Manual No: Revision: I. TLS-350 Series. Board and Software Replacement

Transcription

1 Manual No: Revision: I TLS-350 Series Board and Software Replacement

2 Notice Veeder-Root makes no warranty of any kind with regard to this publication, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this publication. Veeder-Root reserves the right to change system options or features, or the information contained in this publication. This publication contains proprietary information which is protected by copyright. All rights reserved. No part of this publication may be photocopied, reproduced, or translated to another language without the prior written consent of Veeder-Root. DAMAGE CLAIMS 1. Thoroughly examine all components and units as soon as they are received. If damaged, write a complete and detailed description of the damage on the face of the freight bill. The carrier's agent must verify the inspection and sign the description. 2. Immediately notify the delivering carrier of damage or loss. This notification may be given either in person or by telephone. Written confirmation must be mailed within 48 hours. Railroads and motor carriers are reluctant to make adjustments for damaged merchandise unless inspected and reported promptly. 3. Risk of loss, or damage to merchandise remains with the buyer. It is the buyer's responsibility to file a claim with the carrier involved. RETURN SHIPPING For the parts return procedure, please follow the appropriate instructions in the "General Returned Goods Policy" and "Parts Return" pages in the "Policies and Literature" section of the Veeder-Root North American Environmental Products price list. Veeder-Root All rights reserved.

3 Table of Contents Introduction Contractor Certification Requirements...1 Related Manuals...1 Before You Begin...1 Safety Precautions...2 Precautions Against Static Electricity...2 Before Turning Off Power - All Procedures...3 Replacing the CPU Board...4 Reentering System Setup Data...7 Replacing the ECPU Board Record the System Setup Into the EEPROM Chip...8 Removing the ECPU Board...9 Installing the ECPU Board...14 Restoring System Setup Data...15 Replacing PROM Chips on A CPU Board Replacing PROM Chips...17 Restoring System Setup...19 Replacing ROM and RAM Boards on the ECPU Board Archiving the System Setup...20 Replacing the ROM or RAM Board...20 Restoring System Setup...21 Replacing the EEPROM Chip...24 Replacing the CPU/ECPU Board s Battery CPU Board...25 Reentering the System Setup...25 Replacing the ECPU Board s Battery...27 Archiving the System Setup...27 Replacing the Battery...27 Restoring the System Setup...27 Replacing the SEM Module on CPU/ECPU Boards...29 Verifying New System Features...30 Upgrading CPU Board Software from Version 1 to Replacing an ISD NVMEM Board...32 Figures Figure 1. CPU Board Location...4 Figure 2. Removing CPU Board...5 Figure 3. Installing the CPU Board...6 Figure 4. Removing the ECPU Board Figure 5. ECPU Board Layout with Through-Hole Mounted Components...11 Figure 6. ECPU Board Layout with Surface Mounted Components...11 Figure 7. ECPU2 Board Layout...12 Figure 8. Removing the EEPROM Chip from the ECPU Board...12 i

4 Table of Contents Figure 9. Orienting E2 Chip...13 Figure 10. Installing the ECPU Board...14 Figure 11. Through-Hole Component Layout Version of the CPU Board...17 Figure 12. Surface-Mount Component Layout Version of the CPU Board...17 Figure 13. Removing and Installing PROM chips on the CPU Board...18 Figure 14. ROM and RAM Board Component Layouts...20 Figure 15. Removing and Installing a ROM or RAM Board...21 Figure 16. Replacing Battery...25 Figure 17. Replacing SEM Module...29 Figure 18. CPU Board RAM Chip Location...31 Figure 19. ISD NVMEM Board Component Layouts...32 Figure 20. Installing/Removing an ISD NVMEM Board...33 ii

5 Introduction This manual contains instructions for replacing the following components in CPU board ECPU board CPU PROMs ROM and RAM boards (ECPU) ECPU board E 2 integrated circuit CPU board backup battery ECPU board backup battery CPU and ECPU board software module Upgrading CPU board software from Version 1 to Version 2 NVMEM board (ECPU) This manual does not provide troubleshooting information. Contractor Certification Requirements Veeder-Root requires the following minimum training certifications for contractors who will install and setup the equipment discussed in this manual: Level 1 Contractors holding valid Level 1 Certification are approved to perform wiring and conduit routing, equipment mounting, probe and sensor installation, tank and line preparation, and line leak detector installation. Level 2/3 Contractors holding valid Level 2 or 3 Certifications are approved to perform installation checkout, startup, programming and operations training, troubleshooting and servicing for all Veeder-Root Tank Monitoring Systems, including Line Leak Detection and associated accessories. Warranty Registrations may only be submitted by selected Distributors. Related Manuals TLS-3XX Series Consoles Site Prep Manual Before You Begin Before you begin component replacement, read the following guidelines: To avoid electrical shock, be sure AC power to the console is Off when performing the procedures in this manual. Failure to comply with these requirements could result in death, serious personal injury, property loss, or equipment damage. 1

