SB-54: Troubleshooting OMNI Select
Contents
1. s fi Technical service bulletin 54 slectronic control systems OMNI Select troubleshooting guide This guide explains how to recognize and respond to alarms in OMNI Select how to fix communication loss perform a loopback test use TookKit and troubleshoot Phason Wireless Adapters All manuals mentioned are available at www phason ca Start at the Communication Center The Communication Center provides an overview of the status of your system eae OMNI Select Communi cation Center electronic control systems a __ z E yD cy O fis ie SD A V MeW oO OMY System Wide Area G2 Barn Flow Group Central NE Zone asdaqw East Zone Status e v o O m 9 ID S O D D Ne eB Fin1 Feed Finisher Lagoon North Zone Nur Control Nur Heat Mat Nur02 Feed Nursery Room 2 Nursery Tank Phason weather Room 14A Room 15A Section G3 Sow Bin Sow Pit Ea toon Minimize BQ Close A This button displays a window that lists system site and software information B This area lists your devices and their status To see a list of messages for a specific device click the device A green W on a device icon means there are no new problems with the device A yellow means there are non critical warnings or messages Atred x means there are alarm conditions and messages that need your immediate attention C This button opens a window that displays messages for all devices 2015 04 01 Page 1 of 16 4 E2. if the information is the same the test passes When a loopback test passes it means both the send TX and receive RX lines are intact Loopback connectors To perform a loopback test you need loopback connectors to connect to the cable or device A loopback connector package PKG LOOPBACK is available from your dealer or Phason and includes connectors for different locations connector types on the communication cable loopback for most situations by inserting wires into the connectors as shown to the right However this type of loopback connector will not work for a serial port or USB to serial port loopback test If a loopback connector is not available you can create a temporary LS LS Perform a loopback check with ToolKit 1 Connect the appropriate loopback connector to the test location 2 In ToolKit click the Serial Port Loopback tab 3 Click Loopback test The Loopback test window will open 4 Click Run Loopback check This performs a loopback test and displays one of the following responses below the button No Loopback detected this means there is a break in the cable a damaged serial port RS485 Converter or USB serial converter or a PWA radio issue Detected Hardwired loopback this means the cable is intact wp Zo the loopback connector Detected Loopback on PWA ES address lt ADDRESS gt this means the cable is intact between the computer and the PWA ECM and from the PWA E
3. device Address This is the unique communication address of the device Type This is the model name of the device Last Response When manually checking for devices this column will display a time if the device communicates Response Pending When manually checking for devices this column will display a time while waiting for a response from the device Version This is the firmware version of the device 2015 04 01 Page 7 of 16 4 E ic 4 Technical service bulletin 54 2 lectronic control sys em Hit Rate The hit rate is an indication of how well a device is communicating over time PWA ES If using a PWA ES to connect to the device this column displays the wireless radio address Communication Engine This indicator must be on to send and recetve data from the devices If the indicator is not on restart the computer If it remains off there might be something wrong with the OMNI Select installation Reinstall OMNI Select using the installation CD Serial Port Connected This shows the serial port OMNI Select is using If the indicator is off the serial port is not connected Go to the Serial Port Loopback tab and set the serial pott TX RX These indicators flash briefly when ToolKit communicates with devices Refresh device list This button reloads the device list from the database Use this button if you have recently added a device in OMNI Select and it is not in the list Inc
4. ic 4 Technical service bulletin 54 electronic control system Review the devices that have alarm conditions Click each device that has a red x and then determine the types of alarms or problems If there are several devices with a red x click View all messages to display them in one list If there is an alarm cleared message the alarm no longer exists Click Acknowledge to clear the messages and reset the alarm indicator For all modules except Select Water and Select Environments if there is 0 an alarm cleared message the alarm still exists Select Water and Select Environments do not have alarm cleared messages For fault alarms alarms caused by an out of range condition check what is causing the alarm for example a jammed sorter power failure high temperature or other condition Fix the problem that is causing the condition and acknowledge the alarm message For communication alarms continue reading the next section If the devices are connected wirelessly also read Troubleshooting Wireless Adapters PWAs on page 13 For all other problems read Troubleshooting Power Blocks on page 12 Create a site map Before you start troubleshooting communications you need to know the sequence of devices on the communication cable If you do not have this information follow the steps below to create a site map 1 Create a Site Structure Report a Login to OMNI Select b In the
