Download smart weight profiler alarms

SMART WEIGHT PROFILER ALARMS
System Errors
Air Pressure Lost
Explanation:
The measured air pressure is lower than the coldstart variable “Air Pressure Lost
Alarm Limit”. This indicates that the air pressure is too low to move any actuators.
The measured air pressure is displayed as part of the AccuRay Smart Processing
Center (ASPC) SIO data on the Individual SIO Data video page on the Service
Workstation.
Possible Causes:
1). Air compressor is off or not functioning properly
2). Airline is leaking or not connected to the air manifold
3). Air Transducer malfunction
4). The air pressure analog input slope and offset is incorrect for the type of Air
Transducer installed in the system.
5). Air supply exhausted after major actuator movement.
6). The coldstart variable “Air Pressure Lost Alarm Limit” is too large.
Recommended Service Action:
1). Check air compressor.
2). Check air pressure settings on pressure gauges located on the air compressor
and filter regulator assembly. Examine the airline and air manifold for air
leakage.
3). Inspect/replace the air pressure transducer.
4). Verify that the coldstart variables “Air Pressure Analog Input Slope” and “Air
Pressure Analog Input Offset” are correct for the type of Air Transducer used
in the system .
5). The coldstart variable “# of Actrs SIO may simultaneously move if no errors” may be
reduced to alleviate air supply being exhausted during large moves.
The coldstart variable “# of Actrs SIO may all move if ASPC limits
exceeded” may be reduced as long as its value is greater than zero (0) (refer to
the System Coldstart Data and System Coldstart Data Setup Procedure in
Chapter 5 for details).
6). The coldstart variable “Air Pressure Lost Alarm Limit” may be reduced as long
as its value is greater than minimum air pressure required to move actuators
(refer to the System Coldstart Data and System Coldstart Data Setup Procedure
in Chapter 5 for details).
Air Pressure Too Low
Explanation:
The measured air pressure is lower than the coldstart variable “Air Pressure Low
Alarm Limit”. This indicates that the air pressure is too low to simultaneously move
The number of actuators indicated by the coldstart variable “# of Actrs SIO may
Simultaneously move if no errors”. Each SIO will continue to move actuators based
On the coldstart variable “# of Actrs SIO may all move if ASPC limits exceeded”
Until the low air pressure condition goes away. The measured air pressure is
Displayed as part of the ASPC SIO data on the Individual SIO Data video page on
The Service Workstation.
Possible Causes:
1). Air compressor is off or not functioning properly.
2). Airline is leaking or not connected to air manifold.
3). Air Transducer malfunction.
4). The air pressure analog input slope and offset are incorrect for the type of Air
Transducer installed in the system.
5). Air supply exhausted after significant actuator movement.
6). The coldstart variable “Air Pressure Low Alarm Limit” is too large.
Recommended Service Action:
1). Check air compressor.
2). Check air valve and air pressure setting. Examine airline for air leakage.
Pressure gauges are located on air compressor and filter regulator.
3). Inspect/Replace air pressure transducer.
4). Verify that the coldstart variables “Air Pressure Analog Input Slope” and “Air
Pressure Analog Input Offset” is correct for the type of Air Transducer used
in the system (refer to the System Coldstart Data and System Coldstart Data
Setup Procedure in Chapter 5 for details).
5). The coldstart variable “# of Actrs SIO may simultaneously move if no errors”
may be reduced to alleviate air supply being exhausted during large moves (refer
to the System Coldstart Data and System Coldstart Data Setup Procedure in
Chapter 5 for details).
6). The coldstart variable “Air Pressure Low Alarm Limit” may be reduced as long
as the value is greater than the minimum air pressure required to move actuators
(Refer to the System Coldstart Data and System Coldstart Data Setup Procedure
In Chapter 5 for details).
Air Pressure Too High
Explanation:
The measured air pressure is greater than the coldstart variable “Air Pressure High
Alarm Limit”. This indicates that the air pressure is above the recommended
Specification for the linear stepper actuator. The system will prohibit output to any
actuators while the air pressure too high condition exists to prevent damage to the
actuators. The measured air pressure is displayed as part of the ASPC SIO data on
the Individual SIO Data video page at the Service Workstation.
