Micro Innovation MICRO GF1 Touch Screen Troubleshooting and Replacement

Micro Innovation MICRO GF1 Touch Screen Troubleshooting and Replacement

Product positioning and system composition

MICRO PANEL GF1 is a touch visualization unit launched by Micro Innovation AG, designed for medium to high complexity automation systems. It adopts a 10.4-inch TFT LCD color display screen, with a resolution of VGA 640 × 480, supporting 256 colors, a display area of 212.2 × 158.4 mm ², a brightness of 250 cd/m ², and a minimum backlight life of 25000 hours. The device provides an infrared touch matrix with MDS TCL2 operation logic, a physical resolution of 40 × 30, and a logical resolution of 79 × 59, suitable for industrial sites that require medium precision touch operations.

GF1 can only be used after loading project data. Project data is stored in an external plug-in PC card, which can be transferred from the PC via a download cable or written directly into the PC card slot on the PC. The project data was created by GALILEO design software. The device provides two slots (Slot 0 and Slot 1) for installing communication modules or system extensions. The communication module is responsible for connecting the automation system or fieldbus, and specific protocols and wiring should refer to the corresponding module documentation. Slot 0 is typically used for memory cards, while Slot 1 can install communication modules. Two slots can be used simultaneously to achieve parallel communication systems.

GF1 offers three main versions: GF1-10 TVD uses a 24 VDC isolated power supply, GF1-10 TVB uses a 24 VDC non isolated power supply, and GF1-10 TVA uses a 100... 240 VAC, 50/60 Hz power supply. All versions have a corrosion-resistant model with a stainless steel front panel (1.4301). The scope of equipment delivery includes: GF1 host, PC card fixing device, Slot 1 blind plate, 4 fixing screws, installation sealing ring, power plug (DC version with 3-pin screw terminal, AC version with standard instrument plug), and equipment manual. Memory cards are not included in the standard supply range and need to be ordered separately.

Mechanical installation and protection

The GF1 front panel version comes with 4 fixing holes, suitable for installation from the front onto cabinets or control boxes, without the need for rear operation. The installation hole is M5, the front panel opening size is 316 mm × 244 mm, and the fixing hole is centered. The external dimensions of the equipment are approximately 342 mm × 270 mm × 81 mm. During installation, it is necessary to ensure a minimum distance of 10 cm between the equipment and other components to ensure heat dissipation. The cooling trough cannot be obstructed by cables or other objects. The working temperature is 0... 50 ° C, based on vertical installation, natural air convection, and altitude not exceeding 2000 m. If installed in a cabinet, the ambient temperature refers to the air temperature inside the cabinet, and there should be no additional radiation or conduction heat sources in front.

Avoid direct sunlight on the screen, even if the device is turned off, ultraviolet radiation can reduce the lifespan of the LCD. After installation, it is necessary to ensure that the connectors, status LED, download button, and memory card are still accessible, and leave space for cable connectors and bending radius. To meet the IP65 protection level, a specialized counter frame installation kit must be used, which is installed at the rear of the device to ensure the sealing ring pressure on the thin panel. The order number for the 10 inch version of the counter frame is MDS Ord. No.: 6520963100 and needs to be ordered separately. The sealing ring is provided with the equipment.

For the scenario of replacing the old HMI, the key size is the 316 mm × 244 mm opening. If the original openings are different, the panel needs to be reworked or an adapter plate needs to be made. At the same time, confirm whether the depth of the cabinet can accommodate a device thickness of 81mm and rear cables. The fixing screw must use M5 with moderate torque to avoid damaging the sealing ring.

Power wiring and system ports

The AC version uses standard appliance sockets, with a built-in fuse of 4.0 AT, and can be replaced externally. The socket pins are L (phase line), N (neutral line), and PE (protective ground). PE must be connected to the power protection ground, otherwise there is a risk of electric shock. The DC version uses a 3-pin plug-in screw terminal with pins of+24V, PE, and 0V. Power supply range+20.4...+28.8 VDC effective value; When ripple is present, the absolute value is+18.5...+30.5 V. The maximum power consumption is 40 W, the typical current is 1.0 A, and the maximum starting current is 3.0 A for 2 seconds. The power supply is isolated inside GF1, but the PE must be connected. Fuse 4.0 AT, replaceable externally.

The System Port is an RS232 serial interface with a D-Sub 9-pin male connector, used for project data download, system maintenance, and additional functions. Pin definitions: 1 DCD, 2 RxD, 3 TxD, 4 DTR, 5 Gnd, 6 DSR, 7 RTS, 8 CTS, 9 RI (+5V). Note: The system ports are not isolated and are not ground free. Pin 9 can be selected as an external additional hardware to provide+5V, which can be enabled through motherboard jumper JP8. However, this output has no short-circuit protection or overload protection and can only be used for original GF1 additional hardware. When downloading projects, you can use the system port to connect to the PC instead of writing PC cards directly on the PC. It is recommended to use shielded cables when downloading cables, especially when the cables are still connected during normal operation. If only connected during debugging, shielding is not necessary, but it is necessary to ensure that the connector housing is connected to the GF1 housing with low impedance.

