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Spacesaver Corporation

Manual for Power Pro/EC300/EC400 Series

PC Diagnostic

Revision 1.6

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Copyright 2002 Spacesaver Corporation. All rights reserved. Reproduction of this document, in part or in whole, by any means, electrical or otherwise, is prohibited, except by written permission from Spacesaver Corporation. The information contained herein is believed to be accurate as of the date of publication; however, Spacesaver Corporation will not be liable for any damages, including indirect or consequential, from the use of this software product or reliance on the accuracy of this documentation. The information contained herein is subject to change without notice.

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Table of Contents SUBJECT PAGE NUMBER Scope of This Manual 4 Overview and Requirements 5 Installation 7 Power Connection 7 Diagnostic Interface 8 Remote Operation (screen listed below) 8 How to Save Parameters to a disk or file 8 Configure System 9 How to Save Parameters to the system. 20 Diagnose System 21

Table of Illustrations SUBJECT PAGE NUMBER PC Diagnostic Cables 5 Laptop Specifications 6 Installation 7 Diagnostic Interface Screen 8 Configure System Screen 9 Aisle Guard Data Entry 12 Copy Screen 19 Module Config Screen 19 Read Screen 20 Save Screen 20 Diagnose System Screen 21 Remote Operation Screen 25

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Scope of This Manual This manual covers the operation of Spacesaver Corporation System PC Diagnostic Program for the Power Pro, EC300 and EC400 series of Carriage Controls:

Model Power Pro, EC300 and EC400 PC DIAGNOSTIC PROGRAM

The PC Diagnostic Program supports the following functions by control type: Controller Diagnose Remote Control Program Power Pro Yes Yes Yes EC300 Yes Yes - EC300A Yes Yes Yes EC300B Yes Yes Yes EC400 Yes Yes Yes Safety Floor Monitor Yes - -

Any questions or comments about the PC Diagnostic Program, product, mobile storage system controls or this manual should be directed to:

Spacesaver Corporation Field Service Department 1450 Janesville Avenue

Fort Atkinson, Wisconsin 53538-2798

(920) 563-6362 (800) 457-5463 (HLP-LINE)

FAX: (920) 563-0793 E-mail: brian_jira@spacesaver.com

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Power Pro/EC300/EC400 PC Diagnostic Program Overview and Requirements

The Power Pro/EC300/EC400 PC Diagnostic System consists of a Hardware Box, PC interconnecting cable, and a system communication/power cable. This is able to connect to any Spacesaver module of mobile storage fitted with the Power Pro, EC300 or EC400 controls. The PC Diagnostic Hardware Box comes equipped with system communication cable/power cable, interconnecting cable, and a wall-mounted transformer power supply. The PC Diagnostic Program provides the following functions: • Automated troubleshooting of Power Pro, EC300 and EC400 system communication. • Diagnostic testing of Power Pro, EC300 and EC400 board functions such as limit switch and safety

sweep inputs. • Setting of system parameters on the Power Pro, EC300A and EC400 series of control boards. • Remote operation of a Power Pro, EC300 or EC400 module of mobile storage. All functions are available in the PC Diagnostic Program without changing setups or operational modes.

Requirements for Use • Connection to Spacesaver Power Pro, EC300 or EC400 Series Mobile Storage Controls with

provided communication cable. The Power Pro requires a ten-pin connector adapter. • In most instances, power for the Hardware Box can be pulled from the Logic Board with the

communication/power cable provided. One 120-Volt Power Supply 1 located within 5 feet of the unit is necessary only if the logic board cannot supply system power.

Hardware Box to Logic Communication Cable/ Power Adapter PC or Laptop to Hardware Box Cable

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PC/LAPTOP HARDWARE & SOFTWARE REQUIREMENTS FOR THE EXTRANET – LAPTOP DIAGNOSTIC – CBT

NOTE: Windows 2000 SP3 and Adobe Acrobat Reader are included with the

Diagnostic software.

* If a serial port is not available, a USB port must be present and a USB to Serial converter must be used. If this is the case, the recommended USB converter is Model UC-232A. Aten is one supplier of these devices.

HARDWARE REQUIREMENTSProcessor Pentium III, 800 MHz or greaterRam Memory 128 mb or greaterHard Drive 10 gb or greaterCD-ROM Drive 24x or greaterVideo Resolution 8 mb or greaterSound Card YesSpeakers Built in or externalSerial Port * Yes

SOFTWARE REQUIREMENTSWindows 2000 with SP3 or XPAdobe Acrobat 4.0 or greater

FUTURE REQUIREMENTSMicrosoft Internet Explorer 5.5 or greater10Base-T (10/100 auto-sense) Ethernet network port

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Installation

The PC Diagnostic Hardware Box connects to the mobile system through a standard EC300/EC400 diagnostic communication cable supplied with the unit (You will need the PowerPro adapter cable to interface with PowerPro systems). The cable has six or eight wires and is terminated with a twelve position red connector on the end. The Hardware Box must be connected to the left side of any module of Spacesaver mobile storage. This means that the PC Diagnostic Hardware Box has the left end of system jumper on its left communication connector with the supplied communication cable attached to its right communication connector. This cable is then connected to the left communication connector of the first Power Pro, EC300 or EC400 carriage control or safety floor monitor. This communication connection is illustrated below.