Possible Causes:
1). Air compressor is not functioning properly.
2). Air pressure setting is too high.
3). The filter regulator is not functioning properly.
4). Air Pressure transducer malfunction.
5). The coldstart variable “Air Pressure High Alarm Limit” is too low.
Recommended Service Action:
1). Check air compressor.
2). Check the air valve and air pressure settings on the pressure gauges located on
the air compressor and filter regulator assembly.
3). Inspect filter regulator.
4). Inspect/replace the air pressure transducer.
5). The coldstart variable “Air Pressure High Alarm Limit” may be increased if
the new value is less than maximum air pressure specification limit for the
system (refer to the System Coldstart Data and System Coldstart Data Setup
Procedure in Chapter 5 for details).
Not Enough LSP Power Supplies
Explanation:
The number of LSP power supplies working in the system is less than the specified
amount required to simultaneously move the number of actuators configured. The
LSP power supply data is displayed as part of the ASPC SIO data on the Individual
SIO Data video page on the Service Workstation.
Possible Causes:
1). An LSP power supply is not properly fitted into the chassis.
2). An LSP power supply has failed.
3). Not enough LSP power supplies are installed in the system.
Recommended Service Action:
1). Check LSP power supplies in ASPC cabinet to ensure a snug fit into the chassis.
2). Replace failed LSP power supply (refer to Electronics Maintenance in Chapter
10 for details).
3). Ensure enough LSP power supplies are in the system for the number of actuators
configured (refer to the LSP Power Supply Requirements in Chapter 3).
LSP Power Supply Temperature Too High
Explanation:
An LSP power supply temperature exceeds the coldstart variable “LSP Power
Supply High Temperature Limit”. LSP power supply temperatures are displayed
as part of the ASPC SIO data on the Individual SIO Data video page on the Service
Workstation.
Possible Causes:
1). An LSP Power Supply temperature is too hot.
Recommended Service Action:
1). Check ASPC cabinet heat exchanger for power/operation.
2). Reduce ambient temperature around the ASPC cabinet.
3). Refer to the System Coldstart Data and System Coldstart Data Setup Procedure
in Chapter 5 for appropriate LSP Power Supply temperature configuration.
4). The coldstart variable “# of Actrs SIO may all move if ASPC limits
exceeded” may be reduced as long as its value is greater than zero (0) and the
LSP power supply temperature’s too high condition is new (refer to the System
Coldstart Data and System Coldstart Data Setup Procedure in Chapter 5 for
details).
5). The coldstart variable “# of Actrs SIO may all move if ASPC limits
exceeded” may be reduced as long as its value is greater than zero (0) and the
LSP power supply temperature’s too high condition persists (refer to the System
Coldstart Data and System Coldstart Data Setup Procedure in Chapter 5 for
details).
6). Replace the LSP power supply (refer to Electronics Maintenance in Chapter
10 for details).
ECPSR Power Supply Temperature Too High
Explanation:
The ECPSR Power Supply temperature exceeds the coldstart variable “ECPSR
Power Supply High Temperature Limit”. ECPSR power supply temperature is
displayed as part of the ASPC SIO data on the Individual SIO Data video page on
the Service Workstation.
Possible Causes:
1). ECPSR Power Supply temperature is too hot.
Recommended Service Action:
1). Check ASPC cabinet heat exchanger for power/operation.
2). Reduce ambient temperature around APSC cabinet.
3). Refer to the System Coldstart Data and System Coldstart Data Setup Procedure
in Chapter 5 for appropriate ECPSR Power Supply temperature configuration.
4). The coldstart variable “# of Actrs SIO may simultaneously move if no errors”
may be reduced as long as its value is greater than zero (0) and the ECPSR
power supply temperature’s too high condition is new and intermittent (refer to
the System Coldstart Data and System Coldstart Data Setup Procedure in
Chapter 5 for details).
5). The coldstart variable “# of Actrs SIO may all move if ASPC limits
exceeded” may be reduced as long as its value is greater than zero (0) and the
ECPSR power supply temperature’s too high condition persists (refer to the
System Coldstart Data and System Coldstart Data Setup Procedure in Chapter
5 for details).
