Troubleshooting Tips

Calibration Errors

If the AGT400 Thickness Gauge will not ISOcheck™ correctly, repeat the
process then try the ISOcal™ procedure if necessary. If the ISOcal™ fails, repeat
the process or try the Manual Calibration procedure. If the Manual Calibration
fails, or no N.I.S.T.-traceable samples are available, use the following procedure
to isolate the problem:

ISOcheck™ Unsuccessful

1)    If any error messages are generated when the ISOcheck™ process fails, refer to the System Messages list in this manual for an explanation and possible resolution. Contact A.G.T. for further assistance.

2)    If the ISOcheck™ completes unsuccessfully for no apparent reason, retry the ISOcheck™ procedure a second time. If it is still unsuccessful, perform the ISOcal™ procedure.

ISOcal™ Unsuccessful

1)    If any error messages are generated when the ISOcal™ process fails, refer to the System Messages list in this manual for an explanation and possible resolution. Contact A.G.T. for further assistance.

2)    If the ISOcal™ completes unsuccessfully for no apparent reason, retry the ISOcal™ procedure a second time. If it is still unsuccessful, verify the shutter closed A/D value is approximately 130 (65 to 260 acceptable in most cases) and the shutter open A/D value is approximately 62,500 (60,500 to 64,500 acceptable in most cases).

3)    If the measured shutter closed A/D value is significantly different than the nominal shutter closed A/D value or measures 0, see if the amount of error is relatively consistent with the amount of error with the shutter open, and on samples 1, 2 and 3. If the A/D error seems to be a consistent amount or reads 0, this may indicate a defective F.E.T. in the detector head. Refer to the procedure for F.E.T. Replacement.

4)    If the measured shutter open A/D value is significantly different than the nominal shutter open A/D value, this may indicate that the C-frame has been damaged (i.e. bent). A shutter open A/D value of 65,535 is not normal and may indicate a defective pre-amplifier board in the detector head. Close the shutter and inspect the C-frame for any signs of recent physical damage. Repair the C-frame as necessary. Then adjust VR2 on the Multifunction Board for a shutter open reading of 9.50 VDC measuring from TP1 (ground) to TP9. Once this adjustment is made, the shutter open A/D reading (CH0) should be approximately 62,250.

5)    If the measured sample 1, 2 or 3 A/D value is significantly different than the nominal sample 1, 2 or 3 A/D value, this may indicate a problem with the source head cable or source ring assembly. See the procedure for Internal Samples Inoperable.

Manual Calibration Unsuccessful

1)    If any error messages are generated when the Manual Calibration process fails, refer to the System Messages list in this manual for an explanation and possible resolution. Contact A.G.T. for further assistance.

2)    If the Manual Calibration completes unsuccessfully for no apparent reason, verify the shutter closed A/D value is approximately 130 (65 to 260 acceptable in most cases) and the shutter open A/D value is approximately 62,500 (60,500 to 64,500 acceptable in most cases).

3)    If the measured shutter closed A/D value is significantly different than the nominal shutter closed A/D value, see if the amount of error is relatively consistent with the amount of error with the shutter open, and on samples 1, 2 and 3. If the A/D error seems to be a consistent amount, this may indicate a defective F.E.T. in the detector head. Refer to the procedure for F.E.T. Replacement.

4)    If the measured shutter open A/D value is significantly different than the nominal shutter open A/D value, this may indicate that the C-frame has been damaged (i.e. bent). Close the shutter and inspect the C-frame for any signs of recent physical damage. Repair the C-frame as necessary.

5)    If the measured sample 1, 2 or 3 A/D value is significantly different than the nominal sample 1, 2 or 3 A/D value, this may indicate a problem with the source head cable or source ring assembly. See the procedure for Internal Samples Inoperable.

6)    If the Manual Calibration completes unsuccessfully for no apparent reason, and all the measured and nominal A/D values seem to be relatively consistent, there may be an issue with the selected external calibration samples. Print a copy of the screen and contact A.G.T. for further assistance.

C-frame Errors

When trying to resolve C-frame movement issues, the first step should be to qualify the type of problem being experienced. Use the examples below to determine what type of C-frame movement issue you are experiencing:

C-frame Will Not Move

1. If the C-frame will not move, first check that the Auxiliary circuit breaker on the Electronics Shelf has power and is turned on. If not, see the procedure for No AC Power. Note: the Auxiliary circuit breaker also powers the indicator lights and electronics cabinet cooling fan.
    
2.  Verify that the C-frame command button is turning yellow when clicked. If not, the Manual/Auto switch on the Electronics Shelf may be set incorrectly (must be set to Auto), the C-frame may be configured incorrectly on the System Setup screen (must be set to Electric or Oscillating) or you may be attempting to move the frame illegally (can’t move on sheet if the C-frame is already at the on sheet limit for example).
    
3.  Command the C-frame to Move On or Move Off (choose the opposite of the current C-frame position so the command is valid), while measuring the voltage at the Direction Relay on the Electronics Shelf (R2-1 to R2–8). It should read 30 to 120 VDC. If not, there may be a problem with the rectifier or Speed Control, or it may be incorrectly adjusted or turned off. Contact A.G.T. for further assistance.
    
4. Check the fuse in Opto22 module 0 (the first red Opto22 module). Replace it if necessary. See the procedure for Fuse Replacement.
    
5. If the Auxiliary circuit has AC power, the C-frame is properly configured, the C-frame is being commanded to move in a legitimate fashion and the fuse is good, turn the MODE keyswitch on the Electronics Shelf to the PROGRAM position and switch to the Diagnostic Data screen.
    
6. Command the C-frame to Move On or Move Off (choose the opposite of the current C-frame position so the command is valid), while monitoring the digital output for Pwr Command. It should become a 1 shortly after the Move On or Move Off button is clicked. During the period when this digital output is a 1, Opto 22 module 0, LED 1 should be illuminated. If not, there may be a problem with the Digital Computer Board, the Digital Board Cable, or Opto Module 0. Contact A.G.T. for further assistance.
    
