Owner`s Hardware Service Manual
Contents
1. Connect the probe you want to check in place of the outside probe Go to the computer and look at the outside temperature to see if it is working It could take up to 30 seconds to for the computer to receive a new outside temperature Temperature System Some Temperature Values may read 265 266 267 268 or 269 These are error codes letting you know there is a problem with reading the temperature value from the probe Regardless of the actual code value the troubleshooting is the same DAQT Temperature System Green Data Acquisition System The Digital Bulbs are connected to a DAQT system RECOGNIZING THE PROBLEM A single bulb shows an error code consistently Bad broken bulb or broken wire connection to the bulb The corresponding channel on the Bulb Connection board is open A single bulb shows an error code intermittently Problem with an intermittent open connection to that bulb Bulb failure at certain temperatures All the bulb show an error code The DAQT board has lost power The Isolation board has lost power Communication between the DAQT board and Isolation board is lost Frank Controls Ltd 14 Contact 1 250 765 2900 TROUBLESHOOTING THE PROBLEM Measure the Voltage In operation the DC voltage measured at the Isolation board for each DAQT board is shown below This will help to indicate if there is a short between the 5VDC or Data line to Common See table 2 in the Technical Theorv Section of this manual fo2. meter Measure the resistance between pin of the 40 pin bus connector and the 5v Data and Common on the terminal blocks Resistance between Red and pin 1 should be about 3000 ohms with the exception D01 will be about 0 ohms Resistance between White and pin 1 should be about 3000 ohms Resistance between Black and pin 1 should be about 10000 ohms Ground Loops Noise This cause can be difficult to determine without the use of an Oscilloscope A simple test is to disconnect the Isolation board from the Terminal blocks Use an Ohmmeter to Frank Controls Ltd 15 Contact 1 250 765 2900 check for anv connection between Chassis ground and the three leads There should be no connection between Common Data or 45V to ground Frank Controls Ltd Contact l 250 765 2900 16 Frank Controls Ltd Contact l 250 765 2900 17
3. OM chips witch hold the main program that runs the kiln The card comes pre loaded with a program and can only be changed if sent into Frank Controls Ltd It is the brains behind the operation of the kiln SIO Card This card allows the Frank Control Computer System to communicate with the Desktop PC and PLC The top channel Channel 1 is the port for communicating to the PC The bottom channel Channel 2 is the port for communicating to the PLC CPU Card This card is the Z80 CPU It runs the program in the EPROM chips Battery Back Up Card This card holds the Random Access Memory and the Real Time Clock It has a battery so when the Frank Control Computer System is powered down the data in the RAM is not lost There is also an on board charger for the 3v NICAD battery Power Fail Card This card monitors Power Failure If the Frank Control Computer System has power the LED will glow red If there is a loss of power or the card is not working the LED will go out Only the top of the two connectors is used for normal operation Frank Controls Ltd 10 Contact 1 250 765 2900 Digital Temperature Card 8085 microprocessor controlled onboard 8KB EPROM amp 2K RAM This card holds the program for communicating to the Data Acquisition boards It is connected to the Isolation board through a 14 pin bus cable Isolation Board This board has six optically isolated Digital I Os and one non isolated channel The first five Digital I Os conne
4. Owner s Hardware Service Manual Frank Control Computer Svstem Revision 0105 ABOUT THIS MANUAL This section describes the contents of this manual and how to use this manual effectivelv It was designed for a wide range of different tvpes of users Manual Overview This manual is divided into the following sections Section 1 0 Introduction product features list of all components Section 2 0 Component Description describes the use of each component along with a picture Section 3 0 Technical Theorv explains the general electronic theorv and appropriate connections for each component Section 4 0 Troubleshooting How To Use This Manual Your Frank Control Computer System Operating manual is both a reference book and a tutorial of how to solve some common problems Frank Controls Ltd 2 Contact 1 250 765 2900 TABLE OF CONTENTS 1 0 INTRODUCTION 4 1 1 Features 4 1 2 Main Components 4 2 0 COMPONENT DESCRIPTION 6 3 0 TECHNICAL THEORY 10 3 1 FC Card Cage 10 3 2 Data Acquisition Temperature System 11 4 0 TROUBLESHOOTING 14 4 1 General Information 14 4 2 Temperature System 14 Frank Controls Ltd 3 Contact 1 250 765 2900 INTRODUCTION Thank you for purchasing a Frank Control Computer System You made an excellent choice for performance reliability and value Your Frank Control Computer System uses a high performance Z80 CPU and 8085 CPU An 8051 micro controller is used to read in
