Revision Protocol Date Author Company Description 1.1 May 14, Seth LOUTH Revised for formatting

PRODUCT ADC TOPIC ODETICS TCS-2000 CART MACHINE DATE: May 14, 1999 REVISION HISTORY Revision Protocol Date Author Company Description 1.1 May 14, Seth LOUTH Revised for formatting 1999 Olitzky 1.0 Aug. 22, 1997 LOUTH Last revised edition DESCRIPTION VERSIONS USED Firmware: ME 122 (this is the latest version, from 1990) Operator s Manual: Maintenance Manual: Protocol: REQUIREMENTS CABLE REQUIREMENTS The TCS-2000 requires a 25 pin Male to 9 pin Male conversion cable and a B&B Electronics RS-232 to RS-422 Converter or similar converter for control. The cable must have the following connections: TCS-2000 (25 pin Male) Louth ADC (9 pin Male) 7 (GROUND) 4 & 6 (GROUND) 2 (TX -) 2 (RX -) 17 (RX +) 3 (TX +) 14 (TX -) 7 (RX +) 5 (RX -) 8 (TX -) It is also necessary to connect directly to each VTR in the TCS-2000. This could require up to 6 standard db 9 male pin-to-pin to db 9 male serial RS-422 cables. Imagine Communications Corp. 1

CONNECTIONS The 25 pin Male end of the custom conversion cable should be connected to the B&B Electronics RS- 232 to RS-422 Converter and this converter connected to the Main port labeled Manipulator Electronics on the rear of the TCS-2000 and the 9 pin end plugged into the selected port of the ADC server. Do not attach to TCS-2000 port labeled Sequence Controller. Be sure that power is supplied to the B&B Electronics RS-232 to RS-422 Converter. Communications may be erratic without this power connection. Make sure all cable connector screws are tightened securely. Each standard RS-422 cable should connect from the 9 pin Remote 1 port of a VTR to the selected port of the ADC server. This provides machine control for the individual VTR. It may also be desirable to connect a dumb terminal or a computer running a terminal emulator (with or without logging capabilities) to the Odetics Service Manipulator Electronics port. This will provide a real time window into the serial communications between the ADC and the TCS-2000 and may be useful in troubleshooting. This is a standard RS-232 connection. DEVICE HARDWARE SETTING No switches or jumpers are required to be set in the TCS-2000. COMMUNICATIONS PARAMETERS The communications parameters for the TCS-2000 are: Baud Rate: 9600 Data Bits: 8 Parity: None Stop Bits: 1 DEVICE SERVER SET-UP To configure the TCS-2000 in the system follow these steps: Select the Options pull down menu in the ADC device server. 1. Select Configure Devices and choose the device number to which the TCS-2000 is to be assigned. The device number is the port to which the RS-422 cable is connected on the ADC. 2. Select Change. 3. Select Cart Machine from the list of devices and Odetics TCS2000 for the protocol. Select OK and then Save. The system will prompt for confirmation. 4. Select the Options pull down menu again. 5. Select Device Parameters and choose the device Odetics TCS-2000 to set-up the device for Imagine Communications Corp. 2

