troubleshooting en [modalità compatibilità]ntr...receiver all outputs are dereceiver, all outputs...

TROUBLE SHOOTING

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TROUBLE SHOOTING

I t d ti iIntroduction: warning

The repair must be undertaken according to the manufacturerThe repair must be undertaken according to the manufacturer

instructions. Only genuine spares has to be used not to alterate

the radio control featuresthe radio control features.

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TROUBLE SHOOTING

Introduction: preliminary checks

Before you go further into looking for the cause of the problem,

f th f ll i li i h kperform the following preliminary checks:

1. STOP button is released. (This is the most common cause of1. STOP button is released. (This is the most common cause of

customer call we receive at the Service dept).

2. Battery is inserted and charged

3. Magnetic key is in

4. No commands are active while pressing START

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TROUBLE SHOOTING

Introduction: Glossary

Passive Emergency Stop conceptIn case of system failure, the radio control automatically gets into safe status mode. At the receiver all outputs are de-energized and the STOP circuit opened The most commonreceiver, all outputs are de-energized and the STOP circuit opened. The most common cause is an interruption of the radio transmission ( for >0,8s) because of: • strong radio interferences: another radio control is being operated nearby at the same frequency• The action range has been exceeded or a metallic surface is present between the transmitter and the receiver.

TX RXTX, RXTX = transmitter, RX = receiver

EepromRemovable memory card containing information like ID number, channel frequency and system settings (can be intended as a mobile phone SIM card).

Frequency Change (C F )

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Frequency Change (C.F.)It can be performed by the operator entering a procedure directly from the transmitter. This will allow to set a specific frequency for the radio link. 30 different channels are available.

TROUBLE SHOOTINGMost Common Anomalies

ANOMALY(occuring at 1ST

ANOMALY(occuring at

POSSIBLE SOLUTION(occuring at 1

activation)(occuring at

following activations)

The system has a much lower range

• A) Strong radio interferences might be present. Verify it turning off the TX and

h ki if t th RX “RF B ” l d k t i lit If f h ithan the nominalvalue(80-100m). Itmeans the receiverstops and goes intopassive emergency-

checking if at the RX, “RF Busy” led keep staying lit. If yes, a frequency change is

required.

• B) Strong electric interferences generated at the control box might reach the

receiver trough the connection wiring Remove the S STOP fuse (to insulate thepassive emergencystop.

receiver trough the connection wiring. Remove the S-STOP fuse (to insulate the

receiver from the motion contactors) and check if any improvement. “data error ch

A/B” leds frequently turning off, indicate that information is lost. The system has a • Check if the receiver antenna has been damagedymuch lower rangethan the nominalvalue(80-100m). Itmeans the receiverstops and goes into

• Check if the receiver antenna has been damaged

• New source of radio interferences might entered the operation area. Check point

A)

stops and goes intopassive emergency-stop.

Some functions are t t d

• Check out the technical enclosures B and C attached to the manual

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not as expected

Some functions are not as expected

• Check the connection wiring betwen receiver and control panel

• Check the command activation observing the led’s associated to the relays

TROUBLE SHOOTING TXTX

TX led. Meaning of Indications Part1gTransmitter

Led status Anomaly descriptionOFF TX is off or faulty. Causes:

•Battery is absent or totally empty

•The Key is absent or not well inserted

•The logical board or the power supply circuit have been g p pp y

damaged (transmitter crash)

Flashing regularly_ _ _ _ _ _ _ _ _ _ _ _ _ _

Battery has entered the reserve

ON only while START is keptpressed

STOP button is pressedpressed

____________________

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TX led. Meaning of Indications Part2Transmitter

Led status Anomaly descriptionThree short + long flashes You are trying to start the transmitter while a command

g

g_ _ _ ____

y gis active (only for joystick TX type)

The flashing produces a code1 0 1 0 0 1 1 0 __ _ __ _ _ __ __ _

Error code. Morse coding (long flash= 1; short flash=0)

