E-Series OSMAC: Control Panel/ Receiver/Decoder Module Not Reporting Correct Number of 8-Station Output Boards

140 March 2, 2022

LESSON SUMMARY: This lesson is designed to assist the user in troubleshooting what would cause a Control Panel or Receiver/Decoder Module to report 0 or an incorrect number of 8-Station Output Boards.

Special Tools Needed: Long Nose or Needle Nose Pliers, Phillips Screwdriver

⚠ CAUTION: THIS LESSON MAY INCLUDE INSTRUCTIONS TO TEST HAZARDOUS VOLTAGES (120V-240V) THAT CAN CAUSE SERIOUS INJURY OR DEATH. IT IS RECOMMENDED THAT A LICENSED ELECTRICIAN BE CONTRACTED TO PERFORM SUCH TESTS.

🛑 STOP: ALWAYS TURN OFF THE POWER TO THE SATELLITE BEFORE REMOVING OR INSTALLING COMPONENTS.

If a SuperParts Control Panel or SuperParts Receiver/Decoder Module for E-Series OSMAC is not reporting the correct number of 8-Station Output Boards, either 0 or an incorrect number, there could be an issue with the Control Panel, Receiver/Decoder Module, Power Distribution Board, 20-Pin Decoder Cable, Pump Common, or one or more of the 8-Station Output Boards and/or their associated Ribbon Cables. Follow the guided troublehsooting steps below to determine which component(s) require replacement.

Control Panel/ Receiver/Decoder Module

The Control Panel/ Receiver/Decoder Module is located at the top of the satellite under the top lid enclosure. To test the Control Panel/ Receiver/Decoder Module proceed with the following steps:

Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

If using a Receiver/Decoder Module, use a pair of needle nose or long nose pliers to pinch the white clips holding the Receiver/Decoder Module in place to release it from it’s bezel. 

If using a Control Panel, use a Phillips screwdriver to unscrew the screws holding the Control Panel in place. 

Proceed to unplug the 20-Pin Decoder Cable from the Power Distribution Board. 

Remove the Control Panel or Receiver/Decoder Module and the 20-Pin Decoder Cable and take them to a known-working satellite location to test.

*Note: Prior to installing the Control Panel or Receiver/Decoder Module and 20-Pin Decoder Cable at a known-working satellite location, be sure to power off the satellite at the known-working satellite location. Power to the satellite should always be off before installing or removing components.

Once installed in the known-working satellite location, if the Control Panel is not reporting the correct station size, or if the Receiver/Decoder Module does not have the correct number of Output Module Status LEDs illuminated, the Control Panel or Receiver/Decoder Module is damaged and should be replaced. 

If the Control Panel is reporting the correct station size, or if the Receiver/Decoder Module has the correct number of Output Module Status LEDs illuminated when installed in the known-working satellite location, it can be considered good.

Replacement Control Panels can be purchased here.

Replacement Receiver/Decoder Modules can be purchased here.

*Note: It is possible for corrosion on the 20-Pin Decoder Cable to cause the Control Panel or Receiver/Decoder Module to report an incorrect number of stations or 8-Station Output Boards. Visually inspect the 20-Pin Decoder Cable for any signs of corrosion damage. Corrosion damage will typically appear in the cable connectors. If any corrosion is found, discard and replace with a new or known-working 20-Pin Decoder Cable. You may also test the cable itself by installing it in a known-working satellite location. If once the 20-Pin Decoder Cable is installed in a known-working satellite location and the Control Panel/ Receiver/Decoder Module continues to report an incorrect number of stations or 8-Station Output Boards, the 20-Pin Decoder Cable is damaged and should be replaced. If the 20-Pin Decoder Cable is damaged, the Control Panel/ Receiver/Decoder Module should be retested as described above using a new or known-working 20-Pin Decoder Cable.

Replacement 20-Pin Decoder Cables can be purchased here.

If the Control Panel/ Receiver/Decoder Module and 20-Pin Decoder cable have been tested and found to be working properly, you may reinstall them in the original satellite location. Further troubleshooting at the original satellite location is required.

Pump Common:

The Pump Common is located in the satellite along the far left-hand side. To test the Pump Common proceed with the following steps:

Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

Next, unplug the Output/Pump Cable from the Power Distribution Board that is connected to the Pump Common. You may leave the Pump Common mounted in the satellite.

Power the satellite back on.

If the Control Panel is reporting the correct station size, or if the Receiver/Decoder Module has the correct number of Output Module Status LEDs illuminated, the Pump Common is damaged and should be replaced. This can be verified by testing the Pump Common in a known-working satellite location. 

If the Control Panel is not reporting the correct station size, or if the Receiver/Decoder Module does not have the correct number of Output Module Status LEDs illuminated, further troubleshooting is required.

Replacement Pump Commons can be purchased here.

*Note: It is possible for corrosion on the Output/Pump Cable that connects the Pump Common to the Power Distribution Board to cause a Control Panel/ Receiver/Decoder Module to report an incorrect number of stations or 8-Station Output Boards. Visually inspect the Output/Pump Cable for any signs of corrosion damage. Corrosion damage will typically appear in the cable connectors. If any corrosion is found, discard and replace with a new or known-working Output/Pump Cable. You may also test the cable by installing it in a known-working satellite location. If once the Output/Pump Cable is installed in a known-working satellite location and the Control Panel/ Receiver/Decoder Module in the known-working satellite location continues to report an incorrect number of 8-Station Output Boards, the Output/Pump Cable is damaged and should be replaced.