operation and select OK. 6. Select DEVICE NAME. The default device name is CART. If a different device name is desired Click on Change, enter the new name using the keyboard and click on OK. 7. With the VTRs cabled and powered on, select VTR PORTS from the Device Parameters list and click or TAB to the VTRs found in the TCS-2000. The top VTR is VTR1 then VTR2, etc. The last VTR is VTR6. Type the port assignment of each VTR. Note that the VTR ports are assigned from Device Parameters for the TCS-2000 not from the Configure Devices menu. 8. Once again from the Device Parameters, select Audio/Video List for each VTR and list in the system and fill in the appropriate Audio/Video Out and Audio/Video In crosspoints. 9. When satisfied with all parameter selections, select Save and the set-up will be made permanent. To save your settings to disk, select the Options pull down menu and then Save Options. 10. The VTRs of the TCS-2000 must be assigned to a list. Select the Options pull down menu and then select Assign Devices. 11. Click on the desired list then click on Add/Move to assign the VTR to that list. To save the list settings to disk, select the Options menu and then Save List Settings. OPERATION NOTES There are separate service bins for the loading and unloading of tapes in the TCS-2000. These Load and Unload Bins are located in column C. The standard and preferred position of the Load Bin is opened (bin slots visible to the user). The standard and preferred position for the Unload Bin is closed (bin slots available internally in the TCS-2000). NOTE: Do not attempt to load tapes via the Unload Bin. These tapes will not be commissioned into the Cart Bin Collection. All tapes are ejected from the TCS-2000 via the Unload Bin. The Unload Bin automatically rotates when all of its slots are full. At this time remove the tapes and press the Unload Rotate button to restore the Unload Bin to the preferred closed position. If it is necessary to unload a partially full Unload Bin, press the Unload Rotate button above the Unload Bin to open the Unload Bin, unload the tapes and press the Unload Rotate button to restore the Unload Bin to the preferred closed position. NOTE: Do not remove tapes from the internal bins of the TCS-2000 by hand. This may cause future Unusable location errors. Tapes should be loaded into the TCS-2000 via the Load Bin. Place tapes in any open slot of the Load Bin. When the required tapes have been loaded, press either button located above the Load Bin to rotate the Load Bin. All tapes in the slots will be barcode read and stored in the internal bins of the TCS-2000. When all tapes have been removed from the Load Bin, the Load Bin will automatically rotate back to the opened position. The ADC is able to control the TCS-2000 even when one or more arms are taken off-line. The ADC Imagine Communications Corp. 3

normally uses all available arms to effect increased throughput. When a new tape is required in a VTR, and there are at least two arms on-line, the ADC will use the following scheme: 1. Get the new tape in one of the available arms. 2. Retrieve the ejected tape from the VTR with another available arm. 3. Load the VTR with the new tape. 4. Put the retrieved tape back in its bin location. If only one arm is available, the ADC is still able to operate the TCS-2000; however a more limited tape handling scheme will be used: 1. Retrieve the ejected tape from the VTR with the only available arm. 2. Put the retrieved tape back in its bin location. 3. Get the new tape with the only available arm. 4. Load the VTR with the new tape. Whenever the Load or Unload Bins are to be rotated the elevator-arm assembly is positioned to a safe location. The ADC places Arm 4 of the TCS-2000 in position at Tape Transport 4 in Column H, Arm 1 at Column B, Arm 2 at Column D, and Arm 3 at Column F. It also places the barcode reader at Column C which contains the Load and Unload Bins and ensures the arm assembly is not blocking the Load and Unload Bins. In the System pull down menu of the device server, there is a selection Device Diagnostics. From this menu the various devices can be selected and then specialized diagnostic services for the device can be accessed. The TCS-2000 provides the following diagnostic services: Reinitialize Cart Reverify Bins (Not Availble) Elevator Operation VTR External Operation ARM Offline/Online Reinitialize provides full initialization of the cart machine. It will initialize the Elevator, Hub, and Arm mechanism, rotate the Load Bin to the opened position, as well eject any tapes found in the VTRs and replace them into a bin storage or eject them from the cart machine. If the TCS-2000 is running in manual elevator operation, reinitialization will place the elevator and all arms back in service. Any VTRs which have been placed in external mode must be put back in service via the VTR External Operation. They will not be placed back into internal Odetics control automatically by a reinitialize. Reinitialization does not read the bar code ids of the tapes in the TCS-2000 bins. It is necessary to use Reverify Bins to read the tape ids. It is advised that the Unload Bin be rotated to the closed position as soon as possible after reinitialization of the TCS-2000 if it in not in the closed position. Normal position for the Unload Bin is closed, however the ADC will not autoimatically close this bin for operator safety. Reverify Bins (not functioning) provides a non-disruptive verification of the ids found in the bins of the TCS-2000. No threaded cassettes are ejected in this process, thus the list may still continue running during verification without placing the VTRs off-line. The existing entries in the cart s media library will not be automatically deleted, but each one checked as the barcode read of the bin is completed. If a mismatch is found between the id thought to be in the media collection and the physical id input from the barcode read the original id will be removed from the media collection and the newly read id inserted as the data for that bin. This will allow resynchronization of the TCS-2000 real tape collection and the ADC Imagine Communications Corp. 4

