Novanta ScanMaster User manual

1040-0011 Revision
ENGINEERED BY
CAMBRIDGE TECHNOLOGY
ScanMaster Controller
Advanced Laser Positioning and Control
User Manual
For laser steering systems
Read carefully before using.
Retain for future reference.

Table of Contents
TABLE OF CONTENTS
Table of Contents 2
List of Figures 6
List of Tables 8
1Important Information 1
1.1 Safety Symbols 1
1.2 Safety Labels 2
1.3 Customer Support 2
2Introduction 4
2.1 General Notes 4
2.2 Using This Manual 4
2.2.1 Purpose 4
2.2.2 Scope 4
2.2.3 Revision History 4
2.3 Warranty Information 6
3Product Introduction 7
3.1 System Description 7
3.2 Feature Overview 8
3.2.1 Hardware Features 8
3.2.2 Software Features 9
3.3 Technical Specifications 10
4Installation 16
4.1 Storage and Operation Environment 16
4.1.1 Important 16
4.1.2 Electrical ESD safety 16
4.2 Mechanical Layout 17
4.3 System Configuration 19

Table of Contents
4.4 Connector Cross-Reference 21
4.5 SMC Module Connector Pinouts 22
4.5.1 Power Signal Pinouts (Connectors J1 and J3) 23
4.5.2 Serial RS-232 Signal Pinouts (Connector J10) 25
4.5.3 XY2-100 Signal Pinouts (Connector J11) 26
4.5.4 Auxiliary Signal Pinouts (Connector J13) 28
4.5.5 MOTF-1 Signal Pinouts (Connector J14) 33
4.5.6 MOTF-0 Signal Pinouts (Connector J15) 35
4.5.7 Control Signal Pinouts (Connector J16) 36
4.5.8 External Trigger Pinouts (Connector J17) 39
4.5.9 Laser Signal Pinouts (Connector J18) 40
4.5.10 E-STOP (Connector JP6) 44
4.5.11 USB Port 1 Pinouts (Connector J5) 46
4.5.12 USB Port 2 Header Pinouts (Connector J6) 47
4.6 Signal Conditioning 48
4.6.1 Mark-on-The-Fly Inputs –J14 and J15 48
4.6.2 High-speed Laser Synchronization –J18 49
4.6.3 Laser Status 0-5 Signals –J18 49
4.6.4 General Purpose Inputs –J13 and J16 49
4.6.5 System Control Inputs –J13 and J16 50
4.6.6 START Input –J17 and J15 50
4.6.7 System Control Outputs and General Purpose Outputs –J13 and J16 51
4.6.8 Laser Control Outputs –J18 52
4.6.9 Auxiliary XY2-100 Signals –J13 53
5Appendix A - SMC-IO-01 Auxiliary I/O Module 54
5.1 Introduction 54
5.2 Mechanical Layout 55
5.3 Connectors 55
5.3.1 J3 AND J4 - XY2 - 100 PORTS 55
5.3.2 J11 –RS - 485 Communications 56
5.3.3 J10 –RS –232 Communications 57
5.3.4 J15 and J16 –MOTF 0 And MOTF 1 58
5.3.5 J6 and J8 –Extended Digital Inputs 59
5.3.6 J7 and J9 –Extended Digital Outputs 61

