2100 Multiplex. Troubleshooting

Transcription

1 2100 Multiplex Troubleshooting Manual

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3 TABLE OF CONTENTS GENERAL Introduction Outlines Flowcharts OtherTroubleshooting Aids OUTLINES FrontPanelOutline... 4 ConsoleOutline... 5 CPUOutline Transponderoutline Transponder Test Points... 9 CRTOutline...~...l 0 PrinterOutline(OkidatallOPrinter)...l 1 FLOWCHARTS Symbol Definitions BasicFlowchart CPUFlowchart TransponderFlowchart CRTFlowchart PrinterFlowchart...2 3

4 I CAUTION ELECTRICAL HAZARD Disconnect electrical power when making any internal adjustments or repairs. Installation and servicing should be performed by qualified Simplex Representatives.

5 GENERAL Introduction This publication is designed as a troubleshooting aid in locating malfunctions in 2100 Multipiex systems. Using the information in this publication, a troubleshooter tems will be able to isolate most faults to a board level. with a good background in 2100 Multjplex sys- The publication is divided into two major sections: 0 Outlines 0 Flowcharts Outlines The outlines provide details on tests and checks that the flowcharts may ask you to perform. Before you service a 2100 system, we recommend that you read through these outlines to gain a better understanding of troubleshooting procedures. Flowcharts There are five separate flowcharts as shown below: FLOWCHART c CPU TRANSPONDER CRT PRINTER FLOWCHART FLOWCHART FLOWCHART FLOWCHART Your troubleshooting procedure should always begin at the Basic Flowchart, which is a test chart. If you can follow the flow to the end of thischart without being directed to another flowchart, your system is working properly. If there is a malfunction in the system, this chart will direct you to the flowchart necessary to locate the trouble. When using the flowcharts, always follow the flow exactly as directed without skipping any steps. The step you skip could be the one most necessary for locating the trouble. It s equally important that you be sure to read all information referred to in the reference blocks before performing an action. It wasn t possible to list in an action block all steps necessary to perform an action. If references to outlines and other materials aren t heeded, it may prevent you from locating the problem. Note: The flowcharts utilize universal symbols. However, if you are unfamiliar with their meaning, refer to the page of symbol definitions immediately preceding the flowcharts Ed 8 82

6 Other Troubleshooting Aids Publications: l Operating Instructions CRT & Keyboard Service Instructions Installation Instructions Jumper Placement and Switch Settings Printer Service Instructions Special Test Equipment: 0 Diagnostic Program l Line Tester OUTLINES Front Panel Outline 1. Both halves of the POWER indicator (green) are on at all times to indicate the presence of DC and interruptable AC power. 2. The SERVICE indicator (white) is on only when the CPU is not functioning. 3. The TROUBLE indicator (yellow) is on when an uncorrected malfunction exists. Key in the TRO command to obtain a listing of all supervisory fault (trouble) messages. See the Transponder Outline for procedures to insert a trouble (SUPR FAULT) when one is desired. 4. The SECURITY indicator (yellow) is on when a priority 2 alarm is set (tripped). Key in the ALA command to obtain a listing of all set (tripped) alarms. The transponder specification sheets will list the priority level for each alarm. When a priority 2 alarm is desired, see the Transponder Outline for the procedure to initiate the alarm. CAUTION: Building personnel and proper authorities (i.e., Police/Fire Department) must be notified prior to initiating an alarm. 5. The ALARM indicator (red) is on when a priority 1 alarm is set. Key in the ALA command to obtain a listing of all set alarms. The transponder specification sheets will list the priority level for each alarm. Refer to the Transponder Outline for the procedure to initiate an alarm. 6. The tone device sounds when any of the first three indicators (ALARM, SECURITY or TROUBLE) is blinking or if the SERVICE indicator is on. The first three indicators will blink from the time a condition is changed until it is acknowledged. All alarms and troubles must be acknowledged to silence the tone device. The operation of the tone device can be checked by initiating an alarm or a trouble. 7. The PAPER ADVance push button is pressed to make the printer feed paper. (If system is equipped with acentronics Printer, the front panel will not have this switch.) 8. The ACKnowledge push button is pressed to indicate that a changed condition is being recognized. Pressing the ACK push button when one (or more) of the first three indicators is blinking should produce an acknowledge message. This message is preceded by ACK and gives the status of the alarm or trouble message that was acknowledged. Each change in alarm or trouble status must be acknowledged individually. Ed

