6300e

645 Russell StreetBatesburg, SC 29006

January, 1998© 1998, Union Switch & Signal Inc.Printed in the U.S.A.

Service Manual 6300E

An ANSALDO Affiliated Company

GENISYSHARDWARE & MAINTENANCE

TRAINING MANUAL

Table of Contents

SM6300E (1/98) Page i

Contents

GENISYS Hardware Descriptions

General System Limits.................................................................................................. 1-1

Card File Specifications................................................................................................ 1-2

GENISYS PC Boards ................................................................................................. 1-3

9.5 to 35 Volt DC Power Supply Limits....................................................................... 1-3

Controller Board ........................................................................................................... 1-4

Controller Board Switch Selectable Options ................................................................ 1-5

Output Board – Constant Delivery ............................................................................. 1-12

Input Board – High Threshold.................................................................................... 1-15

Interface Wiring Specification and Diagrams

Constant Delivery Relay-Output PCBs ........................................................................ 2-1

Optical-Input PCBs ...................................................................................................... 2-2

Controller PCB ............................................................................................................. 2-3

DC/DC Power Supply Converter PCB ......................................................................... 2-4

Maintenance and Troubleshooting

General Information...................................................................................................... 3-1

Utilization and Application............................................................................... 3-1

Introduction ...................................................................................................... 3-1

Equipment......................................................................................................... 3-2

I. Working and Non-Working Systems................................................................ 3-4

II. Power Supply Converter Board ........................................................................ 3-7

III. System Reset Checkout Procedure ................................................................... 3-9

IV. Local Interface Problems ................................................................................ 3-12

V. Serial Interface Problems................................................................................ 3-17

Tables and Figures

Figure 1-1 Cardfile ................................................................................................. 1-1

Table 1-1 Controller Board LED Indicators.......................................................... 1-5

Table 1-2 Controller Board Slave Baud Rate (SW1) ............................................ 1-6

Table 1-3 Controller Board Control Delivery Time (SW2) .................................. 1-6

Table 1-4 Controller Board Carrier Mode Switch (SW3) ..................................... 1-7

Table of Contents

Page ii SM6300E(1/98)

Table 1-5 Controller Board Slave Address Switch (SW5).................................... 1-7

Table 1-6 Controller Board Key On/Off Delay Switch (SW6)............................. 1-8

Table 1-7 Controller Board Serial Port Test and Data Byte Format (SW7).......... 1-9

Table 1-8 Controller Board System Reset (SW8) ................................................. 1-9

Table 1-9 Controller Board Communication Jumpers .......................................... 1-9

Figure 1-2 Controller Board ................................................................................. 1-10

Figure 1-3 Controller Board Switch Options........................................................ 1-11

Table 1-10 Constant Delivery Output Board LED Indicators............................... 1-13

Figure 1-4 Output Board -Constant Delivery - with LEDs (N451441-7101) ...... 1-14

Table 1-11 High Threshold Input Board Input Limits .......................................... 1-15

Table 1-12 High Threshold Input Board LED Indicators ..................................... 1-16

Figure 1-5 High Threshold Input Board (N451441-7202) ................................... 1-17

Figure 2-1 Typical DC Input Power Circuit........................................................... 2-4

Figure 2-2 Typical Control Delivery or Constant Delivery PCB OutputCircuit Type I........................................................................................ 2-5

Figure 2-3 Typical Control Delivery or Constant Delivery PCB OutputCircuit - Type II .................................................................................... 2-5

Figure 2-4 Typical Input PCB Circuit - Type I ...................................................... 2-6

Figure 2-5 Typical Input PCB Circuit - Type II..................................................... 2-6

Figure 2-6 Typical Master Port to Modem Slave Port to Master PortCommunication Circuit - EIA............................................................... 2-7

Figure 2-7 Typical Master Port to Modem and Multiple Slave PortCommunication Circuit - EIA............................................................... 2-7

Figure 2-8 Typical Slave Port to Modem Communication Circuit - TTL.............. 2-7

Figure 2-9 Typical Master Port to Modem Communication Circuit - TTL............ 2-7

Figure 2-10 Typical Slave Port to Modem Communication - EIA........................... 2-8

Figure 2-11 Typical Master Port to Modem Communication - EIA......................... 2-8

Table 3-1 Basic Tools for GENISYS Installation ................................................. 3-3

Figure 3-1 GENISYS LEDs (Representative Configuration)................................. 3-4

Figure 3-2 Half-Duplex Carrier Control Mode (SW3)......................................... 3-19

Figure 3-3 Full-Duplex Carrier Control Mode .................................................... 3-19

Figure 3-4 Carrier-Duplex Mode.......................................................................... 3-19

SM6300E(1/98)

GENISYSHARDWARE

DESCRIPTIONS


SM6300E (1/98) Page 1-1

General System Limits

INPUT/OUTPUT LIMITS

� There is a limit of 256 output or input bits per card file.

� A card file can have all output boards, all input boards or a combination of output and inputboards.

LOGIC LIMITS

� A GENISYS unit can emulate approximately 1450 Relays, with each relay having anunlimited number of contacts.

COMMUNICATION LIMITS

� There are two communication ports available to pass serial data between units.

Figure 1-1


Page 1-2 SM6300E (1/98)

Card File Specifications

US&S Part Number N085718-1009

� 19-inch rack mounting.

� �14-inches vertical rack space.

� �10.5 inches rack depth.

� Removable front cover with fasteners.

� Card file has 18 PCB positions.

� Position J1 power supply only.

� Position J2 Controller Only.

� Position J3 to J18 output or input (user defined).

� Each card file position has two (2) connection points.

"A" Connector

� A 44-Pin double keyed connector.

� Handles all external connections.

� This connector is externally mounted to the card file with mechanical latches.

"B" Connector

� A 44-pin single keyed connector.

� Handles all internal connections.

� This connector is mounted on an internal mother board.


SM6300E (1/98) Page 1-3

GENISYS PC Boards: 9.5 to 35 Volt DC Power Supply Limits


Input Limits

� 9.5 to 35 Volt DC with less than 5% ripple.

� Maximum input power is 52 watts.

� Nominal input power is 15 watts.

Output Limits

� +5 Volts +/- 2% at 3 Amps

� +12 Volts +/- 2% at 1 Amp

� -12 Volts +/- 2% at 1 Amp

� Ripple 10 millivolts.

� Noise < 75 millivolts.

Input To Output Isolation

� 500 Volts

Efficiency

� 75%

Operating Temperature Range

� -40º to +70ºC

Indicators

� LED 1 + 5 Volts On.

� LED 2 + 12 Volts On.

� LED 3 - 12 Volts On.

� LED 4 input power On.


Page 1-4 SM6300E (1/98)

GENISYS PC Boards: Controller Board


Input Requirements

� Input current requirement without external load.

� +5 Volts at less than 800 milliamperes.

� +12 Volts at less than 100 milliamperes.

� -12 Volts at less than 100 milliamperes.


� -40º to +70ºc

Communication Options

� Two serial ports – one master and one slave

� Each port supports TTL or EIA RS-423/232

Logic Options

� IC24 can be used to house a pre-programmed EPROM.

� That will emulate a field code unit but will not do non-vital logic;

or

� IC24 to IC28 can be used to house user programmed application EPROMS that can emulate acode system or emulate non-vital logic or do both code systems and non-vital logic functions.

� Each EPROM is the 2764 type and has 8K bytes of memory.

� The part number for a blank EPROM is J715029-0409.

� This device has been qualified to operate at –40ºC.

� Off-the-shelf EPROMS are not acceptable for in service use.


SM6300E (1/98) Page 1-5

GENISYS PC Boards: Controller Board Switch Selectable Options

Indicators

(See Figure 1-2.)

