PRODUCT – ADC
TOPIC – SONY FLEXICART / SONY DVCAM FLEXICART
DATE: October 9, 2000
REVISION HISTORY
Revision
1.6
Protocol
1.5
1.4
1.3
1.2
1.1
1.0
Date
09 Oct.
2000
Author
Albano
CEDOLIN
Company
Louth Europe
02 Mar.
2000
28 Apr.
1999
15 Feb.
1999
11 Jan.
1999
28 Nov.
1998
03
Aug.1998
Albano
CEDOLIN
Albano
CEDOLIN
Albano
CEDOLIN
Michel
ROUXEL
Albano
CEDOLIN
Albano
CEDOLIN
Louth Europe
Louth Europe
Louth Europe
Louth Europe
Louth Europe
Louth Europe
Description
Synchronization with LUS
Flexicart.doc v1.6 (DVCAM Flexicart
Information)
Add “Management of the Flexicart
buzzer” paragraph
Add “Error reporting from the Flexicart”
paragraph
Add information on video reference
Add device error messages
Add service bulletin #2 (Standby off)
Add information on the CPU-107
board configuration
Creation
DESCRIPTION
This document is intended for both standard Flexicart systems as well as the DVCAM Flexicart. For
complete information regarding Prom and Software versions for the DVCAM Flexicart contact Sony
directly.
VERSIONS USED
Firmware:
Operator’s Manual:
Protocol:
CPU-107 Rom Version VCC V1.30
CPU-118 Rom Version CP18 V1.30
Flexicart VCC Version 1.30
REQUIREMENTS
The above versions are the latest versions from Sony at the time of this document. Earlier versions
from VCC 1.04 and up may also work. To determine the VCC version running in your Flexicart run Test
35 from the front panel.
A barcode reader installed in the cart is required for use by the automation software. There is no
support for cart machines without a barcode reader. If you are purchasing a Flexicart make sure that
the barcode reader option has also been purchased.
As of May 1, Sony says that the current Rom versions are :
CPU-107 Rom Version VCC V 1.33
CPU-118 Rom Version CP18 V 1.32
IF73 Card
V 1.21
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It has also been found that some machines may have a version of the VCC V 2.02. This may only
occur in Flexicarts designated as a Flexis system. If any question arises please contact your Sony
Representative.
CABLE REQUIREMENTS
The Sony Flexicart communicates via a standard RS422 interface using a standard cable. This cable is
a DB9 (Male) to a DB9 (Male). All connections are pin-to-pin
DB9 (male) Louth
TX+ 8
TX3
RX+ 2
RX7
DB9 (male)Flexicart
8 RX+
3 RX2 TX+
7 TX-
This cable may be purchased directly from Sony.
CONNECTIONS
One end of the cable is attached to the Sony Flexicart Remote 1. This connector is on the CPU-107
board in the Flexicart. This board is in Slot 4. The other end of the cable is attached to the Louth
Automation device server. Attach the cable to the serial port that the Sony Flexicart is to be configured
on.
Connect Reference Video to the Flexicart. Attach it to the top BNC connector on board CK39 Slot 12.
Set the termination switch correctly. The termination switch is located below the Reference Video
output BNC connector.
DEVICE HARDWARE SETTING
Make sure that the Sony Flexicart internal boards are configured correctly. The board layout is
described here but always refer to the Sony documentation for exact configurations.
Slot1
Slot2
Slot3
Slot4
Slot5
Slot6
Slot7
Slot8
Slot9
Slot10
Slot11
Slot12
IF-401
empty or BKFC 200 board
CPU-118
CPU-107
IF373
IF373
IF373
IF373
empty
empty
empty
CK39
(used when barcode reader is installed)
(for VTRS 1 and 2)
(for VTRS 3 and 4) this board is optional
(for VTRS 5 and 6) this board is optional
(for switcher) this board is optional
(for attaching time code and reference video)
When you have only two VTRS make sure that the IF373 board is in Slot5. When you have three or
four VTRS the next IF373 board is in Slot6. VTRS five and six have their IF373 board in Slot7.
Make sure that the VTRS are connected to the VCC. These require RS422 cables (purchased from
Sony).
