MAN 05 003 Service Manual for MC 3 6

8/14/2019 MAN 05 003 Service Manual for MC 3 6

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Micro-control as Service manual for MC-3-6 Page 1 of 16

Service manual for MC-3-6

Document number

MAN-05-003

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Table of contents

1. General............................................................................................................................................ 3

1.1 Warranty.................................................................................................................................... 31.2 Definitions ................................................................................................................................. 31.3 The structure of this manual ..................................................................................................... 3

2. Troubleshooting............................................................................................................................. 3

2.1 General ..................................................................................................................................... 32.2 Useful help resources............................................................................................................... 32.3 Inspection inside the terminal ................................................................................................... 32.4 Assembling of the terminal/transmitter ..................................................................................... 42.5 Method ...................................................................................................................................... 42.6 Systems controlling the machine directly.................................................................................. 52.7 Systems with PLC serial communication.................................................................................. 5

3. Indications and error messages................................................................................................... 6

3.1 Terminal .................................................................................................................................... 63.2 Base unit ................................................................................................................................... 8

4. Procedure for changing radio in the terminal........................................................................... 14

4.1 Warning!.................................................................................................................................. 144.2 Execution ................................................................................................................................ 14

5. Procedure for changing the radio in the base unit................................................................... 14

6. Procedure for configuration........................................................................................................ 15

6.1 General ................................................................................................................................... 156.2 Equipment............................................................................................................................... 156.3 Preparation before transfer to the terminal............................................................................. 15

6.4 Preparation to transfer to the base unit .................................................................................. 156.5 Transferring the setup file ....................................................................................................... 15

Service fax for MC-3-6......................................................................................................................... 16

List of tables

Table 1 Fault symptoms regarding systems controlling the machine directly......................................... 5Table 2 Fault symptoms regarding systems with PLC serial communication......................................... 5Table 3 Possible indications in the BAT light emitting diode ................................................................ 6Table 4 Possible indications in the terminal display................................................................................ 7Table 5 Possible indications on green LED of the base-unit processor module .................................... 8Table 6 Possible indications on red LED on the processor module in the base unit.............................. 8

Table 7 Possible indications of the base units 4 digit LED..................................................................... 9

List of flow charts

Flow chart 1 Troubleshooting function faults......................................................................................... 10Flow chart 2 Troubleshooting communication fault............................................................................... 11Flow chart 3 Troubleshooting the terminal ............................................................................................ 12Flow chart 4 Troubleshooting the base unit .......................................................................................... 13

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1. General

1.1 Warranty

All the systems are delivered with one years warranty against material and manufacturing faults.

Micro-control covers repairs of equipment returned to Micro-control during the period of warranty.Travel expenses for service at the customers site are not covered.

A representative from Micro-control must perform all the repairs of the equipment or the repairs mustbe done in co-operation with Micro-control. If the user himself modifies the equipment, the warranty isnot valid.

1.2 Definitions

Terminal - the system unit carried by the operator.Base unit - the system unit connected to the machine.Link - a base unit connected to the PLC through a serial line

1.3 The structure of this manual

This manual describes indications and error messages that may occur in an MC-3-6 system. Most ofthe error messages indicate defined faults, but some of the error messages require moretroubleshooting. Some of the faults that may occur, will not cause the system to display an errormessage. A chapter about troubleshooting is therefore included in this manual.

If you cannot solve the problem on your own, you should contact Micro-control. A service fax templateis included in this manual. This fax template is made so that Micro-control shall be able to give fasterservice and to help the user to get in touch with Micro-control in an easy way.

2. Troubleshooting

2.1 GeneralThe purpose of the troubleshooting is to isolate the fault to a module so that the defective module(s)can be changed. A representative from Micro-control shall execute all repairs of the modules.

Anyone troubleshooting the MC-3-6 system must have general knowledge of electronics and beacquainted with static electricity protection (ESD-safety).

All service done by the customer is done at the customers risk.

2.2 Useful help resources

You should consult the wiring diagrams and the module specifications often during troubleshooting.The wiring diagram shows which components that are part of the system and how these areconnected both in the terminal and in the base unit. Additionally the wiring diagram shows how the

modules are placed in the base unit. The module specifications give a detailed description of everysingle module.

