FleX Controller – User Manual 21
Version 1.0
4 MAINTENANCE, ADJUSTMENTS AND TROUBLESHOOTING
This section is intended to indicate the way to perform regular maintenance on the FleX controller like
cleaning and servicing when malfunctions occur. It also describes the adjustments of the controller and
the troubleshooting procedures, precautions that need to be taken before servicing the unit, a list of test
equipment needed for trouble shooting. A basic knowledge of electronics is needed when servicing this
unit.
4.1 Preventive Maintenance
Always make sure to be in an antistatic environment before handling the controller for any type of
maintenance, also the power source must be disconnected before any cleaning, visual inspection of the
enclosure, sub-assemblies, connectors and cables.
Remove dust out of the unit.
Check the wiring, terminals and connectors, replace them if necessary.
Check all mounting hardware, tighten them if necessary.
The preventive maintenance should be based on the install and environmental conditions.
4.2 Control Signals Board Adjustment
Only the Control Signals Board (M58574A) is adjusted in order to set the AC input hysteresis between
power failure and power restoration; this is a factory set parameter and should never need further
maintenance.
4.3 Trouble Shooting Analysis
A visual inspection is recommended as a first step on the diagnostics; most problems are related to the
harnesses used for interconnecting the sub-assemblies (broken wires or worn connections on headers
and receptacles connectors).
The trouble analysis should be made by using all available information about the controller’s failure and
all related documentation (assembly drawings, schematics, DAT, etc.) in order to isolate and define the
cause; the deep of such analysis depends on the complexity of the failure and the intended solution
(repair, interchange a module, reconfigure, software change, etc.).
4.3.1 DAT
The DAT (McCain Diagnostic and Acceptance Test) is a set of test programs already loaded into the
controller; it also can be stored into a USB memory stick.
The DAT is used for testing and validating the hardware of the McCain FleX controller units, and it is a
useful tool when troubleshooting the controller.
It includes separated tests menus for the CPU, I/O, Serial Ports and Front Panel. Also includes a
Continuous Test menu for serial ports and I/O.
Error logging report is available to user for troubleshooting purposes.
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