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FLOOR MONITOR

CARRIAGE

CONTROL

LEFT

LEFT

RIGHT

RIGHT

CARRIAGE CONTROL

LEFT RIGHT

CARRIAGE

CONTROL

LEFT RIGHT

HARDWARE

BOX

LEFT RIGHT

END OF SYSTEM JUMPER

END OF SYSTEM JUMPER

LAPTOP

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-- Communication Connections for Hardware Box --

The actual number and arrangement of units within any module of Spacesaver mobile storage will vary from module to module. Keep in mind, however, that in most cases the PC Diagnostic Hardware Box should be connected to the left communication connector of the first Power Pro, EC300 or EC400 carriage control or safety floor monitor. This configuration works for both diagnostic and remote control functions. However, to program a Power Pro, EC300A or EC400 connect to the first carriage controller, bypassing any floor monitor, autocycler or T-Board. The Hardware Box may be plugged into the left communication connector of any logic board in a module. However, the program will only address logic boards to the right of this connection point.

Power Connection

The PC Diagnostic Hardware Box can be run off system power or use the optional power adapter. Plug the power cable into any unused +12VDC power port on the logic board (J10 on the EC-300, J10 or J26 of the EC-300A, EC-300B or EC-400. For PowerPro systems the Aisle Entry Transmitter locations (J12, J13, J18, & J19 or pins 1 & 2 of J24). It may also be run off the adapter provided if no power port is available on the logic board. The adapter will need a 120VAC power outlet to supply power to the Hardware Box.

Optional 120VAC Adapter

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Diagnostic Interface Screen ( Always exit and re-open the program when moving from module to module. ( Configure System: Clicking this button will take you into the programming screen. It will

automatically read the program from the first board. Not available on EC-300 systems, a “Read” failed message will appear if you try to configure an EC-300.

( Diagnose System: Clicking this button will take you to the diagnostic screen allowing you to

view the inputs seen by the processor. ( Remote Move: Clicking this button will allow your laptop/PC to function like the Desktop

Remote option for the system.

( Load Parameters: Click this button to load saved parameters from a disk or the PC/laptop hard drive. Once you find the file open it. After you return to the Interface Screen shown above click on “Configure System”. This will bring up the “Configure Screen” with the saved parameters displayed from the disk or file. They will not be the system parameters.

( Save Parameters: Click this button to save the system parameters to a disk or the hard

drive of your PC/laptop. You must click the “Configure System” to read the parameters before you will be able to save them (click “Read Config” to read the entire module).

( Exit: Allows you to exit the program. Don’t just close the window with the “X”. ( The message displayed beneath the buttons will give you status of the connection.

“Serial Port Connected” means the PC/Laptop is communicating with the Hardware Box, “Diagnostic Unit Present” means the Hardware Box is Communicating to the logic board, and “Ready for use” indicates you are ready to continue.

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Configure System Screen When connected the Diagnostic Program will read the values found in the logic board and display them on this screen. Changing any value will cause the font color to change to red.

The letters indicate the section of the screen discussed in the following pages of the manual.

A: See Page 10 E: See Page 13 B: See Page 10 F: See Page 15 C: See Page 11 G: See Page 18 D: See Page 12 H: See Page 19

B

C

D

E

F

H

G

A

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Section A ( Current Unit: Displays the number of the logic board you have access to within the module.

Changing this value allows you to look at other logic boards and will auto-save all changed parameters to the PC/laptop’s memory. (See the “Revert” button in section H)

( Type: Identifies the system (EC-400, PowerPro, etc.) ( Version: Shows the processor revision number.