5. main window click Reports and then Site c Below Reports select Sz e structure and then click Create report d Inthe report find the Buzddings and devices section Each device has information similar to the following example The important information to note is the device name type and address Buildings and devices Building name North 1 J Power Block name East Zone Device Type PB 1 Address OCBA 2 Enter the information in the site map template at the end of this troubleshooting guide Determine the order of devices by following the cable between devices 2015 04 01 Page 2 of 16 4 E ic 4 Technical service bulletin 54 2 lectronic control sys em Important troubleshooting information When replacing a circuit board use new replacement boards Using a circuit board that has been sitting on a shelf without an anti static bag can cause more problems Because electrical interference from AC power cables can cause communication problems make sure communication cable does not run beside or in the same conduit as AC power cables Because poor grounds or different ground planes between buildings can cause communication problems use a spare wire in the communication cable as a common reference connection at position E between each device For more information read the RS485 installation guide available at www phason ca Troubleshooting communication problems Use ToolKi
6. 855446544 72 7 0 0013266855463452 0 0013266855487653 0 PWA setup Add PWAs to OMNI Select Resethitrates Edit timeout forselected PWA Communication Engine Serial Port Connected Port COM3 RX Find Multi point ECM PWA This button searches and then displays the address of the PWA ECM wireless adapter connected to the system Find Multi point ES PWA s This button searches and then displays the addresses of all PWA ES wireless adapters within range to respond Add PWAs to OMNI Select This button adds all discovered PWA ES addresses to OMNI Select You can also add the addresses manually in the Configuration gt Site gt Wireless Adapters window of OMNI Select PWA setup This button allows you to set up PWAs This is not required for troubleshooting it is required only if there is another OMNI Select system with PWAs within range and it is interfering with communication Refer to the PWA MULII installation guide at http www phason ca pdfs pwa multi_250446 pdf for details 2015 04 01 Page 10 of 16 4 E ic 4 Technical service bulletin 54 electronic control system Performing a loopback test A loopback test verifies the continuity of the communication cable During the test the computer sends information on the communication cable The information bounces back when it gets to the loopback connector The computer then compares the information it received to the information it sent
7. S up to the loopback connector The loopback test does not identify crossed wires You will need to inspect the wiring at the connectors to identify this problem 2015 04 01 Page 11 of 16 4 ie 4 Technical service bulletin 54 electronic control system Perform a cable integrity test with ToolKit 1 Connect the appropriate loopback connector to the test location 2 In ToolKit click the Serial Port Loopback tab 3 Click Loopback test The Loopback test window will open 4 Click Start Test This performs a continuous integrity test on the cable The higher the green bar is on the left the better the integrity of the communication cable Loose and corroded connections will cause poor test results Loopback test x Run Loopback check Detected Hardwired loopback Success Times ms Start Test 76 Stop Test 88 Maximum time 88 Average time 83 Minimum time 76 Do not leave the loopback connector connected after testing It will interfere with normal operations _pereeeeeesenevacsevenenansenenensnsenenens Troubleshooting Power Blocks PROBLEM PB 1 to PB 6 WORKING OK light is not on solid 1 Measure and make sure the incoming voltage 120 VAC or 230 VAC matches the selection switch on the circuit board 2 Switch off the power to the Power Block Remove and then re insert the microboard into the socket When finished restore power to the Power Block 3 Replace the microboard wi