2.3 Inspection inside the terminal

When opening the terminal/transmitter its important to check for humidity or traces of humidity.There are several reasons for humidity. The most usual is condensation on the inside surfaces due tofast temperature drops. Humidity may also be the result of leakage, either in the control handles orcontrol knobs. The most usual reason is the joint between the bottom and top of the cabinet. Thegasket surface have to be clean and the gasket shall be replaced every second or third time thecabinet is opened. In marine environment where IP-56 ore higher IP-class is imperative werecommend You to use Dow Corning high vacuum grease in addition to the gasket. A third reasonmay be that the cabinet is lost on the floor or exposed to severe shocks or very high temperatures.

Then the joint between the battery compartment and the bottom part of the terminal may be leaky.Use of contact cleaners or electronic cleaning solvents shall be avoided inside the terminal becausethey may damage the conformal coatings of the printed circuit boards or the glue of the battery

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compartment. However contact cleaners may be used on the contact terminals, but avoid sprayinginside the cabinet or on the coating of the PCBs.

If there are humidity inside the terminal, allow it to dry up complete in room temperature or in ambienttemperature up to +55C. Heating guns or equivalent shall not be used!

2.4 Assembling of the terminal/transmitterClean the gasket cavity carefully with isopropyl alcohol or similar. Use Q-tips or similar to get thecavity completely clean. Be sure that the gasket is unbroken. In any case the gasket shall be replacedevery 2-3 times the cabinet is opened or if the gasket is older than 3 years.

2.5 Method

Check the fault symptoms that are described in the tables in chapter 2.4. and 2.5. Flow chartsdescribe the troubleshooting of several of the symptoms.

Consult Micro-control if you cannot solve the problem yourself. Either use the service fax template orcontact our service department using e-mail address

[email protected]

When sending e-mail, please include the information requested in the service fax template.

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2.6 Systems controlling the machine directly

Table 1 Fault symptoms regarding systems controlling the machine directly

Symptom Description / ActionFault indication at the BAT

LED (LED=light emittingdiode) or at the display of theterminal.

See chapter 3.1.

Fault indication at the LEDs orthe display of the base unit.

See chapter 3.2.

None of the functions(switches, joysticks, etc.) areworking.

Ensure that the communication between the terminal and the baseunit is OK. Flow chart 2 describes how to do this.

The functions stops and startsagain/ The machine runsuneven / The system suddenlystops.


Fault in some of the functions. Flow chart 1 describes troubleshooting when there is a function fault.

2.7 Systems with PLC serial communication

Table 2 Fault symptoms regarding systems with PLC serial communication

Symptom Description / ActionFault indication at the BATLED (LED=light emittingdiode) or at the display of theterminal.

See chapter 3.1.

Fault indication at the LEDs orthe display of the base unit.

See chapter 3.2.

None of the functions(switches, joysticks and so on)is working.

Ensure that the communication between the terminal and the baseunit is OK. Flow chart 2 describes how to do this.Also ensure that the PLC communication is OK.

The functions stops and startsagain / The machine runsunstable


Fault in some of the functions. Ensure that the control signal from the PLC is OK.Then check the terminal. Flow chart 1 describes how to do this..

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3. Indications and error messages

3.1 Terminal

Table 3 Possible indications in the BAT light emitting diode

Flashing pattern Description ActionSteady light. Normal condition. The terminal is

turned on, the battery voltage is OK,no fault is detected.

Slow flashing lightwithout stop (1 flashper second).

Low battery voltage. Change the battery and recharge theold battery!

Rapid flashes (2flashes per second).

Programming mode. Turn the terminal off and on again tostart normal operation.

1 flash with a long stop(every 2. second).

The same as E001. See Table. The same as E001. See Table.

2 flashes with a stop. The same as E002. See Table. The same as E002. See Table.

3 flashes with a stop. The same as E003. See Table. The same as E003. See Table.4 flashes with a stop. The same as E004. See Table. The same as E004. See Table.5 flashes with a stop. The same as E005. See Table. The same as E005. See Table.6 flashes with a stop. The same as E006. See Table. The same as E006. See Table.7 flashes with a stop. The same as E007. See Table. The same as E007. See Table.