7. Disconnect the two wires at the Direction Relay on the Electronics Shelf (R2-1 to R2-8), and measure the resistance across them. It should measure 5 to 50 Ω. If it measures less than 5 Ω, there may be a shorted Drive Motor Cable or Drive Motor. Disconnect the cable on both ends and measure across the cable conductors and across the motor winding. Replace the defective cable or motor as necessary.
    
8. If the measurement across the two wires at the Direction Realy on the Electronics Shelf (R2-1 to R2-8) measures greater than 50 Ω, there may be an open Drive Motor Cable or Drive Motor. Disconnect the cable on both ends and measure across the cable conductors and across the motot winding. Replace the defective cable or motor as necessary.
    

C-frame Moves Too Slowly

1.  If the C-frame moves, but moves slower than the desired speed, adjust the Speed Control on the Electronics Shelf. Rotating the Speed Control knob clockwise will increase the C-frame speed, while rotating it counterclockwise will decrease the C-frame speed. Note: excessive C-frame speed can cause a variety of problems such as missed strip edges (with Oscillating C-frame)
    
2. Command the C-frame to Move On or Move Off (choose the opposite of the current C-frame position so the command is valid), while measuring the voltage at the Direction Relay on the Electronics Shelf (R2-1 to R2-8). It should read 30 to 120 VDC. If not, there may be a problem with the rectifier or Speed Control. Contact A.G.T. for further assistance.
    
3. Verify drive chain is adjusted properly, and does not have excess slack.
    
4. Disconnect the C-frame drive chain and manually move the C-frame should move freely and without restriction. If not, remove any debris from the C-frame I-beam and/or bend things back into position as necessary in order to facilitate free movement.
    
5. Inspect the motor brushes, remove brush cap on side of motor and verify each brush is in good condition and making good contact.
    
6. Check continuity on the drive motor wires. Replace the drive motor cable if necessary.
    
7. If the C-frame Speed Control is set correctly, the motor voltage is correct, there are no physical C-frame restrictions and the drive motor cable is good, replace the C-frame drive motor.
    

C-frame Moves, But Will Not Oscillate

1. 1. With the shutter closed and the C-frame in an easily accessible location, you should be able to see a red LED in each of the (lower) photocell emitters. If not, there may be a problem with the 13 VDC power supply, the photocell wiring or the photocell emitter(s). This 13 VDC power supply can be tested at the Multifunction Board by measuring between TP1 (ground) and TP5 (+13.2 VDC), in the C-frame junction box between JTB2-5 (ground) and JTB2-6 (+13.2 VDC).
       
   2. There is another terminal block behind the rear access cover in the top of the C-frame and the 13 VDC photocell power supply can be measured here between terminals 1 (+13.2 VDC) and 2 (ground). Replace the photocell cable or photocell emitter(s) as required.
       
   3. Check for power at each of the (upper) photocell receivers by looking for a green LED on each one. If one or both are missing, there may be a problem with the 13 VDC power supply, the photocell wiring, the photocell pull-up resistors or the photocell reciever(s). This 13 VDC power supply can be tested at the Multifunction Board by measuring between TP1 (ground) and TP5 (+13.2 VDC), in the C-frame junction box between JTB2-5 (ground) and JTB2-6 (+13.2 VDC).
       
   4. There is another terminal block behind the rear access cover in the top of the C-frame and the 13 VDC photocell power supply can be measured here between terminals 1 (+13.2 VDC) and 2 (ground). The photocell pull-up resistors (10kΩ) can be inspected on this terminal strip. Replace the photocell cable, photocell pull-up resistors or photocell receiver(s) as required.
       
   5. If both photocell emitters and both photocell receivers have power, the next step is to verify correct operation of the photocell receivers. With no photocell beam obstructions, each photocell receiver should have a yellow LED illuminated in addition to the green power LED describe in step 2 above.
       
   6. Ensure the shutter is closed and use your hand to block each photocell beam with your hand, and the yellow LED on each respective photocell receiver should go out. If one or both of the photocell receivers is not working correctly, verify all four photocells (emitters and receivers) are clean and properly aligned with each other.
       
   7. Once proper photocell operation has been verified, the next step is to verify the correct digital signals are being received  by the gauge software. With no photocell beam obstructions, turn the MODE key on the Electronics Shelf to PROGRAM and look for a one (1) in the Off Photo and On Photo Fields contained in the C-frame Data frame. Since each photocell receiver should should be detecting its respective photocell emitter, there should be a corresponding 1 in each of these boxes. If one or both are low (0), measure for the proper signals (=13.2 VDC) at terminals 3 (off sheet photocell) and 4 (on sheet photocell) on the internal C-frmae terminal strip, then at terminals JTB2-3 (off sheet photocell) and 4 (on sheet photocell) in the C-frame junction box, then at Opto22 module 4-6 (off sheet photocell) and 4-8 (on sheet photocell). Once it is determined where the photocell signal(s) is being lost, repair or replace the cable as required.
       
   8. Contact A.G.T. for further assistance.

Computer Inoperable

If the AGT400 computer is completely inoperable, use this procedure to determine the cause:

1. 1.  Verify AC power is present at the outlet box in the AGT400 Electronics Cabinet where the computer plugs in. If not, see No AC Power.
       
   2. Ensure the computer is plugged in and turned on. If not, plug it in and/or turn it on.
       
   3. Attempt to restart the computer using the computer power switch or the left (Computer/ Electronics) circuit breaker on the AGT400 electronics shelf. If the computer doesn't restart automatically when power is reapplied, press the power button on the computer. In some instances, just restarting the computer will 'solve' unexplained computer problems.
       
   4. If AC power is present, everything is plugged in properly and the computer still will not run, your computer may have a defective internal power supply, defective main board or defective CPU. Contact A.G.T. for further assistance.