8. a PCH Phason Communication Hub a Make sure the incoming voltage is 12 VDC b Perform a loopback test at the end of the cable that is plugged into the To PC port c Perform a loopback test at each used output channel 5 If devices are still not communicating proceed to Communication alarms for SOME devices in the system below Communication alarms for SOME devices in the system Test the PCH channels If all devices on one PCH channel are not communicating 1 Re strip the wires and test with ToolKit 2 Move the connector to another channel and test with ToolKit If communication works on the new channel the old channel is damaged If you need all four channels replace the PCH board If communication does not work on the new channel proceed to the next section Troubleshooting devices after the PCH and RS485 As you troubleshoot the devices make sure to do the following Make sure the device has power and the incoming voltage is correct 12 VDC or 120 230 VAC depending on device WORKING OK light is not on solid go to Error Reference source not found Error Bookmark not defined nove For PB 1 to PB 6 Power Blocks if the incoming voltage is correct but the Remove termination resistors from any device that is NOT at the end of the communication cable See the device s installation guide for termination resistor location Communication wires can become cracked under the wire insulation near t
9. act Phason Support Disconnect the communication cable at each device Perform loopback tests from end of cable and fix any broken wires Plug in last device to provide termination and test communication with ToolKit eS Se Plug in the devices one at a time and test with ToolKit after each one Leave working devices plugged in as you move to the next device 8 Replace the communication board of any device that causes communication loss when plugged in Replacing communication boards For PB 2 Power Blocks replace the microboard with a K329013 PBx 11 display and 329015 PBx 11 display adapter You must be running the OMNI Select software For PB 1 3 4 5 6 Power Blocks contact your dealer for replacement options For PBx 10 and PBx 11 Power Blocks replace the display For PS 1 Scale Heads replace the display For al other devices replace the circuit board Using ToolKit ToolKit is a communication and troubleshooting tool included with OMNI Select Use ToolKit to confirm devices are communicating and help track down where communication problems are occurring 2015 04 01 Page 6 of 16 4 m ic 4 Technical service bulletin 54 electronic control system How to check for devices 1 Login to OMNI Select Default username is sysadmin and the password is omniadmin 2 Inthe Site tab of the Settings section click Start ToolKit 3 In the Devices tab click Check for All Devices The current tim
10. e will appear in the Response Pending column If adevice is communicating a time will appear in the Last Response column If no time appears the device is not communicating ToolKit details Devices tab Devices will appear in the Devices tab when they are added to OMNI Select 5 ToolKit 5 f Devices mMulti point PWAS PSerial Port Loopback Include Inactive Devices Device Name Address Type LastResponse Response Pending Version HitRate PWA ES a Cistern 43434343 LS 0 0 on EAST Dairy Barn 23232323 AF _ 91 7 EAST RM Hog Sorter COOO0SF1 PS 1 64 5 EAST RM Ventilation 12345678 PBx 11 81 3 0013266855A46544 wecheckForallpevicesw EAST RM Water 22222222 OWM 0 0 Nursery 1 Heat Mats 1234 PB 6 0 0 Nursery 1 water 43555544 OWM 0 0 Check Selected Device Nursery 2 Heat Mats 3231 PB 6 0 0 Nursery 2 water 66657757 OWM 0 0 DUNNEN Power Monitoring 33333333 LEM 0 0 Weather Station 18888888 OWS 25 0 WEST Dairy Barn 66666666 AF 87 5 WEST RM Hog Sorter co000619 PS 1 64 5 Send SettingstoAllh WEST RM Ventilation 12345567 PBx 11 81 3 0013266855446544 WEST RM Water 11111111 OWM 0 0 Auto Search Time Sync Devices Resethitrates Edit timeout forselected PWA Communication Engine TX Serial Port Connected Port COM3 RX Device Name This is the name the user sets in OMNI to describe the
11. he green connector Re strip the wires even if they do not look broken Make sure the color sequence is the same at each device Use ToolKit after each step to test communications 2015 04 01 Page 4 of 16 4 ic 4 Technical service bulletin 54 s ctronic control sys em 1 Re strip the communication wires at the first non communicating device after the RS485 Converter or PCH and at the previous device Remove and then re insert the microboard into the socket This helps ensure a good connection between the microboard and the bottom circuit board When finished switch on the power to the Power Block hore If the device is a PB 1 to PB 6 Power Block switch off the power to the device 2 Unplug the communication cable connector at the failed device and then perform a loopback test on the cable For more information read Performing a loopback test on page 11 Ifthe loopback test fails there is a problem with the cable between the failed and previous devices Fix the problem and retest Ifthe loopback test passes you have continuity to that point on the cable The device may be faulty OR another device is faulty and causing this one to fail 3 Unplug the cable from the device and check communications with ToolKit If communication works to the remaining devices replace the communication board of the faulty device See Replacing communication boards below for what to replace on the different device
