Software Manual

Control Panel
Service Guide
 Software Manual
Control Panel Service Guide

Edition AB, September 2008

This manual has part No 51567
 0-1

Part 0: General information

This manual

Intended use of this manual

This manual covers the control panel for use with Quartz Supreme Pre-Bake and
Post-Bake ovens and is intended for service personnel. The manual contains service
information regarding trouble shooting, setup, calibration procedures, etc. The service
technician should also be familiar with the User's Manual and be able to operate the
machine.

#
This manual is for Service Technicians only.
The directions given must not be followed by unauthorized personnel.

Always read the Safety Instruction Manual part No 21741 before working
with the processor.

Reservations
• This manual was written and illustrated using the best possible information
available at the time of publication.
• Any differences between this manual and the equipment reflect improvements
introduced after the publication of the manual.
• Changes, technical inaccuracies and typographic errors will be corrected in
subsequent editions.
• As a part of our policy of continuous improvement, we reserve the right to alter
design and specifications without further notice.

Copyright © 2008 by GLUNZ & JENSEN A/S.

Software Manual - Control Panel Service Guide 0709

0-2

Notes, Cautions, and Warnings!

Throughout the manual notes, cautions, and warnings are written in bold like the
examples below:

Symbol Meaning Explanation

The operator should observe and/or act according to the

" Note information to obtain the best possible function of the

equipment.

The operator must observe and/or act according to the

$ Caution information to avoid any mechanical or electrical damage to

the equipment.

The operator must observe and/or act according to the

# Warning information to avoid personal injury.

0709 Software Manual - Control Panel Service Guide

 0-3

Table of Contents

Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1

This manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1
Intended use of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1
Reservations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1
Notes, Cautions, and Warnings! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2

Part 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

User Interface (UI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Power on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
H3 flash sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Part 2: Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

Confirming, Cancelling and Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Confirming Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Cancelling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

Part 3: Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

Installing a new system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Set Date/Time:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Install software: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Special cases: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Error cases: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Copy program: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
CAL Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Default Program Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Default CAL Control values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Default CAL Control values, continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Setup setter interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Error cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
How to set Ignore busy from exit equipment = yes . . . . . . . . . . . . . . . . . . . . . 3.6
Read Setter ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

Part 4 Change Conveyor Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Error cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Read Conveyor Speed Set point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Part 5: Software Update. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Normal procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Software Manual - Control Panel Service Guide 0709

0-4

Result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Error cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Part 6: IP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Possible problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Direct Computer link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

Part 7: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

Power missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Extracting Software Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Error cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Alarms and status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Message IDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
LED signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Troubleshooting without USB logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Software Update Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
System Messages Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

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 Introduction
1-1
User Interface (UI)

Part 1: Introduction
User Interface (UI)

H1 H4
Power P1 Conveyor ON

H2 H5
Alarm P2 Fan ON

H6
P3 Heater ON

H3 H7
ON P4 Autotune

Power on/off
When the system is powered on, LED H1 should light. You must then wait for
approximately one minute for the system to initialize. During initialization LED H3
will flash on and off in repeated intervals until ready for operation (see diagram
below). When the system is ready, LEDs H2, H3, H4, H5, H6 and H7 should light at
the same time. An audible alarm sounds to confirm that the system is now ready for
operation.

H3 flash sequences
ON
Service Mode
OFF

ON
Configuration
Mode OFF

ON
Cooling
OFF

ON
Working
OFF

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 Introduction
1-2
Power on/off

0709 Software Manual - Control Panel Service Guide

 Service functions
2-1
Confirming, Cancelling and Error handling

Part 2: Service functions

To enter and exit service mode, use the following key combination. Observe the correct
order.

+ P1 + P4 = Service Mode.

Hold down the standby button and then press P4 and P1, keeping all buttons pressed
for about 3 seconds. An audible alarm (buzzer) will be heard when entering service
mode. The standby LED (H3) will flash green (refer to diagram on page 1-1). Once in
service mode the following functions are available:

Press key Function

P1 Start/stop the conveyor. LED flashes when the function is active.

P2 Start/stop the fans. LED flashes when the function is active.

Start/stop the heating. Also starts conveyor and fans. LED flashes when
P3
the function is active.
P4 Start/stop autotune. LED flashes when the function is active.

"
All configuration and service functions described in this manual require the
system to be in service mode.