media collection for this device. A reverify bins cannot be started while the elevator is in manual operation. The reverify operation is a background operation. All loading of cassettes into VTRs and removing of tapes from VTRs is of higher precedence and may temporarily stop the verification process. Also during a library reverify there is a temporary suspension of the loading of new cassettes into the TCS-2000 and removal of cassettes from the TCS-2000. Elevator Operation allows the user to place the TCS-2000 into manual operation or restore it to automated operation. In the manual mode the elevator, hub and arm mechanisms are placed off-line for maintenance or repair and the operator becomes the replacement for the elevator and arm mechanisms. This mode must be run with the main doors of the cart machine opened since the operator must have ready access to all of the bins as well as the vtrs. Prompting will be given to indicate when tapes need to be loaded into VTRs from the TCS-2000 library or removed from VTRs and replaced into the TCS-2000 tape library. It is necessary to Enable Pop up Diagnostic Window from the Errors menu of the Preferences menu on the client being used. This will allow the prompting messages to appear on only that client. Other clients will not be affected. Each pop up window must be closed before the next diagnostic message is displayed. This insures that no message is missed and that tapes are moved in the order they are needed by the vtrs. In this mode no cassettes should be manually removed from the cart machine cassette bins except when requested to thread into a VTR. No tape should be placed into a different cassette storage bin than its original bin location, or be exchanged with a tape of a different id. No tapes should be added into the cart machine. The ADC will not recognize any new tapes physically placed into the storage bins of the cart machine. Also at this time it is not possible to use the load/unload bins of the TCS-2000. VTR External Operation is used in conjunction with the manual mode to remove VTRs from the automatic cart machine threading logic and make them operate like other external VTRs. Ids which are not found in the TCS-2000 library can be loaded into the external VTRs and recognized by the ADC via non-tcs-2000 barcode read, userbits read, or manual events. Any VTR placed into external operation will become a floater and be available to any list running in the ADC. Refer to External VTR operation descriptions in the ADC manual for additional details. Putting one of the cart machine vtrs into external mode can only be done while the elevator is in manual operation. Remember that the main doors of the TCS-2000 must be opened because the operator requires full access to the vtrs and bins. Putting a vtr into external operation allows media which were not loaded into the cart machine at the time it was placed in manual elevator operation to be played. Since the load port does not function during manual elevator operation no additional tapes can be added to the TCS-2000 once it is place in manual elevator mode. Eventually it may be necessary to play spots on tapes not found in the cart bins. The external vtr (in the cart) provide a resource to play these spots. If there are external vtrs which can handle the same tape format as the cart there would be no need to place cart vtrs into external operation. Arm Offline/Online allows one or more of the TCS-2000 arms to be placed out of service for Maintenance or repair and then returned to the pool of arms available for automatic operation. Arms which are placed offline are no longer used to transport cassettes within the cart machine. The TCS- 2000 will operate in an automated mode with as few as one arm online, however if multiple short events occur back to back there may not be sufficient time to keep the vtrs threaded. It may be advisable to use a longer thread time as arms are removed from automation service. Imagine Communications Corp. 5

