AutoScan to MultiScan Replacement Kit

Transcription

1 Instruction Sheet P/N AutoScan to MultiScan Replacement Kit 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 Series 3000 hot melt units that have an AutoScan control system may be field-retrofitted with a MultiScan control system. This service kit contains the parts and instructions necessary for replacing an AutoScan control system with a MultiScan control system. 2. AutoScan to MultiScan Replacement Use the parts from the service kit and the following instructions to replace an AutoScan control system with a MultiScan control system. Refer to Parts for a list of the parts contained in the service kit. Preparing for Replacement Follow this procedure to ensure that personnel and equipment are protected from electrical hazards. WARNING: Risk of personal injury or death. Disconnect equipment from all power sources before servicing. 1. Turn off the unit; then disconnect and lock out electrical power to the unit. 2. See Figure 1. Remove the electrical cabinet lid (1). 3. Loosen the nuts (3) and captive screws (2) that secure the control-end frame (4) and slide the frame out.

2 2 AutoScan to MultiScan Replacement Kit Preparing for Replacement (contd) 1 2 Fig. 1 Opening the Electrical Cabinet 1. Electrical cabinet lid 2. Captive screw A 3. Nut 4. Control-end frame (slides out)

3 AutoScan to MultiScan Replacement Kit 3 Removing the AutoScan Control System Follow this procedure to remove the AutoScan control-end frame. 1. Label or note existing wire connections for later reference. 2. See Figure 2. Disconnect the following ribbon cables and power harness from the AutoScan control-end frame: Tank ribbon cable at XP4 (1) Hose/gun power module ribbon cables at XP5, XP6, and XP7 (2) Power harness at XP8 (3) Motor control ribbon cable at J2 (4) Pressure control ribbon cable at J3 (5) A Fig. 2 Disconnecting the Ribbon Cables and Power Harness 1. Tank ribbon cable at XP4 4. Motor control ribbon cable at J2 2. Hose/gun ribbon cables at XP5, 5. Pressure control ribbon cable at XP6, and XP7 J3 3. Power harness at XP8

4 4 AutoScan to MultiScan Replacement Kit Removing the AutoScan Control System (contd) 3. See Figure 3. Disconnect the terminal block plugs (2) from the AutoScan input/output (I/O) board (1). Do not remove the wiring from the plugs A Fig. 3 Disconnecting the I/O Board Terminal Block Plugs 1. I/O board 2. Terminal block plug

5 AutoScan to MultiScan Replacement Kit 5 4. See Figure 4. Remove the three screws that secure the AutoScan control-end frame to the unit and remove the frame from the unit. Save the screws for later use A Fig. 4 Removing the AutoScan Control-End Frame Installing the MultiScan I/O Board Follow this procedure to install the MultiScan I/O board. CAUTION: Risk of equipment damage. To dissipate static electricity, wear a wrist strap when installing or handling any printed circuit board. 1. Put on the wrist strap from the service kit and connect the copper end securely to a ground lug on a properly grounded unit.

6 6 AutoScan to MultiScan Replacement Kit Installing the MultiScan I/O Board (contd) 2. See Figure 5. Mount the MultiScan I/O board-and-bracket assembly (2) on the center frame (1) using the two screws and washers (3) from the kit. NOTE: Do not remove the ribbon cable, ferrites, or ground wire preassembled on the I/O board-and-bracket assembly. 3. Remove the wrist strap from the ground lug and your wrist. Avoid touching any pins, leads, or circuitry A Fig. 5 MultiScan I/O Board 1. Center frame 2. I/O board-and-bracket assembly 3. Screw and washer 4. Ground wire 4. Install the I/O board cardboard shield on the underside of the electrical cabinet lid using the two blind rivets.

