has the ability to initiate communications. The marker
communicates only in response.
Refer to the TMC470 Controller Operation Manual for details on using Extended Protocol and for information on message
format, response format, and block check codes (message verification).
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1.7.6 Remote I/O Connection
This is an optional connection.
The I/O port is optically isolated. The I/O Port allows you to transmit I/O signals between the controller and a remote I/O device
such as a programmable logic controller (PLC). The I/O device can remotely start or stop the marking cycle and may remotely
select and load patterns. Output signals from the marker may be transmitted to the I/O device to report system status.
Refer to VDC Input Connections, VDC Output Connections, Remote I/O Signal Timing, and Remote Pattern Selection (later
in this section) for more information on using the I/O interface.
¡
Fabricate the appropriate data cable.
The customer/installer must supply the mating connector, switches, cabling, and DC power source.
See Figure 1-16 for VDC input cable specifications, construction, connections.
See Figure 1-17 for VDC output cable specifications, construction, connections.
¡
Ensure the remote I/O device is OFF.
¡
Connect the data cable from the remote I/O source to
] on the controller.
the I/O Port [
¡
Proceed with other optional connections, as applicable.
¡
If finished with all data and electrical connections:
For table-top, wall-mount, or panel-mount installations, proceed to Controller Checkout.
For all TMC470N NEMA enclosure installations, proceed to TMC470N NEMA Enclosure – Cabinet Seal.
Table 1-4. I/O Port – Pin Assignments
PIN
1
SIGNAL
DESCRIPTION
INPUT COMM
Common for all inputs (+ or – supply)
2
START PRINT
Input: Begins a print cycle
3
STOP
Input: Stops the print cycle
4
SELECT_0
Input – see Remote Pattern Selection for details
5
SELECT_1
Input – see Remote Pattern Selection for details
6
SELECT_2
Input – see Remote Pattern Selection for details
7
SELECT_3
8
SELECT_6
9
SELECT_4
10
SELECT_5
Input – see Remote Pattern Selection for details
11
SPARE_IN_1
Input – spare input signal for use with custom applications
12
SPARE_IN_2
Input – spare input signal for use with custom applications
13
SPARE_IN_3
Input – spare input signal for use with custom applications
Input – see Remote Pattern Selection for details
(1)
14-18
19
Input – see Remote Pattern Selection for details
Input – see Remote Pattern Selection for details
not used
OUTPUT COMM
Common for all outputs (+ or – supply)
20
DONE
Output: Indicates print cycle is complete
21
READY
Output: Indicates system is ready for Start Print signal
22
PAUSED
Output: Indicates system is paused.
23
NO_FAULT (2)
Output – ON indicates normal; OFF indicates fault condition
24
SPARE_OUT_1
Output – spare output signal for use with custom applications
25
SPARE_OUT_2
Output – spare output signal for use with custom applications
26
2
not used
(1)
The SEL_6 input may be configured to remotely select and load patterns or to remotely place the
marker online. Refer to the TMC470 Controller Operation Manual (Startup, I/O Options) for details.
(2)
The NO_FAULT output is normal ON to indicate system is operational. It will remain ON during the
print cycle. The signal will turn OFF if an over-temperature condition occurs in the controller. A print
cycle cannot be initiated when this signal is OFF.
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VDC Input Connections
Figure 1-16 shows a simple contact closure circuit for remote VDC input signals.
Figure 1-16. VDC Input Connections
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VDC Output Connections
Figure 1-17 shows connections for the TMC470 output signals. To demonstrate differences in polarity, the graphic illustrates
both sourcing outputs and sinking outputs.
Figure 1-17. VDC Output Connections
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TMC470 Installation & Maintenance
Remote I/O Signal Timing
The controller is configured at the factory to operate with 12-to-24 VDC I/O signals (nominal voltage). The I/O Port provides
access to the marking cycle control circuit. Figure 1-18 illustrates the timing relationship of the three marking control
signals (START PRINT, READY, and DONE).
Figure 1-18. Input/Output Signals – Timing Diagram
READY and DONE are used to determine when the marker is available.
•
The marker will acknowledge a START PRINT command only when READY and DONE are both high (ON).
•
When the marker receives a START PRINT command, both READY and DONE go low (OFF).
•
DONE will go high (ON) after printing is complete. DONE must be high (on) in order to select a pattern.
•
If READY is high (ON) during pattern selection, it will temporarily go low (OFF) until the pattern is loaded and the system
ensures all conditions are okay to proceed. If possible, READY will then go high (ON).
•
READY will go high (ON) after the marker returns to the Park position, provided all parameters to continue printing are within
limits (e.g., serial number limit is not exceeded and variable text fields* contain data).
Note: If the Clear option is enabled for the variable text field(s) in a pattern, the system will clear the field(s) of data
after printing. The READY signal will remain low (OFF) until all variable text fields contain data.
•
If the print cycle is stopped, DONE will go high (ON), but READY will remain low (OFF).
