Is there anybody who can help me to repair my Topwave Gawis test instrument?  - Page 1
Forum section: electronics / beginners

author: menemenli
author_rank: Contributor
timestamp: August 06, 2025, 08:49:46 am
content: Hello to everyoneI need help. We want to repair our old test instrument. It measures thickness and dimensional attributes of plastic (PET etc) containers and preforms.It is a Topwave Gawis. It was made in 1992 by TOPWAVE company. Its manufacturer is already in the dusty pages of history.There is a few information about it on internet. A video in youtube about it; its title is :"Material Distribution with the Gawis TopWave":https://youtu.be/v2GH4B7oGsk?feature=sharedWe have only a manual and a few emails about some faults. However not enough.Also there isn't any user/operator of the instrument.There is a principle of operation sheet attached.And also photos of the instrument.Is there anybody who can help me about it?Any documents, any ideas, whatever.Thanks so much.

author: Sorama
author_rank: Frequent Contributor
timestamp: August 06, 2025, 08:56:14 am
content: maybe you can tell what the issue is??

author: menemenli
author_rank: Contributor
timestamp: August 06, 2025, 10:24:43 am
content: Thanks for quick response. And sorry for my poor English. I hope, i can explain well.Well. It has not been using for a long time.Here some details abuot where we are:-First problem was about the battery of the mainboard. There were some green dusts around it. We renewed it. Electronic components seem fine (I hope so).-There are some small, thin mirrors: 2 piece of 5mmX5mmX1mm and 2 piece 20mmX20mmX1mm. They were not in good condition; bad spots on surfaces. We only found and changed 20mmX20mm mirrors. and still searching replacement for other tiny mirrors.-There is a IR light source. The Light source is very popular halogen one (H4 24V 75/70W 50450). Renewed.- 2 IR receiver cards. The light has 2 way to travel from source to receiver through lenses and mirrors (you can see in the attached figure. We try to set the optical parts, however; we still need procedure steps that may help to set the mirrors and lenses.-When we turn it on, the instrument immediately repeats some steps. Something like a bootloop. We could'nt understand what it means.may be, it is trying to find a home position etc.There are many more unkown things...We really need someone who know this instrument.

author: BILLPOD
author_rank: Frequent Contributor
timestamp: August 06, 2025, 01:26:48 pm
content: Good Morning Menemenli, Welcome to the forum. Photos of your instrument, including the inside would be helpful, (the video doesn't show any electronics). You also mentioned it has a battery...please post all information printed on the battery, and if you have a multimeter, what voltage is the battery now? You also mentioned 'green dust', which indicates the battery may have leaked. Do you have a variable DC power supply, with which you could supply the instrument with, after you remove the battery? Also, is there any circuit power supply, other than the battery, (does it plug into mains power)? The plastic bottle in the video appears to be the same, or similar to bottles manufactured today...so maybe you could contact current manufacturers and see ask what they use to get the information you are seeking. Other than that, I'm out of suggestions, but others here will have some, I'm sure. Good luck, and don't forget to come back here and tell us your progress, and/or the final outcome.

author: menemenli
author_rank: Contributor
timestamp: August 07, 2025, 11:46:10 am
content: Thanks so much for your concern. I hope we will learn new things together and also we may be making the instrument functioning.-The battery was VARTA Ni-Cd 3,6V. I replaced it with a new Ni-Cd 3,6V battery. And fortunately, there isn't any problem on the pcb. (You can see the photo attached)- I think, no need for extra power supply while replacing the battery; because the battery is already dead.-The instrument was produced in 1992. Its manufacturer was TOPWAVE in Finland. And in the fall of 2000, AGR International and TopWave Industries announced the merger of the two businesses into one company, AgrTopWave. Today the company is AGR international. And yes, we contacted with AGR, however they can't of don't want to help us.You may find some photos of the instrument.While searching information, we will keep on control and renew components on pcb; as electrolytic capacitors etc.Every suggestions will be welcome, thanks so much.

