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Control Panel
Service Guide
Software Manual
Control Panel Service Guide
#
This manual is for Service Technicians only.
The directions given must not be followed by unauthorized personnel.
Always read the Safety Instruction Manual part No 21741 before working
with the processor.
Reservations
• This manual was written and illustrated using the best possible information
available at the time of publication.
• Any differences between this manual and the equipment reflect improvements
introduced after the publication of the manual.
• Changes, technical inaccuracies and typographic errors will be corrected in
subsequent editions.
• As a part of our policy of continuous improvement, we reserve the right to alter
design and specifications without further notice.
Table of Contents
Table of Contents
Part 1: Introduction
User Interface (UI)
H1 H4
Power P1 Conveyor ON
H2 H5
Alarm P2 Fan ON
H6
P3 Heater ON
H3 H7
ON P4 Autotune
Power on/off
When the system is powered on, LED H1 should light. You must then wait for
approximately one minute for the system to initialize. During initialization LED H3
will flash on and off in repeated intervals until ready for operation (see diagram
below). When the system is ready, LEDs H2, H3, H4, H5, H6 and H7 should light at
the same time. An audible alarm sounds to confirm that the system is now ready for
operation.
H3 flash sequences
ON
Service Mode
OFF
ON
Configuration
Mode OFF
ON
Cooling
OFF
ON
Working
OFF
+ P1 + P4 = Service Mode.
Hold down the standby button and then press P4 and P1, keeping all buttons pressed
for about 3 seconds. An audible alarm (buzzer) will be heard when entering service
mode. The standby LED (H3) will flash green (refer to diagram on page 1-1). Once in
service mode the following functions are available:
Start/stop the heating. Also starts conveyor and fans. LED flashes when
P3
the function is active.
P4 Start/stop autotune. LED flashes when the function is active.
"
All configuration and service functions described in this manual require the
system to be in service mode.
Confirming Operation
Press and hold the standby key for 3 seconds after configuration to confirm settings
and exit configuration mode.
Cancelling Operation
Most configuration operations can be cancelled before confirming operation by
pressing the standby key .
Error handling
If you enter an invalid value or if the system detects an error, the buzzer will sound
and the alarm LED H2 will flash red.
$
Only use this procedure when the system has not yet been loaded with any
software (for example in connection with replacing spare parts).
"
This installation will most likely cause the system to lose its current
configuration. If software is already installed on the system, use the
procedure described on page 5-1.
Set Date/Time:
1 Create a text file called autorun.gj on your USB stick. It should contain the
following two lines:
• date -s MMDDhhmmYYYY
• hwclock -w
MM = month, e.g. 07
DD = day of month, e.g. 09
hh = 24 hour, e.g. 15
mm = minutes, e.g. 54
YYYY = year, e.g. 2007
Install software:
2 Copy the software package (*.gjpkg and autorun.gj) to your USB memory stick:
4 The text file should contain just one line. Open the bootswupdate.txt file and add
the name of the .gjpkg package, e.g. xxx-20070330.gjpkg.
5 Save file.
6 Safely remove the USB memory stick.
7 Power off the oven.
8 Insert the USB memory stick into the left side of the electronics cabinet and then
power on with the mains switch.
9 Wait for about two minutes. LED H3 should start flashing.
10 Wait 1-15 minutes (or up to 30 minutes if the installation program detects
problems). The LED H3 should now be off.
11 Check that the installation has been successful by viewing the status file
swupdate.log.txt that should be written on the USB memory stick (see also page 7-7,
“Software Update Messages” and “System Messages Overview on page 7-9.
You can now proceed with the system configuration.
System Configuration
Enter service mode:
Hold down the standby button and then press P1 and P4, keeping all buttons pressed
for about 3 seconds. Use the following key sequences to automatically configure CAL
and GNUC 2:
Special cases:
• If the Copy Program key has been pressed, and neither the CPO/PBO nor the unit
has been selected, the system will only copy the program parameters without
resetting the CAL control.
