Control. Part B, Section 2. This section covers the following unit configurations. 3400V 3500V Voltage 1, 2, 3 Pump Piston (D, E, F, G)

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1 Part B, Section 2 Model This section covers the following unit configurations. 3100V 3400V 3500V Voltage 1, 2, 3 Pump Piston (D, E, F, G) Manifold 4-Port (A) 6-Port (B or C) 2-Port (S or T) Vista Temperature (TC)

2 B 2-0

3 B 2-1 Section B 2 WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This section includes control system troubleshooting procedures and repair procedures. Refer to the parts lists in the Parts section for the part number of any component that needs to be replaced. If you try all the troubleshooting suggestions in this section and still need assistance solving control system problems, call your Nordson representative The following sections of this manual contain additional information on the control system: Description includes an overview of each of the functional areas of the operator panel. Installation includes procedures for connecting output contacts, connecting electrical service, and programming your unit. Wiring Diagrams includes a set of wiring diagrams for your system. If your unit has any special options, such as an input/output (I/O) board or a low-level indicator, refer to the Options section at the end of this manual for troubleshooting and repair procedures. Refer to the Hydraulics section for troubleshooting procedures and repair procedures. Refer to the Parts section for all parts information.

4 B Overview of the System The Vista control system controls how your unit operates. The control system includes a variety of printed circuit boards (hereafter referred to as boards) and other components that you should be familiar with to safely troubleshoot and repair your unit. Assembly See Figure B 2-1. The main components of the control system are the control-end frame, the control assembly, and the operator panel. The control assembly is mounted on the inside of the control-end frame. The operator panel is mounted on the front of the control-end frame. The control assembly is made up of three boards that are required for your unit to function properly. Refer to the following table. Table B 2-1 Assembly Boards Assembly Function Board Power board board Display board Provides power to the unit and supplies the heater power for most of the unit s heated components Contains the Vista software chip and controls how the unit operates Allows the displays to function Fig. B 2-1 Assembly Components 1. Power board 4. -end frame 2. board 5. Operator panel 3. Display board

5 B 2-3 Unit-Specific Boards See Figure B 2-2. The control system also includes any unit-specific boards that are required for your unit to function properly. The presence of these boards varies depending on the configuration of the unit. Refer to the following table. Unit-Specific Board Contactor board 400 VAC tank board Table B 2-2 Unit-Specific Boards Function Provides the additional switching circuitry needed when a unit has certain features, such as a grid Supplies the heater power for the tank in 400 VAC 3 units Optional Input/Output Board See Figure B 2-2. Your unit may have an optional input/output (I/O) board. The I/O board is not required for a unit to function properly. Refer to Series 3000V TC Input/Output Board in the Options section at the end of this manual for information about the I/O board, including troubleshooting procedures, repair procedures, and a parts list.

6 B 2-4 Optional Input/Output Board (contd.) Fig. B 2-2 Unit-Specific Boards and I/O Board 1. Contactor board VAC tank board 3. I/O board

7 B Troubleshooting Tables The following troubleshooting tables describe the kinds of control system problems you may encounter and provide corrective actions for handling those problems. When necessary, the tables refer to more detailed troubleshooting procedures. Refer to the appropriate troubleshooting table for the type of problem you are experiencing: Tank, Hose, or Gun Not Heating Settings Changed or Lost Unit Not Powering On System Indicating an Under-Temperature (UT) Warning System Indicating a Fault - Over-Temperature (OT) Fault - Resistance Temperature Detector (RTD) Fault - Fault-Code Fault (F1 F6) Electrical Safety During Troubleshooting Before performing troubleshooting activities inside the unit s electrical enclosure, you should exhaust all methods of troubleshooting the problem with the electrical enclosure closed or with the power off. The troubleshooting tables and procedures in this section are organized using this methodology. In general, you should perform troubleshooting activities as follows: Check the displays and lights for warnings, faults, and other status information. Check your programmed settings to make sure they haven t been changed. Refer to Records of System Settings in the Installation section. Check for continuity and grounding between system components (unit, guns, hoses, and other equipment). Make sure your branch circuit disconnect switch is properly installed. Make sure your power supply is supplying the proper voltage. Prioritize troubleshooting activities to limit exposure to live power. Perform troubleshooting activities involving live power last. Understand your system electrically and mechanically before opening the electrical enclosure. Pay special attention to system power distribution and to I/O interfaces with other equipment. Identify and eliminate potential electrical shock hazards in the environment surrounding your unit.