Confirming, Cancelling and Error handling

Confirming Operation
Press and hold the standby key for 3 seconds after configuration to confirm settings
and exit configuration mode.

Cancelling Operation
Most configuration operations can be cancelled before confirming operation by
pressing the standby key .

Error handling
If you enter an invalid value or if the system detects an error, the buzzer will sound
and the alarm LED H2 will flash red.

Software Manual - Control Panel Service Guide 0709

 Service functions
2-2
Confirming, Cancelling and Error handling

0709 Software Manual - Control Panel Service Guide

 Software Installation
3-1
Installing a new system

Part 3: Software Installation

Installing a new system

$
Only use this procedure when the system has not yet been loaded with any
software (for example in connection with replacing spare parts).

"
This installation will most likely cause the system to lose its current
configuration. If software is already installed on the system, use the
procedure described on page 5-1.

Set Date/Time:
1 Create a text file called autorun.gj on your USB stick. It should contain the
following two lines:
• date -s MMDDhhmmYYYY
• hwclock -w

MMDDhhmmYYYY should be replaced with the current date and time:

MM = month, e.g. 07
DD = day of month, e.g. 09
hh = 24 hour, e.g. 15
mm = minutes, e.g. 54
YYYY = year, e.g. 2007

Install software:
2 Copy the software package (*.gjpkg and autorun.gj) to your USB memory stick:

Software Manual - Control Panel Service Guide 0709

 Software Installation
3-2
Installing a new system

3 Create a text file and name it bootswupdate.txt. :

4 The text file should contain just one line. Open the bootswupdate.txt file and add
the name of the .gjpkg package, e.g. xxx-20070330.gjpkg.

5 Save file.
6 Safely remove the USB memory stick.
7 Power off the oven.
8 Insert the USB memory stick into the left side of the electronics cabinet and then
power on with the mains switch.
9 Wait for about two minutes. LED H3 should start flashing.
10 Wait 1-15 minutes (or up to 30 minutes if the installation program detects
problems). The LED H3 should now be off.
11 Check that the installation has been successful by viewing the status file
swupdate.log.txt that should be written on the USB memory stick (see also page 7-7,
“Software Update Messages” and “System Messages Overview on page 7-9.
You can now proceed with the system configuration.

0840 Software Manual - Control Panel Service Guide

 Software Installation
3-3
System Configuration

System Configuration
Enter service mode:

+ P1 + P4 (keep pressed for three seconds, observe order)

Hold down the standby button and then press P1 and P4, keeping all buttons pressed
for about 3 seconds. Use the following key sequences to automatically configure CAL
and GNUC 2:

Configuration CAL setup CBO/PBO Unit selection Confirm Wait

mode selection
Hold for three Press Press Hold for
seconds Set CAL three
ADDR = 1 seconds
See P1 (CPO) or P3 (metric) or Configuration
+ P4
sequence of GNUC and
P2 (PBO) P4 (US)
observe order below CAL Control
in progress
beep+ slow P flash P flash beep fast

Special cases:
• If the Copy Program key has been pressed, and neither the CPO/PBO nor the unit
has been selected, the system will only copy the program parameters without
resetting the CAL control.

Error cases:
• If bad CAL connection or missing power supply
• CAL control has not been set to ADDR=1

Copy program:
While in service mode + configuration mode you can copy a program setting to other
programs by pressing + P function key and holding down for three seconds.

Troubleshooting
If the configuration fails, try configuring the CAL manually. Refer to the table above
under “Configuration mode”.

Software Manual - Control Panel Service Guide 0840

 Software Installation
3-4
System Configuration

CAL Setup
Follow the steps in the first column to set the CAL address to “1”.

Press Function Indication

+ and hold for 3 s to access CAL configuration
or = scroll up/down to access LEVL Display flashes alternately C,
1, 2, 3, 4 & 5
+( or ) = scroll up/down to access LEVEL C
(communication)
or to select ADDR Flashes 0 - 254
+( or ) to select setting “1”
+ and hold for 3 s to save settings and exit
CAL configuration

Default Program Values

When configuring a system, the following default parameters are set:

Program Prebake Postbake

cm/min in/min C F cm/min in/min C F
P1 85 33 140 284 85 33 250 482
P2 91 36 140 284 91 36 250 482
P3 110 43 140 284 110 43 250 482
P4 130 51 140 284 130 51 250 482

