Micro-control as Service manual for MC-3-6 Page 1 of 16

Service manual for MC-3-6

Document number
MAN-05-003

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Table of contents
1. General ............................................................................................................................................ 3
1.1 Warranty.................................................................................................................................... 3
1.2 Definitions ................................................................................................................................. 3
1.3 The structure of this manual ..................................................................................................... 3
2. Troubleshooting ............................................................................................................................. 3
2.1 General ..................................................................................................................................... 3
2.2 Useful help resources ............................................................................................................... 3
2.3 Inspection inside the terminal ................................................................................................... 3
2.4 Assembling of the terminal/transmitter ..................................................................................... 4
2.5 Method ...................................................................................................................................... 4
2.6 Systems controlling the machine directly.................................................................................. 5
2.7 Systems with PLC serial communication.................................................................................. 5
3. Indications and error messages ................................................................................................... 6
3.1 Terminal .................................................................................................................................... 6
3.2 Base unit ................................................................................................................................... 8
4. Procedure for changing radio in the terminal ........................................................................... 14
4.1 Warning!.................................................................................................................................. 14
4.2 Execution ................................................................................................................................ 14
5. Procedure for changing the radio in the base unit................................................................... 14

6. Procedure for configuration........................................................................................................ 15

6.1 General ................................................................................................................................... 15
6.2 Equipment ............................................................................................................................... 15
6.3 Preparation before transfer to the terminal ............................................................................. 15
6.4 Preparation to transfer to the base unit .................................................................................. 15
6.5 Transferring the setup file ....................................................................................................... 15
Service fax for MC-3-6......................................................................................................................... 16

List of tables
Table 1 Fault symptoms regarding systems controlling the machine directly......................................... 5
Table 2 Fault symptoms regarding systems with PLC serial communication......................................... 5
Table 3 Possible indications in the ”BAT light emitting diode” ................................................................ 6
Table 4 Possible indications in the terminal display................................................................................ 7
Table 5 Possible indications on green LED of the base-unit processor module .................................... 8
Table 6 Possible indications on red LED on the processor module in the base unit.............................. 8
Table 7 Possible indications of the base unit’s 4 digit LED..................................................................... 9
List of flow charts
Flow chart 1 Troubleshooting function faults......................................................................................... 10
Flow chart 2 Troubleshooting communication fault............................................................................... 11
Flow chart 3 Troubleshooting the terminal ............................................................................................ 12
Flow chart 4 Troubleshooting the base unit .......................................................................................... 13

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1. General
1.1 Warranty
All the systems are delivered with one year’s warranty against material and manufacturing faults.
Micro-control covers repairs of equipment returned to Micro-control during the period of warranty.
Travel expenses for service at the customer’s site are not covered.
A representative from Micro-control must perform all the repairs of the equipment or the repairs must
be done in co-operation with Micro-control. If the user himself modifies the equipment, the warranty is
not valid.

1.2 Definitions
Terminal - the system unit carried by the operator.
Base unit - the system unit connected to the machine.
Link - a base unit connected to the PLC through a serial line

1.3 The structure of this manual

This manual describes indications and error messages that may occur in an MC-3-6 system. Most of
the error messages indicate defined faults, but some of the error messages require more
troubleshooting. Some of the faults that may occur, will not cause the system to display an error
message. A chapter about troubleshooting is therefore included in this manual.
If you cannot solve the problem on your own, you should contact Micro-control. A service fax template
is included in this manual. This fax template is made so that Micro-control shall be able to give faster
service and to help the user to get in touch with Micro-control in an easy way.

2. Troubleshooting
2.1 General
The purpose of the troubleshooting is to isolate the fault to a module so that the defective module(s)
can be changed. A representative from Micro-control shall execute all repairs of the modules.
Anyone troubleshooting the MC-3-6 system must have general knowledge of electronics and be
acquainted with static electricity protection (ESD-safety).
All service done by the customer is done at the customer’s risk.

