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6.0 DIAGNOSTICS AND TROUBLESHOOTING

1. indicates an invalid drop number This will only occur if the drop number on the thumbwheel switches is greater than 07 Use the following procedure to clear the error code Step 1 Set the correct drop number on the thumbwheel switch Step 2 Cycle power to the rack Remote I O Network Failures Problem Error code C appears on any Remote I O module s 7 segment display This error code indicates a network failure If the module is a master drop no other drops will be able to function on the network If the module is a slave drop it is not receiving any messages from the master drop This fault code is reset whenever the line becomes active The causes of a Remote I O network failure are cable failure master rack failure or a slave rack failure 6 1 If the Processor in the master rack fails or issues a BOARD RESET command clears all outputs in the rack the entire image in the master s dual port memory will be cleared All Remote I O slave drops will detect that the master has failed Their response to this will be to clear all AutoMax module outputs in remote drops The remote drops will then wait for the master to re establish communication The failure of a slave drop to communicate with the master can result from a bus error or failure of the rack power supply or backplane If a Multibus slave drop fails the Remote I O module in the slave rack will issue a BOARD RESET command This command will clear all outputs in the slav
2. is malfunctioning DANGER THE FOLLOWING STEPS ARE PERFORMED WITH POWER ON EXERCISE EXTREME CAUTION BECAUSE HAZARDOUS VOLTAGE EXISTS FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE Step 1 Using a voltmeter verify that the power source is 120 VAC or 240 VAC whichever is appropriate and that it is functioning correctly Verify that the jumper on the terminal strip is set correctly Step 2 Stop any application programs that may be running Step 3 Turn off power to the Remote I O Head or Remote Drive Interface Head Step 4 Inspect the Head fuse using the directions below If the fuse is blown replace it CAUTION The fuse must be replaced only with another fuse of the exact same type an AGC 2 amp fuse Failure to observe this precaution could result in damage to or destruction of the equipment a Using a screwdriver press down and turn counterclockwise to release the fuseholder located on the faceplate b Pull the fuseholder out of the Head c Remove the old fuse from the fuseholder and replace it with the new fuse d Re insert the fuseholder into the Head e Press down and turn the screwdriver clockwise to reinstall the fuseholder The fuseholder must be flush against the faceplate Step 5 Turn on power to the Head If the LEDs on the Head do not turn on replace the Head 6 4 6 7 Error Code A is on the Remote I O Head or Remote Drive Interf
3. 6 0 DIAGNOSTICS AND TROUBLESHOOTING This section describes how to troubleshoot the Remote I O module Remote I O Head Remote Drive Interface Head the Shark Interface module and the Remote I O network See Appendix D for a list of the error codes that can be displayed by the Remote I O module or Remote Heads If the problem cannot be corrected using the procedures below the modules are not user serviceable See appendix K for information on troubleshooting the fiber optic link and its components DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL AND OTHER APPLICABLE MANUALS IN THEIR ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE 6 1 6 2 6 3 The Remote I O Module s OK LED is Off Problem The green OK status LED on the Remote I O module s faceplate is off This LED should be on when the module has passed its internal diagnostics after power up If the LED is off and no error code is displayed a local watchdog failure has occurred Try cycling power to the rack If the LED remains off replace the module Error Code A is on the Remote I O Module s 7 Segment Display Problem Error code A appears on the Remote I O module s seven segment display at power up This error code
4. S CRC OVERRUN and ABORT for the entire network A few errors may accumulate over a period of time such as a few days but when these parameter values increase consistently over a short period of time there is a problem with the integrity If this occurs monitor the error parameters of each network drop using the Status command except for Shark racks to isolate the problem Use the following general procedure to isolate the cause of a Remote I O network failure Step 1 Verify that the drop number of each slave module is unique and the thumbwheel switches are set correctly The thumbwheel switches are read only once at power up If any changes have been made to the thumbwheel 6 2 6 4 6 5 switches you must cycle power to the rack or reset the module using the self test function in order for the new settings to be recorded in register 12 Note Use steps 2 through 8 if you have a coaxial cable network If you have a fiber optic network see section K3 1 Step 2 Verify that the network connections to each module are secure Check the drop cable connection at the module faceplate and at the passive tap Verify that the coax cable connections are secure Step 3 Verify that the coaxial cable is terminated correctly There must be a line terminating load at each end of the network Step 4 Verify that the coaxial cable system was installed correctly Refer to section 3 3 for additional information Step 5 Verify the