author: BILLPOD
author_rank: Frequent Contributor
timestamp: August 07, 2025, 12:43:00 pm
content: Well Menemenli, Much better photos. The second photo from the bottom shows what appears to be a vacuum tube, which will certainly not work on the power from a 3.6 volt battery. There must be mains power, (230 volts AC/50 Hz), entering the instrument somewhere. Find where it enters the machine and follow it's route with a multimeter to see where it ends. That is where I would start. It MUST have a cord that plugs into an outlet, or is it hard-wired? As always, use great care when probing mains voltage.

author: wraper
author_rank: Unknown
timestamp: August 07, 2025, 12:55:47 pm
content: Quote from: BILLPOD on August 07, 2025, 12:43:00 pmLooks like IR emitter.

author: madires
author_rank: Super Contributor
timestamp: August 07, 2025, 01:27:59 pm
content: That 'vacuum tube' is a standard 12V H4 bulb for car headlights.Other things to check are supply voltages, electrolytic caps, especially the blue Philips (known to go bad after 20 or 30 years), and the EPROMs (having a copy of the firmware is a good idea anyway).

author: menemenli
author_rank: Contributor
timestamp: August 07, 2025, 01:59:49 pm
content: Sorry for misunderstandingI supposed that you were talking about a continoues power supply that is for memory ICs.Sorry for my poor English:)Sure, It uses 220VAC mains power.And there are 2 toroidal transformers, regulators with heatsinks etc.I am checking, measuring one by one.Thanks so much for your support.

author: menemenli
author_rank: Contributor
timestamp: August 07, 2025, 02:01:10 pm
content: I think so.Honestly, I am not sure about the lamp, as if the right one or not.There isn't any note or part list.

author: menemenli
author_rank: Contributor
timestamp: August 07, 2025, 02:05:25 pm
content: Yes, these are basic point about electronics: I am going on them one by one.-supply voltages-electrolytic caps-EPROMs (unfortunatelyno backup)Thanks

author: wraper
author_rank: Unknown
timestamp: August 07, 2025, 02:35:53 pm
content: Quote from: madires on August 07, 2025, 01:27:59 pmIn essence it's the same as specialized filament type IR emitters. So if they run it at low voltage, it likely could do a sufficient job. BTW I know of similar case. LECO AMA 254 mercury analyzer uses off the shelf T5 germicidal UV bulb as the light source for spectral analysis of mercury.

author: tunk
author_rank: Super Contributor
timestamp: August 07, 2025, 03:17:25 pm
content: Would really know, but you could try to reseat all connectors, socketed ICs, etc.

author: menemenli
author_rank: Contributor
timestamp: August 08, 2025, 05:24:29 am
content: Thanks for your support.Well, there isn't any document or part list about the original lamp type, so I must use the H4 24V 75/70w 50450.However, it has 24V DC supply right now. It is not lower than its optimal voltage. I hope, it is fine

author: menemenli
author_rank: Contributor
timestamp: August 08, 2025, 05:31:20 am
content: Thanks for support.Yes exactly. I am checking all connectors and cables.And also there are some ICs that have IC sockets. Probably they had some inspection before.I am checking those sockets too.So far so good.

author: BILLPOD
author_rank: Frequent Contributor
timestamp: August 08, 2025, 12:58:24 pm
content: Meneminli, There is a push-button switch, (red), in the lower left corner of the last photo. Is there access to operate from the outside if the instrument?

author: menemenli
author_rank: Contributor
timestamp: August 11, 2025, 08:44:51 am
content: Hi BILLPOD,The reset button of the MC6802 microproccessorThe button is between the MC6802 microproccessor and a DC-DC converter on the PCB.No, there is no access to the button from outside, and also inside. There are two electronic cards and the button is between them.You can see in the photos.

author: BILLPOD
author_rank: Frequent Contributor
timestamp: August 11, 2025, 01:19:46 pm
content: So you say the push button resets the MC6802 microproccessor, maybe the MC6802 needs resetting,or have you already tried that?