Computer Slow or Locked Up

If the AGT400 computer operation has slowed, or the computer is completely locked up, use this procedure to determine the cause:

1. Reboot the computer. Attempt to do a proper shutdown by exiting the AGT400 software, then properly shutting down Windows®. If this isn’t possible, use the computer power switch or the left (Computer/Electronics) circuit breaker on the AGT400 electronics shelf to remove power. If the computer doesn’t restart automatically when power is reapplied, press the power button on the computer. In some instances, just rebooting the computer will ‘solve’ unexplained computer problems.
    
2. After the reboot, check the print queue for backed up print jobs. Note: a simple paper jam or printer error can cause the AGT400 to fill up the print queue to the point where the CPU can only function very slowly if at all. Delete any and all jobs in the print queue. If the print queue was empty, and the computer seems to be running at normal speed, monitor the system for the next week or so.
    
3. If the computer is still running slow or exhibits a tendency to lock up, check the ZIP disk to be sure it isn't more than 85% full. If so, replace the ZIP disk.
    
4. If the computer is still running slow or exhibits a tendency to lock up, remove the computer cover and inspect the CPU cooling fan with the computer running. It must operate at full speed in order to keep the CPU from overheating and slowing down to a crawl. If the fan is turning slowly or not at all, it must be replaced.
    
5. If the computer is still running slow or exhibits a tendency to lock up, disconnect the plant network (if applicable) and reboot the AGT400 computer again. If the problem disappears, it was probably a network related issue and the Network Administrator should investigate the situation.
    
6. If the computer is still running slow or exhibits a tendency to lock up, contact A.G.T. for further assistance.

Indicator Light(s) Inoperable

1. Check each of the indicator lamps to ensure it is not defective, loose or missing. Replace the lamp(s) as necessary.
    
2. If all four lamps (red and green shutter indicators and amber and blue classifier indicators) are inoperable, verify that the Auxiliary circuit breaker on the Electronics Shelf has power and is turned on. If not, see the procedure for No AC Power.
    
3. If all four lamps (red and green shutter indicators and amber and blue classifier indicators) are inoperable, check the fuse in Opto22 module 5 (the only black Opto22 module). Replace the fuse if necessary. See the procedure for Fuse Replacement.
    
4. If both shutter indicators (red and green) are inoperable, switch the PROGRAM Keyswitch to the PROGRAM position and go to the Diagnostic Data screen. Command the shutter to close and verify the Closed Lamp command in the Digital Data frame is a ‘1’. If not, skip to step 9 below.
    
5. Verify that LED 2 on Opto22 module 5 is illuminated. If not, there may be a problem with the Digital Computer Board, Digital Board Cable or Opto22 Rack. Contact A.G.T. for further assistance.
    
6. Measure the voltage between Opto22 TB-9 and Opto22 module 5-4. It should measure ~ 120 VAC. If so, locate the cable problem, and repair/replace the cable as necessary. If not, contact A.G.T. for further assistance.
    
7. If only the closed (green) shutter indicator is inoperable switch the PROGRAM Keyswitch to the PROGRAM position and go to the Diagnostic Data screen. Command the shutter to close and verify the Closed Lamp command in the Digital Data frame is a ‘1’ and LED 2 is illuminated on Opto22 module 5. If not, proceed to step 9 below.
    
8. If only the open (red) shutter indicator is inoperable, switch the PROGRAM Keyswitch to the PROGRAM position and go to the Diagnostic Data screen. Command the shutter to open, verify the Open Lamp command in the Digital Data frame is a ‘1’, LED 1 is illuminated on Opto22 module 5, and measure the voltage between Opto22 TB-9 and Opto22 module 5-2. It should measure ~ 120 VAC. If so, locate the cable problem, and repair/replace the cable as necessary. If not, skip to step 9 below.
    
9. If the shutter is commanded to open or close, but the AGT400 software is not commanding the corresponding digital output for the respective shutter status indicator, there may be a problem with the source head microswitch(es). When the shutter is closed, look in the Switch Status frame for the Closed digital input, and when the shutter is open, look in the Switch Status frame for the Open digital input. If one or both of these digital inputs is not functioning correctly, there may be a problem with the source head cable or the source ring assembly inside the source head. In this case, contact A.G.T. for further assistance. Only licensed individuals are permitted to perform any service on the source head and/or source ring assembly.
    
10. If the low (amber) classifier indicator is inoperable, verify the user limits are set correctly on the Main Screen. If so, switch the PROGRAM keyswitch to the PROGRAM position and go to the Diagnostic Data screen. Command the shutter open with no thickness in the beam. This will force the AGT400 software to issue the low (amber) classifier indicator command. Verify the Low Lamp command in the Digital Data frame is a ‘1’. If not, there may be a problem with the Digital Computer Board, Digital Board Cable or Opto22 Rack. Contact A.G.T. for further assistance.
     
11. Verify that LED 4 on Opto22 module 5 is illuminated. Measure the voltage between Opto22 TB-9 and Opto22 module 5-8. It should measure ~ 120 VAC. If so, locate the cable problem, and repair/replace the cable as necessary. If not, contact A.G.T. for further assistance.
     
12. If the high (blue) classifier indicator is inoperable, follow the procedure in step 7 above, looking for the High Lamp command in the Digital Data frame, and LED 3 on Opto22 module 5, measuring the voltage between Opto22 TB-9 and Opto22 module 5-6. It should measure ~ 120 VAC. If so, locate the cable problem, and repair/replace the cable as necessary. If not, there may be a problem with the Digital Computer Board, Digital Board Cable or Opto22 Rack. Contact A.G.T. for further assistance.

Internal Sample(s) Inoperable

If one or more of the internal samples in your AGT400 thickness gauge do not function properly, use this procedure to determine the cause:

1. Verify the shutter is operating correctly. If not, see the procedure for Shutter Inoperable.
    
2. If the shutter is operating correctly, but one or both of the internal samples is not functioning, use the Diagnostic Data screen and TP5 on the Multifunction Board on the Electronics Shelf to verify the 13VDC Power Supply reads 13.20 ±50 VDC. If so, skip ahead to step 5 below. If not, disconnect each circuit from this supply individually in order to determine where the short is originating. Start by unplugging J3 on the Multifunction Board. This supply also powers the Source Head, which can be disconnected at the Opto22 module rack (two purple wires on screw terminal #2).
    
