Document Accelerometer Kit KBTXACTEXT

Transcription

1 Published Document Number: BICJNR01 Specified Date: As-of Date: Access Date: Depth: Detail Custom: n/a Applicability: CJN Language Code: ENG01, Purpose: publication, Format: 1colA Document Accelerometer Kit KBTXACTEXT POST OFFICE BOX 400, KENNER, LOUISIANA , U.S.A.

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3 BICJNR01 (Published) Book specs- Dates: / / Lang: ENG01 Applic: CJN Accelerometer Kit KBTXACTEXT Kit KBTXACTEXT contains the parts needed by a qualified Milnor technician to add an accelerometer to a Milnor 42030V6J model machine. The machine will run with less vibration when the load is not balanced after this kit is installed. NOTICE P1: "Remove electrical power from the machine" means use the necessary safety procedure for your location. In the USA, this is the OSHA lockout/tagout (LOTO) procedure. More local requirements can also apply. 1. Kit Contents The items listed in Table 1 are included in this kit. Table 1: Kit KBTXACTEXT Item Number Part Number Quantity Description 1 EACCLRM7 1 Accelerometer Assembly 2 08BSBADCTV 1 Serial Accelerometer Balance Board with Software 3 03 BC515E 1 Mounting Bracket for 1 Serial Board 4 09C024D37 1 Relay: 4PDT "KH" 110/120V 5 09B323 1 KH Socket, 14-pin DIN Mount 6 03 BV106X 1 DIN Mounting Rail, 6 Inches Long 7 09B002GA 10 IEC Terminal Block 600V Gray 8 10Y75V7JEE 1 Wiring Harness 9 15P Sheetmetal Screw, #8 x 3/8-inch long 10 15P149 3 Selfdrilling Screw, 1/4-inch x 14tpi x 3/4-inch long 11 09B002INSE 1 Terminal Block Insulating Divider 12 08AG4X1 2 Card Edge Guides, 4-inch 13 12P40M6X10 10 Snap-in Labels for Terminal Blocks 14 98R400C15A 1 Pin Extractor Tool 15 WUV7J1B/2300M 1 Machine Controller Software: V_J Models 16 BICJNR01 1 Document: Accelerometer Kit KBTXACTEXT 17 W7V6JEC 1 Schematic: Extract Speed Limit Control 18 W7V6JVPB 1 Schematic: Variable Speed Controller 19 B22FM Document: Formula Worksheet 2. How to Install the New Software This retrofit requires machine controller software version WUV7J1B/2300L or later. The latest available version of the controller software is included. You must configure the machine after you change the software. Use Table 2 to make a record of the configure values.

4 Table 2: Machine Configure Values Language Temperature Control Temperature Units Steam Error Cooldown Error Water Level Units Offset Height Level 1 Height Level 2 Height Level 3 Height Level 4 Height Level 5 Height Level 6 Height Decision Value Decision Value Extra Water Reuse Drain Machine Type Alternate On Time Alternate Off Time Fill Error Time RinSave The factory default formulas will be available after you change the software. You might need to manually program any modified formulas. You can use a serial memory storage device to keep the formula data. The machine controller will require you to manually configure the machine with the new software. 1. Turn the machine on. 2. Do a check of the machine software version. 3. If the software version is earlier than version 2300L, use Table 2 to make a record of how the machine is configured. Also, use the included formula worksheets to make a record of any formulas that are different from the factory default formulas. 4. Turn the machine off. 5. Install the software from this kit in the machine. 6. Turn the machine on. 7. Configure the machine with the data you recorded in Table Turn the machine off before you go to Section 3 How to Install the Kit.