Section B ( ZFS: Select this box if ZFS is one of the safeties on the system. This parameter allows the user to set the system to be equipped with Zero Force Sensors (ZFS) by checking the box. The values displayed on the diagnostic unit are the parameters as stored in the EC300A/EC400 board, not in the ZFS board. When the SAVE function is performed all the parameters are sent to and saved on the EC300A/EC400 board, which then forwards the ZFS parameters to the ZFS controller board (if its I2C cable is plugged in, from EC300A/EC400-J24 to ZFS-J15). If the ZFS board is changed or a new I2C chip is installed, it will have to be reprogrammed. The ZFS board will toggle the right sweep relay after it receives new parameters. ( Front & Rear Quads: Select where the quads are positioned for this system. Checking the

front box only means this system has front quads and no rear quads. ( Excessive Background Light Left & Right: Allows selectivity for the Excessive

Background Light setting. The ZFS controller will normally test for "no light" seen by the receivers before energizing the transmitter. If there is an exceptional amount of infrared background light the "no light" test will fail, indicating a bad transmitter and receiver pair. This parameter allows for the setting of the option to skip the "no light" test. ( Supervisor Reset: when an aisle locks up pushing the reset button on the control head can

normally reset it. The EC300A/EC400 sends the reset command to the ZFS controller via the I2C cable. When this parameter option is set it requires that a Program Key (also known as an ON/OFF/STAT/MOVE key) be inserted into the front control head of an EC300A of the locked aisle. Then pressing the "ON" key and the reset button together should clear the aisle. It requires pressing the reset key on the infrared "Managerial Key" for an EC400 controller system.

( Number of Web Lights: Enter the number of ZFS web lights for the right and left aisle. If you

have only one aisle with ZFS, set the other aisle to match. This value can be set from 5 to 127 LEDs. NOTE: After entering the value in one side you can double-click the other side to automatically copy the value.

( Both Aisles / Right Aisle Only: If the carriage is a leader configured with left aisle ZFS then

select "Both." If the carriage is a follower configuration with right aisle ZFS then select "Right Only."

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Section C ( Auto Stop Timeout: This parameter screen allows the user to set the amount of time the motor

can continue running in an effort to complete the movement cycle. After running for the entered amount of time, in seconds, the motor will shut down. This prevents damage from misadjusted or malfunctioning limit switches. Any value from 20 to 255 seconds can be entered for this parameter. Any value from 15 to 63 seconds can be entered for this parameter on PowerPro systems.

( Creep Timeout: This parameter screen allows the user to set the amount of time the motor can

continue running at its slowest possible speed. After creeping for the entered amount of time, in seconds, the motor will automatically shut down. This prevents damage from misadjusted or malfunctioning limit switches. Any value from 10 to 60 seconds can be entered for this parameter. Any value from 10 to 31 seconds can be entered for this parameter on PowerPro systems.

( Aisle Light Timeout: When a mobile system is equipped with aisle lighting, this parameter

specifies the amount of time the aisle lights will stay on after activation. This value can be set from 6 to 255 seconds or minutes (approximately 4.25 hours maximum). See the “Minute Timers” option of Section “F” (page 17) for information relative to selecting seconds or minutes for the light timeouts.

( Bay Lights Timeout: When equipped with bay lighting (only the controller that has the bay lighting

control box needs to be set), this parameter specifies the amount of time the bay lights will remain on after an activation. This value can be set from 1 to 255 seconds or minutes (approximately 4.25 hours maximum). See the “Minute Timers” option of Section “F” (page 17) for information relative to selecting seconds or minutes for the light timeouts.

( Start Beep Timeout: This parameter deals with the warning beep duration that occurs anytime a

movement cycle is started. For most Office and Institutional systems, this value is set very low, 3 for 0.3 seconds for instance. For an S6 system, however, usually has this value set higher, for a longer audible warning before movement begins.

( Aisle Relock Timer: This PowerPro feature is only available if manual reset mode has been

selected. This feature permits a cleared aisle to be locked again if the user does not select another aisle within the specified time. Minimum value of 10. For this Timer to be active the “Enable Aisle Relock check box must be checked (see section F page 17)

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Section D

( Photo Sweep I: Most PowerPro systems will be configured with Photo Sweep II, however when ambient light may cause problems, Photo Sweep I can be provided. Select this box to enable Photosweep 1 on PowerPro systems.

( Left & Right Photo Active: If the PowerPro carriage has mechanical sweep or shares a sweep

with the adjacent carriage the photosweep needs to be disabled. It also requires a jumper on the JP4 header on the control board. Make sure these boxes match the location of the Photosweeps on this carriage!

( Aisle Guard: Check this box if your system is equipped with the Aisle Guard Safety. ( Two Aisle Guards: Check this box if you have a second pair of Aisle Guard scanners in the aisle

due to carriage length. ( Aisle Guard Reflectors: Similar to entering the number of ZFS Web Lights you will need to enter

the number of reflectors in each Aisle Guard aisle. There are 4 places to enter values and they are arranged this way. They are labeled (FL) Front Left and (FR) Front Right, the bottom two are(RL) Rear Left and (RR) Rear Right - see the example picture below (the only time the Rear values will be entered is when the carriage length requires two sets of Aisle Guard units per aisle. One set of Aisle Guard units has a maximum range of 21’.) Left and Right refer to the aisle when facing the front of the carriage.