2.2 Useful help resources

You should consult the wiring diagrams and the module specifications often during troubleshooting.
The wiring diagram shows which components that are part of the system and how these are
connected both in the terminal and in the base unit. Additionally the wiring diagram shows how the
modules are placed in the base unit. The module specifications give a detailed description of every
single module.

2.3 Inspection inside the terminal

When opening the terminal/transmitter it’s important to check for humidity or traces of humidity.
There are several reasons for humidity. The most usual is condensation on the inside surfaces due to
fast temperature drops. Humidity may also be the result of leakage, either in the control handles or
control knobs. The most usual reason is the joint between the bottom and top of the cabinet. The
gasket surface have to be clean and the gasket shall be replaced every second or third time the
cabinet is opened. In marine environment where IP-56 ore higher IP-class is imperative we
recommend You to use Dow Corning high vacuum grease in addition to the gasket. A third reason
may be that the cabinet is lost on the floor or exposed to severe shocks or very high temperatures.
Then the joint between the battery compartment and the bottom part of the terminal may be leaky.
Use of contact cleaners or electronic cleaning solvents shall be avoided inside the terminal because
they may damage the conformal coatings of the printed circuit boards or the glue of the battery

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compartment. However contact cleaners may be used on the contact terminals, but avoid spraying
inside the cabinet or on the coating of the PCB’s.
If there are humidity inside the terminal, allow it to dry up complete in room temperature or in ambient
temperature up to +55°C. Heating guns or equivalent shall not be used!

2.4 Assembling of the terminal/transmitter

Clean the gasket cavity carefully with isopropyl alcohol or similar. Use Q-tips or similar to get the
cavity completely clean. Be sure that the gasket is unbroken. In any case the gasket shall be replaced
every 2-3 times the cabinet is opened or if the gasket is older than 3 years.
2.5 Method
Check the fault symptoms that are described in the tables in chapter 2.4. and 2.5. Flow charts
describe the troubleshooting of several of the symptoms.
Consult Micro-control if you cannot solve the problem yourself. Either use the service fax template or
contact our service department using e-mail address
support@micro-control.no
When sending e-mail, please include the information requested in the service fax template.

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2.6 Systems controlling the machine directly

Table 1 Fault symptoms regarding systems controlling the machine directly

Symptom Description / Action
Fault indication at the ”BAT See chapter 3.1.
LED” (LED=light emitting
diode)” or at the display of the
terminal.
Fault indication at the LEDs or See chapter 3.2.
the display of the base unit.
None of the functions Ensure that the communication between the terminal and the base
(switches, joysticks, etc.) are unit is OK. Flow chart 2 describes how to do this.
working.
The functions stops and starts Ensure that the communication between the terminal and the base
again/ The machine runs unit is OK. Flow chart 2 describes how to do this.
uneven / The system suddenly
stops.
Fault in some of the functions. Flow chart 1 describes troubleshooting when there is a function fault.

2.7 Systems with PLC serial communication

Table 2 Fault symptoms regarding systems with PLC serial communication

Symptom
Fault indication at the ”BAT
LED” (LED=light emitting
diode)” or at the display of the
terminal.
Fault indication at the LEDs or
the display of the base unit.
None of the functions
(switches, joysticks and so on)
is working.
The functions stops and starts
again / The machine runs
unstable
Fault in some of the functions.
Description / Action
See chapter 3.1.
See chapter 3.2.
Ensure that the communication between the terminal and the base
unit is OK. Flow chart 2 describes how to do this.
Also ensure that the PLC communication is OK.
Ensure that the communication between the terminal and the base
unit is OK. Flow chart 2 describes how to do this.
Ensure that the control signal from the PLC is OK.
Then check the terminal. Flow chart 1 describes how to do this..