LED No. Name Function

1 MTXD Master Port Transmit Data

2 MRTS Master Port Request to Send

3 MRXD Master Port Receive Data

4 MDCD Master Port Data Carrier Detect

5 STXD Slave Port Transmit Data

6 SRTS Slave Port Request to Send

7 SRXD Slave Port Receive Data

8 SDCD Slave Port Data Carrier Detect

9 WATCHDOG Microprocessor Monitor

10 DELIVER Data Output to Output Boards

Table 1-1


Page 1-6 SM6300E (1/98)

GENISYS PC Boards: Controller Board (Continued)

Hardware Switches And Jumpers

Slave Baud Rate **

(See Figure 1-3.)

SW 1 Position Function

0 Slave Port Baud Rate of 150







7 Not Used

Table 1-2

Control Delivery Time **

(See Figure 1-3.)


0 Delivery Time of 10 mSEC.





5 Delivery Time of 1 SEC.



Table 1-3

** Indicates function can be set in application EPROM.


SM6300E (1/98) Page 1-7


Carrier Mode Switch


Operate Master Port Carrier goes On-Off

Carrier Master Port Carrier always On

Table 1-4

Slave Address Switch **

(See Figure 1-3.)

SW 5 Position Function - Open = 1

1 Slave Address Binary Weight 1








Table 1-5

** Indicates function can be set in application EPROM.


Page 1-8 SM6300E (1/98)


Key On/Off Delay Switch

(See Figure 1-3.)


1 Key-On Delay - Bit Time Weight 4




5 Key-Off Delay - Bit Time Weight 4




Table 1-6


SM6300E (1/98) Page 1-9


Serial Port Test And Data Byte Format

(See Figure 1-3.)


1 Selects Slave Port for Test

2 Selects Master Port for Test

3 Selects 50% Duty Cycle Test

4 Selects Default Space Test

5 Not Used

6 Select Even/Odd Parity

7 Select Parity Enabled

8 Selects 1 or 2 Stop Bits

Table 1-7

System Reset

(See Figure 1-2.)


In Unit Reset

Table 1-8

Communication Jumpers

Jumper Position Function

J1 – J5 A – B Slave Port = RS-423/RS232

J1 – J5 B – C Slave Port = TTL

J6 – J10 A – B Master Port = RS-423/RS232

J6 – J10 B – C Master Port = TTL

Table 1-9


Page 1-10 SM6300E (1/98)

Figure 1-2 - Controller Board


SM6300E (1/98) Page 1-11

Figure 1-3


Page 1-12 SM6300E (1/98)

Constant Delivery Output Board


Output Type

� Sixteen (16) PCB mounted Mercury Wetted Reed Relays

Contact Output Limits

� Maximum Resistive Switching Load

� 2 Amps or� 500 Volts or� 100 Volt Amps

Life Expectancy

� 20 billion operations.


� 1000 Volts RMS


� -38º to +70ºc


SM6300E (1/98) Page 1-13

Indicators

LED No. Function LED No. Function

3-1 Output No. 0 5-9 Output No. 8








1 Delivery 1 Address

Table 1-10

Input Requirements

Normal Load +12 volts at less than 2 milliamperes.

Normal Load Plus LEDs On +12 volts at less than 50 milliamperes.

Normal Load Plus LEDs On andRelay Delivery Circuit Active

+12 volts at less than 150 milliamperes.


Page 1-14 SM6300E (1/98)

Figure 1-4


SM6300E (1/98) Page 1-15

High Threshold Input Board


Input Type

� Sixteen (16) PCB Mounted Optical Isolators

Input Limits

8.0 To 32 Volts DC Guaranteed Turn-On

5.7 To 24 Volts AC RMS Guaranteed Turn-On

5.0 Volts DC Minimum Turn-On

3.8 Volts AC RMS Minimum Turn-On

Less Than 4.5 Volts DC Guaranteed Turn-Off

Less Than 3.4 Volts AC RMS Guaranteed Turn-Off

Table 1-11

Input Impedance

� 1800 OHMS

Input Requirements

� +12 volts at less than 2 milliamperes.


� 2500 Volts RMS


� -40º to +70ºC


Page 1-16 SM6300E (1/98)

Indicators

LED No. Function LED No. Function

3-1 Input No. 0 5-9 Input No. 8








1 Address Low Byte 2 Address High Byte

Table 1-12


SM6300E (1/98) Page 1-17

Figure 1-5

SM6300E (1/98)

INTERFACE WIRING SPECIFICATIONAND DIAGRAMS

Interface Wiring Specificationsand Diagrams

SM6300E (1/98) Page 2-1

Constant Delivery Relay-Output PCBs

Applicable PCBs: Constant Delivery: N451441-7101

Cardfile Location(s): J3 to J18 as required by the application

Keying Plugs: Between positions 6/7 and 14/15

Label: “OUTPUT”

Circuits: Typical Constant Delivery PCB Output Circuit – Type I:Figure 2-2.

• All active circuits wired

Typical Constant Delivery PCB Output Circuit – Type II:Figure 2-3.

• All active front circuits wired

• Common jumper

• Single cable


Page 2-2 SM6300E (1/98)

Optical-Input PCBs

Applicable PCBs: Optical-Input (High Threshold): N451441-7202

Cardfile Location(s): J3 to J18 as required by the application


Label: “INPUT”

Circuits: Typical Input Circuit – Type I:Figure 2-4.

• All active circuits wired

Typical Input Circuit – Type II:Figure 2-5.

• Plus input wired

• Negative input jumpered

• Single cable


SM6300E (1/98) Page 2-3

Controller PCB

Applicable PCB: Controller: N451441-5602

Cardfile Location(s): J2 (always)


Label: “COMMUNICATION”

Circuits: Typical Master Port to Modem and Slave Port to Master PortCommunication Circuit – EIAFigure 2-6.

Typical Master Port to Modem and Multiple Slave PortCommunication Circuit – EIAFigure 2-7.

Typical Slave Port to Modem Communication Circuit – TTLFigure 2-8.

Typical Master Port to Modem Communication Circuit – TTLFigure 2-9.

Typical Slave Port to Modem Communication Circuit – EIAFigure 2-10.

Typical Master Port to Modem Communication Circuit – EIAFigure 2-11.


Page 2-4 SM6300E (1/98)

DC/DC Power Supply Converter PCB

Applicable PCB: DC/DC Power Supply Converter PCB: N451441-7601

Cardfile Location(s): J1 (always)


Label: “POWER”

Circuit: Typical DC Input Power CircuitFigure 2-1.

Figure 2-1


SM6300E (1/98) Page 2-5

Figure 2-2 Figure 2-3(See Circuits on Figure 1-4.)


Page 2-6 SM6300E (1/98)

Figure 2-4. Typical Input PCB Circuit - Type I - Figure 2-5. Typical Input PCB Circuit - Type II(See Circuits on Figure 1-18.)


SM6300E (1/98) Page 2-7


Page 2-8 SM6300E (1/98)

SM6300E (1/98)

MAINTENANCE AND TROUBLESHOOTING


SM6300E (1/98) Page 3-1

General Information

A. Utilization and Application

In order to use this Guide, you should have a basic knowledge of general electronicequipment and the product GENISYS. You should be able to perform resistance and voltagereadings with a multimeter or oscilloscope, be familiar with the various boards (PowerSupply, Controller & I/O) that comprise a GENISYS Cardfile and have a basic understandingof each board’s function.

The Field Service Guide was prepared to provide a systematic approach to identifying,repairing and eliminating problems related to GENISYS installations. It was meant toaddress those types of problems that occur most often and should not be regarded as acomplete definition of all possible problems and solutions. If a GENISYS problem isencountered, please use the Guide in trying to eliminate common problems while installing,maintaining and repairing these systems. If situations are encountered beyond thisdocument’s scope, please record the problem symptoms and any steps that may have beentaken to attempt to correct it. Have as much necessary data regarding the specific installationand its configuration readily available before contacting a US&S product specialist forassistance.

