42004-739L2A

42004-739L2A
Pub. 42004-739L2A
GAI-TRONICS® CORPORATION
A HUBBELL COMPANY
69635-001
Master Control Unit PCBA
Confidentiality Notice
This manual is provided solely as an operational, installation, and maintenance guide and contains
sensitive business and technical information that is confidential and proprietary to GAI-Tronics.
GAI-Tronics retains all intellectual property and other rights in or to the information contained herein,
and such information may only be used in connection with the operation of your GAI-Tronics product or
system. This manual may not be disclosed in any form, in whole or in part, directly or indirectly, to any
third party.
General Information
The 69635-001 Master Control Unit (MCU) is the central component of SmartSeries system operations,
processing all operations through its associated system software, as part of an ADVANCE control unit. It
is installed in the 10457 Card Rack Assembly and maintains constant communication with all other
SmartSeries devices installed in the card rack and the system.
The MCU constantly supervises operations to ensure proper working condition. It is exclusively designed
for use in a SmartSeries system; the MCU is not intended for use with other types of equipment.
CAUTION
Connections to the MCU are reserved for use by authorized factory-trained
personnel unless explicitly stated otherwise in your system manual.
Description of Major Components
MCU Front Panel LEDs
The LED Array provides status on internal operation of the MCU. Abbreviated text labels to the right of
the LEDs help to locate a particular LED. Both the LEDs and their labels are divided into two columns;
the left column of labels corresponds to the left column of LEDs; the right column of labels corresponds
to the right column of LEDs.
GAI-Tronics Corporation 400 E. Wyomissing Ave. Mohnton, PA 19540 USA
610-777-1374  800-492-1212  Fax: 610-796-5954
VISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS
69635-101 Master Control Unit PCBA
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These LEDs are ON, they have the following meanings:
LED
Description (When ON)
-12V
The card rack is providing –12 volts dc to the MCU.
+12V
The card rack is providing +12 volts dc to the MCU.
+5V
The card rack is providing +5 volts dc to the MCU.
BEEP
This LED simulates the CPU module speaker function. The LED emits light instead of a
speaker emitting sound.
NOTE: If the CPU Module detects an error during boot-up, this LED will flash more than
once. In this error condition, the CPU Module generates, a one-time “beep code” to aid
in diagnosing the fault. Momentarily pressing the reset button will cause the beep code
to repeat.
LINK
Shows Ethernet network status. The MCU has established a communications link with
another Ethernet network device.
ACT
Shows Ethernet network status. The MCU detects activity on the attached Ethernet
cable.
BP
The MCU is using the data bus in the card rack.
The card rack is sometimes referred to as “back plane,” which gives this LED its
abbreviation (BP).
SPD
This LED operates in conjunction with LINK LED to indicate the speed of the Ethernet
network connection.
LINK (On) SPD (Off) = 10 MB Ethernet connection
LINK (On) SPD (On) = 100 MB Ethernet connection
LINK (Off) SPD (Off) = no network connection established
SEC
The MCU is accessing the CompactFlash® card connected to the secondary IDE
controller.
PRI
The MCU is accessing the hard disk drive connected to the primary IDE controller.
B7, B6, B5,
B4, B3, B2,
B1, or B0
These LEDs are referred to as the Port 80 LEDs. They are used to show diagnostic
information that can be used by factory trained technicians as a troubleshooting aid.
NOTE: Some of the MCU LEDs are red. While red typically is an error indicator, this is not so here.
MCU Front Panel Connections
The PS/2 keyboard and PS/2 mouse connectors enable connecting a PS/2 keyboard and a PS/2 mouse,
respectively, to the MCU. These connectors are color-coded to match the PC99 standard. In order for the
mouse to function properly, it must be connected at power-up. There is no benefit in attaching a mouse at
this time.
The COM2 RS232 port provides an RS-232 serial connection to the MCU. This connector’s pin-out
matches that of a standard PC’s 9-pin serial connector pin-out.
NOTE: The COM2 RS-232 port is logically in parallel with the COM2 RS-485 half-duplex port on the
rear of the card rack; therefore, both of the ports may not be used simultaneously.
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The VGA connector enables connecting a VGA monitor to the MCU. This connector is color coded to
match the PC99 standard.
The USB Port 0 and USB Port 1 connectors enable connecting USB 1.0 or USB 2.0 devices to the MCU.
The Reset button resets the MCU. Momentarily depress the RESET button to reset and re-boot the
MCU. Holding in the RESET button will keep the MCU in reset mode, and it will not re-boot. The
button is recessed to prevent accidental depressions.