7 AutoScan to MultiScan Replacement Kit 7 Connecting Ground Wires Follow this procedure to build up the slide tray ground stud and to connect the MultiScan control system ground wires. 1. See Figure 5. Connect the I/O board ground wire (4) to the main ground stud next to the center frame. 2. Connect one end of ground wire G9 to the main ground stud next to the center frame. 3. Make sure the encoder cable drain wire is connected to the main ground stud next to the center frame. 4. See Figure 6. Build up the ground stud on the slide tray as follows: a. Remove the adhesive backing from the ground tag (5) and place the ground tag over the ground stud (7), sticking it to the slide tray (6). b. Secure the lug (3) to the ground stud with the nut (1) and lock washer (2). 5. Connect ground wire G9 (4) from the main ground stud to the slide tray ground stud.

8 8 AutoScan to MultiScan Replacement Kit Connecting Ground Wires (contd) Fig. 6 Building up the Slide Tray Ground Stud 1. Nut 4. Ground wire G9 2. Lock washer 3. Lug 5. Ground tag 6. Slide tray 7. Ground stud 8. Ground wire G A

9 AutoScan to MultiScan Replacement Kit 9 Making the MultiScan Control System Connections Follow this procedure to install the control-end frame and make the MultiScan control system connections. The MultiScan control-end frame includes the door assembly; the main control, motor control, display, and hose/gun boards; and the control panels. Figure 7 shows the location of each board. 1. See Figure 7. Connect the motor control ribbon cable (8) to J2 on the motor control board (7). 2. Connect the pressure control ribbon cable (9) to J3 on the motor control board. 3. Secure the MultiScan control-end frame to the base with the screws you removed earlier. 4. Connect ground wire G11 from the main control board to the slide tray ground stud. Figure 6 shows how G11 connects to the slide tray ground stud. 5. Connect the power harness (6) to XP8 on the main control board (5). 6. Connect the hose/gun ribbon cable (1) from each hose/gun power module to the J1 connector on each hose/gun control board (2). You may need to loosen the hose/gun boards to make the connection. 7. Connect the tank ribbon cable (4) to J2 on the display board (3).

10 10 AutoScan to MultiScan Replacement Kit Making the MultiScan Control System Connections (contd) A Fig. 7 MultiScan Control System Connections (shown disassembled for clarity) 1. Hose/gun ribbon cable (1 of 3) 2. Hose/gun board (1 of 3) 3. Display board 4. Tank ribbon cable 5. Main control board 6. Power harness 7. Motor control board 8. Motor control ribbon cable 9. Pressure control ribbon cable

11 AutoScan to MultiScan Replacement Kit 11 Making the I/O Board Connections Follow this procedure to connect the old AutoScan I/O board wiring to the new MultiScan I/O board. Your AutoScan I/O connections may vary significantly from the connections described in this instruction sheet. If you have trouble making the transition between the AutoScan and MultiScan I/O board connections, contact your Nordson representative for assistance. 1. Connect the I/O board ribbon cable to XP6 on the main control board. 2. Remove the AutoScan I/O board wires, one at a time, from the XT1 terminal block plugs and connect them to the MultiScan I/O board and control system as shown in Table 1. AutoScan I/O Board XT1 Terminal Block Position Table 1 I/O Board Connections for AutoScan to MultiScan Replacement On most AutoScan I/O boards, this position was Corresponding MultiScan I/O Board Position 1 and 2 Not used I/O board, TB1, positions 3 and 4 (setback active output) 3 and 4 Not used I/O board, TB2, positions 9 and 10 (auto mode output) 5 and 6 Not used I/O board, TB2, positions 1 and 2 (motor on output) 7 and 8 Used I/O board, TB2, positions 5 and 6 (drive alarm output) 9 and 10 Used I/O board, TB1, positions 11 and 12 (temperature warning output) 11 (common) Used I/O board, TB1 positions 6 and 10, TB2 positions 4, 8 and 12, and all hose/gun disable terminal blocks, positions 1 and 3 12 and 13 Used Hose/gun 1 disable input terminal block, position 2 14 and 15 Used Hose/gun 2 disable input terminal block, position 4 16 and 17 Used Hose/gun 3 disable input terminal block, position 2 18 Used I/O board, TB1, position 5 (remote setback input) 19 Not used I/O board, TB1, position 9 (remote shutdown input) Continued on next page