0709 Software Manual - Control Panel Service Guide

 Software Installation
3-5
System Configuration

Default CAL Control values

Settings for CAL 3300
Item LEVEL 1 LEVEL 2 LEVEL 3
1 TUNE oFF SP.IP Read only SP1.D SSD
2 BAND Set by Autotune HAND oFF SP2.D RLY
3 INT.T Set by Autotune PL1 100 BURN UP.SC
4 DERT Set by Autotune PL2 100 REV.D 1R 2R
5 DAC Set by Autotune SP2.A FS.lo REV.L IN 2N
6 CYC.T 1,5 SP2.B none SPAN 0.0
7 OF.ST 0 DI.SP 1 ZERO 0.0
8 SP.LY oFF HI SC CPO: 175 CHEK OFF
PBO: 280
9 SPRR 0 LO.SC 0 READ VAR
10 SPRN oFF INPT TCK TECH CTA
11 SOAK – UNIT °C/°F VER 392
12 SET 2 80 RSET NONE
13 BAND 2 2.0
14 CYC 2 on.oF

Default CAL Control values, continued

Settings for CAL 3300
Item LEVEL 4 LEVEL C
1 Addr 1 (set manually)
2 DIS.SDIS.S 32 RLY

Software Manual - Control Panel Service Guide 0709

 Software Installation
3-6
System Configuration

Setup setter interface

• Enter service mode:

+ P1 + P4 (keep pressed for three seconds, observe order)

beep+ long slow

• Enter setter configuration

Setter mode Enter Setter, e.g. #13 Confirm setting

Hold for 3 seconds Press 1 time Press 3 times Hold for 3 seconds

+ P2
P2 P3
observe order
beep+ slow 1* P flash 3* P flash beep

Result
Setter interface logic is changed.

Error cases
Entered setter ID not within valid range 1-17.

How to set Ignore busy from exit equipment = yes

• Enter service mode:

+ P1 + P4 (keep pressed for three seconds, observe order)

beep+ long slow

• Enter setter configuration:

Setter mode Enable Ignore busy Return to Service Mode

Hold for 3 seconds Press 1 time Press 1 time

P2 P3
+ +
observe order observe order
beep+ slow 1* P flash beep

0840 Software Manual - Control Panel Service Guide

 Software Installation
3-7
System Configuration

Read Setter ID
It is possible to read out the selected setter interface. In setter mode, press P4 and the
program LED’s will flash the setter ID.

Read Speed Read out of setter, e.g.#13

P4 P4 H5 H6

P P flash 4* P P flash 3* P P flash

Software Manual - Control Panel Service Guide 0709

 Software Installation
3-8
System Configuration

0709 Software Manual - Control Panel Service Guide

 Change Conveyor Speed
4-1

Part 4 Change Conveyor Speed

To change the conveyor speed for a specific program, turn on the oven and select the
program to change.

Turn On Select Program

P1 or P2 or P3 or P4

1 Enter service mode:

+ P1 + P4 (keep pressed for three seconds, observe order)

beep+ long slow

2 Enter speed configuration (units depend on unit setup).

Confirm
Speed Mode Enter Speed. e.g.: 143 cm/min Wait
setting
Hold 3 seconds Press x 1 Press x 4 Press x 3 Hold 3 s approx. 1 s

+ P1 Configuration
P1 P2 P3
in progress
(observe order)
beep+H3 1 x H4 4 x H5 3 x H6 beep H3 fast
slow flash flash flash

"
+ P1 resets all values to zero. Enter the new speed with a combination of
keys P1-P3.

Result
The conveyor motor changes to the new speed and a new set point is stored (not lost
when power is off).

Error cases
Entered speed not within valid range 50-225 cm/min.

Read Conveyor Speed Set point

It is possible to read the speed setpoint. In Service Mode (see above for key
combination) + Speed Mode, press P4. The program LEDs will flash the speed and the
program number.

Software Manual - Control Panel Service Guide 0709

 Change Conveyor Speed
4-2

Read out of active program

Read Speed Read out of Speed, e.g.: 143 cm/min
e.g.: 4

P4 P4 H4 H5 H6 H7

flash 1 x flash 4 x flash 3 x flash 4 x flash

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 Software Update
5-1
Normal procedure

Part 5: Software Update

Normal procedure

"
The following procedure should be used to update software if the oven
already has software installed. The advantage of using this method is that all
configuration parameters are left intact.

