Replacing a Precision Controller Circuit Board

Transcription

1 Instruction heet Replacing a Precision Controller Circuit Board WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. Introduction This section contains instructions for replacing Precision Controller circuit boards in an FM-190 or eries 5600 unit. 2. General Information When performing these procedures, be sure to note the position of all wires and cables prior to their removal from their circuit boards or terminal positions. CAUTION: Risk of equipment damage. Always use an electrostatic discharge (ED) wrist strap when handling any printed circuit board. Failure to observe this caution can result in equipment damage. WARNING: Risk of electrical shock. Never use an electrostatic discharge (ED) wrist strap when working on a unit that is connected to any power source. Disconnect and lock out all power if you are using a wrist strap. Failure to observe this warning can result in equipment damage, personal injury, or death. WARNING: Disconnect equipment from the line voltage. Failure to observe this warning may cause equipment damage, personal injury, or death.

2 2 Precision Controller Circuit Board Power Disconnection Before disconnecting the power, you should power down the unit in an orderly fashion, which includes relieving hydraulic pressure, stopping the motor, purging gas lines, and other procedures that may be unique to the repair task you are performing. Power to your processor is controlled at two locations: the main disconnect switch on the cabinet door and the input power source (such as a wall-mounted breaker box). Many mechanical repairs can be performed after you place the main disconnect switch in the OFF position. Most electrical repairs require that you also disconnect and lock out the input power source that feeds into the processor. 1 2 Fig. 1 Input Power Disconnect on the Unit (Typical) 1. Main disconnect switch in OFF position 2. Input power source in locked out OFF position

3 Precision Controller Circuit Board 3 Replacing Circuit Boards Follow this procedure to replace any of the Proet circuit boards in the electrical cabinet. CAUTION: The static electricity carried in your body can destroy circuit boards, making your processor inoperable. Certain conditions, such as dry weather or walking across a floor, cause static electricity to build up in your body. When you touch a circuit board, the discharge of this electricity can damage or destroy it. The damage will not be apparent until the board is placed in service and is not always immediately noticeable. 1. Transport the board to your workstation in the static-safe shipping container. 2. Disconnect and lock out input power to the processor, including power to all remote input/output devices. 3. Ground yourself by using one or more of the following methods: - Wrap the copper end of a wrist strap around the ground lug at the top of the electrical cabinet, or attach it to some other unpainted metal surface in the cabinet. Wrap the other end of the strap snugly around your wrist. - Use a static-dissipating work mat. - Use conductive tools (only if user is grounded via wrist strap or static-dissipating work mat).

4 4 Precision Controller Circuit Board Replacing Circuit Boards (contd.) WARNING: Risk of electrical shock. Never use an electrical discharge (ED) wrist strap when working on a unit that is connected to any power source. Disconnect and lock out all power if you are using a wrist strap. Failure to observe this warning can result in equipment damage, personal injury, or death. Fig. 2 Using a Wrist trap Open the electrical cabinet door. Refer as needed to the product manual for specific instructions. 5. Remove each wiring harness, ribbon cable, or other connector from the defective board. 6. Remove the mounting hardware that holds the board in place and then remove the board. Keep the hardware to install the new board. 7. Remove the new board from its static-safe container, making sure to handle the board by its edges without touching pins, leads, or circuitry. 8. et all rotary, toggle, and DIP switches on the new board to the correct settings. Refer to the old board for correct settings, or refer to tables 1 through 3 and Figure Install the new board in the unit with the hardware removed earlier in this procedure. CAUTION: Take care not to damage the AUTO TART TIMER LED at the bottom corner of the board during installation. Failure to observe this caution can result in equipment damage.

5 Precision Controller Circuit Board 5 Replacing Circuit Boards (contd.) 10. Plug all wiring harnesses, ribbon cables, or other connectors back into the new board. Refer to the electrical schematic in the product manual as needed. WARNING: Risk of electrical shock. Never use an electrical discharge (ED) wrist strap when working on a unit that is connected to any power source. Disconnect the wrist strap from the unit before restoring power. Failure to observe this warning can result in equipment damage, personal injury, or death. 11. If you used a wrist strap to ground yourself, remove the wrist strap from the ground and your wrist. Avoid touching any pins, leads, or circuitry. 12. Close the electrical cabinet door. 13. Reconnect power and restore the unit to normal operation (refer to the product manual).