8 B 2-6 Opening and Closing the Electrical Enclosure To troubleshoot control system problems or to make any repairs, you may need to access the electrical enclosure. Use these procedures as needed to safely access the electrical enclosure. Opening WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. See Figure B 2-3. Loosen the captive screws on the electrical enclosure lid, lift the lid from the unit, and prop it against the pump cover. Take care not to disconnect the ground wire. 3. Make sure the support strap is not wrapped around any board components. Untangle the strap if necessary. 4. Loosen the two captive screws on either side of the control-end frame and lower the frame. You may need to pull the front and rear covers apart to release the frame. 5. Avoid direct contact with internal electrical connections, components, or wiring. 6. Make sure all ground wires are securely connected. Î Î ÎÎ Î Î A Fig. B 2-3 Opening the Electrical Enclosure

9 B 2-7 Closing 1. Reconnect any ground wires that were disconnected during troubleshooting or repair activities. 2. Raise the control-end frame into place and tighten the captive screws on each side of the frame. You may need to pull the front and rear covers apart to position the frame. 3. Position the electrical enclosure lid on top of the unit and secure it with the captive screws. 4. Remove the lock-out and restore power to the system. Tank, Hose, or Gun Not Heating If a tank, hose, or gun will not heat, use this troubleshooting table. Problem Possible Cause Corrective Action Tank, hose, or gun not heating Zone setpoint temperature below 38 C (100 F) Check the setpoint temperature for the zone. The setpoint temperature must be 38 C (100 F) or above for the zone to heat. Refer to Programming TEMPERATURE s in the Installation section to program setpoint temperatures.

10 B 2-8 Settings Changed or Lost Use the following table to troubleshoot changed or lost settings (memory). Because the control system memory is stored on the microprocessor chip and does not require the protection of a battery backup, your settings cannot be lost during a brownout or a power failure. Problem Possible Cause Corrective Action 1. One or more settings changed Someone entered programming mode and changed one or more settings 2. All settings lost Software upgraded to latest version by replacing software chip (all custom settings are lost during this procedure and are replaced by the factory default settings) Defective microprocessor chip Use the password-enable feature to protect your settings. Refer to System Programming Procedures in the Installation section. Be sure to record your settings in the Records of System Settings at the end of the Installation section. Reprogram your unit. Refer to System Programming Procedures in the Installation section. Replace the control board. Refer to Replacing a Assembly Board in Repair Procedures. Unit Not Powering On If your unit will not power on, use this troubleshooting table. WARNING: Risk of equipment damage, personal injury, or death. Some troubleshooting procedures require you to perform work inside the electrical enclosure with the power on. Follow electrical safety procedures and observe all high-voltage indicators. Refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure before performing any troubleshooting procedure.

11 B 2-9 Problem Possible Cause Corrective Action Displays do not illuminate or displays illuminate but unit will not power on and no faults are displayed No input power Defective POWER switch Incorrect voltage plug at X3 (and X4 if applicable) on power board or incorrect contactor board harness 400 VAC 3 units only: defective surge guard 400 VAC 3 units only: defective transformer Blown fuse or fuses Contactor K1 on power board not engaging Power board not properly connected to control board Defective power board or control board Make sure the power is turned on at your branch circuit disconnect switch and that your power supply is supplying the proper voltage to the unit. Check the voltage at TB1 on the power board. If necessary, check your electrical connections at TB1. Refer to Connecting Electrical Service in the Installation section. Check the POWER switch. Refer to Checking the POWER Switch in Troubleshooting Procedures. Check for the correct plug or harness. Refer to Checking the Voltage Plug and Contactor Board Harness in Troubleshooting Procedures. Check the surge guard. Refer to Checking a Surge Guard in Troubleshooting Procedures Check the transformer. Refer to Checking the Transformer in Troubleshooting Procedures. Use an ohmmeter to check fuses F9 and F10 on the power board. Replace blown fuses. Refer to Replacing a Fuse in Repair Procedures. While pressing the unit s HEATERS key on and off, listen for the K1 contactor to engage. You can also open the unit and visually examine the contactor to see if it engages. See Figure B 2-4 for the location of K1 on the power board. If K1 is not engaging, replace the power board. Refer to Replacing a Assembly Board in Repair Procedures. Make sure the power board is properly connected to the control board at XP1. The pins from the control board should extend through XP1 on the power board. Replace the control assembly. Refer to Replacing the Assembly in Repair Procedures.

12 B 2-10 Unit Not Powering On (contd.) X1 XP6 XP1 XP1 K1 X3 XP3 X2 XS3 XS4 X4 XP5 XP4A Q17 TB1 TB J4 J9 J2 XS2 XS1 L1 L2 L3 N XP2 1 2 XS4A XS4B XS4C XIT J2C J1C X2C XS3A XS3B XS3C XS3D XS2A XS2B L1 XS1A L2 L3 X1C TH2 AC_2 TH A Fig. B 2-4 Location of Connectors on Boards 1. Power board 3. Contactor board VAC tank board 2. board

13 B 2-11 System Indicating an Under-Temperature (UT) Warning During an under-temperature warning condition, the unit continues to function normally. The control system indicates the warning as follows: The FAULT light flashes and turns off or flashes continuously. The Selector display shows a zone number. Refer to Table B 2-3 to determine the affected zone. NOTE: Each heated component (each hose, each gun, and the tank) is referred to as a zone. The Multipurpose display shows a flashing UT. Table B 2-3 Determining the Affected Zone Zone Number in Selector Display Affected Zone 0 Tank 1 Hose 1 2 Hose 2 3 Hose 3 4 Hose 4 5 Gun 1 6 Gun 2 7 Gun 3 8 Gun 4

