Pro-face GP3000 Series Operating instructions

Maintenance/Troubleshooting

Preface
Maintenance/Troubleshooting 1
Preface
Thank you for purchasing Pro-face’s GP3000 Series Programmable Operator Interface
(Hereafter referred to as the “GP unit”) and the GP Screen Editor Software, “GP-Pro EX”.
Please read this manual carefully in order to use these products properly, and be sure to keep
this manual handy for future reference.
© Copyright 2007 Digital Electronics Corporation. All rights reserved.
Digital Electronics Corporation, August 2007
For the rights to trademarks and trade names, see “Trademark Rights”.
NOTES
(1)The copyrights to all programs and manuals included in these products are reserved
by the Digital Electronics Corporation. Digital grants the use of these products to its
users as described in the “Software Operating License Conditions” documentation,
included with GP-Pro EX’s CD-ROM. Any actions violating the above-mentioned con-
ditions are prohibited by both Japanese and foreign regulations.
(2)The contents of this manual have been thoroughly inspected. However, if you should
find any errors or omissions in this manual, please inform your local GP representa-
tive of your findings.
(3)Regardless of article (2), the Digital Electronics Corporation shall not be held respon-
sible for any damages or third party claims resulting from the use of these products.
(4)Differences may occur between the descriptions found in this manual and the actual
functioning of these products. Therefore, the latest information on these products is
provided in data files (i.e. Readme.txt files, etc.) and in separate documents. Please
consult these sources as well as this manual prior to using the product.
(5)Even though the information contained in and displayed by these products may be
related to intangible or intellectual properties of the Digital Electronics Corporation or
third parties, the Digital Electronics Corporation shall not warrant or grant the use of
said properties to any users and/or other third parties.
(6)The specifications set out in this manual are for overseas products only. As a result,
some differences may exist between the specifications given here and for those of the
identical Japanese product. Digital Electronics Corporation accepts no liability for
issues related to the intellectual property rights of third parties or any issues related to
the use of the information contained in or displayed by these products.

Trademark Rights
Maintenance/Troubleshooting 2
Trademark Rights
Trademark Rights
All company or product names used in this manual are the trade names, trademarks (includ-
ing registered trademarks), or service marks of their respective companies. these products
omits individual descriptions of each of these rights.
The following terms differ from the formal trade names and trademarks.
Trademark / Trade Name Right Holder
Microsoft, Windows, Windows 98, Windows Me,
Windows 2000, Windows XP, Windows Explorer,
Microsoft Excel, Internet Explorer
Microsoft Corporation,
USA
Intel, Pentium Intel Corporation, USA
Pro-face Digital Electronics Corporation (in Japan and
other countries)
Ethernet Western Digital Electric
Corporation, USA
Term used
in this manual Formal Trade Name or Trademark
Windows 98 MicrosoftWindows98 Operating System
Windows Me MicrosoftWindowsMe Operating System
Windows 2000 MicrosoftWindows2000 Operating System
Windows XP MicrosoftWindowsXP Operating System

Manual Symbols and Terminology
Maintenance/Troubleshooting 3
Manual Symbols and Terminology
Safety Symbols and Terms
This manual uses the following symbols and terms to identify important information related
to the correct and safe operation of GP and GP-Pro EX.
The symbols and the descriptions are as follows.
General Information Symbols and Terms
This manual uses the following symbols and terms for general information.
Symbol Description
Indicates a hazardous situation that could result in serious
injury or death.
Indicates a potentially hazardous situation that could result
in serious injury or death.
Indicates a potentially hazardous situation that could result
in minor injury or equipment damage.
Indicates instructions or procedures that must NOT be per-
formed to ensure correct product use.
Indicates instructions or procedures that MUST be per-
formed to ensure correct product use.
Indicates a potentially damaging action or dangerous situa-
tion that could result in abnormal equipment operation or
data loss.
Symbol Description
Provides hints on correct product use, or supplementary information.
∗Indicates an item with an explanatory footnote.
)Indicates an item’s related information.
1, 2
(1),(2) Indicates an operation procedure. Operate according to the numbers.