6 Safety Precautions Safety Precautions The following safety symbols may be used throughout this manual to alert you to important safety hazards and precautions. ELECTRICITY High voltage exists in, and is supplied to, the device. A potential shock hazard exists. OFF TURN POWER OFF Live power to a device creates a potential shock hazard. Turn Off power to the device and associated accessories when servicing the unit. INJURY Careless or improper handling of tools can cause bodily injury. STATIC SENSITIVE COMPONENTS Wear grounded anti-static wrist strap before handling the printed circuit board. READ ALL RELATED MANUALS Knowledge of all related procedures before you begin work is important. Read and understand all manuals thoroughly. If you do not understand a procedure, ask someone who does. OFF WARNING This system operates on 115 VAC power. Serious injury or death from electrical shock could occur if the power ON/OFF warnings in this manual are not heeded. 1. Read and follow all instructions in this manual, including all safety warnings. 2. Remove rings from hands, metal watch bands and bracelets, and loose hanging neck jewelry before performing these procedures. 3. Do not modify or use service parts other than those provided by. Precautions Against Static Electricity Before removing electronic components from their antistatic bags read the following static electricity precautions. 1. Before handling any components, discharge your body's static electric charge by touching a grounded surface. 2. Do not remove parts from their antistatic bags until you are ready to install them. 3. Do not lay parts on the antistatic bags! Only the insides are antistatic. 4. When handling parts, hold them by their edges and their metal mounting brackets. 5. Avoid touching components or edge connectors that plug into slots. 6. Never slide parts over any surface. 2

7 Before Turning Off Power - All Procedures 7. Avoid plastic, vinyl, and styrofoam in your work area. 8. Wear the antistatic wrist strap included in your component replacement kit. 9. The antistatic caution icon shown to the left appears in several places in this manual to remind you to wear an antistatic wrist strap (Part No ) when handling static sensitive devices. Before Turning Off Power - All Procedures 1. If you have a printer and it is usable, from the Operations Mode press the PRINT key to print out a copy of the system status [active alarms (if any), and in-tank inventory]. 2. From the Setup Mode press the PRINT key to print out a copy of the system setup. 3. From the Diagnostic Mode press FUNCTION then PRINT for each of the Diagnostic Mode functions to print out copies of all of the system diagnostic reports. 3

8 Replacing the CPU Board Important! All operating, setup and historical data will be lost when the console is turned off and the CPU board is replaced OFF Switch Off power to console. Open the left front door of the Console and locate the CPU board [Figure 1]. CPU Board consoles\cpu.eps Figure 1. CPU Board Location 4. Follow the steps in Figure 2 to remove the CPU board. 4

9 Before Turning Off Power - All Procedures consoles\cpubdout.eps CPU Board Installation guide slots (one at top and bottom) 2 Remove the grounding wrist strap from its package and wrap one end around your wrist. Ahere the other end to the side of the comm board cage. CPU Board J10 Pivot edge of tool against inner partition of console. 4Place curved end of the removal tool under front end of CPU board at each retention pin location (3 places) and rotate tool to pry the board off of the retention pin. Replace removal tool in its storage position. 3 5 Retrieve Board Removal tool from its storage position on the top of the comm cage by pulling on black knob in center of tool. Disconnect each of the two cables attached to the CPU board, and the printer cable from the Local Printer Com Board. 6 Pull the board straight out until you disconnect it from the motherboard connector and it clears the top and bottom guides. Rotate it towards you to clear the door. Hold the CPU board by its edges and avoid touching components and connector pins. OFF 1 Remove ac power to the console. Push S2 down to turn battery backup OFF. S2 BATT OPEN S1 OFF Figure 2. Removing CPU Board 5. Place old and new CPU boards side by side on a clean work surface. Make sure the Battery Backup switches on both boards are in the Off position. Remove the SEM (see Figure 17 on page 29) and the PROM chips (see page 17) from the old CPU board and plug them into the identical sockets on the new CPU board. 5

10 Before Turning Off Power - All Procedures 6. Install the new CPU board by following the steps in Figure 3. CPU Board Installation guide slots (one at top and bottom) Comm board cage 1 Attach one end of the antistatic wrist strap to your left wrist and adhere the other end to the comm board cage. With your right hand, hold the ribbon cables out of the way. Holding the CPU board in your left hand as shown, slide the board around the Comm Board cage and straight back into top and bottom guide slots. Place your thumbs on the front edge of the board at the top and bottom and push the board firmly toward the back of the console to seat the board connector in the motherboard connector. Antistatic wrist strap adhered to side of comm board cage Local Printer Com Board (could be in another slot) Board connector 3 Connect cables: - Top 16-pin cable from display to CPU board J10 - Middle 16-pin cable from keyboard to CPU board J9-6-pin cable from printer to J1 on the Local Printer Com Board. Pin 1 is identified by the number 1 screened on the surface of the board. Look at the connector on the end of the ribbon cable. On one side you will see embossed socket numbers 1 through 6. Orient connector so that the #1 socket is aligned over the #1 pin of the board connector before attaching it. (see diagram below for additional printer connection information.) Correct Printer Connector Orientation Make sure that tabs of the ribbon cable connector face the locking ridge of board connector J1 as you push the connector down over J1's pins. (Check also that the locking ridge is centered between the tabs.) To printer card 2 Push board down onto each retention pin until it snaps through board (3 places). consoles\cpubdin.eps S2 4 BATT OPEN S1 Push S2 down to turn battery backup OFF. consoles\pj1cpu.eps Tabs (2) Locking ridge Connector J1 Front of console Ribbon cable connector Local printer com board Figure 3. Installing the CPU Board 6