6). Replace the ECPSR power supply (refer to Electronics Maintenance in Chapter
10 for details).
Actuator Errors
Invalid Feedback
Explanation:
An invalid feedback condition automatically disables the actuator from being
moved. Adjacent actuators are also disabled to prevent slice bending.
Possible Causes:
• This error occurs whenever an invalid feedback occurs as a feedback error.
Recommended Service Action:
• Because this actuator error is caused by a feedback error, refer to the Actuator
Feedback Errors section:
Insufficient Movement
Explanation:
The sensor position did not change properly when a set point change was requested.
This can be caused in two ways:
1). The actuator did not achieve set point position within a specified number of
tries. The maximum number of attempts an actuator will take to achieve a set
point position is determined by the coldstart variable “Control Action Count
Limit - Adjustment Timeout”. If an actuator cannot achieve a set point position
within the coldstart variable “Actuator Change Complete Deadband”, the Smart
Weight Profiler will test the actuator position against the coldstart variable “Actr
Change Complete Deadband for Insufficient Move Alarm”. If the sensor position is
outside this deadband, an insufficient movement error will occur.
2). When an actuator change was requested, the feedback for that actuator did not
change a specified minimum amount. When the expected actuator set point
change is greater than the coldstart variable “Min Actr Change requested to
Test Insufficient Move” and the change in feedback is less than the coldstart
variable “Min Feedback Change to Not Alarm Insufficient Movement”, the
insufficient movement counter in incremented. If the value of the insufficient
move counter becomes greater than the coldstart variable “Max Number of
Consecutive Insufficient Moves Allowed”, an insufficient movement error will
occur.
Possible Causes:
1). Inadequate Air Pressure.
2). Defective actuator (wiring, shorted/open solenoid).
3). Defective feedback (wiring, bad Position Sensor, Position Sensor sticks).
4). Insufficient movement coldstart data on is improperly set up.
5). Slice lip bent or too rigid to allow actuator movement.
6). Defective SIO.
Recommended Service Action:
1). Check air supply to actuators.
2). Service/Replace Actuator (refer to the Smart Weight Profiler Linear Stepper
Actuator Service Manual, 101794-004 for details).
3). Service/Replace Position Sensor (refer to the Smart Weight Profiler Linear
Stepper Actuator Service Manual, 101794-004 for details).
4). The coldstart variables “Actr Change Complete Dead Band for Insufficient Move
Alarm”, “Min Actr Change Requested to Test Insufficient Move”, and/or “Max
Number of Consecutive Insufficient Moves Allowed” may be increased, or
“Min Feedback Change to Not Alarm Insufficient Movement” may be
decreased, to alleviate nuisance insufficient movement alarms (refer to the
System Coldstart Data and System Coldstart Data Setup Procedure in Chapter
5 for details).
5). Adjust slice or move adjacent actuators.
6). If a spare port on the SIO exists, move actuators and reconfigure software for
new port-to-actuator table (refer to the Port-to-Actuator Data and Port-to-Actuator
Data Setup Procedure sections in Chapter 5 for details). Otherwise
replace the SIO (refer to Electronics Maintenance in Chapter 10 for details).
Digital Feedback Error
Explanation:
Motor output and digital feedback do not match.
Possible Causes:
1). Defective LSP power supply.
2). Insufficient DC voltage available to drive actuators.
3). Not enough LSP power supplies are installed in the system.
4). Shorted or defective solenoid in actuator.
5). SIO power cable defects (corrosion, bad contacts, broken wires).
6). Driver failure on SIO port.
Recommended Service Action:
1). Check the status of LSP power supplies displayed as part of the ASPC SIO data
on the Individual SIO Data video page on the Service Workstation. Replace
any failed power supplies (refer to Electronics Maintenance in Chapter 10 for
details).
2). The coldstart variable “# of Actrs SIO may simultaneously move if no errors”
may be reduced to alleviate overload of the LSP power supplies during large
moves (refer to the System Coldstart Data and System Coldstart Data Setup
Procedure in Chapter 5 for details).
