IMET HYDRA Operating instructions

TROUBLE SHOOTING
1

TROUBLE SHOOTING
It d ti i
I
n
t
ro
d
uc
ti
on: warn
i
ng
The repair must be undertaken according to the manufacturer
The
repair
must
be
undertaken
according
to
the
manufacturer
instructions. Only genuine spares has to be used not to alterate
the radio control features
the
radio
control
features
.
2

TROUBLE SHOOTING
Introduction: preliminary checks
Before you go further into looking for the cause of the problem,
fthflli
li i h k
per
f
orm
th
e
f
o
ll
ow
i
ng pre
li
m
i
nary c
h
ec
k
s:
1.
STOP button is released. (This is the most common cause of
1.
STOP
button
is
released.
(This
is
the
most
common
cause
of
customer call we receive at the Service dept).
2. Battery is inserted and charged
3. Magnetic key is in
4. No commands are active while pressing START
3

TROUBLE SHOOTING
Introduction: Glossary
Passive Emergency Stop concept
In case of system failure, the radio control automatically gets into safe status mode. At the
receiver all outputs are de
-
energized and the STOP circuit opened The most common
receiver
,
all
outputs
are
de
-
energized
and
the
STOP
circuit
opened
.
The
most
common
cause is an interruption of the radio transmission ( for >0,8s) because of:
• strong radio interferences: another radio control is being operated nearby at the same
frequency
• The action range has been exceeded or a metallic surface is present between the
transmitter and the receiver.
TX RX
TX
,
RX
TX = transmitter, RX = receiver
Eeprom
Removable memory card containing information like ID number, channel frequency and
system settings (can be intended as a mobile phone SIM card).
Frequency Change (C F)
4
Frequency
Change
(C
.
F
.
)
It can be performed by the operator entering a procedure directly from the transmitter. This
will allow to set a specific frequency for the radio link. 30 different channels are available.

TROUBLE SHOOTING
Most Common Anomalies
ANOMALY
(
occuring
at 1
ST ANOMALY
(occuring at
POSSIBLE SOLUTION
(
occuring
at
1
activation)
(occuring
at
following
activations)
The system has a
much lower range •A) Strong radio interferences might be present. Verify it turning off the TX and
hki
if
tth RX “RF
B
”l d
k
ti
lit
If
f
h
i
than the nominal
value(80-100m). It
means the receiver
stops and goes into
passive
emergency
-
c
h
ec
ki
ng
if
a
t
th
e
RX
,
“RF
B
usy
”
l
e
d
k
eep s
t
ay
i
ng
lit
.
If
yes, a
f
requency c
h
ange
i
s
required.
•B) Strong electric interferences generated at the control box might reach the
receiver
trough
the connection
wiring
Remove
the S
STOP fuse (
to
insulate
the
passive
emergency
stop.
receiver
trough
the
connection
wiring
.
Remove
the
S
-
STOP
fuse
(
to
insulate
the
receiver from the motion contactors) and check if any improvement. “data error ch
A/B” leds frequently turning off, indicate that information is lost.
The s
y
stem has a
•
Check
if
the
receiver
antenna
has
been
damaged
y
much lower range
than the nominal
value(80-100m). It
means the receiver
stops
and
goes
into
•
Check
if
the
receiver
antenna
has
been
damaged
•New source of radio interferences might entered the operation area. Check point
A)
stops
and
goes
into
passive emergency-
stop.
Some functions are
ttd
•Check out the technical enclosures B and C attached to the manual
5
no
t
as expec
t
e
d
Some functions are
not as expected •Check the connection wiring betwen receiver and control panel
•Check the command activation observing the led’s associated to the relays

TROUBLE SHOOTING TX TX
TX led. Meanin
g
of Indications Part1
g
Transmitter
Led status Anomaly description
OFF TX is off or faulty. Causes:
•Battery is absent or totally empty
•The Key is absent or not well inserted
•
The lo
g
ical board or the
p
ower su
pp
l
y
circuit have been
gpppy
damaged (transmitter crash)
Flashing regularly
_ _ _ _ _ _ _ _ _ _ _ _ _ _ Battery has entered the reserve
ON only while START is kept
pressed
STOP button is pressed
pressed
____________________
6