14 B 2-12 Under-Temperature (UT) Warning WARNING: Risk of equipment damage, personal injury, or death. Some troubleshooting procedures require you to perform work inside the electrical enclosure with the power on. Follow electrical safety procedures and observe all high-voltage indicators. Refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure before performing any troubleshooting procedure. When the FAULT light. And the Selector display And the Multipurpose display It means Do this Flashes (See Note A) Shows a zone number (refer to Table B 2-3) Flashes UT (See Note B) The indicated zone s actual temperature is more than 19.5 C (35 F) below the setpoint temperature. Refer to the following procedure. NOTE A: When the FAULT light flashes, the warning output contact is open and the fault output contact is closed. When the FAULT light is off, both output contacts are closed. For more information on these output contacts, refer to Connecting Output Contacts in the Installation section. B: UT (under-temperature) occurs when a heater zone is more than 19.5 C (35 F) under the setpoint temperature.

15 B Turn the indicated zone off and back on, or toggle the POWER switch off and back on, and wait for the system to return to the system-ready state. 2. If the warning disappears and the unit appears to be working again, the voltage to the unit may have temporarily sagged or you may have an intermittent problem. Repetitive warnings in the same zone indicate a problem with the circuitry in that zone or an intermittent RTD failure. Take the following steps to troubleshoot intermittent under-temperature warnings: a. Check for a change in environmental conditions, such as added ventilation or sources of drafts. A cold draft can keep your unit, hoses, and guns from heating. b. Make sure the power is turned on at your branch circuit disconnect switch and that your power supply is supplying the proper voltage to the unit. c. Check all hose and gun electrical plugs. Make sure the connections are tight and free of corrosion. d. Check your operating temperature setpoints to make sure they haven t been changed. Refer to Records of System Settings in the Installation section. e. If the affected zone is a hose or gun, replace the hose or gun with a hose or gun that is known to be good. If the warning disappears, replace the defective hose or gun. If the warning still appears, continue to the next step. 3. If the warning still appears after you press the CLEAR FAULTS key and after you have taken the actions in step 2, take the following steps. a. Check for loose heater connections on the board that supplies the heater power for the affected zone. Refer to Table B 2-5 for heater connector locations. For example, check the harnesses connected to X1 and X2 on the power board to check the heater connections for hoses 1 4 or guns 1 4. See Figure B 2-4 for the location of connectors on boards. b. Use an ohmmeter to check the fuse or fuses on the board that supplies the heater power for the affected zone. Refer to Figure B 2-9 for fuse locations. Replace the appropriate fuse or fuses. Refer to Replacing a Fuse in Repair Procedures. If the fuse blows again, make sure the heater is not shorted to the ground.

16 B 2-14 Under-Temperature (UT) Warning (contd.) c. If the affected zone is the tank, make sure the harness connected to J2 on the power board is secure or check the thermostat. See Figure B 2-4 for the location of J2 on the power board. To check a thermostat, refer to Checking a Thermostat in Troubleshooting Procedures. d. Check the K1 contactor on the power board. While pressing the unit s HEATERS key on and off, listen for the K1 contactor to engage. You can also open the unit and visually examine the contactor to see if it engages. See Figure B 2-4 for the location of K1 on the power board. If K1 is not engaging, replace the power board. Refer to Replacing a Assembly Board in Repair Procedures. e. Check the heater or heater circuit of the affected zone. Refer to Checking a Heater or Heater Circuit in Troubleshooting Procedures. f. If the warning condition still appears after you have taken all the actions in this step, replace the control assembly. Refer to Replacing the Assembly in Repair Procedures.

17 B 2-15 System Indicating a Fault A fault condition causes the unit to shut down. The control system indicates a fault as follows: The FAULT light either turns on and stays on or flashes for two minutes and then stays on. The Selector display shows either a zone number or the letter F. If the Selector display shows a zone number, refer to Table B 2-4 to determine the faulted zone. NOTE: Each heated component (each hose, each gun, and the tank) is referred to as a zone. The Multipurpose display shows either a flashing OT or RTD for the faulted zone or a fault code (F1 F6). The heaters turn off. Whenever the heaters turn off, the pump stops. Table B 2-4 Determining the Faulted Zone Zone Number in Selector Faulted Zone Display 0 Tank 1 Hose 1 2 Hose 2 3 Hose 3 4 Hose 4 5 Gun 1 6 Gun 2 7 Gun 3 8 Gun 4