12 12 AutoScan to MultiScan Replacement Kit AutoScan I/O Board XT1 Terminal Block Position On most AutoScan I/O boards, this position was Corresponding MultiScan I/O Board Position 20 Not used I/O board, TB2, position 11 (manual mode input) 21 and 22 Not used I/O board, TB1, positions 7 and 8 (power on output) 23 and 24 Used Main control board, XT1, positions 1 and 2 (ready output) 25 and 26 Used Main control board, XT1, positions 3 and 4 (fault output) 27 through 30 Not applicable You should not have any wires connected to these positions. 31 (common) Used I/O board, TB1 positions 6 and 10, TB2 positions 4, 8 and 12, and all hose/gun disable terminal blocks, positions 1 and 3 32 and 33 Used Hose/gun 4 disable input terminal block, position 4 34 and 35 Used Hose/gun 5 disable input terminal block, position 2 36 and 37 Used Hose/gun 6 disable input terminal block, position 4 38 Used Any wire connected to this position cannot be used. 39 (see Note A) Used I/O board, TB2, position 3 (remote motor start input) 40 (see Note A) Not used I/O board, TB2, position 7 (remote motor stop input) NOTE A: Until the parent machine can be reprogrammed, the motor will start normally but will have to be stopped manually by placing the motor start/stop switch in the off position. The motor start/stop switch must then be placed in the run position for the motor to start again remotely.

13 AutoScan to MultiScan Replacement Kit 13 Installing Ferrites Install ferrites on the MultiScan control system wiring as directed in the following tables. Each table has a corresponding illustration. The tables are organized by the type of ferrite to be installed. Refer to Parts for the part number of each ferrite. Table 2 Round Ferrite (1.41-in.) Installation Quantity Installation Location Installation Instructions See Figure 3 Customer s incoming power cable or wiring (2) Install the ferrites (1) as close to the unit base (3) as possible ACTUAL SIZE Fig. 8 Round Ferrite (1.41-in.) Installation 1. Ferrite 2. Incoming power cable/wiring 3. Unit base A

14 14 AutoScan to MultiScan Replacement Kit Installing Ferrites (contd) Table 3 Rectangular Ferrite (24-Position) Installation Quantity Installation Location Installation Instructions See Figure 6 Ribbon cables (3) between hose/gun power modules and hose/gun boards 1 Ribbon cable (4) between J2 on the display board and J1 on the tank power module Install two ferrites (1) on each ribbon cable. Use electrical tape (2) to keep the ferrites from moving. Install the ferrite as close to the display board as possible. 9A 9B A B ACTUAL SIZE A Fig. 9 Rectangular (24-Position) Ferrite Installation 1. Ferrite 2. Electrical tape 3. Hose/gun ribbon cable (1 of 3) 4. Tank ribbon cable

15 AutoScan to MultiScan Replacement Kit 15 Table 4 Square Ferrite (7-mm diameter) Installation Quantity Installation Location Installation Instructions See Figure 6 Wiring for each hose/gun disable input 1 Voltage code 1 units only: wires (4D and 6D) connected to J2, positions 3 and 9, on the motor control interface board 1 Voltage code 2 units only: wires (5H and 6D) connected to J2, positions 3 and 9, on the motor control interface board 1 Encoder wires to TB1, positions 1, 2, and 3, on the motor control interface board 2 Tank resistance temperature detector (RTD) wires (11 and 12) 4 Wire 19 between J2 on the motor control interface board and I1 on the motor control board 5 Customer s incoming parent machine interlock/fault wiring to XT1 on the main control board Install the ferrites as close to the knockout as possible. Install the ferrite as close to the motor control interface board as possible. Install the ferrite as close to the motor control interface board as possible. Install the ferrite as close to the knockout as possible; do not include the drain wire (2) that extends from the jacketed encoder wiring (1). Install the ferrites as close to the center frame as possible. Cut the wire ties to gain access to wire 19. Install the ferrites as close to the knockout as possible. 10A 10A 10A 10B 10C 10D 10E 2 A 1 B C D E ACTUAL SIZE Fig. 10 Square Ferrite (7-mm diameter) Installation 1. Jacketed encoder wiring 2. Drain wire A