__ _ __ _ _ __ __ _

Flashing fastly_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

STOP circuit anomaly (see STOP test procedure aheadslides 12-13)

Single short flash while Start is pressed

__

EEPROM is missing or out of order (see dedicatedsection ahead slide 14)

Lighting with low intensity Battery contacts to be cleanedLighting with low intensity Battery contacts to be cleaned

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TransmitterLed status Description

TX led. Meaning of Indications Part3

Led status DescriptionON

____________________________Transmitter is working correctly

flashing with groups of 5 flashes Frequency Change procedure has been succesfullyg g p_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

q y g p yentered at the TX. Waiting for the new channel selection

(Only for systems with proportionalcommands and PIN code)

Analogue output calibration procedure has beensuccessfully entered. Waiting for the PIN code

Flashing regularlyEs: _ _ _ _ _ _ _ _ _ _ _ _ _


Analogue output calibration procedure in progress.Minimum speed limit calibrationcommands and PIN code)

Single flash with pause Es: _ _ _ _ _ _ _ _

Minimum speed limit calibration.


Analogue output calibration procedure in progress.Maximum speed limit calibrationcommands and PIN code)

Double flash with pause Es: _ _ _ _ _ _ _ _ _ _ _ _ _ _

Maximum speed limit calibration.

(Only for systems with proportional Analogue output calibration procedure in progress

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Rapid regular flashes_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Analogue output calibration procedure in progress.Direction change


How to read an error code

transmitterLed status Anomaly description

Flashing in Morse codeFlashing in Morse code1 0 1 0 0 1 1 0 __ _ __ _ _ __ __ _

Error description

b b b …. 0 .…

….1….

….

0 ….

0 …..

….1….

….

0 ….

0 .… ….1….

….

b b b

The Led repeats the morse code twice. The code is

made of 8 flashes (long or short). A sequence of rapid

flashes (b) indicates the code is going to be produced.

The error code keep being produced till the cause of

9the failure is not removed.


Binary code part 1 (MS)* Binary code part 2 (LS)* hexadecimal

List of transmitter Error codes. Binary and Hexadecimal values

y p ( ) y p ( )

0000 0001 01

0001 0001 11

0001 0011 13

1011 0011 B3

0010 0000 20

0010 1000 28

0011 0000 300011 0000 30

1100 0101 C5

1100 0110 C6

10*: MS = Most Significant; LS = Less Significant


hexadecimal Error description details solution

TX

01 STOP button failure Microswitch contacts of STOP button do not open synchronously

In case of repeated error, replace the STOP button

11 Battery voltage out of range for the logic board The voltage is higher than 3,2V (risk of board damage)

Replace the battery with a genuine one or correctly charged

13 / B3 Battery totally empty (remaining charge The voltage is lower than the minimum admitted value Replace the battery with a charged one13 / B3 y y p y ( g g

insufficient to start properly the TX) admitted value(Wave=2Vdc Thor/Zeus=3Vdc)

p y g

20 a) Active command at Start (only for Wave)b) bad comunication between micro’s

a) Not allowed at Start command b) Time out in micro’s data exchange

a) Deactivate the commandb) Replace TX logic board

28 Bad comunication between micro and eeprom Probable damage along the comunication path Change the mother board

START push button is mechanically blocked30 START command blocked START push button is mechanically blocked (dirt or broken spring) Clean or change the STARTcontact

C5 Joystick failed“forward direction” and “analogue” sensing do not match; or the joystick is unplugged; or the joystick has been damaged inside

Check the joystick plug; replace the joystick

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j y g

C6 Joystick failed

“backward direction” and “analogue” sensing do not match; or the joystick is unplugged; or the joystick has been damaged inside

Check the joystick plug; replace the joystick


“STOP” test procedure Part1


If following a transmitter Start the led keeps flashing rapidly

Flashing rapidly_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

potential anomaly in the trasmitter STOP circuit

If following a transmitter Start, the led keeps flashing rapidly,

this signals the existing of a potential anomaly in the

transmitter STOP circuit. The radiocontrol thus turns into a

waiting status asking the operator to test the STOP circuit.