5 .. Accelerometer Kit KBTXACTEXT 3. How to Install the Kit Figure 1: Accelerometer Balance Board Assembly A. Connection from accelerometer B. Mounting bracket C. Connection to machine processor board D. Connection to voltage threshhold jumpers E. Electric power 3.1. Mount the Accelerometer to the Machine Frame 1. Remove the top from the accelerometer case. 2. Locate the accelerometer on the right end of the horizontal frame member behind the machine cylinder. See Figure 2. Figure 2: Location of Accelerometer Accelerometer on Machine Frame A. Accelerometer unit B. Machine shell C. Chemical injection manifold D. Control box

6 . Accelerometer Kit KBTXACTEXT 3. Use a soft marker to transfer the mounting hole locations from the bottom of the accelerometer case to the frame member. CAUTION 1 : Avoid damage to the accelerometer. High g-forces can cause damage to the accelerometer. The accelerometer is more likely to be damaged before it is mounted to the machine frame. Do not submit the accelerometer to sudden g-forces before it is mounted securely on the machine frame. Do not drop or strike the accelerometer. 4. Remove the accelerometer case to a safe location. 5. Drill two 3/16-inch (5 mm) diameter holes in the frame member for the self-tapping bolts (Part number 15P149). 6. Without the accelerometer case in place, start the self-tapping bolts. Remove any metal chips or shavings from the area. 7. Carefully bolt the accelerometer case to the frame member. Make sure that the accelerometer cable exits the case toward the centerline of the machine, on the side opposite the water valves. Check again for metal chips or shavings. Figure 3: Accelerometer Case Internal View A. Mounting bolts (Part number 15P149) B. Connector MTA-83 on balance board 8. Do a check inside the accelerometer case for metal chips and shavings from the mounting bolts Mount the Balance Board 1. Use 3 screws (Item D in Figure 4) to attach the card bracket (Item A) to the rear inside of the control panel. Drill pilot holes for the screws if necessary.

7 . Accelerometer Kit KBTXACTEXT Figure 4: Balance Board Bracket Bracket and Fasteners A. Part number 03 BC515E card bracket (1) B. Plastic card support (2) C. Holes D. Part number 15P100 screws (3 ) 2. Insert the plastic card supports in the top and bottom of the bracket. 3. Slide the balance board (Part number 08BSBADCTV) in the plastic card supports and to the rear of the bracket. 4. As shown in Figure 5, use 2 screws (Part number 15P100) to mount the balance board in the bracket. Figure 5: Balance Board in Bracket

8 3.3. Change the DIN Rails The control panel contains two lengths of DIN rail for mounting components. The left DIN rail is long enough to hold the additional components that this retrofit requires, but you must replace the right one with a longer unit Left Rail: Add the New Components 1. On the left DIN rail, loosen the retaining screw on the right end stop. 2. Move the right end stop to the end of the DIN rail. 3. Move the contactor to the right end stop. 4. Move the 2 fuse holders to the right. 5. Move the 6 green/yellow ground terminal blocks to the right. 6. Move the 7 gray terminal blocks to the right. 7. Attach 3 gray terminal blocks (Part number 09B002GA) in the open space on the DIN rail. 8. Label the new terminal blocks 103, 104, and Slide all components together against the left end stop and tighten the retaining screw on the right end stop Right Rail: Replace the Rail and Add the New Components 1. Remove all components from the existing right DIN rail. Do not remove any wires from the components. 2. Remove the existing DIN rail from the rear of the control panel. 3. Install the 6-inch length of DIN rail (Part number 03 BV106X) in place of the rail you just removed. 4. Replace all components on the new DIN rail. Push these components to the right end of the rail. 5. Attach 7 gray terminal blocks (Part number 09B002GA) to the left of the existing components. 6. Attach the relay base (Part number 09B323) to the DIN rail. The side of the relay base with 8 terminals is the top of the base. 7. Tighten the retaining screws on the 2 end stops. 4. Wire the Circuits Refer to Figure 7 while you do the steps described below. When required, use the pin extractor tool (Part number 98R400C15A) to remove terminal pins from connectors. See Figure 6 for the correct procedure. Be sure to push the extractor tool prongs between the locking tabs and the housing.