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Remote Pattern Selection
The Remote Pattern Selection feature allows the system to monitor up to seven dedicated input signals transmitted from a
remote, customer-supplied I/O device. These signals (SEL_6 through SEL_0) are received at the TMC470 I/O Port. The
ON/OFF combinations of the seven input signals generate binary codes ranging from 0000000 (0) through 1111111 (127).
Each code corresponds to specific reserved pattern name. As the seven input signals are received, the system interprets
their codes, then loads the pattern with reserved pattern name associated with that code. Note that if all seven input
signals are OFF, the resulting code is 0000000. This effectively disables the Remote Pattern Selection feature so the
pattern may be loaded manually by the operator.
Note that the SEL_6 input signal may be configured either to remotely select patterns stored in the controller or to remotely
place the marker online. If configured for online usage, its ON/OFF state will be ignored during remote pattern selection. This
will reduce the number of patterns available for remote selection from 127 to 63.
If this feature is used, all patterns that will remotely selected and loaded must be stored in the controller using the following
specific pattern names as listed below.
Table 1-5. Reserved Pattern Names for Remote Pattern Selection
Signal State
Sel_ (n)
6543210
Reserved
Pattern
Name
Signal State
Sel_ (n)
6543210
Reserved
Pattern
Name
Signal State
Sel_ (n)
6543210
Reserved
Pattern
Name
Signal State
Sel_ (n)
6543210
Reserved
Pattern
Name
0000000
(disabled)
0I00000
PAT032
I000000
PAT064
II00000
PAT096
000000I
PAT001
0I0000I
PAT033
I00000I
PAT065
II0000I
PAT097
00000I0
PAT002
0I000I0
PAT034
I0000I0
PAT066
II000I0
PAT098
00000II
PAT003
0I000II
PAT035
I0000II
PAT067
II000II
PAT099
0000I00
PAT004
0I00I00
PAT036
I000I00
PAT068
II00I00
PAT100
0000I0I
PAT005
0I00I0I
PAT037
I000I0I
PAT069
II00I0I
PAT101
0000II0
PAT006
0I00II0
PAT038
I000II0
PAT070
II00II0
PAT102
0000III
PAT007
0I00III
PAT039
I000III
PAT071
II00III
PAT103
000I000
PAT008
0I0I000
PAT040
I00I000
PAT072
II0I000
PAT104
000I00I
PAT009
0I0I00I
PAT041
I00I00I
PAT073
II0I00I
PAT105
000I0I0
PAT010
0I0I0I0
PAT042
I00I0I0
PAT074
II0I0I0
PAT106
000I0II
PAT011
0I0I0II
PAT043
I00I0II
PAT075
II0I0II
PAT107
000II00
PAT012
0I0II00
PAT044
I00II00
PAT076
II0II00
PAT108
000II0I
PAT013
0I0II0I
PAT045
I00II0I
PAT077
II0II0I
PAT109
000III0
PAT014
0I0III0
PAT046
I00III0
PAT078
II0III0
PAT110
000IIII
PAT015
0I0IIII
PAT047
I00IIII
PAT079
II0IIII
PAT111
00I0000
PAT016
0II0000
PAT048
I0I0000
PAT080
III0000
PAT112
00I000I
PAT017
0II000I
PAT049
I0I000I
PAT081
III000I
PAT113
00I00I0
PAT018
0II00I0
PAT050
I0I00I0
PAT082
III00I0
PAT114
00I00II
PAT019
0II00II
PAT051
I0I00II
PAT083
III00II
PAT115
00I0I00
PAT020
0II0I00
PAT052
I0I0I00
PAT084
III0I00
PAT116
00I0I0I
PAT021
0II0I0I
PAT053
I0I0I0I
PAT085
III0I0I
PAT117
00I0II0
PAT022
0II0II0
PAT054
I0I0II0
PAT086
III0II0
PAT118
00I0III
PAT023
0II0III
PAT055
I0I0III
PAT087
III0III
PAT119
00II000
PAT024
0III000
PAT056
I0II000
PAT088
IIII000
PAT120
00II00I
PAT025
0III00I
PAT057
I0II00I
PAT089
IIII00I
PAT121
00II0I0
PAT026
0III0I0
PAT058
I0II0I0
PAT090
IIII0I0
PAT122
00II0II
PAT027
0III0II
PAT059
I0II0II
PAT091
IIII0II
PAT123
00III00
PAT028
0IIII00
PAT060
I0III00
PAT092
IIIII00
PAT124
00III0I
PAT029
0IIII0I
PAT061
I0III0I
PAT093
IIIII0I
PAT125
00IIII0
PAT030
0IIIII0
PAT062
I0IIII0
PAT094
IIIIII0
PAT126
00IIIII
PAT031
0IIIIII
PAT063
I0IIIII
PAT095
IIIIIII
PAT127
Note: Pattern names shaded in gray may be remotely selected only if the SEL_6 input is configured for pattern selection.
Refer to the TMC470 Controller Operation Manual (Startup, I/O Options) for details.
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TMC470 Installation & Maintenance
1.7.7 Ethernet/Merlin Connection
This is an optional connection.
This port may be used to connect the TMC470 Controller to a remote device or application over a TCP/IP network.