18 B 2-16 Over-Temperature (OT) Fault WARNING: Risk of equipment damage, personal injury, or death. Some troubleshooting procedures require you to perform work inside the electrical enclosure with the power on. Follow electrical safety procedures and observe all high-voltage indicators. Refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure before performing any troubleshooting procedure. When the FAULT light And the Selector display And the Multipurpose display It means Do this Turns on (See Note A) Shows a zone number (refer to Table B 2-4) Flashes OT (See Note B) A zone s actual temperature has reached the over-temperature setpoint entered in Feature 3. The default setting is 200 C (392 F). Refer to the following procedure. NOTE A: When the FAULT light turns on, the warning output contact is closed and the fault output contact is open. When the FAULT light is off, both output contacts are closed. For more information on these output contacts, refer to Connecting Output Contacts in the Installation section. B: You should base your over-temperature setpoints on your adhesive application requirements. Refer to System Programming Procedures in the Installation section to program over-temperature setpoints. 1. Toggle the POWER switch off and back on and wait for the system to return to the system-ready state. 2. If the fault disappears and the unit appears to be working again, you may have an intermittent problem. Repetitive faults in the same zone indicate a problem with the circuitry in that zone or an intermittent RTD failure. Electrical noise from DC-drive motors may cause the triacs that control heater power on the power board to close independent of the control system. Take the following steps to troubleshoot intermittent over-temperature faults: a. Check your operating temperature setpoints to make sure they haven t been changed. Refer to Records of System Settings in the Installation section.

19 B 2-17 b. If electrical noise from DC drives is causing the overheating problem, then you may be experiencing problems with other equipment in your facility. Take the following steps to solve electrical noise problems: Install the proper line reactor. Consult with the DC drive manufacturer for the appropriate line reactor size. Electrically ground the hot melt unit to the parent machine using as short a length of twisted cable as possible. If the triacs continue to close after the hot melt unit is grounded to the parent machine, install a line filter on each input power line to the hot melt unit. Connect the filter line-to-line. Refer to Parts for the line filter part number. For a three-phase system, order three filters. c. If the faulted zone is a hose or gun, replace the hose or gun with a hose or gun that is known to be good. If the fault disappears, replace the defective hose or gun. If the fault remains, continue to the next step. 3. If the fault remains after you press the CLEAR FAULTS key and after you have taken the actions in step 2, check the heater or heater circuit of the faulted zone. Refer to Checking a Heater or Heater Circuit in Troubleshooting Procedures. 4. If the fault remains after you have taken all the actions in this procedure, replace the control assembly. Refer to Replacing the Assembly in Repair Procedures.

20 B 2-18 Resistance Temperature Detector (RTD) Fault Nordson offers two test plugs that simplify the troubleshooting of RTD faults. These test plugs help you quickly and easily determine whether the problem is a gun, hose, or tank RTD problem or a control system problem. Refer to Parts for the kit part number. When the FAULT light And the Selector display And the Multipurpose display It means Do this Flashes for two minutes then stays on continuously (See Note A) Shows a zone number (refer to Table B 2-4) Flashes RTD (See Note B) The RTD or RTD circuit of the indicated zone is open or shorted. Refer to Checking an RTD or RTD Circuit in Troubleshooting Procedures. A hose or gun was incorrectly removed or replaced. (See Note B) Clear the fault by changing the Hoses Temperature Setpoint and the Guns Temperature Setpoint to the default setting ( ) and pressing the Enter key. Then reset your operating setpoint temperature. Refer to System Programming Procedures in the Installation section. NOTE A: When the FAULT light flashes, the warning output contact is open and the fault output contact is closed. After a two-minute delay, the warning output contact closes and the fault output contact opens. When the FAULT light is off, both output contacts are closed. For more information on these output contacts, refer to Connecting Output Contacts in the Installation section. B: To determine how many hoses and guns the unit is controlling, scan through the temperature zones beginning with zone 1 (the tank). Count how many zone 2s (hoses) and zone 3s (guns) the unit is monitoring. This is how many hoses and guns the unit recognizes as connected to it. To properly remove or replace a hose or gun, refer to Procedure for Adding, Removing, or Replacing a Hose or Gun in the Operation section.

21 B 2-19 Fault-Code Fault (F1 F6) When the FAULT light And the Selector display And the Multipurpose display It means Do this Turns on (See Note A) Shows the letter F Shows the number 2 The power board screws are loose, causing a faulty ground connection. Tighten the power board screws. Shows the letter F Shows the letter F Shows the number 1, 2, 3, 5, or 6 Shows the number 4 The control board is defective. There is a brownout condition. (See Note B) Turn the unit off, then back on again to see if the problem recurs. If it recurs, replace the control board or replace the control assembly. Refer to Replacing a Assembly Board or Replacing the Assembly in Repair Procedures. Correct the cause of the brownout. NOTE A: When the FAULT light turns on, the warning output contact is closed and the fault output contact is open. When the FAULT light is off, both output contacts are closed. For more information on these output contacts, refer to Connecting Output Contacts in the Installation section. B: A brownout occurs when the power supply voltage falls below the voltage needed to maintain system operation. When this happens, the control system stops normal operation. The system will resume normal operation once the brownout condition is corrected.