9 .. Accelerometer Kit KBTXACTEXT Figure 6: Pin Extractor Tool (Part number 98R400C15A) Procedure 1. Insert tool into housing. 2. Pull wire and terminal out of housing A. Terminal B. Housing C. Slots for extractor tool D. Extractor tool Figure 7: Control Panel Components Inside View A. Machine processor board B. Power supply board C. Ground bar D. Left DIN rail components E. Balance board F. Inverter G. Right DIN rail components H. Relay base for CRATL 1. Use the pin-removal tool (Part number 98R400C15A) to remove pin 3 and wire #103 from the connector on M1 of the machine processor board.

10 2. One end of replacement wire #103B has a pin attached. Insert the pinned end of wire #103B where you just removed wire #103 (connector M1 pin 3). Put the free end of wire #103B through the ferrite bead near the bottom of the machine processor board. 3. Connect the wire #103B you just installed to TBA-103 on the left DIN rail. 4. Use the pin removal tool to remove pin 6 and wire #104 from the connector on M1 of the machine processor board. 5. One end of replacement wire #104B has a pin attached. Insert the pinned end of wire #104B where you just removed wire #104 (connector M1 pin 6). Put the free end of wire #104B through the ferrite bead near the bottom of the machine processor board. 6. Connect the wire #104B you just installed to TBA-104 on the left DIN rail. 7. There is no wire in position 6 on connector MTD at the power supply. Connect wire #105B to MTD-6 and TBA-105 on the left DIN rail. 8. Use a small screwdriver to remove pin 3 from MTD (wire #103) on the power supply board. Remove this wire from the harness. 9. One end of replacement wire #103C has a pin attached. Insert the pinned end of wire #103C where you just removed wire #103 (connector MTD pin 3). 10. Connect the free end of wire #103C to TBA-103 on the left DIN rail. 11. Use a small screwdriver to remove pin 1 from connector MTD (wire #104) on the power supply board. Remove this wire from the harness. 12. One end of replacement wire #104C has a pin attached. Insert the pinned end of wire #104C where you just removed wire #104 (connector MTD pin 1). 13. Connect the free end of wire #104C to TBA-104 on the left DIN rail. Wires #7A, #115A, #115B, and #122A are already installed in the 10-pin connector labelled MTA Connect the free end of wire #7A to the ground bar. 15. Connect the free ends of wires #115A and #115B to the bottom of TBA-115 on the right DIN rail. Wires #118A, #119A, #120A, and #121A are already installed in the 6-pin connector labelled MTA Connect the free end of wire #118A to the top side of TBA-118 on the right DIN rail. 17. Connect the free end of wire #119A to the top side of TBA-119 on the right DIN rail. 18. Connect the free end of wire #120A to the top side of TBA-120 on the right DIN rail. 19. Connect the free end of wire #121A to the top side of TBA-121 on the right DIN rail. 20. Connect TBA-118 to TBA Insert the pinned end of wire #115C into the pin 6 position of the connector on M6 of the machine processor board. 22. Connect the free end of wire #115C to the top side of TBA-115 on the right DIN rail. 23. Connect wire #7C from the bottom side of TBA-7 on the right DIN rail to the ground bar. 24. Connect a wire between TBA-7 and TBA-18. Wires #7B, #103A, #104A, and #105A are already installed in the 6-pin connector labelled MTA82. Plug this connector into socket MTA82 on the balance board. 25. Connect the free end of wire #7B to the bottom side of TBA-7 on the right DIN rail. 26. Connect the free end of wire #103A to the bottom side of TBA-103 on the left DIN rail.