Table of Contents
5.3.7 J13 and J14 –External Motor Control 63
5.3.8 J5 and J12 - System Control Inputs and Outputs 64
6Appendix B - SMC-LSR-01 IPG Laser Adapter 66
6.1 Introduction 66
6.2 Mechanical Layout 66
6.3 Connectors 67
6.3.1 Laser Signal Mappings 67
6.3.2 SMC-LSR-01 Usage with IPG YLP-HP Type B Interface 68
7Appendix C –SMC-LSR-02 SPI Laser Adapter 73
7.1 Introduction 73
7.2 Mechanical Layout 74
7.3 Connectors 74
7.3.1 J2 SPI Laser Connector 74
7.3.2 J3 E-STOP Connector 75
8Appendix D - SMC-LRS-04 High-power Laser Adapter 77
8.1 Introduction 77
8.2 Mechanical Layout 78
8.3 Connectors 78
8.3.1 J2 - Laser Signal Set 1 79
8.3.2 J3 - Laser Signal Set 2 80
8.3.3 J5 - BNC Laser Modulation Output 81
8.4 Local Laser Modulation Control 81
8.5 Selective Pull-up/Pull-down of Control Signals 82
9Appendix E - SMC-LSR-05 Coherent C70 Laser Adapter 83
9.1 Introduction 83
9.2 Mechanical Layout 84
9.3 Connectors 84
9.3.1 J5 - RJ-45 Laser Control Signals 84
9.3.2 J2 - Auxiliary Laser Control Signals 85
9.4 Local Laser Modulation control 86

Table of Contents
10 Appendix F - XY2-100 Protocol Interface 88
10.1 Connections and signal descriptions 88
10.2 Clock 89
10.3 Sync 89
10.4 X, Y, & Z Data 89
10.5 Status Data 90
11 Index 92

List of Figures
LIST OF FIGURES
SMC, Auxiliary I/O, and High-power Laser Adapter Assembly...............................................18
SMC Main Module Mechanical Layout ..................................................................................19
SMC Interconnection Options................................................................................................20
Connectors J1 and J3 (Power) Pinouts ...................................................................................23
Recommended Power Supply Connections ...........................................................................24
Connector J10 (RS-232) Pinouts.............................................................................................25
Connector J11 (XY2-100) Pinouts...........................................................................................26
Connector J13 (Auxiliary) Pinouts ..........................................................................................28
Connector J14 (MOTF-1) Pinouts ...........................................................................................34
Connector J15 (MOTF-0) Pinouts .........................................................................................35
Connector J16 (Control) Pinouts ..........................................................................................37
Connector J17 (External Trigger) Pinouts.............................................................................39
Connector J18 (Laser) Pinouts..............................................................................................41
Connector JP6 (E-STOP) Pinouts...........................................................................................45
Connector J5 (USB Port 1 Pinouts).......................................................................................46
Connector J6 (USB Port 2 Header) Pinouts ..........................................................................47
Signal Conditioning for Mark-on-the-Fly Inputs (J14 and J15).............................................48
Signal Conditioning for High-speed Laser Synchronization (J18).........................................49
Signal Conditioning for Laser Status 0-5 Signals (J18)..........................................................49
Signal Conditioning for General Purpose Inputs (J13 and J16) ............................................49
Signal Conditioning for System Control Inputs (J13 and J16)...............................................50
Signal Conditioning for START Input (J17 and J15)...............................................................50
Signal Conditioning for System Control and General O/P (J13 & J16) .................................51
Expected Usage of Digital Outputs.......................................................................................52
Signal Conditioning for Laser Control Outputs (J18)............................................................52

List of Figures
Signal Conditioning for Auxiliary XY2-100 Signals (J13) .......................................................53
Auxiliary I/O module outline drawing..................................................................................55
J3 XY2-100 Port 1 and J4 XY2-100 Port 2 .............................................................................56
J11 RS-485 Communications................................................................................................57
J10 RS-232 Communications................................................................................................58
J15 MOTF Port 0 (X) and J16 MOTF Port 1 (Y) ....................................................................59
J6 Extended Inputs Bank 0 ...................................................................................................60
J8 Extended Inputs Bank 1 ...................................................................................................60
Extended Inputs Signal Conditioning ...................................................................................61
J7 Extended Outputs Bank 0................................................................................................62
J9 Extended Outputs Bank 1 ................................................................................................62
Extended Outputs Signal Conditioning ................................................................................63
J13 and J14 External Motor Control Port 0 and Port 1........................................................64
J5 System Control Inputs......................................................................................................64
J12 System Control Outputs ...............................................................................................65
IPG Laser Adapter Cable Mechanical Layout .......................................................................66
Connector JP6 (E-STOP) Pinouts...........................................................................................70
SPI Laser Adapter Mechanical Layout..................................................................................74
SPI Laser Connector Signal Assignments.............................................................................75
E-STOP Connector Signal Assignments.................................................................................76
High-Power laser adapter mechanical layout ......................................................................78
J5 BNC Laser Modulation Output.........................................................................................81
Remote Modulation Control Configuration .........................................................................82
Control Signal Pull-up/Pull-down Configuration..................................................................82
Coherent C70 Laser Adapter Mechanical Layout................................................................84
Remote Modulation Control Configuration .........................................................................87
X2-100 Timing Diagram........................................................................................................89