For example: Your PowerPro carriage is equipped with Aisle Guard in both aisles. The left aisle has 10 reflectors and the right aisle has 12 (normally both aisles will be equal). You would enter 10 in the FL location and 12 in the FR location.

Aisle Guard Two Aisle Guards FL 10

RL 0

FR 12

RR 0

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Section E ( Full Speed: All Auto-Motion settings will move at ½ speed from the factory. This increases the

safety level for the customer. If the customer requests the Auto-Motion to run at normal operating speed select this setting and the system will Auto-Move at full speed.

( Fire Park Mode: This determines the function of the module when jumper J23 option 2 is closed

on the carriage controller (usually by the building management system normally closed contacts, interfaced to only one controller per module - see drawing 480268.001). Locked aisles are reset and safeties remain active. Note: EC400 control heads remain functional to allow fire fighting personnel access after parking.

Close Right Close Left Alt. Close Even Space Select both the desired method of closing and “Even Space” when evenly spaced is required (Alternate Closing is only available with Evenly Spaced). See “Carriage Spacing” & “Last Aisle Spacing” for information relative to programming the “Even Space” mode.

( Carriage Spacing: Double click the number in the box for an automatic calculation based on the “Aisle Width” setting (Section G). This first option value parameter determines the space between carriages when the module initiates any evenly spacing function. Only the logic board that interfaces with the Fire/Night Park box or has the hardware jumper in place has to be programmed. The value is a time expressed in tenths of seconds of carriage travel.

For EC300A systems version 4.6 and earlier use the following equation for a starting point:

Aisle Spacing Parameter = (Aisle Width in inches ÷ Number of Aisles) X 2.9

For EC400 systems and EC300A systems version 4.7 and later use the following equation:

Aisle Spacing Parameter = (Aisle Width in inches ÷ Number of Aisles) X 5.8 ( Last Aisle Spacing: Automatic calculation is available as part of double clicking the number

in the box of the “Carriage Spacing” parameter. This parameter relates to the travel time of the last carriage when the system is evenly spacing. The travel time of the last carriage needs to be reduced to allow for the entire module to coast to a stop. This parameter is an amount of time, expressed in tenths of seconds, which is subtracted from the aisle spacing parameter set in “Carriage Spacing”. This helps make the “last” aisle spacing consistent with the others.

( Night Park Mode: This determines the function of the module when jumper J23 option 1 is closed

on the carriage controller (usually generated by the building management system normally closed contacts, interfaced to only one controller per module - see drawing 480268.001). Locked aisles are reset and safeties remain active (See options on next page)

***NOTE*** For EC-300A processor revisions 4.7 – 5.3 Night Park will always appear enabled.

The Software relies on the hardware jumper to tell the system if Night Park is activated.

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Close Right Close Left Alt. Close Even Space: Select both the desired method of closing and “Even Space” when evenly spaced is required (Alternate Closing is only available with Evenly Spaced). See “Carriage Spacing” & “Last Aisle Spacing” for information relative to programming the “Even Space” mode.

( Fire/Night Park Timer: This option value parameter deals with the delay before the initiation of

the night park and fire park functions on the same controller that interfaces to the fire/night box. It is a value expressed in seconds. CAUTION: DO NOT SET THE VALUE TO “0” WITH MULTIPLE MOTOR CARRIAGES.

( Auto Move Timer: With version 9.2 of EC-400 software the auto-move will be preceded by a 10

second warning. The reset lights will flash and the LCD display on the control will say “Scanning” (if so equipped). An audible alarm will also be heard if programmed (see section F - “Beeper On Auto Move”). This option value parameter functions as a timer measured in minutes. It determines the amount of time a module must remain unused (not accessed or any safety activated) before the roving aisle, priority aisle or ventilation park functions work. The 10 second move warning requires Control Head Processor version 1.2 or later.

NOTE!: The following features rely on option register 3 when Jumper J22 Option 3 is closed on the carriage controller. Select which feature(s) the customer requires. Note that "Ventilation Park" is not supported by software versions prior to 4.7. Hardware Jumper J22 Option 3 (on one controller) has to be installed for the selected feature to work. It is recommended to use only one controller to make it easier if the feature needs to be removed. The Auto Move timer is active only when the module is in the “Green” or “Ready For Use” state. ( Priority Aisle: This feature will automatically open the selected aisle (the aisle is programmed by

the aisle number entered in the box) as the value of the Auto Move Timer dictates in minutes. ( Roving Aisle: This feature will exercise the system by selecting and opening an aisle at

random. The Auto Move Timer dictates the time between moves. ( Ventilation Park: This feature will evenly space the carriages allowing easier airflow

between them. It is very similar to the “Even Space” mode of Night & Fire Park but the Auto Move Timer sets the time delay.

