C232 Smart Platform

ASPC Hardware

ECPSR
The ECPSR is the Power Supply Regulator
It has the regulator module, which is the source of +15, -15 and +5 volts
DC to the card cage
The DC IN indicator is lit, if +12 and -12 volts DC are present from the
EC24V Power supply. These voltages can be measured at J23, DC IN.
The top row of pins 1, 2, and 3, are +12
The middle row of pins 4,5 and 6 are ground
The Bottom row of pins 7,8 and 9 are -12

If the DISABLE indicator is lit, it means that one of the power supplies has
failed. Check the voltages at J23 to determine which voltage is missing.
The EC24V also has indicators, for +12 and -12 volts DC.
The +5, +15 and -15 indicators will be lit, if those voltages are present at
the regulator. Verify -12 -12 +15, and -15 voltages are present at the TOP
power and BOTTOM Power Connector.

There is no way to check +5 volts with a Digital Volt Meter, because this
voltage is not on any power connector outside the card rack. +5 volts DC
DC IN
can only be checked using the ELECTRONICS (E) Health report, at the
Smart Platform Work Station.
DISABLE

+15
The old -001 version of the circuit board has a capacitor problem. If a
smart sensor is removed with power on it will couple a pulse to the BRAM,
causing the BRAM to forget.
-15

The -002 version of the board solves the problem, but is always best to
+5 TURN POWER OFF, before removing any sensor.

Ther is an un-documented fuse to ground, on the board

ECPSR

MODULE:
UNIT:

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086349-001 or -002 MPRC - 91 to 8/98

Two versions of the MicroPRoCessor card have been used since the Smart platform was
introduced.
086349-001 MPRC - 25 MHz clock rate.Thjis circuit board can be used with any software.
086349-002 MPRC - 33 MHz clock. This circuit board requires SP260 or greater
software. When replacing a -001 with a -002 board, software must be upgraded, if the
platform software is below SP260.
The MPRC has the following components:
• M68030 Micro processor
• M68882 Floating point unit
• 1 Meg of EEPROM divided into two areas:
ERROR
— AVOS -AccuRay Virtual Operating System
RUN
— /lib01 - Prom Disk
• 4 Meg of DRAM
• 3 Meg BRAM, Which is used as a loading device, to load software in to DRAM.
The battery will maintain BRAM software for 7 -14 days (Maximum of 30 days).
BRAM is divided into to areas. A minimum of 24 hours is requires to fully charge
the battery, if it has lost its charge. BRAM is divided into two areas:
— /ss01- SubSystem01,.5 Meg, which contain all platform specific information
such as head constants,standrdizelimits and platform tuning
— /appl - application software, 2.5 Meg, contains that application program
libraries.
• Clock/Calendar - an integrated circuit, with battery. This replaceable component
START MODE has a battery with a life of three years. If the battery fails, the symptom is a strange
EXTEN
date, in 1986, in response to the date command.
DIAG

SHORT
DIAG
STOP/
DEBUG

BRAM
Board

RX HOST
RESET

MPRC

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Controls and indicators

ERROR
• After a reset:
— ON- performing diagnostics
ERROR — Flashing - loading software from BRAM to DRAM

RUN — OFF - Software loading complete. Banner displayed at the

SPWS, if 1190 or 1180 host.
• During normal operation:
— ON - Memory panic. The processor attempted to address a
memory location greater than 4 Meg. This halts the
microprocessor. Special commands can be typed to determine
the cause of the failure.
RUN
RUN flashes every time the microprocessor accesses memory. Normally
flashing. Off means the processor is halted.
RX TERMINAL
Flashing indicates communication with the SPWS.
RX HOST
Flashing indicates communication with the HOST system. If the LED flash
Exten can easily be seen during Frame Reload, the BAUD rate is 9600. If it is
Diag
necessary to block outside light to see the flashing, the communication
Short BAUD rate is set to 19200.
Diag
Stop/ START MODE SWITCH
Debug
EXTENded DIAGnostics -
SHORT DIAGnostics - Normal position
STOP/DEBUG- Enter offline debug >> mode
RX Terminal RESET SWITCH
Pressing the reset switch will cause the Smart platform to:
• Halt
RX Host • Perform diagnostics
RESET • Load application software from /appl
• Start AVOS
MPRC • Load Initialization files from /ss01
• Print the Banner