11 Reentering System Setup Data Reentering System Setup Data 1. Restore AC power to the console. 2. The console front panel display will cycle through the following screens: CLEARING ALL RAM SYSTEM COLD START SYSTEM SELF TEST SYSTEM STARTUP COMPLETE Wait until the printer prints: *** SYSTEM RESET *** MMM DD, YYYY HH:MM XM and the front panel display reads: BATTERY IS OFF 3. Push the CPU board s Battery Backup Switch (S2) up (ON). 4. Press the ALARM/TEST key to acknowledge the alarm. The printer prints: and the front panel display reads: MMM DD, YYYY HH:MM XM SYSTEM STATUS REPORT ALL FUNCTIONS NORMAL ALL FUNCTIONS NORMAL 5. Reenter the system setup data following the procedure outlined in your console System Setup manual while referencing the system setup data print-out and/or other setup information you have. 7

12 Replacing the ECPU Board Record the System Setup Into the EEPROM Chip 1. If possible, from the Setup Mode press the FUNCTION key until the display reads: 2. Press the STEP key until the display reads: ARCHIVE UTILITY PRESS <STEP> TO CONTINUE 3. Press the CHANGE key: ARCHIVE UTILITY SAVE SETUP DATA: NO 4. Press the ENTER key: ARCHIVE UTILITY SAVE SETUP DATA: YES 5. Press the STEP key: SAVE SETUP DATA: YES PRESS <STEP> TO CONTINUE 6. Press the CHANGE key: SAVE SETUP DATA: YES ARE YOU SURE?: NO 7. Press the ENTER key: SAVE SETUP DATA: YES ARE YOU SURE?: YES ARE YOU SURE?: YES PRESS <STEP> TO CONTINUE 8. Press the STEP key and the printer prints: ARCHIVE UTILITY SAVE SETUP DATA: START TIME: And the front panel display reads: ARCHIVE UTILITY SAVE SETUP DATA: BUSY 8

13 Removing the ECPU Board 9. The console is now writing the current system setup to the EEPROM (E 2 ) chip. After this task is completed, the printer prints: ARCHIVE UTILITY SAVE SETUP DATA: END TIME: BYTES: XXXX And the front panel display reads: ARCHIVE UTILITY PRESS <STEP> TO CONTINUE Removing the ECPU Board Important! All operating, setup and historical data will be lost when the console is turned off and the ECPU board is replaced 1. Switch Off power to the Console. Open the left front door of the console. Follow the steps in Figure 4 to remove the ECPU board. 9

14 Removing the ECPU Board 3 Disconnect each of the three cables attached to the ECPU board. ECPU Board Installation guide slots (one at top and bottom). 4 Retrieve Board Removal tool from its storage position on the top of the comm cage by pulling on black knob in center of tool. 6 Pull the board straight out until you disconnect it from the motherboard connector and it clears the top and bottom guides. Rotate it towards you to clear the door. Hold the ECPU board by its edges and avoid touching components and connector pins. 5 Place curved end of the removal tool under front end of CPU board at each retention pin location (3 places) and rotate tool to pry the board off of the retention pin. Replace removal tool in its storage position. Pivot edge of tool against inner partition of console. OFF SW2 SW1 Turn OFF ac power to the console. Push SW1 down to turn 1battery backup OFF. 2 Remove the grounding wrist strap from its package and wrap one end around your wrist. Ahere the other end to the side of the comm board cage. consoles\ecpuout.eps Figure 4. Removing the ECPU Board. 1. Place old and new ECPU boards side by side on a clean work surface. Make sure that the Battery Backup switches on both boards are turned Off. 10

15 1 Board & Software Replacement 1 Removing the ECPU Board Required ROM Board (either J1 or J2 slot) Software Enhancement Module (SEM) Battery Backup Sw (S1) & DIP Sw 1-4 (S2) J3 TO DISPLAY J4 TO KEYBOARD RX TX J5 J6 GRN LED1LED2 RED SW1 U OPEN SW2 J1 SOFTWARE MOD BT1 J2 U2 U5 U8 U13 U16 U21 U23 U24 U25 U27 U31 Optional RAM Board or NVMEM board (either J1 or J2 slot) U28 CPU Static Sensitive Avoid Touching J7 Component leads pass through holes in the board and are soldered on the back side. E 2 Chip Replaceable Lithium Battery consoles\ecputh1.eps Figure 5. ECPU Board Layout with Through-Hole Mounted Components Required ROM Board (either J1 or J2 slot) Software Enhancement Module (SEM) Battery Backup Sw (S1) & DIP Sw 1-4 (S2) U3 U11 TO DISPLAY TO KEYBOARD J4 RX TX J5 GRN LED1LED2 RED J6 SW1 U7 J OPEN OPEN J1 U31 SW2 J2 U1 U6 U9 U13 U16 U23 U35 Replaceable Lithium Battery Optional RAM Board or NVMEM board (either J1 or J2 slot) U2 U5 U10 U12 U27 U32 U4 U39 U41 Y2 U37 U36 U40 U42 U R R127 consoles\ecpusf1.eps 2 E Chip CPU Static Sensitive Avoid Touching ECPUBoard Group Installed Component U4 U36 R126 R127 Figure 6. ECPU Board Layout with Surface Mounted Components 11