TROUBLE SHOOTING TX TX
TX led. Meanin
g
of Indications Part2
Transmitter
Led status Anomaly description
Three short + lon
g
flashes You are tr
y
in
g
to start the transmitte
r
whileacommand
g
g
_ _ _ ____
yg
is active (only for joystick TX type)
The flashing produces a code
1 0 1 0 0 1 1 0
__
_
__
_
_
__
__
_
Error code. Morse coding (long flash= 1; short flash=0)
__ _ __ _ _ __ __ _
Flashing fastly
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ STOP circuit anomaly (see STOP test procedure ahead
slides 12-13)
Single short flash while Start is
pressed
__
EEPROM is missing o
r
out of orde
r
(see dedicated
section ahead slide 14)
Lighting with low intensity
Battery
contacts
to
be
cleaned
Lighting
with
low
intensity
Battery
contacts
to
be
cleaned
7

TROUBLE SHOOTING TX TX
Transmitter
Led status
Description
TX led. Meaning of Indications Part3
Led
status
Description
ON
____________________________ Transmitter is working correctly
flashin
g
with
g
rou
p
s of 5 flashes Fre
q
uenc
y
Chan
g
e
p
rocedure has been succesfull
y
g
gp
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
qy
g
p
y
entered at the TX. Waiting for the new channel selection
(Only for systems with proportional
commands and PIN code) Analogue output calibration procedure has been successfully entered. Waiting for the PIN code
Flashing regularly
Es: _ _ _ _ _ _ _ _ _ _ _ _ _
(Only for systems with proportional
commands
and PIN code)
Analogue output calibration procedure in progress.
Minimum
speed
limit
calibration
commands
and
PIN
code)
Single flash with pause
Es: _ _ _ _ _ _ _ _
Minimum
speed
limit
calibration
.
(Only for systems with proportional
commands
and PIN code)
Analogue output calibration procedure in progress.
Maximum
speed
limit
calibration
commands
and
PIN
code)
Double flash with pause
Es: _ _ _ _ _ _ _ _ _ _ _ _ _ _
Maximum
speed
limit
calibration
.
(
Only
for
systems
with
proportional
Analogue
output
calibration
procedure
in
progress
8
(
Only
for
systems
with
proportional
commands and PIN code)
Rapid regular flashes
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Analogue
output
calibration
procedure
in
progress
.
Direction change

TROUBLE SHOOTING TX TX
How to read an error code
transmitter
Led status Anomaly description
Flashing
in Morse code
Flashing
in
Morse
code
1 0 1 0 0 1 1 0
__ _ __ _ _ __ __ _ Error description
bbb…. 0.
…
….1
…. … .0… .0… .. ….1 …. … .0… .0.… ….1 …. … .bbb
The Led repeats the morse code twice. The code is
made of 8 flashes (long or short). A sequence of rapid
flashes (b) indicates the code is going to be produced.
The error code keep being produced till the cause of
9
the failure is not removed.

TROUBLE SHOOTING TX TX
Binar
y
code
p
art 1
(
MS
)
*Binar
y
code
p
art 2
(
LS
)
* hexadecimal
List of transmitter Error codes. Binary and Hexadecimal values
y
p()
yp()
0000 0001 01
0001 0001 11
0001 0011 13
1011 0011 B3
0010 0000 20
0010 1000 28
0011
0000
30
0011
0000
30
1100 0101 C5
1100 0110 C6
10
*: MS = Most Significant; LS = Less Significant

TROUBLE SHOOTING TX TX
hexadecimal Error description details solution
TX
01 STOP button failure Microswitch contacts of STOP button do not
open synchronously In case of repeated error, replace the STOP button
11 Battery voltage out of range for the logic board The voltage is higher than 3,2V (risk of board
damage) Replace the battery with a genuine one or correctly charged
13 / B3
Batter
y
totall
y
em
p
t
y
(
remainin
g
char
g
e The voltage is lower than the minimum
admitted value
Re
p
lace the batter
y
with a char
g
ed one
13
/
B3
yypy( gg
insufficient to start properly the TX)
admitted
value
(Wave=2Vdc Thor/Zeus=3Vdc)
pyg
20 a) Active command at Start (only for Wave)
b) bad comunication between micro’s a) Not allowed at Start command b) Time out in micro’s data exchange a) Deactivate the command b) Replace TX logic board
28 Bad comunication between micro and eeprom Probable damage along the comunication path Change the mother board
START push button is mechanically blocked
30 START command blocked
START
push
button
is
mechanically
blocked
(dirt or broken spring) Clean or change the STARTcontact
C5 Joystick failed “forward direction” and “analogue” sensing do not match; or the joystick is unplugged; or the
j
o
y
stick has been dama
g
ed inside
Check the joystick plug; replace the
joystick
11
jy
g
C6 Joystick failed
“backward direction” and “analogue” sensing
do not match; or the joystick is unplugged; or
the joystick has been damaged inside Check the joystick plug; replace the joystick