22 B Troubleshooting Procedures Use these procedures as directed in Troubleshooting Tables to further troubleshoot control system problems. Checking the POWER Switch Follow this procedure to check the POWER switch. WARNING: Risk of equipment damage, personal injury, or death. This procedure requires you to perform electrical troubleshooting with the power on. Use extreme caution and refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure for instructions on safely working inside the electrical enclosure. 1. Turn on power to the unit at the branch circuit disconnect switch. 2. With the unit s POWER switch in the off position, measure the voltage across J4 positions 1 and 4 on the power board. Voltage does not measure 230 VAC: replace the POWER switch and harness. Voltage measures 230 VAC: normal indication. Continue to the next step. 3. With the unit s POWER switch in the on position, measure the voltage across J4 positions 2 and 5 on the power board. Voltage does not measure 230 VAC: replace the POWER switch and harness. Voltage measures 230 VAC: normal indication. Return to the Unit Not Powering On troubleshooting table.

23 B 2-21 Checking the Voltage Plug and Contactor Board Harness Follow this procedure to make sure your unit has the correct voltage plug and, if applicable, contactor board harness. To make this check, you will need to know the voltage code of your unit. Refer to Explanation of Configuration Code in the Description section to determine the voltage code. the electrical service of your unit. Your unit may be wired for single-phase (1 ) or three-phase (3 ) service. To determine the electrical service of your unit, refer to the tables and illustrations in Connecting Electrical Service in the Installation section and compare them to the connections at TB1 on the power board in your unit. if your unit has a contactor board. To determine if your unit has a contactor board, see Figure B 2-5. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. Make sure the voltage plug at X3 (and X4 if applicable) on the power board is connected. Refer to the Parts section for the location of the voltage plug.

24 B 2-22 Checking the Voltage Plug and Contactor Board Harness (contd.) 4. Make sure your unit has the correct voltage plug at X3 (and X4 if applicable) on the power board. Refer to the following table. NOTE: If you have a voltage code 3 unit, the voltage plug is part of the contactor board harness. Go to the next step. Unit Voltage Code and Electrical Service Voltage Plug Part Number Voltage code 1, Voltage code 2, Voltage code 1, Voltage code 2, If your unit has a contactor board, make sure the correct contactor board harness is installed. Refer to the following table. Refer to the Parts section for the location of the contactor board harness. NOTE: If you have a voltage code 3 unit, the contactor board harness is connected to the contactor board and to X3 on the power board. Unit Voltage Code and Electrical Service Contactor Board Harness Part Number Voltage code 1, Voltage code 2, Voltage code 1, Voltage code 2, Voltage code 3,

25 B 2-23 Checking a Surge Guard Follow this procedure to check a surge guard on a 400 VAC 3 unit. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. WARNING: Risk of burns. Surge guards can reach temperatures as high as 81 C (177 F). Wear heat-protective gloves and do not touch the surge guards. 3. Connect an ohmmeter set on the highest resistance scale across the surge guard. Refer to the Parts section for the location of the surge guards. NOTE: The unit has two surge guards. 4. If you measure infinite resistance, the surge guard is defective. Refer to Replacing a Surge Guard in Repair Procedures. Checking the Transformer Follow this procedure to check the transformer on a 400 VAC 3 unit. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure.

26 B 2-24 Checking the Transformer (contd.) 3. See Figure B 2-6. Check for continuity across the primary and secondary transformer windings. If you do not measure continuity, replace the transformer. Refer to the Parts section for the location of the transformer VAC PRIMARY VAC SECONDARY A Fig. B 2-6 Transformer Wiring Diagram Checking a Heater or Heater Circuit Follow this procedure to check a heater or heater circuit. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure.

27 B Check the heater by measuring its resistance at the heater connector harness pins. Refer to Table B 2-5 to determine which board the zone s heater connectors are located on. See Figure B 2-4 for the location of the connectors on the boards. Remove the harness from the connector and measure the resistance across the harness pins identified in Table B 2-5. Resistance reading of zero (0): heater short circuit. Check for a short in the heater circuit and repair the short. Infinite resistance reading: open heater circuit or heater. Go to the next step. Zone Number in Selector Display Table B 2-5 Heater Connector Locations and Harness Pins for Measuring Resistance Problem Zone 0 Tank (See Note A) Heater Connector: Harness Pin Resistance Range XS1 and XS Hose 1 X1: 1 and X2: ohms 2 Hose 2 X1: 3 and X2: ohms 3 Hose 3 X1: 5 and X2: ohms 4 Hose 4 X1: 7 and X2: ohms 5 Gun 1 X1: 2 and X2: ohms 6 Gun 2 X1: 4 and X2: ohms 7 Gun 3 X1: 6 and X2: ohms 8 Gun 4 X1: 8 and X2: ohms NOTE A: On 400 VAC 3 units, make this check on the 400 VAC tank board and the contactor board instead of the power board. For the first of the two tank heaters, use connector TH1 on the 400 VAC tank board and XS3B on the contactor board. For the other tank heater, use connector TH2 on the 400 VAC tank board and XS1A on the contactor board. See Figure B 2-2 for the location of these boards in the unit. See Figure B 2-4 for the location of the heater connectors on the boards.