Optionally, this may include connecting to the Telesis Merlin®III Visual Design Software, either over the network or directly
to the computer running the Merlin III software.
Table 1-6. Ethernet Port – Pin Assignments
PIN
SIGNAL
1
TXP
DESCRIPTION
Transmit Data +
(bi-directional pair +A)
2
TXN
Transmit Data –
(bi-directional pair –A)
3
RXP
Receive Data +
(bi-directional pair +B)
4
TP45
(bi-directional pair +C)
5
TP45
(bi-directional pair –C)
6
RXN
7
TP78
Receive Data –
(bi-directional pair +D)
(bi-directional pair –B)
8
TP78
(bi-directional pair –D)
There are several options when connecting the TMC470 to a computer running the Merlin III software.
Option 1
Direct Connection
Neither the computer nor the TMC470 are on a network.
The TMC470 connects directly to the computer.
Option 2
Direct Connection
The computer is on a network, but the TMC470 is not.
The TMC470 connects directly to the computer or to the computer through a switch.
This requires the computer to have two (2) Ethernet ports – one for the network and one for the TMC470.
Option 3
Network Connection
Both the computer and the TMC470 are on the network.
The TMC470 connects indirectly to the computer through a network hub or switch.
While connected to the Merlin III software:
¡
The Merlin III interface (via the computer) provides complete operational control of the marking system.
¡
The TMC470 I/O Port remains functional for remote input/output signals. Refer to Remote I/O Connection for details.
¡
The PRINT key and the STOP (ABORT) key on the TMC470 keyboard remain functional.
¡
All other keys on the TMC470 keyboard are disabled.
1-30
34701F
TMC470 Installation & Maintenance
Perform the following steps to connect and configure the TMC470 Ethernet port.
NOTICE
If the TMC470 Controller will connect directly to the PC running the Merlin III
software, you must use an Ethernet crossover adapter (or crossover cable) to
connect the devices.
If the TMC470 Controller will connect to the PC running the Merlin III software
across a LAN (through a network hub or a network switch), you must contact
your LAN administrator to obtain a Local IP Address for the controller.
¡ Obtain Connection Hardware
You will need the following items to connect the TMC470 to the Merlin III software.
• PC with Merlin III software installed
• Standard CAT 5 Ethernet cable
• Ethernet crossover adapter (if connecting directly to the PC)
Note: Merlin III Kit P/N 66666 contains the following components.
Merlin III Software CD
P/N 64832, Qty. 1
CAT 5 Ethernet Cable (3m)
P/N 66685, Qty. 1
Ethernet Crossover Adapter P/N 66689, Qty. 1
¡
Connect the TMC470
Direct Connection
Use these procedures if the TMC470 will connect directly to the PC running the Merlin III software.
Turn the PC and TMC470 OFF.
Connect the Ethernet crossover adapter to the Ethernet port [
Controller.
] on the back panel of the TMC470
Connect the CAT 5 Ethernet cable to the Ethernet crossover adapter.
Connect the CAT 5 Ethernet cable to an available Ethernet port on the PC.
Network Connection
Use these procedures if the TMC470 will indirectly connect to the PC running the Merlin III software via a network
hub or network switch.
Turn the TMC470 OFF.
Connect the CAT 5 Ethernet cable to the Ethernet port [
] on the back panel of the TMC470 Controller.
Connect the CAT 5 Ethernet cable to an available Ethernet port on the network hub or network switch.
Contact your LAN administrator to obtain a Local IP Address for the TMC470 Controller.
You will need this information to properly configure the TMC470 network parameters.
¡
Configure the TMC470 Ethernet parameters.
Refer to the TMC470 Controller Operation Manual for details. See Ethernet/Merlin Communication Properties.
¡
Proceed with other optional connections, as applicable.
¡
If finished with all data and electrical connections:
For table-top, wall-mount, or panel-mount installations, proceed to Controller Checkout.
For all TMC470N NEMA enclosure installations, proceed to TMC470N NEMA Enclosure – Cabinet Seal.
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TMC470 Installation & Maintenance
1.7.8 TMC420N NEMA Enclosure – Cabinet Seal
This is a required procedure for installations that use the TMC420N NEMA enclosure.
¡
Ensure all electrical and data connections are complete before proceeding.
¡
Locate and examine the rubber grommet blocks that were removed from the cabinet seal module.
Each block is made up of two halves. The blocks contain pre-cut, concentric rings that provide multiple layers of rubber
sheeting. Each layer may be peeled off and removed to provide a custom fit around each cable that passes through the
cabinet seal module.
¡
Separate the blocks and, for each cable, peel off the MINIMUM NUMBER OF LAYERS necessary to fit the cable in the
block when the halves are reassembled. Do not remove any more layers of the rubber sheeting than necessary
to provide a tight fit around the cable.
¡
Working from the inside of the enclosure, place the block halves around the cables and insert the rubber grommet
blocks into the cabinet seal module.
¡
From the inside of the enclosure, press the blocks outward until the back edge of the blocks are flush against the
outside edge of the cabinet seal module.
¡
Tighten the single hex nut in the expansion plug to seal the rubber grommets around the cables.