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3. Indications and error messages

3.1 Terminal

Table 3 Possible indications in the ”BAT light emitting diode”

Flashing pattern Description Action
Steady light. Normal condition. The terminal is
turned on, the battery voltage is OK,
no fault is detected.
Slow flashing light Low battery voltage. Change the battery and recharge the
without stop (1 flash “old” battery!
per second).
Rapid flashes (2 Programming mode. Turn the terminal off and on again to
flashes per second). start normal operation.
1 flash with a long stop The same as E001. See Table. The same as E001. See Table.
(every 2. second).
2 flashes with a stop. The same as E002. See Table. The same as E002. See Table.
3 flashes with a stop. The same as E003. See Table. The same as E003. See Table.
4 flashes with a stop. The same as E004. See Table. The same as E004. See Table.
5 flashes with a stop. The same as E005. See Table. The same as E005. See Table.
6 flashes with a stop. The same as E006. See Table. The same as E006. See Table.
7 flashes with a stop. The same as E007. See Table. The same as E007. See Table.
The light emitting Ensure that there is a battery in the
diode ”BAT” does not terminal and that the terminal is turned
light. on. If the terminal has turned itself off
because of inactivity, turn it off and on
again to start normal operation. Try to
replace the battery with a recharged
one. If the problem persists, see ”Flow
chart 3 Troubleshooting the terminal”.

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Table 4 Possible indications in the terminal display

If the system has a 4 digit LED module the indicated codes are displayed there. If the system has a
LCD module the error codes are displayed in a field in the display.

Display Description Action

”XXX” System ID code.
Normally displayed a short moment when the
terminal is turned on. Displayed only in systems with
one terminal.
”XXX.Y” System ID code and terminal number.
Normally displayed a short moment when the
terminal is turned on. Displayed only in systems with
more than one terminal.
”X.YY” The battery voltage measured in Volts.
(The number displayed has two decimals, the values
will be between 6.40 and 9.00).
Normally displayed a short moment when the
terminal is turned on.
”A-XX” Analog channel that can be programmed. (The
number displayed is an integer between 1 and 13.)
Displayed only when the terminal is in programming
mode.
” A-00” No analog channel is activated. Activate the analog channel you wish
Only displayed when the terminal is in programming to program!
mode.
E001 Processor fault. Check that the BOOT-jumper on the
Indicates a processor module fault and/or a processor module is not turned on!
processor fault. Change the processor module and/or
the processor!
E002 Activity by start-up. Set all switches/joysticks to OFF-
A joystick is out of center position, or a switch is in position and/or neutral position!
ON-position. See Flow chart 3 for further
troubleshooting.
E003 Radio fault. The radio must probably be changed.
See chapter 4.
E004 Shutdown because of low battery voltage. Change battery!
E005 Keyboard fault. The KB-card probably must be
The terminal is not able to ”read” switches, joysticks changed. See Flow chart 3.
etc.
E006 Shutdown because of inactivity. To avoid that the terminal ”turns itself
The terminal will soon ”turn itself off” since no off” you must activate one or more
switches, joysticks etc. has been activated. functions.
E007 Priority stop. Turn the terminal OFF and ON again
The stop button or the shock detector has been to start normal operation!
activated.

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3.2 Base unit

Table 5 Possible indications on green LED of the base-unit processor module

Flashing pattern Description Action
Steady light. Normal condition.
Short flashes (2 flashes Programming mode. Turn the base unit OFF and ON again
per second). to start normal operation.
1 flash with a long stop The same as E001. The same as E001.
(every 2. Second).
2 flashes with a stop. The same as E002. The same as E002.
3 flashes with a stop. The same as E003. The same as E003.
5 flashes with a stop. The same as E005. The same as E005.
7 flashes with a stop. The same as E007. The same as E007.
The light emitting diode Ensure that the processor module has
does not light. the correct input voltage. Also check
the processor module fuses.
Table 6 Possible indications on red LED on the processor module in the base unit
Flashing pattern Description
The light emitting Communication with the terminal is OK. The START-relay is activated.
diode does not
light.
Steady light.* No communication with the terminal.
Flashing now and Each time the red LED is flashing, there is a communication fault between the
then. base unit and the terminal. The radios should be checked and tuned.
* In polled systems the base unit must communicate with all the system terminals before the red light
is switched off.