28 B 2-26 Checking a Heater or Heater Circuit (contd.) 4. Check the continuity of the heater circuit by measuring the heater resistance at a point in the circuit that is closer to the heater. If the faulted zone is a hose or gun, measure the resistance at the hose or gun electrical plug. Refer to your hose or gun manual for a diagram of the electrical plug and for procedures for replacing the gun heater. If a hose heater is defective, replace the hose. If the faulted zone is the tank, measure the resistance at the tank heater connectors (refer to Table B 2-5). If you measure infinite or zero (0) resistance at the tank heater connectors, you must install a new tank. Refer to the Tank section. 5. If you do not find a continuity problem, replace the control board or the control assembly. Refer to Replacing a Assembly Board or Replacing the Assembly in Repair Procedures. Checking a Thermostat Use this procedure to check a thermostat. WARNING: System or material pressurized. Relieve pressure. Failure to observe this warning may result in serious burns. 1. Relieve system pressure. Refer to Relieving System Pressure in the Maintenance section. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 2. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 3. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 4. Remove the thermostat. Refer to RTD or Thermostat Removal in Repair Procedures.

29 B Connect an ohmmeter set on the lowest resistance scale across the thermostat; then heat the thermostat with a flameless electric heat gun. Short circuit before thermostat reaches temperature and open circuit when thermostat reaches temperature: normal indication. Return to the appropriate troubleshooting table. Short circuit or low resistance at high temperature: defective thermostat. Replace the thermostat. Refer to Replacing an RTD or a Thermostat in Repair Procedures. Checking an RTD or RTD Circuit Follow this procedure to check an RTD or RTD circuit. NOTE: If the faulted zone is a hose or a gun, you can remove the hose or gun and replace it with a hose or gun that is known to be good. If the fault disappears, then the problem is in the hose or gun, not inside the unit. As an alternative to using this procedure, you can refer to your hose or gun manual for instructions on checking the hose or gun RTD and replacing the gun RTD. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. Check the RTD by measuring its resistance. Refer to Table B 2-6. If the RTD is defective, replace the RTD. If a hose RTD is defective, you must replace the hose. To replace a gun RTD, refer to your gun manual. To replace a tank or grid RTD, refer to Replacing an RTD or a Thermostat in Repair Procedures. NOTE: Flex the hose when you are checking a hose RTD. Some hose RTDs exhibit problems intermittently. If the RTD is good, go to the next step.

30 B 2-28 Checking an RTD or RTD Circuit (contd.) Table B 2-6 Measuring RTD Resistance Quick Methods In-Depth Methods Using a surface-temperature sensing device, such as a thermocouple, measure the temperature of the RTD at or near the end of the RTD that is accessible. Then use an ohmmeter to measure its resistance (see Note A). See Figure B 2-7 and compare the resistance reading to the RTD s normal resistance at the known temperature. Roughly estimate the temperature of the RTD to the nearest 50 C (100 F). Use an ohmmeter to measure its resistance (see Note A). See Figure B 2-7 and compare the resistance reading to the RTD s normal resistance at the estimated temperature. Because RTDs usually fail open or closed, any resistance reading from approximately ohms strongly indicates that the RTD is good. Let the system cool down to room temperature. When the RTD has had time to reach room temperature, use an ohmmeter to measure its resistance (see Note A). See Figure B 2-7 and compare the resistance reading to the RTD s normal resistance at room temperature. Remove the RTD and heat it to a known temperature by using an oven or by placing it in boiling water (protect the wires and hold them above the water). Then use an ohmmeter to measure its resistance (see Note A). See Figure B 2-7 and compare the resistance reading to the RTD s normal resistance at the known temperature. NOTE A: If the faulted zone is a hose or gun, measure the RTD resistance at the hose or gun electrical plug. Refer to your hose or gun manual for a diagram of the electrical plug and for procedures for checking RTD resistance. Because the core elements of a hose are not accessible, you cannot use some of the methods described in this table to measure the temperature of a hose RTD. If the faulted zone is a tank or grid, measure the RTD resistance at the control board. For a tank RTD, measure the resistance at pins 33 and 34 of the harness attached to connector XP2 on the control board. For a grid RTD, measure the resistance at pins 21 and 22 of the harness attached to connector XP2 on the control board.