¡
Locate the power switch on the back panel of the controller (mounted in the lid of the enclosure). Position the power
switch to ON ( I ).
¡
Carefully close the enclosure lid. Ensure the interior cables do not interfere with the rubber seal around the perimeter
of the lid.
¡
Secure the enclosure lid by tightening the two hold-down screws.
¡
Proceed to Controller Checkout.
1.8 CONTROLLER CHECKOUT
¡
Once all data and electrical connections have been made, connect the controller power cable to facility power.
¡
Turn the controller on. Position the controller power switch (on power entry module) to ON ( I ).
¡
Confirm the marking system software starts and is displayed on the controller LCD screen.
¡
Auxiliary Axis Configuration. If the marking system will use the Z-axis or Theta-axis, you must setup parameters in
the marking system software to enable and configure the axis. Refer to the TMC470 Controller Operation Manual.
¡
Host Interface Configuration. If the marking system uses a host interface (RS232, RS485, TCP/IP), you must setup
parameters in the marking system software for the controller to communicate with the host. Refer to the TMC470
Controller Operation Manual for details on using and configuring the marking system software.
¡
TTL and Remote I/O Configuration. If the marking system uses a remote I/O device or remote TTL device, you
should test the interface for proper operation. Refer to the TMC470 Controller Operation Manual for details on using and
testing the marking system.
¡
Turn the controller off. Position the controller power switch (on power entry module) to OFF ( O ).
¡
Perform all other adjustments that may be required for the marking system.
For details, refer to Installation Adjustments located in the marking head Installation/Maintenance Manual.
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TMC470 Installation & Maintenance
Section 2
Maintenance
2.1 OVERVIEW
This section provides troubleshooting, testing, repair, and replacement procedures for the TMC470 Controller. Any
servicing, maintenance, or repair of the controller that is not explicitly contained in this document must be performed only
by repair agencies authorized by Telesis Technologies, Inc.
2.2 MAINTENANCE PRECAUTIONS
WARNING
Turn all power OFF when performing maintenance on the controller.
Ensure that all equipment energy sources are turned off or disconnected and that
the switches are either locked or tagged while equipment is cleaned or serviced.
The controller contains a lithium battery. Improper disposal of lithium batteries
may cause an explosion. Always dispose of the lithium battery in a proper manner.
2.3 CLEANING PROCEDURES
Perform the following steps to clean the controller.
CAUTION
Do not press on the LCD display nor apply heavy pressure to the keyboard.
Be extremely careful not to scratch the LCD display or the membrane keyboard.
Do not apply liquids directly to the controller. Apply liquid to cleaning cloth instead.
Application of excessive liquid may enter the case and damage internal components.
¡
Remove electrical power from the marking system.
¡
Brush loose dust and debris from the controller.
¡
Ensure the fan inlet and vent outlet louvers (on the bottom of the controller) are not obstructed.
Remove dust and debris as required.
¡
Apply isopropyl alcohol or mild, water-based solvent to a soft, clean, lint-free cloth.
Wipe the case, keyboard, and LCD.
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2-1
TMC470 Installation & Maintenance
2.4 TROUBLESHOOTING
This section provides troubleshooting information for the controller. Refer to Table 2-1 to identify problems, their probable
causes, and corrective action. If a defective component has been identified, refer to appropriate maintenance instructions
to repair or replace the component. If these procedures fail to correct the problem, contact Telesis Customer Support.
Table 2-1. Troubleshooting
PROBLEM
Controller not energized (no display)
CORRECTIVE ACTION
1. Check power to the controller.
2. Ensure switch on controller power entry module is positioned ON.
3. Check the controller inlet fuse. Refer to Replacement Procedures.
4. verify proper fuse configuration. Refer to Replacement Procedures.
5. If no problem is found, contact Telesis Customer Support for assistance or contact a
Telesis-authorized maintenance agency for repair.
Serial communication fault
1. Ensure host is connected to proper controller port.
2. Check the communication cable.
3. Using the marking system software, display the Host Setup parameters and verify
the parameters are properly configured.
4. Connect an RS232 diagnostic light box between the communication cable and the
controller. Verify signals to and from the host computer are operating properly.
Discrete I/O fault
If the problem is an input fault, disconnect the I/O cable and verify the input voltages.
Refer to Testing Procedures.
If the problem is an output fault, disconnect the I/O cable and verify the output
resistance. Refer to Testing Procedures.
TTL Input fault
Disconnect the I/O cable from the TTL Port and verify the resistance at the connector.
Refer to Testing Procedures.
Note: Resistance values are based on closed switches.
Loss of system parameters or data after
power is down
2-2
Contact Telesis Customer Support for assistance.
34701F
TMC470 Installation & Maintenance
2.5 TESTING PROCEDURES
This section provides reference tables for the connectors on the controller back panel. These tables include pin
assignments, signal names, signal descriptions, and acceptable test values.
2.5.1 Comm 1 and Comm 2 Port Testing
The following information is provided to check the Comm 1 and Comm 2 Ports.
¡
Remove electrical power from the marking system.