TROUBLE SHOOTING TX TX
“STOP” test procedure Part1
transmitter
Led status Anomaly description
If
following
a
transmitter
Start
the
led
keeps
flashing
rapidly
Flashing rapidly
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ potential anomaly in the trasmitte
r
STOP
circuit
If
following
a
transmitter
Start
,
the
led
keeps
flashing
rapidly
,
this signals the existing of a potential anomaly in the
transmitte
r
STOP circuit. The radiocontrol thus turns into a
waiting status asking the operator to test the STOP circuit.
12

TROUBLE SHOOTING TX TX
“STOP” test
p
rocedure Part2
p
Push the STOP button (and let it pressed) while the led is flashing, then press START.
At this point one of the following three cases can occur:
A) if the STOP circuit is perfectly working, after releasing the STOP button and pressing
the START button, the transmitter will turn on and work normally
B) if after the first test the LED keeps flashing rapidly, it is necessary to repeat the test
procedure (up to 4 times) untill you turn into case A) o C)
C) If the LED starts to flash indicating the error code
“
STOP circuit failure
”
contact your
C)
If
the
LED
starts
to
flash
indicating
the
error
code
STOP
circuit
failure
,
contact
your
dealer for repairing/replacing the STOP Button
13

TROUBLE SHOOTING TX TX
Missing EEPROM. Deepening.
Transmitter
Led status Anomaly description
Single short flash
while
Start
is
EEPROM
is
missing
or
out
of
order
(see
dedicated
This
kind
of
error
occurs
typically
when
the
eeprom
is
not
correctly
fit
in
its
Single
short
flash
while
Start
is
pressed
__
EEPROM
is
missing
or
out
of
order
(see
dedicated
section ahead)
This
kind
of
error
occurs
typically
when
the
eeprom
is
not
correctly
fit
in
its
connector or if cancelled. In the first case, check the electrical connection of the
eeprom, in the second case ask for a replacement eeprom
14

TROUBLE SHOOTING RX RX
RX LED INDICATIONS L, K, H
Data Error ch. B
Data Error ch A
Passive Emergency ch. B
receiverunit
Led indication
Data error ch. A
(yellow) Normally on when the system is working. Turns off while errors are detected on channel
RF Busy
Data
Error
ch
.
A
Passive Emergency ch. A
A.
Passive emergency
ch. A
(red)
Normally off when the system is working.
When on it indicates that channel A is in STOP
status.
Morse coded flashes in case of system errors Power Supply
Working
Data error ch. B
(yellow) Normally on when the system is working. Turns off while errors are detected on channel
B.
Passive emergency Normally off when the system is working. RF BUSY
POWER SUPPLY
EMERGENCY CH. A
ch. B
(red) When on it indicates that channel B is in STOP
status. Morse coded flashes in case of system
errors
RF bus
y
When on it indicates the
p
resence of radio
DATA ERROR CH B
EMERGENCY CH. B
EMERGENCY CH. A
DATA ERROR CH. A M
y
(green)
p
signal on the transmission channel. With
datafeedback transmission it flashes very
fastly.
Power Supply
(g
reen
)
The receiver is powered .
15
WORKING
DATA ERROR CH
.
B
(g )
Working
(green) When on, it indicates that the E-STOP relays
are energized and commands can be
executed.

