SEF 90 Additional Troubleshooting Guide

	Sef 90 Troubleshooting guide for both S8 and S7
	Electrical and Electronic troubleshooting guide
Series 7, HP and Spectrum
Series 8 Pre Advantage
1. No video							Start up sequence
2. Manual control but no video.							1. Turn on the power.
							2. Manual, Semi and Automatic LEDs are on.
3. The controller boots up but no Menu is display.							3. Normal LEDs are on.
4. A Eprom reads "Bad" during Eprom test							4. Heater status LED is on.
5. All the Mode of operation lights are illuminated during boot up.							5. The Controller performs its Eprom test.
6. The Controller boots up but no page select.							6. After the Eprom test the Menu page is displayed.
7. Scrammed video.							7. After the Eprom test is performed.
8. Scrammed video during high current draw.							The Maintenance mode, The Normal and the last heater status is illuminated.
9. "Press not operating" alarm is display after the boot up sequence.
10. No Manual Control Panel operation.
11. No 5 Vdc
12. No 15 Vdc
13. No -15 Vdc
14. No 24 Vdc
15. No temperature display on the Barrel Heating page.
16. Temperature overshooting set point.
17. The heats will not turn on.
18. The controller boots up, passes the Eprom test and No menu page is display only the Cursor is displayed.
19. No pressure reading on the Video screen
20. The video display freezes during operation
21. A Maintenance or Manual function remains on after the function has been terminated.
22. Normal and Start up LEDs are illuminated together before, during and after the Eprom test.
23. Heats and (or) the motors stop automatically during operation
24. The Controller will not change from the Start up mode to Normal mode.
25. Transducer zero adjustment will not adjust the transducer postion to zero.
26. The transducer actual position reads zero after the transducer rod has traveled a short distance from the zero position.
27. The transducer reads but skips or jumps from one position to a higher (or lower) position without any actuator movement for more than one (or all transducer readings)
28. The transducer reads but skips or jumps from one position to a higher (or lower) position without any actuator movement for only one transducer input.
29. The Transducer does not read actual positions.  All displays are zero except for the Ejector transducer.  The ejector transducer actual reading of 4095.  Also the a "Press not operating" alarm is displayed initially at boot up.
30. No input for the Hydraulic safety limit switch FCSI to the controller
1. No video
Problem:
1. A blown fuse on the Incoming power supply 28VAC on the I/O board.
	1a. Check the incoming fuses in the upper right-side of the I/O.
2. No power to the CRT tube.
	2a. Check to see if the CRT tube is glowing in the bad.					If the CRT is glowing then the tube is in good condition.
3. Faulty Video interface board.
	3a. Replace the Video interface board.
4. Faulty CPU  board
	4a. Replace the Mirco AB board Series 7 pn# 2990104 and Series 8 pn# 2990105.
5. Faulty or low 5 volts power
	5a. Check the 5 volts on the I/O board.  The voltage should be 5.0vdc no less than 3.9 volts.
6. Disconnected or broken video cable from the Video board to the CRT video board.
	6a. Check the condition of the Video cable.
7. Disconnected or broken ribbon cable from the Video interface board to the CPU board.
	7a. Check the condition and the connections.
2. Manual control but no video display.
Problem:
2.1 No power to CRT tube.
	2.2.1a.	2a. Check to see if the CRT tube is glowing in the bad.					If the CRT is glowing then the tube is in good condition.
2.2 No Video Interface board.
	2.2.2a. Replace the Video interface board.
2.3 Disconnected or faulty video cable.
	2.3.3a. Check the connections and conditions of the cable.
2.4 Faulty CRT video display unit.
	2.4.4.a Replace the CRT unit.
4. A Eprom reads "Bad" during Eprom test
4.1 One or more of the Eproms are corrupt or bad.
	4.1a. Try to reset the Eproms and retry.
	4.1b. Replace the Faulty Eprom or Eproms.
4.2 One or both Eprom carrier boards are faulty.
	4.3a. Try to reseat the Eprom carrier boards.
	4.3b. Replace the Eprom carrier board.
4.3 The CPU board could be faulty.
	4.3a. Replace the CPU board.
5. All the Mode of operation lights are illuminated during boot up.
5.1 Faulty I/O board
5.2 Faulty Expansion board.
6. The Controller boots up but no page select.
6.1 Faulty keyboard interface board.
6.2 Faulty Video interface board.
6.3 Loose or broken Ribbon cable to the Video interface board.
6.4 No 5 vdc power to the keyboard interface board.
6.5 Faulty or broken Keyboard Front panel or the Ribbon cable is loose or broken.
6.6 The Key lock in broken.
6.7 The CPU is not responding to the page selection.
7. Scrammed video.
7.1a. Inconsistant or low power supply
7.2a. Bad power connections on the CPU board (Green connector).
7.3 Bad power connection on the Video interface board (Green connector).
7.4 Faulty Video Interface board.
7.5 Broken or loose Video Cable.
7.6 Earth ground problem on the console board.
7.7
25. Transducer zero adjustment will not adjust the transducer postion to zero.
25.1a Transducer rod is too short to reach the zero position.
25.2 The adjustment pot on the I/O board is broken.
25.3 The cable is broken or has large amount of internal resistance.
25.4 Loose or bad connections.
26. The transducer actual position reads zero after the transducer rod has traveled a short distance from the zero position.
26.1 The transducer rod is too long and it's surpassing the zero position.
26.2 The adjustment pot on the I/O board is broken.
26.3 The cable is broken or has huge amount of internal resistance.
26.4 Loose or bad cable connections.
99
27. The transducer reads but skips or jumps from one position to a higher (or lower) position without any actuator movement for more than one (or all transducer readings)
27.1 Check the incoming power to the I/O board for excessive noise or transents.
27.2 Check the different power supplies on the I/O board +15 and -15volts.
27.3 Check the J7 and J9 connectors on the I/O board.
27.4 On the Series's 8 check the P1, P2 and P3 connector plugs on back of the Sef 90 control cabinet.
27.5 On the Series 8's check the SMC and SM1 interface boards connections.
27.6 On the Series 7 disconnect one transducer at a time and check for ground faults within the cables running throughout the frame of the machine.
27.7 Check the ribbon cables from the I/O board to the CPU board.  Check for cracks and broken traces.
27.8 Check the condition of the J7 and J9 connectors and male pins on the I/O board.
28. The transducer reads but skips or jumps from one position to a higher (or lower) position without any actuator movement for only one transducer input.
28.1 The rod is mechanically loose.
28.2 The case of the transducer body is cracked.
28.3 The case is broken or loose, possible the cable has a broken wire, bad splice or a cut wire inside the cable.
28.4 The connections on the I/O board are loose.
28.5 Faulty channel on the I/O board.
28.6 Possible a broken pin or bent pin on the J7 or J9 connector
28.7 Broken wire or bad female clip inside the J7 or J9 connector
29. The Transducer does not read actual positions.  All displays are zero except for the Ejector transducer.  The ejector transducer actual reading of 4095.  Also the a "Press not operating" alarm is displayed initially at boot up.
29.1 Check the operation of the transducers.
29.2 Check the voltage on the I/O board (+15 volts)
29.3 Check the dip switch settings on the CPU board.
29.4 Check the dip switch settings on the I/O expansion board.
29.5 Check the J7 and J9 connectors for security.
30. No input for the Hydraulic safety limit switch FCSI to the controller
30.1 Check the mechanical connection for the Hydraulic limit switch.
30.2 FCSI goes into connector P34 (I/O extension board pn# 29900130
30.3 FCSI goes into P2 connector in the back of the Sef 90 controller.