gtfan wrote:It sounds to me like your switch machines may have worked previously more out of luck than anything else. If the method of communication on the data wire is truly RS-232, then the designers chose the wrong medium. RS-232 is the specification for a point-to-point communication system of up to 25 feet maximum. While it can support (and has supported) much longer distances, the key is "point-to-point," which means ONE transmitter and ONE receiver. Driver and receiver chips designed to this specification are not intended to be placed in a circuit with multiple drops and multiple receivers. Instead, the designers should have used RS-422, (http://en.wikipedia.org/wiki/RS-422) which allows for a multi-drop architecture, and uses differential signalling, as opposed to RS-232's single-ended signalling scheme.
That said, it sounds like the best thing you can do to make and keep your current system working, is to ensure that ALL devices on the network have a solid ground reference. This ground reference is necessary because it is what the devices use to determine what is a "one" and what is a "zero" in the data stream.
Gtfan, I may have mispoken about the protocol used. It might well be RS-422. It's been at least 25 years since I played with these protocols or "dumb terminals" that used them. I don't believe these switch machines have worked just because of good fortune. While an individual switch machine or two has been flaky, the majority have operated first time, every time for years.
Your point on grounding is well taken. Thank you.
George