B. Introduction

The best way to avoid problems when installing GENISYS units is to take time when firstdesigning a system to determine what effect the value of software and hardware switchsettings will have on the entire system operation. This Guide, Sections I – V, deal with fieldinstallation and should be used to help identify areas that are most likely to cause operationalproblems. If consideration is given to these issues prior to actual field installation, manyproblems can be prevented.

Before any attempt is made to get a GENISYS unit working, the application logic should becompiled and simulated to remove the majority, if not all, of application logic errors. Acardfile must have the correct boards installed to agree with application logic plus propervoltage inputs to the power supply.

If serial links are defined in the application logic, a unit on the other end of the link shouldbe connected and operational. If the unit at the other end of a serial link is non-operational,be sure the validation option is turned off on the unit where you are working, until all otherproblems have been resolved or the link is eventually connected.

Insert the application PROM(s) in the correct socket(s) on the GENISYS controller board.Make sure all boards are in the correct slots and firmly seated in the cardfile. Place physicalinputs in the positions you wish them to be to start your testing and turn on the GENISYSpower supply. If the correct outputs are displayed on the output boards, continue to test logic.If any logic problems are found, correct them and continue testing.


Page 3-2 SM6300E (1/98)

If a GENISYS unit is functioning improperly, the problem may be the result of variouscauses. There are numerous ways to approach troubleshooting a GENISYS system,depending on the kind of problems experienced. For that reason, this guide has been dividedinto categorized sections. Section I deals with proper operation of a working system. Itshould be used to help narrow down the area of a system where you may be having trouble.Section II is a guide on power supply problems. Section III is a guide for non-operationalsystems in which a Controller Board is resetting. Once a system is at least partiallyoperational, Section IV can be used to eliminate Local I/O and interface problems. Serialinterface problems are handled in Section V.

WARNING:

Please remember to turn off power when installing or removing any board in a cardfile.This is not always explicitly stated in different steps performed throughout this guide,but it should always be done before handling boards. For Controller and/or I/OBoards, it is only necessary to turn off the Power Supply Converter. If a Power SupplyBoard is being removed or installed, input power to a Power Supply Converter shouldbe turned off or disconnected, if possible. Removing or inserting boards while power isapplied to them can cause damage to a board or a system.

C. Equipment

When attempting to locate and correct problems with a GENISYS installation, several basictools will be required. These items should be part of a standard field troubleshooting kit.Items such as screwdrivers, pliers, extra wire, etc. should also be available. Some of thesemay not be needed for locating and/or correcting problems with existing installations, buteach item is marked to define its importance for various service levels. Some items aredesignated with more than one letter. They fall in between the categories and may or may notbe necessary, depending on the scope of the operation.

R for Required Items needed to attempt installation, maintenance or repair operations

S for Suggested should be taken if work other than simple board swapping is to beperformed.

O for Optional will only be used for installation or major repair efforts.


SM6300E (1/98) Page 3-3

Item Used For

R GENISYS Manual – SM6300 series Reference

R GENISYS location fact sheet Reference

R Spare boards(min. of 1 of each type used)

Replacement parts

R/S I/O configuration listing Reference

R/S Circuit plans for I/O Reference

R/S Isolated Oscilloscope Checking noise levels

R/S Multimeter Accurate voltage readings and continuitychecks

S Soldering iron & solder Fixing broken connections

S Crimp pin extraction tool Removing connections

S Crimp pins Replacement parts

S Crimp tools Fixing connections

S Clip leads Miscellaneous measurements andconnections

O Card mountable switch panel Checking input boards

O Card mountable LED panel Checking output boards

O GENISYS extender card Checking controller board

O Spare cardfile Replacement parts

O GENISYS development system Changing application logic

O Application logic program Changing application logic

O Datascope Troubleshooting serial links

Table 2-1


Page 3-4 SM6300E (1/98)

I. Working and Non-Working Systems

To effectively troubleshoot a GENISYS system, you must first determine what kind ofproblems the system is experiencing. To accomplish this, normal conditions of a correctlyoperating system should be known, so check your system in the following prescribed order.If a problem is encountered, correct it before continuing on.

A. Working Systems – Perform a visual inspection of a normally operating system,which should appear as follows: See Figure 3-1, which shows a representation of allGENISYS LEDs.

Step 1. Power Supply Board

a. Switch is turned on

b. All LEDs are on

Step 2. Controller Board – LEDs on this board may show signs of functionalproblems other than power.

a. LED 9 – Watchdog Indicator

1) When system is normal, LED should always be dark.

2) If LED is flashing, system is going through reset.


SM6300E (1/98) Page 3-5

b. LEDs 1 to 4 – Master Serial Port

1) If no MASTER port is defined in the application logicinterface section, there should be no connections to theMASTER transmit and receive lines on the Controller Boardtop edge connector. In this case, LEDs 1, 2 and 4 should bedark; LED 3, when unconnected, is a floating input. It willlikely be on but could also be dark and not cause problems.

2) If there is a MASTER port defined in the interface section ofthe application logic, these LEDs will tell the serialcommunications status. LEDs monitor status of the four maincommunication lines. See details on serial communications inSection V.

c. LEDs 5 to 8 – Slave Serial Port

1) If no slave port is defined in the application logic interfacesection, there should be no connections to the SLAVE transmitand receive lines on the Controller Board top edge connector.In this case, LEDs 5, 6 and 8 should be dark; LED 7, whenunconnected, is a floating input. It will likely be on but couldalso be dark and not cause problems.

2) If a slave port is defined in the interface section of theapplication logic, these LEDs will tell the serialcommunications status. LEDs monitor status of the four maincommunication lines. See details on serial communications inSection V.

d. LED 10 – Deliver Line

1) LED 10 is normally dark when the system is stable and nophysical outputs are being delivered. If no location outputs aredefined, this LED will always be dark.

2) When the executive delivers a change to output boards, LED10 will be on for the duration of the deliver pulse. This timewill vary, depending on the selected control delivery time.

Step 3. Output Boards

a. Address LEDs * – Two LEDs are on the Output Boards that indicatea board is being addressed. They are dark normally, except when theexecutive is delivering data to that particular board. These LEDsshould correspond with the deliver LED on the Controller Board. TheAddress LED on the Output Board should come on shortly before the


Page 3-6 SM6300E (1/98)

Deliver LED on the Controller as the executive sends data to theboard. The Deliver LED on the Output Board and the Deliver LEDon the Controller Board should come on at the same time. All threeLEDs should stay on for the duration of the control deliver pulse.There should never be a case when LEDs on more than one OutputBoard are lit at the same time.

b. Output Status LEDs – On the new version of the Constant ControlDelivery Board only, (US&S part number N451441-7101), there areLEDs on the upper front edge of the board to indicate status of theoutput bits. Normally they are all dark. In order to see the outputstatus, a push button on the card front should be pushed in. The LEDswill display status of the outputs while the push button is held in. Adark LED indicates a low (de-energized) output. A high (energized)output will have the LED on.

Step 4. Input Boards

a. Address LEDs * – Two LEDs are on the Input Boards that indicatethe board is being addressed. Access time to scan the inputs is tooquick for the LEDs to reflect the board addressing. These LEDsnormally appear to be dark at all times but a slight flicker may benoticeable.

b. Input Status LEDs – On the new version of Standard Input Boardonly, (US&S part number N451441-7201), LEDs on the upper frontedge of the board indicate the status of the input bits. A dark LEDindicates a low (de-energized) input. A high (energized) input willhave the LED on.

c. Note* There is one case where address LEDs on an I/O board may beon when the board is not being addressed. This will occur if 16 I/Oboards are defined in the system.

d. The I/O board in the last slot (J18) will have its address, but not itsdeliver LED on when no outputs are being delivered to OutputBoards. This is caused by no spare board addresses left in the system.Some addresses must be present on the I/O bus at all times. Whenactive I/O is not being performed, the address of the last slot is left onthe bus.