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Table 7 Possible indications of the base unit’s 4 digit LED

Display Description Action
”XXX” System ID code.
Normally displayed a short moment when the base
unit is turned on. Displayed in systems with only one
base unit.
”XXX.Y” System ID code and base unit number.
Normally displayed a short moment when the base
unit is turned on. Only displayed in systems with more
than one base unit. In polled systems ”XXX.0” is
displayed.
”-” The base unit communicates with the terminal.
”0” Communication fault with the terminal.
”1” No communication with the terminal, because the
base unit is “locked” to another terminal.
E001 Processor fault. Ensure that no link are placed on
Indicates a processor module fault and/or a processor the BOOT jumper pins!
fault. Replace the processor module
and/or processor!
E002 Start-up activity. Set the switches/joysticks to OFF-
A joystick is out of center position, or a switch is in position and/or neutral position.
ON-position.
E003 Radio fault. The radio must probably be
changed, see chapter 5.
E005 Keyboard fault. The KB card probably has to be
The base unit is not able to ”read” inputs and outputs. changed. See E005/Flow chart 3.
E007 Priority stop. Start the terminal again for normal
operation.
E010 PLC communication fault (the PLC does not update Check the PLC, the communication
the PLC status register). cable and the processor module in
the base unit.
E011 Processor module for communication together with Change the processor module
the PLC does not work. and/or the processor!

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Flow chart 1 Troubleshooting function faults
Warning!
Before you start testing the machine you must take care so that neither people are injured nor equipment are damaged during the testing. If possible you
should find a place where you can control the base unit at the same time as you have full survey of the machine. For safety precautions another person
should look after the machine while you are testing the MC-3000 system.
Preparation
Bring the terminal to the base unit. If the base unit does not have a transparent door, you must open the door/cover so that you can easily see the modules
inside the base unit.

Incorrect programming of MIN / MAX-values may also be interpreted as function fault. Check this if the terminal has MIN / MAX-programming!
NO: Check the flashing pattern against the descriptions in Table! Continue with
START: Turn the terminal on! ”troubleshooting the terminal” (separate flow chart)!
Has the terminal’s BAT light emitting diode normal (steady)
light? YES: Is only the green light emitting diode at the base unit’s processor module
lighting?

YES: Activate the function(s) that is/are not working. Are some of the NO: Are both the green and the red light emitting diodes at the base
output modules giving a response? unit’s processor module lighting?

YES: Measure the signal from the NO: Continue with YES: Communication fault! NO: None of the light emitting
module(s) that is/are responding! ”troubleshooting the base unit” Continue with ”troubleshooting diodes are lighting. Ensure that
Does the signal correspond with (separate flow chart) or communication fault” (separate there is power to the base unit!
the description in the wiring ”troubleshooting the terminal” flow chart)! Continue with ”troubleshooting
diagram? (separate flow chart)! the base unit” (separate flow
chart)!
NO: Change the output module and measure once
more!

YES: Follow/measure the signal from the module(s) via screw terminals to
the load (valves, contactors etc)!
If the signal reaches the load, there is probably some fault at the load.

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Flow chart 2 Troubleshooting communication fault
Warning!
Before you start testing the machine you must take care so that neither people nor equipment are hurt during the testing. If possible you should find a place
where you can control the base unit at the same time as you have full survey of the machine. For safety precautions another person should look after the
machine while you are testing the MC-3000 system.
Preparation
Bring the terminal to the base unit. If the base unit does not have a glass door you must open the door/cover so that you can easily see the modules inside
the base unit.

START: Turn the terminal on! NO: Check the flashing pattern against the descriptions of Table! Continue with
Has the terminal’s BAT light emitting diode normal (steady) ”troubleshooting the terminal” (separate flow chart)!
light?
YES: Are both the green and the red light emitting diodes at the base unit’s
processor module lighting?

YES: Does your system have cable communication as an option? NO: Is only the green light emitting diode at the base unit’s processor
module lighting?

YES: Turn the terminal off.