Close Right Close Left Alt. Close See “Carriage Spacing” & “Last Aisle Spacing” for information relative to programming the “Ventilation Park” mode. It uses the same parameters as the “Even Space” mode.

***NOTE*** Ventilation Park will not work on systems with a programmed Stationary unless you program the left half of the system to pack left and the right half of the system to pack right. One board on each side of the Stationary will have to be programmed. Alternate Closing is not available if the system has a programmed Stationary in the module.

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Section F

( One Touch: Selecting this feature puts the system in the “One Touch” mode. If not selected the program will default to the “Touch & Hold” setting. TOUCH AND HOLD, requires the operator to continue holding the move button on the face panel control until the movement is complete. ONE TOUCH, allows the operator to release the move button on the face panel control and have the module complete the movement cycle on its own.

( Manual Reset: This parameter allows the user to set the type of reset mode the system uses.

Check this box if the MANUAL option is desired. The system will remain "locked" at the last aisle accessed, with the Check Aisle - Press Reset display (or a red arrow for EC300/A) indication showing the last selected aisle. In order to select a different aisle the user must first press the reset button on the face panel control at the "locked" aisle. After the system has returned to Ready For Use (or all green) a different aisle may be accessed. If AUTOMATIC is desired do not check the box and the program will default to the “Automatic” setting. The system will return to the Ready For Use display (all green) immediately after successfully completing a movement cycle.

( Auto Power Up: This parameter allows the user to set the system to "power up" to the operational

mode without requiring the use of a System ON/OFF key. If this parameter is checked, the system will go through its power-up test and come up to the operational mode any time power is first applied to the system. If this option is not selected, the system will require a System ON/OFF key to place it in the operational mode.

( Stationary Carriage: This parameter allows the user to set a particular carriage control to be

programmed as a stationary automatically upon power up. ( Share Left & Right Limits: This parameter deals with how limit switches are handled on an

individual carriage. For example: if the carriage does not have its own left limit switch, but instead is using the limit switch information from the right side of the carriage to its left, this parameter should be selected. However, if this carriage has its own left limit switch (and the carriage to its left has a right limit switch), this parameter should not be selected. This option might be used when the loaded weight of an adjacent carriage is significantly different or when split carriages are used to accommodate columns or obstructions.

( Security Lock Left: For an EC300A controller, when the security lock signal is received, the

entire module is locked. However, if the carriage control (with security lock input) is set as a stationary, the security lock can function in one of two ways. In this parameter screen, if RIGHT is selected, by not checking the box, and the stationary is security locked, only the carriages to its right are security locked. If LEFT is selected, by checking the box, only the carriages to its left are security locked.

Five carriage system example: "Right" (no check), park carriages 3, 4 and 5 to the right, set carriage 3 as a stationary and security lock it, use carriages 1 and 2 normally. "Left" (check), park carriages 1, 2 and 3 to the left, set carriage 3 as a stationary and security lock it, use carriages 4 and 5 normally.

For the EC400 controller, when the security lock signal is received, the carriage is automatically set as a stationary and uses this parameter to determine direction of security lock. If it is desired to have the entire module locked then the input must be on either the first or last carriage controller with appropriate direction selected.

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( Use S/6 Ramp Table: Since the speed of the motor on an S6 style carriage is much greater than a motor on a standard Office and Institutional carriage, it cannot use the same values for proper operation. Checking this parameter will switch the carriage control to S6 motor values. NOTE: JP1 jumper on the EC300A/EC400 board is required when using S6 motors.

( Heavy Carriage: When a carriage is very heavily loaded, the motor must react more quickly to

maintain a constant speed over the distance traveled. If this parameter is checked, the motor on the carriage will react more quickly to conditions that vary motor speed over the course of travel. Most carriages will never need this option selected.

( Safety Fault Warning: The safety fault warning is an audible beeping sound which is heard any

time the movement cycle has been interrupted by a safety activation, such as a safety sweep, aisle entry sensor or ZFS. The beeper itself is optional and is not found on all systems.

( 50 Hz Power: Operation of DC motor controls varies a great deal when the power line frequency

changes. This parameter allows the user to select the European 50 Hz frequency for proper operation in some overseas installations.

( Bay Lights/Access Indicator: Checking this box enables the Access Indicator option and

disables the Bay Lights option.

Attention: Regarding EC-400 logic only. When the system is equipped with bay lighting, all carriages within the system must have “bay lighting” selected.