Connect the following Remote in of each VTR to the VCC :
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VTR1
VTR2
VTR3
VTR4
VTR5
VTR6
Connector 2 on IF373 in Slot 5
Connector 4 on IF373 in Slot 5
Connector 2 on IF373 in Slot 6
Connector 4 on IF373 in Slot 6
Connector 2 on IF373 in Slot 7
Connector 2 on IF373 in Slot 7
Set the following switches on the CPU-107 Board Slot 4 (see page 4-6 in Sony Installation manual) for
control by automation.
Dip Switch (S1) RS-422A Termination, set to ON
Dip Switch (S5)
S5-1
S5-2 & 3
S5-4
S5-5
S5-6
S5-7 & 8
Interface port, set to OFF for RS-422A active
Baud Rate, set to OFF & OFF for 38.4 rate
Not used
Off if barcode reader is installed, on is no barcode reader.
Off for DF Mode (NTSC only), On for Non DF Mode
Select video mode.
Video mode :
PAL
NTSC
SECAM
S5-7
OFF
OFF
ON
S5-8
ON
OFF
OFF
Rotary Switch (S6), Set to 1 for Cart 1 (Set this to Cart 1 even when multiple carts)
Set the following switches on the IF-373 Board Slots5, 6, and 7 (see page 4-8 in Sony Installation
manual) for control by automation.
Dip Switch (S3)
S3-1,2,3,4,5,6
S3-7
set to OFF
set to ON for BVW, Off for DVR
S3-8
set to OFF
COMMUNICATIONS PARAMETERS
The communications parameters for the Sony Flexicart are :
Baud Rate :
38 400 Bauds
Data Bits :
8
Parity :
Even
Stop Bits :
1
DEVICE SERVER SET-UP
To configure a Sony Flexicart in the ADC follow these steps :
Select the Options pull down menu on the ADC device server.
1.
Select Configure Devices and choose the device number to which the Sony Flexicart is to be
assigned to. The device number is the port to which the RS-422 cable is connected on the ADC.
2.
Select Change.
3.
Select Cart Machine under listed devices and Sony Flexicart for the protocol.
4.
Press OK and Save. The system will prompt for confirmation.
Select the Options pull down menu again.
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1.
Select Device Parameters to set up the device for operation. A variety of options will be
available.
2.
Select Device Name and assign a name to the Flexicart.
Select Usable VTRS and make sure that each VTR that is in the Flexicart is enabled under this option.
4.
If the Flexicart has a built in switcher (not controlled directly by the automation) then there are
three more options that must be configured. Refer to the ADC manual for more information.
Internal Switcher Dimensions
Switchers Audio/Video Out
Black, Logo, Colorbars, etc.
5.
For each list (or cached) on the system, select Audio/Video and fill in the appropriate Video
Out and Video In crosspoints. Do this for each VTR in the Flexicart.
6.
When you are done with all the device set up, press Save and the set-up will be made
permanent.
TEST PROCEDURES
1.
Ensure that the serial RS-422 cable is attached to both the automation server and the Sony
Flexicart.
2.
Bring up the ADC software. When you finish configuring the Sony Flexicart on the device
server, open the Device Status Window and verify that the device status is something other than NOT
COMMUNICATING. If the status is NOT COMMUNICATING or UNKNOWN then the device server
and Flexicart are not communicating properly. A status of NO COM indicates a failure of the ADC serial
port being used or non-existent. A status of ON-LINE indicates the Flexicart is communicating correctly.
If there is a communications problem then verify that the cables are properly connected, the
device is powered on and you have completed the configuration on the device server. If there is still no
communication, 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.
A RS-422 analyzer may also be used in-line to verify communications.
If the Flexicart’s status look correct then check the VTR status for each VTR in the Flexicart.
The VTR's status is displayed in the Device Status Window. Put each VTR into LOCAL then REMOTE
and see that the status changes appropriately.
3.
The Flexicart should be tested with the ADC software to insure that the Flexicart computer has
been configured correctly and is communicating with the ADC server. Put some tapes in the bins and
use a playlist that contains these tapes to test the system.
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 that 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 bins.
The rules concerning the management of the LED’s are the following:
LED ON :
Bin containing a tape : the tape is used in one transmission list.
