Dual Gun Controller Card Troubleshooting

Use the fault codes on the Gun Control screens, the fault messages on the Alarm screen, and the LEDs on the gun control cards to diagnose problems with the gun control cards.

Gun Card Error Codes and Fault Codes

These faults, except for E16, will activate the alarm relay.

Error Code	Message	Fault Code	Meaning/Correction
301	Micro-Amp fault detected	-	Microamp value out of range.
302	Foldback fault detected	E15	Current foldback detected. Unplug the cable from the gun and trigger the gun. If the fault changes to E7, check the resistance of the multiplier as described in the gun manual. If the fault code stays E15, check the continuity of the cable as described in the gun manual.
303	Feedback fault detected	E3	Microamp feedback not detected. Check the gun current with no parts in front of the gun. If the current is 105 >µA, check for a short circuit of the current feedback wires in the gun cable: Unplug the cable from the gun and trigger the gun. If the fault stays E3, replace the cable. If the fault changes to E7, check the resistance of the multiplier as described in the gun manual.
304	Open circuit detected	E7	Gun cable or multiplier open circuit. If the current display is 1 µA or less, check the multiplier cable and electrode assembly for loose connections. If the connections are secure, check the multiplier with an ohmmeter as described in the gun manual. If the multiplier reading is acceptable, check for a defective cable as described in the gun manual.
305	Short circuit detected	E8	Gun cable or multiplier short circuit. Unplug the cable from the gun and trigger the gun. If the fault changes to E7, check the resistance of the multiplier as described in the gun manual. If the fault code stays E8, check the continuity of the cable as described in the gun manual.
306	Internal hardware failure	E11	Internal DSP fault in gun control card. Turn off the power to the system. Unplug the cable from the back of the gun. Turn on the power to the system. If the fault code changes to E7 (open circuit), the card is working correctly. Check the gun multiplier. If the fault code remains at E11, replace the gun control card.
307	Tribo	E17	Tribomatic µA feedback below setpoint. Check the powder flow for poor charging. Check for moisture in the compressed air supply.
308	Gun not detected	E16	Gun not connected to system. Check the gun cable connections and make sure the gun card is seated securely into the backplane. This is a normal indication if power to cards is removed, such as when the booth exhaust fan is shut off.
531	System heartbeat lost	-	Check circuit board connections.
532	5/24 volt power	-	Check circuit board connections.
533	Error writing to internal EEPROM	-	Hardware error. Replace card.
534	Error reading from internal EEPROM	-	Hardware error. Replace card.
535	Node address changed from last power up	-	Saved address does not match current address. Address switches were changed. Informational message only.
536	Internal database version changed - resetting to defaults	-	An update to the database was detected and the current data is no longer valid. Informational message only, operation should not be affected.
537	Preset out of range	-	The preset sent to the remote device was out of range. Check preset settings and reset as required.
538	Trigger ON message received - controller in lockout	-	The card was commanded to trigger but the system is locked out. Trigger ON commands will be ignored until the system is returned to the Run state.

Gun Card LEDs

Use the card LEDs to help diagnose problems.

LED	Color	Function	Correction
Fault	Red	Lights when a fault is detected (communication, gun cable, RAM, or hardware).	If two guns are not connected to the card this LED will light. If you have an odd number of guns in the system, unplug the unused harness and install the jumper plug shipped with the console. Make sure the card is seated in the backplane. Open the Alarm screen and clear all faults. Replace the card if the malfunction cannot be corrected.
Status	Green	Flashing (heartbeat) when communicating properly with system.	If the status LED is not flashing, make sure the card is seated in the backplane. Turn console power off and on. Replace the card if the other gun control cards have heartbeats.
Foldback B (even-numbered gun Foldback A (odd-numbered gun)	Yellow	Lights if over-current protection circuit triggered due to high current draw from gun drive circuit.	Refer to the corrections for Fault Code E15.
Power	Green	Lights when power (5 volts) is applied to the board).	If the card has no power, make sure it is properly seated in the backplane and the locking tab is working correctly. Replace the card if the other gun control cards have power.