Card Rack Rear Panel Connections
The LPT1 parallel port provides a parallel port connection to the MCU. This is typically used for
connecting a printer. This connector’s pin-out matches that of a standard PC’s 25-pin parallel port
connector pin-out.
The COM1 RS-485 half-duplex port provides a half-duplex RS-485 connection to the MCU. This
connector’s pin-out is proprietary. Also, this connection provides a dry contact closure output. If
applicable, the operation of this connector is described in your system manual. This port shares the
connector with COM2.
The COM2 RS-485 half-duplex port provides a half-duplex RS-485 connection to the MCU. This
connector’s pin-out is proprietary. Also, this connection provides a dry contact closure output. If
applicable, the operation of this connector is described in your system manual. This port shares the
connector with port 1.
NOTE: The COM2 RS-232 port is logically in parallel with the COM2 RS-485 half-duplex port on the
front panel of the MCU; therefore, both of the ports may not be used simultaneously.
MCU Internal Connections
The CPU Module holds the microprocessor that controls the system.
The Ethernet port provides an Ethernet connection to the CPU Module.
The battery allows the CPU Module to keep track of the date and time in the event of a power failure.
NOTE: CMOS settings are stored in EEPROM; their storage does not rely on battery power during a
power failure.
A 2.5-inch IDE Hard Drive connects to the CPU Module. The 2.5-inch IDE hard drive is formatted and
proper software is factory installed.
A CompactFlash® card connects to the CPU Module. The CompactFlash® card is formatted and proper
software is factory-installed (when required).
The Upper VME Connectors provides the mechanical connection to the card rack’s backplane.
The Lower VME Connector provides the mechanical connection to the rear panel of the card rack. It is
used for connection of external devices described above under “Card Rack Rear Panel Connections”
section.
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Operation
After installation and power-up, the MCU starts automatically. It requires no direct user intervention
during normal operations.
In general, the MCU maintains data communication with all other cards in the card rack and with
SmartSeries devices located throughout the system. Its software configuration file defines the actual
operation of the MCU. Your system manual provides specific information how the MCU controls the
operation of your specific system.
The connections on the MCU are for use by factory-trained personnel only, unless explicitly stated
otherwise in your system manual. Although these connections are the same as those found on a PC, and
the MCU functions similarly to a PC, it is to be used strictly for operating the SmartSeries system and
should not be used for performing other functions. Failure to follow this advice could result in the failure
of your system.
Installation and Maintenance
Direct questions about installation and updating the system software configuration of this product to the
GAI-Tronics Field Service Department at 800-492-1212 inside the USA or 610-777-1374 outside the
USA.
WARNING
Disconnect power to the card rack before performing any maintenance.
Installation Instructions
Refer to Figure 1 for component location and installation details.
1. Verify that power is disconnected to the card rack prior to installation.
2. Find the slot located on the farthest left side of the card rack.
3. Align the MCU into the upper and lower tracks in the card rack.
4. Connect the Ethernet cable supplied within the card rack.
5. Slide the MCU toward the rear of the card rack until it comes in contact with the connectors on the
backplane.
6. Firmly press on the front bezel until the MCU is seated in the back-plane connectors, and tighten the
two retaining screws located on the front bezel to secure it to the card rack.
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Removing the MCU from the Card Rack
1. Remove power from the card rack.
2. Loosen the two retaining screws on the front bezel that secures the MCU to the card rack.
3. Gently disengage the MCU from the connector on the backplane and slide the MCU out of the card
rack.
4. Disconnect the Ethernet cable.
Battery Replacement
1. Lift the retainer clip away from battery and pry the battery out of the holder. See Figure 1 for location.
2. Insert the new battery into the battery holder under the retainer clip.
3. Reinstall the MCU into the card rack per above procedure.
4. Set the date and time as instructed in the system manual.
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69635-101 Master Control Unit PCBA
Figure 1. Model 69635-001 PCBA Master Control Unit
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69635-101 Master Control Unit PCBA
Troubleshooting
Symptom
Action
The –12V, +12V, or +5V LED on
front bezel is not ON.
1. Verify power is applied to the card rack.
The Port 80 LEDs’ light pattern
remains constant after applying
power.
1. One time only, disconnect and reconnect power to the card
rack.
2. Disconnect power to the card rack.
 Verify the MCU is properly inserted into the card rack.
 Reconnect power to the card rack.
 If at least one of those LEDs is still not ON, call for
service for the MCU and the card rack.
2. Press the RESET button.
3. Call for service of the MCU.
Date and time settings do not stay
current after a period of system power
interruption.