5. all the digital temperatures freeing time for the main processors to do more important things The Frank Control Computer System talks to a PC to allow for a user friendly control interface It also talks to an Allen Bradley PLC that handles all the I O s Here are some of the professional features of your new Frank Control Computer System Features Up to 48 Isolated Digital Temperatures per Kiln Easy Temperature Probe Replacement Control up to 5 Kilns per System Triple Processor Computer System Battery Back Up and Real Time Clock Power Fail Monitor and Watchdog Timer RS232 communication to Allen Bradley PLC 80 inputs 32 outputs and 32 analog outputs RS232 communication to PC 0 0 0 Note Each cabinet is customize depending on the kilns design Main Components Note Components included depend on the Kilns needs All components and connections are defined in the Operating instructions of this manual 110 Volt 220 Volt Power Supply Board Programmable Data Acquisition Temperature Board DAQT Bulb Connection Board Eprom Card CPU Card Ooocdo Frank Controls Ltd 4 Contact 1 250 765 2900 Power Fail Card Batterv Back Up Card Digital Temperature Card DIGT Digital to Analog Board Isolation Board ATX Power Supplv Hammond 166F16 Curtis Line Filter Ovovovooooocoo Frank Controls Ltd Contact 1 250 765 2900 COMPONENT DESCRIPTION This section has been designed to assist the user in un
6. ct to the DAQT boards one channel for each kiln up to five kilns The sixth channel is used for resetting the DAQT boards The non isolated channel connects to the outside Digital Bulb The 14 pin bus cable connects to the DIGT card It is powered by 12 VDC from the Hammond 166F6 transformer Data Acquisition Temperature System This sub section explains the Technical Operation of all the boards in the Data Acquisition Temperature System Figure 15 Data Acquisition System Mounted on Din rail Power Supply Board 110 Volts is connected to the terminal labeled 110V AC L1 is HOT and L2 is NEUTRAL If 220 Volt supply is required contact Frank Controls Ltd for further information on jumpering the Power Supply board for 220 Volt operation The three pin connector on the cable shown in Figure is connected to J6 on the Data Acquisition Board Data Acquisition Temperature Board DAQT This board can operate in four different modes Board modes must be programmed at Frank Controls Ltd Mode I Normal Operation Mode 2 Master Operation Mode 3 Slave Operation Mode 4 PLC Operation Normal Operation Mode 1 gt J2 is connected to the Frank Control Isolation board gt J6 is the socket for the power supply board connector Frank Controls Ltd 11 Contact 1 250 765 2900 gt J7 has no connection gt JI Digital Bulbs Connection socket is used to connect to the Bulb Connection board Master Operation Mode 2 gt J2 is connec
7. derstanding how the Frank Control Computer System functions It shows a picture of each component with a description about its use 110 Volt 220 Volt Power Supply Board supplies 12V AC to the regulator on the Data Acquisition board Note See Installation Instructions for 220 Volt operation Figure 1 Power Supply Board WARNING Power Supply is shipped as a default of 110 Volt operation Programmable DAQT Board holds the firmware that determines the functions of the Data Acquisition System Figure 2 Data Acquisition Temperature Board Bulb Connection Board allows connection of digital devices Figure 3 Digital Connection Board Frank Controls Ltd 6 Contact 1 250 765 2900 40 Pin Bus Cable connects the Bulb Connection board to the DAQT board Figure 4 40 Pin Bus Cable 6 Pin Serial Communication Connector allows connection to the serial communication on the DAQT Board Figure 5 Serial Communication Connector Eprom Card holds the main program that runs the kilns Figure 6 Eprom Card SIO Card converts parallel data from the STD bus to serial data The ports the Frank Control Computer Svstem uses to talk with the PC and PLC Figure 7 SIO Card Frank Controls Ltd 7 Contact l 250 765 2900 CPU Card The Motherboard that controls all the other cards Runs the program in the Eprom Card Figure 8 CPU Card Power Fail Card Monitors the power line Figure 9 Power Fail Card Battery Bac