3). The coldstart variable “# of Actrs SIO may all move if ASPC limits
exceeded” may be reduced as long as its value is greater than zero (0) (refer to
the System Coldstart Data and System Coldstart Data Setup Procedure in
Chapter 5 for details).
4). Service/replace actuator (refer to the Smart Weight Profiler Linear Stepper
Actuator Service Manual, 101794-004 for details).
5). Swap SIO power cables between adjacent SIOs to determine if digital feedback
errors follow power cable. Ensure actuator connector locked into SIO
receptacle.
6). If a spare port on the SIO exists, move actuators and reconfigure software for
new port-to-actuator table (refer to the Port-to-Actuator Data and Port-to-Actuator
Data Setup Procedure in Chapter 5 for details). Otherwise, replace
the SIO (refer to Electronics Maintenance of this manual for details).
Actuator Moving in Wrong Direction
Explanation:
The direction of actuator feedback change was not the same as the direction of a
requested set point change. If an actuator set point change is greater than the
coldstart variable “Min Actr Change Requested to Test Insufficient Move” and the
change in actuator feedback is less than the coldstart variable “Min Feedback
Change to Not Alarm Insufficient Movement”, then the direction of feedback
change is checked against the direction of set point change. If the directions are
not the same, then a wrong direction error occurs.
Possible Causes:
1). The Actuator Direction and Sensor Direction on the Sensor Coldstart Data
video page do not match the actuator and Position Sensor hardware
configuration.
2). An adjacent actuator moved such that its force on the slice lip caused the
actuator in question to move in the wrong direction.
3). Incorrect slew rate configured for the actuator.
4). The actuator is wired incorrectly.
5). Noisy or defective feedback (defective Position Sensor or wiring).
Recommended Service Action:
1). Correct the Actuator and Sensor Direction Data Configuration (refer to the
Sensor Coldstart Data and Sensor Coldstart Data Setup Procedure in Chapter
5 for details).
2). The coldstart variable “Min Feedback Change to Not Alarm Insufficient
Movement” may be increased to alleviate nuisance wrong direction alarms
(refer to the System Coldstart Data and System Coldstart Data Setup Procedure
in Chapter 5 for details).
3). Refer to the Sensor Coldstart Data in Chapter 6 for specific actuator slew rates.
4). Service/replace actuator (refer to the Smart Weight Profiler Linear Stepper
Actuator Service Manual, 101794-004 for details).
5). Service/replace Position Sensor (refer to the Smart Weight Profiler Linear
Stepper Actuator Service Manual, 101794-004 for details).
Shorted Solenoid
Explanation:
The current limit interrupt in the SIO detected an actuator solenoid current greater
than the coldstart variable “Actuator Current High Limit” during an actuator
movement. Defective solenoids are indicated on the Individual Actuator Data video
page in the Smart Weight Profiler System Utility.
Possible Causes:
1). Short circuit in the solenoid.
2). The SIO power cable is defective (corrosion, bad contacts, shorted wires).
3). Driver failure on SIO port.
Recommended Service Action:
1). Service/Replace Solenoid or Service Module (refer to the Smart Weight Profiler
Linear Stepper Actuator Service Manual, 101794-004 for details).
2). Swap SIO power cables between adjacent SIOs to determine if open solenoid
errors follow power cable. Ensure actuator connector is locked into SIO
receptacle.
3). If a spare port on the SIO exists, move actuators and reconfigure software for
new port-to-actuator table (refer to the Port-to-Actuator Data and Port-to-Actuator
Data Setup Procedure in Chapter 5 for details). Otherwise replace
the SIO (refer to Electronics Maintenance in Chapter 10 for details).
Shorted Select Line
Explanation:
The current limit interrupt in the SIO detected a current greater than the coldstart
variable “Actuator Current High Limit”. The solenoid causing the short is known,
but not the exact actuator.
Possible Causes:
1). A short circuit across the high side of the solenoid.
Recommended Service Action:
1). View the Individual Actuator Data video page on the Service Workstation to
determine the exact solenoid shorted.
2). Remove all but one of the actuators with the shorted select line error by
disconnecting the actuator from the SIO.
3). Clear errors using the C command on the Local Operator Panel Utility.