There is one option output on the EC300A/EC400 control board that can function as an access indicator light output or as a bay lighting control output. The access indicator signal is on when the module is moving, a safety is activated (ZFS, sweep, floor, etc.) or an aisle is locked (when set for manual reset mode). It turns off when the module is restored to the Ready For Use (all green) state. If the Bay Lighting option is selected, the signal is turned on in the same manner, however there can be some delay before the signal turns off. It will turn off when the module is restored to the Ready For Use state and after the set Bay Light Timeout value has expired (provided that the timed option is selected). When set for not timed the bay lights will remain on until the user presses the last accessed aisle reset button and then allows the set Bay Light Timeout to expire (EC400 turns off immediately after pushing reset).

( Aisle Lights Instant On: If not selected the lights will only turn on in the requested aisle after the

movement cycle is complete and all carriages have stopped. If selected, the lights will turn on in the requested aisle as soon as movement begins or shortly after.

( Lights Timed: Aisle lights that are set to “Not Timed” (no check) will remain on until the user

presses the reset button at the open aisle or requests another aisle. If set to be timed aisle lights will turn off after their set period of time. In most cases activating a sweep, aisle entry, safety floor, ZFS or pushing an Open Aisle button will reinitialize the timer to its set value. Whether set for timed or not timed, pushing reset at the open aisle will turn the aisle lights off.

Bay lights that are set for not timed will remain on until the user presses the last accessed aisle reset button and allows the set bay light time-out to expire (EC400 turns off immediately after pushing reset). When set to be timed the bay lights will turn off after their corresponding set period of time. In most cases activating a sweep, aisle entry, safety floor, ZFS or pushing an Open Aisle button will reinitialize the bay light timer to its set value.

For PowerPro Only: When set for not timed the bay lights will remain on until the user presses the last accessed aisle reset button and allows the Aisle Relock Timeout to expire. This permits the user

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to request another aisle to open without the bay lights turning off and then back on when carriages start to move.

( Minute Timers: Selecting this option changes the Aisle and Bay Lighting timers that are counted in

seconds to counting in minutes. Instead of a range from 1 to 255 seconds (1 second to 4 minutes 15 seconds; it will enable programming from 1 minute to 4 hours 15 minutes.

( Beeper On Auto Move: Selecting this option will add an audible alert to the 10 second warning

before an Auto Move takes place. The beeper in the control heads will chirp. EC-400 processor revision level 9.2 and later and Control Head processor revision level 1.2 and later.

( Block Move: Available with EC-400 processor revision level 9.2 and later. Selecting this option

enables the Block Move feature. This feature allows module movement without carriage separation (peel-off).

( Enable Auxiliary Inputs: Selecting this feature will enable the Aux. Inputs (J30, J31, J33, J34).

Typically used for Aisle Entry Sensors in special situations if no Photo Sweep Adder Board is available.

( Control Head Beep: (PowerPro or EC-400 9.20 +) This parameter allows the user to disable

the control head activation beep (either the reset button or a valid move request). However, the override beep still sounds when the override key is used with an activated sweep.

( Enable Aisle Relock: (PowerPro Only) This feature must be used in the Manual Reset Mode

only. When in Manual Reset the open aisle will automatically be locked at the end of system movement. If this open aisle is then Reset by pushing the Reset Button of the appropriate control head the system will relock the aisle in the time set in the Aisle Relock Timer.

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Section G

( Aisle Width: Enter the nominal aisle width of your system (36” is the default). See the “Carriage Spacing” parameter in section E for information relative to the automatic calculation feature available. The auto calculation will give you a starting point to test your evenly spaced auto move feature.

( Option: Used for special software options only. Contact the factory. ( IR Option: 0 - IR Option Key Disabled

1 - Module packs alternate directions, evenly spaces, controls remain active. 2 - Module closes left, evenly spaces, controls remain active. 3 - Module closes right, evenly spaces, controls remain active.

( Motor Skew: This parameter should only be altered when dealing with multiple motor carriages.

Each motor on the carriage should move at exactly the same speed. Unfortunately, there is always some variation, a small amount of which can be tolerated. This parameter sets the amount of allowable variation between motors on the same carriage. The smaller this value can be set, with the carriage finishing its movement cycle, the better. This value can be set anywhere between 10 and 80 motor counts inclusively. HOWEVER, please consult the factory before using values that exceed 30 counts.

( Motor Position: On an EC300A/EC400 system, the same controller board is used in all multiple motor carriage configurations. If the carriage controller is in a single motor configuration, pick ALONE. Select FRONT if the carriage controller is the first in line on a multiple motor carriage. If the carriage controller is neither the first nor last on a multiple motor carriage MIDDLE. If the controller is the last in line on a multiple motor carriage, select REAR. Remember that the unit number displayed shows the controller unit in the module, not the carriage number. For example, if there were a three carriage module with four motors per carriage, unit’s number 9, 10, 11 and 12 would be the front, middle, middle and rear positions respectively on the third carriage.

NOTE: It is very important that the A and B hardware jumpers (JP3 and JP2 respectively) correspond with this parameter for each controller.