List of Tables
LIST OF TABLES
Revision History.........................................................................................................................5
Safety Labels and Symbols..........................................................Error! Bookmark not defined.
Technical Specifications...........................................................................................................10
SMC Connector Part Number Reference.................................................................................21
Connector J1 (Power) Signal Descriptions...............................................................................24
Connector J3 (+24 Signal) Signal Descriptions.........................................................................25
Connector J10 (RS-232) Signal Descriptions............................................................................25
Connector J11 (XY2-100) Signal Descriptions..........................................................................27
Connector J13 (Auxiliary) Signal Descriptions .........................................................................29
Connector J14 (MOTF-1) Signal Descriptions........................................................................34
Connector J15 (MOTF-0) Signal Descriptions........................................................................35
Connector J16 (Control) Signal Descriptions.........................................................................37
Connector J17 (External Trigger) Signal Descriptions............................................................40
Connector J18 (Laser) Signal Descriptions.............................................................................41
Connector JP6 (E-STOP) Signal Descriptions .........................................................................45
Connector J5 (USB Port 1 Header) Signal Descriptions .........................................................46
Connector J6 (USB Port 2 Header) Signal Descriptions .........................................................48
IPG Laser Adapter Cable Signal Mappings.............................................................................68
Modifications of SMC-LSR-01 for IPG YLP-HP Type B Connection ........................................69
Custom Cable Pinouts for IPG YLP-HP Type B Interface........................................................71
Laser Signal Set 1 ...................................................................................................................79
Laser Signal Set 2 ...................................................................................................................80
RJ-45 Laser Control Signals....................................................................................................84
Auxiliary Laser Control Signals...............................................................................................85
DB-25 Connector to an XY2-100-based Scan Head ...............................................................88

List of Tables
Control Codes ........................................................................................................................90
Status Data Formats ..............................................................................................................90

Important Information
1040-0011 Revision 1
1IMPORTANT INFORMATION
For your protection, carefully read these instructions before installing and operating the scan
head.
Retain these instructions for future reference.
Novanta reserves the right to update this user manual at any time without prior notification.
If product ownership changes, this manual should accompany the product.
1.1 SAFETY SYMBOLS
This manual uses the following symbols and signal words for information of importance.
DANGER
Indicates a hazardous situation which, if not avoided, will result in serious injury or death.
WARNING
Indicates a hazardous situation which, if not avoided, could result in serious injury or death.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
IMPORTANT
Indicates information considered important but not directly hazard related (e.g. security, hygiene,
or equipment or property damage).

Important Information
1040-0011 Revision 2
1.2 SAFETY LABELS
DANGER
Laser radiation
can cause severe retinal and corneal burns, burns on the skin, and may pose a fire risk.
•To avoid injury and reduce risk of fire, please follow the control measures and safety
guidelines provided by the laser’s manufacturer, and those established by your Laser Safety
Officer (LSO), Radiation Safety Officer (RSO), or safety department of your business or
institution.
ESD WARNING
Electrostatic discharge and improper handling
can damage MOVIA scan head’s electronics.
•Keep the equipment sealed until it is located at a proper static control station.
1.3 CUSTOMER SUPPORT
Before contacting Novanta for assistance, review appropriate sections in the manual that may
answer your questions.
After consulting this manual, please contact one of our worldwide offices between 9 AM and 5 PM
local time.
Americas, Asia Pacific
Novanta Headquarters, Bedford, USA
Phone: [phone]
Email: [e-mail]

