EMC 10/4 "CE" Mechanical Upgrade Procedure

Transcription

1 EMC 10/4 "CE" Mechanical Upgrade Procedure Kit Part Number: This procedure upgrades a non-ce compliant machine to the mechanical requirements of a CE compliant machine. Properly upgraded machines comply with the CE Mechanical Directives EN292-1 and EN This upgrade requires replacing the Trimmer Interface PCB, installing a new programmed IC in the CPU PCB, replacing several new key caps on the keyboard, and installing new Start/Stop panels and associated cables. Cable connections to the Backplane PCB in the EMI box require precise pin insertions into existing cable connectors. It is recommended that a Melco-trained service technician perform this procedure. The estimated time for a trained technician to complete this upgrade is 90 minutes. When the machine upgrade is completed, various labels are placed on the machine, a new RSA file must be loaded into the EDS computer, and the old Trimmer Interface PCB must be returned to Melco. Upgrade Kit Parts List: Tools Required: 2 ea Assembly, Start/Stop Panels ( S) 1 ea Keycap, Menu ( ) 1 ea Keycap, Alt ( ) 1 ea Keycap, Jog ( ) 1 ea Keycap, Color Change ( ) 1 ea Keycap, Fast/Slow ( ) 1 ea Keycap, Enter ( ) 1 ea PCB, Trimmer Interface ( ) 2 ea Cables, E-Stop ( ) 1 ea Cable, E-Stop, CE Upgrade ( ) 1 ea IC, Programmed, Disk BIOS, Firmware (CE) ( S) 10 ea Wire Ties ( ) 10 ea Bases, Wire Tie ( ) 1 ea Upgrade Instructions ( ) 2 ea Warning Label ( ) 2 ea Warning Label ( ) 2 ea Warning Label ( ) 2 ea Warning Label ( ) 1 ea RSA file disk ( ) 1 ea RSA file disk ( ) 1 set Disk Drive Option Disks (2ea) ( ) 1 ea Button Head Cap Screw ( ) 2 ea Cable Clamp ( ) 1 set Star Washer ( ) Standard Technician s Tool Kit , Rev. D 1 of 8

2 Kit Number Procedure: 1. Turn the EMC 10/4 power switch OFF. 2. Remove rear covers #4 and #3. Refer to Figure 1. Cover #1 Cover #2 Cover #3 Cover #4 Cover #5 EMC 10/4 REAR COVERS AS VIEWED FROM THE REAR rear screws rear screws Figure 1 3. Remove the screws holding the lower front covers (between needle cases) as shown in Figure Pull down slightly on the covers to remove the pin in the top of the covers from the grommet in the bottom of the upper front covers (between the tensioner brackets), then carefully remove the lower front covers from the area. 5. Remove the two blank upper front covers. rear tensioner cover.a.b.b.b.a.b.b.b.e.d.d head.d.d.d.d head head.e #4.d.d #3.d.d #2.d.d.e.c.c.c.c.c.c head #1..f.b.f.f Left end tensioner cover upper front cover (2 ea) Keyboard and cover lower front cover (3 ea) right end tensioner cover Figure 2 2 of 8 Melco Embroidery Systems

3 EMC 10/4 "CE" Mechanical Upgrade 6. Locate the 2 Start/Stop panels from the upgrade kit. 7. Locate the 2 new E-Stop cables (p/n ) from the upgrade kit and connect them to the 2 Start/Stop panels. 8. Using the same hardware that held the blank covers, install the 2 Start/Stop Panels from the kit at the locations where you removed the upper front covers. 9. Direct the cable from the rear of the Start/Stop panel between heads #1 & #2 toward head #2 and down through the opening in the bottom of the cover behind the tensioner of head # Direct the cable from the rear of the Start/Stop panel between heads #3 & #4 toward head #3 and down through the opening in the bottom of the cover behind the tensioner of head # Keeping enough slack to let the machine perform the full color change range without tugging on the cables, secure the cables to heads #2 and #3 with the cable clamps from the kit as follows: a. Use the existing hardware that connects the diode assembly to head #2 to mount one cable clamp to head #2 as shown in Figure 3. b. Refer to Figure 3 and secure the other cable clamp to head #3 using the star washer and button head cap screw from the kit as shown. e-stop cable existing hardware cable clamp e-stop cable cable clamp button head cap screw star washer 12. Route one cable along the right side of head #2 to the rear of the head. 13. Route the other cable along the left side of head #3 to the rear of the head. 14. Direct both cables into the rear of the machine behind the heads, and using the wire ties and bases provided in the upgrade kit, tie the cables to the sides of the heads. 15. Remove the EMI box cover and set it aside. Figure Install a static grounding strap between yourself and a good earth ground location on the EMC 10/4, such as the EMI box housing. (The machine power cord should be plugged in, but the machine power switch should be turned OFF.) , Rev. D 3 of 8