Parameter JP3 JP2 Alone Normal Normal Front A Normal Middle A B,B (2 jumpers required) Rear Normal B,B (2 jumpers required) ( Move On Safety: This must be on when using Photosweep and Aisle Entry with Manual Reset

Select the appropriate movement from the drop down menu:

0: Aisle must be open off the far limit switch and any safety activation 1: Aisle must be open off the far limit switch and an Aisle Entry or ZFS activation. 2: Any safety activation will open the aisle 3: An Aisle Entry or ZFS activation will open the aisle Off – Turns “Move From Safety” off

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Section H ( Copy Config.: Clicking on this button allows you to copy the program from any logic board within

the module to any other logic board within the module. This means you don’t have to write all the parameters down on paper.

( Module Config: Allows you to program every carriage in the module automatically. Clicking this

button gives you a screen asking you to input how many logic boards (the number of logic boards will always match the number of motors) are on each carriage. An auto calculation will be done and will calculate every time you change a value for any carriage. Click on “Build Config” and the PC/laptop will use the same parameters of the last carriage the PC/laptop read and auto program all the motor positions (in the memory of the PC/laptop only, you haven’t saved anything to the logic boards yet). Once complete you can go through each logic board and change parameters as required. Once you have made all the changes you can save each logic boards individual program automatically.

Enter the number of motors per carriage.

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( Read Config.: Will give you the option of reading the information of the logic board the PC/laptop is interfaced with only, or all carriages to the right (We recommend always connecting to the Left Communication Jack of the first logic board in the system). It will store the information so you may switch from logic board to logic board without delay.

( Save Config.: Allows you to save the parameters to each logic board you have made changes to,

or only the logic board you are currently viewing. When complete the parameters in red will change back to black.

( Revert: This button will erase all of the changes you have made while on this screen. As you

change parameters the text will turn red. Clicking on “Revert” will return the PC/laptop to the parameters before you changed any of them.

( Close: Will close you out of the screen you are in without disconnecting from the unit. ( Exit: You must exit to leave the program. Just closing the window with the “X” in the upper right

hand corner of the screen will generate a “run time error”.

If the screen shown to the right appears you have tried to exit the program without saving the changes you made.

( The message displayed beneath the buttons will give you status of the connection.

“Serial Port Connected” means the PC/Laptop is communicating with the Hardware Box, “Diagnostic Unit Present” means the Hardware Box is Communicating to the logic board, and “Ready for use” indicates you are ready to continue.

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Diagnose System Screen

A: See Page 22 B: See Page 22 C: See Page 23 D: See Page 23 E: See Page 24 F: See Page 24 G: See Page 25

A

B C

DE

F

G

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Section A ( Unit: Displays the number of the logic board you are looking at. This will not correspond to the

carriage number in multiple motor systems (the exception is carriage #1 and logic #1). ( Type: Displays the type of system the PC/laptop is connected to. ( Version: Displays the revision level of software of the logic board you are looking at. ( Number of Units: The number of logic boards within the system. This will not correspond to the

number of carriages in multiple motor systems. ( Number of Aisles: The number of aisles within the system.

Section B ( Option Input 1: EC-400: Presence of a jumper or cable connection at the Night Park input.

See Section “E”, pages 13 & 14 PowerPro: Shows the condition of the Stationary Lock input (J23 pins 1&2). ( Option Input 2: EC-400: Presence of a jumper or cable connection at the Fire Park input.

See Section “E” page 13 PowerPro: Shows the condition of the Global Lock input (J23 pins 3&4). ( Option Input 3: EC-400: Presence of a jumper or cable connection at the Auto Move input.

See Section “E” page 14 ( Option Input 4-6: EC-400: Presence of a jumper or cable connection at the Special Option inputs.

These options will be specific to this particular job and not available as a standard offering.

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Section C ( Move Left & Right Request: These buttons will appear pushed in and the text will turn red if the

right or left move button is stuck or being pressed. It does not mirror the move relays. ( Reset Request: This button will appear pressed and the text will turn red any time a reset request

is received from the carriage you are looking at. This is a good way to find a stuck reset button. ( Left & Right Limit Switches: The status of the limit switch rod will be shown as being read by

the processor.

Extended = The rod is all the way out, the carriage will move normally in that direction. Acel/Decel = The rod is compressed off the far limit (front) switch but has not reached the near

limit (rear) switch. The carriage will only creep in this direction. Compressed = The rod is compressed far enough to reach the near (rear) switch stopping

carriage movement. ( Left & Right Safety Sweeps: The condition of the sweep circuit will be displayed.