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There are three ways to restart the Smart Platform:

• Press the RESET SWITCH
• Power On Reset - occurs when power is re-applied to the Smart Platform after a
POWER FAILURE.
WARNING!
Using Power On Reset as a regular method of restarting the Smart Platform can
cause damage to the circuit boards due to power surge. Sites that use this method will
use one third more spare cards, over the life of the system.
• Software command:
$$ reset(cr) - Reload and restart Smart Platform software
$$ reset 1 - reset 1 (one) loads AVOS only. Use this option when the contents of
Abrams been damaged and the Smart Platform will not restart. Do a reset 1 and use
gonzo to reload PRODUCT,SENSOR,APPL1, APPL2 and SSO1 Diskettes to BRAM,
using the Smart platform work Station.
$$ reset f(cr) - Reset and setup for FLASH MEMORY (EEPROM maintenance. Use
this option to load software to EEPROM, according to the procedure in the Software
manual. Spare MPRC cards re blasted with a base load, in prom at the time of
manufacture.EEProm must be loaded with the current software version, in the platform.
If the AVOS revision is not the same as the Software revision (EXAMPLE: SP280.0
AVOS and SP280.4 BRAM) the Smart Platform will not restart. Allow approximately
one hour to load EEPROM
If the Smart Platform looses the $$ prompt force the platform to reload by doing the.
following procedure:
• put the toggle switch down, to the STOP/DEBUG position.
• Press the RESET SWITCH.
• Put the toggle switch to the middle, SHORT DIAGnostic position.
• Check the SPWS Health Report Terminal page for the prompt:
OFFLINE DEBUG>>
• type one of the following commands:
— g(cr) - to perform a normal restart
— g 1 (cr) - to load and start AVOS, so you can load new software into BRAM
— g f(cr) - to load EEPROM
AVOS can now be used to perform the necessary function

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086444-XXX MPRC - 9/98 to present

The 086444-001 is backward compatible (can replace 086349-001 or 86349-002 MPRC)
This circuit board requires ESP300.4 or greater software. When replacing a -001 with a -
002 board, software must be upgraded, if the platform software is below E300.4, using
Software Manual 101760-004-004 Rev. H or higher.
The MPRC has the following components:
• M68040 Micro processor with hardware Floating Point Unit, 25 MHz clock,
double clocked.
• 4 Meg of EEPROM divided into two areas:
— Base AVOS -AccuRay Virtual Operating System and /lib01
— Rev. Specific AVOS and /lib01 - Prom Disk
ERROR • 16 Meg of DRAM
RUN • 4 Meg BRAM, Which is used as a loading device, to load software in to DRAM.
The battery will maintain BRAM software for 7 -14 days (Maximum of 30 days)
A minimum of 24 hours is requires to fully charge the battery, if it has lost its
charge. /bram1 /ss01- SubSystem01 contains all platform specific information
such as head constants,standrdizelimits and platform tuning
• 4 Meg of Sequential Access Flash EEPROM, called NRAM (Non-volatile RAM).
/nram1 /appl - application software, contains the application program libraries.
• Clock/Calendar - an integrated circuit, with battery. This replaceable component
has a battery with a life of three years. If the battery fails, the symptom is a strange
date, in 1986, in response to the date command
• 4 HDLC serial ports for local data transfer
• Two Ethernet AUI ports for high speed data transfer
START MODE
• Service port
EXTEN
DIAG • RS485 host port.
SHORT
DIAG Revision History:
STOP/
DEBUG
-001 initial production
BRAM
Board
-002 Componant changes
-003 prom change to support ftp
-004 new matrix, increased processor speed Requires a -002 (faster) BRAM