3. If the power supply voltage returns to normal when a specific load is disconnected, check for shorts in that circuit. A typical failure in this area would include a situation where the Tachometer Cable or connector has been damaged by scrap steel.
    
4. If every 13VDC load has been disconnected and the supply still has low or no output, the power supply itself may need to be replaced. Contact A.G.T. for further assistance.
5. If the 13VDC power supply measures correctly, but one or both of the internal samples is not functioning, command the shutter to open and insert sample 3 from the Diagnostic Data Screen while monitoring the same voltage. If the voltage stays constant, or only drops ~ .03 volts, most likely there is not an excessive load or power supply problem. Reboot the AGT400 computer to ensure the digital board does not need to be reset.
    
6. If there is not an excessive load or a power supply problem, open the shutter, command sample 3 into the beam and measure the DC voltage on the Opto22 rack between Opto22 module 1-4 (ground) and Opto22 terminal number 6. Also measure the DC voltage on the Opto22 rack between Opto22 module 1-6 (ground) and Opto22 terminal number 6. It should read 13.20 ±50 VDC in both locations. If not, check the fuse in Opto22 module 1. If the fuse is defective, replace it. See the procedure for Fuse Replacement. If the fuse is good, there may be a problem with the digital computer board, digital cable or Opto22 module.
    
7. If the reading was 13.20 ±50 VDC in step 6 above, go to the C-frame junction box and measure the same voltage between JTB2-11 (ground) and JTB2-7. Also measure between JTB2-12 (ground) and JTB2-7. Both points should measure 13.20 ± 0.50 VDC, allowing for some voltage loss depending on the length of your source head cable. If both of the voltages are slightly low, one or both of the spares (red and/or red with white stripe) may be used in parallel with the black and black with white stripe in your source head cable. If one or both of the voltages are not present, then your source head cable should be replaced between the Electronics Cabinet and the C-frame junction box. If both of the voltage measure good, most likely the source head cable needs replaced between the C-frame junction box and the source head or there is a problem with the source ring assembly. Contact A.G.T. for further assistance. Only licensed individuals are permitted to perform any service on the source head and/or source ring assembly.

Keyboard Inoperable

If your AGT400 keyboard is inoperable, use this procedure to determine the cause:

1. Ensure the computer is functioning otherwise (i.e. has video, etc.). If not, see Computer Inoperable or Computer Slow or Locked.
    
2. Ensure the keyboard is plugged in.
    
3. Ensure the keyboard lock switch on the computer is turned OFF. The ‘0’ end of this rocker switch should be pressed down. If this switch was turned on, turn it OFF and restart the computer. Note: most industrial computer models have this keyboard lock switch, but most standard computer models do not.
    
4. If your computer is working properly, the keyboard is plugged in, and the keyboard lock is turned OFF, see procedure for Keyboard Replacement.

Length or Weight Errors

If the AGT400 system counts footage incorrectly, calculates weight incorrectly orfails to measure length correctly, use the examples below to first determine what type of length or weight issue your gauge is experiencing:

Length Measurement Incorrect

1. Check a few Coil Reports with incorrect lengths to see if there is a pattern to the length reporting error. For example, is the reported length error always in the same direction and/or approximately the same percentage?
    
2. If the reported length is consistently low by roughly the same percentage, the most likely causes are tachometer roll slippage, incorrect tachometer, incorrect system setup or a damaged or defective tachometer or cable. See step 5 below.
    
3. If the reported length is consistently high by roughly the same percentage, the most likely causes are incorrect tachometer, incorrect system setup or a damaged or defective tachometer or cable. See step 6 below.
    
4. If the reported length seems to be random, with no obvious pattern when compared to the actual length, the most likely causes are tachometer roll slippage, or a damaged or defective tachometer or cable. See step 5 below.
    
5. Check the tachometer roll for slippage.
    
6. Verify your tachometer is a 300 PPR (pulses per revolution) model.
    
7. Go to the System Setup page and verify the Tach, Pulses/Rev and Tach Roll Diam are set up correctly. See the System Setup page for an explanation of these parameters.
    
8. Inspect your tachometer, cable and connector. Replace the cable or connector as required. If no problem is found, see the procedure for Tachometer Replacement.
    

Weight Calculation Incorrect

The AGT400 software calculates the weight of each coil using the measured length, measured thickness and density as entered on the Product Menu screen.

1. Refer to the procedure for ISOcheck™ to verify thickness measurement accuracy.
2. Check a few Coil Reports to verify the correct length is being reported. If not, see the above procedure for Length Measurement Incorrect.
3. If the AGT400 is reporting length correctly, but the weight in inaccurate, verify the Density of each product in your Product Menu using the Product Menu Examples list in this manual.

No Length

1. 1. Inspect the tachometer fuse on the Multifunction Board. Replace the fuse if necessary.
       
   2. Inspect your tachometer cable and connector. Replace the cable or connector as required.
       
   3. Measure the voltage on the Multifunction Board at J2-1 in reference to ground (TP1). It should read 13.20 ±50 VDC. If not, disconnect each circuit from this power supply individually in order to determine where the short is originating. Start by disconnecting the Tachometer wires at J2 on the Multifunction Board. This supply also powers the Source Head, which can be disconnected by removing the two purple wires at Opto22 terminal #2.
       
   4. If the power supply voltage returns to normal when a specific load is disconnected, check for shorts in that circuit. A typical failure in this area would include a situation where the Tachometer Cable or connector has been damaged by scrap steel.
       
   5. Have an assistant slowly rotate the tachometer roll and verify the tachometer is actually rotating. Observe the LED on the Multifunction Board and verify that it flashes as the roll is turned (18.75 FPR).
       