Bin empty : the bin is reserved for a tape loaded into a vtr. The operator MUST NOT insert a tape in this
bin.
LED OFF :
Bin containing a tape : the tape is not used in any transmission list.
Bin empty : the bin is not used. The operator can insert a tape in this bin.
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Note:
The storage unit of the Flexicart is able to contain 30 small tapes, or 15 large tapes or a blend of small
and large tapes. Each bin is equipped with an LED.
Note : The Sony Flexicart doesn’t have any load port ; tapes are inserted in the cart machine through
the front door.
MANAGEMENT OF THE FLEXICART BUZZER
In ADC v9.2 appeared the following enhancement: the Sony Flexicart will sound its buzzer if the door is
open and the automation has made a request to move a tape either to or from a VTR or bin. To
terminate the buzzer, close the door. If this situation occurs because the Transmission List was
threading, then after closing the door, use the Air Client control panels for any Transmission List that
was using the Sony Flexicart. Push the Program Run button again to inform the List it is ok to rethread
the events on the list.
MANAGEMENT OF THE “BIN” FIELD OF THE TRANSMISSION LIST, AND THE “LOC” FIELD OF THE DEVICE
STORAGE WINDOW
The “BIN” field of the transmission list displays the bin number from where the tape was taken before
being inserted into a vtr.
The “Loc” field of the cart device storage window displays the bin number where a tape inserted into a
vtr will be put back after playback.
OPERATION NOTES
The Flexicart can be used by ADC as a play out device. The VTRS in the Flexicart can be assigned to
either the same play list or different play lists. The Flexicart can also be used as a source for a Disk
Server Cache in ADC. To assign the VTRS to a list or Cache object select Assign Devices under the
Options menu on the device server. Assign the VTR to the appropriate list or cache.
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 Flexicart provides the following diagnostic services:
Reinitialize Cart provides full initialization of the cart machine. It will initialize the Elevator and Arm
mechanism, as well as delete all entries in the cart machine’s media storage window and then bar code
read each bin in the Flexicart inserting the id into the media storage window. It will also eject any tapes
found in the VTRs and replace them into bin storage or eject them from the cart machine.
TROUBLESHOOTING
Ensure that the cable is attached to both the server and the cart machine. Verify that the pin
connections in the cable are as shown above.
Ensure that the cart machine is functioning properly. Verify that the installation of the cart machine is
complete.
Verify that signals are being sent and received through the cable. To do this, a VOM may be attached to
the transmit and receive lines. Also, while issuing a command, watch for a change in voltage.
Alternatively, attach an analyzer in-line and watch for a transmission and acknowledgment of
commands being sent to the cart machine. If a command is being sent and not returned, check to
ensure that the cable is connected properly at the cart machine. If the command is being returned,
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check to ensure that the setup in the software is correct. If commands are not being sent at all, check
the cable connection to the server and the setup in the software.
Run the ADC software. From the “System” menu, select “System Diagnostics | Sony Flexicart |
Reinitialize cart”. The cart will start the re-initialization process.
Check the video reference provided to the cart machine and to the internal vtrs. This cart machine is
using the video reference to synchronize the emission of data on the communication port. If the video
reference is not provided to the controller block (slot 12 : CK-39 board) or to one or more internal vtrs of
the cart machine, then some problems of communication between the automation and the cart machine
may happen.
ERROR CONDITIONS AND RECOVERY
If you have problems with ADC recognizing the VTRS within the Flexicart they may not be properly
configured. Check the following.
1.
Make sure that the IF373 cards are installed in the correct slots.
2.
Make sure that the cables to each VTR are attached to the Remote connector on the VTR and
to the proper connection on the IF373. Make sure that the cables are in working condition also.
The Flexicart’s internal software handles the reading of barcodes automatically whenever a tape is
inserted into the cart. If the tape has no barcode label the Flexicart will not return an error to the
automation software indicating a problem. Do not use non-barcoded tapes in the Flexicart. Only use
Sony format barcode labels.
1. RECOVERING THE DEVICE STORAGE AFTER REMOVING A TAPE FROM THE FRONT DOOR OF THE FLEXICART
THAT SHOULD BE IN A BIN.
•
•
•
•
•
The operator opens the front door.