Important Information
1040-0011 Revision 3
Europe, Middle East, Africa
Novanta Europe GmbH, Wackersdorf, Germany
Phone: [phone]
Email: [e-mail]
Milan, Italy
Phone: [phone]
Email: [e-mail]
China
Novanta Sales & Service Office, Shenzhen, China
Phone: [phone]
Email: [e-mail]
Novanta Sales & Service Office, Suzhou, China
Phone: [phone]
Email: [e-mail]
Japan
Novanta Service & Sales Office, Tokyo, Japan
Phone: [phone]
Email: [e-mail]

Introduction
1040-0011 Revision 4
2INTRODUCTION
2.1 GENERAL NOTES
Novanta reserves the right to make changes to the products covered in this manual to improve
performance, reliability or manufacturability.
Although every effort has been made to ensure accuracy of the information contained in this
manual, Novanta assumes no responsibility for inadvertent errors. Contents of the manual are
subject to change without notice.
2.2 USING THIS MANUAL
2.2.1 Purpose
This manual provides directions to help users safely and effectively install and operate the
ScanMaster Controller (also known as SMC) for various laser processing applications using
Galvanometer based laser scanning head and laser. The manual also includes material such as system
specifications and optimization guidelines. It is assumed that the reader has a general knowledge of
galvos and command controllers.
2.2.2 Scope
This manual covers the SMC board and optional modules only. The optional modules include the
SMC-IO-01 Auxiliary I/O Module, the SMC-LSR-01 IPG Laser Adapter, the SMC-LSR-02 SPI Laser
Adapter, and the SMC-LSR-04 High-power Laser Adapter, and the SMC-LSR-05 Coherent C70 Laser
Adapter.
2.2.3 Revision History
The following table shows the revision history for this document.

Introduction
1040-0011 Revision 5
Revision History
REVISION
DATE
Changes from previous revision
A
December 5, 2014
First release of this manual.
B
November 2, 2015
Added recommended power connection diagram
Added Coherent C70 Laser Adapter
Fixed errors in High-power Laser Adapter pin-outs
C
December 5, 2016
Updated Aux I/O module outline drawing to show female COM connector
Use new CT logo and fixed Japan support e-mail address
Added appendix covering the IPG YLP laser adapter
Added notes to the high-power laser adapter about mislabeled silkscreen on
the Rev C adapter boards
Deleted “Future use” references where the feature is now supported
Fixed AUX_GPI and AUX_GPO numbering to go from 1-4
D
May 19, 2017
Fixed reference to GP input conditioning in Aux I/O module
E
June 23, 2017
Fixed GPI and GPO pin names on MOTF connectors
F
June 2018
Added additional info on IPG YLP-HP Type B interface
Adjusted J3 image to match physical view
Added scan-head power supply to wiring recommendation
G
September 2018
Refined the definition of the AUX_READY signal which is renamed to
AUX_ERROR_READY_N
H
January 2019
Updated to new format.
J
January 2020
Changed 25P D-Sub M from 25P D-Sub F on the IPG laser adapter
Added signal conditioning diagrams for the extended I/O
K
April 2022
Clarified description of AUX_RESET signal
Updated GPIO module figures regarding AUX_ERROR_READY_N signal
Updated the SPI Laser connector diagram

1040-0011 Revision 6
2.3 WARRANTY INFORMATION
The Customer shall examine each shipment within 10 days of receipt and inform Novanta of any
shortage or damage. If no discrepancies are reported, the shipment will be considered as delivered
complete and defect-free. Novanta warranties products against defects up to 1 year from
manufacture date, barring unauthorized modifications or misuse. Repaired product is warrantied for
90 days after the repair is made, or one year after manufacture date - whichever is longer.
Contact Customer Service at [phone] to obtain a Return Materials Authorization (RMA)
number before returning any product for repair.
All orders are subject to the Terms and Conditions and Limited Warranty. Contact your local sales
office for the latest version of these documents and other useful information.
Customers assume all responsibility for maintaining a laser-safe working environment. OEM
customers must assume all responsibility for CDRH (Center for Devices and Radiological Health)
certification.