8. k Up Card Holds the RAM that the Frank Control Computer System uses A real time clock chip allows the computer to keep track of time Contains a battery to hold memory in the RAM on a power failure Figure 10 Battery Back Up Card Frank Controls Ltd Contact 1 250 765 2900 DIGT Card Holds the program that allows communication through the Isolation board to the DAQT boards Figure 11 Digital Temperature Card DAC Board Converts serial data from the DAQT board to eight 4 20mA analog output channels Figure 12 Digital to Analog Board Isolation Board Optically isolates the Digital Temperature card from the Data Acquisition Temperature Svstem Figure 13 Isolation Board ATX Power Supplv Supplies power to the Card Cage See Appendix for details on connections Hammond 166F16 Supplies 12v power to the Isolation board and AC to J4 on the PFA card Curtis Line Filter Filters the AC line before the ATX Power Supplv and the Hammond 166F 16 transformer 10 Pin Bus Cable Connects the DIGT card to the Isolation board Frank Controls Ltd 9 Contact 1 250 765 2900 TECHNICAL THEORY This section has been broken down into two sub sections explaining in detail each component in the Frank Control Computer System FC Card Cage This sub section explains the Technical Operation of all the STD cards in the Frank Control Computer System Figure 14 Most common card configuration Eprom Card This card has six 64k EPR
9. n has the Wet Bulbs will always be the last two bulbs Frank Controls Ltd Contact 1 250 765 2900 Table 3 Digital Bulb Connections Terminal Label Device D1 Dry Bulb 1 D2 Dry Bulb 2 D3 Dry Bulb 3 D4 Dry Bulb 4 D5 Dry Bulb 5 D6 Dry Bulb 6 D7 Dry Bulb 7 D8 Dry Bulb 8 D9 Dry Bulb 9 D10 Dry Bulb 10 D11 Dry Bulb 11 D12 Dry Bulb 12 D13 Wet Bulb 1 D14 Wet Bulb 2 D15 Spare D16 Spare Digital to Analog Board DAC The DAC boards have eight 4 20mA channels They communicate only with a DAQT programmed in either Slave or PLC operation The six pin connector is connected to the six pin connector on the DAQT See table 3 They are powered by 24 VDC Ifthe 24 OK and 5 OK lights are on they have power Each of the eight analog output channels has a led when on the channel is not connected or has a problem Digital Bulb The Digital Bulb has three connections 5VDC Power White Wire Frank Controls Ltd Contact 1 250 765 2900 Data Common Red Wire Black Wire 13 TROUBLESHOOTING This section was included to help the maintenance troubleshoot common problems that could occur while operating the Frank Control Computer System It should be used to recognize a problem and troubleshoot to fix the problem General Information Test a probe to see if it is good or bad Disconnect the outside temperature probe from the isolation board terminal block T4
10. r terminal block descriptions If some bulbs are working still then test these voltages for each bulb Between Common amp 5VDC constant 5 0VDC Between Common amp Data pulsating 2 8 5 0VDC If there is a short in the communication do the following steps 1 Disconnect the wires to the Isolation board amp measure the voltages at the Isolation board to determine if the problem is at the Isolation board 2 Disconnect the wires to the DAQT board amp measure the voltages at the DAQT board to determine if the problem is at the DAQT board If there is a short in the bulb itself 1 Disconnect the Red and White wires on the shorted bulb Connect that bulb in place of a bulb that is working and measuring the voltages again to see if the bulb is still shorted This will determine if the bulb is shorted or the channel on Bulb Connection board is shorted Keep in mind it could be the wire that is shorted 2 To test the bulb one at a time connect it in place of the outside temperature and see if it works If there is no short but the bulb doesn t work 1 Disconnect the wires from the Bulb Connection board of the bulb that doesn t work 2 Connect a bulb that you know works into the channel of the Bulb Connection board that doesn t seem to work If it works then the bulb that was taken out must be bad open If it doesn t work then the channel on the Bulb Connection board must be open Testing the Bulb Connection boards with an ohm
11. ted to the Frank Control Isolation board gt J6 is the socket for the power supply board connector gt J7is connected to J7 on the Data Acquisition board programmed as a Slave gt JI Digital Bulbs Connection socket is used to connect to the Bulb Connection board Slave Operation Mode 3 gt J2 is connected to the Digital to Analog board s if available gt J6 is the socket for the power supply board connector gt J7 is connected to J7 on the Data Acquisition board programmed as a Master gt JI Digital Bulbs Connection socket is used to connect to the Bulb Connection board PLC Operation Mode 4 gt J2 is connected to the Digital to Analog board s if available gt J6 is the socket for the power supply board connector gt J7 is connected to the RS232 comport on the PLC gt JI Digital Bulbs Connection socket is used to connect to the Bulb Connection board Table 2 Isolation board and DAQT board connections Isolation Board Terminals DAQT Terminals EG XGND D1 EXT Data 5 EXT 5 Table 3 Digital to Analog board and DAQT board connections DAC 1 Terminals DAC 2 Terminals Data Acquisition Terminals GND GND XGND SCL SCL S CLOCK SDT SDT S DATA SYNC NC EXT 5 NC SYNC EXT DATA Bulb Connection Board JI 40 Pin bus socket is used to connect to the Data Acquisition board The most common bulb configuration is shown below No matter how many Dry Bulbs your kil
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