SM6300E (1/98) Page 3-7

B. Non-Working Systems – The most common GENISYS problems can be resolvedthrough the Sections listed below:

Step 1. Check Power Supply for problems (refer to Maintenance andTroubleshooting, Section II).

Step 2. Check Controller Board for reset problems (refer to Maintenance andTroubleshooting, Section III).

Step 3. See Maintenance and Troubleshooting, Section IV for interface problemsif the system is not resetting and does not appear to be performing Local I/O.

Step 4. If serial lines do not appear operational, see Maintenance andTroubleshooting, Section V for information to correct serial interfaceproblems.

II. Power Supply Converter Board

If there is a problem with a Power Supply Converter Board, several simple steps should befollowed to locate and correct the problem. These steps apply to all GENISYS PowerSupply Converter Boards. Test points, input pins and voltage levels may vary on differentsupplies but the basic theory is the same. GENISYS Service Manual 6300B should be usedto determine correct test points and voltage specifications for the supply used.

A. Power Supply Converter Checkout Procedure

Step 1. Check input voltage and connections

Information regarding correct input voltage specifications and card edgeconnections can be found in GENISYS manuals. Make sure the input voltageis within specifications for the Power Supply Converter that you are using.Check also that input power is entering the correct pins on edge connector. Ifany problems are encountered with inputs to the Power Supply ConverterBoard, they must be corrected before any further action is taken.

Step 2. Check output(s) from converter module(s)

If the input voltage is within specifications and all connections are correct onthe card edge, check output(s) from converter module(s) on the Power SupplyBoard. If any of the power converter modules are not producing the correctoutput voltage, get a known good Power Supply Board and try it. If theproblem does not reoccur, the original Power Supply Board is bad and shouldbe returned to US&S for repair.


Page 3-8 SM6300E (1/98)

Step 3. Check Power Supply Board seating in cardfile

If a known good board does not work, there must be some other problem withthe system. Make sure the Power Supply Board is seated correctly in thecardfile and making good connections to the cardfile backplane.

Step 4. Check cardfile motherboard

Check the motherboard in the cardfile to make sure the traces that carry powerto the other boards are intact and not shorted. Check to make sure that allother boards are correctly seated in the cardfile.

Step 5. Isolate problem

If problem is still present, remove all other boards in the cardfile and try again.If the problem clears up at this point, it is most likely not the Power SupplyBoard, but the cardfile, one of the other boards or an external connection to thefield.

Step 6. Localize problem

Remove all edge connectors except the one supplying input voltage to thePower Supply Board. Plug in the boards that were removed during Step 5,one at a time until the problem returns. At this time, do not connect the boardsto the external world. If the problem returns, try swapping the board thatcauses the problem with a known good board. If this does not correct problemit may be caused by a bad cardfile. Swap cardfile for a known good one andtry again.

Step 7. Reinstall connectors and recheck

If all boards are plugged in and the problem does not return, start connectingthem to the external field, one at a time. If problem returns, check theconnector that caused the problem to return. Verify cable connections andmake certain that grounds are satisfactory. If all connections check outproper, it may still be a board that a connector is attached to. Swap it with aknown good board.

Step 8. Recheck source of voltage supply to connector

If problem persists, check the source of the voltage supply to the connector(for I/O cards only). If it is a separate supply from the input voltage to thePower Converter Card, make sure that there are not crossed wires orgrounding problems with both supplies. If the system is reconnected and theproblem does not return, it may be the result of a poorly seated card.


SM6300E (1/98) Page 3-9

Step 9. Check input voltage with oscilloscope for noise

If the problem appears to be intermittent, check input voltage with anoscilloscope capable of detecting noise or glitches on input voltage. A voltagemeter will not be able to detect noise on the line since it gives only a DC orRMS level. If the input voltage appears to be a good, clean signal, re-checkthe entire system. If all else fails, try swapping out the cardfile for a knowngood one. If this does not resolve the problem, there MUST be a problem withthe input voltage. CHECK IT AGAIN. Make sure there is sufficient currentavailable, that input voltage is steady and that it does not drop significantlywhen a load is placed upon it.

III. System Reset Checkout Procedure

A. Controller Board is Resetting

Step 1. Check Power Supply Module Outputs

If any LEDs on the power supply are dark or the Watchdog LED is flashing,check Power Supply Module outputs to make certain that proper voltages arebeing produced. See Section II for power supply problems.

Step 2. Check Controller Board Components

If power supply outputs appear to be correct and Watchdog LED is stillflashing, check all components on Controller Board for correct installation,which includes executive, application PROMs, and switches.

Verify checksums on executive and application PROMs are correct. Checkexecutive revision numbers against the revision history for any applicablenotes.

Make sure PROMs are installed in correct sockets and have not been insertedbackwards: verify that pin 1 markers on the chips are in the correct positionas identified on the silkscreen.

Step 3. Check Power Supply and Controller Cards

Check both Power Supply and Controller Cards for proper seating in theircorrect slots in cardfile. If in doubt, try reseating them. Verify that they havebeen correctly installed and are fully inserted into the connector on the cardfilebackplane.

Step 4. Swap Controller Cards

If everything appears correct, try swapping the Controller Card with a knowngood board. Remove an application PROM from an old board and place it


Page 3-10 SM6300E (1/98)

correctly in the board you plan to try, plus also check executive PROM of newboard. If it is not installed, take the executive PROM out of old board andplace it correctly in board you want to use. If system is now running,Controller Board is probably bad and should be returned to US&S for repair.

Step 5. Remove I/O Boards, Connectors and Cables

If system is still resetting, remove all I/O boards plus connectors anddisconnect any cables on the back of the Controller Board. The only externalconnection to cardfile should be the ground connections and the input to thePower Supply Converter Board. If system stops resetting, go to Step 11.

Step 6. Check Controller Card power inputs

If Watchdog is still flashing, check power inputs at test points on theController Card. Controller Board voltages should read as follows:

Between test points VDC VDC

TP2 (ov) & TP1 � +5 +/- 0.10

TP2 (ov) & TP3 � -12 +/- 0.10

TP2 (ov) & TP4 � +12 +/- 0.10

If voltage readings on Controller Card are within these limits, continue toStep 9.

Step 7. Double check power supply outputs

If any voltages are incorrect, double check power supply outputs as in Step 1.If power supply outputs are correct, remove Controller Card and checkvoltages present at the connector on the cardfile motherboard. This isreferenced as the B connector and voltages should read as follows:

Between points VDC VDC

B22 (ov) & B17 � +5 +/- 0.10

B22 (ov) & B 9 � -12 +/- 0.10

B22 (ov) & B19 � +12 +/- 0.10

If voltages are not correct at connector, replace Power Supply Converter Boardwith a known good board. Even through voltage outputs may be correct at testpoints on Power Supply Board, it is still possible that voltages never reach theconnector.


SM6300E (1/98) Page 3-11

Step 8. Recheck Controller Board voltages

Recheck voltage presence at Controller Board bottom connector as in Step 7.If voltage readings are still incorrect, try swapping out the cardfile.

Step 9. Check power supply with oscilloscope for noise

Monitor +5 volt output of the power supply with an oscilloscope. The signalshould be a steady +5 volts with no dips or spikes. If this signal is not clean,see power supply troubleshooting portion in Section II. Check inputs to powersupply and make sure that input voltage is within spec for the module beingused and that the ground is connected. Be certain also that you have sufficientcurrent flow.

