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MAN 05 003 01 Service Manual MC 3 6
MAN 05 003 01 Service Manual MC 3 6
Document number
MAN-05-003
MAN-05-003 Rev. 1
Micro-control as Service manual for MC-3-6 Page 2 of 16
Table of contents
1. General ............................................................................................................................................ 3
1.1 Warranty.................................................................................................................................... 3
1.2 Definitions ................................................................................................................................. 3
1.3 The structure of this manual ..................................................................................................... 3
2. Troubleshooting ............................................................................................................................. 3
2.1 General ..................................................................................................................................... 3
2.2 Useful help resources ............................................................................................................... 3
2.3 Inspection inside the terminal ................................................................................................... 3
2.4 Assembling of the terminal/transmitter ..................................................................................... 4
2.5 Method ...................................................................................................................................... 4
2.6 Systems controlling the machine directly.................................................................................. 5
2.7 Systems with PLC serial communication.................................................................................. 5
3. Indications and error messages ................................................................................................... 6
3.1 Terminal .................................................................................................................................... 6
3.2 Base unit ................................................................................................................................... 8
4. Procedure for changing radio in the terminal ........................................................................... 14
4.1 Warning!.................................................................................................................................. 14
4.2 Execution ................................................................................................................................ 14
5. Procedure for changing the radio in the base unit................................................................... 14
List of tables
Table 1 Fault symptoms regarding systems controlling the machine directly......................................... 5
Table 2 Fault symptoms regarding systems with PLC serial communication......................................... 5
Table 3 Possible indications in the ”BAT light emitting diode” ................................................................ 6
Table 4 Possible indications in the terminal display................................................................................ 7
Table 5 Possible indications on green LED of the base-unit processor module .................................... 8
Table 6 Possible indications on red LED on the processor module in the base unit.............................. 8
Table 7 Possible indications of the base unit’s 4 digit LED..................................................................... 9
List of flow charts
Flow chart 1 Troubleshooting function faults......................................................................................... 10
Flow chart 2 Troubleshooting communication fault............................................................................... 11
Flow chart 3 Troubleshooting the terminal ............................................................................................ 12
Flow chart 4 Troubleshooting the base unit .......................................................................................... 13
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1. General
1.1 Warranty
All the systems are delivered with one year’s 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 customer’s site are not covered.
A representative from Micro-control must perform all the repairs of the equipment or the repairs must
be done in co-operation with Micro-control. If the user himself modifies the equipment, the warranty is
not 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
2. Troubleshooting
2.1 General
The 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 be
acquainted with static electricity protection (ESD-safety).
All service done by the customer is done at the customer’s risk.
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compartment. However contact cleaners may be used on the contact terminals, but avoid spraying
inside the cabinet or on the coating of the PCB’s.
If there are humidity inside the terminal, allow it to dry up complete in room temperature or in ambient
temperature up to +55°C. Heating guns or equivalent shall not be used!
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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 damaged during the testing. If possible you
should find a place where you can control the base unit at the same time as you have full survey of the machine. For safety precautions another person
should look after the machine while you are testing the MC-3000 system.
Preparation
Bring the terminal to the base unit. If the base unit does not have a transparent door, you must open the door/cover so that you can easily see the modules
inside the base unit.
Incorrect programming of MIN / MAX-values may also be interpreted as function fault. Check this if the terminal has MIN / MAX-programming!
NO: Check the flashing pattern against the descriptions in Table! Continue with
START: Turn the terminal on! ”troubleshooting the terminal” (separate flow chart)!
Has the terminal’s BAT light emitting diode normal (steady)
light? YES: Is only the green light emitting diode at the base unit’s processor module
lighting?
YES: Activate the function(s) that is/are not working. Are some of the NO: Are both the green and the red light emitting diodes at the base
output modules giving a response? unit’s processor module lighting?
YES: Measure the signal from the NO: Continue with YES: Communication fault! NO: None of the light emitting
module(s) that is/are responding! ”troubleshooting the base unit” Continue with ”troubleshooting diodes are lighting. Ensure that
Does the signal correspond with (separate flow chart) or communication fault” (separate there is power to the base unit!
the description in the wiring ”troubleshooting the terminal” flow chart)! Continue with ”troubleshooting
diagram? (separate flow chart)! the base unit” (separate flow
chart)!
NO: Change the output module and measure once
more!
YES: Follow/measure the signal from the module(s) via screw terminals to
the load (valves, contactors etc)!
If the signal reaches the load, there is probably some fault at the load.
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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 testing. If possible you should find a place
where you can control the base unit at the same time as you have full survey of the machine. For safety precautions another person should look after the
machine while you are testing the MC-3000 system.
Preparation
Bring the terminal to the base unit. If the base unit does not have a glass door you must open the door/cover so that you can easily see the modules inside
the base unit.
START: Turn the terminal on! NO: Check the flashing pattern against the descriptions of Table! Continue with
Has the terminal’s BAT light emitting diode normal (steady) ”troubleshooting the terminal” (separate flow chart)!
light?
YES: Are both the green and the red light emitting diodes at the base unit’s
processor module lighting?
YES: Does your system have cable communication as an option? NO: Is only the green light emitting diode at the base unit’s processor
module lighting?
YES: The system is communicating via cable (RS-485/422), but not via
radio.
The fault may be found in the base unit and/or in the terminal. Continue
with ”replacing radio in the base unit” (separate flow chart)!
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Flow chart 3 Troubleshooting the terminal
Warning!
The radio signal from the terminal to the base unit may reach several kilometers. It also penetrates walls. Therefore you must never start the terminal without
having full control with / survey over the machine/base unit. If you cannot use an anti-static working place you must not touch the terminals PCBs (printed
circuit boards). The working place also must be dry.
Preparation
Turn off the power to the base unit! Bring the terminal to a dry place. If you have access to an electronic workshop, you should bring the terminal there. Before
you open the terminal you should ensure that no other part of the system causes the fault (the base unit, electronic activating of valves etc).
START: Ensure that the terminal is turned off and remove the battery!
Place the terminal upside-down on a table, so that the five screws at the bottom part are available. Use a 5mm hexagon socked set screw key to unlock
the five screws that keep together the top and bottom part. Carefully lift the bottom part and turn it so that you can see the printed circuit boards. Note! It
is not necessary to loosen the cables between the top and bottom part! If the base unit is turned off, you can now put in the battery and turn the terminal
on.
Measure the input Check the cables to Try to uncouple joysticks Check the cables to the
voltage at the screw the switch / joystick and switches one and one KB card! If the problem
terminals! that are controlling at a time until the error persists, the KB card
Check the fuses! the function! messages disappears. The must be changed! The
Change the Change the switch / fault may also be found at fault may also be found
processor module! joystick if it is the KB card or the at the processor
defective! processor module. module.
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Flow chart 4 Troubleshooting the base unit
YES: Measure the power module output voltage. Is the output voltages NO: Check the power module fuse!
OK?
YES: Check the processor module fuses! Are the fuses OK?
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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 don’t 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).
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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
screws
3. Install the processor module’s ”BOOT-jumper”.
4. Uncouple the processor module’s 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 module’s ”BOOT-jumper”.
2. Uncouple the processor module’s TX-bus and connect it to the MC-RS232 module.
3. Connect the null-modem cable to the MC-RS232 DSUB-contact and the PC’s 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”
11. The terminal / base unit is ready for normal operation with a new setup file.
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System information:
Serial number (ID-code):
Frequency:
Unit (base / terminal)
Problem description:
Sender information:
Company
Contact person
Fax no.
Email
Postal address
MAN-05-003 Rev. 1