The operator takes the tape that should be in a bin. This tape was fallen down, remained
in the gripper or remained ejected from a VTR.
The operator inserts this tape in a bin where the attached led IS NOT ON.
The operator closes the front door. Then, the cart will read this tape and recover the
device storage.
Now (and only now), if this tape is not used anymore, the operator can remove
manually this tape from the cart machine device storage.
2. RECOVERING THE CART MACHINE FROM THE LOST OF A TAPE THAT SHOULD BE INSIDE A VTR.
•
The operator opens the front door and takes the tape that should be in VTR. This tape was
fallen down, remained in one gripper or remained ejected from a VTR.
• In the device status window, the ID of the tape is supposed to be in a VTR.
• The operator must take this tape and insert it in the VTR that is supposed to have this
tape. The VTR will cue the tape automatically.
• The operator closes the front door.
• The problem is corrected; the VTR will play the tape and eject it when the spot will
finish. Then, the cart will move the tape from the VTR to a bin.
ERROR REPORTING FROM THE FLEXICART
This section describes the current error codes that might be returned from the Flexicart and other Sony
cart machines.
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BASIC ERRORS
MEDIA UNABLE TO CUE - ID: XXXX
This error occurs when a VTR with a piece of material is sent a cue command and the VTR ends up in
STOP for two seconds.
BAD BARCODE READ ON BIN: NNNN
This error occurs when the cart machine tries to read a barcode label and fails. The
Sony cart machines will retry the barcode read up to three times depending on the
type of cart machine.
DUPLICATE TAPE: XXXX BIN: NNNN ALREADY IN VTR
This error occurs when a tape with a barcode label is put into the cart machine and a tape with that label
already exists loaded into a VTR.
DUPLICATE TAPE: XXXX IN BIN: NNNN
This error occurs when a tape with a barcode label is put into the cart machine and a tape with that label
already exists in the cart machine.
DOOR IS OPEN
This error occurs when a door in the cart machine is opened which would prevent operation of the cart
machine. Operation means having the robot move a tape.
OUTPORT IS FULL - PLEASE EMPTY IT
In an LMS that has an output port, this indicates that the port needs to be emptied by an operator.
NO MORE BINS TO STORE MEDIA
This error will occur when a tape has been put into the cart machine and only one empty bin then
remains.
MACRO GENERATED ERRORS
Many of the internal commands used, require macro numbers passed to the cart machine. These
commands take time to complete and the macro number is used to return a completion code. When an
error is returned some of these macros may be displayed to the user in different messages. Some
messages may include the hex representation of the macro return code.
MACRO BUSY ERROR
This error should never occur. If it does please send a copy of the error logs to Louth.
TROUBLE WITH OUTPORT - PLEASE CHECK
There is a mechanical problem with the output port in an LMS that has an output port. The following
macro errors might have caused this.
AFT_OUTPORT_TROUBLE
BEF_OUTPORT_TROUBLE
NO_SPACE_IN_OUTPORTBINS
DEH
BEH
56H
ID: XXXX REMOVED FROM BIN: NNNN DURING THREAD
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The robot went to fetch a tape that was no longer in the bin. The following macro errors might have
caused this.
AFT_SOURCE_BIN_NO_CASSETTE
BEF_SOURCE_BIN_NO_CASSETTE
SOURCEBINERROR
5FH
3FH
BBH
THREAD FAILURE - DOOR OPEN OR SYSTEM DOWN - MACRO_ERROR
A failure occurred when moving a tape to a VTR. This error displays the macro error code.
AFT_DOOR_OPEN
BEF_DOOR_OPEN
BIN_NOT_INITIALIZED1
SYSTEM_MUSTBE_RECOVERED
SYSTEM_DOWN
58H
38H
54H
48H
6CH
VTR PROBLEM - CHECK FOR JAM - MACRO_ERROR
A problem occurred when moving a tape to or from a VTR. This error displays the macro error code.
VTR_NOT_ALIGNED
CASSETTE_STUCK
AFT_ADAPTOR_TROUBLE
BEF_ADAPTOR_TROUBLE
VTR_PULLED1
VTR_PULLED2
AFT_ELEVATOR_ERROR
BEF_ELEVATOR_ERROR
5AH
5BH
DCH
BCH
55H
35H
D7H
B7H
CASSETTE STUCK IN ELEVATOR - POSSIBLE VTR PROBLEM
A problem occurred when moving a tape to or from a VTR. The following macro errors might have
caused this.