¡
Disconnect the interface cable from the Comm 1 or Comm 2 Port, as applicable.
NOTICE
Voltage measurements are to be taken with power ON.
¡
Apply electrical power to the marking system.
¡
Check for the appropriate signals at the Comm 1 or Comm 2 Port connector, as applicable. Refer to Table 2-2.
Table 2-2. Comm Port Connectors
COMM 1
PIN
COMM 1
SIGNAL
1
X–
2
RXD
Receive Data (to controller)
3
TXD
Transmit Data (from controller)
4
X+
RS485 bi-directional data +
(internal jumper to pin 6 through a 220 ohm resistor
6
T+
RS-485 Terminator +
(internal jumper to pin 4 through a 220 ohm resistor
DESCRIPTION
RS485 bi-directional data
(internal jumper to pin 9)
7
(internal jumper to pin 8)
8
(internal jumper to pin 7)
9
X–
RS485 bi-directional data –
(internal jumper to pin 1)
COMM 2
PIN
COMM 2
SIGNAL
2
RXD
Receive Data (to controller)
3
TXD
Transmit Data (from controller)
4
+5VDC
DESCRIPTION
Power for optional bar code scanner
7
(internal jumper to pin 8)
8
(internal jumper to pin 7)
Note: Pin 5 is RS232 Signal Return (ground) on both Comm 1 and Comm 2.
34701F
2-3
TMC470 Installation & Maintenance
2.5.2 I/O Port Testing
The I/O port is optically isolated. The following information is provided to check the discrete input and output signals at the
I/O Port on the controller back panel.
¡
Remove electrical power from the marking system.
¡
Disconnect the interface cable from the I/O Port on the controller back panel.
NOTICE
All discrete I/O signals are to be checked in their ON state.
For testing input signals, 12-24 VDC must be supplied from an external source.
¡
Apply electrical power to the marking system.
¡
Apply electrical power to the remote I/O source.
¡
Measure the resistance at the I/O Port connector. Refer to Table 2-3 for acceptable values.
Table 2-3. I/O Port Connector
PIN-to-PIN
SIGNAL
DESCRIPTION
1 to 2
START PRINT
Input: Begins a print cycle
12 to 24 VDC
1 to 3
STOP
Input: Stops the print cycle
12 to 24 VDC
1 to 4
SELECT_0
Input – see Remote Pattern Selection for details
12 to 24 VDC
1 to 5
SELECT_1
Input – see Remote Pattern Selection for details
12 to 24 VDC
1 to 6
SELECT_2
Input – see Remote Pattern Selection for details
12 to 24 VDC
1 to 7
SELECT_3
Input – see Remote Pattern Selection for details
12 to 24 VDC
1 to 8
SELECT_6
Input – see Remote Pattern Selection for details
12 to 24 VDC
1 to 9
SELECT_4
Input – see Remote Pattern Selection for details
12 to 24 VDC
1 to 10
SELECT_5
Input – see Remote Pattern Selection for details
12 to 24 VDC
1 to 11
SPARE_IN_1
Input – spare signal for use with custom applications
12 to 24 VDC
1 to 12
SPARE_IN_2
Input – spare signal for use with custom applications
12 to 24 VDC
1 to 13
SPARE_IN_3
Input – spare signal for use with custom applications
12 to 24 VDC
19 to 20
DONE
Output: Indicates print cycle is complete
2 ohms (maximum)
19 to 21
READY
Output: Indicates system ready for Start Print
2 ohms (maximum)
19 to 22
PAUSED
Output: Indicates system is paused.
2 ohms (maximum)
2
19 to 23
NO_FAULT
Output – ON indicates normal; OFF indicates fault condition
19 to 24
SPARE_OUT_1
Output – spare signal for use with custom applications
2 ohms (maximum)
19 to 25
SPARE_OUT_2
Output – spare signal for use with custom applications
2 ohms (maximum)
Note: Pin 1 is Input Common for all input signals (+ or –)
Pin 19 is Output Common for all output signals (+ or –)
2-4
ACCEPTABLE VALUE
34701F
2 ohms (maximum)
TMC470 Installation & Maintenance
2.5.3 TTL Port Testing
The following information is provided to check the input signals at the TTL Port on the controller back panel.
¡
Remove electrical power from the marking system.
¡
Disconnect the interface cable from the TTL Port on the controller back panel.
NOTICE
All TTL input signals are to be checked in their ON state.
¡
Apply electrical power to the remote I/O source.
¡
Measure the resistance at the TTL connector. Refer to Table 2-4 for acceptable values.
Table 2-4. TTL Port Connector
PIN-to-PIN
SIGNAL
DESCRIPTION
ACCEPTABLE VALUE
2 to 3
START PRINT
Input signal: Begins a print cycle
10 ohms (maximum)
2 to 4
STOP
Input signal: Stops the print cycle
10 ohms (maximum)
Note: Pin 2 is System Digital Ground (common)
34701F
2-5
TMC470 Installation & Maintenance
2.5.4 Marker Port Testing
The following information is provided to check the signals at the Marker Port on the controller back panel.