Step 10. Swap multiple components

If you reach this point and the system is still resetting, get a known goodcardfile, power supply, power supply cable, and Controller Board. The onlyconnections that you should have at this time will be the input to the PowerSupply Board. Do not install any I/O boards at this time. Double checkpower input, cable and grounds. If this system also resets, there must be aproblem with the input to the Power Supply Converter Board. Refer toSection II and repeat procedures.

Step 11. Localize problem

If you have removed all I/O cards and the Watchdog LED quits flashing, youmay have a bad cardfile, I/O Board or serial connection. At this time, do notconnect the boards to the external world. Remove all edge connectors exceptthe one supplying input voltage to the Power Supply Board. Plug in the I/OBoards one at a time until the problem returns. If Watchdog starts resettingagain, try swapping the board that caused the problem with a known goodboard.

If this fails to correct problem, it may be caused by a bad motherboard in thecardfile. Swap cardfile with a known good one and try again.

Step 12. Isolate problem

If all I/O boards are plugged in and system does not reset, start connectingthem to the field, one at a time. If a reset problem returns, check connectorthat caused it to appear. Do a continuity check on the cable to make sure thatthere are good grounds and all connections are correct. If the connections arecorrect, it may still be the board attached to the connector. Swap it with aknown good board.


Page 3-12 SM6300E (1/98)

Step 13. Recheck source of voltage supply to connector

If the problem persists, check source of voltage supply to the connector (forI/O cards only). If it is a separate supply from the input voltage to the PowerConverter Card, be sure there are no crossed wires or grounding problems withboth supplies. If connector in question is the serial interface cable on theController Card, make sure that signal common is connected betweenController and its serial partner or modem.

If the system is reconnected and the problem does not return, it may have beendue to a poorly seated card.

IV. Local Interface Problems

If the controller board is not resetting and does not appear to be performing LOCAL I/O, theproblem is most likely due to either lack of communication with some I/O point or errors inapplication logic. To determine if there is an application problem, we first attempt toeliminate all other causes, assuming that the application logic has been properly compiled,simulated, and debugged. If this assumption is invalid, please check the application programfor logic errors before continuing.

A. Local I/O Problems

Step 1. Check Controller Card LEDs for serial line status

At this point, the system should have all boards installed and connected. Thepower supply converter board should have input power applied and the switchshould be turned on. If there are serial ports defined, check appropriate LEDs onthe Controller Card to determine status of the serial lines. If normalcommunications do not seem to be established, skip to Section V for informationon troubleshooting serial lines. Proper functioning of these LEDs does not assurethat the serial link is functioning correctly, but they are normally good indicators.There are several other possible problem areas to check out before dealing with theserial line in more detail.

Check top two bits (rockers 1 & 2) on switch SW7 on GENISYS ControllerBoard. They must be in the CLOSED position for system to operate. If either ofthe rockers are open, the executive will go into a modem test mode and will notperform logic or I/O.

Step 2. Check physical I/O

Check the physical I/O. If controls, even though they may be wrong, can bedelivered to each output board, you know that all boards are being accessedthrough a backplane. Likewise, try changing indications to make sure that there issome result. This verifies that all input boards are installed and recognized by the


SM6300E (1/98) Page 3-13

executive. If any I/O boards can not be accessed, go to Step 3 for information ontroubleshooting I/O Boards.

If all I/O boards can be accessed and the system is still not functioning properly,take a closer look at the serial link, if one is present. Continue to Section V ifthere is a serial link, even though the LEDs indicate that there is communicationon the serial line.

If there is no serial line and all physical I/O boards can be accessed, there may stillbe a bad board in the system, but it is more likely that the problems beingencountered are related either to external field wiring or application logic. Skip toStep 11 for details to resolve these problems.

Step 3. Verify I/O construction

If a serial link appears to be functioning normally or is not defined in theapplication program, check physical I/O. Be sure that I/O Boards installed in thecardfile are the same as those defined in the application logic. Remember, outputboards must be installed in the cardfile in a group to the left of the inputs. Theremay be blank slots left anywhere in the cardfile, but they should only have sparebits defined on them in the application logic. If a blank slot is to be left in thecardfile anywhere other than after all defined boards, there must still be a boarddefined for that slot in the application logic. Inputs must start in the correctposition in the cardfile in order for a system to work.

Once you have verified that I/O construction is correct, continue with Step 4.Remember that the GENISYS system does not check to see that the I/O cardsinstalled match those requested. The Controller will simply not be able to deliveroutputs to or read inputs from an incorrect board.

Step 4. Verify output boards can be accessed

Now make sure the output boards can be accessed by the Controller Board. Thiscan be done by resetting the system and using the option of clearing the outputboards. To accomplish this, you can reset the system by using the push buttons onthe edge of the Controller Board.

Push in and hold switch SW4. This is the upper of the two push buttons. Whileholding the button in, reset the system by pushing in and then releasing switchSW8. This is the lower of the two push buttons and is marked “RESET”. Whilethe reset switch is pushed in, Watchdog (LED 9) should start flashing. Theexecutive should now access each output board in order to clear it. Once theexecutive has started to clear output boards, SW4 can be released.

There should be a series of deliver pulses, one for each output board. The deliverLED on the Controller Board (LED 10) should pulse on and off. Each time it


Page 3-14 SM6300E (1/98)

pulses on, the address/deliver LEDs on an output board should also pulse startingwith the first board and continuing through the cardfile to the last output boardinstalled.

If any output boards are not cleared or an attempt is made to clear an input board,recheck the application program. The LOCAL I/O requirements defined in theINTERFACE Section may not match the boards installed. If the proper boards areinstalled in the cardfile, then the cardfile itself may be bad. Try swapping it for aknown good cardfile and see if all output boards can now be cleared.

Step 5. Check if output boards can have controls delivered

Once it has been determined that all output boards can be cleared, check to see ifany of them can have a control delivered to them. Reset the unit by pushing inreset button (SW8) on Controller Board. The GENISYS unit should reset, readinputs, process logic and attempt to deliver outputs. All output boards should havesome controls delivered to them shortly after reset. If some, but not all boardsreceive controls, go on to Step 7. If some incorrect controls are delivered to allboards, go to Step 9.

Step 6. Check application logic for cyclic logic

If controls can not be delivered to any output board, check the application logicfor continuous or cyclic logic. This is any point in the application logic that willcause some logic to always be on the logic queues. For example, if you wanted tocreate a flasher by using the equation

ASSIGN ˜ FLASH TO FLASH

and FLASH is not a timer bit, this equation would continue to toggle the value ofFLASH and never reach a stable state. As long as there is logic to be done, nooutputs can be delivered. You should use the simulator to check the logic. Makesure that input bits in the simulator reflect the state that physical input bits were inwhen the system came out of reset. It is possible for a cyclic logic state to bemasked under some input conditions. If there is cyclic logic in your applicationprogram, correct it.

Step 7. Check status of validation switch

Next, determine status of the V (validation) switch, which is software set inapplication logic. If validation is turned on (V+), check to see if unassigned bitsare on the output boards. If there are, either write logic equations to assign valuesto them or make them spare. If this does not resolve the problem, check inputboards in cardfile for proper seating.


SM6300E (1/98) Page 3-15

Step 8. Contact US&S product specialist

At this time, if there is an output board that has not had controls delivered to it, tryturning validation off (V-). Once all other problems have been resolved, it can beturned back on.

If validation is off and no cyclic logic is occurring, but output boards are not beingdelivered, a major problem still remains. Fill out a GENISYS fact sheet and callthe US&S product specialist.

Step 9. Swap boards and cardfile

If all output boards can now receive controls, there may still be problems withsome input. If there is any type of serial link, be sure that correct communicationsprotocol is being followed. See Section V for troubleshooting serialcommunications.