16 Removing the ECPU Board Required ROM Board (either J1 or J2 slot) 2 E Chip Software Enhancement Module (SEM) Battery Backup Sw (S1) & DIP Sw 1-4 (S2) Optional RAM Board or NVMEM board (either J1 or J2 slot) Lithium battery SOCKET CPU Static Sensitive Avoid Touching consoles\ecpu2.eps Figure 7. ECPU2 Board Layout 2. Using a chip removal tool similar to the one shown (IC Extraction tool, Digikey Part No. K158-ND, or equivalent), follow the steps outlined in Figure 8 remove the E 2 chip from the old ECPU board and install it the identical socket on the new board reversing the procedure shown in Figure 8. Observe chip oreintation as shown in Figure 9. 1 Rest bottom of tool on socket. Push down with thumb to hold tool on socket. 4 Continuing to apply pressure with fingers, gently lift the tool straight up until the chip pins are clear of the socket. Slides Lifting clamps Lifting hooks 2 Pull up with fingers on slides to close lifting clamps against ends of E 2 chip and lifting hooks under ends of chip 3 Continue to pull up with fingers until chip is lifted up against bottom of tool. consoles\chipto.eps Figure 8. Removing the EEPROM Chip from the ECPU Board 12

17 Removing the ECPU Board U13 U16 Notch (Painted on board) U27 U23 U32 U12 Indented semicircle (On chip) CPU Static Sensitive Avoid Touching Y2 Check to see that chip pins are aligned and not bent. Orient chip so that the small indented semicircle on the top of the chip is on the same end as the small notch painted on the board above the socket (in this example on the top). Carefully align the chip pins over the socket holes and gently push the chip down until all the pins are in the socket holes. Then push down firmly and evenly on the chip until it is down against the socket. Check to see that each of the pins is in its socket. U33 Figure 9. Orienting E 2 Chip 3. Remove the SEM chip from the old board and install it in the SEM socket of the new board (ref Figure 17 on page 29). Note: Either type SEM will only plug in one way. Remove the ROM board from the old ECPU board and install it on the new board (ref Figure 15 on page 21). If present, also remove the RAM or NVMEM board from the old ECPU board and install it on the new board (see Figure 15 on page 21 or Figure 20 on page 33 as appropriate). 13

18 Installing the ECPU Board Installing the ECPU Board 1. Install the new ECPU board in the console following the steps outlined in Figure 10. ECPU Board Installation guide slots (one at top and bottom) 1 Attach one end of the antistatic wrist strap to your left wrist and adhere the other end to thecomm board cage. With your right hand, hold the ribbon cables out of the way. Holding the ECPU board in your left hand as shown, slide the board around the Comm Board cage and straight back into top and bottom guide slots. Place your thumbs on the front edge of the board at the top and bottom and push the board firmly toward the back of the console to seat the board connector in the motherboard connector. Comm Board cage Antistatic wrist strap adhered to base of console Board connector J3 3 Connect cables: - Top 16-pin cable from display to ECPU board J3 - Middle 16-pin cable from keyboard to ECPU board J4-6-pin cable from printer to ECPU board J6 (see below for additional printer connection information) Correct Printer Connector Orientation J6 J4 Make sure that tabs of the ribbon cable connector face the locking ridge of board connector J6 as you push the connector down over J6's pins. (Check also that the locking ridge is centered between the tabs.) To printer card Tabs (2) Ribbon cable connector Locking ridge Push board down onto each retention pin until it snaps through board SW12 (three places). consoles\ecpuin.eps SW2 4 Push SW1 down to turn battery backup OFF. ECPU board consoles\pj6ecpu eps Front of console Connector J6 Figure 10. Installing the ECPU Board 14

19 Restoring System Setup Data Restoring System Setup Data 1. With the console s left front door open, restore AC power to the console. 2. The console front panel display will cycle through the following screens: CLEARING ALL RAM SYSTEM COLD START SYSTEM SELF TEST SYSTEM STARTUP COMPLETE Wait until the printer prints: *** SYSTEM RESET *** MMM DD, YYYY HH:MM XM and the front panel display reads: RESTORE SETUP DATA: NO 3. Push the Battery Backup switch (SW1) up to the ON position. 4. Press the CHANGE key: 5. Press the ENTER key: RESTORE SETUP DATA: YES RESTORE SETUP DATA: YES PRESS <STEP> TO CONTINUE 15