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“STOP” test procedure Part2p

Push the STOP button (and let it pressed) while the led is flashing, then press START. At this point one of the following three cases can occur:

A) if the STOP circuit is perfectly working, after releasing the STOP button and pressing the START button, the transmitter will turn on and work normally

B) if after the first test the LED keeps flashing rapidly, it is necessary to repeat the test procedure (up to 4 times) untill you turn into case A) o C)

C) If the LED starts to flash indicating the error code “STOP circuit failure” contact yourC) If the LED starts to flash indicating the error code STOP circuit failure , contact your dealer for repairing/replacing the STOP Button

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Missing EEPROM. Deepening.

TransmitterLed status Anomaly description

Single short flash while Start is EEPROM is missing or out of order (see dedicated

This kind of error occurs typically when the eeprom is not correctly fit in its

Single short flash while Start ispressed

__

EEPROM is missing or out of order (see dedicatedsection ahead)

This kind of error occurs typically when the eeprom is not correctly fit in its

connector or if cancelled. In the first case, check the electrical connection of the

eeprom, in the second case ask for a replacement eeprom

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TROUBLE SHOOTING RXRX

RX LED INDICATIONS L, K, HData Error ch. B

Data Error ch A

Passive Emergency ch. B

receiver unit

Led indicationData error ch. A

(yellow)Normally on when the system is working.Turns off while errors are detected on channel

RF Busy

Data Error ch. A

Passive Emergency ch. A

A.Passive emergency

ch. A(red)

Normally off when the system is working.When on it indicates that channel A is in STOP status.Morse coded flashes in case of system errors

Power Supply

WorkingData error ch. B

(yellow)Normally on when the system is working.Turns off while errors are detected on channel B.

Passive emergency Normally off when the system is working.

RF BUSYPOWER SUPPLYEMERGENCY CH. A

ch. B(red)

When on it indicates that channel B is in STOP status. Morse coded flashes in case of system errors

RF busy When on it indicates the presence of radio

DATA ERROR CH BEMERGENCY CH. B

EMERGENCY CH. ADATA ERROR CH. A M

y(green)

psignal on the transmission channel. With datafeedback transmission it flashes very fastly.

Power Supply(green)

The receiver is powered .

15WORKINGDATA ERROR CH. B(g )

Working(green)

When on, it indicates that the E-STOP relays are energized and commands can be executed.


Receiver checkANOMALY

(if it occurs at 1° use only)ANOMALY POSSIBLE SOLUTION

The receiver does notturn on

The receiver does not turnon

• Check the fuses

• Check the power linesp

The receiver turns on but themachine do not react. Thetwo yellow Leds are on.

• Check the fuse protecting the common of the motion relays

• Check the wiring between the receiver and the machine

• Check the fuse protecting the STOP circuit relays• Check the fuse protecting the STOP circuit relaysThe receiver turns on butthe machine does notreact. The two red Ledsare on.

• Check if the radiocontrol operation range is normal

• Check the radiocontrol ID trough the serial number (TX and RX

ID must match)ID must match)The receiver turns on but the machine do not react. The two red Leds are on.

• Check if the radiocontrol operation range is normal

Some commands are not • Check the wiring between the receiver and the applicationexecuted

• Check the wiring between the receiver and the application

Some commands are notexecuted any more

• Check the wiring between the receiver and the application

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executed any more• Check if the commands cards, in the receiver, are correctly

working.


Error code readingD t E h BData Error ch. B

RF B

Data Error ch. A


Passive Emergency ch. BThe Led repeats the morse code continuously. The

code is made of 8 flashes (long or short). A

sequence of rapid flashes (b) indicates the code is RF Busy

Power Supply

Working

sequence of rapid flashes (b) indicates the code is

going to be produced. The error code keep being

produced till the cause of the failure is notRF BUSY

EMERGENCY CH. B

POWER SUPPLYEMERGENCY CH. ADATA ERROR CH. A

removed.