If there are no serial lines or they are operating correctly and you are havingtrouble with input boards, look at the application logic versus current outputs andtry to determine which inputs are not being received. Try changing the indicationsand check results. At this point, the problems should be at board level and notrelated to individual input bits.

If the problem can be narrowed down to particular board(s), swap in known goodinput boards. If all suspect boards have been replaced and there are still indicationboard(s) that can not be read, you may have a bad cardfile. Try swapping thecardfile for a known good one.

Step 10. Verify executive can read inputs from input boards.

At this point, the system should be capable of delivering controls to all of theoutput boards. Now verify that executive can read inputs from all of the inputboards. Change at least one indication on each input board to make sure that theyare all being accessed. As long as there is some result from the changedindication, even though it may be incorrect, you know that board is beingaccessed.

If there is any board that does not produce a result, check the logic to see if theinputs are being used in logic equations and are not just spares. Make sure thatyou have chosen an input that will have some effect on the physical outputs so thechanged input state can be verified. If there is still no action taken whenindications are changed, the input board may be bad. Try swapping it for a knowngood input board. If this board still appears not to be responding to changedinputs, check the connector. Check input cable to verify that inputs are correctlywired.


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Step 11. Monitor I/O

If this is a first attempt to get a particular installation working, it is a good idea tohave a method of monitoring the I/O other than through actual connections. If youare using either of the new I/O boards (N451441-7101 or –7201), this is takencare of by board LEDs. Otherwise, small switch and LED panels that mount onedge connectors in place of actual connections to the field would be useful to helpseparate wiring problems from bad boards.

If you have N451441-7201 input boards, check LEDs on the board to verify thatinputs you are requesting are connected the way you expect them to be. As youchange inputs, LEDs on the board should change state. If LEDs on the board donot follow the field inputs, there is either a bad board or wiring problem. Tryswapping board for a known good board. If the LEDs are still not following thefield requests, there must be a wiring error. Trace connection to find out wherethe error has occurred.

If you do not have 7201 input boards, try connecting the edge mountable switchpanel. If system still responds the same way as it did previously, it may beassumed that the problem is not with input wiring. You may either reconnect theproper input cable or continue with the switch panel until a phase of the testinghas been reached for you to verify field connections.

If a switch panel is not available or you get different results than were obtainedwith field wiring, reconnect input cable and check voltage inputs at the test pointson the input board to verify that they follow field inputs.

Step 12 Use simpler application program in a test PROM

If you still seem to have problems that are not related to logic, a simplerapplication program may help narrow down where problems are originating.Write and compile a small application program that defines nothing other thanLOCAL I/O in the same configuration that you have in the cardfile. Do simplemapping from input to output. Make sure that validation is turned off (%$V-).Remove the current application PROM and put this test PROM in the unit andcheck out the I/O. If any bad inputs or outputs are found, swap out any boardsthat seem to have problems. If board swapping does not correct problem, checkinput wiring and I/O power supply. If all else fails, try swapping the ControllerBoard and finally the cardfile.


SM6300E (1/98) Page 3-17

V. Serial Interface Problems

Serial interface problems must be viewed from an entire system perspective. Any unit of amulti-unit installation could cause an entire system to malfunction. In the followingdiscussion, the terms MASTER and SLAVE will be used to refer to a unit acting in thatcapacity, even though it may not be a GENISYS unit. By now the Controller Board shouldbe a good board; if not, swap it for a good working board to eliminate the possibility of adefective serial port.

A. Introduction

Before any attempt is made to troubleshoot serial links, several terms and concepts mustbe understood. The following is a brief treatment on control/data lines used in serialcommunications and their functions in different GENISYS operating modes.

Control/data lines and their functions are also described with respect to the ControllerBoard. If other devices are connected to serial ports, the control/data lines may have otherfunctions and designations than those presented here. For example, the receive data lineis actually a modem output line and would be connected to a receive data input line on aGENISYS Controller Board. In the Guide, it has been assumed that GENISYS units, aredirectly connected and the control/data lines referred to are those on GENISYS unitsunless stated otherwise.

Three output and four input lines are available for each serial communications port on aController Board. They are:

1. DTR – Data Terminal Ready – output control

A control line that indicates the serial port is enabled and ready to performcommunication functions. In a GENISYS system, this line is normally notconnected, but it may be connected to a modem Data Set Ready line if required bymodem specifications.

2. RTS - Request to Send – output control

A control line is enabled when this unit is ready to transmit. It should be connectedto a Data Carrier Detect line on the correct port of a receiving unit.

3. TXD - Transmit Data – output data

Data that is transmitted from the unit. It should be connected to the Receive Dataline on the correct port of a receiving unit.

4. DSR - Data Set Ready – input control

An unused input control line on the GENISYS serial ports. It may be tied to plus orminus voltage but should not be allowed to float. It should not be tied to the receive


Page 3-18 SM6300E (1/98)

common, since this would cause the internal value to oscillate from one state to theother, overloading the executive with interrupts.

5. DCD - Data Carrier Detect – input control

The control line that signals when incoming data is to be expected. It should beconnected to a Request To Send line on the correct port of transmitting unit.

6. RXD - Receive Data – input data

A line for data being received by this unit. It should be connected to a Transmit Dataline on the correct port of the transmitting unit.

7. CTS - Clear To Send – input control

A control line that enables the transmitter that can be connected to an output controlline RTS to a modem CTS output or to plus voltage.

Four LEDs monitor the status of four major signals for serial communications to eachport, and they are arranged in the same sequence on each port. The first group of four arefor MASTER port (LEDs 1-4), the second group of four monitor slave port (LEDs 5-8).From top to bottom they are:

Master Slave

1 & 5 - TXD - Transmit Data

2 & 6 - RTS - Request To Send

3 & 7 - RXD - Receive Data

4 & 8 - DCD - Data Carrier Detect

B. Carrier Control (Half, Carrier and Full Duplex)

Another major function is carrier control, which refers to the functioning of theRTS/DCD pair. Several terms will be used interchangeably throughout this documentand other GENISYS service manuals. The following information on Carrier Controlshould clarify these terms.

The first item to be covered is the meaning of full versus half duplex. In a full duplexsystem, a single serial port may be transmitting and receiving data at the same time. In ahalf duplex system, a unit may be transmitting or receiving at any time but may not doboth at the same time. GENISYS protocol defines a HALF DUPLEX system as no unitmay be transmitting and receiving data at the same time. There are times in this Guide ora GENISYS manual when a full duplex state may be mentioned. This terminology is


SM6300E (1/98) Page 3-19

inaccurate and actually refers to a state called carrier duplex. In order to understand thedifferences, look at an illustration of half duplex communications below.

Figure 3-2

In a half duplex system, neither control or data lines from the different ports are allowedto overlap. Next look at an illustration of full duplex communications.

Figure 3-3

In a full duplex system, control and data lines from the different ports are allowed tooverlap. Now look at an illustration of carrier duplex communications.

Figure 3-4

In a carrier duplex system, control lines are allowed to overlap but data line lines are not.

GENISYS will work in a half duplex mode or a carrier duplex mode but not in a true fullduplex mode. A half duplex mode may be selected by placing Controller Board carrier


Page 3-20 SM6300E (1/98)

control toggle switch (SW3) in the OPERATE position. Placing this switch in CARRIERposition allows the system to function in a carrier duplex mode.

In order to make this explanation a little clearer, we start with a sequence when units areoperating in half duplex mode. The four LEDs, which are monitoring control/data linesshown above, should function as follows on the MASTER port:

1. MRTS comes on – MASTER is ready to send data. At this time, the key-on delayis started. When the key-on delay has expired, data transmission starts.