6 6 Precision Controller Circuit Board Resetting the Circuit Board After replacing the circuit board, complete the following tasks: Both FM-190 and eries 5600 Units Record the version of software displayed during the power-on self test (lamp test). Re-enter all desired temperature control information (setpoints, overtemperature, etc.). Refer to the product manual. et the clock. Refer to the product manual. FM-190 Units Only Make the following motor speed adjustments: - Potentiometer R52 (speed) on AP2. Refer to Calibrating Motor peed in ection 7 of the product manual. - MIN and MAX potentiometer on AP8 (speed). Refer to Calibrating Motor peed in ection 7 of the product manual. Adjust the current limit potentiometer on AP5 or AP8. Refer to Adjusting Current Limits in ection 7 of the product manual. Adjust the IR COMP potentiometer on AP8. Refer to Adjusting IR Compensation in ection 7 of the product manual.

7 Precision Controller Circuit Board 7 eries 5600 Units Only Calibrate the load cell. 1. Power up the unit as described in the product manual. 2. Note the software version displayed during the self-test. 3. Complete the appropriate procedure listed below. oftware Version Equal to or Higher than 31 Note: This action also stores a default value for empty. If a more accurate setting is desired, use the procedure for software version less than 31 to set both the full and the empty points. Less than 31 Action 1. Fill the unit with adhesive (approximately 1.5 drums or 272 kg [600 lb]). 2. lide switch 14 to the CAL (up) position, and while holding it in this position, depress and release the 1 reset push button. 3. When the green LED D4 (ACK) goes out, release 14. This will store the calibration point of a full unit and set empty at a predetermined level below full. 1. Complete the previous procedure for setting the full point. 2. Remove all adhesive from the unit. 3. lide switch 14 to the empty (down) position, and while holding it in this position, depress and release the 1 reset push button. 4. When the green LED D4 (ACK) goes out, release 14. This will store the calibration point for empty.

8 8 Precision Controller Circuit Board XP4 J6 J7 XP16 XP XP8 XP XP5 J1 1 D4 XP2 XP Fig. 3 witch Locations on AP2 (Main Circuit Board)

9 Precision Controller Circuit Board 9 Position 5600 Factory Default Table 1 Factory Default DIP witch ettings 2 DIP witch FM-190 Factory Default 1 ON ON equential start-up Description 2 OFF ON 5600: Drum mode FM-190: FM-190 unit 3 OFF (English language control panel) ON (non-english language control panel) 4 OFF (non-demand melt unit) ON (demand melt unit) OFF Off: Fahrenheit ON: Celsius 5600: ON enables Demand melt control FM-190: FM-190 unit 3 DIP witch 1 ON ON Watchdog enabled 2 OFF (non-pur unit) OFF ON (PUR unit) 3 OFF OFF Maximum setpoint temperature 4 OFF OFF 5600: OFF - Load cell-equipped unit ON - Discrete level sense unit FM-190: FM-190 unit 5 OFF OFF Reserved 6 OFF OFF Nickel RTD 7 OFF (single-manifold unit) ON (dual-manifold unit) OFF 5600: Number of manifolds FM-190: FM-190 unit 8 OFF OFF OFF (motor runs continuously) ON (motor runs only when trigger active) 9 OFF OFF Reserved 10 OFF ON OFF for 5600 units ON for all other unit types 11 OFF (non-pur unit) ON (PUR unit) OFF OFF: non-pur units PN: PUR units 12 OFF OFF OFF: save temperature settings ON: reset temperatures to factory defaults

10 10 Precision Controller Circuit Board witch 5600 Factory Default Table 2 Factory Default Rotary witch ettings 2 DIP witch FM-190 Factory Default Description 4 10 or A (120 minutes) 1 (12 minutes) Ready Interlock Delay 5 5 (60 minutes) 15 or F (disabled) Auto tandby Timeout 6 1(6 Celsius) 1(6 Celsius) Temperature Band 7 3 (60 minutes) 9 (disabled) Auto hutdown Timeout 8 0(19 Celsius) 0(19 Celsius) Low Temperature hutoff 10 5 (30 minutes) : New drum heat time FM-190: Not used 15 Table 3 Factory Default Toggle witch etting Factory default: Normal (middle position; other two positions not used) Original copyright date Nordson and the Nordson logo are registered trademarks of Nordson Corporation.