   6. Have an assistant slowly rotate the tachometer roll and verify the presence of tachometer pulses on the Diagnostic Data screen.
       
   7.  If a problem is not found, see the procedure for Tachometer Replacement.

No AC Power

If the AGT400 cabinet does not have AC power on one or both of its circuits, use this procedure to determine the cause:

1. Verify both AGT400 circuit breakers (on the electronics shelf) are turned on. If not, turn them on. If so, determine which breakers actually do or do not have power. Note: these two circuit breakers should be on individual AC power feeds.
    
2. If circuit breakers are both turned on, and there is an absence of AC power, check for AC power at each of the outlets in the electrical box inside the AGT400 electronics cabinet. Note: two separate AC feeds should be located in this electrical box, so it will be necessary to check each outlet for power.
    
3. If there is still no AC power at any of the outlets, locate the main circuit breaker box that feeds the AGT400 and resolve the issue at the origin.
    
4. If only the left (Computer/Electronics) circuit breaker was tripped, reset the breaker and see if it trips again. If so, you may have a single device loading down the 5-amp circuit, or the breaker itself may need to be replaced.
    
5. If both circuit breakers are turned on, and there is an absence of AC power on the left (Computer/Electronics) circuit, check the AGT400 U.P.S. for AC power out. If it does not have AC power output, check its AC feed. If it does not have AC power in, see step 3 above. If it has AC in, but no AC out, ensure it is turned on. If it is turned on, but still does not have AC out, the U.P.S. may need to be repaired or replaced. Contact A.G.T. for further assistance.
    
6. If only the right (Auxiliary) circuit breaker was tripped, reset the breaker and see if it trips again. If so, there may be a single circuit loading down the 5-amp circuit, or the breaker itself may need to be replaced. Note: this circuit powers the indicator lights, C-frame drive circuit and cabinet cooling fan.
    
7. Contact A.G.T. for further assistance.

Printer or Report Errors

If the AGT400 system has any type of report/printout error, ranging from portions of reports missing to a complete failure to generate reports, use the examples below to first determine what type of report issue you are experiencing:

Portion of Reports Missing

1. Check a few incorrectly printed Coil Reports to see if there is a pattern to which portions are actually being printed and which portions are missing.
2. If all or most of the black ink portions of the report seem to be missing, but the color ink portions are present, replace the black printer ink cartridge. If some of the color ink portions of the report seem to be missing, but all the black ink portions are present, replace the color printer ink cartridge.
3. If a certain piece of information is missing from the Coil Reports, check the Report Setup screen to verify that parameter is enabled.
4. If the Profile Graph is missing from the Coil Reports, check the Report Setup screen to verify that parameter is enabled.
5. If the Defect Details are missing from the Coil Reports, check the Report Setup screen to verify that parameter is enabled.
6. If the Coil Mapping Data is missing from the Coil Reports, check the Report Setup screen to verify that parameter is enabled.
7. If the entire ISOgraph™ is missing from the Coil Reports, check the Report Setup screen to verify that parameter is enabled. If so, shut down the AGT400 software and restart the AGT400 computer.
8. If a certain piece of information is missing from the Shift Summary Reports, check the Report Setup screen to verify that parameter is enabled.
9. If there is still a report printing problem, check Windows® to verify the default printer driver corresponds to the printer used on this computer and is correctly installed.
10. If the printer ink cartridges have been replaced, the computer has been rebooted and the appropriate printer driver is correctly installed, see procedure for Printer Replacement or contact A.G.T. for assistance.

Printer Prints Gibberish

1. Turn the printer power off.
2. Shut down the AGT400 software and restart the AGT400 computer.
3. Turn the printer back on.
4. Check Windows® to verify the default printer driver corresponds to the printer used on this computer and is correctly installed.
5. Replace the printer cable.
6. If the computer has been rebooted, the appropriate printer driver is correctly installed, and the printer cable has been replaced, test the printer on another computer if feasible.
7. See procedure for Printer Replacement.
8. If there is still a report gibberish issue, contact A.G.T. for assistance.

No Reports

1. If the printer will not print Coil Reports, but does not have trouble printing System Startup or other reports, verify gauge is in Run mode and length is being measured on the Main Screen. If the length remains at zero, see the procedure for No Length.
2. Verify the printer has paper, does not have a paper jam and is ready (steady green LED is illuminated, but no other LEDs are illuminated or flashing).
3. Verify that the Printer button on the Main Screen is set to On.
4. Check the print queue for backed up print jobs. Note: a simple paper jam or printer error can cause the AGT400 to fill up the print queue to the point where the CPU can only function very slowly if at all. Delete any and all jobs in the print queue.
5. Reboot the computer. Do a proper shutdown by exiting the AGT400 software, then properly shutting down Windows®. In some instances, just rebooting the computer will ‘solve’ unexplained computer problems.
6. If there is still a report printing problem, check Windows® to verify the default printer driver corresponds to the printer used on this computer and is correctly installed.
7. Replace the printer cable.
8. If the printer is ready to print, enabled in the AGT400 software, the computer has been rebooted, print queue cleared, and the appropriate printer driver is correctly installed, test the printer on another computer if feasible.
9. See procedure for Printer Replacement.
10. If replacing the printer does not resolve the issue, contact A.G.T. for further assistance.

Shutter Inoperable

If the shutter on your AGT400 thickness gauge will not open or close, use this procedure to determine the cause:

1. If the AGT400 shutter appears to be stuck open or will not close, see step 9 below.

2. If the AGT400 shutter will not open, verify the SHUTTER Keyswitch on the Electronics Shelf is turned to the UNLOCK position.

3. Use the Diagnostic Data screen and TP5 on the Multifunction Board on the Electronics Shelf to verify the 13VDC Power Supply reads 13.20 ±50 VDC. If so, skip ahead to step 5 below. If not, disconnect each circuit from this supply individually in order to determine where the short is originating. Start by unplugging J3 on the Multifunction Board to rule out the tachometer circuit. This supply also powers the Source Head, which can be disconnected at the Opto22 module terminal (two purple wires on screw terminal #2).