2. MTXD starts flashing – MASTER is now sending data. The length of time forTXD depends on message length and baud rate. Not all messages are of the samelength.

3. MTXD goes dark – MASTER has finished transmitting its message. At this time,key-off delay starts. When key-off delay has expired, carrier (MRTS) is turnedoff.

4. MRTS goes dark – Key-off time has expired and the MASTER is waiting for aresponse.

5. MDCD comes on – Signifies a slave station will be sending data as soon as thatslave’s key-on delay expires.

6. MRXD starts flashing – Slave is now transmitting. The length of time for TXDwill depend on message length and baud rate. Not all messages are of the samelength.

7. MRXD goes dark – The slave has finished transmitting a message. At this time,the slave’s key-off delay starts. When key-off delay expires, carrier (SRTS) isturned off.

8. MDCD goes dark – The slave’s key-off time has expired. MASTER now formatsa new message and goes back to number 1.

The slave port is basically the same but in the opposite order.

1. SDCD comes on – Signifies master station will transmit data as soon as themaster’s key-on delay expires.

2. SRXD starts flashing – Master is now transmitting. Length of time for TXDdepends on message length and baud rate. Not all messages are of the samelength.

3. SRXD goes dark – Master has finished transmitting its message. At this time,Master’s key-off delay starts. When key-off delay has expired, carrier (MRTS)turns off.


SM6300E (1/98) Page 3-21

4. SDCD goes dark – Master’s key-off time has expired. If the message wasaddressed to this slave, the sequence will continue to number 5. If the messagewas addressed to a slave with a different address, all LEDs on the slave port willgo dark, while the other SLAVE answers the message. When the master starts thenext message, the sequence will continue as in number 1.

5. SRTS comes on – SLAVE is ready to send data. At this time, the SLAVE’s key-on delay starts. When key-on delay has expired, data transmission starts.

6. STXD starts flashing – SLAVE is now sending data. The length of time for TXDdepends on message length and baud rate. Not all messages are of the samelength.

7. STXD goes dark – SLAVE has finished transmitting this message. At this time,key-off delay starts. When key-off delay has expired, the carrier (SRTS) turnsoff.

8. SRTS goes dark – Key-off time has expired and the SLAVE is waiting for thenext message from the MASTER.

GENISYS will work in a half duplex mode or a carrier duplex mode. The only differencebetween carrier and half duplex involves the carrier timing. In carrier duplex, MASTERRTS is on steady. This should also cause SLAVE DCD to be on steady. A slave unit,since it will accept a constant incoming carrier, does not wait for a DCD signal to goaway before setting outgoing carrier high and starting key-on delay. Therefore, carriersignals may overlap. Under no conditions, however, should transmit data signals fromMASTER and slave units overlap.

Depending upon baud rate used, it may or may not be possible to distinguish the flashingof TXD/RXD LEDs. It may look as though they are on steady but not quite as bright asRTS/DCD LEDs. At higher baud rates, it may not even be possible to distinguish thetiming difference between transmit and receive portions of the communication.

Before going any further, check top two bits (rockers 1 & 2) on switch SW7 onGENISYS controller board. They must be in a CLOSED position in order for the systemto operate. If either of these rockers are open, the executive will go into a modem testmode and will do no logic or I/O. Also check that jumpers J1 – J10 on the GENISYScontroller board are in the correct position for your communications format.

Step 1. Check MASTER RTS and TXD line LEDs

First, determine if the MASTER unit is transmitting. If the MASTER unit is aGENISYS unit, check the LEDs that correspond to MASTER RTS and TXDlines. If a unit is operating correctly, there will be periodic active transmissionstate followed by a receive state. If a MASTER TXD line is never active, the


Page 3-22 SM6300E (1/98)

MASTER unit is never attempting to send any data. Go to Step 3 for informationon troubleshooting this type of problem.

If a MASTER is not a GENISYS unit, check SLAVE DCD and RXD lines. Ifthey are connected to the RTS and TXD lines on the unit, which is acting as aMASTER, it should be possible to monitor master transmit activity in this manner.If a GENISYS SLAVE is not receiving information from a non-GENISYSMASTER, correct this problem before going further.

Step 2. Check if SLAVE is attempting to respond to MASTER

If a MASTER is attempting to transmit data, check to see if a SLAVE is makingany attempt at a response. If the SLAVE is not responding at all, there should be await state after MASTER transmission equal to the MASTER’s no response timeout (default) for a GENISYS MASTER. This indicates a SLAVE, for whateverreason, cannot respond correctly to this message. Go to Step 4 to attempt toresolve problem.

If a slave unit is attempting to respond to the message, you can assume at this timethat the MASTER transmit and SLAVE receive lines are functioning correctly.Skip to Step 13 for information on SLAVE transmit and MASTER receive pairs.

If any unit starts to transmit a message but aborts the message before it iscompleted, there may be noise on the incoming CTS or DCD lines. This willoften be recognized by seeing the RTS line key on but the transmit data line neverbecomes active. If a Datascope is being used to monitor the communication lines,you may also notice messages that are started but never terminate with the correcttermination character $F6. Check CTS and DCD lines with an oscilloscope forpossible noise and glitches. If any noise is present, find the cause and eliminate itbefore continuing.

Step 3. Determine cause of GENISYS MASTER not transmitting

If a GENISYS MASTER is not transmitting at all, it could be due to one ofseveral causes;

a - incoming DCD in half duplex

b - no CTS signal

c - continuous interrupts

d - incorrectly defined interface

e - unstable logic


SM6300E (1/98) Page 3-23

Check position of carrier control toggle switch (SW3) on GENISYS controllerboard. If it is in OPERATE mode, be sure that MASTER’s DCD LED is not on.An active incoming DCD signal will prevent a MASTER from startingtransmission. If a constant active state of a DCD signal is an acceptablecondition, carrier control toggle switch should be moved to CARRIER positionand the GENISYS unit should be reset. If the active DCD signal is not a normaloperating condition, see if it is caused by an active RTS from one of the slaveunits or by a false active state on a modem line. Correct this problem and thencontinue.

If the DCD line is inactive or the unit is operating in carrier duplex, an inputsignal to the CTS line may not be connected. This line must be active for thetransmitter to be enabled. The CTS line should be tied high locally or connectedto the CTS modem output. If the MASTER is in half duplex and this signal isbeing fed back from a modem, make certain that the MASTER’s key-on delay islong enough to allow the modem to key on and enable the CTS line. If possible,this line should be tied high. It can be connected to +12 volts for EIA or +5 voltsfor TTL. These voltages are available on the GENISYS cardfile edge connector.

Check Data Set Ready (DSR) line. It does not matter whether this line is pulled toplus or minus voltage but it should not be allowed to float, which could causecontinuous processor interrupts. In most cases, the CTS and DSR lines can be tiedto plus voltage.

If all connections appear to be correct, make sure you have defined the properinterface in the application program. This should be a MASTER station.

Next check to see if any LOCAL output can be done. If not, you may have aproblem within the application program. Check the logic for continuous or cycliclogic. This is any part of the application logic that will cause some logic to alwaysbe on the logic queues. For example, if you wanted to create a flasher by using anequation:

ASSIGN ˜ FLASH TO FLASH

And FLASH was not defined as a timer bit, this equation will continuously togglethe FLASH value and never come to a stable state. As long as there is logic to bedone, no physical or serial output can be done. Use the simulator to check logic.If cyclic logic is in an application program, correct it.

Step 4. Verify MASTER is accepting incoming data

At this time, the MASTER should be transmitting data. If a Datascope isavailable to monitor serial lines, the first message that is transmitted by theMASTER should be a $FD to the first slave defined in the application logic. Ifthe slave does not respond, a $FD message will be repeated one time. If there is


Page 3-24 SM6300E (1/98)

no response to the second message, a MASTER will go on and attempt to establishcommunications with the rest of the slave stations.