1 Copy the software package to your USB memory stick (*.gjpkg).

2 Create a text file called swupdate.txt.
3 The text file should contain one line: pbo-XXXXXXXX.gjpkg
(xxxxxxxxx = date/version.
4 Insert the USB memory stick in GNUC 2.
5 Enter service mode:

+ P1 + P4 keep pressed for three seconds, observe order).

6 Activate the update function:

USB Mode Select SW update Confirm selection Wait

Hold for 3 seconds Press Hold for 3 seconds 1-30 minutes

+ P3 P1 Software update in
progress
observe order!
beep +H3 slow H4 flashes beep H3 fast

Result
A status file called swupdate.log.txt is copied to the USB memory stick. The system
will reboot automatically and enter OFF mode, if the software update is successful.
Refer to this log file for information when troubleshooting (see page 7-7, “Software
Update Messages“ and “System Messages Overview on page 7-9).

Error cases
• Software package not found on the USB memory stick
• Checksum error on software package
• Faulty SOM

Software Manual - Control Panel Service Guide 0840

 Software Update
5-2
Normal procedure

0709 Software Manual - Control Panel Service Guide

 IP Setup
6-1
Steps

Part 6: IP Setup
To set up the IP address to e.g.:

Processor: 172.16.0.10
Subnet Mask: 255.255.255.0
Default Gateway: 172.16.0.1
(IP settings should be obtained from the local IT administrator)

Steps
• Open a simple ASCII text editor such as Notepad and enter the following:

• Save the text on the USB memory stick (filename: autorun.gj):

It is important to select “all files” to ensure the correct file extension.

• Power off the processor at main power.
• Insert the USB in the processor USB slot.

Software Manual - Control Panel Service Guide 0840

 IP Setup
6-2
Steps

• Power on the processor

• Wait 2 minutes
• Remove the USB memory stick. The autorun.gj should now be renamed to
oldautorun.gj
• A file startup.log.txt should have been generated on the USB containing the IP
address and the start up status:
Log Start: Thursday 2007-09-11 16:01 IP: 172.16.0.10
Software is started
Log End: Thursday 2007-09-11 16:02

Possible problems
• Misspelling in autorun.gj
• USB not properly inserted
• No power supply to the MIO board

Additional information
During power up the processor looks for the file autorun.gj. If the file is found, the
system will execute the statements listed in the file. The setubenv keyword sets a boot
parameter in the system.
setubenv = set uboot environment variable

autorun.gj line Explanation

setubenv dhcp no Disable DHCP (enable usage of above static IP address)
setubenv ipaddr 172.16.0.10 Set the IP address to 172.16.0.10
setubenv netmask 255.255.255.0 Set net mask to 255.255.255.0
setubenv gatewayip 172.16.0.1 Set default gateway to 172.16.0.11

0840 Software Manual - Control Panel Service Guide

 IP Setup
6-3
Direct Computer link

Direct Computer link

Requirements
1. Crossed Ethernet cable (usually red)
2. PC with remote client

Activation
1. Turn the oven power on
2. Unplug the LAN network
3. Wait for about two minutes
4. Connect the PC and GNUC with the (red) Ethernet cable
5. Activate the service connection

IP Mode Select service Confirm setting Wait

connection
Hold for 3 seconds Press Hold for 3 seconds a few seconds

+ P2 Configuration in progress
P1
observe order!

beep + slow flash beep fast

Result
It should now be possible to connect the Remote Enabling System to IP 169.254.13.0.
The system will exit this mode as soon as the Ethernet cable is removed, or the link
connection is lost to the laptop.

Error cases
1. The laptop is not set to DHCP.
2. The laptop has an alternative static IP setup assigned if the DHCP server is not
found.
3. Link is lost (Can be lost if the user logs in/out on the laptop)(Windows 2000 PC's
have powered off until the Direct Link function has been activated on the MMI).

Software Manual - Control Panel Service Guide 0840

 IP Setup
6-4
Direct Computer link

0840 Software Manual - Control Panel Service Guide

 Troubleshooting
7-1
Power missing

Part 7: Troubleshooting
Power missing
If there is no power to the system (H1 not ON), please check the following:
• Check whether the emergency stop S9-S11 has been activated.
• Check the supply voltage on the mains switch. For measurement, see the label at the
bottom of the electrical enclosure.
• Check the voltage to transformers T1 + T2 on X1 on the PCB transformer filter.
• Check interconnection X40 - X41 between the transformers and the HPU board.
• Check the cable between the HPU, P1 and MIO, P1 board.
• Check the cables from HPU, J11 and MIO, J11-J12 to interconnecting PCB.
• Check that the flat cables are connected to interconnecting PCB.