20 Restoring System Setup Data 6. Press the STEP key and the printer prints: ARCHIVE UTILITY RESTORE SETUP DATA START TIME: MMM DD, YYYY HH:MM XM The console begins the restoring process of copying the system setup data you archived in the E 2 chip into the new ECPU board s RAM. Depending on how complicated your system setup data is, this procedure could last for several minutes. When the restoring process is complete the printer prints out: ARCHIVE UTILITY RESTORE SETUP DATA END TIME: MMM DD, YYYY HH:MM XM SYSTEM SETUP MMM DD, YYYY HH:MM XM This information is followed by a complete printout of the system setup. The front panel display should read: BATTERY IS OFF 7. Press the ALARM/TEST key to acknowledge the alarm. The printer prints: And the front panel display reads: MMM DD,YYYY HH:MM XM SYSTEM STATUS REPORT ALL FUNCTIONS NORMAL ALL FUNCTIONS NORMAL 8. Close and secure the left front door. 9. If necessary, refer to your System Setup manual to make any corrections or additions to your system setup. It is good practice to archive your system setup to the E 2 chip after you have made any additions or corrections to the setup (see Reentering System Setup Data on page 7, for this procedure). 16

21 1 Replacing PROM Chips on A CPU Board Important! All operating, setup and historical data will be lost when the console is turned off and the PROM chips are replaced. Replacing PROM Chips OFF 1. Open the left front door of the console. Remove AC power from the console and push the Battery Backup switch down to the OFF position. Refer to Figure 1 on page 4 to locate the CPU board. 2. If you want to remove the CPU board before replacing the PROMs, follow the board removal procedure in Replacing the CPU Board on page Refer to Figure 11 on page 17 and Figure 12 on page 17 to locate the PROM chips on the CPU board. J10 J9 SOFTWARE MODULE U10 U11 S1 TO DISPLAY U4 U5 U6 TO KEYBOARD U7 U8 U9 U26 BATT 1 PROM chips Software Enhancement Module DIP Sw 1-4 (S1) & Battery Backup Sw (S2) TLS-350 CPU BOARD U12 U2 U OPEN S2 VR1 U25 U27 U17 U18 U13 U14 U15 U16 U20 VR2 U25 U21 U22 U23 U24 BT1 J1 consoles\cputh.eps CPU Static Sensitive Avoid Touching Replaceable Lithium Battery Figure 11. Through-Hole Component Layout Version of the CPU Board PROM chips (System Software) Software Enhancement Module DIP Sw 1-4 (S1) & Battery Backup Sw (S2) TO DISPLAY TO KEYBOARD U2 TLS-350 CPU BOARD U3 J10 U1 J9 U26 U10 U11 U S1 OPEN SOFTWARE MODULE BATT VR1 S2 U6 U7 U8 U9 D1 U4 U5 RP4 U18 RP1 U27 RP9 Y4 VR2 U13 Y1 U17 U14 D2 RP2 U15 U16 U20 RP3 BT1 U19 D4 U22 J1 U21 U23 U24 Component leads pass through holes in the board and are soldered on the back side. CPU Static Sensitive Avoid Touching Replaceable Lithium Battery consoles\cpusf.eps Figure 12. Surface-Mount Component Layout Version of the CPU Board 17

22 1 1 Board & Software Replacement Replacing PROM Chips 4. Attach one end of the antistatic wrist strap around your wrist and adhere the other end to the base of the console. 5. On each PROM chip is a label with the part number and its circuit board position (U2 or U3). The PROM labeled U2 must go in the socket labeled U2, and the PROM labeled U3 must go in the socket labeled U3 (the socket labels are printed on the board). The console will not function if these PROMs are reversed. 6. Follow the procedure in Figure 13 to remove the old PROM chips and replace them with the new ones. Remove PROM Chip Rock hand slightly back and forth while lifting up to remove PROM chips. PROM chips TO DISPLAY TO KEYBOARD TLS-350 CPU BOARD J10 U1 J9 U26 S1 U2 U3 SOFTWARE MODULE U10 U11 U OPEN VR1 S2 U6 U7 U8 U9 D1 U4 U5 RP4 RP1 RP9 U27 U18 Y4 VR2 U13 Y1 U17 U14 D2 RP2 U15 U16 U20 BT1 U19 D4 RP3 U22 J1 U21 U23 U24 CPU Static Sensitive Avoid Touching Single-tab end of PROM chip caddy Single-notched end of PROM chip socket TO DISPLAY TO KEYBOARD TLS-350 CPU BOARD J10 U1 J9 U26 S1 U2 U3 SOFTWARE MODULE U10 U11 U OPEN VR1 S2 U6 U7 U8 U9 D1 U4 U5 RP4 U18 RP1 U27 RP9 Y4 VR2 U13 Position single tab end of chip U14 caddy over single notch end of socket and insert chip caddy gently down into socket. Push on both ends of chip until U21 caddy is seated down in socket as far as it will go. Y1 D2 RP2 U22 U15 U23 U16 U24 U17 RP3 BT1 J1 U20 U19 D4 consoles\cpuprorm.eps Figure 13. Removing and Installing PROM chips on the CPU Board 18