16 16 AutoScan to MultiScan Replacement Kit Installing Ferrites (contd) Table 5 Cable Clamp Ferrite Installation Quantity Installation Location Installation Instructions See Figure 1 Tank thermostat wires (7B and 13E) and tank heater wires (10 and 15) Install the ferrite as close to the center frame as possible. 6 Each hose/gun wire group Cut the wire ties if necessary. Install the ferrites as close to center frame as possible. 5 Voltage code 1 units only: customer s incoming power cable or wiring 6 Voltage code 2 units only: Customer s incoming power cable or wiring Install one ferrite on each wire (except the ground wire) to TB1 (3 wires); then install two ferrites on all wires (except the ground wire) to TB1. Install one ferrite on each wire (except the ground wire) to TB1 (4 wires); then install two ferrites on all wires (except the ground wire) to TB1. 5 Customer s wiring to the I/O board Install the ferrites as close to the knockout as possible. 11A 11B 11C 11C 11D A B ACTUAL SIZE C D Fig. 11 Cable Clamp Ferrite Installation A

17 AutoScan to MultiScan Replacement Kit 17 Restoring the System to Normal Operation Follow this procedure to ensure that personnel and equipment are protected from electrical hazards. WARNING: Risk of personal injury or death. Remove the wrist strap before restoring electrical power. 1. If you have not already done so, remove the wrist strap from the ground lug and your wrist. Avoid touching any pins, leads, or circuitry. 2. Slide the control-end frame into the unit and tighten the securing nuts and captive screws. 3. Reinstall the electrical cabinet lid. 4. Refer to the unit manual included in the kit for information on operating the MultiScan control system.

18 18 AutoScan to MultiScan Replacement Kit 3. Parts To order parts, contact the Nordson Customer Service Center or your local Nordson representative. Use the following parts list to describe and locate parts correctly. Item Part Description Quantity Note Service kit, MultiScan for AutoScan Frame, tank, hose/gun disable, 6-hose, motor and pressure control Input/output board, MultiScan, with shield Screw, hi-lo, pan-head, recessed, cut, 6-19 x 0.50 in. 2 A Washer, flat, E, in. x in. x in. 2 A NS Shield, I/O board, electric cover (cardboard) 1 NS Rivet, blind, 3 / 32 x in. 2 B NS Suppressor, ferrite, 7 mm diameter 19 NS Suppressor, ferrite, 24-position 7 NS Inductor, bead (ferrite), 1.41 in. diameter 3 NS Suppressor, cable clamp, ferrite 18 NS Strap, ground, wrist, anti-static 1 NS Wire, ground, 17.5 in., G9 1 NS Tag, ground 1 C NS Washer, lock, M, split, M4 1 C NS Lug, 45, double, in. 1 C NS Nut, hex, M4 1 C NOTE A: Use these screws and washers to secure the I/O board to the center frame bracket. B: Use these rivets to secure the I/O board cardboard shield to the electrical cabinet lid. C: Use these parts to build up the slide tray ground stud. NS: Not Shown

19 AutoScan to MultiScan Replacement Kit Fig. 12 AutoScan to MultiScan Replacement Kit Parts A Original copyright date MultiScan and the Nordson logo are registered trademarks of Nordson Corporation. AutoScan is a trademark of Nordson Corporation.

20 20 AutoScan to MultiScan Replacement Kit