4). Output new set points to SIO reporting Shorted Select Line error. If error
reoccurs, the shorted solenoid is in the actuator being tested; otherwise retry
Steps 2-4 with another actuator.
5). Service/replace Solenoid or Service Module (refer to the Smart Weight Profiler
Linear Stepper Actuator Service Manual, 101794-004 for specific actuator
troubleshooting).
6). Replace the SIO (refer to Electronics Maintenance in Chapter 10 for details).
Shorted Sequence Line
Explanation:
The current limit interrupt in the SIO detected a current of greater than the coldstart
variable “Actuator Current High Limit”. The actuator causing the short is known,
but not the exact solenoid.
Possible Causes:
1). A short circuit across the low side of the solenoid.
Recommended Service Action:
1). Check for defective or disconnected LEMO connector.
2). Refer to the Smart Weight Profiler Linear Stepper Actuator Service Manual,
101794-004 for specific actuator troubleshooting.
3). Service/replace Solenoid or Service Module.
4). Replace the S1O (refer to Electronics Maintenance in Chapter 10 for details).
SIO Offline
Explanation:
The MPRC board in the ASPC is not receiving message responses from the MOTOR
SIO associated with the actuator displaying the error.
Possible Causes:
1). Power or serial communications cable is not connected to the SIO.
2). The SIO software has not been loaded or the existing software on the SIO has
become corrupted.
3). The SIO is defective. The error LED on the SIO is solid whenever SIO startup
diagnostics have failed, indicating the board is unusable.
Recommended Service Action:
1). Check power and communications cable connections.
2). Load SIO with software (refer to Smart Profiler System Software Manual,
101794-002 for SIO programming procedures).
3). Replace the SIO (refer to Electronics Maintenance in Chapter 10 for details).
Actuator Not Configured on SIO Port
Explanation:
The actuator is not configured on any SIO port.
Possible Causes:
1). Incorrect port-to-actuator data configuration.
Recommended Service Action:
1). Check port-to-actuator data configuration using the Port-to-Actuator Data video
page on the Service Workstation. Reconfigure software for correct port-to-actuator
data (refer to the Port-to-Actuator Data and Port-to-Actuator Data
Setup Procedure in Chapter 5 for details).
Actuator Manually Disabled by the User
Explanation:
The actuator has been put out of service by an operator using the Local Operator
Panel Utility of the Smart Weight Profiler System Utility.
Possible Causes:
1). This is usually done when a known defective actuator exists.
Recommended Service Action:
2). If the actuator is still defective, take no action. Only after the defective actuator
has been repaired or replaced should the actuator be put back into service (refer
to the Procedure to Take Actuators Out of Service in Chapter 7 for details).
Actuator Feedback Errors
Invalid Feedback
Explanation:
The Actuator Position Sensor input voltage is greater than the coldstart variable
“Position Sensor Upper Linear Range Voltage Hard Limit” or less than the coldstart
variable “Position Sensor Lower Linear Range Voltage Hard Limit”.
Possible Causes:
1). Position Sensor wired incorrectly, noisy, faulty, or removed from mount.
2). Position Sensor position grossly out of acceptable range.
3). Incorrect mechanical offsets generated by sensor calibration.
4). Software limits set too narrow for range of actuator movement.
Recommended Service Action:
1) Inspect the Position Sensor and replace if necessary (refer to the Smart Weight
Profiler Linear Stepper Actuator Service Manual, 101794-004 for details).
2). Using the manual adjustment shaft at the top of the actuator, manually move
the actuator inside the acceptable range.
3). View mechanical offsets on the Sensor Calibration Data video page for
correctness. If necessary, rerun sensor calibration to generate new mechanical
offsets (refer to the Sensor Calibration Data in Chapter 6 for details).
4). Increase the value of the coldstart variable “Position Sensor Upper Linear
Range Voltage Hard Limit” and/or lower the value of the coldstart variable
“Position Sensor Lower Linear Range Voltage Hard Limit” (refer to the System
Coldstart Data and System Coldstart Data Setup Procedure in Chapter 5 for
details).
Note: Be very careful when widening these limits; if limits are set too wide,
slice kinking caused by a defective Position Sensor can result.