23 Restoring System Setup Restoring System Setup 7. Restore AC power to the console. 8. The front panel display will cycle through the following screens: CLEARING ALL RAM SYSTEM COLD START SYSTEM SELF TEST SYSTEM STARTUP COMPLETE At this point the printer prints: *** SYSTEM RESET *** MMM DD, YYYY HH:MM XM and the front panel display reads: BATTERY IS OFF 9. Push the CPU board s Battery Backup Switch (S2) up (ON). 10. Press the ALARM/TEST key to acknowledge the alarm. The printer prints: and the front panel display reads: MMM DD, YYYY HH:MM XM SYSTEM STATUS REPORT ALL FUNCTIONS NORMAL ALL FUNCTIONS NORMAL 11. Reenter the system setup data following the procedure outlined in the console System Setup manual while referencing the System Setup printout. 19

24 Replacing ROM and RAM Boards on the ECPU Board Archiving the System Setup Follow the procedure Record the System Setup Into the EEPROM Chip on page 8. Replacing the ROM or RAM Board 1. Switch Off power to the console. Open the front door of the console and locate the ECPU board Figure 4 on page Figure 14 shows the layout of a ROM and the two RAM boards (version with jumper J2 is out of production). ROM BOARD U1 XXXXX MM\DD\YY U1 U2 XXXXX MM\DD\YY U2 Mounting notch (seats over ridge in base of connector - typ all boards) Mounting notch (seats over ridge in edge of connector) - typ all boards) NOTE: Leave jumper J2 on ONLY when you have greater than 8 tanks or BIR with manifolded tanks. J2 RAM BOARD (This board no longer in production) U6 A The default mode for this board is for 3XX software. For 1XX software a ground must be opened by clipping the corner of the board effectively breaking the trace. Cut along lines shown. If reonnection is desired, attach a wire from hole A to B (see dotted line in circle. B Cut lines U6 RAM BOARD (Current production) consoles\romrambd.eps Figure 14. ROM and RAM Board Component Layouts 20

25 Restoring System Setup 3. Follow the instructions in Figure 15 to install or replace a ROM or a RAM board. When adding or replacing a RAM board, read the note about J2 in Figure 14 on page 20. Seat ROM board in connector J1 at an angle with component side facing the front of the console. Make sure that notch in the bottom of the board is over ridge in base of connector, then push board back until retaining clips snap around the board's edges. DON'T FORCE BOARD or you may damage socket! Check that notch and ridge are aligned correctly then try again. RAM board is installed exactly the same as the ROM board and usually behind the ROM board. You have to remove the ROM board before you install the RAM board. ECPU board Retaining clip (2) Front of console J1 View A-A J2 Installing ROM and RAM Boards 2 Attach one end of the antistatic wrist strap to your wrist and the other end to the base of the console. ECPU Board A A 3 ROM board usually in front, RAM board (when needed) in back Removing ROM or RAM Boards - Use your fingers to spread retaining clips away from the ROM or RAM board edges, tilt the board to the front of the console and lift it out. ROM board retaining clips (one on each end) SW2 SW1 Turn ac power to console OFF. Push SW1 down to turn 1 battery backup OFF. consoles\romin.eps Removing ROM and RAM Boards Figure 15. Removing and Installing a ROM or RAM Board Restoring System Setup 1. Restore AC power to the console. 2. The front panel display cycles through the following screens: 21

26 Restoring System Setup CLEARING ALL RAM SYSTEM COLD START SYSTEM SELF TEST SYSTEM STARTUP COMPLETE At this point the printer prints: *** SYSTEM RESET *** MMM DD, YYYY HH:MM XM 3. Push the Battery Backup switch (SW1) up to the ON position. 4. Press the CHANGE key: RESTORE SETUP DATA: YES 5. Press the ENTER key: RESTORE SETUP DATA: YES PRESS <SETUP> TO CONTINUE 6. Press the STEP key and the printer prints: ARCHIVE UTILITY RESTORE SETUP DATA START TIME: MMM DD, YYYY HH:MM XM 22

27 Restoring System Setup The console begins the process of copying into the new RAM board, the system setup data you archived in the E 2 chip. Depending on how complicated your system setup data is, this procedure could last for several minutes. When the restoring process is complete the printer prints: ARCHIVE UTILITY RESTORE SETUP DATA END TIME: MMM DD, YYYY HH:MM XM SYSTEM SETUP MMM DD, YYYY HH:MM XM This information is followed by a complete printout of the system setup. The front panel display should read: BATTERY IS OFF 7. Press the ALARM/TEST key to acknowledge the alarm: The printer prints: SYSTEM STATUS REPORT ALL FUNCTIONS NORMAL And the front panel display reads: ALL FUNCTIONS NORMAL 8. Close and secure the left front door. 9. If necessary, refer to your System Setup manual to make any corrections or additions to your system setup. [It is good practice to always archive your system setup after you have made any additions or corrections to it (see Record the System Setup Into the EEPROM Chip on page 8, for this procedure).] 23