WORKINGDATA ERROR CH. B


Flashing in Morse codeFlashing in Morse code1 0 1 0 0 1 1 0 __ _ __ _ _ __ __ _

Error description

17b b b 0 1 0 0 1 0 0 1 b b b


List of receiver Error codes. Binary and Hexadecimal values

Binary code part 1 (MS)* Binary code part 2 (LS)* hexadecimal

0000 0101 05

1011 0111 B7

0000 0110 06

0000 1000 080000 1000 08

0000 1010 0A

0001 0000 10

0001 0001 11

0001 0100 14

18*: MS = Most Significant; LS = Less Significant


RX

hexadecimal Error description details solution

05-B7 Error during EEPROM reading The EEPROM memory cannot be correctly read by the micro’s

Check if the EEPROM is correctly plug in its socketcorrectly read by the micro s. correctly plug in its socket

06 Error detected during Safety-Stop monitoring

The S-STOP status does not match its command signal

Check the S-STOP relay. If necessary replace it

0808Error detected during E-STOP monitoring

The E-STOP status does not match its command signal

Check the E-STOP relay. If necessary replace it

0A

10 SAFETY-STOP detected closed during START phase

The S-STOP status does not match its command signal

Check the S-STOP relay. If necessary replace it

Error detected on the voltage The voltage coming out from the

The power source might ce instable with frequent drops out. Otherwise the board Graetz11

gvalue of the logical board power supply during receiver start up.

g gswitching transformer is no valid (too low or too high)

Otherwise the board Graetz bridge is defective (change the Graetz Bridge or the complete mother board)

The dip-switches are not set according

1914 Wrong dip switch configuration

(only for WAVE)to an allowed configuration, so, the software does not allow the receiver to operate.

Check out the technical enclosures.


RX error code 11: deepeningp g

Note that in this case, only led CH.B flashes

1) In presence of a voltage value lower than the

Data Error ch. B

Data Error ch A

Passive Emergency ch. B

) p g

allowed threshold, check the power supply lines

and operate a power reset. RF Busy

Data Error ch. A


2) If point1) can be excluded, the problem is

cased by a defect of the Graetz diode bridge

( f h i hi l i i )

Power Supply

Working

(part of the switching power supply circuit).

Replace the diode bridge or the complete

board.

RF BUSYPOWER SUPPLYEMERGENCY CH. ADATA ERROR CH Aboard.

WORKINGDATA ERROR CH. BEMERGENCY CH. BDATA ERROR CH. A

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TROUBLE SHOOTING HYDRAHYDRA

HYDRA:

Error description Details Solution

The S STOP fuse is broken Replace the fuseThe S-STOP fuse is broken Replace the fuse

The S-STOP fuse is OK but The S-STOP output is not present on the receiver connector

Check the S-STOP relay output. If necessaryreplace it

Power pack is notoperating

The S-STOP fuse and relay are OK but the S-STOP output is not present on the plug

Check the continuity of the external wiring bycontrolling the power supply voltage and S-STOP signal presence on the plugp g

Remove the electronic card and power directly the motor: 1 If the motor is now running the fault is in theThe S-STOP fuse, relay, the external wiring

and the plug are OK, the signals are present on the plug, but the motor is not running

1. If the motor is now running, the fault is in the electronic card (replace it).

2. If the motor is not running replace it, and checkthe voltage output on the electronic card output connectors. If there is not voltage output

l l th l t i d

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replace also the electronic card .

TROUBLE SHOOTINGRX

FINAL WARNINGSFor all the cases that are not here listed, please contact the manufacturer reporting the following

information:

• Model (WAVE, ZEUS, THOR…) and project number

i l b• serial number

• description of the encountered defect

d i ti f th t t f d b f t ti IMET i• description of the test performed before contacting IMETservice

• description of the problem, cronology of the problem, LED indication and condition in

which it occurswhich it occurs.

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troubleshooting en [modalità compatibilità]ntr...receiver all outputs are dereceiver, all outputs...

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