¡
Remove electrical power from the marking system.
¡
Disconnect the marker cable from the Marker Port on the controller back panel.
¡
Take measurements at Marker Port connector. Refer to Table 2-5 for acceptable values.
¡
If any motor phase readings are higher than listed as acceptable, the controller internal fuses must be checked.
If any motor phase readings are lower than listed as acceptable, contact Telesis Customer Support for service.
Table 2-5. Marker Port Connector
PIN-to-PIN
SIGNAL
DESCRIPTION
1 to 2
PHS 1A
X-axis Motor Phase A
21.4K ohms ± 5%
3 to 4
PHS 1/B
X-axis Motor Phase B
21.4K ohms ± 5%
5 to 6
PHS 2/A
Y-axis Motor Phase A
21.4K ohms ± 5%
7 to 8
PHS 2/B
Y-axis Motor Phase B
12 to 31
SOL DRV 1
Solenoid #1 Driver Diode Check
place + lead on pin 12
0.55 volts DC
13 to 31
SOL DRV 2
Solenoid #2 Driver Diode Check
place + lead on pin 13
0.55 volts DC
14 to 31
SOL DRV 3
Solenoid #3 Driver Diode Check
place + lead on pin 14
0.55 volts DC
15 to 31
SOL DRV 4
Solenoid #4 Driver Diode Check
place + lead on pin 15
0.55 volts DC
16 to 31
SOL DRV 5
Solenoid #5 Driver Diode Check
place + lead on pin 16
0.55 volts DC
17 to 31
SOL DRV 6
Solenoid #6 Driver Diode Check
place + lead on pin 17
0.55 volts DC
18 to 31
SOL DRV 7
Solenoid #7 Driver Diode Check
place + lead on pin 18
0.55 volts DC
19 to 31
SOL DRV 8
Solenoid #8 Driver Diode Check
place + lead on pin 19
0.55 volts DC
20 to 22
HOME MTR1
X-axis Motor Home
place + lead on pin 22
9.4K ohms ±5%
20 to 25
HOME MTR2
Y-axis Motor Home
place + lead on pin 25
9.4K ohms ±5%
20 to 26
TAG SENSE
(unused signal)
place + lead on pin 26
9.4K ohms ±5%
20 to 27
INTERLOCK
(unused signal)
place + lead on pin 27
9.4K ohms ±5%
20 to 29
/START
Start Print
place + lead on pin 29
9.4K ohms ±5%
20 to 33
X DIR
Optional signal for custom use
place + lead on pin 33
> 800K ohms
20 to 34
X STEP
Optional signal for custom use
place + lead on pin 34
> 800K ohms
20 to 35
Y DIR
Optional signal for custom use
place + lead on pin 35
> 800K ohms
20 to 36
Y STEP
Optional signal for custom use
place + lead on pin 36
> 800K ohms
Note: Pins 21 and 24 are +5 VDC
Pins 31 and 32 are +48 VDC
Pins 9, 10, and 11 are Solenoid Common
Pins 20, 23, 28, and 30 are +5 VDC Return
Pin 37 is Chassis Ground
2-6
ACCEPTABLE VALUE
34701F
21.4K ohms ± 5%
TMC470 Installation & Maintenance
2.5.5 Auxiliary Axis Port Testing
The following information is provided to check the signals at the Auxiliary Axis Port on the controller back panel.
NOTE: This connector is available only if the controller has the optional Auxiliary Axis board installed.
¡
Remove electrical power from the marking system.
¡
Disconnect the auxiliary axis cable from the Auxiliary Axis Port on the controller back panel.
¡
Take measurements at the Auxiliary Axis Port connector. Refer to Table 2-6 for acceptable values.
¡
If any motor phase readings are higher than listed as acceptable, the controller internal fuses must be checked.
If any motor phase readings are lower than listed as acceptable, contact Telesis Customer Support for service.
Table 2-6. Optional Auxiliary Axis Port Connector
PIN-to-PIN
SIGNAL
DESCRIPTION
ACCEPTABLE VALUE
1 to 2
PHS 1A
Aux-axis 1 Motor Phase A
typically Z-axis
21.4K ohms ± 5%
3 to 4
PHS 1/B
Aux-axis 1 Motor Phase B
typically Z-axis
21.4K ohms ± 5%
5 to 6
PHS 2/A
Aux-axis 2 Motor Phase A
typically Theta-axis
21.4K ohms ± 5%
typically Theta-axis
21.4K ohms ± 5%
PHS 2/B
Aux-axis 2 Motor Phase B
22 to 20
7 to 8
HOME MTR1
Aux-axis 1 Motor Home
place + lead on pin 22
9.4K ohms ±5%
25 to 20
HOME MTR2
Aux-axis 2 Motor Home
place + lead on pin 25
9.4K ohms ±5%
33 to 20
X DIR
Optional signal for custom use
place + lead on pin 33
> 800K ohms
34 to 20
X STEP
Optional signal for custom use
place + lead on pin 34
> 800K ohms
35 to 20
Y DIR
Optional signal for custom use
place + lead on pin 35
> 800K ohms
36 to 20
Y STEP
Optional signal for custom use
place + lead on pin 36
> 800K ohms
Note: Pins 21 and 24 are +5 VDC; Pins 31 and 32 are +48 VDC
Pins 20, 23, 28, and 30 are +5 VDC Return
Pin 37 is Chassis Ground
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TMC470 Installation & Maintenance
2.6 REPLACEMENT PROCEDURES
Replacement of controller components is limited to the power module inlet fuses. Any other component must be replaced by
repair agencies authorized by Telesis Technologies, Inc.