4. If the power supply voltage returns to normal when a specific load is disconnected, check for shorts in that circuit. A typical failure in this area would include a situation where the Tachometer Cable or connector has been damaged by scrap steel.

5. If every 13VDC load has been disconnected and the supply still has low or no output, the power supply itself may need to be replaced. Replace this power supply or contact A.G.T. for further assistance.

6. If the 13VDC power supply measurement is correct, but the shutter will not open, command the shutter to open and insert sample 3 from the Diagnostic Data Screen while monitoring the same voltage. If the voltage stays constant, or only drops ~ .03 volts, there is not an excessive load or power supply problem. Try rebooting the AGT400 computer just to make certain the digital board isn’t in need of a reset.

7. If there is not an excessive load or power supply problem, command the shutter to open and measure the DC voltage on the Opto22 rack between Opto22 module 1-2 (ground) and Opto22 terminal number 6. It should read 13.20 ± 0.50 VDC. If not, check the fuse in Opto22 module 1. If the fuse is defective, replace it. See the procedure for Fuse Replacement. If the fuse is good, there may be a problem with your digital computer board, digital cable or Opto22 module. Contact A.G.T. for further assistance.

8. If the reading was 13.20 ±50 VDC in step 7 above, go to the C-frame junction box and measure the same voltage between JTB2-9 (ground) and JTB2-7. It should measure close to the original 13.20 ± 0.50 VDC, allowing for some voltage loss depending on the length of your source head cable. Insert internal sample 3 and check for increased voltage loss. If the voltage is slightly low, one or both of the spares (red and/or red with white stripe) may be used in parallel with the black and black with white stripe in your source head cable. If the voltage is not present, then your source head cable should be replaced between the Electronics Cabinet and the C-frame junction box. If the voltage measures good, most likely the source head cable needs replaced between the C-frame junction box and the source head or there is a problem with the source ring assembly. Contact A.G.T. for further assistance.

9. If the AGT400 shutter appears to be stuck open or will not close, command the shutter closed, go to the C-frame junction box and measure the voltage between JTB2-9 (ground) and JTB2-7. It should measure 0.0 VDC. If so, there is most likely a problem with the source ring assembly inside the source head. In this case, contact A.G.T. for further assistance, since only licensed individuals are permitted to perform any service on the source head and/or source ring assembly.

10. If the voltage in step 9 measures ~13.20 VDC, remove the fuse from Opto22 module 1 and repeat the measurement. If the voltage now measures 0.0 VDC, there may be a problem with the digital computer board, digital cable or Opto22 module. Contact A.G.T. for further assistance.

Software Inoperable

If the AGT400 software will not start, run or is inoperable, use this procedure to determine the cause:

1. Start by rebooting the AGT400 computer in case Windows® needs to be restarted.
    
2. If the AGT400 software starts but does not run, see step 3 below. If your software still will not start, record the specific error message encountered and refer to the System Messages list. If no specific error message is encountered, contact A.G.T. for further assistance.
    
3. If the AGT400 software starts but does not run, record the specific error message encountered and refer to the System Messages list.
    
4. If the AGT400 software starts but does not run and there is not a specific error message, see the procedure for Computer Slow or Locked Up.
    
5. If none of the above steps serve to resolve the issue, please contact A.G.T. for further assistance.

Thickness Measurement Errors

When trying to resolve thickness measurement issues, the first step should be to qualify the type of problem being experienced. Most thickness measurement errors can be broken down into six different error groups. Observe the ISOgraph™ on your AGT400 video monitor or Coil Report and use the examples below to determine what type of measurement error you have:

Thickness Measurement Spikes (up)

1. Upward thickness spikes are most commonly caused by a reduction in beam strength due to metal blocking all or a portion of the radiation beam. If the C-frame is Oscillating, and the spikes seem to occur at the same point during each pass across the strip, verify nothing is interfering with the beam at that point. On most Braner slitting lines, for example, if the C-frame speed control is set too fast, the measuring heads will interpret the edge guide rails as thickness spikes each time the C-frame reaches a strip edge. The solution in this case may be as simple as slowing down the C-frame drive motor speed.
    
2. If the C-frame is Oscillating, the spikes seem to occur at the same point during each pass across the strip, and nothing is interfering with the beam, the most likely cause is a damaged or defective source or detector head cable. Stop the C-frame at or near the point where the spikes seem to occur, then also stop the processing line. Once the C-frame and strip are stationary, have an assistant monitor the measured thickness on the AGT400 video monitor while you manually manipulate the head cables on the C-frame. Many damaged or defective head cables can be pinpointed in this manner. Once the problem is isolated, repair or replace the head cable(s) as necessary. See the procedure for Cable Replacement.
    
3. Note: on Oscillating C-frames, it is prudent to replace the source and detector head cables at the same time, even though only one may be defective at the time.
    
4. Verify the strip does not contact the C-frame or either measuring head when the spikes occur. If so, take the necessary steps to prevent this in the future.
    
5. If the spikes seem to be related to C-frame movement, but do not necessarily occur at the same point in each pass across the strip, there may be a problem with the mounting or internals of one or both of the measuring heads. Close the shutter, stop the C-frame and stop the processing line. Once the C-frame and strip are stationary, verify both heads are securely mounted in the C-frame. Then have an assistant monitor the measured thickness on the AGT400 video monitor while you tap on the side of each measuring head in the C-frame. Many loose or broken components inside the measuring heads can be pinpointed in this manner. Caution: be sure your assistant maintains a safe distance of at least three feet from the Source Head while the shutter is open. If the problem seems to be in the detector head, see the procedure for Detector Head Inspection. If the problem seems to be in the source head, contact A.G.T. for further assistance. Only licensed individuals are permitted to perform any service on the source head and/or source ring assembly.
    
6. If the spikes do not seem to be related to C-frame movement, check all the screw terminals in the C-frame junction box. Many C-frame related issues are resolved at this point.
    