RX HOST
RESET

MPRC

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Controls and indicators

ERROR
• After a reset:
ERROR — ON- performing diagnostics
RUN
— Flashing - loading software from BRAM to DRAM
— OFF - Software loading complete. Banner displayed at the SPWS, if 1190 or
1180 host.
• During normal operation:
— ON - Memory panic. The processor attempted to address a memory location
J2
greater than 16 Meg. This halts the microprocessor. Special commands can be
typed to determine the cause of the failure.
RUN
RUN flashes every time the microprocessor accesses memory. Normally flashing. Off
means the processor is halted.
NET TX_A
NET TX-B Flashing indicates transmit/receive on Net Port A, via the J 6 Host connection.
NET TX_B
Flashing indicates transmit/receive on Net Port B, via the J2 connection.
NET TX_a
RX TERMINAL
EXTEN
DISG
Flashing indicates communication with the SPWS.
SHORT
DIAG RX HOST
STOP/
Flashing indicates communication with the HOST system. If the LED flash can easily be
DEBUG
seen during Frame Reload, the BAUD rate is 9600. If it is necessary to block outside light
RTS 0 to see the flashing, the communication BAUD rate is set to 19200.
RTS 1
START MODE SWITCH
RTS 2
RTS 3 EXTENded DIAGnostics - Default reset 1, with TCP/IP address 192.168.1.20

RX TERMINAL SHORT DIAGnostics - Normal position

RX HOST
STOP/DEBUG- Enter offline debug >> mode. This position selects local AVOS, located
in EEPROM, on the board. Performing a g f restart allows the correct version of AVOS to
be programmed into EEPROM
RESET RESET SWITCH
Pressing the reset switch will cause the Smart platform to:
MPRC • Halt
• Perform diagnostics

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• Load application software from /appl

• Start AVOS
• Load initialization files from /ss01
• Print the Banner

Note:
The ETHER NET Version of the Software load does not print a banner

There are three ways to restart the Smart Platform:

• Press the RESET SWITCH
• Power On Reset - occurs when power is re-applied to the Smart Platform after a
POWER FAILURE.
WARNING!
Using Power On Reset as a regular method of restarting the Smart Platform can
cause damage to the circuit boards due to power surge. Sites that use this method will
use one third more spare cards, over the life of the system.
• Software command:
$$ reset(cr) - Reload and restart Smart Platform software
$$ reset 1 - reset 1 (one) loads AVOS only. Use this option when the contents of
Abrams been damaged and the Smart Platform will not restart. Do a reset 1 and use
gonzo to reload PRODUCT,SENSOR,APPL1, APPL2 and SSO1 Diskettes to BRAM,
using the Smart platform work Station.
$$ reset f(cr) - Reset and setup for FLASH MEMORY (EEPROM maintenance. Use
this option to load software to EEPROM, according to the procedure in the Software
manual. Spare MPRC cards re blasted with a base load, in prom at the time of
manufacture.EEProm must be loaded with the current software version, in the platform.
If the AVOS revision is not the same as the Software revision (EXAMPLE: SP280.0
AVOS and SP280.4 BRAM) the Smart Platform will not restart. Allow approximately
one hour to load EEPROM
If the Smart Platform looses the $$ prompt force the platform to reload by doing the.
following procedure:
• put the toggle switch down, to the STOP/DEBUG position.
• Press the RESET SWITCH.
• Put the toggle switch to the middle, SHORTDIAGnostic position.
• Check the SPWS Health Report Terminal page for the prompt:

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OFFLINE DEBUG>>
• type one of the following commands:
— g(cr) - to perform a normal restart
— g 1 (cr) - to load and start AVOS, so you can load new software into BRAM
— g f(cr) - to load EEPROM
Local AVOS can now be used to perform the necessary function

Modifications to support FTP

ECN E42433
This ECN cjanges the BASE PROM load to support FTP communication. The
modification can be made to any MPRC manufactured p[rior to january, 2001. This makes
the MPRC compativle with ESP322.0 Software.ESP322.0n software is required to support
Windows Health Reports.
No startup messages will be printed in the AVOS window. Startup messages are stored in
an _out file.
To print the contents of the file:

[01_0] $$
[01_0] $$ cd /ss01
[01_0] $$ ll
total 17
drwxrwxrwx 2 0 0 32 05-03 13:05 airProfiles
drwxrwxrwx 2 0 0 704 05-16 09:38 clm
-rw-rw-rw- 1 0 0 10 05-16 14:06 cons_dev
drwxrwxrwx 2 0 0 160 05-03 14:53 history
drwxrwxrwx 2 0 0 1024 01-01-1970 lost+found
drwxrwxrwx 2 0 0 48 05-03 14:48 scn
drwxrwxrwx 2 0 0 176 05-03 14:48 smi
-rw-rw-rw- 1 0 0 60 05-17 11:04 start.log
-rw-rw-rw- 1 0 0 4363 05-17 11:06 startup_out
-rw-rw-rw- 1 0 0 0 05-16 11:04 startup_out0
-rw-rw-rw- 1 0 0 1092 05-03 14:38 startup_out1
-rw-rw-rw- 1 0 0 1959 05-03 14:08 startup_outf
[01_0] $$
[01_0] $$
[01_0] $$ cat startup_out

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Use the cat or more command to display the contents of :

startup_out - normal restart
startup_out0 - default reset 1
startup_out1 - reset 1
startup_outf - reset f

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ECF, ECS, ECC AND SMI

The -003 Backplane used standard slot location for circuit boards, beginning with the ECF
in slot 0. ECS function is slots 1-7 was defined by board position. Slot 7 - GENERAL was
reserved for sensors such as MICROWAVE MOISTURE, SMOOTHNESS,
TEMPERATURE and HEATED AIR WIPES for TLK-5/TLK-8 BASIS WEIGHT. With
the introduction of SMART SCANNING COLR SENSOR, slot 7 was reserved for the
COLOR SENSOR ECC board.
The -004 Backplane has no standard slot assignments. Circuit board function is
determined at the time of load building. A special report is printed and placed in the
Engineering Data book.
Board function for both versions of the Backplane can be confirmed by printing the I/O
map for a Smart Platform.

IR MOIST
BASIS WT
OPTIPAK
CALIPER

FRAME
GLOSS
ECS or ECC
ASH

ECPSR
MPRC
ECS
ECS
ECS
ECS
ECS
ECS
ECF

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To print the I/Omap, perform the following:

$$ inspect(cr)
I>()[ucHardware printLevels](cr)
I>:q(cr)
$$
This sequence of commands causes the smart platform uchardware object to print the Slot
and Port Assignment of all the circuit boards in the rack.
Analog channel assignment can be determined buy the following:
$$ inspect(cr)
I>()[lucGroup printLevels](cr)
NOTE: the first character in lucGroup is a lower case L
I>:q(cr)
$$
This command causes the uchardwsre object to print the analog input configuration for a
specific Smart Platform.
SMI - Smart Measurement Interface
The SMI daughter card attaches to an ECF, ECS, or ECC. It is a micro computer which
has:
RXA
RXB
RXC • a M68332 micro computer
RXD
RXE
RXF • 128K of EEPROM
• 256K of DRAM
RTSA
ERROR
RUN SMI
Board
Two versions of SMI cards are current currently in the field
RTSB
• 086339-001 - The original part currently used in conjunction with ECF cards. This
version will work with all sensors except IR Coat Weight
• 086339-002 - This version was developed especially for the IR Moisture sensor. It
uses a faster clock rate to improve IRSensor processing. This board only works on
ESC boards. It is required, for the IR Coat Weight Sensor.
WARNING!
Using a -002 SMI card used with an ECF board to causes if to LOCKUP.

ECF A replacement SMI must be blasted with current revision software, before it will function
a Smart Platform. Consult the Soft ware manual for blasting instructions.