Connect the terminal and the
base unit with a cable and turn
the selector switch ”RADIO /
CABLE” to the position CABLE.
Turn the terminal on! Is the
communication OK now?
NO: Continue with YES: Communication between
”troubleshooting the base unit” the terminal and the base
(separate flow chart)! seems to be OK.
There may be a function fault.
Continue with ”troubleshooting
function fault” (separate flow
chart)!
NO: None of the light emitting
diodes are lighting. Check if
there is power to the base unit!
Continue with ”troubleshooting
the base unit” (separate flow
chart)!

NO: Check that the cable you are using is OK!

YES: The system is communicating via cable (RS-485/422), but not via
radio.
The fault may be found in the base unit and/or in the terminal. Continue
with ”replacing radio in the base unit” (separate flow chart)!

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Flow chart 3 Troubleshooting the terminal
Warning!
The radio signal from the terminal to the base unit may reach several kilometers. It also penetrates walls. Therefore you must never start the terminal without
having full control with / survey over the machine/base unit. If you cannot use an anti-static working place you must not touch the terminals PCBs (printed
circuit boards). The working place also must be dry.
Preparation
Turn off the power to the base unit! Bring the terminal to a dry place. If you have access to an electronic workshop, you should bring the terminal there. Before
you open the terminal you should ensure that no other part of the system causes the fault (the base unit, electronic activating of valves etc).

START: Ensure that the terminal is turned off and remove the battery!
Place the terminal upside-down on a table, so that the five screws at the bottom part are available. Use a 5mm hexagon socked set screw key to unlock
the five screws that keep together the top and bottom part. Carefully lift the bottom part and turn it so that you can see the printed circuit boards. Note! It
is not necessary to loosen the cables between the top and bottom part! If the base unit is turned off, you can now put in the battery and turn the terminal
on.

Is the light missing NO

Is there a function NO
Does the terminal NO
Does the terminal NO
Check chapter 3.1 if the
in both the fault and no error indicate ”activity by indicate fault at the KB terminal indicates other
processor module’s message? start-up” (2 flashes at card (5 flashes at the error messages.
light emitting the BAT-LED/ E002)? BAT-LED / E005)?
diodes?
YES YES YES
YES

Measure the input
voltage at the screw
terminals!
Check the fuses!
Change the
processor module!
Check the cables to
the switch / joystick
that are controlling
the function!
Change the switch /
joystick if it is
defective!
Try to uncouple joysticks
and switches one and one
at a time until the error
messages disappears. The
fault may also be found at
the KB card or the
processor module.
Check the cables to the
KB card! If the problem
persists, the KB card
must be changed! The
fault may also be found
at the processor
module.

Placing together the top and bottom part:

Carefully place the bottom part at the top part while checking that no cables are squeezed between the top and bottom part.
Fasten the 7 screws so that there is an even pressure at the silicone rubber seal (O-ring).

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Flow chart 4 Troubleshooting the base unit

NO: Check the supply voltage.

START: Is the power module supply voltage correct?
YES: Are both lights at the power module lighting?

YES: Measure the power module output voltage. Is the output voltages NO: Check the power module fuse!
OK?

YES: Measure the processor NO: Change the power module!

module input voltage! Is the input
voltage OK?

NO: Check the cables between the power module and

the processor module!

YES: Check the processor module fuses! Are the fuses OK?

YES: Does the green lamp of NO: Change the fuse(s)!

the processor module light
constantly?

YES: The processor module is NO: If the lamp is flashing, it

apparently working normally. indicates a fault. Check the
Check all the connections to the descriptions in Table.
module!

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4. Procedure for changing radio in the terminal

4.1 Warning!
The radio signal from the terminal to the base unit may reach several kilometers. It also penetrates
walls. You must therefore never start the terminal without having full control with / survey over the
machine.
If you cannot work in an anti-static working place you must not touch the terminals printed circuit
boards. The working place also must be dry.