7 Console Outline 1. Measure AC voltage at input of printer or fan plug. (115 f 7 VAC) 2. Measure DC voltage at plug (Pl) on motherboard. Pin 1 = (+ 0.3) VDC; Pin 2 = 12 (2 0.3) VDC; Pin 3 = GND; Pin 4 = -12 (-c 0.3) VDC. The +5VDC used in the CPU can be checked by reading across capacitor C2 on the lower right front of the motherboard. Caution: A number of false messages are generated when power is applied to the console. Wait five minutes for these to reset prior to continuing with the troubleshooting. 3. Disconnect power when replacing PC boards by: a. removing one of the battery connectors (front of pedestal). b. opening both AC circuit breakers inside back door. 4. Lights on the front panel are plugged in from the top. 5. Access to the front panel board is gained by removing the access plate on the bottom of the shelf. 6. Keyboard switches are replaceable. Two pins from the switch are soldered into the PC board. Access to the PC board is obtained by removing the access panel (four screws) beneath the support for the keyboard. Remove the friction-held key caps by pulling them free. Unsolder the two pins from the bottom of the PC board. Use a solder sucker to remove molten solder. Remove the switch from the keyboard. Place a new switch in position. While applying pressure on the switch from above, solder the two pins to the PC board from below. To replace the key cap, position it on the switch shaft and push down until the cap is seated. 7. Measure output signals at the terminals on the l/o boards. 8. Batteries are removed from the front. 9. The printer is removed from the back of the cabinet. 10. The power supply is removed from the back. It is most easily removed when the printer is removed first. 11. The CRT, when removed, is removed from the back of the cabinet. 12. The CRT (Logic) PC board is removed from the back of the cabinet. The back of the unit and the connectors are the only objects retaining the board. 13. The 2100 System Specification Sheet will give you such necessary troubleshooting information as: a. Number of channels used. b. Number of transponders and encoders per channel. c. Type of transmission boards used.. d. Whether channel is 2-or 4-wire Ed 8 82

8 CPU Outline 1. The Central Processing Unit (CPU) is located in the pedestal of the central console. It consists of the console s motherboard and all of the PC boards housed in the motherboard rack. Access is obtained by pulling off the two snap covers of the pedestal, exposing the cover of the CPU card file. Remove this cover (six screws) to gain access to the PC boards. 2. Disconnect power when replacing PC boards by performing the two following steps: a. Disconnect battery by removing one of the battery connectors (front of pedestal). b. Open both AC circuit breakers inside back door. Carefully remove and replace PC boards so that motherboard connector pins will not be damaged. 3. To check DC voltages for the CPU, measure tham at plug Pl on the motherboard. Access to Pl can be gained from the back of the console. (Pin 1 = +8.5 [z 0.31 VDC; Pin 2 = +12 [a 0.31 VDC; Pin 3 = GND; Pin4= -12 [k 0.31 VDC). The +5VDC from VRl on the motherboard should also be checked. The +8.5 VDC input to VRI can be checked by putting your meter across capacitor Cl on the motherboard. The +5VDC can be checked by putting your meter across capacitor C2 on the motherboard. Cl, C2, and VRl are located on the lower right front of the motherboard. 4. If illumination of the service light is caused by a hang-up in a software routine, it is possible that it may be reset using the reset switch on the Front Panel PC board. Placing this switch in the down position will reset the microprocessor and should clear the service light if no serious problem exists. After the system is reset, return the switch to the up position. (This is a three-position switch: down for reset, middle for off, up for normal operation.) 5. When checking the motherboard, remove all of the PC boards from the card file. These boards are subject to static shock damage and must be handled carefully. Place them where they will not be damaged. Visually inspect each board as you remove it. Note: Make sure all proms on the label and executive prom boards are pressed firmly in their sockets. If it is obvious that a board has damaged components, replace that board. Be sure that the board s markings are clear enough to read and that their location can be identified. (Remember, PROM boards look alike but contain different PROM chips and therefore must be installed in their proper locations.) Check the motherboard by performing a close physical inspection of its components. A flashlight is helpful on this type of inspection. a. Check connectors Jl through J20 for rolled or bent pins. b. Check for good solder connections throughout the motherboard. c. Check cables to and from the.motherboard to ensure that the connectors are good and the cables are aligned properly. 6. If the CPU has stopped processing information (service light is on) and one of the PC boards is suspected, use the CPU troubleshooting flow chart to determine which board is defective. Hint: The CPU will normally operate without a service light when the Printer l/o, Communication, and Transmission boards are removed. With these boards removed, we can determine whether the problem is with one or more of these boards or with one or more of the remaining boards. 7. Make sure only defective boards are sent for repair and return. By following the CPU flowchart, you can systematically determine which board (or boards) are bad. Send a description of the board s problem along with the returned board. Ed