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ECF
The ECF card provides servo control of the Scanning Head
Package. Only one version, 086348-001, is available.
An ECF has five I/O ports:
• Port 0 - 16 analog inputs

RXA • Port 1 - 16 digital input, from the limits switches, and

RXB process inputs.
RXC • Port 2 - 16 Digital Outputs, only one is used - POWER
RXD OFF.
RXE
RXF • Port 3 - 16 Digital inputs, from the Frame Control Panel
push buttons,.
• Port 4 - 16 Digital outputs, to the Frame Control panel,
to light indicators.
Port and channel assignments are listed in the I/O Map.
A 086339-001 SMI must be used with an ECF board. Using a -
RTSA 002 board will cause the ECF to lockup.
INDICATORS
ERROR
RXA flashes when the Far End Column Control panel
RUN communicates with the ECF board.
RXB flashes when the Home End Column Control panel
RTSB communicates with the ECF board.
RXC flashes when the Remote Control panel communicates
with the ECF board.
A Remote Control Panel, using RS-432 communication
protocol can be located up 75 feet from the Remote Junction
box, or Smart Platform End Column
These indicators are on the SMI board:
RTSA flashes when the SMI mounted, on the ECF card
communicates with the MPRC.
ERROR lights to indicate a software error
RUN flashes during normal operation when the M68882 micro
processor accesses memory.
RTSB is not currently used.
ECF
The programming connector is use during manufacturing, to
blast a base load into the EEPROM on the SMI

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ECS
The ECS card provides an interface for a sensor
• 086329-001, initial version
• 086329-002 - Modified to add digital channel checking.
• 086329-003 - Digital channel checking removed.
• 086329-004 - new version, required for IR COAT WEIGHT,
but will work for all sensors.
An ECS has three I/O ports:
• Port 0 - 16 analog inputs
• Port 1 - 16 digital input, from sensor.
• Port 2 - 16 Digital Outputs, to the sensor.
Port and channel assignments are listed in the I/O Map.
An ECS can be used with either an 0863339-001 or -002 SMI.
RTSA INDICATORS
These indicators are on the SMI board:
ERROR
RTSA flashes when the SMI mounted, on the ECSF card communicates
RUN with the MPRC.
ERROR lights to indicate a software error
RTSB
RUN flashes during normal operation when the M68882 micro
processor accesses memory.
RTSB is not currently used.
The programming connector is use during manufacturing, to blast a
base load into the EEPROM on the SMI

ECS

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ECC
The ECC card communicates with the SMART Scanning Color Sensor modules. The
current version is 086387-001. The color sensor is the first truly smart sensor, that has its
own built in micro processors communicating over dedicated serial lines. The Color
Measurement Module uses a Z80 processor in the spectrum analyzer. The Backing Tile
Module uses a specially programmed SMI to operate the six position tile changer.
INDICATORS
A flashes, indicating that the ECC is communicating with color modules on the upper head
A
package.
B B flashes, indicating that the ECC is communicating with color modules on the lower head
package.

These indicators are on the SMI board:

RTSA flashes when the SMI mounted, on the ECSF card communicates with the MPRC.
RTSA
RROR lights to indicate a software error
ERROR RUN flashes during normal operation when the M68332 micro processor accesses
memory.
RUN
RTSB is not currently used.
RTSB The programming connector is use during manufacturing, to blast a base load into the
EEPROM on the SMI

Special procedures are used to blast new software in to a Backing Tile Module SMI
• One method requires loading the BTC software in to BRAM, then performing a
ucblast
• The other method is:
— Disassemble the Backing Tile Module
— Move the SMI to the ECC card
— Use the procedures outlined in the Smart Color Sensor Manual to perform the
blast.
ECC
The procedures should only be performed when replacing an SMI, or during a software
upgrade.

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086349-001/002 MPRC Block Diagram)

MPRC

EEPROM 1Meg COM 0/A F I O A

AVOS

/lib01 - PROMDISK
COM 2/B B C G COL

DRAM 4 Meg

CMM

BRAM 2.5 Meg

BTM
/ss01

/appl
< ss01.put

UNIX

< ss01.sav

DOS

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086444-XXX MPRC Block Biagram

MPRC

EEPROM 4 Meg
Base AVOS

Base /lib01
COM 0/A F I O A
AVOS

/LIB01
PROM DISK
COM 2/B B C G COL

DRAM 16 Meg

CMM

NRAM 4 Meg
BTM
/appl

BRAM 4 Meg
< ss01.put
/ss01

< ss01.sav

DOS

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