1. Replace the battery.
The Port 80 LEDs appear to be
changing in a periodic pattern, and the
system does not function at all. This
problem usually occurs immediately
after power-up.
Call for service of the card rack.
2. Call for service of the MCU.
This situation arises if the +5 volt power provided by the card
rack to the MCU is too low. In this circumstance, the reset
circuitry on the CPU Module oscillates in and out of reset.
Specifications
Electrical
Power ......................................................................................................... 3 A maximum @ +5 V dc 5%
20 mA maximum @ +12 V dc 10%
20 mA maximum @ −12 V dc 10%
Battery ............................................................................................................................................... 3 volts
0.03 mA standard load; Lithium Coin Cell/48 mAh capacity
Environmental
Temperature range (operating/storage) ................................................. +32º F to +120º F (0º C to +49º C)
Humidity: ................................................................................. 10–85% non-condensing relative humidity
Mechanical
Unit dimensions ....................................... 10.30 H  1.63 W  9.07 D inches (262.0  41.3  231.0 mm)
Unit weight....................................................................................................................... 1.55 lbs. nominal
Replacement Parts
GTC Model No.
40005-005
Manufacturer /Model No.
Panasonic - BR1225
Rayovac – BR1225
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Description
Battery, 3V Lithium Coin Cell
Warranty
Equipment.
GAI-Tronics warrants for a period of one (1) year from the date of shipment, that any
GAI-Tronics equipment supplied hereunder shall be free of defects in material and workmanship, shall
comply with the then-current product specifications and product literature, and if applicable, shall be fit
for the purpose specified in the agreed-upon quotation or proposal document. If (a) Seller’s goods prove
to be defective in workmanship and/or material under normal and proper usage, or unfit for the purpose
specified and agreed upon, and (b) Buyer’s claim is made within the warranty period set forth above,
Buyer may return such goods to GAI-Tronics’ nearest depot repair facility, freight prepaid, at which time
they will be repaired or replaced, at Seller’s option, without charge to Buyer. Repair or replacement shall
be Buyer’s sole and exclusive remedy. The warranty period on any repaired or replacement equipment
shall be the greater of the ninety (90) day repair warranty or one (1) year from the date the original
equipment was shipped. In no event shall GAI-Tronics warranty obligations with respect to equipment
exceed 100% of the total cost of the equipment supplied hereunder. Buyer may also be entitled to the
manufacturer’s warranty on any third-party goods supplied by GAI-Tronics hereunder. The applicability
of any such third-party warranty will be determined by GAI-Tronics.
Services.
Any services GAI-Tronics provides hereunder, whether directly or through subcontractors,
shall be performed in accordance with the standard of care with which such services are normally
provided in the industry. If the services fail to meet the applicable industry standard, GAI-Tronics will
re-perform such services at no cost to buyer to correct said deficiency to Company's satisfaction provided
any and all issues are identified prior to the demobilization of the Contractor’s personnel from the work
site. Re-performance of services shall be Buyer’s sole and exclusive remedy, and in no event shall GAITronics warranty obligations with respect to services exceed 100% of the total cost of the services
provided hereunder.
Warranty Periods.
Every claim by Buyer alleging a defect in the goods and/or services provided
hereunder shall be deemed waived unless such claim is made in writing within the applicable warranty
periods as set forth above. Provided, however, that if the defect complained of is latent and not
discoverable within the above warranty periods, every claim arising on account of such latent defect shall
be deemed waived unless it is made in writing within a reasonable time after such latent defect is or
should have been discovered by Buyer.
Limitations / Exclusions.
The warranties herein shall not apply to, and GAI-Tronics shall not be
responsible for, any damage to the goods or failure of the services supplied hereunder, to the extent
caused by Buyer’s neglect, failure to follow operational and maintenance procedures provided with the
equipment, or the use of technicians not specifically authorized by GAI-Tronics to maintain or service the
equipment. THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE IN LIEU OF AND
EXCLUDE ALL OTHER WARRANTIES AND REMEDIES, WHETHER EXPRESS OR IMPLIED BY
OPERATION OF LAW OR OTHERWISE, INCLUDING ANY WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Return Policy
If the equipment requires service, contact your Regional Service Center for a return authorization number
(RA#). Equipment should be shipped prepaid to GAI-Tronics with a return authorization number and a
purchase order number. If the equipment is under warranty, repairs or a replacement will be made in
accordance with the warranty policy set forth above. Please include a written explanation of all defects to
assist our technicians in their troubleshooting efforts.
Call 800-492-1212 (inside the USA) or 610-777-1374 (outside the USA) for help identifying the
Regional Service Center closest to you.
(Rev. 10/06)
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