VTR_NOT_ALIGNED
CASSETTE_STUCK
AFT_ADAPTOR_TROUBLE
BEF_ADAPTOR_TROUBLE
VTR_PULLED1
VTR_PULLED2
AFT_ELEVATOR_ERROR
BEF_ELEVATOR_ERROR
5AH
5BH
DCH
BCH
55H
35H
D7H
B7H
MACRO DISTURBED
The internal computer in the Sony cart machine had a problem with the macro. The following macro
errors might have caused this.
MACRO_DISTURBED
MACRO_TERMINATED
23H
FBH
UNKNOWN THREAD ERROR - MACRO_ERROR
An error occurred when moving a tape from a bin to the VTR. A variety of macro errors could have
caused this. This error displays the macro error code.
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VTR EJECT FAILURE - CHECK FOR JAM - MACRO_ERROR
An error occurred when the VTR was ejected. A variety of macro errors could have caused this. This
error displays the macro error code.
DEVICE ERROR MESSAGES
OUTLINE
An error message is displayed on the front panel display of the Flexicart in following case :
• Error was detected during self-diagnosis, which is performed when turning on the power.
• Error was detected during normal operation.
• Error was detected during normal test mode.
When the error messages are displayed, the information written below will help you to identify the
erroneous place.
ERROR MESSAGE DISPLAY
When an error is detected, an error message is displayed on the display window with the following
format: XXXX-****; XXXX is the device type and **** is the error code.
The device type indicates the error occurred place and can have the following value:
Device Type
ELV
XXX
BIN
PRT
INI
SRV
K39
RAM
ERR
F73
VTR
BCR
Error occurred place
Elevator
Bin relation (during access)
Bin controller
Cassette protrusion detector
Elevator (when initialization)
Servo
CK-39 board
Common memory
CPU loaded board
IF-373 board
VTR
Barcode reader
Error item
Elevator error
Access with BINs error
Error at BIN controller
Cassette protrusion detector error
Elevator initialization error
Error occurred at servo
CK-39 board error
Common memory error
Self-diagnosis error
IF-373 board error
VTR error
Barcode reader error
ERROR MESSAGE LIST
The Error Message list is the following:
Error message
ELV-0011
ELV-0012
ELV-0016
ELV-0021
ELV-0022
ELV-0023
ELV-0024
ELV-0025
ELV-0026
ELV-0032
Meaning of the error message
The elevator is not connected to the cart machine.
The hand remains having a cassette, so initialization cannot be done.
The hand is not holding a cassette correctly.
Pulses from the X-axis encoder cannot be detected.
Pulses from the Z-axis encoder cannot be detected.
Pulses from the hand encoder cannot be detected.
The elevator cannot detect the X-origin.
The elevator cannot detect the Z-origin.
The cassette detection sensor of the hand has fault.
The limit sensor of the hand has fault.
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XXX-0011
XXX-0012
XXX-0021
BIN-0001
through 0008
PRT-0010
PRT-0020
INI-0001
INI-0002
INI-0010
INI-0020
INI-0021
SRV-0022
SRV-0023
SRV-0071
SRV-0072
SRV-0073
SRV-0074
SRV-0081
Error message
K39-0011
K39-0012
RAM-CP18
RAM-DP17
RAM-F731
RAM-F732
RAM-F733
RAM-F734
RAM-RD24
ERR-0001
through 0012
F73-0011
F73-0012
VTR-0011
VTR-0012
VTR-0021
VTR-0022
BCR-0011
The elevator tried to extract a cassette but failed.
The elevator tried to load a cassette into the BIN but failed.
The elevator loaded a cassette into the BIN but cannot detect “cassette in” mode.
The boards of BIN block No. 1 through No. 8 are not connected or cannot be
recognized.
A cassette protrusion detector is not connected to the cart machine.
A cassette is protruding.
The Y-initial sensor has fault.
Y-origin cannot be detected.
A cassette remains at cassette compartment of the VTR, so operation cannot be done.