31 B Check the continuity of the RTD circuit by measuring the RTD resistance at other points in the circuit. Refer to Table B 2-7 for the plug or harness pins for each check. For a gun RTD, you can check continuity at two points: first at the hose electrical plug and then at the harness connected to XP2 on the control board. For a hose RTD, you can check continuity at the hose electrical plug or at the harness connected to XP2 on the control board. See Figure B 2-4 for the location of XP2 on the control board. For the tank RTD, there are no further checks you can make: go to the next step. Zone Number in Selector Display Table B 2-7 Pins for Checking RTD Resistance Faulted Zone Gun Electrical Plug Hose Electrical Plug Pins Pins Connector XP2 Harness Pints 0 Tank N/A N/A 33 and 34 1 Hose 1 N/A 5 and 8 1 and 2 2 Hose 2 N/A 5 and 8 3 and 4 3 Hose 3 N/A 5 and 8 5 and 6 4 Hose 4 N/A 5 and 8 7 and 8 5 Gun 1 3 and 5 3 and 5 9 and 10 6 Gun 2 3 and 5 3 and 5 11 and 12 7 Gun 3 3 and 5 3 and 5 13 and 14 8 Gun 4 3 and 5 3 and 5 15 and If you find a continuity problem in the gun RTD circuit, replace the hose or replace the gun RTD harness inside the unit as appropriate. If you find a continuity problem in the hose RTD circuit, replace the hose RTD harness inside the unit. If you do not find a continuity problem, go to the next step. 6. Replace the control board or the control assembly. Refer to Replacing a Assembly Board or Replacing the Assembly in Repair Procedures.

32 B 2-30 Checking an RTD or RTD Circuit (contd.) RESISTANCE IN OHMS C 32 C 54 C (50 F ) (90 F) (130 F ) 77C 99C 121C 143C 166C 188C 210C 232C (170 F ) (210 F ) (250 F ) (290 F ) (330 F ) (370 F ) (410 F ) (450 F ) Fig. B 2-7 RTD Resistance vs. Temperature

33 B Repair Procedures Use these procedures to replace control system components. You can use the parts list illustrations in the Parts section as a guide as you perform these procedures. Refer to the Parts section for the part numbers of any components to be replaced. WARNING: Risk of electrical shock. Failure to observe electrical safety procedures may result in personal injury or death. Allow only qualified personnel to perform these repair procedures. Observe all high-voltage indicators. Replacing a Surge Guard Use this procedure to replace a defective surge guard on 400 VAC 3 units. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. WARNING: Risk of burns. Surge guards can reach temperatures as high as 81 C (177 F). Wear heat-protective gloves. CAUTION: Risk of equipment damage. Make sure surge guards do not contact each other or any other component within the enclosure. Maintain 10-mm spacing. 3. See Figure B 2-8. Disconnect the defective surge guard and replace it with a new one. Position the surge guards so they do not contact each other or any other component within the enclosure.

34 B 2-32 Replacing a Surge Guard (contd.) Fig. B 2-8 Surge Guards 1. Surge guard 2. Transformer 4. Close and secure the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. Replacing a Fuse Follow this procedure to replace a fuse. A fuse may be secured by a vertical or horizontal fuse holder. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. See Figure B 2-9 and use the following table to locate the fuse to be replaced.

35 B 2-33 Table B 2-8 Board Fuses Board Fuse for Fuse Numbers Power board Hose 1, gun 1 F1, F5 Contactor board (400 VAC 3 units) Hose 2, gun 2 Hose 3, gun 3 Hose 4, gun 4 Tank power Tank heater 1 Tank heater 2 F2, F6 F3, F7 F4, F8 F11, F12 F9, F10 F1, F3 F2, F3 F1 F1 F2 F3 F5 F6 F7 F8 F9 F10 F3 F4 F11 F12 2 F A Fig. B 2-9 Location of Fuses on Boards 1. Power board 2. Contactor board

36 B 2-34 Replacing a Fuse (contd.) 4. See Figure B Remove the fuse from the fuse holder and install the new fuse. Refer to the following table. Fuse Holder To Remove To Install Vertical 1. Press down on the fuse cap and turn it counterclockwise until you feel the cap release. Horizontal 2. Lift the cap and fuse from the connector. Lift the fuse from its two-station connector. 1. Pull the fuse from the cap and replace it with a new fuse. 2. Insert the cap and fuse into the fuse holder. Turn the fuse and cap clockwise and press down until you feel the cap lock into place. Press the replacement fuse into the two-station connector until the fuse snaps into place. 2 1 Fig. B 2-10 Fuse Holders 1. Vertical 2. Horizontal A 3. Close and secure the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure.

37 B 2-35 Replacing a Assembly Board Use these procedures to replace the power board, control board, or display board. As an alternative, you can save time by replacing the entire control assembly. Refer to Replacing the Assembly. Preparation for Removal WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. Unscrew the support strap from the control-end frame and disconnect the electrical service from TB1 on the power board. Power Board Removal 1. If you have not already done so, complete Preparation for Removal. 2. Label or note all power board connections for later reference. NOTE: Refer to the Parts section for an exploded drawing of the control assembly parts. The wiring diagram contained in the Wiring Diagrams section may also be helpful. 3. Disconnect the voltage plug from X3 (and X4 if applicable) on the power board. NOTE: Replacement power boards do not have a voltage plug. You must keep the voltage plug from your old board. On 400 VAC 3 units the voltage plug is part of the contactor board harness. 4. Disconnect all harnesses, ribbon cables, and other connections from the power board. 5. Remove the mounting hardware from the power board.