9 8. Executive Prom boards and customer label Prom boards are identical; only the Prom chips are unique. Prom boards can be replaced if the Prom chips are carefully removed and placed in the new Prom board. Remember that Prom boards must go back in the same position that they came from. If the customer label or executive Prom chips are bad, new chips will have to be programmed. Each Prom chip is labeled with its IC socket location as well as the motherboard slot location for the Prom board on which it is placed. 9. Transmission over the system s communication lines (both primary and secondary) can be observed with a Triplett 310 meter. Set your meter on the 12VDC scale. On the console s l/o panel, locate the terminal block for the channel you wish to check. If you want to check for communication on the primary lines, place the black meter lead on the A Terminal and the red meter lead on the B Terminal. Note the meter s deflection. No deflection indicates that the query word is not leaving the Control Console and that the problem is most likely with the channel s communication and/or transmission boards. One or more distinct deflections every few seconds indicates that the CPU is transmitting to the encoders but not receiving a reply. This means that either there is a problem with the communication lines or the encoders on that channel are not replying. Rapid Fluctuation of the meter needle usually indicates normal communication. This same procedure can be used with the A and B Terminals for the secondary communication lines. Note: On some systems, you may have to reverse your meter leads when checking transmission ov-+ _ the communication lines (black lead on B Terminal and red lead on A Terminal). Also, when checking for communication on a 4-wire channel, remove the secondary lines from the l/o panel when checking the primary lines and vice versa. 10. The following chart will,show proper PC board locations. LOCATION OF CPU BOARDS *Note: 512 Comb. Board may be used for channels 1-6 but must be used for channels 7 & Ed 8 82

10 Transponder Outline 1. Jumper verification is necessary if you are having problems with a new installation or if you suspect that jumpers may have been changed. See the Transponder Specification Sheet and Jumper Placement and Switch Settings (Pub. No ). 2. Monitor zone wiring. a. A normally open monitor zone requires a47k-ohm EOL resistor. b. A normally closed monitor zone does not require an EOL resistor, but it does require a 47K-ohm resistor across each normally closed contact. (Unused zones should be jumpered out at the panel.) 3. When tripping (activating) an alarm for test: a. Determine priority level from specification sheet for indications. b. Determine control-by-events from specification sheet and ensure that these may be activated. c. Notify proper personnel. d. Activate normally open alarm zones by shorting between positive (+) and negative (-) zone points. e. Activate normally closed alarm zones by first connecting a 47Kohm resistor to the zone points and then removing one of the zone wires. (Remove resistor when alarm zone is restored to normal.) 4. A trouble may be simulated as follows: a. Disconnect the battery connector while AC input is intact. This results in a Power Supply (P.S.) fault message from every encoder in the transponder. b. Connect one of the positive (+) zone points to ground. This results in a ground (GND) fault message from every encoder in the transponder. c. Disconnect one of the zone leads on a normally open zone (NO). This results in an initiating device circuit (INIT DEV CKT) fault message from the affected encoder. d. Remove power to a transponder by disconnecting the battery and removing one AC fuse. This results in a nonreport fault message (CHL 0 ENCODER 00) from every encoder in the transponder. Caution: to reset. When power is restored, false fault messages are generated. Wait five minutes for these 5. A noncritical control point may be operated with the manual (MAN) command. Check specification sheets to determine which point may be operated without danger of damage. 6. The easiest way to check a suspect PC board for proper operation is to replace it with a board that you know is good. If the problem or fault clears, you know that the original board is bad. Make sure a board is bad before sending it in for repair and return. Send a description of the board s problem along with the returned board. Ed

11 7. When all the encoders in a transponder are reporting ENC faults for both the primary and secondary communication pairs, each pair can be checked for transmission of the query word from the CPU by using atriplett 310 meter. This can be done by setting the meter on the 12VDC scale and placing the black meter lead on the A line and the red meter lead on the B line. No deflection on the meter indicates that the query word from the CPU is not being received. One or more distinct deflections every few seconds indicates that the word is being received. Check one pair and then the other. Note: If the meter deflects the wrong way, simply reverse the meter leads. If all the encoders are reporting ENC faults for only one of the two communication pairs (either primary or secondary), you can assume that the encoders are operating properly. If this is the case, the problem is probably in the communication pair that was reported with the ENC faults. Remove that communication pair from the transponder terminals and check for the query word from the CPU. 8. A Simplex Line Tester (CPU Simulator) can be used to test transponder operation. A Diagnostic Exercisor is also available to help diagnose problems within a transponder. Transponder Test Points 1. A reduced AC input voltage of 25 (e3) VAC can be measured at the motherboard s terminal block between the terminals labeled AC. 2. A battery charging voltage of 27.5 (20.1) VDC can be measured at the motherboard s terminal block between the terminals labeled Battery + and Battery (k 0.3) VDC can be measured at the address jumper point (choose one that does not contain a jumper) or on azone interface board between the +12 and GND terminals. 4. Approximately 27.5 VDC should be measured between Battery Sense + and Battery - on the motherboard terminal block. Loss of power to the Battery Sense terminal will result in a Power Supply (P.S.) fault message. 5. Batteries must be disconnected to be checked. The best place for this is the harness connector. You should measure 24VDC (+3.0 or -1.O). 6. When replacing PC boards, power must be removed. a. Disconnect the batteries at the connector on the harness. b. Remove one of the AC fuses. 7. Test a transponder alarm point by tripping one that does not have excessive control-by-events. See Transponder Specification Sheet to determine the priority of the alarm. 8. Test control points by using the (MAN) command Ed 8 82

