Installation/Maintenance

TMC470
Marking System Controller
This document contains installation and maintenance information
for the Telesis® Marking System Controller.

Document No. 34701 Rev. –

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 is a registered trademarks of Telesis Technologies, Inc. in the United States and/or other countries.

© 2008 Telesis Technologies, Incorporated – All Rights Reserved

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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.

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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.

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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

1.6 Installation Procedures ............................................................................................................... 1-5

1.6.1 Site Preparation........................................................................................................... 1-5
1.6.2 Table-top Installation ................................................................................................... 1-6
1.6.3 Wall-mounted Installation ............................................................................................. 1-6
1.6.4 Panel-mounted Installation ........................................................................................... 1-8

1.7 Data and Electrical Connections ................................................................................................... 1-10

1.7.1 Marker Connection ....................................................................................................... 1-11
1.7.2 Power Connection ........................................................................................................ 1-11
1.7.3 Auxiliary Axis Connection.............................................................................................. 1-12
1.7.4 TTL Connection............................................................................................................ 1-12
1.7.5 Comm 1 / Comm 2 Connections .................................................................................... 1-13
RS232 Interface ....................................................................................................... 1-14
RS485 Interface ....................................................................................................... 1-14
Programmable Protocol ............................................................................................. 1-16
Extended Protocol ..................................................................................................... 1-16
1.7.6 Ethernet Connection..................................................................................................... 1-16
1.7.7 Remote I/O Connection ................................................................................................ 1-17
VDC Input Connections.............................................................................................. 1-18
VDC Output Connections ........................................................................................... 1-19
Remote I/O Signal Timing.......................................................................................... 1-20
Remote Pattern Selection .......................................................................................... 1-21

1.8 Controller Checkout ................................................................................................................... 1-22

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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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List of Illustrations
FIGURE PAGE
1-1 TMC470 Controller Back Panel ................................................................................................... 1-1
1-2 Power Entry Module – Fuse Configurations .................................................................................. 1-5
1-3 TMC420 Controller – Table-top/Wall-mounted Installation ............................................................. 1-7
1-4 TMC420 Controller – Panel Installation........................................................................................ 1-9
1-5 TTL Connections....................................................................................................................... 1-12
1-6 RS232 Cable Diagrams ............................................................................................................. 1-14
1-7 RS485 Connections for Networked Markers.................................................................................. 1-15
1-8 VDC Input Connections ............................................................................................................. 1-18
1-9 VDC Output Connections ........................................................................................................... 1-19
1-10 Input/Output Signals – Timing Diagram ...................................................................................... 1-20

2-1 Power Entry Module / Fuse Holder Assembly................................................................................ 2-8

List of Tables
TABLE PAGE
1-1 Comm 1 Port – Pin Assignments................................................................................................. 1-13
1-2 Comm 2 Port – Pin Assignments................................................................................................. 1-13
1-3 Ethernet Port – Pin Assignments ................................................................................................ 1-16
1-4 I/O Port – Pin Assignments....................................................................................................... 1-17
1-5 Reserved Pattern Names for Remote Pattern Selection.................................................................. 1-21

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 Auxiliary Axis Port Connector ..................................................................................................... 2-7
2-7 Controller Power Inlet Fuses ...................................................................................................... 2-9
2-8 Spare Parts ............................................................................................................................. 2-10

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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.

The back panel provides various ports for connections to facility power, the marking head, and optional, remote
input/output devices.

Figure 1-1. TMC470 Controller Back Panel

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1.3 SPECIFICATIONS
The controller design and specifications are subject to change without prior notice.

Controller
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 enclosure)
Dimensions (H x W x D)............ Table-top Configuration:
3.04 x 13.71 x 7.71 in. (77.1 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

Weight.................................... 3.69 lb. (1.68 kg) controller only

3.90 lb. (1.77 kg) controller and wall-mounting hardware
5.52 lb. (2.51 kg) controller and panel-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; 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%

 Store all containers away from splashing or sprayed moisture.

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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)
• 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.

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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 Controller 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.

• 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 on optional kit for panel 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.

