MCU resets and controller communication loss

Problem

Intermittent communication loss to controller AND MCU resets with the following symptoms:

  • On the software- there will be an error stating "unable to retrieve information from controller ensure you have a valid connection and try again"

  • On the MCU- the display will always go back to the Board Monitor screen

Causes

  1. Loose wiring

  2. Bad connections or connectors

  3. Bad power supply

  4. Malfunctioning controller card or Rabbit card

Solution

  1. Determine if the problem occurs when the planer line is running, the line is down, or both.

    1. If the line is running, the problem is likely in the MCU or the Sensor (due to vibration from the planer).

  • Unplug the Ethernet connector from the sensor. If the disconnection error stops then focus on the wiring in the sensor. Begin by looking for any loose wires. This can include the grounding to the chassis, grounding to the backplate, connections to the terminals, connections to the boards and damaged wires.

  • If the disconnection error continues start at the MCU and check for any bad connections or bad wiring. This can include the ethernet connection/fitting, enough wire stripped for the connections to the controller or I/O board and/or all components secured to the backplate. In the MCU it is important to check the power supply for proper voltage or loose connections.

  • If the sensor and MCU wiring and voltage are good then check the painter for an excessive power draw.

  • If all wiring and voltage have been checked an verified and the problem persists replace the rabbit card.

  • If the rabbit card is replaced and the problem continues replace the controller card.