12 CRT Outline 1. Power on/off switch, power fuse, and power receptacle are located on the back of the CRT power supply assembly (towards the front of the console). 2. The brightness control knob is located in the rear of the CRT assembly. To adjust brightness, turn the knob clockwise until the raster appears and then turn counterclockwise until the raster just disappears. 3. Power supply voltages may be checked on the back of plug Pl (located at upper back of power supply). See page 25 of CRT & Keyboard Service Manual (Pub. No ) for further details. Pl Pin # Voltage 1 - Ground 2 - Not used volts volts 5 - Not used volts 4. Monitor adjustments (i.e. vertical hold, linearity, etc.) can be made on the monitor main chassis PC board which is located on the CRT monitor assembly. See page 25 of CRT & Keyboard Service Manual (Pub. No ) for adjustments. 5. If the keyboard lockout switch is in an unlocked position but commands still cannot be entered by the keyboard, you can use the following procedures to verify whether or not the keyboard switch is good. a. Remove access plate under keyboard. b. Locate 2 pluggable wires under keyboard (2 white wires with orange stripes connected to 2 white wires with brown stripes). c. Unplug white with orange wires and plug them together. d. Switch is now bypassed and keyboard should operate unless there are other problems. e. In an unlocked position, a short should exist between the 2 white with brown wires connected to the switch. 6. The CRT Logic PC board is located in a slide-in track underneath the CRT assembly. To remove it, turn off power, remove both cables connected to it and slide it out the backof the unit. 7. The CRT terminal can be locally tested by using the following procedure: a. Remove CRT ribbon cable from J21 (22,or 23) on back of CPU motherboard. b. Jumper pin 5 (TSO) to pin 7 (RSI) on the ribbon cable plug. c. CRT terminal is no longer connected to CPU and all keys can be tested locally. This test should tell you whether the problem is in the CRT terminal or in the Printer l/o board (provided the CRT Logic Board switch settings are proper). If the CRT works properly during this test but does not function when the ribbon cable is connected to the motherboard, it is an indication that serial data is not being properly transmitted from the CPU. If this is the case, the problem is probably with the Printer l/o Board in the CPU. If the CRT does not function properly during this test, it is an indication that the problem is in the CRTTerminal. Ed

13 Printer Outline (Okidata 110 Printer) 1. The power on/off switch and the printer s circuit breaker are located in the rear of the printer. 2. Removal of the printer from the Control Console is necessary to perform the self-test operation and make voltage checks. Use the following procedure to remove the printer: 0 Turn printer power switch off and disconnect AC power cord. 0 Remove RS232 connector on left side of printer. 0 Remove screws and nuts which hold printer bracket to console. 0 Pull out printer far enough to disconnect plug for paper advance control wires (connected to Logic [OEM] board on printer). 0 Carefully remove printer from console. 0 To apply power to printer: a. Connect printer power cord. b. Turn on power switch. c. Momentarily short out top two pins on Logic (OEM) board where plug was removed from paper advance control. This will stop paper from feeding continuously. 3. Power supply voltage levels may be checked at the Logic (OEM) board jack J2. Voltage Level Plug and Pin t AC Neutral 115 VAC +5 VDC -12 VDC Logic Ground (Common) +30 VDC +30 VDC Solenoid Ground (Common) Solenoid Ground (Common) J2-1 J2-2 J2-4 J2-5 J2-6 J 2-7 J2-8 J2-9 J is located on the bottom right side of the Logic (OEM) board. Gain access to J2 by removing the two upper screws holding the RS232 board and letting the board pivot away from the Logic (OEM) board. *Note: The RS232 board is in front of the printer, and the Logic (OEM) board is sandwiched between the RS232 board and the printer Ed 8 82