28 Replacing the EEPROM Chip OFF This procedure assumes you are changing the EEPROM (E 2 ) chip, but not the ECPU board. 1. Switch Off power to the console. Open the left front door of the console and locate the ECPU board [reference Figure 4 on page 10]. 2. Remove the ECPU board following the instructions in Removing the ECPU Board on page 9 with one exception - DO NOT turn the Battery Backup switch OFF as instructed in that procedure. 3. Locate the E 2 chip on your ECPU board [see Figure 5 on page 11, Figure 6 on page 11, and Figure 7 on page 12 for the three possible ECPU board layouts]. 4. Remove the E 2 chip following the instructions shown in Figure 8 on page Replace the E 2 chip following the instructions shown in Figure 9 on page Replace the ECPU board following the instructions shown in Figure 10 on page 14 with one exception. The exception is that you can ignore step 4 since you did not turn off battery backup when you removed the board. 7. Restore AC power to the console. 8. The display will cycle through the following screens: SYSTEM WARM START SYSTEM SELF TEST SYSTEM STARTUP COMPLETE At this point front panel display reads: ALL FUNCTIONS NORMAL 9. You should archive the current system setup data in the blank E 2 chip following instructions in Record the System Setup Into the EEPROM Chip on page Close and secure the left front door. 24

29 1 Replacing the CPU/ECPU Board s Battery CPU Board OFF Important! All operating, setup and historical data will be lost when the console is turned off and the battery is replaced. 1. Remove the CPU board following the instructions beginning on page 4. Push the Battery Backup switch (S2) down to the OFF position. 2. Locate battery BT1 on the CPU board layout in Figure 11 on page 17 or Figure 12 on page 17 as appropriate. 3. Following the instructions in Figure 16, pull off the battery cover and replace the battery. Replace CPU board following instructions in Figure 3 on page 6. CPU/ECPU board J5 J6 SW1 Cover mounting holes (4) BT SW2 OPEN OPEN Remove battery cover to access battery BT1 Battery mounting holes (3) Center hole is positive (+). Y3 + U35 Board Battery (3 pins) Push pins down into 3 holes with center pin in hole labeled + To replace cover, push 4 posts down into 4 mounting holes until they snap into board. consoles\replacebatt.eps J7 Figure 16. Replacing Battery Reentering the System Setup 1. Restore AC power to the console. 2. The console front panel display will cycle through the following screens: CLEARING ALL RAM 25

30 Reentering the System Setup SYSTEM COLD START SYSTEM SELF TEST SYSTEM STARTUP COMPLETE At this point the printer prints: *** SYSTEM RESET *** MMM DD, YYYY HH:MM XM and the front panel display reads: BATTERY IS OFF 3. Push the CPU board s Battery Backup Switch (S2) up (ON). 4. Press the ALARM/TEST key to acknowledge the alarm. The printer prints MMM DD, YYYY HH:MM XM SYSTEM STATUS REPORT ALL FUNCTIONS NORMAL and the front panel display reads: ALL FUNCTIONS NORMAL 5. Close and secure the left front door. 6. Reenter the system setup data following the procedure outlined in the console System Setup manual while referencing the system setup printout. 26

31 Replacing the ECPU Board s Battery Replacing the ECPU Board s Battery ARCHIVING THE SYSTEM SETUP Follow the instructions to Record the System Setup Into the EEPROM Chip on page 8. REPLACING THE BATTERY OFF OFF 1. Remove the ECPU board following the instructions beginning on page 8. Make sure the Battery Backup switch (S1) is in the OFF position. 2. Locate battery BT1 on the ECPU board layout in Figure 5 on page 11 (battery s location is similar on all ECPU board types). 3. Following the instructions in Figure 16 on page 25, pull off the battery cover and replace the battery. Replace ECPU board following instructions in Figure 10 on page 14. RESTORING THE SYSTEM SETUP 1. Restore AC power to the console. 2. The console front panel display will display the following screens: CLEARING ALL RAM SYSTEM COLD START SYSTEM SELF TEST SYSTEM STARTUP COMPLETE At this point the printer prints: and the front panel display reads: *** SYSTEM RESET *** MMM DD, YYYY HH:MM XM RESTORE SETUP DATA: NO 3. Push the Battery Backup switch (SW1) up to the ON position. 27

32 Replacing the ECPU Board s Battery 4. Press the CHANGE key: RESTORE SETUP DATA: YES 5. Press the ENTER key: RESTORE SETUP DATA: YES PRESS <SETUP> TO CONTINUE 6. Press the STEP key and the printer prints: ARCHIVE UTILITY RESTORE SETUP DATA START TIME: 7. The console begins restoring the system setup data you archived earlier. Depending on how complicated your system setup data is, this procedure could last for several minutes. When the restoring process is complete the printer prints: ARCHIVE UTILITY RESTORE SETUP DATA END TIME: SYSTEM SETUP MMM DD, YYYY HH:MM XM 8. This information is followed by a complete printout of the system setup. The front panel display reads: BATTERY IS OFF 9. Press the ALARM/TEST key to acknowledge the alarm. The printer prints: 10. And the front panel display reads: MMM DD,YYYY HH:MM:SS XM SYSTEM STATUS REPORT ALL FUNCTIONS NORMAL ALL FUNCTIONS NORMAL 11. Close and secure the left front door. 28