TEST PROCEDURES The TCS-2000 should be tested with the ADC software to insure all cabling is correct and the TCS-2000 and its VTRs are communicating with the ADC server. Ensure that the serial RS-422 cable is attached to the server and that the appropriate RS-232 converter has been included in the cable connections as described above. Bring up the ADC software. When finished configuring the TCS-2000 on the device server, open the Device Status Window and verify that the device status is something other than NO DEV. If it is NO DEV then the device server and the TCS-2000 are not communicating. A status of NO COM indicates a failure of the ADC serial port being used or a non-existent serial port. Verify that the cable are properly connected, the device is powered on and configured in the device server. If there is still no communications, verify that the signals are being sent and received through the RS-422 cable using a VOM attached to the transmit and receive lines. There should be change in the voltage on these lines. An RS-422 analyzer may also be used in-line to verify communications. The communications with the Manipulator Electronics of the TCS-2000 will be tested by device initialization or Re-Initialization. This will initialize the Elevator, Hub, and Arms and rotate the Load Bin to the opened position. It will also eject any tapes found in the VTRs and replace them into bin storage or eject them. It is advised that the Unload Bin be rotated to the closed position as soon as possible after initialization or reinitialization of the TCS-2000. Normal position for the Unload Bin is closed, however the ADC will not autoimatically close this bin for operator safety. Test the eject mechanism for the TCS-2000 bins by ejecting a number of tapes. Open the Cart Machine Bin window and mark tapes to eject. Then under the Devices Menu option select Eject Bins and make sure that the tapes are moved to the Unload Bin. The Unload Bin should rotate to the opened position as soon as the last slot in it is filled with an ejected tape. Empty the tapes and press the Unload Rotate button above the Unload Bin to return the Unload Bin to the closed position. Test the loading of tapes by putting one or more tapes into the Load Bin of the TCS-2000. When the tapes have been loaded, press the Load Rotate button or the Load Immediate button. Make sure that the TCS-2000 barcode reads the tapes and moves them to internal bins. If any tape fills the next to last bin of the TCS-2000 the ADC should determine which bin is not needed for List operation and should eject a tape to the Unload Bin. The Unload Bin will automatically rotate to the open position when its last bin is full. One bin should always remain empty in the TCS-2000. With tapes in the TCS-2000, build a playlist that contains these tape ids. Load the list into a Transmission list. Make sure KEEP LIST THREADED is enabled under List Type under Transmission Menu options. Use Program Run on the Control Panel to thread the list. Make sure the elevator moves tapes to the VTRs and that they cue correctly. Unthread the list using Unthread on the Control Panel and make sure the tapes are returned to their respective bins. ERROR CONDITIONS AND RECOVERY: Before a VTR is uncabled or powered off, the VTR must be disabled first. 1. Make sure that the VTR is in eject status. 2. De-assign the VTR from the list. 3. Under Device parameters for the TCS-2000, select VTR PORTS. 4. Click or use the space bar to clear the VTR that is to be disabled. 5. Press OK, then SAVE to change the TCS-2000 Parameter. 6. When putting a deck back on line it must be powered on and cabled before it is enabled Imagine Communications Corp. 6

in the Server. 7. If this setup is permanent, it can be saved when a saved options is done. Before Device Initialization or Re-Initialization is initiated, be sure that the Service Door of the TCS-2000 is closed and preferably latched. If the door is not closed and the ADC detects a Service Door Open state the initialization sequence WILL NOT COMPLETE. These commands will remain in the internal command queue for the TCS-2000 and execute as soon as the Service Door is closed. This is to ensure the Tape Bins located in columns C, D and E, and the Load and Unload Bins can be correctly serviced and tape ids in these columns read and stored in the Cart s Library. At any time during operation, if the Service Door is opened, commands to move tapes to or from bins located in columns C, D, and E will not be executed and the Load and Unload bins will not be serviced. These commands will remain in the internal command queue for the TCS- 2000 and execute as soon as the Service Door is closed. It is best not to attempt to run the TCS-2000 with the Service Door opened for any extended period of time. (If the Service door is opened while the ADC is executing a command to access a bin located in the door it is possible that an Unusable Location Error will occur. The TCS-2000 may have failed to fetch a tape from a door location and the Gripper Closed without a tape. Or the TCS-2000 may have failed to insert a tape into door location. In this case the tape may have dropped. Either open the gripper or place the fallen tape in the gripper of the arm at the Service Door and shut the Service Door. The ADC should attempt to retry the operation.) Certain commands given to the TCS-2000 Manipulator Arm can cause Unable to Execute Responses. The ADC should decode these responses and output a descriptive entry into the Error Log if one of these conditions occurs. The following table is provided as a guide to these responses. Response UA UB UC UE UF UG UH UI UJ UL UM UN US UW UX Description or Cause Arm is off-line Bin inaccessible No cart in gripper Elevator is off-line Arm is off-line Can t go on-line Gripper not closed Hub is off-line Invalid parameter Cart jarred Load/Unload bin not fully closed Mechanical interference Buffer not open Slider not home Arm/Wand in the way Arm extended In the event that the TCS-2000 exhibits a mechanical malfunction the ADC will output a line to the Error Log CART MALFUNCTION - Mnnn. The following table is provided as a guide to these Malfunction Codes. CODE MALFUNCTION DESCRIPTION Imagine Communications Corp. 7