Extracting Software Logs

"
Software logs contain useful information which will be of help when
troubleshooting the system. See page 7-3 for a list of alarm messages.

1 Insert your USB memory stick in GNUC 2.

2 Enter service mode.

3 Activate log function.

USB Mode Select Logging Confirm selection Wait

Hold for 3 seconds Press Hold for 3 seconds 1-3 minutes

+ P3 P4 Configuration in
observe order! progress
beep +H3 H7 flashes beep H3 fast
slow

Result
A gnuc2……tar.gz file is generated with software debug information when the
function has ended. Unzip the file on your PC and open the index.html file to see the
information.

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Extracting Software Logs

Error cases
• USB not writable
• USB full
• Operating system has not started correctly: Insert USB and power off and on at main
power. Wait for about one and a half minutes. Check startup.log.txt file on USB and
error codes on page 7-9.

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Alarms and status messages

Alarms and status messages

Message IDs
The save logs to USB function extracts alarm and message events. The following table
lists the possible message identifiers.

ID Text Comment
8 Motor speed is too low The speed has been measured as being too slow.

Possible explanations:
• The transport is blocked
• The tacho disc is defective or loose
• The motor is defective
• The power supply is low

9 Motor speed is too high The speed has been measured as being too high

Possible explanations:
• The tacho disc is defective or loose
• The motor is defective
14 Temperature is not The temperature is being regulated to the desired level. The
stabilized alarm ceases as soon as the temperature is ok.

Possible explanations:
• The processor has just been activated and needs to warm up
• The temperature has fallen out of process range due to
environmental influence
• The program has been changed specifying a different
temperature
• The desired temperature set point has been changed
18 tacho signal missing The speed is not being measured – stopping and starting the
motor should clear the alarm.

Possible explanations:
• The transport is blocked
• The tacho disc is defective or loose
• The motor is defective
• A fuse has blown

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Alarms and status messages

ID Text Comment
25 Motor current sensor is The motor has been overloaded and caused the current limiter
activated to activate – stopping and starting the motor should clear the
alarm.

Possible explanations:
• The transport is blocked
• A fuse has blown
• Maintenance of all moving parts may be required
30 Checksum or bad magic Statistic data and date/time have been lost – power off and on
word error from RTC RAM, to reset alarm.
e.g. battery low
Possible explanations:
• Low battery power due to long period with main power turned
off. (Please check time and date)
• Note that the battery should re-power itself when the
processor is turned on.

67 Connection to IO boards The MIO cannot connect to one or more slave IO boards (E.g.
failed. HPU, MFU, CAL etc).
• Power down, solve the problem and then power up the
system

Possible explanations:
• Cable not connected
• Bad connection
• No power supply to slave
• Slave IO address not set correctly
• Faulty slave board
If present at power up, the problem will be the HPU board or the
connection to the board, otherwise the CAL connection/unit is
the problem.

68 Unknown error occurred The software has encountered an unexpected situation.

Create a log file on a USB memory stick and contact your
service technician who can then forward the data to the
manufacturer. Make a note on how the problem was detected
(in that context) and if possible how to reproduce the problem.

69 CAL Device Busy The software is unable to communicate with the CAL device

Possible explanations:
• Device is blocked because the user is operating the device
manually
• Faulty device

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7-5
LED signals

ID Text Comment
130 System has started in safe The software has attempted to start three times without
mode due to failed start up success. This can be provoked by turning power on and off
again three times before the system is fully initialized.
Turn the system off and on. If the alarm reoccurs, please check
the DataàConfigurationàInformationàHardwareàService
Code parameter and the alarm list for other alarms for more
in-depth explanation.
If no other alarms or no service code, create a log file on a USB
memory stick and contact your service technician who can then
forward the data to the manufacturer. Make a note on how the
problem was detected (in that context) and if possible how to
reproduce the problem.

131 Voltage missing Power supply to the HPU missing somewhere in the system.

Possible explanations:
• Slave fuse blown (e.g. HPU)
• Power supply connection disconnected
• Faulty IO board
132 Phase Sequence Alarm One or more phases missing or sequence invalid

135 Circuit broken The power circuit to the specified device(s) is broken or
disconnected by a safety monitoring device.
Please check circuit for errors or overload.