The light emittingdiode BAT does notlight.

Ensure that there is a battery in theterminal and that the terminal is turnedon. If the terminal has turned itself offbecause of inactivity, turn it off and onagain to start normal operation. Try toreplace the battery with a rechargedone. If the problem persists, see Flow

chart 3 Troubleshooting the terminal.

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Table 4 Possible indications in the terminal display

If the system has a 4 digit LED module the indicated codes are displayed there. If the system has aLCD module the error codes are displayed in a field in the display.

Display Description ActionXXX System ID code.

Normally displayed a short moment when theterminal is turned on. Displayed only in systems withone terminal.

XXX.Y System ID code and terminal number.Normally displayed a short moment when theterminal is turned on. Displayed only in systems withmore than one terminal.

X.YY The battery voltage measured in Volts.(The number displayed has two decimals, the valueswill be between 6.40 and 9.00).Normally displayed a short moment when the

terminal is turned on.A-XX Analog channel that can be programmed. (The

number displayed is an integer between 1 and 13.)Displayed only when the terminal is in programmingmode.

A-00 No analog channel is activated.Only displayed when the terminal is in programmingmode.

Activate the analog channel you wishto program!

E001 Processor fault.Indicates a processor module fault and/or aprocessor fault.

Check that the BOOT-jumper on theprocessor module is not turned on!Change the processor module and/orthe processor!

E002 Activity by start-up.A joystick is out of center position, or a switch is inON-position.

Set all switches/joysticks to OFF-position and/or neutral position!See Flow chart 3 for furthertroubleshooting.

E003 Radio fault. The radio must probably be changed.See chapter 4.

E004 Shutdown because of low battery voltage. Change battery!

E005 Keyboard fault.The terminal is not able to read switches, joysticksetc.

The KB-card probably must bechanged. See Flow chart 3.

E006 Shutdown because of inactivity.The terminal will soon turn itself off since noswitches, joysticks etc. has been activated.

To avoid that the terminal turns itselfoff you must activate one or morefunctions.

E007 Priority stop.The stop button or the shock detector has beenactivated.

Turn the terminal OFF and ON againto start normal operation!

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3.2 Base unit

Table 5 Possible indications on green LED of the base-unit processor module

Flashing pattern Description ActionSteady light. Normal condition.

Short flashes (2 flashesper second).

Programming mode. Turn the base unit OFF and ON againto start normal operation.

1 flash with a long stop(every 2. Second).

The same as E001. The same as E001.

2 flashes with a stop. The same as E002. The same as E002.3 flashes with a stop. The same as E003. The same as E003.5 flashes with a stop. The same as E005. The same as E005.7 flashes with a stop. The same as E007. The same as E007.

The light emitting diodedoes not light.

Ensure that the processor module hasthe correct input voltage. Also checkthe processor module fuses.

Table 6 Possible indications on red LED on the processor module in the base unitFlashing pattern DescriptionThe light emittingdiode does notlight.

Communication with the terminal is OK. The START-relay is activated.

Steady light.* No communication with the terminal.

Flashing now andthen.

Each time the red LED is flashing, there is a communication fault between thebase unit and the terminal. The radios should be checked and tuned.

* In polled systems the base unit must communicate with all the system terminals before the red lightis switched off.

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Table 7 Possible indications of the base units 4 digit LED

Display Description Action

XXX System ID code.Normally displayed a short moment when the baseunit is turned on. Displayed in systems with only one

base unit.XXX.Y System ID code and base unit number.

Normally displayed a short moment when the baseunit is turned on. Only displayed in systems with morethan one base unit. In polled systems XXX.0 isdisplayed.

- The base unit communicates with the terminal.

0 Communication fault with the terminal.

1 No communication with the terminal, because thebase unit is locked to another terminal.

E001 Processor fault.Indicates a processor module fault and/or a processorfault.

Ensure that no link are placed onthe BOOT jumper pins!Replace the processor moduleand/or processor!

E002 Start-up activity.A joystick is out of center position, or a switch is inON-position.

Set the switches/joysticks to OFF-position and/or neutral position.

E003 Radio fault. The radio must probably bechanged, see chapter 5.

E005 Keyboard fault.The base unit is not able to read inputs and outputs.