33 Replacing the SEM Module on CPU/ECPU Boards OFF 1. Remove AC power to the console. 2. Open the front door of the console and locate the CPU board [Figure 1 on page 4] or ECPU board [Figure 4 on page 10]. 3. Locate the Software Enhancement Module (SEM) on your CPU board [Figure 11 on page 17] or ECPU board [Figure 5 on page 11]. The SEM is in the same general area of all CPU/ECPU board types. 4. Replace the SEM as shown in Figure 17. Note: Either type SEM will only plug in one way. Type 1 Type 2 SEM modules (2 types) View A-A TO KEYBOARD J4 RX TX J5 GRN LED1LED2 RED J6 1 SW1 A SOFTWARE MOD A BT OPEN OPEN SW2 Y3 Figure 17. Replacing SEM Module 5. Restore AC power to the console. The display will cycle through the following screens: SYSTEM WARM START SYSTEM SELF TEST SYSTEM STARTUP COMPLETE 29

34 Verifying New System Features At this point the front panel display reads: ALL FUNCTIONS NORMAL Verifying New System Features 1. Press the MODE key until the front panel display reads DIAG MODE PRESS <FUNCTION> TO CONT 2. Press the FUNCTION key until the front panel display reads: SYSTEM DIAGNOSTIC PRESS <STEP> TO CONTINUE 3. Print out a description of the software currently in your system. Press the PRINT key and the printer prints: SOFTWARE REVISION LEVEL VERSION XXX.XX SOFTWARE# XXXXXX-XXX-XXX CREATED - YY.MM.DD.HH.MM S-MODULE# XXXXXX-XXX-X 4. After the SEM (S-Module) part number prints, a list of your system s current features follows. 5. Press the MODE key to return to the main screen: ALL FUNCTIONS NORMAL 6. Close and secure the left front door. 7. Refer to the System Setup manual to program the new features you added. 30

35 1 Upgrading CPU Board Software from Version 1 to 2 OFF Important! All operating, setup and historical data will be lost when the console is turned off and the PROM and RAM chips are replaced. 1. Remove AC power from the console. Open the left front door of the console and push the Battery Backup switch down to the OFF position. Refer to Figure 1 on page 4 to locate the CPU board. 2. Remove the CPU board following the board removal procedure in Replacing the CPU Board on page Refer to Figure 18 and locate the PROM (U3 & U4) and RAM chips (U4 & U5) on the CPU board. Note: Later releases of Version 1 may only have one RAM chip in U4. PROM chips RAM chips J10 J9 U2 CPU BOARD U3 TO DISPLAY U4 U5 U6 TO KEYBOARD U7 U8 U9 U10 U11 U S1 OPEN S2 BATT VR1 U25 U17 U18 U19 U13 U14 U15 U16 U20 VR2 BT1 U25 U21 U22 U23 U24 J1 consoles\cputhold.eps CPU Static Sensitive Avoid Touching 4. Replace the 2 PROM chips following the instructions in Replacing PROM Chips on page 17. Figure 18. CPU Board RAM Chip Location 5. With a small straight-slot screwdriver, pry one end of the existing RAM chip or chips up and remove them from their sockets. 6. Take the single replacement Version 2 RAM chip and orient the notched end of the chip with the notched end of the U4 socket. Carefully position the chip pins in the socket holes and press it down until it rests on the socket base. 7. Perform a Cold Start following the instructions in Restoring System Setup on page

36 Replacing an ISD NVMEM Board 1. Switch Off power to the console. Open the front door of the console and locate the ECPU board Figure 4 on page Figure 19 shows the general layout of the two types of ISD NVMEM boards. U5 U8 U10 U12 NVMEM Card (Front side) 4 MB Flash, 2 MB SRAM TLS Console software versions - 1XX P/N U3 Mounting notch- typ. (seats over ridge in base of connector) Mounting notch- typ. (seats over ridge in edge of connector) U5 U8 U10 U12 U3 NVMEM Card (Front side) 4 MB Flash, 3 MB SRAM TLS Console software versions - 3XX P/N Back side (Typ. all boards) isd-evr\nvmem.eps 3. The ISD NVMEM board is installed or removed as shown in Figure 20. Figure 19. ISD NVMEM Board Component Layouts 32

37 Verifying New System Features To Insert Board Seat ISD NVMEM board in connector J1 at an angle with top side facing the front of the console. Make sure that notch in the bottom of the board is over ridge in base of connector, then push board back until retaining clips snap around the board's edges. DON'T FORCE BOARD or you may damage socket! Check that notch and ridge are aligned correctly then try again. ROM board ECPU board Retaining clip (2) Front of console J1 View A-A J2 Installing ISD NVMEM Board ECPU Board ISD NVMEM board First Attach one end of an antistatic wrist strap to your wrist and the other end to the base of the console. A A To Remove Board Removing ISD NVMEM Board - Use your fingers to spread retaining clips away from the board's edges, tilt the board to the front of the console and lift it out. Board retaining clips (one on each end) SW2 SW1 1 Turn ac power to console OFF. Push SW1 down to turn battery backup OFF. isd-evr\nvmemin.eps Removing ISD NVMEM Board Figure 20. Installing/Removing an ISD NVMEM Board 33

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