If any of the slave stations are responding, verify the MASTER is accepting theincoming data. This can be done by looking at the $FD sequence. When theMASTER sends a $FD message, the SAVE should respond with a $F2 message.The MASTER should then send a $FA and the SLAVE will respond with either a$F1 or $F2 message. If it is a $F2 message, the MASTER will send another $FAand this sequence will continue until the SLAVE sends a $F1 message. At thistime, the MASTER should go on with the next SLAVE in the polling cycle. If theMASTER is not accepting the incoming data, skip to Step 9.

If the MASTER has established communications with any of the SLAVEs, non-responding slave station(s) should be checked and set up in the same fashion asthe responding stations.

Step 5. Verify the SLAVE is not attempting to respond

If a GENISYS slave station is not responding to the MASTER poll, check thehardware connections. Be sure that MASTER TXD and RTS signal arephysically being received by a slave station. Verify also that SLAVE is notattempting to respond by checking LEDs on the slave unit. If the SLAVE isattempting to respond but no indication of this is being received at the MASTERstation, there must be a wiring of modem problem. Check all connections and themodem settings to attempt to rectify the situation. Confirm also that a commonsignal from the MASTER or the modem is connected to the proper pin on theslave port.

Step 6. Confirm SLAVE station information is in application program.

Confirm that SLAVE station has a proper interface description and station addressin the application program. The SLAVE’s address may be defined in the SLAVEinterface section or on a hardware switch. In order to use the hardware setting, anaddress of 0 must be used in the application program. If any other value is used,the address in the application program is the address to which this unit willrespond, regardless of hardware switch setting.

Step 7. Check slave unit for proper connections

Next check slave unit for the same connections defined for the MASTER unit inStep 3.

Check position of carrier control toggle switch. If it is in the OPERATE position,make sure that SLAVE's DCD LED is not on. An active incoming DCD signalwill prevent the SLAVE from starting a transmission. If a constant active state ofthe DCD signal is an acceptable condition, carrier control toggle switch should be


SM6300E (1/98) Page 3-25

moved to CARRIER position and the GENISYS unit should be reset. If theactive DCD signal is not a normal operating condition, see if it is caused by anactive RTS from the MASTER unit or by a false active state on a modem line.Correct this problem and then continue. If MASTER unit has carrier controlswitch in the CARRIER position, the slave unit also must be set to CARRIER.

If the DCD line is inactive or the unit is operating in carrier duplex, and inputsignal to the CTS line may not be connected. This line must be active for thetransmitter to be enabled. The CTS line should be tied high locally or connectedto the CTS output of the modem. If this signal is being fed back from a modem,make sure the SLAVE key-on delay is long enough to allow the modem to key onand enable the CTS line. If possible, this line should be tied high. It can beconnected to +12 volts for EIA or +5 volts for TTL. These voltages are availableon the edge connector of the GENISYS cardfile.

Check Data Set Ready (DSR) line. It does not matter whether this line is pulled toplus or minus voltage, but it should not be allowed to float, which could causecontinuous processor interrupts. In most cases, the CTS and DSR lines can be tiedto plus voltage.

Step 8. Check baud rates

Check baud rates. Both MASTER and slave units must be set to the same baudrate. For the MASTER unit, a software switch may be set in the applicationprogram. If it has not been set, baud rate will take a default value of 1200 BPS.For the slave unit, baud rate may also be set with a software switch. However, ifthe switch is not set, baud rate will default to a value determined by the hardwareswitch on the Controller Board. The current values of software switches shouldappear at the bottom of the application program list file. Values associated withthe hardware switch can be found in the GENISYS Service Manual. If units arenot set to the same baud rate, decide what baud rate you wish to operate and setMASTER and all SLAVEs to that rate.

Check modem baud rate setting. If one is being used, it must be operating at thesame rate as GENISYS units.

Step 9. Check data byte format

Check data byte format. GENISYS default is one start bit, eight data bits, noparity and one stop bit. If the revision of the GENISYS executive PROM(N451575-0901) is 0-6, this is the format that must be used. In revisions 7 andup, an extra stop bit or a parity bit may be selected by a system designer. Rockers6, 7 and 8 on switch SW7 on Controller Board are used to select these options. Inorder to use default byte format, all three of these bits should be in the CLOSEDposition. Make sure the modem is also set to the chosen parameters.


Page 3-26 SM6300E (1/98)

Step 10. Check key-on and key-off delays

If MASTER unit is operating in carrier duplex, make sure the key-on and key-offdelays are long enough to allow proper framing of data transmission. If they areset improperly, the first or last byte could be lost. Do not forget to account formodem timing factors when determining settings for key-on and key-off delays.

Step 11. Check modem transmission parameters

If modems are being used, check the transmission parameters of modems on bothends of line. Make sure that none of the modems have drifted out of theacceptable bandwidth and the signal on the SLAVE receive port has not beendegraded to a point that a GENISYS receiver can not detect it correctly. If you aremonitoring the communications with a Datascope, please keep in mind that someDatascopes are capable of detecting a signal that GENISYS will not. What maylook like valid messages on the Datascope may not be received properly by aGENISYS unit. Check the incoming signal with an oscilloscope to confirm thatpulses are not skewed and that the voltage level is high enough to be receivedcorrectly. If there is a problem with a modem signal, the modem test feature ofthe GENISYS executive can be used to help adjust the modem to the correctlevels.

Step 12. Record MASTER and SLAVE communication information

By this point, the slave unit should at least be attempting to respond to aMASTER poll. If it is not, record all the communication information for bothMASTER and SLAVE on the GENISYS station fact sheet and call the productspecialist.

Step 13. Check connections and modem settings

If the SLAVE is attempting to respond but no indication of this is being receivedat the MASTER station, there must be a wiring or modem problem. Check allconnections and mode settings to attempt to rectify the situation. Confirm alsothat the common signal from the MASTER or modem is connected to the properpin on the slave port.

Step 14. Verify only one SLAVE is responding to same address.

If a MASTER unit receives, but does not accept a SLAVE’s transmission, be sureonly one SLAVE is responding to the same station address. If more that oneSLAVE attempts to transmit at the same time, the data will overlap and a validmessage cannot be decoded. Each SLAVE should have a unique address.


SM6300E (1/98) Page 3-27

Step 15. Confirm key-on and key-off delays are long enough

Confirm key-on and key-off delays are long enough to allow proper framing of thedata transmission. If they are set improperly, the first or last byte could be lost.Do not forget to account for modem timing factors when determining settings forkey-on and key-off delays. Make sure that key-on delay of slave unit is not longerthan a no response time out of MASTER. If it is, the MASTER will have timedout before the SLAVE starts its transmission, since the no response time out ishalted by the first data character received and not by the DCD signal. In executivePROM (N451575-0901) Revisions 0-6, the MASTER no response time out is 1second. In Revisions 7 and up, this is a user definable time with a default value of1 second. See the GENISYS Service Manual section on compiler switches.

Step 16. Check modem transmission parameters on both ends

If modems are being used, check transmission parameters of modems on both endsof the line. Make sure that none of the modems have drifted out of the acceptablebandwidth and that the signal on MASTER receive port has not been degraded toa point that a GENISYS receiver can not detect it correctly. If you are monitoringcommunications with a Datascope, please keep in mind that some Datascopes arecapable of detecting a signal that GENISYS will not. What may look like validmessages on a Datascope might not be received properly by GENISYS. Checkincoming signal with an oscilloscope to confirm that pulses are not skewed andvoltage level is high enough to be received correctly. If a modem signal problemoccurs, the modem test feature of the GENISYS executive can be used to helpadjust the modem to correct levels.

6300e

Documents

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