4 Kit Number Remove the interface cables connected to the CPU PCB at the rear of the EMC 10/4. Also remove any additional logic cables that may be connected to the CPU PCB top edge. 18. Remove the various cables from the connectors of the Trimmer Interface PCB. 19. Remove the screw and washer attaching the CPU PCB bracket to the EMI box side (refer to Figure 4). interface cables PCB attaching screws and washers Backplane PCB Top view of EMI Box with the 2 upright PCBs installed and most cables removed. CPU PCB Trimmer Interface Board Figure 4 REAR OF MACHINE 20. Remove the screw and washer attaching the Trimmer Interface PCB bracket to the EMI box side (refer to Figure 4). 21. Carefully remove the CPU PCB and the Trimmer Interface PCB as an assembly. (There is an unseen ribbon cable connecting the two boards together.) 22. Using an ESD static bag as a mat to place the PCBs on, remove the ribbon cable connecting the CPU PCB to the Trimmer Interface PCB. 23. Locate the IC on the CPU PCB labeled U19, and with the static grounding strap still installed between yourself and the EMC 10/4 remove the IC from the socket. IC notch U With the new IC from the kit, align the notch in IC the end of the IC with the notch in the end of the empty socket as shown in Figure Insert the IC and continue to allow the two PCBs to set on the ESD static bag for later installation. notch orientation socket Figure 5 4 of 8 Melco Embroidery Systems

5 EMC 10/4 "CE" Mechanical Upgrade The backplane PCB sits on bottom of the EMI box, and contains the connectors where both the CPU and trimmer interface PCBs are inserted. Additionally several other connectors are located on the backplane PCB. 26. Refer to Figure 6 and locate connectors J9 and J10 on the backplane PCB. Additionally identify the pin number locations at each of the 2 connectors. J10, pin 4 J10, pin 14 J10, pin 16 J9, pin 2 J9, pin 3 J9, pin 9 J9, pin 10 J10 J9 Figure Locate the new E-Stop Upgrade cable (p/n ) from the upgrade kit. 28. Refer to Figures 6 and 7 and push the loose wire pins from cable into the proper pin locations of the 2 cable connectors going into the backplane PCB connectors J9 & J10 as follows: NOTE: Ensure to insert the pins with the tabs on the pins into the matching slots in the connectors as illustrated in Figure 7. a) Push the pin with a single black wire marked (T1) into the backplane PCB connector J10, pin 16. b) Push the pin with a single black wire marked (T6) into the backplane PCB connector J10, pin 14. c) Push the pin with 2 red wires marked (T2) into the backplane PCB connector J9, pin 9. d) Push the pin with 2 black wires marked (T3) into the backplane PCB connector J9, pin 3. e) Push the pin with 2 white wires marked (T4) into the backplane PCB connector J9, pin 2. f) Push the pin with a single black wire marked (T5) into the backplane PCB connector J10, pin 4. g) Push the pin with a single green wire marked (T7) into the backplane PCB connector J9, pin , Rev. D 5 of 8

6 Kit Number EMC 10/4 Backplane PCB Connector-Pin J J J J Cable loose wire pins wire tag ID number (T1) (T6) (T2) (T3) Cable wires Black from P1-1 Black from P2-1 Red from P1-2 Red from P2-2 Black from P1-3 Black from P2-3 connector pin J J J (T4) (T5) (T7) White from P1-4 White from P2-4 Black from P1-6 Green from P2-5 NOTE: Tabs on the pins go into matching slots in the connector heatshrink --- Green from P1-5 Black from P2-6 Figure Route the two connector ends of the E-Stop upgrade cable out of the EMI box toward the cable ends of the 2 new E-Stop panel cables that were earlier routed to the rear areas of heads #2 and # Route the new cabling from the rear of heads #2 and #3 toward the E-Stop upgrade cable ends coming from the EMI box and mate the connectors. 31. Check your work in this area and make certain the cables do not interfere with any mechanical movements. 32. Reconnect the small ribbon jumper cable between the new Trimmer Interface PCB from the upgrade kit and the CPU PCB. 33. Reinstall the CPU PCB (with the new IC) and the upgrade kit Trimmer Interface PCB. 34. Reconnect interface cables and the other logic cables to the same PCBs/connectors from which they were removed. Caution! Be certain not to allow any wires and cables to be pinched when reinstalling screws and covers in the following steps. 35. Reinstall the attaching screws and washers on the CPU and Trimmer Interface PCBs. 36. Reinstall the EMI cover and the two rear machine covers. 6 of 8 Melco Embroidery Systems

7 EMC 10/4 "CE" Mechanical Upgrade 37. Transfer the new key caps onto the keyboard referring to Figure 8 and using the following guidelines: a) Replace the old Menu key cap with the new key cap. b) Replace the old Alt key cap with the new key cap. c) Replace the old Fast/Slow key cap with the new key cap (This key position is now Jog). d) Replace the old Enter key cap with the new key cap (This key position is now Color Change). e) Replace the old Stop key cap with the new key cap (This key position is now Fast/Slow). f) Replace the old Start key cap with the new key cap (This key position is now Enter). 38. Reinstall the front covers and any other covers removed during the upgrade. 39. Attach the labels per Figure Install the new RSA file to the EDS computer. 41. The CPU BIOS IC was changed so you must "reconfigure" the EMC 10/4 embroidery peripheral. Refer to Section 1 of the manual for information regarding the configuration process. The new Peripheral Programs are EMC 10/4 CE and EMC 10/4T CE. Figure Carefully package the old Trimmer Interface PCB in the same ESD static bag that the new one was shipped in and return it to Melco. Place RA number RA on the box for Melco to know that the board was replaced by this kit , Rev. D 7 of 8

8 Kit Number Figure 9 8 of 8 Melco Embroidery Systems