Error cases:
• If bad CAL connection or missing power supply
• CAL control has not been set to ADDR=1
Copy program:
While in service mode + configuration mode you can copy a program setting to other
programs by pressing + P function key and holding down for three seconds.
Troubleshooting
If the configuration fails, try configuring the CAL manually. Refer to the table above
under “Configuration mode”.
CAL Setup
Follow the steps in the first column to set the CAL address to “1”.
+ P2
P2 P3
observe order
beep+ slow 1* P flash 3* P flash beep
Result
Setter interface logic is changed.
Error cases
Entered setter ID not within valid range 1-17.
P2 P3
+ +
observe order observe order
beep+ slow 1* P flash beep
Read Setter ID
It is possible to read out the selected setter interface. In setter mode, press P4 and the
program LED’s will flash the setter ID.
P4 P4 H5 H6
Confirm
Speed Mode Enter Speed. e.g.: 143 cm/min Wait
setting
Hold 3 seconds Press x 1 Press x 4 Press x 3 Hold 3 s approx. 1 s
+ P1 Configuration
P1 P2 P3
in progress
(observe order)
beep+H3 1 x H4 4 x H5 3 x H6 beep H3 fast
slow flash flash flash
"
+ P1 resets all values to zero. Enter the new speed with a combination of
keys P1-P3.
Result
The conveyor motor changes to the new speed and a new set point is stored (not lost
when power is off).
Error cases
Entered speed not within valid range 50-225 cm/min.
P4 P4 H4 H5 H6 H7
"
The following procedure should be used to update software if the oven
already has software installed. The advantage of using this method is that all
configuration parameters are left intact.
+ P3 P1 Software update in
progress
observe order!
beep +H3 slow H4 flashes beep H3 fast
Result
A status file called swupdate.log.txt is copied to the USB memory stick. The system
will reboot automatically and enter OFF mode, if the software update is successful.
Refer to this log file for information when troubleshooting (see page 7-7, “Software
Update Messages“ and “System Messages Overview on page 7-9).
Error cases
• Software package not found on the USB memory stick
• Checksum error on software package
• Faulty SOM
Part 6: IP Setup
To set up the IP address to e.g.:
Processor: 172.16.0.10
Subnet Mask: 255.255.255.0
Default Gateway: 172.16.0.1
(IP settings should be obtained from the local IT administrator)
Steps
• Open a simple ASCII text editor such as Notepad and enter the following:
Possible problems
• Misspelling in autorun.gj
• USB not properly inserted
• No power supply to the MIO board
Additional information
During power up the processor looks for the file autorun.gj. If the file is found, the
system will execute the statements listed in the file. The setubenv keyword sets a boot
parameter in the system.
setubenv = set uboot environment variable
Activation
1. Turn the oven power on
2. Unplug the LAN network
3. Wait for about two minutes
4. Connect the PC and GNUC with the (red) Ethernet cable
5. Activate the service connection
+ P2 Configuration in progress
P1
observe order!
Result
It should now be possible to connect the Remote Enabling System to IP 169.254.13.0.
The system will exit this mode as soon as the Ethernet cable is removed, or the link
connection is lost to the laptop.
Error cases
1. The laptop is not set to DHCP.
2. The laptop has an alternative static IP setup assigned if the DHCP server is not
found.
3. Link is lost (Can be lost if the user logs in/out on the laptop)(Windows 2000 PC's
have powered off until the Direct Link function has been activated on the MMI).
Part 7: Troubleshooting
Power missing
If there is no power to the system (H1 not ON), please check the following:
• Check whether the emergency stop S9-S11 has been activated.
• Check the supply voltage on the mains switch. For measurement, see the label at the
bottom of the electrical enclosure.
• Check the voltage to transformers T1 + T2 on X1 on the PCB transformer filter.
• Check interconnection X40 - X41 between the transformers and the HPU board.
• Check the cable between the HPU, P1 and MIO, P1 board.
• Check the cables from HPU, J11 and MIO, J11-J12 to interconnecting PCB.
• Check that the flat cables are connected to interconnecting PCB.