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1.6 INSTALLATION PROCEDURES

The TMC470 controller may be installed as a table-top unit, a wall-mounted unit, or an panel-mounted unit. Refer to the
appropriate procedures below for details.

1.6.1 Site Preparation

1. Before beginning installation, refer to Installation Requirements and ensure all conditions for installation are satisfied.

2. 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).

3. 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 1-3 for details.
 Do not block the vents on the bottom of the controller.

4. Position the controller power switch (power entry

module on back panel of controller) to OFF (O).

5. 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 1-2. Gently pry the cover open.

Figure 1-2. Power Entry Module – Fuse Configurations

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TMC470 Installation/Maintenance

 Pull the fuse holder out of the power entry module.

 Verify the fuse arrangement is correctly 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 1-2.
• 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 1-2.
• 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.

6. Proceed to Table-top Installation, Wall-mounted Installation, or Panel-mounted Installation as applicable.

1.6.2 Table-top Installation

 Place the controller on a solid, sufficiently sturdy base.

 Proceed to Data and Electrical Connections.

1.6.3 Wall-mounted Installation

 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 illustration.
Proper Wall-mount Bracket Orientation
 Attach each bracket with two #6 self-tapping screws
(provided). Tighten securely.

 Drill the mounting surface for attaching the brackets. See Figure 1-3 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.

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1.6.4 Panel-mounted Installation

See Figure 1-4 for mounting details, dimensions, locations, and hardware.

 Locate the optional panel mounting kit #63150.

 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.

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 up (away from the controller) and the smaller
flange outward (toward the edge of the controller). See
illustration.
Proper Panel-mount Bracket Orientation
 Attach each bracket with two #6 self-tapping screws
(provided). Tighten securely.

 Prepare the panel for controller installation. See Figure 1-4

for locations and dimensions.
• Cut out an area in the panel for controller insertion.
• Drill mounting holes around the perimeter of the cutout.

 Orient the bezel on the front side of the panel with the wide
edge toward the top. See illustration.

NOTE
The M3-0.50 x 8mm screws provided in the kit are
sufficient for mounting in panels up to 5mm thick.
Panels thicker than 5mm will require the customer
or installer to supply screws of sufficient length.

 Attach (from the back side of the panel) using ten M3 pan
head screws (provided). See illustration (below) for screws
locations. Torque to 10 in-lb (1.12 N-m) max.
Proper Bezel Orientation

 Locate the six remaining mounting holes drilled in the panel.

 From the back side of the panel, 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 (provided).

Torque to 10 in-lb (1.12 N-m) max.

 From behind the panel, insert the controller

(display/keyboard side first) into the cutout area while
aligning the holes in the mounting flanges with the four
threaded rods near the corners of the panel cutout.

 Secure the controller with one locking hex nut (provided) on

each threaded rod. Torque to 10 in-lb (1.12 N-m) max.

 Position the clamping bar (provided) across the back of the

controller and align the mounting holes with the two
remaining threaded rods. See Figure 1-4. Bezel Hardware Locations

 Secure the clamping bar with one locking hex nut (provided) on each threaded rod. Torque to 10 in-lb (1.12 N-m) max.

 Proceed to Data and Electrical Connections.

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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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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

 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.

230 VAC Systems

 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.

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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 equipment.

 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, proceed to Controller Checkout.

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 1-6 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 1-5 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,

proceed to Controller Checkout.

Figure 1-5. 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 1-6), 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 1-6 for RS232 cable specifications, construction, and connections.
See Figure 1-7 for RS485 cable specifications, construction, and connections.

 Ensure the host device is OFF.

 Connect the data cable from the host to the

Comm 1 [ ] or Comm 2 Port [ ],
as applicable.

 Proceed with other optional connections, as applicable.

 If finished with all data and electrical connections,

proceed to Controller Checkout.