=
Unexpected Position Change
Explanation:
The actuator feedback changed by more than the coldstart variable “Unexpected
Position Change Dead Band” when a set point change was not in progress.
Possible Causes:
1). Manual removal of the Position Sensor from the actuator mounting.
2). Manual adjustment of the actuators when system is not in local.
3). Position Sensor failed, noisy, or sticking.
4). Adjacent actuator movement caused slice cross talk.
5). Severe temperature change in wireway (headbox).
6). Gross slice change on headbox.
7). Slice connection slipped.
Recommended Service Action:
1). Manual movement of the actuators or tampering with the Position Sensors will
trigger the unexpected position change error unless the ACTUATORS IN
LOCAL message is on the Local Operator Panel video page.
2). Inspect Position Sensor and clean/replace as required. Increasing the coldstart
variable “Unexpected Position Change Dead Band” may alleviate the error, but
this value is recommended to be no more than 3 mils (refer to the System
Coldstart Data and System Coldstart Data Setup Procedure in Chapter 5 for
details).
3). Investigate reasons for sudden temperature shift on headbox.
4). Investigate slice on headbox.
Sensor at High Range Limit
Explanation:
The Position Sensor output voltage is greater than the coldstart variable “Position
Sensor Upper Linear Range Voltage Soft Limit”.
Possible Causes:
1). Actuator position is approaching high operating range of the Position Sensor.
2). Position Sensor wired incorrectly, noisy, faulty, or not properly installed in
mount.
3). Slice connection loosened or slipped.
Recommended Service Action:
1). Since the result of this error condition is an alarm only, no action need be taken.
If you want to eliminate the error condition, increase the value of the coldstart
variable “Position Sensor Upper Linear Range Voltage Soft Limit” (refer to the
System Coldstart Data and System Coldstart Data Setup Procedure in Chapter
5 for details).
2). Inspect Position Sensor and replace if needed.
3). Inspect/repair loose slice connections.
Sensor at Low Range Limit
Explanation:
The Position Sensor output voltage is less than the coldstart variable “Position
Sensor Lower Linear Range Voltage Soft Limit”.
Possible Causes:
1). Actuator position is approaching low operating range of Position Sensor.
2). Position Sensor wired incorrectly, noisy, faulty, or not properly installed in
mount.
3). Slice connection loosened or slipped.
Recommended Service Action:
1). Since the result of this error condition is an alarm only, no action need be taken.
If you wish to eliminate the error condition, lower the value of the coldstart
variable “Position Sensor Lower Linear Range Voltage Soft Limit” (refer to the
System Coldstart Data and System Coldstart Data Setup Procedure in Chapter
5 for details).
2). Inspect Position Sensor and adjust/replace if needed.
3). Inspect/repair loose slice connection.
Invalid AI Reference
Explanation:
The Analog input reference voltage deviates from an acceptable “Invalid AI
Reference” specification limit.
Possible Causes:
1). Defective SIO
Recommended Service Action:
1). Replace SIO (refer to Electronics Maintenance in Chapter 10 for details).
Bend Limit
Explanation:
The Actuator Feedback has violated first or second bend limits with respect to
adjacent actuators.
Possible Causes:
1). Manual movement of an actuator, replacement of actuator or Position Sensor.
Recommended Service Action:
1). When system is taken from local to remote, the Smart Weight Profiler will
attempt to relieve the bending condition. If the bending condition exists due
to an actuator malfunction, the actuator can be manually moved to relieve the
bending condition, until the malfunction is resolved.
Sensor Manually Disabled by the User
Explanation:
The Position Sensor has been put out of service by an operator using the Local
Operator Panel Utility of the Smart Weight Profiler System Utility.
Possible Causes:
1). This is usually done when a known defective Position Sensor exists.
Recommended Service Action:
1). If the Position Sensor is still defective, take no action. Only after the defective
actuator has been repaired or replaced should the actuator be put back into
service (refer to the Procedure to Take Sensors Out of Service in Chapter 7 for
details).