7. Turn the MODE key on the electronics shelf to the PROGRAM position and go to the Diagnostic Data screen. Observe each of the DC Power Supplies, looking for a voltage that may be spiking. Pay particular attention to the high voltage power supply. If a problem is found in this area, the next step will be to begin disconnecting the individual loads for that particular power supply.
    
8. Contact A.G.T. for further assistance.
    

Thickness Measurement Spikes (down)

1. Downward thickness spikes are most commonly caused by an increase in beam strength due to all or a portion of the radiation beam going off the strip edge. If the C-frame is Oscillating, and the spikes seem to occur at the same point during each pass across the strip, verify the measuring heads are not getting too close to the edge of the strip at that point. On most processing lines, for example, if the C-frame speed control is set too fast, the measuring heads will interpret the strip edges as thickness spikes. The solution in this case may be as simple as slowing down the C-frame drive motor speed.
    
2. If the C-frame is Oscillating, the spikes seem to occur at the same point during each pass across the strip, and nothing is interfering with the beam, the most likely cause is a damaged or defective source or detector head cable. Stop the C-frame at or near the point where the spikes seem to occur, then also stop the processing line. Once the C-frame and strip are stationary, have an assistant monitor the measured thickness on the AGT400 video monitor while you manually manipulate the head cables on the C-frame. Many damaged or defective head cables can be pinpointed in this manner. Once the problem is isolated, repair or replace the head cable(s) as necessary. See the procedure for Cable Replacement.
    
3. Note: on Oscillating C-frames, it is prudent to replace the source and detector head cables at the same time, even though only one may be defective at the time.
    
4. Verify the strip does not contact the C-frame or either measuring head when the spikes occur. If so, take the necessary steps to prevent this in the future.
    
5. If the spikes seem to be related to C-frame movement, but do not necessarily occur at the same point in each pass across the strip, there may be a problem with the mounting or internals of one or both of the measuring heads. Close the shutter, stop the C-frame and stop the processing line. Once the C-frame and strip are stationary, verify both heads are securely mounted in the C-frame. Then have an assistant monitor the measured thickness on the AGT400 video monitor while you tap on the side of each measuring head in the C-frame. Many loose or broken components inside the measuring heads can be pinpointed in this manner. Caution: be sure your assistant maintains a safe distance of at least three feet from the Source Head while the shutter is open. If the problem seems to be in the detector head, see the procedure for Detector Head Inspection. If the problem seems to be in the source head, contact A.G.T. for further assistance. Only licensed individuals are permitted to perform any service on the source head and/or source ring assembly.
    
6. If the spikes do not seem to be related to C-frame movement, check all the screw terminals in the C-frame junction box. Many C-frame related issues are resolved at this point.
    
7. Turn the MODE key on the electronics shelf to the PROGRAM position and go to the Diagnostic Data screen. Observe each of the DC Power Supplies, looking for a voltage that may be spiking. Pay particular attention to the high voltage power supply. If a problem is found in this area, the next step will be to begin disconnecting the individual loads for that particular power supply.
    
8. Contact A.G.T. for further assistance.
    

Thickness Measurement Shifts

1. Measurement shifts are most commonly caused by a change in beam strength. If the C-frame is Oscillating, and the shifts seem to occur at the same point during each pass across the strip, verify the gap between the measuring heads is not being interfered with or changing at that point.
    
2. If the C-frame is Oscillating, the shifts seem to occur at the same point during each pass across the strip. and nothing is interfering with the beam, the most likely cause is a damaged or defective source or detector head cable. Stop the C-frame at or near the point where the shifts seem to occur, then also stop the processing line. Once the C-frame and strip are stationary, have an assistant monitor the measured thickness on the AGT400 video monitor while you manually manipulate the head cables on the C-frame. Many damaged or defective head cables can be pinpointed in the manner. Once the problem is isolated, repair or replace the head cable(s) as necessary. See the procedure for Cable Replacement.
    
3. Note: on Oscillating C-frames, it is prudent to replace the source and detector head cables at the same time, even though only one may be defective at the time.
    
4. Verify the strip does not contact the C-frame or either measuring head when the shifts occur. If so, take the necessary steps to prevent this in the future.
    
5. Verify the strip passline height and angle are remaining unchanged while the measurement shifts occur. Passline height and angle must remain constant while the line is running and the gauge is measuring. If the passline height and/or angle changes during the measurement, the gauge reading will shift. If this is found to be the case, take the necessary steps to prevent this in the future.
    
6. If the shifts seem to be related to C-frame movement, but do not necessarily occur at the same point in each pass across the strip, there may be a problem with the mounting or internals of one or both of the measuring heads. Close the shutter, stop the C-frame and stop the processing line. Once the C-frame and strip are stationary, verify both heads are securely mounted in the C-frame. Then have an assistant monitor the measured thickness on the AGT400 video monitor while you tap on the side of each measuring head in the C-frame. Many loose or broken components inside the measuring heads can be pinpointed in this manner. Caution: be sure your assistant maintains a safe distance of at least three feet from the Source Head while the shutter is open. If the problem seems to be in the detector head, see the procedure for Detector Head Inspection. If the problem seems to be in the source head, contact A.G.T. for further assistance. Only licensed individuals are permitted to perform any service on the source head and/or source ring assembly.
    
7. If the shifts do not seem to be related to C-frame movement, check all the screw terminals in the C-frame junction box. Many C-frame related issues are resolved at this point.
    
8. Turn the MODE key on the electronics shelf to the PROGRAM position and go to the Diagnostic Data screen. Observe each of the DC Power Supplies, looking for a voltage that may be shifting. Pay particular attention to the high voltage power supply. If a problem is found in this area, the next step will be to begin disconnecting the individual loads for that particular power supply.
    
9. Contact A.G.T. for further assistance.
    

Thickness Measurement Drift

1. Measurement drift is most commonly caused by a slow and steady change in beam strength. If the C-frame is Oscillating, and the shift seems to occur at the same point during each pass across the strip, verify the gap between the measuring heads is not being interfered with or changing at that point.
    
