Aimil Ltd.

THE TROUBLESHOOTING MANUAL Compression Testing Machine

TABLE OF CONTENTS

WARNINGS AND PRECAUTIONS..............................................................................................3 WHAT DOES THIS MANUAL DO?.............................................................................................4 LIST OF ABBREVIATIONS..........................................................................................................4 THE VERY FIRST STEP................................................................................................................4 HOW IS THIS MANUAL TO BE USED?.....................................................................................5 VERSIONS OF THE CTM: A Brief Overview.............................................................................6 HARDWARE BASICS.....................................................................................................................9 The functions of each microcontroller..................................................................................... Cables and Connectors inside the CTM box.......................................................................... Cables and Connectors outside the CTM box:....................................................................... .9 11 13

THE TROUBLESHOOTING TABLE.........................................................................................16 INFORMATION ON DATA CORRUPTION.............................................................................21 INFORMATION ON NEW CALIBRATION..............................................................................24 INFORMATION ON DATE CORRUPTION.............................................................................24 APPENDIX - HOW TO CHANGE MICROCONTROLLERS.................................................25

WARNINGS AND PRECAUTIONS

1. DO NOT PUT HEAVY OBJECTS ON THE PRODUCT OR SIT UPON IT.

-If the product collapses or is dropped, you may be injured.

2. THE MACHINE IS POWERED BY THE MAINS.

-Check that these are not fluctuating wildly. Safety Measures

1. HIGH FORCES ARE OFTEN INVOLVED WITH THE MATERIAL TESTING PROCESSES.

- Keep the cage of the Loading Unit closed when the run is in progress.
2. DO NOT SWITCH THE DIGITAL HEAD OFF WHILE THE PUMP IS RUNNING.

- The pump will keep running in that case. Remember that the emergency stop button on the Pumping Unit can be used to bring it to a halt.
3. DO NOT OPERATE THE MACHINE WET HANDED

- Avoid getting an electric shock.

WHAT DOES THIS MANUAL DO?

The manual explains how malfunctions in the CTM digital heads can be understood and corrected. We explain the essentials of the hardware and then tabulate the problems known to have occurred along with a set of possible solutions for each.
LIST OF ABBREVIATIONS

CTM ACTM MCTM (CTM) DPU ADC LCD EEPROM RTC MM SCC

Compression Testing Machine Automatic Compression Testing Machine Semi-Automatic Compression Testing Machine Display Unit (The manual CTM) Analog to Digital Converter Liquid Crystal Display Electrically Erasable Programmable Read Only Memory Realtime Clock Multimeter Signal Conditioner card

THE VERY FIRST STEP

Start by taking careful note of the configuration of the unit you are servicing. This is because the action you take to rectify a fault depends critically on the units configuration. To help you do this, we are providing a form which you should routinely fill out.

HOW IS THIS MANUAL TO BE USED?

1. Study the malfunctioning unit carefully along with its operating environment. Every little bit of useful information helps improve the diagnosis. 2. Try to map the problem you are facing onto one of those listed in the troubleshooting table. 3. If you find a match, try the solutions out with imagination in the order listed. If you do not find a match, please contact Aimils technical support staff, even if you manage to solve the problem. Your feedback will help us improve and update our trouble-shooting table.

VERSIONS OF THE CTM: A Brief Overview

VERSION 2.2(launched on 21/08/03)
1. This version initially came with an external relay card for the pump. Relays were subsequently (i.e. from 21/01/05 on) placed on the main PCB card inside the digital head. 2. Date n time in the digital head was continuously maintained by the RTC. 3. Only one copy of the calibration data was stored in the EEPROM. 4. While checking the EEPROMs integrity, MAIN3 made only one attempt to read from it

VERSION 2.3(19/01/06)
1. The output of the transformer was regulated through a 12 V regulator. 2. CNC PCBs were used to make the product more robust. 3. 6 V relays were actuated by a 12V supply. 4. Date-n-time was maintained by MAIN3 as long as the machine was powered.

VERSION 2.4(15/05/06)
1. There were now 2 copies of the calibration data in the EEPROM. 2. In checking the EEPROM, MAIN3 made three attempts to read from it.

VERSION 2.5
1. The sample breaking point was made variable.

VERSION 2.6(08/01/07)
The release motor was replaced by a solenoid valve and the control motor now rotated anti-clock-wise while initializing. To incorporate these changes in the mechanical set-up appropriate changes were made in firmware. Nothing changed, however, for the user.

VERSION 2.7
1. The RTC chip was given an additional power-backup, in the form of a 1 mf tantalum capacitor connected between pins 3 and 4 with the +ve terminal at pin3. 2. The Main Menu pages for Date, Time and Global settings were shifted to the User Mode. 3. A new page was added to (re)-enter the calibration data (directly without a proving ring) and to set the break-point.

VERSION 2.8
The features of version 2.7 also apply to version 2.8 except for the fact that version 2.8 is for machines having a solenoid valve and a control motor which moves anticlockwise while initializing.

VERSION 2.9.4(07/09/07, only one DPU)

1. An additional Signal Conditioner card was mounted on the back plate to take care of the Calibration Shift issues. 2. The grounding of all the plates of the digital head was made more robust by shorting them through wires. 3. The EEPROM was formatted block-wise. This meant that if the data of a particular block got corrupted, only that block would get re-formatted. Furthermore, the user would now be informed about the (re)formatting when he switched the machine ON. 4. Touch-sense was now (for added accuracy) to be entered manually.

VERSION 3.0.0(10/09/07)
1. Calibration data is loaded automatically after its manual re-entry by the Service Engineer. 2. The validity of date-n-time is checked while these are being loaded from the RTC. 3. The validity of all the record headers is checked for all stored records. The logged data are erased in case any one of the record headers is found corrupted. 4. During Check Calibration, the calibration data is recalculated even for the last point. 5. The Service Engineer can configure the system for either Release MOTOR or Solenoid valve. He can also configure the system for either Clockwise Control Motor or Anti-clockwise Control Motor.

VERSION 3.1.0(19/09/07)
1. The LVDT has been made independent of the loading unit so that the digital head can be used to calibrate the LVDT independent of the load frame. 2. An extra function has been assigned to the LOAD HOLD key when the machine is idle. It now toggles the 7-segment display, between the load and compression readings. The functionality of the LOAD HOLD key DURING A RUN remains unchanged.

HARDWARE BASICS
Every DPU and uCTM has three micro-controllers, clearly labeled along with the firmware they carry (see figure) as MAIN1, MAIN2, MAIN 3, while the ACTM additionally has MAIN4. These micro-controllers are mounted (for ease of upgradation) on IC bases. Each of these micro-controllers controls a well-defined section of the digital head. This means that if a micro-controller is loose or defective, the corresponding section of the unit will malfunction. As a general rule, therefore, press all the micro-controllers down properly into their bases, while servicing any digital head. Furthermore, while changing a micro-controller please follow the instructions given in the Appendix (page 18).

The functions of each microcontroller

MAIN1 takes inputs from the Pressure Cell / LVDT and displays the LOAD / COMPRESSION on the 7-segment display and bar-graph.