12. he loopback connector connected after testing It will interfere with normal operations Set Port Communication Engine Serial Port Connected Port COM3 RX Get Serial Ports This button refreshes the serial port list with all serial ports recognized by the computer Click the button if you add a USB serial port to make the port display in the list Set Port Click this button to set the selected serial port as the active port If you are using an RS485 FD or an RS 485A with a USB serial cable USC each time you plug into a different USB port you are using a different COM serial port and need to change the port in OMNI Select To determine which COM port the RS485 FD is connected unplug the RS485 FD click Get Serial Ports and the COM port that disappears is the one the RS485 FD is using Plug the RS485 FD back in and set the port that appears Loopback test This button opens the loopback test window Read Performing a loopback test on page 11 for details 2015 04 01 Page 9 of 16 4 EC 4 Technical service bulletin 54 EC lectronic control system Multi point PWAs tab This section is for systems that use the PWA multipoint wireless adapters 5 ToolKit 5 Devices i Serial Port Loopback Find Multi pointECM PWA Find Multi point ES PWA s PWA ECM address Discovered PWA ES address es OMNI Select PWA ES adapters Hitrate Timeout 0013266855A32232 0 0013266855A33442 0 0013266
13. lude Inactive Devices Select this box to include inactive devices on the list Check For All Devices This button starts a search for all devices in the list Check Selected Device This button starts a search for the currently selected device Clear Responses This button clears the times from the Last Response column Send Settings to All This button sends settings to all devices Use this if settings don t match between device and OMNI Select Auto Search This button will start a search for all devices even ones that are not programmed in OMNI Select Use this to find a device that has an unknown address Time Sync Devices This button sends the computer time to the devices OMNI Select does this routinely but if you add a device with a clock such as a ProSort sorter PBx 10 11 ot Autoflex you can send the time manually instead of waiting for OMNI Select Reset hit rates This button resets the hit rate percentages and last reset date for all devices Use this button after fixing communication problems Edit timeout for selected PWA This allows the user to give more time for a PWA wireless radio to handle communications Adjust this only if instructed by Phason 2015 04 01 Page 8 of 16 4 ie 4 Technical service bulletin 54 electronic control system Serial Port Loopback tab 5 ToolKit 0 Devices Multi point PWAs Get Serial Ports Loopback test Do not leave t
14. rt or the signal is not being blocked by obstacles like buildings or trees The typical range through objects is 300 feet 91 meters line of sight range is 1 mile 1 6 kilometers Test for an out of range condition by bringing the remote PWA closer to the coordinator and then testing to see if it joins If it does join find a better location for the PWA Add another PWA ES in between to improve the signal 2 Make sure the other PWA has sufficient power 9 to 14 VDC find the PWA in your chosen location nore You can use the Multi point PWAs section in ToolKit to see if you can consistently PROBLEM The RECEIVE or TRANSMIT lights are not flashing when searching with ToolKit 1 Cut and then re strip the wiring at the PWA and previous device 2 Perform a loopback test at the PWA to test the cable back to the computer Fix any cable problems nore If the PWA does not have a device assigned to it a device search will not make the RX TX lights flash 2015 04 01 Page 14 of 16 Technical service bulletin 54 Position on channel Building Noth 1 Device type OAMI Address 2345678 Name Nath Lai 2015 04 01 Page 15 of 16 Position on channel Building Noth 1 Device type OM Address 2345678 Name Nath Lai Phason Inc 2 Terracon Place Winnipeg Manitoba Canada Phone 204 233 1400 R2J 4G7 Fax 204 233 3252 2015 04 01 Technical service bulletin 54 E mail Web site support phason ca w