Section D Last Stop Message Possible Cause ( Normal Stop: This controllers last stop was normal. ( OKTM Dropped: Reset button pushed or a sweep activated in the module while moving. ( Move Too Long: Auto stop time exceeded (value too small for aisle width or wheel slip). ( Creep Too Long: Motor creep time exceeded (near limit not working properly). ( Motor Speed Diff.: Multiple motor carriage motor counts not synchronized. ( No Motor Counts: Bad or missing motor sensor/cable or locked rotor. ( Floor Activated: Safety Floor is activated by a presence or a fault. ( Aisle Guard: Aisle Guard detected a presence in the aisle or has faulted. ( IR Key Stop: The Infra-red Remote Key’s stop button was pressed. Note: “1” indicates “On” and “0” indicates “Off” for the Dipswitch and Jumper inputs. Note: Double Clicking on the dipswitch window will bring up the dipswitch parameters. ( Dipswitch SW1: This window shows the dipswitch settings of the EC-300 (Under the heat sink) ( Dipswitch SW2: This window shows the dipswitch settings of the EC-300 (Outside the heat sink) ( Jumpers JP2: This window shows the condition of JP2 on the EC-300

Position 1: Beeper active during a safety fault Position 2: Fire Park Close Right (fire park input on security lock J21) Position 3: Fire Park Close Left (fire park input on security lock J21)

( Jumpers JP3: This window shows the condition of JP3 on the EC-300 Position 1: Doubles all movement timeouts Position 2: A programmed carriage’s Security Lock will deactivate left

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Section E ( Left & Right ZFS: The button will say “Normal” in green when ZFS considers the aisle clear. The

button will depress, turn red and say “Latched” when ZFS has detected a presence in the aisle and is searching for it.

The windows beneath “ZFS” & “Normal” / “Latched” will show the first web light pair or quad that is not receiving. ( First AG Board: The Left & Right windows below display the first reflector not detected by the laser

(similar to the ZFS portion showing the first bad receiver). If “Latched’ is on the Aisle Guard board has the aisle locked and is waiting for an exit signal to scan and clear the aisle. If not “Latched” the correct number of reflectors will be shown in the window (any time the aisle is green) and the window will say “Normal”.

( Second AG Board: Displays the info for the second laser on carriages longer than 21’. **Note** - “HOME” will appear in the Aisle Guard window if the laser does not detect it’s home switch. (The home switch tells the logic the laser has made a complete sweep and is back at it’s starting point.) ( Left & Right Photo: PowerPro only. Shows the status of the Photo Sweep Circuit. ( Disabled: PowerPro only. Indicates one or both Photo Sweep inputs are disabled. JP4 of the

PowerPro Logic Board must have a jumper in place as a visual cue that one or both of the Photosweep circuits has been disabled by the programming.

( Intensity JP1: These three jumper positions will show you the Photo Sweep calibration ( Intensity JP2: setting for the PowerPro logic board. JP1 = 1, JP2 = 2, and JP3 = 4 ( Intensity JP3:

Section F ( J8: This window shows the condition of J8 on the Safety Floor Monitor Logic Board

Position 1: Auto Power Up Position 2: An expansion board is present

( Leader Stop Loop: A stop button is depressed somewhere within the system. Check the Leader Stop and Stop LED’s on the logic boards to determine the guilty carriage. The last logic board with both LED’s out is the one causing the stop condition when working from the leader carriage to the right. Check this carriages control head (s) stop button to see if it’s stuck.

( On: The EC-300/EC-300A “On-Off-Stat-Move” keys “On” signal is being received by the system. ( Off: The EC-300/EC-300A “On-Off-Stat-Move” keys “Off” signal is being received by the system. ( Override: The EC-300/EC-300A Override key signal is being received by the system

( All the Floor Monitor buttons will appear depressed and the lettering will turn red if

that particular input is activated. The name of the button will also change from “CLOSED” to “OPEN”.

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Section G ( ZFS Trigger: Clicking this option puts the Diagnostic into “ZFS mode”. It will auto-update only ZFS

and it will latch and hold any change (for catching ghosts). ( Auto Update: Sets the rate (time) when the diagnostic will read the logic board and update it’s

display to match current conditions. If not checked you must click on “Update Display” for changes within the system.

( Update Display: Reads the processor and updates the conditions so you can view the changes

within the system. ( Configure System: Takes you to the Configure Parameters Screen (See page 9). ( Remote Move: Moves you to the Remote function. This allows your laptop/PC to function like the

Desktop Remote option of PE systems.

Enter the aisle you wish to open and click “Go”. The Reset button acts just like the Reset button on the front of the control.

( Close: Closes this screen. ( Exit: You must exit from the program. If you just close the window with the “X” in the upper right

hand corner of the screen you will generate a “run time error”. OP-0220

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Power Pro Configure Screen

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Power Pro Diagnose Screen

OP-0220