ASPC SIO Errors
ASPC SIO Board Temperature Too High
Explanation:
The ASPC SIO temperature exceeds the coldstart variable “ASPC SIO Board High
Temperature Limit”. The ASPC SIO temperature is displayed as part of the ASPC
SIO data on the Individual SIO Data video page at the Service Workstation.
Possible Causes:
1). Internal temperature of the ASPC cabinet is too hot.
Recommended Service Action:
1). Check ASPC cabinet heat exchanger for power/operation.
2). Reduce ambient temperature around ASPC cabinet.
3). Refer to the System Coldstart Data and System Coldstart Data Setup Procedure
in Chapter 5 for appropriate configuration of the coldstart variable “ASPC SIO
Board High Temperature Limit”.
4). Reduce the coldstart variable “# of Actrs SIO may simultaneously move if no
errors” as long as its value is greater than zero (0) and the ASPC SIO temperature
too high condition is new and intermittent (refer to the System Coldstart Data
and System Coldstart Data Setup Procedure in Chapter 5 for details).
5). Reduce the coldstart variable “# of Actrs SIO may all move if SIO temp too
high” as long as its value is greater than zero (0) and the ASPC SIO temperature
too high condition persists (refer to the System Coldstart Data and System
Coldstart Data Setup Procedure in Chapter 5 for details).
ASPC SIO Offline
Explanation:
The MPRC board in the ASPC is not receiving message responses from the ASPC
SIO.
Possible Causes:
1). Power or serial communications cable not connected to the SIO.
2). SIO software has not been loaded or contains unexecutable software.
3). The SIO is defective. The error LED on the SIO is solid whenever SIO startup
diagnostics have failed, indicating the board is unusable.
Recommended Service Action:
1). Check power and communications cable connections.
2). Load SIO with software (refer to Smart Profiler System Software Manual,
101794-002 for SIO programming procedures).
3). Replace the SIO (refer to Electronics Maintenance in Chapter 10 for details).
Motor SIO Errors
Motor SIO Board Temperature Too High
Explanation:
A Motor SIO temperature exceeds the “Motor SIO Board High Temperature Limit”.
The Motor SIO temperature is displayed as part of the Motor SIO data on the
Individual SIO Data video page at the Service Workstation.
Possible Causes:
1). Internal temperature of the Motor SIO is too hot.
Recommended Service Action:
1). Refer to the System Coldstart Data and System Coldstart Data Setup Procedure
in Chapter 5 for appropriate configuration of the coldstart variable “Motor SIO
Board High Temperature Limit”.
2). Reduce the coldstart variable “# of Actrs SIO may simultaneously move if no
errors” as long as its value is greater than zero (0) and the MOTOR SIO
temperature too high condition is new and intermittent (refer to the System
Coldstart Data and System Coldstart Data Setup Procedure in Chapter 5 for
details).
3). Reduce the coldstart variable “ # of Actrs SIO may all move if SIO temp
too high” as long as its value is greater than zero (0) and the MOTOR SIO
temperature too high condition persists (refer to the System Coldstart Data and
System Coldstart Data Setup Procedure in Chapter 5 for details).
Motor SIO Offline
Explanation:
The MPRC board in the ASPC is not receiving message responses from a MOTOR
SIO.
Possible Causes:
1). Power or communications cable defective or not connected to the SIO.
2). SIO has not been loaded or contains unexecutable software.
3). SIO is defective. The error LED on the SIO is solid whenever SIO startup
diagnostics have failed indicating the board is unusable.
Recommended Service Action:
1). Check power and communications cable and cable connections.
2). Load SIO with software (refer to Smart Profiler System Software Manual,
101794-002 for SIO programming procedures).
3). Replace the SIO (refer to Electronics Maintenance in Chapter 10 for details).
Motor SIO Communication Channel Chip Failure
Explanation:
SIO startup diagnostics indicate communications chip is defective.
Possible Causes:
1). SIO communications chip diagnostic failed.
Recommended Service Action:
1). SIO is unusable. Replace the SIO (refer to Electronics Maintenance in Chapter
10 for details).
Motor SIO Communication Channel Driver Failure
Explanation:
MPRC board in ASPC not communicating with the MOTOR SIO on the channel
referenced in alarm message.