"
Software logs contain useful information which will be of help when
troubleshooting the system. See page 7-3 for a list of alarm messages.
+ P3 P4 Configuration in
observe order! progress
beep +H3 H7 flashes beep H3 fast
slow
Result
A gnuc2……tar.gz file is generated with software debug information when the
function has ended. Unzip the file on your PC and open the index.html file to see the
information.
Error cases
• USB not writable
• USB full
• Operating system has not started correctly: Insert USB and power off and on at main
power. Wait for about one and a half minutes. Check startup.log.txt file on USB and
error codes on page 7-9.
Message IDs
The save logs to USB function extracts alarm and message events. The following table
lists the possible message identifiers.
ID Text Comment
8 Motor speed is too low The speed has been measured as being too slow.
Possible explanations:
• The transport is blocked
• The tacho disc is defective or loose
• The motor is defective
• The power supply is low
9 Motor speed is too high The speed has been measured as being too high
Possible explanations:
• The tacho disc is defective or loose
• The motor is defective
14 Temperature is not The temperature is being regulated to the desired level. The
stabilized alarm ceases as soon as the temperature is ok.
Possible explanations:
• The processor has just been activated and needs to warm up
• The temperature has fallen out of process range due to
environmental influence
• The program has been changed specifying a different
temperature
• The desired temperature set point has been changed
18 tacho signal missing The speed is not being measured – stopping and starting the
motor should clear the alarm.
Possible explanations:
• The transport is blocked
• The tacho disc is defective or loose
• The motor is defective
• A fuse has blown
ID Text Comment
25 Motor current sensor is The motor has been overloaded and caused the current limiter
activated to activate – stopping and starting the motor should clear the
alarm.
Possible explanations:
• The transport is blocked
• A fuse has blown
• Maintenance of all moving parts may be required
30 Checksum or bad magic Statistic data and date/time have been lost – power off and on
word error from RTC RAM, to reset alarm.
e.g. battery low
Possible explanations:
• Low battery power due to long period with main power turned
off. (Please check time and date)
• Note that the battery should re-power itself when the
processor is turned on.
67 Connection to IO boards The MIO cannot connect to one or more slave IO boards (E.g.
failed. HPU, MFU, CAL etc).
• Power down, solve the problem and then power up the
system
Possible explanations:
• Cable not connected
• Bad connection
• No power supply to slave
• Slave IO address not set correctly
• Faulty slave board
If present at power up, the problem will be the HPU board or the
connection to the board, otherwise the CAL connection/unit is
the problem.
69 CAL Device Busy The software is unable to communicate with the CAL device
Possible explanations:
• Device is blocked because the user is operating the device
manually
• Faulty device
ID Text Comment
130 System has started in safe The software has attempted to start three times without
mode due to failed start up success. This can be provoked by turning power on and off
again three times before the system is fully initialized.
Turn the system off and on. If the alarm reoccurs, please check
the DataàConfigurationàInformationàHardwareàService
Code parameter and the alarm list for other alarms for more
in-depth explanation.
If no other alarms or no service code, create a log file on a USB
memory stick and contact your service technician who can then
forward the data to the manufacturer. Make a note on how the
problem was detected (in that context) and if possible how to
reproduce the problem.
131 Voltage missing Power supply to the HPU missing somewhere in the system.
Possible explanations:
• Slave fuse blown (e.g. HPU)
• Power supply connection disconnected
• Faulty IO board
132 Phase Sequence Alarm One or more phases missing or sequence invalid
135 Circuit broken The power circuit to the specified device(s) is broken or
disconnected by a safety monitoring device.
Please check circuit for errors or overload.
LED signals
H3 (green) H2 (red) Possible cause
Off Flashing Fast Toggling Alarm 132
Off Flashing Off Alarm 130
On On - Message 14
- Flashing Slow Toggling Alarm 18, 25
- Flashing Normal Toggling Alarm 67, 68, 69
On Flashing Fast Toggling Other alarms
Wait 1 minute H2
H1 ON flash If alarm Try to start the fans
Power
missing
Buzzer Alarm 67
not ON (HPU)