The KB card probably has to bechanged. See E005/Flow chart 3.

E007 Priority stop. Start the terminal again for normaloperation.

E010 PLC communication fault (the PLC does not updatethe PLC status register).

Check the PLC, the communicationcable and the processor module in

the base unit.E011 Processor module for communication together with

the PLC does not work.Change the processor moduleand/or the processor!


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Micro-control as Service manual for MC-3-6

Flow chart 1 Troubleshooting function faults

Warning!Before you start testing the machine you must take care so that neither people are injured nor equipment are damagedshould find a place where you can control the base unit at the same time as you have full survey of the machine. For sashould look after the machine while you are testing the MC-3000 system.

PreparationBring the terminal to the base unit. If the base unit does not have a transparent door, you must open the door/cover so inside the base unit.

Incorrect programming of MIN / MAX-values may also be interpreted as function fault. Check this if the terminal has MI

START: Turn the terminal on!Has the terminals BAT light emitting diode normal (steady)light?

NO: Are both the green and the red

units processor module lighting?

NO: Change the output module and measure oncemore!

YES: Communication fault!Continue with troubleshootingcommunication fault (separateflow chart)!

YES: Measure the signal from themodule(s) that is/are responding!Does the signal correspond withthe description in the wiringdiagram?

NO: Continue withtroubleshooting the base unit(separate flow chart) ortroubleshooting the terminal(separate flow chart)!

YES: Follow/measure the signal from the module(s) via screw terminals tothe load (valves, contactors etc)!If the signal reaches the load, there is probably some fault at the load.

YES: Is only the green light emitting diode at li htin ?

YES: Activate the function(s) that is/are not working. Are some of the

output modules giving a response?

NO: Check the flashing pattern against the detroubleshooting the terminal (separate flow

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Flow chart 2 Troubleshooting communication fault

Warning!Before you start testing the machine you must take care so that neither people nor equipment are hurt during the testinwhere you can control the base unit at the same time as you have full survey of the machine. For safety precautions anmachine while you are testing the MC-3000 system.

PreparationBring the terminal to the base unit. If the base unit does not have a glass door you must open the door/cover so that yothe base unit.

START: Turn the terminal on!Has the terminals BAT light emitting diode normal (steady)light?

NO: Is only the green light emittinmodule lighting?

NO: Check that the cable you are using is OK!

YES: Communication betweenthe terminal and the baseseems to be OK.There may be a function fault.Continue with troubleshootingfunction fault (separate flowchart)!

NO: Continue withtroubleshooting the base unit(separate flow chart)!

YES: Turn the terminal off.Connect the terminal and thebase unit with a cable and turnthe selector switch RADIO /CABLE to the position CABLE.Turn the terminal on! Is thecommunication OK now?

YES: The system is communicating via cable (RS-485/422), but not viaradio.

The fault may be found in the base unit and/or in the terminal. Continuewith replacing radio in the base unit (separate flow chart)!

YES: Are both the green and the red light emprocessor module lighting?

YES: Does your system have cable communication as an option?

NO: Check the flashing pattern against the detroubleshooting the terminal (separate flow

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Flow chart 4 Troubleshooting the base unit

START: Is the power module supply voltage correct?

NO: Check the power module fus

NO: Check the cables between the power module andthe processor module!

NO: Change the power module!

NO: If the lamp is flashing, it

indicates a fault. Check thedescriptions in Table.

YES: The processor module is

apparently working normally.Check all the connections to themodule!

NO: Change the fuse(s)!YES: Does the green lamp ofthe processor module lightconstantly?

YES: Measure the processormodule input voltage! Is the inputvoltage OK?

YES: Check the processor module fuses! Are the fuses OK?

YES: Are both lights at the power module ligh

YES: Measure the power module output voltage. Is the output voltagesOK?

NO: Check the supply voltage.


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4. Procedure for changing radio in the terminal

4.1 Warning!

The radio signal from the terminal to the base unit may reach several kilometers. It also penetrateswalls. You must therefore never start the terminal without having full control with / survey over the

machine.

If you cannot work in an anti-static working place you must not touch the terminals printed circuitboards. The working place also must be dry.