The communication module is installed in Slot 0 or Slot 1. The plug-in module must be powered off and comply with ESD protection. The module must be tightened and fixed before it can operate. Non Micro Design components are not allowed to run in the slot. Communication cables must be shielded using metal or metalized connector housings, with the shielding layer directly connected to the low impedance connector housing of GF1. If GF1 and PLC are installed in different control cabinets or with different PE potentials, and the shielding layer is grounded at both ends, equipotential connection wires must be set up to prevent excessive compensation current from occurring in the shielding layer and shielding terminals. Recommended steps for shielding connection: Strip the wire, expose the shielding braid and shorten it by about 3 cm, flip back the braid, cover it with heat shrink tubing, leave 5 to 8 mm of exposed shielding at the sheath end, install the connector, and fix the cable together with the exposed shielding and sheath under the cable clamp of the connector housing.

Memory card and project data

The project data of GF1 is stored in a PC card with a slot of PC card JEIDA/PCMCIA Type I or Type II. Supports Flash linear 5V/5V or 5V/12V, up to 64 MB; supports ATA Flash starting from motherboard firmware version 1.10. PC cards are not within the delivery scope and need to be ordered separately. The project data is created by GALILEO design software and can be directly written to the PC card drive on the PC, or downloaded to GF1 through the system port. After writing, insert the PC card into the GF1 slot, and the application can start after powering on.

Attention: The randomly provided card fixing device must be used during operation to prevent the PC card from falling off. Especially when the equipment is installed vertically, the lack of a fixing device cannot guarantee the reliable fixation of the PC card. The PC card slot is located at System Slot 0, and Slot 1 can be used to install communication modules. If the PC card cannot be recognized, check the card type, format, capacity, and firmware version. If the project cannot start, check if the GALILEO project is compatible with GF1 firmware, if the PC card is write protected, and if the card slot is in good contact.

Touch screen principle and self check

The GF1 touch screen is based on the principle of infrared active light matrix. The infrared emitting and receiving components are located behind the IR transparent plastic frame on the front panel, with radiation slightly exceeding the front panel. Each transmitter corresponds to the receiver on the other side, with a total of 70 closely arranged IR channels. When touching the screen, one or more channels on the X or Y axis are simultaneously interrupted, and the touch controller detects and calculates the position. Repeated touches or touches with a coverage area greater than 20mm x 20mm are not evaluated. Continuous interruption channels caused by severe pollution or optical component failure will be identified and excluded from evaluation by the controller.

Every time it starts, GF1 will run a touch screen function test. All IR channels are evaluated, and the signal levels are compared with the initial values stored in non-volatile memory at the factory. If one or more channel signals are below the minimum value, the screen displays an error message and the DEF/DIRTY LED lights up. This is usually caused by severe contamination of IR transparent plastic frames and requires cleaning. At this time, the touch screen is still fully functional. If pollution continues to increase, one or more IR channels will be continuously interrupted, and the controller will exclude them. In extreme cases, some areas cannot be touched. Do not touch the screen during startup and wait for the application to complete startup.

Use a damp soft cloth to regularly clean the inside of the plastic frame during cleaning. Avoid scratching or scratching the surface, especially when removing hard deposits and abrasive dust. Do not use solvents to prevent corrosion and loosening of the plastic frame (made of PMMA polymethyl methacrylate).

LED function and diagnosis

GF1 is equipped with 3 touch controller LEDs and 1 power monitoring LED below System Slot 1.

Supply OK: When lit, it indicates that the system voltage of+12V and+5V is normal. If it doesn't light up but the power is connected, check the fuse. When powered on, all three touch screen monitoring LEDs will light up for 0.3 seconds for functional inspection.

Initiat/COM: It goes off when powered on and is activated when the system electronics successfully initialize the touch controller. When the touch screen is pressed, the LED will turn off for about 0.3 seconds.

COM ERROR: Illuminates when there is a communication issue between the touch controller and the system electronics. Intermittent or continuous illumination indicates a system malfunction. Turn off during normal operation.

DEF/DIRTY: Illuminates when one or more IR channel signals are below the minimum value during function testing. The reason is contamination of the IR transparent plastic frame or malfunction of the optical components. Clean the plastic frame of the front panel when illuminated.

If the Supply OK does not light up, first check the fuse, and then check the 24V or AC power supply. If COM ERROR is constantly on, check whether the touch controller is connected to the motherboard, firmware version, and communication module are interfering. If DEF/DIRTY lights up but still does not turn off after cleaning, it may be due to aging or malfunction of the optical components, and the touch box or the entire machine needs to be replaced.