Precautions
Maintenance/Troubleshooting 4
Precautions
Precautions
This manual describes safety symbols and terms for the correct and safe operation of GP-Pro
EX. Read carefully this manual and the related manual to understand the correct operation
and features of GP and GP-Pro EX.
System Design
Touch panel switches should NOT be used to make a switch that could result in human injury
or equipment damage. Trouble with the GP main unit, units, and cables which keeps the output
ON or OFF could result in a serious accident. An output signal that could result in a serious
accident must be equipped with a monitoring circuit such as a limiter. Also, the system must be
designed for important actions to be conducted from a device other than the GP main unit, to
prevent an accident due to false output or malfunction.
Touch panel switches should NOT be used for a device’s Emergency Stop Switch. Minister of
Health, Labor and Welfare speaking, all industrial machinery/systems must be equipped with a
mechanical, manually operated emergency stop switch. Also, for other kinds of systems, simi-
lar mechanical switches must be provided to ensure safe operation of those systems.
Be sure to design your GP control system so that, in the event of a main power supply failure or a GP
accident, the user system’s overall safety integrity will be maintained. If this is not done, incorrect output
signals or a GP malfunction may cause an accident.
1) Interlock and other circuits designed to interrupt or oppose normal machine movement (such as
Emergency Stop, General Protection, and forward and reverse rotation), as well as those designed to
prevent machine damage (such as upper, lower, and traverse movement limit positioning) should all be
designed to be located outside of the GP.
2) When the GP generates a “Watchdog Timer Error,” GP operation will halt. Also, when Errors occur in
Input/Output control areas that the GP cannot detect, unexpected movement may occur in those areas.
Therefore, and to prevent unsafe machine movement, a “Failsafe Circuit” should be created which is
completely external to the GP.
For a failsafe circuit, refer to "Installation Precautions" in the hardware manual.
3) If a problem arises with an external unit’s relay or transistor, causing an output (coil) to remain either
ON or OFF, a major accident can occur. To prevent this, be sure to set up external watchdog circuits
that will monitor vital output signals.
Design a circuit that will supply power to the GP unit’s I/O before starting up the GP. If the GP unit’s
internal program enters RUN mode prior to the I/O unit’s load control power turning ON, an incorrect
output (signal) or malfunction could cause an accident.

Precautions
Maintenance/Troubleshooting 5
Handling
Design a user program that ensures the safety of the user’s system, in the event of a GP display or control
error, or either a data transmission error or power failure between the GP and a connected unit. These
types of problems can lead to an incorrect output (signal) or malfunction, resulting in an accident.
Do not create GP touch panel switches to control machine safety operations, such as an emergency stop
switch. Install these switches as separate hardware switches, otherwise severe bodily injury or equipment
damage can occur.
Be sure to design your system so that a communication fault between the GP and its host controller will
not cause equipment to malfunction. This is to prevent any possibility of bodily injury or equipment dam-
age.
Do not use the GP as a warning device for critical alarms that can cause serious operator injury, machine
damage or can halt system operation. Critical alarm indicators and their control/activator units must be
designed using stand-alone hardware and/or mechanical interlocks.
Do not use the GP with aircraft control devices, aerospace equipment, central trunk data transmission
(communication) devices, nuclear power control devices, or medical life support equipment, due to these
devices’ inherent requirements of extremely high levels of safety and reliability.
Be sure to design your system so that a communication fault between the GP and its host controller will
not cause equipment to malfunction. This is to prevent any possibility of bodily injury or equipment
damage.
After the GP unit’s backlight burns out the touch panel is still active, unlike the GP unit’s “Standby Mode”.
If the operator fails to notice that the backlight is burned out and touches the panel, a potentially
dangerous machine operation error can occur. Therefore, do not create GP unit touch panel switches that
may cause injury and/or equipment damage. If your GP unit’s backlight suddenly turns OFF, use the
following steps to determine if the backlight is actually burned out.
1) If the GP unit’s “Backlight Control” is not set and the screen has gone blank, your backlight is burned
out.
2) If the GP unit’s “Backlight Control” is set to Standby Mode and the screen has gone blank, and touching
the screen or performing another input operation does not cause the display to reappear, your backlight
is burned out.
The GP-Pro EX install disk is a CD-ROM. Never play the CD-ROM on an audio CD player.
Unexpected volume can cause hearing problems or speaker damage.
Do not disassemble or modify the GP unit. Doing so may cause a fire or an electric shock.
Do not operate the GP in an environment where flammable gases are present, since it may cause an
explosion.

Precautions
Maintenance/Troubleshooting 6
Precautions
Wiring
Maintenance
Wiring Layout Precautions
To prevent a GPunit malfunction due to excessive noise, isolate all GPinput/output signal lines from all
power wiring or power cables via a separate wiring duct.
To prevent electrical shock or equipment damage, unplug the GP unit’s power cord from the power supply
prior to installing or wiring the GP.
After completing any GP wiring work, be sure the terminal block’s protective plastic cover is reattached. If
this cover is not reattached, an electrical shock could easily occur.
To prevent an electric shock be sure to disconnect your GP unit’s power cord from the power supply
before wiring the GP.
Do not use voltage beyond the GP unit’s specified range. Doing so may cause a fire or an electric shock.
The cables connected to the GP should be secured by cable clamps to prevent weight or tension of the
cables added to the connectors or terminals.
The GP unit’s wiring should be checked to confirm that both the operating voltage and wiring terminal
locations are correct. If either the voltage or the wiring terminal location is incorrect, it can cause a fire or
accident.
NEVER touch a live power terminal. Doing so could cause an electrical shock or a machine malfunction.
To prevent an electrical shock, unplug the GP unit’s power cord before either cleaning the GP or attaching/
detaching the power terminal attachment screws.
When replacing the GP unit’s backlight, be sure to unplug the unit’s power cord to prevent an electrical
shock, and wear safety gloves to prevent burns.
Do not connect or disconnect Host and GP unit communication cables while the GP is turned ON.
Do not replace the GP unit’s battery yourself. The GP uses a lithium battery for backing up its internal
clock data and the battery may explode if it is replaced incorrectly. When replacement is required, please
contact your local GP distributor.
Do not turn off your personal computer’s power switch during the execution of a program. It
might destroy the project files.
Do not change the contents of GP-Pro EX’s project files using the Text Editor software. It might
destroy the project files.