4.2 Execution
1. Turn off the power to the base unit!
2. Bring the terminal to a dry place. If you have access to an electronic workshop, you should bring
the terminal there.
3. Ensure that the terminal is turned off and remove the battery!
4. Place the terminal upside-down on a table, so that the seven screws at the bottom part are
available.
5. Use a 5 mm hexagon socket set screw key and unlock the seven screws that keep together the
top- and bottom part.
6. Carefully lift the bottom part and turn it so that the printed circuit boards are visible. Note! It is not
necessary to loosen the cables between the top- and bottom part!
7. Uncouple the antenna and the 10-pins flat cable to the radio module!
8. Unlock the screws that secure the radio! Take care that you don’t lose any of the metal washers!
Remove the radio.
9. Put the new radio where the old one was placed.
10. Connect the antenna and the 10-pins flat cable to the radio module.
11. Turn the HEX-switch of the new radio to the same position as the old one (if not the radio will not
transmit at the correct frequency).

Placing together the top and bottom part:

12. Carefully place the bottom part at the top part while checking that no cables are squeezed
between the top and bottom part.
13. Fasten the 7 screws so that there is an even pressure at the silicone rubber seal (O-ring).
14. Test that the radio communication between the base unit and the terminal is OK.

5. Procedure for changing the radio in the base unit

1. Turn off the power to the base unit!
2. Uncouple the antenna and the 10-pins flat cable to the radio module!
3. Loosen the radio from the DIN mounting rail and remove it.
4. Put the new radio where the old one was placed.
5. Turn the HEX-switch of the new radio to the same position as the old one (if not the radio will not
transmit at the correct frequency).
6. Connect the antenna and the 10-pins flat cable to the radio module.
7. Turn on the power to the base unit.
8. Test that the radio communication between the base unit and the terminal is OK.

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6. Procedure for configuration

6.1 General
All the MC-3-6 systems have a unique configuration file (setup file). The content of the setup file
determines the system functionality. The setup file is saved in the processor’s non-volatile memory
(EEPROM). In contradiction to the processor’s main program (which is saved in OTPROM), the setup
file may be changed and saved several times. If you wish to change the system’s functionality you can
do this by changing the setup file. A new setup file must be ordered from Micro-control.

6.2 Equipment
To be able to transfer a new setup file you need the following equipment:
• MC-RS232 module
• Null-modem cable
• 10-pins flat cable
• PC
• Software
• Terminal program (for example ProComm, HyperTerminal etc)
• Setup file
6.3 Preparation before transfer to the terminal
1. Turn off the terminal and bring it to a dry room where you have access to a PC.
2. Use an hexagon socket set screw key and separate the top and bottom parts by unlocking the 7
screws
3. Install the processor module’s ”BOOT-jumper”.
4. Uncouple the processor module’s TX-bus and connect it to the MC-RS232 module.
5. Connect the null-modem cable to the MC-RS232 DSUB-contact and the PC serial port.
6.4 Preparation to transfer to the base unit
1. Turn off the power to the base unit. Install the processor module’s ”BOOT-jumper”.
2. Uncouple the processor module’s TX-bus and connect it to the MC-RS232 module.
3. Connect the null-modem cable to the MC-RS232 DSUB-contact and the PC’s serial port.
6.5 Transferring the setup file
1. Start the terminal program at the PC.
2. The terminal program must be set up with:
2400 bps, 8 data-bit, 1 stop-bit, no parity, ASCII character set, delay 200ms.
3. Turn on the terminal / base unit.
4. The following text is now written on the screen:
”Awaiting configuration file …………..”
5. Transfer the setup file by giving the command:
”Send text file”, ”ASCII upload” etc. in the terminal program.
6. After a successful transfer the following text is written on the screen:
”………..succeeded”

7. Turn off the terminal / base unit.

8. Remove the ”BOOT-jumper” from the processor module.
9. Uncouple the MC-RS232 module.
10. Connect the TX-bus on the processor module.

11. The terminal / base unit is ready for normal operation with a new setup file.

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Service fax for MC-3-6

Send to: Micro-control as
Fax no: (+47) 74821610

System information:
Serial number (ID-code):
Frequency:
Unit (base / terminal)

Problem description:

What have you done to solve the problem (troubleshooting)?

Sender information:
Company
Contact person
Fax no.
Email
Postal address

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