CODE MALFUNCTION DESCRIPTION 11 Slider didn t leave home within n milliseconds 12 Slider over-extended to limit switch 13 Slider over-extended too many tachs 14 Slider didn t complete extension within n seconds 15 Gripper not open/closed in time 16 Gripper motor rotated past sensor 17 Gripper sensor is in wrong state after rotation 18 Cart contact not made 19 Slider over-retracted to many tachs 20 Slider didn t complete retraction within n seconds 21 Extend or retract operation not completed in n seconds 22 Gripper open or close operation not completed in n seconds 23 Cart can t be pushed into transport within n seconds 24 Hub locating pin can t be pulled 25 Hub stopped before completion (long tach) 26 Pin drop didn t stop hub rotation 27 Hub didn t index to home within n seconds 28 Pin drop didn t stop hub indexing 29 Pin drop didn t stop hub within n seconds 30 Hub locating pin didn t drop properly 31 Cart can t be pushed into bin within n seconds 32 Mechanical hub malfunction during Barcode Read 35 Load/Unload bin assembly didn t complete rotation within n secs 36 Service door opened while arm extended into or toward it 41 Wrong echo from arm-hub to Manipulator after n tries 42 No response from Arm-Hub to Manipulator received within n secs 43 Wrong/indecipherable response from Arm-Hub to Manipulator 49 Elevator LED did not read stripe correctly 50 Elevator did not end movement on correct bin 51 Elevator did not complete movement within n seconds 52 Elevator did not complete indexing sequence within n seconds 53 Elevator reached lower mechanical limit 54 Elevator reached upper mechanical limit 55 Elevator stalled Certain error conditions may occur in the TCS-2000 which require operator intervention to completely correct the problem. Always try to remedy the situation by allowing the ADC to complete the failed operation. If an error is generated during a thread operation on a cart machine VTR, it is nercessary to determine the cause of the error. There may be a problem with the gripper or arm mechanism or the tape may be missing from its storage bin. Open the door of the TCS-2000 and investigate the cause of the error. If the error was caused by gripper malfunction, correct the problem, close the door of the TCS-2000 and allow the ADC to retry the operation. If the error was not caused by a gripper problem and the tape is physically missing from the storage bin it belongs in, then the event must be cut from the list. Any other use of this id should also be cut from the list or the tape loaded into the cart s library via the Load Bin before the tape is to be cued again. Next, the VTR should be switched from Remote, to Local, and back to Remote. When the door of the Imagine Communications Corp. 8

TCS-2000 is closed, the ADC s retry mechanism will attempt the failed command again. It may be necessary to re-execute this recovery procedure at this time, but after this the ADC will toss the failed command. The ADC will only retry TCS-2000 commands one time. INTERNAL DOCUMENT # 81311-00 FILE P:\Engineering\Public Documents\Usernote\Current User Notes\Devices\Cart Machine\Odetics\Odetics TCS2000 Imagine Communications Corp. 9