The power inlet fuses are located in the power entry module on the controller back panel. Systems using 115 VAC power
require one fuse. Systems using 230 VAC require two fuses since both sides of the incoming line voltage are not
at ground potential.
Perform the following steps to remove and replace the controller fuses.
¡
Position the controller power on/off switch to OFF (O).
¡
Remove the power supply cord from the power entry module on the controller back panel.
¡
Insert a very small, flat-tip screwdriver into the slot on the top of the power entry module cover.
See Figure 2-1. Gently pry the cover open.
Figure 2-1. Power Entry Module / Fuse Holder Assembly
2-8
34701F
TMC470 Installation & Maintenance
¡
Pull the fuse holder out of the power entry module.
¡
Remove and discard old fuse(s). Obtain replacement fuse(s). Refer to Table 2-7.
Table 2-7. Controller Power Inlet Fuses
¡
POWER IN
FUSE
QUANTITY
115 VAC
MDL-2
1
230 VAC
GDC2A
2
Configure the fuse holder per facility-supplied power (115 or 230 VAC).
115 VAC systems
Ensure the metal clip is installed on one side of the fuse holder. See Figure 2-1.
Install one fuse in the fuse holder, on the side opposite of the clip.
When installing the fuse holder, orient the metal clip toward the top.
230 VAC systems
Remove the small metal clip from the fuse holder. See Figure 2-1.
Install two fuses in the fuse holder, one on each side.
Note that the fuses for 230 VAC systems are smaller in diameter and shorter in length.
Ensure the fuses are installed in the inward-most position in the fuse holder (at the end where the clip would
normally be installed). Fuses must be positioned away from the exposed end of the fuse holder.
¡
Slide the fuse holder into the power entry module.
¡
Close the cover.
¡
Connect the power supply cord to the power entry module the back panel of the controller.
¡
Position the controller power on/off switch to ON ( I ).
34701F
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TMC470 Installation & Maintenance
2.7 REFERENCE DATA
The following information will assist you in obtaining components to maintain the controller.
2.7.1 Replacement Parts
To minimize down-time, you should keep an appropriate number of spare parts on-hand for quick replacement or
substitution.
Table 2-8. Spare Parts
PART NO.
2-10
DESCRIPTION
42453
Controller Assembly, TMC470
20122
Fuse (115 VAC systems), Glass, MDL-2
( one required )
19443
Fuse (230 VAC systems), Glass, Time Delay, GDC2A
( two required )
42477
Kit for Wall-mount Configuration
63150
Kit for Panel-mount Configuration
66738
Kit for Enclosure-mount Configuration
(brackets and attaching hardware)
(bezel, brackets, and attaching hardware)
(enclosure, bezel, brackets, and attaching hardware)
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TMC470 Installation & Maintenance
2.7.2 Ordering Parts
If you need parts for the marking system, be sure to specify the marking head model number and serial number when
ordering. Telesis Customer Support also offers the following assistance.
Phone Support
Telesis Customer Support offers free phone support to answer questions during normal business hours.
On-Site Service
Telesis can send Customer Support professionals to your facility to perform equipment start-up,
repair, maintenance, and training.
Service Contracts As part of your Service Contract, you receive periodic maintenance and quick on-site customer
support if a problem should occur.
Factory Service
Telesis Customer Support can repair defective parts in our factory to save you money.
Contact Telesis at one of the following locations for more information on any of these services.
If you need parts or service for your marking system, be sure to specify the equipment model number and serial number.
Telesis Technologies, Inc.
Corporate Headquarters
28181 River Drive
P.O. Box 1000
Circleville, Ohio, USA 43113
+1 (740) 477 5000
+1 (800) 654 5696 (U.S. and Canada)
+1 (800) 867 8670 (after hours)
+1 (740) 477 5001 (fax)
email: sales@telesistech.com
email: technical_services@telesistech.com
Telesis Worldwide Locations
For contact information, please visit our website at: www.telesis.com
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TMC470 Installation & Maintenance
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TMC470 Installation & Maintenance
Appendix A
ASCII Character Cross Reference
Standard ASCII Characters
This table may be convenient when devising communications between the controller and a host device.
ASCII
DEC
HEX
ASCII
DEC
HEX
ASCII
DEC
HEX
ASCII
DEC
HEX
NULL
0
00
SPACE
32
20
@
64
40
'
96
60
ctrl A SOH
1
01
!