5. ace Head 7 Segment Display Problem Error Code A appears on the seven segment display of the Remote I O Head or Remote Drive Interface Head at power up This error code indicates an invalid drop number This will occur only if the drop number on the thumbwheel switch is 0 8 or 9 Use the following procedure to clear the error code Step 1 Set the correct drop number on the thumbwheel switch Step 2 Cycle power to the Remote I O Head or Remote Drive Interface Head IN APPLICATIONS WHERE IT IS IMPERATIVE THAT OUTPUT DEVICES BE DISABLED OR DE ENERGIZED WHEN THE DROP FAILS IT IS RECOMMENDED THAT THE SUPPLY POWER TO THE OUTPUT DEVICES BE ROUTED THROUGH THE READY RELAY ON THE REMOTE I O HEAD POWER SUPPLY FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY 6 8 The Remote I O Head s Rail Fault LED is On Problem The RAIL FAULT LED on the Remote I O Head faceplate is on This indicates that there has been a loss of communication between the Remote I O Head and one of the Local Heads or Rails connected to the I O ports The FAULT MSB and FAULT LSB LEDs will display a binary code that indicates which of the ports has had an interruption in communication rail fault Refer to figure 6 1 FAULT MSB LED OFF OFF ON ON FAULT LSB LED OFF ON OFF ON Rail Fault on port 0 1 2 3 Figure 6 1 AutoMax Rail Fault LED Codes Refer to the Digital I O Rails and Modules instruction manual J 3012 for detailed troubleshoo
6. e rack FOREIGN I O MODULES NON RELIANCE MODULES DO NOT RESPOND TO THE BOARD RESET COMMAND THEREFORE IF FOREIGN I O MODULES ARE USED IN AN AUTOMAX SYSTEM AND IT IS REQUIRED THAT THEIR OUTPUTS BE SET TO A KNOWN STATE WHEN A FAILURE OCCURS OTHER METHODS MUST BE EMPLOYED TO SATISFY THIS REQUIREMENT FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY If a Remote I O Head slave drop fails the Remote I O Head will attempt to clear all outputs at that drop In this situation the outputs connected to the rails or Local Heads may not be cleared IN APPLICATIONS WHERE IT IS IMPERATIVE THAT OUTPUT DEVICES BE DISABLED OR DE ENERGIZED WHEN THE DROP FAILS POWER TO THE OUTPUT DEVICES SHOULD BE ROUTED THROUGH THE READY RELAY ON THE REMOTE I O HEAD OR REMOTE DRIVE INTERFACE HEAD POWER SUPPLY FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY If a Shark slave drop fails the Shark Interface module in the slave rack will issue a reset I O command This command will clear all outputs in the slave rack When the master recognizes that a slave drop Multibus Shark Remote Drive Interface Head or Remote I O Head has failed it will clear all inputs in its dual port memory and the status bit indicating the slave drop s status will be turned off for a minimum of 120 milliseconds Monitoring registers 15 18 in the drop 0 area will indicate network integrity The master logs the error parameters RECEIVE TIMEOUT
7. integrity of the coaxial cable system Refer to section 3 9 for additional information The Shark Interface Module s CPU OK LED is Off Problem The green CPU OK status LED on the Shark Interface module s faceplate is off This LED should be on when the module has passed its power up diagnostics If the green status LED is off a local watchdog failure has occurred First try cycling power to the rack If the CPU OK status LED remains off replace the module The Shark Interface Module s COM OK LED is Blinking Problem The green COM OK status LED on the Shark Interface module s faceplate is blinking This LED should be on when the module is communicating over the Remote I O network The LED should be off when the module is not communicating over the network If the green status LED is blinking an invalid drop number has been selected on the 16 position rotary switch on the module s faceplate Set the rotary switch to the proper position and cycle power to the rack The rotary switch drop number settings are e 1 to 7 for racks containing both analog and digital modules e 9to F for racks containing all digital modules 6 3 6 6 All LEDs on the Remote I O Head or Remote Drive Interface Head are Off Problem All LEDs on the Remote I O Head or Remote Drive Interface Head are off This problem indicates that the Head is not receiving 120 VAC or 240 VAC power within the specified ranges the fuse has blown or that the Head
8. ting procedures for I O Rail failures 6 5 6 9 6 6 Error Code 31 is on the Processor Module s LED Display Problem Error code 31 appears on a Processor module s LED display This error indicates the system has a problem accessing the module though the backplane bus A bus error may be caused by removal of an I O module an I O module failure a rack backplane failure attempting to access an invalid address or incorrect cabling 45C8 45C5 Use the following procedure to isolate a bus error Step 1 Step 2 Step 3 Decode the error specific information listed in the Processor Info Log See J 3650 or J 3669 for the procedure for decoding bus errors Verify that the address being written to is a Read Write location Read Only registers and bits cannot be written to by application tasks Verify that the hardware is working correctly Systematically replace the Remote I O module the Processor module s and the rack backplane assembly one at a time with a corresponding module or assembly known to be operating correctly After replacing each module or assembly if the problem is not corrected replace the original before going on to the next item

6.0 DIAGNOSTICS AND TROUBLESHOOTING

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