Table 1-1. Comm 1 Port – Pin Assignments Table 1-2. Comm 2 Port – Pin Assignments
PIN SIGNAL DESCRIPTION PIN SIGNAL DESCRIPTION
1 X– RS485 bi-directional data – 1 not used
2 RXD Receive Data (to controller) 2 RXD Receive Data (to controller)
3 TXD Transmit Data (from controller) 3 TXD Transmit Data (from controller)
4 X+ RS485 bi-directional data + 4 +5VDC power for optional bar code scanner
5 GND Signal Ground 5 GND Signal Ground
6* T+ RS485 Terminator + 6 not used
7 ( internal jumper to pin 8 ) ** 7 ( internal jumper to pin 8 ) **
8 ( internal jumper to pin 7 ) ** 8 ( internal jumper to pin 7 ) **
9* X– RS485 bi-directional data – 9 not used

** See 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 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 1-6 shows connections to both DTE (data terminal equipment) and DCE (data circuit-terminating) devices.

Figure 1-6. RS232 Cable Diagrams

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 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.

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NOTICE
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 1-7 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 1-7.
Specifically, jumper pins 6 and 9 on the Comm 1 Port mating connector on the last controller of the network.

Figure 1-7. RS485 Connections for Networked Markers

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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.

NOTE
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 multi-
drop 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).

1.7.6 Ethernet Connection

This is an optional connection.
This port may be used to connect to a TCP/IP network.

 Use a standard CAT5 cable terminated with a standard

RJ45 connector.

 Connect the data cable from the network (TCP/IP) to

the Ethernet Port [ ] on the controller.

 Proceed with other optional connections, as applicable.

 If finished with all data and electrical connections,

proceed to Controller Checkout.

Table 1-3. Ethernet Port – Pin Assignments

PIN SIGNAL DESCRIPTION

1 TXP 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 Receive Data – (bi-directional pair –B)
7 TP78 (bi-directional pair +D)
8 TP78 (bi-directional pair –D)

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1.7.7 Remote I/O Connection

This is an optional connection.
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 1-8 for VDC input cable specifications, construction, connections.
See Figure 1-9 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

the I/O Port [ ] on the controller.

 Proceed with other optional connections, as applicable.

 If finished with all data and electrical connections,

proceed to Controller Checkout.

Table 1-4. I/O Port – Pin Assignments

PIN SIGNAL DESCRIPTION

1 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 Input – see Remote Pattern Selection for details
8 SELECT_6 (1) Input – see Remote Pattern Selection for details
9 SELECT_4 Input – see Remote Pattern Selection for details
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
14-18 not used
19 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.
2
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 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 1-8 shows a simple contact closure circuit for remote VDC input signals.

Figure 1-8. VDC Input Connections

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VDC Output Connections

Figure 1-9 shows connections for the TMC470 output signals. To demonstrate differences in polarity, the graphic illustrates
both sourcing outputs and sinking outputs.

Figure 1-9. VDC Output Connections

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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 1-10 illustrates the timing relationship of the three marking control
signals (START PRINT, READY, and DONE).

Figure 1-10. 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 Reserved Signal State Reserved Signal State Reserved Signal State Reserved
Sel_ (n) Pattern Sel_ (n) Pattern Sel_ (n) Pattern Sel_ (n) Pattern
6543210 Name 6543210 Name 6543210 Name 6543210 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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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 TMC420 Operation Manual for details.

 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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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.

1. Remove electrical power from the marking system.

2. Brush loose dust and debris from the controller.

3. Ensure the fan inlet and vent outlet louvers (on the bottom of the controller) are not obstructed.
Remove dust and debris as required.

4. 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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2.4 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 CORRECTIVE ACTION

Controller not energized (no display) 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 Contact Telesis Customer Support for assistance.
power is down

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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.

1. Remove electrical power from the marking system.

2. Disconnect the interface cable from the Comm 1 or Comm 2 Port, as applicable.

NOTE
Voltage measurements are to be taken with power ON.

3. Apply electrical power to the marking system.

4. 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 COMM 1
DESCRIPTION
PIN SIGNAL

1 X– RS485 bi-directional data (internal jumper to pin 9)

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
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 COMM 2
DESCRIPTION
PIN SIGNAL

2 RXD Receive Data (to controller)

3 TXD Transmit Data (from controller)

4 +5VDC 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.

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2.5.2 I/O Port Testing

The following information is provided to check the discrete input and output signals at the I/O Port on the controller back
panel.