33
21
A
65
41
a
97
61
ctrl B STX
2
02
"
34
22
B
66
42
b
98
62
ctrl C ETX
3
03
#
35
23
C
67
43
c
99
63
ctrl D EOT
4
04
$
36
24
D
68
44
d
100
64
ctrl E ENQ
5
05
%
37
25
E
69
45
e
101
65
ctrl F ACK
6
06
&
38
26
F
70
46
f
102
66
ctrl G BEL
7
07
'
39
27
G
71
47
g
103
67
ctrl H BS
8
08
(
40
28
H
72
48
h
104
68
ctrl I HT
9
09
)
41
29
I
73
49
i
105
69
ctrl J LF
10
0A
*
42
2A
J
74
4A
j
106
6A
ctrl K VT
11
0B
+
43
2B
K
75
4B
k
107
6B
Ctrl L FF
12
0C
,
44
2C
L
76
4C
l
108
6C
Ctrl M CR
13
0D
-
45
2D
M
77
4D
m
109
6D
ctrl N SO
14
0E
.
46
2E
N
78
4E
n
110
6E
ctrl O SI
15
0F
/
47
2F
O
79
4F
o
111
6F
ctrl P DLE
16
10
0
48
30
P
80
50
p
112
70
ctrl Q DC1
17
11
1
49
31
Q
81
51
q
113
71
ctrl R DC2
18
12
2
50
32
R
82
52
r
114
72
ctrl S DC3
19
13
3
51
33
S
83
53
s
115
73
ctrl T DC4
20
14
4
52
34
T
84
54
t
116
74
ctrl U NAK
21
15
5
53
35
U
85
55
u
117
75
ctrl V SYN
22
16
6
54
36
V
86
56
v
118
76
ctrl W ETB
23
17
7
55
37
W
87
57
w
119
77
ctrl X CAN
24
18
8
56
38
X
88
58
x
120
78
ctrl Y EM
25
19
9
57
39
Y
89
59
y
121
79
ctrl Z SUB
26
1A
:
58
3A
Z
90
5A
z
122
7A
ctrl [ ESC
27
1B
;
59
3B
[
91
5B
{
123
7B
ctrl \ FS
28
1C
<
60
3C
\
92
5C
|
124
7C
ctrl ] GS
29
1D
=
61
3D
]
93
5D
}
125
7D
ctrl ^
RS
30
1E
>
62
3E
^
94
5E
~
126
7E
ctrl _ US
31
1F
?
63
3F
_
95
5F
DEL
127
7F
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TMC470 Installation & Maintenance
Extended ASCII Characters
Extended ASCII characters may be created using the Telesis Logo/Font Generator software.
ASCII
DEC
HEX
ASCII
DEC
HEX
ASCII
DEC
HEX
ASCII
DEC
HEX
€
128
80
none
160
A0
À
192
C0
à
224
E0
none
129
81
¡
161
A1
Á
193
C1
á
225
E1
‚
130
82
¢
162
A2
Â
194
C2
â
226
E2
ƒ
131
83
£
163
A3
Ã
195
C3
ã
227
E3
„
132
84
¤
164
A4
Ä
196
C4
ä
228
E4
…
133
85
¥
165
A5
Å
197
C5
å
229
E5
†
134
86
¦
166
A6
Æ
198
C6
æ
230
E6
‡
135
87
§
167
A7
Ç
199
C7
ç
231
E7
ˆ
136
88
¨
168
A8
È
200
C8
è
232
E8
‰
137
89
©
169
A9
É
201
C9
é
233
E9
Š
138
8A
ª
170
AA
Ê
202
CA
ê
234
EA
‹
139
8B
«
171
AB
Ë
203
CB
ë
235
EB
Œ
140
8C
¬
172
AC
Ì
204
CC
ì
236
EC
none
141
8D
-
173
AD
Í
205
CD
í
237
ED
none
142
8E
®
174
AE
Î
206
CE
î
238
EE
none
143
8F
¯
175
AF
Ï
207
CF
ï
239
EF
none
144
90
°
176
B0
Ð
208
D0
ð
240
F0
‘
145
91
±
177
B1
Ñ
209
D1
ñ
241
F1
’
146
92
²
178
B2
Ò
210
D2
ò
242
F2
“
147
93
³
179
B3
Ó
211
D3
ó
243
F3
”
148
94
´
180
B4
Ô
212
D4
ô
244
F4
•
149
95
µ
181
B5
Õ
213
D5
õ
245
F5
–
150
96
¶
182
B6
Ö
214
D6
ö
246
F6
—
151
97
·
183
B7
×
215
D7
÷
247
F7
˜
152
98
¸
184
B8
Ø
216
D8
ø
248
F8
™
153
99
¹
185
B9
Ù
217
D9
ù
249
F9
š
154
9A
º
186
BA
Ú
218
DA
ú
250
FA
›
155
9B
»
187
BB
Û
219
DB
û
251
FB
œ
156
9C
¼
188
BC
Ü
220
DC
ü
252
FC
none
157
9D
½
189
BD
Ý
221
DD
ý
253
FD
none
158
9E
¾
190
BE
Þ
222
DE
þ
254
FE
Ÿ
159
9F
¿
191
BF
ß
223
DF
ÿ
255
FF
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