Product Introduction
1040-0011 Revision 7
3PRODUCT INTRODUCTION
3.1 SYSTEM DESCRIPTION
The SMC is a self-contained controller that provides advanced hardware and software control
technology to drive laser scanning systems. The Ethernet-connected SMC board is designed to permit
remote embedding and control of a scan head and laser system. It is capable of controlling two scan
heads with up to three motion axes each with concurrent laser timing control. It also provides
integrated synchronization I/O for connection to factory automation equipment.
Connection to a PC for job download and administrative control is made via Ethernet® network using
industry standard TCP/IP protocols. In addition to Ethernet connectivity, the SMC provides external
USB connections to support job file distribution via industry standard USB Flash drives. RS232 and
RS485 Serial I/O is also provided for, laser control, external automation control, and diagnostic
access.
In a typical installation, the SMC is a “smart controller” device, which can be installed remotely in a
laser scanning system. Positioning vectors are organized as packets which represent an entire job, or
sequential parts of a job. These packets are then sent from a networked PC to the SMC for local
processing. The SMC sequentially processes these vectors in real-time and sends them to the laser
steering galvo servos as digital signals. Alternatively, the job packets can be saved to FLASH memory
on the SMC and the loaded for execution from there.
There is no requirement to dedicate a full-time host PC to a laser scanning system, as the SMC can
process vectors while the PC is used for other purposes. In fact, one PC can support multiple SMC-
based scanning systems with no loss in performance. This is due to the large amount of buffer
memory available on the controller, the use of a separate supervisory processor on the controller to
handle network communication processing, and the complete off-loading of time-critical tasks to a
second real-time processor on the SMC.
Direct cabling for scan head communication to the SMC is possible for both XY2-100-based scan
heads and Novanta LightningTM II scan heads. Laser interfacing is done through a standard 0.1” 50-

Product Introduction
1040-0011 Revision 8
pin IDC ribbon-style connector to laser personality cards or cables that present laser-specific
connectorization. Direct connection is also possible with sparsely populated pin-in-shell-style
connectors. The laser signals are organized such that an IPG YLP fiber laser with type E interface can
be directly connected using a ribbon cable.
I/O signals for automation are presented in a 0.1” 20-pin header for easy access. All I/O signals are
also presented in an inter-board transition connector that can be direct-connected to an expansion
I/O board. This arrangement permits alternate connector usage and additional signal conditioning
options.
3.2 FEATURE OVERVIEW
3.2.1 Hardware Features
•Tethered and stand-alone operation for "embedded" installation in scanning
equipment
•Dual processor architecture with integrated 100/1000BaseT Ethernet
communication capability
•Real-time processing engine for precise, synchronized scanner movement and
laser control
•Direct 24-bit GSBus interface to Novanta LightningTM II digital galvo systems
•Standard support of the 16-bit XY2-100 protocol for non-LightningTM II heads
•Dual scan head control via the XY2-100 or GSBus interface
•Software-selectable polarity and timing of six TTL laser control signals
•Two auxiliary analog output channels (12-Bit) 0-10V for control of laser current
or pulse intensity
•One 8-Bit TTL digital output port for laser power control
•Four 24V-compatible general-purpose digital outputs
•Four 24V-compatible general purpose optically isolated digital inputs
•Seven 24V-compatible dedicated outputs and optically isolated inputs for system
control and external equipment synchronization
•One USB socket and one USB header for portable flash disk access
•3GBytes of on-board Micro SD card flash for storage of firmware, local jobs, and
parameters
•300MB RAM for downloadable job data storage
•One RS232 serial port for console and smart-display use