Common troubleshooting

Unable to start, black screen: Check if the power supply voltage is within the range. Check the AC version for appliance sockets and 4.0 AT fuses; Check the+24V, PE, 0V wiring and fuses for the DC version. If the power supply is normal but there is no display, check whether the backlight is damaged, whether the PC card is plugged in properly, and whether the Slot 1 module is short circuited. Attempt to power off, unplug all communication modules, keep only the power supply and PC card, and power on again. If the screen is still black, it may be a malfunction of the motherboard or display screen.

Touch unresponsive or local failure: Observe DEF/DIRTY LED. If it lights up, clean the IR plastic frame. If the cleaning is still ineffective, run the startup self-test to check if there are any continuous channel interruptions. Check if there is strong light directly shining on the infrared frame and if there are any objects blocking it. If the local area fails, it may be a malfunction of the infrared emitter/receiver tube, and the touch frame needs to be replaced. If COM ERROR lights up, check the touch controller and motherboard wiring.

Download failed: Confirm that the system port cable is connected correctly, RS232 pins 2, 3, and 5 are cross connected. Check the PC serial port and download software settings. If writing directly using a PC card, confirm the card type, capacity, format, and GALILEO version. Ensure stable power supply during download and do not cut off power. If the project does not start after downloading, check if the PC card fixing device is tightened and if the card slot is in good contact.

Communication failure: Check if the communication module is installed in Slot 0 or Slot 1 and if it is tightened. Confirm that the module protocol matches the PLC, and that the address, baud rate, and terminal resistance are correct. Check the shielding of communication cables and the casing of connectors. If GF1 and PLC are in different control cabinets, check the equipotential connection. If the module is not recognized, check the firmware version and GALILEO configuration.

Frequent melting of power fuse: Check if the power voltage is too high, if the load is short circuited, and if the communication module is faulty. Unplug all modules and PC cards, only power on to see if they are blown. If it still melts, it may be a power board malfunction. The same specification 4.0 AT must be used to replace the fuse.

Shutdown and replacement strategy

When GF1 is discontinued or damaged, priority should be given to replacing it with the same series or upgraded model. Check the following key items:

Hole size: 316 mm × 244 mm, fixed hole M5. If the new equipment has different holes, the panel needs to be reworked.

Power version: AC 100... 240 V or DC 24 V, isolated or non isolated. When replacing, the power type must match, otherwise a power module needs to be added.

Display size and resolution: 10.4-inch VGA, touch type infrared. If capacitors or resistors are replaced, the operating experience and project adaptation may change.

Communication module: protocols and mechanical dimensions for Slot 0 and Slot 1. If the original module is discontinued, it is necessary to find a compatible module or replace the communication protocol.

PC Card and Project Data: PC Card Type, Capacity, GALILEO Project Compatibility. If the new device uses a CF card or SD card, the project needs to be recompiled.

System port: RS232 pin and download method. If the new device uses USB or Ethernet, the debugging process needs to be adjusted.

Protection level: IP65 requires a counter frame. If the new equipment is different, the sealing needs to be redesigned.

Replacement steps: Power off, record the original device model, power supply, communication module, PC card, and project version. Remove the old equipment and keep the fixing screws and sealing rings. Install new equipment, connect power, plug in PC card or communication module. Turn on the power and check for Supply OK, Initiate/COM, COM ERROR, DEF/DIRTY. Download or insert projects, test touch and communication. If communication fails, check the address, baud rate, shielding, and equipotential. After passing the test, fix all screws and buckles.

If unable to find a replacement for the same series, consider upgrading to Micro Innovation's subsequent HMI or other brands. At this point, it is necessary to redesign the openings, power supply, communication, and project, which requires a significant amount of work. Suggest keeping old devices as spare parts or backing up PC cards and GALILEO projects in advance.

Maintenance and spare parts recommendations

Daily maintenance: Check power supply voltage and fuses, clean touch screen plastic frame, check PC card fixing device, check communication cable shielding and connectors, check slot module fixing and LED status. Backup PC card projects and GALILEO projects every six months. Spare parts recommendations: 4.0 AT fuse, power plug, PC card, communication module, touch box, complete machine. Spare parts storage temperature -20... 60 ° C, relative humidity 10... 90% non condensing.

As a classic HMI, the stability of GF1 touch screen depends on the correct power supply, shielding, PC card, and communication configuration. By using SUPLY, INI/COM, COM ERROR, DEF/DIRTY LED, it is possible to quickly determine whether the fault is located in the power supply, touch controller, communication, or contamination. Mastering the self checking and cleaning methods of infrared touch screens can significantly reduce misjudgments. Faced with production stoppage, as long as the hole opening, power supply, communication, PC card, and project compatibility are checked, a suitable replacement solution can be selected to quickly resume production.