38 1 B 2-36 Power Board Removal (contd.) CAUTION: Risk of equipment damage. Do not bend the XP1 connector pins. 6. Starting from the edge opposite the XP1 connector, carefully separate the power board from the control board. Take care not to bend the XP1 connector pins that join the power board and control board. NOTE: The XP1 connector may remain attached to the power board. If it does, remove it and attach it to connector XP3 on the control board. NOTE: If the optional I/O board is connected to the control board on your unit, take care not to damage the I/O board as you remove the power board. Power Board Installation 1. Remove the new board from its static-safe container. Handle the board by its edges without touching any pins, wires, or circuitry. 2. See Figure B Align XP1 on the new power board with the connector pins on the control board. Press the board into place, making sure the connector pins are properly inserted into their sockets Fig. B 2-11 Aligning the XP1 Connector Pins

39 B Install the mounting screws and lock washers you removed earlier. Be sure to use lock washers on the three screws located at the three ground pads on the power board. Tighten all screws to Nm (18 20 in.-lb). NOTE: Refer to the Parts section for an exploded drawing of the control assembly parts. 4. Install the large triac (Q17) screw, which is to the left of TB1. Tighten the screw to Nm (7 8 in.-lb). 5. Install the two triac clamps and, starting with the center screw, tighten the securing screws to Nm (18 20 in.-lb). 6. Connect the voltage plug you kept from your old board to X3 (and X4 if applicable) on the power board. 7. Connect all other harnesses, ribbon cables, and other connections to the power board. 8. Go to System Restoration. Board Removal 1. If you have not already done so, complete Preparation for Removal. 2. Remove the power board. Refer to Power Board Removal. 3. Label or note all control board connections for later reference. NOTE: Refer to the Parts section for an exploded drawing of the control assembly parts. The wiring diagram contained in the Wiring Diagrams section at the end of this manual may also be helpful. 4. Disconnect all harnesses, ribbon cables, and other connections from the control board. 5. Remove the mounting hardware from the control board. NOTE: If your unit has the optional I/O board, you must also disconnect this board from the control board. Refer to Series 3000V TC Input/Output Board in the Options section for instructions on I/O board removal. 6. Carefully separate the control board from the display board. Take care not to bend the XP4A connector pins that join the control and display boards. Retain the connector.

40 1 B 2-38 Board Installation 1. Remove the new board from its static-safe container. Handle the board by its edges without touching any pins, wires, or circuitry. 2. See Figure B Align the XP4A connector pins (2) with the connector (1) on the display board, then carefully press the control board into place. 1 2 Fig. B 2-12 Aligning the XP4A Connector 1. XP4A connector 2. XP4A connector pins A 3. Reinstall the mounting hardware. Be sure to use lock washers on the two screws located at the two ground pads on the control board. Tighten all screws to Nm (18 20 in.-lb). NOTE: Refer to the Parts section for an exploded drawing of the control assembly parts. 4. Connect all other harnesses, ribbon cables, and other connections to the control board. NOTE: If your unit has the optional I/O board, you must also connect this board to the control board. Refer to Series 3000V TC Input/Output Board in the Options section for instructions on I/O board installation. 5. Install the power board. Go to step 2 in Power Board Installation.

41 B 2-39 Display Board Removal 1. If you have not already done so, complete Preparation for Removal. 2. Remove the power board and control board. Refer to Board Removal. 3. Remove the mounting hardware that secures the display board to the control-end frame and remove the display board. NOTE: Refer to the Parts section for an exploded drawing of the control assembly parts. Display Board Installation 1. Remove the new board from its static-safe container. Handle the board by its edges without touching any pins, wires, or circuitry. 2. Align the display board with the control-end frame and attach it with the mounting hardware. Tighten all screws to Nm (18 20 in.-lb). 3. Install the control board and power board. Go to step 2 in Board Installation. System Restoration 1. Reattach the support strap to the control-end frame. Tighten the screw to Nm (18 20 in.-lb). 2. Make sure the electrical service connections at TB1 on the power board are correct. If necessary, refer to Connecting Electrical Service in the Installation section. 3. Close and secure the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 4. If you replaced the control board, re-enter your customized system settings, if any. Refer to System Programming Procedures and Records of System Settings in the Installation section.

42 B 2-40 Replacing the Operator Panel Follow this procedure to replace the operator panel. As an alternative, you can save time by replacing the entire control assembly. Refer to Replacing the Assembly. Operator Panel Removal WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. Remove the power board. Refer to Power Board Removal in Replacing a Assembly Board. 4. Disconnect the ribbon cable from XP1 on the control board. 5. Close the control-end frame and secure it with the captive screws. 6. See Figure B Using a flat-blade screwdriver and pliers, pull the operator panel away from the control-end frame and guide the ribbon cable through the hole in the control-end frame A Fig. B 2-13 Removing the Operator Panel

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