14 4. There are two potentiometers located on the Logic (OEM) board (R2 + Rll). Potentiometer Rll (optic sensor adjustment) often has to be adjusted when the Logic (OEM) board is replaced. a. R2 (labeled R4 on some boards) adjusts the length of the print pulse. If this adjustment is off, the result could be light or no print or activation of the two-second jam circuit which causes the drive motor to shut off. This adjustment should be made with an oscilliscope by following the procedure in Section of the Printer Service Instructions (Pub. No ). If a scope is not available, this adjustment can be made by following this procedure. 1. Sequentially set switches 3,7, and 8 of switch-package Q on to drive the head printing the character H. 2. If the head stops during adjustment, reset the two-second jam circuit by turning switch 8 off and then on. 3. Adjust potentiometer R2 so that the print is neither too light nor too heavy. (Counterclockwise lengthens print pulse and clockwise shortens print pulse.) Do not run continuously for more than five minutes without pausing for an equal length of time. 4. Sequentially turn off switches 8,7, and 3. b. Potentiometer Rll adjusts the optical sensor on the printhead. If this adjustment is off, you could be missing vertical dot columns or have no print. It could also cause activation of the two-second jam circuit which causes the drive motor to shut off. This adjustment should also be made with a scope in accordance with the procedure in Section of the Printer Service Instructions (Pub. No ). If a scope is not available, this adjustment can be made by following this procedure: 1. Sequentially set switches 3,7 and 8 of switch-package %I on to drive the head printing the character H. 2. Adjust potentiometer Rll so that there are no missing dots in the pattern. Do not run continuously for more than five minutes without pausing for an equal length of time. Otherwise, the result could be solenoid overheating and failure. 3. If the printhead stops during adjustment, reset the two-second jam circuit by turning switch % off and then on. 4. Rotate Rll clockwise until misprinting occurs (note position of Rll) and then counterclockwise until misprinting occurs (again note the position of Rll). Set the potentiometer in the middle of the two positions noted above. 5. Sequentially turn off switches 8,7 and With the printer in self-test, there should be 120VAC to the print motor between motor leads J3-8 (yellow) and J3-10 (black). If pots R2 and Rll are not adjusted properly, the two-second jam circuit could cut power to the drive motor. 6. The 30 (*0.3) VDC used by the printhead can be checked between J2-8 (+30VDC) and J2-10 (common) on the Logic (OEM) board. Refer to Section of the Printer Service Instructions (Pub. No ). 7. Missing vertical dot columns can be caused by a dirty timing rack. If dirt particles are in the rack, remove with a soft brush or forced air. Ed

15 SYMBOL DEFINITIONS This symbol is used to request a certain act, test or performance. Perform the action before continuing. This symbol will contain a simple question - usually based on the action that preceded it. Two points will be labeled - one point yes, the other no. Exit at the point which provides the correct answer to the question. This symbol indicates that the-steps are continued on another page. The page number and some connecting information will be written within the symbol. A similar symbol with identical information will be on the page indicated. w 0 0 The reference symbol is used when additional information is available, and it is always connected to an action symbol. Refer to the referenced material prior to performing the action. This symbol indicates that the steps are continued on another part of the same page. The number within the circle will match the number in a circle at the point where the flow continues. This symbol indicates that a very serious malfunction exists and additional assistance is required. The information within the symbol will recommend a source of aid Ed 8 82

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17 REMOVE ALL POWER BEFORE REMOVING OR REF DC POWER INPUTS CHECK IIARNESS- P.S. TO MOTHERBOARD %2 COMMAND TURN PRINTER KEY IN COkiiND Ed 8 82

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19 LACING BOARDS CHECK FRONT PANELRIBBON INTERPRET F.$LT TPR YES 8 TPR 3

20 BASIC FLOWCHART 15

21 REMOVE ALL POWER BEFORE REMOVING OR REPk Ed 8 82

22

23 ACING BOARDS

24 CPU FLOWCHART

25 REMOVE ALL POWER BEFORE REMOVING OR REPI Ed 8 82

26

27 If-7 A

28 TRANSPONDER FLOWCHART 19

29 -, REMOVE ALL POWER BEFORE REMOVING OR REPL \ Ed 8 82

30

31 HZING BOARDS / \ I, 1

32 CRT FLOWCHART

33 REMOVE ALL POWER BEFORE REMOVING OR RE 23 Ed 8 82

34

35 PLACING BOARDS

36 PRINTER FLOWCHART (OKIDATA 110 PRINTER) 23

37

38 CC; 1982 Simplex Time Recorder Co., Gardner, Mass., U.S.A. Ed