Possible Causes:
1). Defective driver output on communications processor in SIO
2). Shorted driver output in communications processor in SIO.
Recommended Service Action:
Since each Motor SIO communicates over 2 channels, all messages will be
transmitted through the single remaining channel. System operation is
uninterrupted however failure of both communication channels will result in loss
of all actuators connected to the SIO.
1). Replace SIO with spare SIO if spare is available. If not replace with the ASPC
SIO. Label the defective SIO indicating the failed open channel and utilize as
the ASPC SIO.
2). A shorted driver on one Motor SIO will disable the associated channel on ALL
Motor SIOs. To isolate the defective SIO unplug all the Motor SIOs power
cables and replug ONE at a time. Examine the newly plugged SIOs diagnostic
status on the Individual SIO Data video page at the Service Workstation to
determine the faulty SIO. Replace SIO with ASPC SIO or spare SIO.
Maintenance procedures
Electronics Maintenance
Power and Temperature Checks
Use the Service Workstation software periodically to check voltages and
temperatures.
AccuRay Smart Processing Center (ASPC) Environmental
Checks
Check the heat exchanger filter daily until the correct replacement schedule for your
particular installation is identified. After that, follow the schedule.
Each time the filter is replaced (depending on your maintenance schedule), or if
any of the temperatures in the AccuRay Smart Processing Center (ASPC) are
abnormally high, check to see if the heat exchanger core needs to be cleaned and
verify all the fans are operating.
ASPC Air Filter Replacement
The air filter is made of a special material and should only be replaced, not cleaned.
The air filter can be replaced by opening the louvered filter door and keeping the
ASPC closed. Install the new filter with the blue side in and the white side out.
Heat Exchanger Core Removal and Replacement
The heat exchanger core is designed to be easily removable for cleaning. For
removal and replacement of the Heat Exchanger Core, follow the procedure below.
Note: According to the PROAIR logo, the heat exchanger cover is upside
down (the heat exchanger would have to be mounted the opposite
way if it were mounted on the outside of the Electronics Box).
1. Unlatch the two spring latches on the top of the heat exchanger and swing the
cover down and away. The core is now visible. Note how the core is mounted.
It is not symmetrical and must be replaced the same way it was removed.
2. Slide the core out of the plastic slides. There are no wires or plumbing to worry
about.
3. Blow off any accumulated dust with compressed air. The core has a brown,
Heresite baked phenolic coating for corrosion protection that can be cleaned
with detergents or solvents but should not be cleaned with caustic solutions like
sodium hydroxide or trisodium phosphate (TSP).
Be careful not to bend the cooling fins when removing
or cleaning the heat exchanger core.
4. Replace the dry core by sliding it back into the grooves in the plastic slides. Do
not put it back upside down. It is the cover that has the upside down logo.
5. Hook the cover on the bottom of the heat exchanger. Swing it up and latch the
two spring latches.
Replacement
Smart Input/Output (SIOs)
SIOs are designed to be hot plugged. They may be replaced with the rest of the
system operating. It is not necessary to turn power off when replacing an SIO.
Printed Circuit Board
The Printed Circuit Boards in the ASPC ARE NOT hot pluggable. There is no
redundancy for the MPRC or ECPSR. Removing either of them would take the
system down any way so they are not designed for hot plugging. LSPs are not to
be hot plugged due to the hazardous voltage on them and the high current capability
of the ±12 Volt buss.
The LSPs are designed with significant power outage ride through capability. It is
therefore necessary to wait a short time after powering down the ASPC before the
DC supplies are actually off. Wait until the +400 volt light goes out before removing
a Printed Circuit Board.
It will be necessary to do a “PMM Reload” after restarting the ASPC.
Rack Fan Replacement
There are five fans in the fan subassembly under the ASPC card rack. To check or
replace a fan, use the following procedure.
1. Unplug the fan cable harness from J1 on the backplane.
2. While pulling the two spring plungers, the entire fan subassembly should slide
out of the rack.
3. When replacing the fan subassembly, make sure that none of the cables will be
pinched or will obstruct any of the fans.
Be careful working around the fan while it is running.
Keep your fingers clear of the blades.