TROUBLE SHOOTING RX RX
Receiver check
ANOMALY
(if it occurs at 1° use only)
A
NOMALY POSSIBLE SOLUTION
The receiver does not
turn on The receiver does not turn on •Check the fuses
•
Check the
p
ower lines
p
The receiver turns on but the
machine do not react. The
two yellow Leds are on.
•Check the fuse protecting the common of the motion relays
•Check the wiring between the receiver and the machine
•
Check
the
fuse
protecting
the
STOP
circuit
relays
•
Check
the
fuse
protecting
the
STOP
circuit
relays
The receiver turns on but
the machine does not
react. The two red Leds
are on.
•Check if the radiocontrol operation range is normal
•Check the radiocontrol ID trough the serial number (TX and RX
ID
must
match)
ID
must
match)
The receiver turns on but the
machine do not react. The
two red Leds are on.
•Check if the radiocontrol operation range is normal
Some commands are not
•
Check
the
wiring
between
the
receiver
and
the
application
executed
•
Check
the
wiring
between
the
receiver
and
the
application
Some commands are not
executed
any
more
•Check the wiring between the receiver and the application
16
executed
any
more
•Check if the commands cards, in the receiver, are correctly
working.

TROUBLE SHOOTING RX RX
Error code reading
Dt E hB
D
a
t
a
E
rror c
h
.
B
RF B
Data Error ch. A
Passive Emergency ch. A
Passive Emergency ch. B
The Led repeats the morse code continuousl
y
.The
code is made of 8 flashes (long or short). A
sequence
of
rapid
flashes
(b)
indicates
the
code
is
RF
B
usy
Power Supply
Working
sequence
of
rapid
flashes
(b)
indicates
the
code
is
going to be produced. The error code keep being
produced till the cause of the failure is not
RF BUSY
EMERGENCY CH. B
POWER SUPPLY
EMERGENCY CH. A
DATA ERROR CH. A
removed.
WORKING
DATA ERROR CH. B
transmitter
Led status Anomaly description
Flashing in Morse code
Flashing
in
Morse
code
1 0 1 0 0 1 1 0
__ _ __ _ _ __ __ _ Error description
17
bbb 0 1 0 0 1 0 0 1 bbb

TROUBLE SHOOTING RX RX
List of receiver Error codes. Binary and Hexadecimal values
Binary code part 1 (MS)* Binary code part 2 (LS)* hexadecimal
0000 0101 05
1011 0111 B7
0000 0110 06
0000
1000
08
0000
1000
08
0000 1010 0A
0001 0000 10
0001 0001 11
0001 0100 14
18
*: MS = Most Significant; LS = Less Significant

TROUBLE SHOOTING RX RX
RX
hexadecimal Error description details solution
05-B7 Error during EEPROM reading The EEPROM memory cannot be
correctly read by the micro
’
s
Check if the EEPROM is
correctly plug in its socket
correctly
read
by
the
micros
.
correctly
plug
in
its
socket
06 Error detected during Safety-Stop
monitoring The S-STOP status does not match its command signal Check the S-STOP relay. If necessary replace it
08
08
Error detected during E-STOP
monitoring The E-STOP status does not match its command signal
Check the E-STOP relay. If
necessary replace it
0A
10 SAFETY-STOP detected closed
during START phase The S-STOP status does not match its command signal Check the S-STOP relay. If necessary replace it
Error detected on the volta
g
e The volta
g
e comin
g
out from the
The power source might ce
instable with frequent drops out.
Otherwise the board Graetz
11
g
value of the logical board power
supply during receiver start up.
gg
switching transformer is no valid (too low
or too high)
Otherwise
the
board
Graetz
bridge is defective (change the
Graetz Bridge or the complete
mother board)
The dip-switches are not set according
19
14 Wrong dip switch configuration
(only for WAVE) to an allowed configuration, so, the software does not allow the receiver to
operate.
Check out the technical
enclosures.

TROUBLE SHOOTING RX RX
RX error code 11: dee
p
enin
g
pg
Note that in this case, only led CH.B flashes
1
)
In
p
resence of a volta
g
e value lower than the
Data Error ch. B
Data Error ch A
Passive Emergency ch. B
)p g
allowed threshold, check the power supply lines
and operate a power reset. RF Busy
Data
Error
ch
.
A
Passive Emergency ch. A
2) If point1) can be excluded, the problem is
cased by a defect of the Graetz diode bridge
(fhihi lii)
Power Supply
Working
(
part o
f
t
h
e sw
i
tc
hi
ng power supp
l
y c
i
rcu
i
t
)
.
Replace the diode bridge or the complete
board.
RF BUSY
POWER SUPPLY
EMERGENCY CH. A
DATA ERROR CH A
board.
WORKING
DATA ERROR CH. B
EMERGENCY CH. B
DATA ERROR CH
.
A
20