Precautions
Maintenance/Troubleshooting 7
Installation
Wiring
Maintenance
Unit Disposal
General Safety Precautions
Be sure all cable connectors are securely attached to the GP unit. A loose connection may cause incorrect
input or output signals.
Be sure to ground the GP unit’s FG wire separately from other equipment FG lines. Also, be sure to use a
grounding resistance of 100. or less and a 2mm2[0.0062inch2] or thicker wire, or your country’s applicable
standard. Otherwise, electric shock or malfunctions may result.
Be sure to use only the designated torque to tighten the GP unit’s terminal block screws. If these screws
are not tightened firmly, it may cause a short-circuit, fire or incorrect unit operation.
Be sure that metal particles and wiring debris do not fall inside the GP unit. They can cause a fire,
malfunction or incorrect unit operation.
Be sure to read the GP unit’s manual carefully before performing program changes, entering forced
output, or using the RUN, STOP, or PAUSE commands while the GP is operating. Mistakes made when
using these items can cause machine accidents or damage.
Be sure the electricity is turned OFF before attaching or detaching an I/O unit. If the electricity is ON when
an I/O unit is attached or detached, damage or malfunction to the I/O unit may occur.
Be sure to turn the GP unit’s CF Card ACCESS switch OFF and confirm that the ACCESS lamp is not lit
prior to inserting or removing a CF Card. Otherwise, CF Card internal data may be damaged or lost.
Do not reset or turn the GP OFF, or insert or remove the CF Card while the GP unit’s CF Card is being
accessed. Create special application screens to perform operations like turning power OFF, resetting the
GP or inserting or removing the CF Card.
When the product is disposed of, it should be done so according to your country’s regulations for similar
types of industrial waste.
Do not press on the GP unit’s display with excessive force or with a hard object, since it can damage the
display. Also, do not press on the touch panel with a pointed object, such as the tip of a mechanical pencil
or a screwdriver, since doing so can damage the touch panel.
Do not install the GP where the ambient temperature exceeds the specified range. Doing so may cause a
unit malfunction.
To prevent abnormally high temperatures from occurring inside the GP, do not restrict or block the GP
unit’s rear-face ventilation slots.

Precautions
Maintenance/Troubleshooting 8
Precautions
Do not operate the GP in areas where large, sudden temperature changes can occur. These changes can
cause condensation to form inside the GP, possibly causing it to malfunction.
Do not allow water, liquids or metal fragments to enter inside the GP unit’s case, since they can cause
either a malfunction or an electric shock. The allowable pollution degree is 2.
Do not operate or store the GP in locations where it can be exposed to direct sunlight, high temperatures,
excessive dust, moisture or vibration.
Do not operate or store the GP where chemicals evaporate, or where chemicals are present in the air.
Corrosive chemicals: Acids, alkalines, liquids containing salt
Flammable chemicals: Organic Solvents
Do not use paint thinner or organic solvents to remove dirt or oil from the GP unit’s surface. Instead, use a
soft cloth moistened with a diluted neutral detergent.
Do not use or store the GP in areas with direct sunlight, since the sun’s ultraviolet rays may cause the
LCD’s quality to deteriorate.
Do not store the GP in an area where the temperature is lower than that recommended in the GP unit’s
specifications. Doing so may cause the LCD display’s liquid to congeal, which can damage the LCD.
Also, if the storage area’s temperature becomes higher than the specified level, the LCD’s liquid may
become isotropic, causing irreversible damage to the LCD. Therefore, only store the GP in areas where
temperatures are within the GP unit’s specifications.
After turning OFF the GP, be sure to wait a few seconds before turning it ON again. The GP may not
operate correctly if it is restarted too quickly.
Be sure to back up the GP screen data and logic programs in case they are lost accidentally.

Precautions
Maintenance/Troubleshooting 9
LCD Panel Usage Precautions
• The LCD panel’s liquid contains an irritant. If the panel is damaged and any of this liquid contacts your skin,
immediately rinse the area with running water for at least 15 minutes. If the liquid gets in your eyes, immediately
rinseyour eyes with running water for at least 15 minutes and consult a doctor.
• The GP unit’s LCD screen may show unevenness in the brightness of certain images or at some contrast settings. This
is an LCD characteristic and not a product defect.
• The GP unit’s LCD screen pixels may contain minute black and white-colored spots. This is an LCD characteristic and
not a product defect.
• The color displayed on the GP unit’s LCD screen may appear different when seen from outside the specified viewing
angle. This is an LCD characteristic and not a product defect.
• When the same image is displayed on the GP unit’s screen for a long period, an afterimage may appear when the image
is changed. If this happens, turn off the GP, wait 10 seconds and then restart the unit. This is an LCD characteristic and
not a product defect.
• To prevent an afterimage:
* Set the GP unit’s display OFF feature when you plan to display the same screen image for a long period of time.
* Change the screen image periodically and try to not display the same image for a long period of time.