Replacement Output/Pump Cables can be purchased here.

Power Distribution Board:

The Power Distribution Board is located at the top of the satellite below the Control Panel/ Receiver/Decoder Module and above the 8-Station Output Boards. To test the Power Distribution Board proceed with the following steps:

Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

Next, unplug the Output/Pump Cables from the Power Distribution Board for all 8-Station Output Boards installed in the satellite. The Output/Pump Cable is the cable that connects the 8-Station Output Boards to the Power Distribution Board.

Using a Phillips screwdriver, unscrew the mounting screws used to hold the 8-Station Output Board located in the first position of the Power Distribution Board in place. The 8-Station Output Board in the first position will be located on the left side of the satellite directly next to the Pump Common.

Disconnect the 8-Station Output Board from the 16-Station Switch & Surge Board and remove it from the satellite.

Proceed to install a known-working 8-Station Output Board in the first position of the Power Distribution Board. 

*When installing a known-working 8-Station Output Board in the first position of the Power Distribution Board, make sure to reconnect the 8-Station Output Board to the 16-Station Switch & Surge Board and plug the Output Pump Cable back into the Power Distribution Board.

Power the satellite back on.

If the Control Panel is not reporting a station size of 8, or if the Receiver/Decoder Module does not have the Output Module Status 1 LED illuminated, the Power Distribution Board is likely damaged and should be replaced. This can be verified by testing the Power Distribution Board in a known-working satellite location.

If the Control Panel is reporting a station size of 8, or if the Receiver/Decoder Module does have the Output Module Status 1 LED illuminated, follow the steps in this article under ‘8-Station Output Board’ to test the functionality of all 8-Station Output Boards installed in the satellite. Once all 8-Station Output Boards have been tested and only working units are installed in the satellite, complete the testing of the Power Distribution Board as follows:

Power off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

Proceed to install a known-working 8-Station Output Board in the lowest-numbered empty position in the satellite. Example: If there is an 8-Station Output Board installed in the first position of the Power Distribution Board, install the next 8-Station Output Board in the second position of the Power Distribution Board.  

Power the satellite back on. 

Verify that the Control Panel is reporting the correct station size corresponding to the number of 8-Station Output Boards installed, or verify that the Receiver/Decoder Module has the correct number of Output Module Status LEDs illuminated corresponding to the number of 8-Station Output Boards installed. Example: If there are two 8-Station Output Boards installed in the satellite, the Control Panel should display a station size of 16 or the Receiver/Decoder Module should have the Output Module Status LEDs 1 and 2 illuminated.

If the Control Panel is displaying the correct station size or if the Receiver/Decoder Module has the correct number of Output Module Status LEDs illuminated, repeat the preceding steps for the remainder of the 8-Station Output Boards, continuing until a station-size discrepancy is observed or all of the 8-Station Output Boards have been installed and the Control Panel/ Receiver/Decoder Module are displaying the correct station size or Output Module Status.

If the station size reported on the Control Panel or the Output Module Status reported on the Receiver/Decoder Module does not match the number of 8-Station Output Boards installed, the Power Distribution Board is damaged and should be replaced.

Replacement Power Distribution Boards can be purchased here.

8-Station Output Board:

The 8-Station Output Boards are located in the middle of the satellite and connect to both the Power Distribution Board and the 16-Station Switch & Surge Boards. To test the 8-Station Output Boards, proceed with the following steps:

Start by powering off the satellite using the On/Off rocker switch located on the front of the Power Supply Assembly.

Next, unplug the Output/Pump Cables from the Power Distribution Board for all 8-Station Output Boards installed in the satellite, with the exception of the 8-Station Output Board located in the first position. 

With the 8-Station Output Board still plugged into the first position of the Power Distribution Board, power the satellite back on.

If the Control Panel is displaying a station size of 8, or if the Receiver/Decoder Module does have the Output Module Status 1 LED illuminated, the 8-Station Output Board connected to the Power Distribution Board is considered good.

If the Control Panel is not displaying a station size of 8, or if the Receiver/Decoder Module does not have the Output Module Status 1 LED illuminated, the 8-Station Output Board and/or the Ribbon Cable connecting the 8-Station Output Board to the Power Distribution Board is damaged. 

To test the functionality of the Ribbon Cable, power off the satellite and replace the ribbon cable with a new or known-working Ribbon Cable and repeat the test again.

Proceed to test each 8-Station Output Board in the satellite in the first position of the Power Distribution Board to verify that each 8-Station Output Board is functioning properly.

If during the course of testing you find that one of your 8-Station Output Boards is the source of the incorrect number of stations being reported to the Control Panel/ Receiver Decoder Module, you may further verify by testing the 8-Station Output Board in a known-working satellite location.

*Note: Prior to installing the 8-Station Output Board at a known-working satellite location, be sure to power off the satellite at the known-working satellite location. Power to the satellite should always be off before installing or removing components.

If the incorrect number of stations being reported to the Control Panel/ Receiver Decoder Module persists when the 8-Station Output Board is installed in a known-working satellite location, the 8-Station Output Board is damaged and should be replaced.

Replacement 8-Station Output Boards can be purchased here.

Lesson tags: toro, eosmac, toro eosmac, e series osmac, eosmac repair, eosmac help, eosmac troubleshooting, eosmac exchange, eosmac motherboard, receiver decoder, decoder module, control panel, eosmac output board, eosmac receiver decoder, osmac decoder, pump common, power distribution board, boardtronics

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