LED signals
H3 (green) H2 (red) Possible cause
Off Flashing Fast Toggling Alarm 132
Off Flashing Off Alarm 130
On On - Message 14
- Flashing Slow Toggling Alarm 18, 25
- Flashing Normal Toggling Alarm 67, 68, 69
On Flashing Fast Toggling Other alarms

• Slow toggling (every 2 seconds)

• Normal toggling (every second)
• Fast toggling (2 times per second)

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LED signals

Power up the system

Wait 1 minute H2
H1 ON flash If alarm Try to start the fans

Try to start conveyor Conveyor

Fans ok ok Alarm 30

Power
missing

Fans not Conveyor Alarm 131

See Part 7, “Power not ok
missing” ok

Buzzer Alarm 132

ON or 135

Buzzer Alarm 67
not ON (HPU)

Press standby key to Alarm after 5 s

No alarm enter On mode Alarm 18
+ motor stop

Alarm after Or boot problems, see

Alarm 67
1 min. (CAL) startup.log.txt on USB key

Motor stops Alarm 25

Motor does Alarm 8

not stop or 9

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Troubleshooting without USB logs

Troubleshooting without USB logs

Use the diagnostic flow chart opposite as an aid when troubleshooting the system
without an USB memory stick to record log messages.

Software Update Messages

The following messages can be written to the USB file swupdate.log.txt after a
software update:

Code Problem Remedy

S1040 Writing system parameters failed 1 Power off/on and retry
2 Replace SOM if error continues
S1050 MIO Avr writing failed 1 Power off/on and retry
2 Replace SOM or AVR if error continues
S1051 Preparing update script failed See details in swupdate.log.txt file for more
information
S1052 Finishing update script failed
S1053 Copying gmi configuration failed
S1054 Failed to setup SOM flash for writing
S1055 Formatting SOM data partition failed
1 Power off/on and retry
S1056 Writing partition to SOM flash failed
2 Try replacing SOM if error continues
S1057 Writing checksum failed
3 Contact manufacturer
S1058 Clearing boot marks failed
S1059 Updating boot marks failed
S1060 Calculating boot marks failed
S1098 Software Update successful
S1099 Software Update not needed
S1100 Please power off and on to continue
software update.
S1101 swupdate.txt missing on USB
S1102 No software package name in
swupdate.txt
S1103 Software package %s missing on USB
S1104 Wrong platform name %: expecting
%s
S1105 Checksum error in %s Please copy software to USB again
S1111 Error reading SIO hex file 1) Try again, 2) Replace SOM/MIO
S1112 Error in SIO hex file 1) Try again, 2) Replace SOM/MIO

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Software Update Messages

Code Problem Remedy

S1115 SIO software update error 1) Try again, 2) Replace SOM/MIO
S1120 SIO script error 1) Try again, 2) Replace SOM/MIO
S1121 SIO unknown error 1) Try again, 2) Replace SOM/MIO
S1122 SIO flash programming error 1) Try again, 2) Replace SIO board
S1123 SIO not connected Resolve connection problem and try again
S1201 Software install program not found Replace SOM module
S1202 Software update requires 16Mb flash Replace SOM module

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System Messages Overview

System Messages Overview

The following messages will be written to the USB file startup.log.txt in case of errors.
The file is written to a USB key while the system boots approximately 1½ minutes after
power on at main power. The USB key must be inserted before power on.

Code Problem Remedy

S1001 Software Checksum Error! Please insert USB with qtlib.tar.gz and
lib-XXXX.gjsw, and restart
S1002 Platform is not set! Please install software
S1003 Program(s) missing! Please reinstall software
S1004 Data Missing! 1 Power off/on and reconfigure
2 Replace SOM if error continues
S1005 Safemode forced! Return to normal mode with
sys-safemode-no.gjs
S1006 Invalid application flash image Please reinstall software
S1007 Invalid lib flash image Please reinstall software
S1008 Invalid text flash image Please reinstall software
S1009 Please restart remote software update
S1010 Remote software update in progress Wait for software update to finish
S1011 Resuming software update Wait for software update to finish
S1012 Local SW Update in progress
S1013 Ready for remote SW Update
S1014 Remote SW Update OK Acknowledge message on remote client

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