4.2 Execution

1. Turn off the power to the base unit!2. Bring the terminal to a dry place. If you have access to an electronic workshop, you should bring

the terminal there.3. Ensure that the terminal is turned off and remove the battery!4. Place the terminal upside-down on a table, so that the seven screws at the bottom part are

available.5. Use a 5 mm hexagon socket set screw key and unlock the seven screws that keep together the

top- and bottom part.6. Carefully lift the bottom part and turn it so that the printed circuit boards are visible. Note! It is not

necessary to loosen the cables between the top- and bottom part!7. Uncouple the antenna and the 10-pins flat cable to the radio module!8. Unlock the screws that secure the radio! Take care that you dont lose any of the metal washers!

Remove the radio.9. Put the new radio where the old one was placed.10. Connect the antenna and the 10-pins flat cable to the radio module.11. Turn the HEX-switch of the new radio to the same position as the old one (if not the radio will not

transmit at the correct frequency).

Placing together the top and bottom part:

12. Carefully place the bottom part at the top part while checking that no cables are squeezedbetween the top and bottom part.13. Fasten the 7 screws so that there is an even pressure at the silicone rubber seal (O-ring).14. Test that the radio communication between the base unit and the terminal is OK.

5. Procedure for changing the radio in the base unit1. Turn off the power to the base unit!2. Uncouple the antenna and the 10-pins flat cable to the radio module!3. Loosen the radio from the DIN mounting rail and remove it.4. Put the new radio where the old one was placed.5. Turn the HEX-switch of the new radio to the same position as the old one (if not the radio will not

transmit at the correct frequency).6. Connect the antenna and the 10-pins flat cable to the radio module.7. Turn on the power to the base unit.8. Test that the radio communication between the base unit and the terminal is OK.

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6. Procedure for configuration

6.1 General

All the MC-3-6 systems have a unique configuration file (setup file). The content of the setup filedetermines the system functionality. The setup file is saved in the processors non-volatile memory

(EEPROM). In contradiction to the processors main program (which is saved in OTPROM), the setupfile may be changed and saved several times. If you wish to change the systems functionality you cando this by changing the setup file. A new setup file must be ordered from Micro-control.

6.2 Equipment

To be able to transfer a new setup file you need the following equipment:

MC-RS232 module

Null-modem cable

10-pins flat cable

PC

Software

Terminal program (for example ProComm, HyperTerminal etc)

Setup file

6.3 Preparation before transfer to the terminal

1. Turn off the terminal and bring it to a dry room where you have access to a PC.2. Use an hexagon socket set screw key and separate the top and bottom parts by unlocking the 7

screws3. Install the processor modules BOOT-jumper.4. Uncouple the processor modules TX-bus and connect it to the MC-RS232 module.5. Connect the null-modem cable to the MC-RS232 DSUB-contact and the PC serial port.

6.4 Preparation to transfer to the base unit

1. Turn off the power to the base unit. Install the processor modules BOOT-jumper.

2. Uncouple the processor modules TX-bus and connect it to the MC-RS232 module.3. Connect the null-modem cable to the MC-RS232 DSUB-contact and the PCs serial port.

6.5 Transferring the setup file

1. Start the terminal program at the PC.2. The terminal program must be set up with:

2400 bps, 8 data-bit, 1 stop-bit, no parity, ASCII character set, delay 200ms.3. Turn on the terminal / base unit.4. The following text is now written on the screen:

Awaiting configuration file ..5. Transfer the setup file by giving the command:

Send text file, ASCII upload etc. in the terminal program.6. After a successful transfer the following text is written on the screen:

..succeeded

7. Turn off the terminal / base unit.8. Remove the BOOT-jumper from the processor module.9. Uncouple the MC-RS232 module.10. Connect the TX-bus on the processor module.

11. The terminal / base unit is ready for normal operation with a new setup file.

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Service fax for MC-3-6

Send to: Micro-control asFax no: (+47) 74821610

System information:Serial number (ID-code):Frequency:Unit (base / terminal)

Problem description:

What have you done to solve the problem (troubleshooting)?

Sender information:CompanyContact personFax no.EmailPostal address

MAN-05-003 Rev. 1

Documents

MAN 05 003 Service Manual for MC 3 6