Product Introduction
1040-0011 Revision 9
•One RS232 serial port for general purpose use
•One RS232 serial port for laser control (included in the laser connector)
•One RS485 serial port for smart-controller motion control
•Two quadrature encoder inputs for Mark-on-the-fly use
3.2.2 Software Features
The SMC is designed with a client-server architectural model. The SMC implements all required
server code functions including the broadcast of identification and status information, vector packet
handling, command and control communications, and real-time positioning operations. Host-to-SMC
communications uses TCP/IP as a transport mechanism over Ethernet.
To simplify integration with third-party application software, a Microsoft Windows-compatible
Application Programming Interface (API) is provided. Two API formats are supported: .NET and
Win32 DLL. The APIs take care of all network connection requirements, and they abstract many of
the discrete functions of the module into higher-level vector-oriented instructions.
While this document describes the low-level EC1000 compatible XML API, the recommended
interface for new application development for the SMC is Novanta’s high-level ScanMaster API. This
API provides a high-level hardware abstraction, graphical file importing and advanced shape
rendering. In addition to these features, the ScanMaster API permits access to ScanScript, the
powerful embedded scripting language feature that enables flexible automation integration and local
rendering of bar codes, text, and various other shapes. This capability is very useful in structuring
custom applications that require real-time rendering of serial numbers and data-codes as in some
mark-on-the-fly situations.
In addition to the programming interface DLLs, example code and administrative management tools
are provided to facilitate setup, configuration, and calibration.

Product Introduction
1040-0011 Revision 10
3.3 TECHNICAL SPECIFICATIONS
Technical Specifications
Category
Feature
Specification
Galvo control
Axes
XY2-100
3 (X, Y, Z), 1 standard + 1 with optional
Auxiliary I/O board
LightningTM II direct
3 (X, Y, Z) x 2 heads
Position
command output
XY2-100
16-bit (-32768 to +32767) industry
standard
XY2-100 Novanta
extended
20-bit (-524288 to +524287) for
appropriately configured LightningTM
II scan heads
LightningTM II direct
GSBus
24-bit (-8388608 to +8388607)
LightningTM II compatible protocol
Dual scan head operation supported using separate correction
tables with the same command stream
Status sensing
XY2-100
Standard 16-bit status decoding
XY2-100 Novanta
extended
Standard plus direct in-position
sensing for appropriately configured
LightningTM II scan heads
LightningTM II direct
Real-time servo-produced status and
variable monitoring
Laser control
Digital output
signals
15, software programmable polarity and timing
LASER_ENABLE
Asserted a programmable time prior
to a sequence of mark instructions and
de-asserted after a programmable
period of laser inactivity
LASER_GATE
Asserted when the laser is active

Product Introduction
1040-0011 Revision 11
Technical Specifications
Category
Feature
Specification
LASER_MOD1
Programmable laser modulation or
Q-switch pulse stream
Laser control
(continued)
Digital output
signals (Conti.)
LASER_MOD2
Programmable laser modulation or
Q-switch pulse stream, 180 degrees
phase shifted from LASER_MOD1
LASER_MOD3
Programmable laser modulation; used
for first pulse suppression or
programmable modulation source for
synchronous operation
LASER_POINTER
Laser pointer control signal
LASER_DATA[7..0]
Digital data representing the laser
power setting
LASER_DATALATCH
Strobe signal asserted when the
LASER_DATA[7..0] value changes
Electrical
5 volt TTL compatible, 32mA source, 64mA sink
Resolution
20ns (LASER_GATE, LASER_MOD[3..1])
Analog output
signals
LASER_ANALOG0
Normally mapped to the laser power
setting; can be optionally made
independent
LASER_ANALOG1
Independent setting
Electrical
0 –10V, 33 ohm source impedance, 10mA max
Digital status
input
LASER_STAT[5..0]_ISO
General purpose status read back
Electrical
Optically isolated, 5- to 24V-compatible, 1mA min, 5mA max, 4.7K
ohm current limiting provided
Digital sync input
LASER_STAT6_ISO
High-speed laser sync input