15. s If communication fails to one or more remaining devices leave the device unplugged You will come back to this device since other others could be causing this one to fail 4 Repeat troubleshooting steps 1 to 3 on the next failed device until you find the device that is causing the problem 5 Plug in and then test communications one at a time on any devices that were previously left unplugged Replacing communication boards For PB 2 Power Blocks replace the microboard with a K329013 PBx 11 display and K329015 PBx 11 display adapter For PB 1 3 4 5 6 Power Blocks contact your dealer for replacement options For PBx 10 and PBx 11 Power Blocks replace the display For PS 1 Scale Heads replace the display For a other devices replace the circuit board 2015 04 01 Page 5 of 16 4 E ic 4 Technical service bulletin 54 s ctronic control sys em Complete communication overhaul When there are multiple problems with a system it is often best to do a complete communication overhaul Steps for a communication overhaul 1 Check input power at each device 2 Re strip communication wires at each device 3 Confirm that the E connection is wired on all communication connectors This is the 5th wire from the communication cable that provides stability to communications If not installed refer to the RS485 FD installation guide for details For devices that only have a 4 position connector cont
16. ss and hold Unlock for 3 sec until the control beeps and the unlock indicator is lit 2 Press MANUAL OVERRIDE The display shows the output percentage for variable 1 The MANUAL OVERRIDE indicator is lit and the VAR 1 AC indicator flashes 3 Adjust the output of the variable stages or states of the relays To move through the stages press MANUAL OVERRIDE 4 When finished press Lock to return to the main display The control returns to normal operation Troubleshooting Wireless Adapters PWAs PWA indicator light descriptions Radio The light is on when the wireless transmitter radio is on Joined For ES models the light flashes continuously when the radio is connected to a wireless network For ECM models the lights flash continuously at all times Transmit The light flashes when data is sent Receive The light flashes when data is recetved Power The light is on when the PWA has power 2015 04 01 Page 13 of 16 4 ic 4 Technical service bulletin 54 electronic control systerr Signal This light flashes when data is sent or received When operating properly and connected to a wireless network the Power and RadZo lights are on and the Jozved light flashes PROBLEM The RADIO or POWER lights are off 1 Make sure the PWA has sufficient power 9 to 14 VDC 2 Ifthe PWA is still not functioning replace it because it is damaged PROBLEM The JOINED light is off 1 Make sure the PWAs are not too far apa
17. t to get a current status of communication Because multiple communication alarms can occur over time start by using ToolKit to determine the current state of communications Read the Using ToolKit section for details Determine the type of communication problem Communication alarms will be one of two categories Use the section that applies to you Communication alarms for ALL devices in the system e Communication alarms for SOME devices in the system Communication alarms for ALL devices in the system The problem is between the computer and the PCH or RS485 Converter if you are not using a PCH After each of the steps below use ToolKit to test communications 1 On the RS485 Converter make sure the power light is on If the light is not on it could mean the USB or power cable is unplugged It could also mean the software drivers are not installed properly Refer to the RS485 FD installation guide for driver installation 2 Repair any loose or broken wires on the RS485 Converter 3 Perform loopback tests on the following devices to determine which one is causing the problem and then replace the problem device For more information read Performing a loopback test on page 11 a Serial port only used with RS485 lt A b USB to serial converter only used with RS485A c RS485A or RS485 FD converter 2015 04 01 Page 3 of 16 4 E ic 4 Technical service bulletin 54 electronic control system 4 Ifyou are using
18. th a new one 4 Replace the bottom circuit board If the Power Block functions properly retest the original microboard to see if it functions 2015 04 01 Page 12 of 16 4 E ic 4 Technical service bulletin 54 2 lectronic control sys em PROBLEM PB 1 to PB 6 output fan heater and so on is not operating 1 Test the Power Block using the Power Block test card to determine if the relay or variable stage works Insert the test card in the slot below the microboard Each press of the white button will turn on an output and its corresponding light on the display If a load doesn t turn on there is a problem with the output wiring or load 2 Ifthe test passes the hardware is fine Review the settings in the software and make sure they are set to operate the load at the current temperature 3 Use ToolKit to test communication to the Power Block The settings in the software cannot be sent if there are communication problems to the Power Block PROBLEM PBx 10 11 output fan heater and so on is not operating Use manual override to determine if the relay or variable stages work If the test passes the hardware is fine Review the settings in the software and make sure they are set to operate the load at the current temperature Use ToolKit to test communication to the Power Block The settings in the software cannot be sent if there are communication problems to the Power Block To use manual override 1 Pre
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