author: daisizhou
author_rank: Super Contributor
timestamp: August 11, 2025, 11:31:53 pm
content: Can you find the calibration bottles or similar that were used for the initial calibration?Clean the optical pathNeed to check the inside of the infrared receiving box and the bulbIs there any online software?It is best not to press the RESET button, as the stored data may be easily lost.

author: menemenli
author_rank: Contributor
timestamp: August 13, 2025, 02:21:36 pm
content: Quote from: BILLPOD on August 11, 2025, 01:19:46 pmYes. I tried it. However the reaction is the same.Unfortunately the reaction makes me feel bad about the situation.Because whenever i press the reset button, the instrument do the same thing that it does when it is idle, waiting.I had supposed that it was waiting a good IR signal or searching a home position etc.I am afraid, i was wrong.it is probably a bootloop.The program is not functioning, not running.Something is reseting the software.I am keeping on digging

author: menemenli
author_rank: Contributor
timestamp: August 13, 2025, 02:25:12 pm
content: Quote from: daisizhou on August 11, 2025, 11:31:53 pmTherer isn't any bottles for calibration.Even there isn't any one who can operate the instrument.While working on electronics, i am also working on optic parts. I am trying to improve it, however I don't feel good about the electronics.Optics will be in the second step.There isn't any online software etc.

author: daisizhou
author_rank: Super Contributor
timestamp: August 13, 2025, 10:34:23 pm
content: At present, it seems that this is a testing instrument for mass production of transparent bottles.Maybe it is used for quality control testing in production lines.What is the current status? It is best to shoot a video or other more detailed introduction so that others can help you.

author: gcewing
author_rank: Regular Contributor
timestamp: August 14, 2025, 08:39:19 am
content: The two small chips in sockets are RS232 line drivers/receivers, suggesting it has a serial port somewhere. Can you find somewhere to connect a terminal? Maybe you can get some diagnostic information that way.

author: menemenli
author_rank: Contributor
timestamp: August 14, 2025, 11:54:12 am
content: There is procedure that i can set the date and time by keyboard.You can see attached photos and sheets.I am trying to set it, sometimes i can. But, sometimes, i can complete the set; because randomly, the cpu resetsEven i complete the set, it can't keep it.It can only keep it, until i turn it off and on...And there is not time and date information.I replaced the battery, and the M5M51008P 128K x 8 SRAM is in good condition.Where does it keep the data? There isn't a Timekeeping RAM etc around.There is a usual suspect. What may be this IC? Inside the red rectangle.Is it a RAM? It is directly connected to the battery.And the device keeps on repeating same thing. A bootloop.

author: menemenli
author_rank: Contributor
timestamp: August 14, 2025, 12:03:23 pm
content: Do you mean 1488 and 1489?There is also a printer connection and one more electronic card.And there may be some more optional parts that we dont have.There may be a test port, however there isn't anything about it in my handYou can see sockets and connectors in attached photos

author: daisizhou
author_rank: Super Contributor
timestamp: August 14, 2025, 12:23:50 pm
content: Quote from: menemenli on August 14, 2025, 11:54:12 amAX 131A-13 is a Astralux DIL Relay

author: daisizhou
author_rank: Super Contributor
timestamp: August 14, 2025, 12:29:05 pm
content: You need a digital multimeter and a digital oscilloscope to check whether the voltage of each line is within the normal range and whether the frequency waveform of the crystal oscillator is normal.The blue and black electrolytic capacitors are best replaced because they usually leak.Or the inside has dried up and lost the function that the electrolytic capacitor should have.(If you want long-term stable use)

author: gcewing
author_rank: Regular Contributor
timestamp: August 14, 2025, 11:17:09 pm
content: Quote from: menemenli on August 14, 2025, 12:03:23 pmYes. You could try tracing the connections from those chips to see where they go.