2. If the C-frame is Oscillating, the drift seems to occur at the same point during each pass across the strip, and nothing is interfering with the beam, the most likely cause is a damaged or defective source or detector head cable. Stop the C-frame at or near the point where the shift seems to occur, then also stop the processing line. Once the C-frame and strip are stationary, have an assistant monitor the measured thickness on the AGT400 video monitor while you manually manipulate the head cables on the C-frame. Many damaged or defective head cables can be pinpointed in this manner. Once the problem is isolated, repair or replace the head cable(s) as necessary. See the procedure for Cable Replacement.
    
3. Note: on Oscillating C-frames, it is prudent to replace the source and detector head cables at the same time, even though only one may be defective at the time.
    
4. Verify the strip passline height and angle are remaining unchanged while the measurement drift occurs. Passline height and angle must remain constant while the line is running, and the gauge is measuring. If the passline height and/or angle changes during the measurement, the gauge reading will drift. If this is found to be the case, take the necessary steps to prevent this in the future.
    
5. If the drift seems to be related to C-frame movement, but do not necessarily occur at the same point in each pass across the strip, there may be a problem with the mounting or internals of one or both of the measuring heads. Close the shutter, stop the C-frame and stop the processing line. Once the C-frame and strip are stationary, verify both heads are securely mounted in the C-frame. Then have an assistant monitor the measured thickness on the AGT400 video monitor while you tap on the side of each measuring head in the C-frame. Many loose or broken components inside the measuring heads can be pinpointed in this manner. Caution: be sure your assistant maintains a safe distance of at least three feet from the Source Head while the shutter is open. If the problem seems to be in the detector head, see the procedure for Detector Head Inspection. If the problem seems to be in the source head, contact A.G.T. for further assistance. Only licensed individuals are permitted to perform any service on the source head and/or source ring assembly.
    
6. If the drift does not seem to be related to C-frame movement, check all the screw terminals in the C-frame junction box. Many C-frame related issues are resolved at this point.
    
7. Turn the MODE key on the electronics shelf to the PROGRAM position and go to the Diagnostic Data screen. Observe each of the DC Power Supplies, looking for a voltage that may be drifting. Pay particular attention to the high voltage power supply. If a problem is found in this area, the next step will be to begin disconnecting the individual loads for that particular power supply.
    
8. Contact A.G.T. for further assistance.
    

Will Not Measure

1. If the gauge always reads ‘0’ or close to zero when the shutter is commanded open, proceed to step 6 below. If the gauge always reads ‘400’ when the shutter is commanded open, this typically indicates that the shutter is not opening, or there is no signal returning from the detector head. Open the shutter and see if the red Open light is coming on. If not, see the procedure for Shutter Inoperable. If so, proceed to step 2 below.
    
2. If the gauge always reads ‘400’ when the shutter is commanded open, and the red light is coming on, this typically indicates that there is no signal returning from the detector head.
    
3. Turn the MODE key on the Electronics Shelf to PROGRAM, go to the Diagnostic Data page and observe the five DC Voltages. If one or more of the DC voltages appear to be incorrect, there may be a problem with that power supply or the load for that particular supply. This can usually be determined by disconnecting each load for that supply individually until the power returns. Refer to the Schematics in this manual, or contact A.G.T. for further assistance.
    
4. Observe the reading in the Preamp A/D frame. With the shutter open, this should read approximately 62,250 with no metal in the air gap. The shutter closed reading should be approximately 131. Open and close the shutter a few times to determine if the reading is actually changing.
    
5. If the Preamp A/D stays at or near 0 or 131 with the shutter opening and closing, there is most likely an issue with the detector head or detector head cable. Inspect the detector cable for damage, then refer to the procedure for Detector Head Inspection.
    
6. If the Preamp A/D stays at 65,535 with the shutter opening and closing, there is most likely an issue with the detector head or detector head cable. Inspect the detector cable for damage, then refer to the procedure for Detector Head Inspection.
    
7. If the Preamp A/D changes when the shutter is commanded to open and close, but the gauge does not measure, perform an ISOcheck™, then print the report and make an analysis of the A/D numbers. If the nominal and actual A/D numbers have approximately the same error amount for each measurement point (1,000 counts low or high for example), this almost always indicates a defective F.E.T. in the detector head. Refer to the procedure for F.E.T. Replacement.
    
8. Contact A.G.T. for further assistance.
    

Inaccurate Measurement

1. Perform an ISOcheck™. See the procedure for ISOcheck™. If the procedure is successful, try running the gauge on another coil. If not, or the gauge continues to measure inaccurately, proceed to step 2 below.
    
2. Perform an ISOcal™. See the procedure for ISOcal™. If the procedure is successful, try running the gauge on another coil. If not, or the gauge continues to measure inaccurately, proceed to step 3 below.
    
3. Verify the operator has selected the correct Product on the Product Menu.
    
4. Verify the strip passline height and angle are correct. Passline height and angle must be consistent with the original gauge startup settings while the line is running, and the gauge is measuring. If the passline height and/or angle has changed since our last manual calibration, the gauge will read incorrectly. If there has been a change in this area, make the necessary passline height and/or angle corrections.
    
5. Contact A.G.T. for further assistance.

Video Monitor Inoperable

If your AGT400 has no video, use this procedure to determine the cause:

1. Ensure there is AC power where the video monitor receives its power. If not, see No AC Power.
    
2. Ensure the video monitor is plugged into AC power, plugged into the computer and turned on. If not, plug it in and/or turn it on.
    
3. Ensure the computer is turned on. If not, turn it on.
    
4. Test the video monitor on another computer elsewhere in the plant. If you suspect the monitor to be defective, you can verify your suspicion by testing a known good video monitor by connecting it to the AGT400 computer.
    
5. If you have AC power, your video monitor and computer are both turned on and you still have no video, the problem is most likely a defective video card or main board inside the AGT400 computer. Contact A.G.T. for further assistance.