The number does not correspond between the BIN unit and the shutter plate.
The number does not correspond between the VTR unit and the shutter plate.
The Y motor driver has overheated.
The Y motor protection thermal relay has overheated.
The servo turned off because servo of Y-direction could not follow the commands.
The servo turned off because it could not keep the elevator at the designated position.
The servo turned off because the Y-drive motor encoder pulse was not detected.
The servo turned off because the acceleration of Y-direction exceeeded the specified
value.
The electric current is shut off in an instant.
Meaning of the error message
No reference video signal is input to the board.
The board is not ready for operation.
The cart machine cannot access common RAM on the CPU-118 board.
The cart machine cannot access common RAM on the DP-178 board.
The cart machine cannot access common RAM on the first IF-373 board (VTR 1 and
2).
The cart machine cannot access common RAM on the second IF-373 board (VTR 3
and 4).
The cart machine cannot access common RAM on the third IF-373 board (VTR 5 and
6).
The cart machine cannot access common RAM on the fourth IF-373 board
(VIDEO/AUDIO SWITCHER).
The cart machine cannot access common RAM on the RD-24 board.
Each error code 0001 through 0012 corresponds to slot No. 1 through 12. The error is
self-diagnostic error of the board that corresponding slot No.
The board is not installed in the appropriate slot.
The board is not ready for operation.
The elevator tried to extract a cassette from the VTR but failed.
The elevator tried to load a cassette into the VTR but failed.
The elevator loaded a cassette into the VTR but cannot detect “cassette in” mode.
The VTR cannot eject a cassette.
The header of the barcode reader does not install or trouble.
CONTROLLER BLOCK PHYSICAL INFORMATION
First IF-373 board :
The IF-373 board whose slot No. is 5, and VTR1 / VTR2 are connected.
Second IF-373 board : The IF-373 board whose slot No. is 6, and VTR3 / VTR4 are connected.
Third IF-373 board :
The IF-373 board whose slot No. is 7, and VTR5 / VTR6 are connected.
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Fourth IF-373 board : The IF-373 board whose slot No. is 8, and VIDEO / AUDIO Switcher are
connected.
Slot : The slot on the controller block of rear panel for the printed circuit boards. The following figure
shows slot No. that each board is installed.
Slot #
Board
Optional
1
IF401
board
2
RD-24
board
3
CPU-118
board
Yes
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5
CPU-107 IF-373
board
board
6
IF-373
board
7
IF-373
board
8
IF-373
board
Yes
Yes
9
10
11
11
12
CK-39
board
Service Bulletin
#2
TOPIC: SONY DIGITAL BETACAM VTRS RUNNING IN A SONY FLEXICART DO NOT GO
INTO STANDBY OFF WHEN THEIR INTERNAL STANDBY OFF TIMEOUT VALUE IS
REACHED.
The Sony Digital BetaCam VTRs have demonstrated that they do not go into Standby Off mode when
they are running in a Sony Flexicart, when a Tension Release command is issued by the automation
system. The result is that the decks appear to not respond to the internal Standby Off timeout value.
When this occurs, the decks continue to stay in Tension Release mode but not in Standby Off. The
result of this is excessive wear to the brushes on the VTR’s Head Drive.
This problem is a result of the ADC Automation system issuing a Tension Release command to the
Flexicart VCC. Unfortunately, the Flexicart VCC will always keep the decks’ heads tensioned even if the
internal timeout value has exceeded. The Tension Release command issued by the automation system
will override the internal Standby Off command.
The problem has been examined, and a way to work around this problem has been found. This is done
by turning off the Release Tension When Cued function on any list that the decks in the Flexicart are
currently assigned to. This will stop the VCC from issuing the tensioned off command to the decks.
The result of which is when the internal standby timer in the decks issues the command to bring the
heads down they will stay down until the automation list issues a Standby On command to the deck.
The default value for the list is to issue a Standby On command to the next event when it is 30 seconds
away from playing. This value may be adjusted in the list configuration dialog in the ADC Device Sever.
INTERNAL DOCUMENT #
FILE
P:\Engineering\Public Documents\Usernote\Current User Notes\Devices\Cart
Machine\Sony\Flexicart_DVCAM Flexicart
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