1. Remove electrical power from the marking system.

2. Disconnect the interface cable from the I/O Port on the controller back panel.

NOTE
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.

3. Apply electrical power to the marking system.

4. Apply electrical power to the remote I/O source.

5. 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 ACCEPTABLE VALUE

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 2 ohms (maximum)

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 –)

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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.

1. Remove electrical power from the marking system.

2. Disconnect the interface cable from the TTL Port on the controller back panel.

NOTE
All TTL input signals are to be checked in their ON state.

3. Apply electrical power to the remote I/O source.

4. 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)

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2.5.4 Marker Port Testing

The following information is provided to check the signals at the Marker Port on the controller back panel.

1. Remove electrical power from the marking system.

2. Disconnect the marker cable from the Marker Port on the controller back panel.

3. Take measurements at Marker Port connector. Refer to Table 2-5 for acceptable values.

4. 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 ACCEPTABLE VALUE

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 21.4K ohms ± 5%
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

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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.

1. Remove electrical power from the marking system.

2. Disconnect the auxiliary axis cable from the Auxiliary Axis Port on the controller back panel.

3. Take measurements at the Auxiliary Axis Port connector. Refer to Table 2-6 for acceptable values.

4. 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%
7 to 8 PHS 2/B Aux-axis 2 Motor Phase B typically Theta-axis 21.4K ohms ± 5%
22 to 20 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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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.

1. Position the controller power on/off switch to OFF (O).

2. Remove the power supply cord from the power entry module on the controller back panel.

3. 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

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 TMC470 Installation/Maintenance

6. Pull the fuse holder out of the power entry module.

7. 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

8. 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.

9. Slide the fuse holder into the power entry module.

10. Close the cover.

11. Connect the power supply cord to the power entry module the back panel of the controller.

12. Position the controller power on/off switch to ON ( I ).

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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. 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 (brackets and attaching hardware)

63150 Kit for Panel-mount Configuration (bezel, brackets, and attaching hardware)

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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 us for more information on any of these services. You may contact Telesis at any of the following locations:

United States

Telesis Technologies, Inc. Telesis Technologies, Inc.

Corporate Headquarters Great Lakes Office
28181 River Drive 740 Welch Road
P.O. Box 1000 Commerce Township, Michigan, USA 48390
Circleville, Ohio, USA 43113 +1 (248) 624 4249
+1 (740) 477 5000 +1 (248) 624 4431 (fax)
+1 (800) 654 5696 (U.S. and Canada) email: inquires.telesistech.com
+1 (800) 867 8670 (after hours) web: www.telesis.com/greatlakes.htm
+1 (740) 477 5001 (fax)
email: [email protected]
email: [email protected]
web: www.telesis.com

Europe

Telesis Europe B.V. Telesis Systèmes de Marquage

Innsruckweg 104 Parc International d'Entreprises Arlington
3047 AH Rotterdam 4 Boulevard Michael Faraday
The Netherlands 77 716 Marne la Vallee Cedex 4
+31 10 462 21 36 +33 1 60 42 88 19
+31 10 462 38 63 (fax) +33 1 60 42 87 80 (fax)
email: [email protected] email: inquiries.telesistech.com
web: www.telesis.com/europebv.htm web: www.telesis.com/france.htm

TelesisEagle Telesis MarkierSysteme GmbH

Dolphin Street Wülfingstrasse 6
Colyton, Devon, UK EX24 6LU D-42477 Radevormwald
+44 1297 551313 Germany
+44 1297 551319 (fax) +49 2191 60 90 80
email: [email protected] +49 2191 60 90 88 (fax)
web: uk.telesis.com email: [email protected]
web: www.telesis.com/german.htm

Asia

Telesis China Telesis Taiwan

Building #1, First Floor 1F, No 175, Dexiang Road
180 Zhangheng Road Nanzi District
Zhangjiang Hi-Tech Park Kaohiung City 811, Taiwan
Pudong New District +886 (7) 3686678
Shanghai 201204, China +886 (7) 3680289 (fax)
+86-021-33933851 email: [email protected]
+86-021-33933852 (fax) web: www.telesischina.com
email: [email protected]
web: www.telesischina.com

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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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