11 27. Connect the free end of wire #104A to the bottom side of TBA-104 on the left DIN rail. 28. Connect the free end of wire #105A to the bottom side of TBA-105 on the left DIN rail. Terminals SC, SN, S7, M3, and M4 are behind the cover at the bottom of the inverter. 29. Connect the free end of wire #122A to terminal M3 on the inverter. 30. Connect wire #7D from the top side of TBA-7 on the right DIN rail to terminal M4 on the inverter. 31. Insert the pinned end of wire #999A into the pin 11 position of the connector on M3 of the machine processor board. 32. Connect the free end of wire #999A to relay CRATL contact A on the right DIN rail. Figure 8: CRATL Terminals 33. Connect the ring terminal end of wire #6A to CRATL contact B. 34. Connect the free end of wire #6A to the bottom side of TBA-6 on the left DIN rail. 35. Remove wire #9 from connection TBV-SN on the inverter. 36. Connect wire #9 to pin 7 on relay CRATL on the right DIN rail. 37. Connect wire #9B from pin 7 on relay CRATL to connection TBV-SN on the inverter. 38. Connect wire #132 between pin 4 on CRATL and TBV-S7 on the inverter. 5. How to Configure the Inverter Check the voltage of your machine, then set the inverter constants according to Figure 9 or Figure 10. The inverter constants given here were current when this document was made. Check with Milnor customer service to find out if these constants have changed. The inverter documentation provided with the machine describes the detailed procedure to use when you set the constants.

12 Figure 9: Inverter Constants for Low Voltage Models ( VAC) with Accelerometer

13 Figure 10: Inverter Constants for High Voltage Models ( VAC) with Accelerometer

14 . Accelerometer Kit KBTXACTEXT 6. About the Standard Accelerometer and ExactXtract Systems [Document BICJUT01] This document uses Simplified Technical English. Learn more at The ExactXtract system is optional on some rigid washer-extractor models with the E-P Plus controller. The system senses the machine vibration while the cylinder speed increases to the set extract speed. Acceleration stops if the vibration goes above the set value before the cylinder turns at the maximum extract speed. The extract step continues at the speed where the vibration went above the set value. If the machine has a balanced load, then the machine vibration will not go above the set value. If the ExactXtract system does not sense too much vibration, the cylinder speed will increase to the maximum speed How to Identify Machines with the ExactXtract Accelerometer System Washer-extractors with the ExactXtract accelerometer system have a green label on a plastic accelerometer box behind the shell (Figure 11). For models 36021V7J, 36026V7J, and 42026V6J, the ExactXtract system increases the maximum extract force to 300 G's. For 30022V6J models, the ExactXtract system increases the maximum extract force to 200 G's. Figure 11: ExactXtract Identification Identification Label Accelerometer Box A. The accelerometer box B. The rear side of the machine shell C. A valve for water All 42030V6J models have the accelerometer box shown in Figure V6J models with no ExactXtract label have a maximum extract force of 215 G's V6J models with ExactXtract have a maximum extract force of 300 G's The Parts of the ExactXtract System 1. Figure 12 shows the accelerometer analog-to-digital converter board. 2. Figure 11 and Figure 13 show the accelerometer used in the ExactXtract system.

15 6.3. How the Accelerometer System Operates A washer-extractor can make vibration during an extract step. This vibration can cause damage to the machine if the extract speed is high and the cylinder is out of balance. The accelerometer system senses the quantity of vibration and holds the extract speed at a speed that will not cause damage. Figure 12: Accelerometer Analog-to-Digital Converter Board 1. The plug at MTA84 on the analog-to-digital balance board connects to jumpers on a terminal block. The jumpers tell the machine controller the maximum voltage from the accelerometer that agrees with the maximum permitted vibration. 2. The machine controller monitors the balance board during all extract steps. A pair of contacts in the inverter close to tell the machine controller that the cylinder is at the slowest extract speed. Machine models 30022V6J, 36021V7J, 36026V7J, and 42026V6J use the model GPD315 inverter or equivalent. For this inverter model, contacts P1-PC close when the cylinder is at the slowest extract speed. Machine model 42030V6J uses the model F7 inverter or equivalent. For this inverter model, contacts M3-M4 close when the cylinder is at the slowest extract speed. 3. The accelerometer puts out more voltage when the machine vibration is large. 4. The voltage from the accelerometer must be in the known range, or the inverter will not make the cylinder go faster. Output light number 0 on the analog-to-digital converter is on. 5. If the voltage from the accelerometer reaches the set maximum value during normal operation, the inverter holds the current speed. Output light number 3 on the analog-to-digital converter is on.

16 .. Accelerometer Kit KBTXACTEXT 6.4. How to Repair the Accelerometer System Figure 13: Inside of Accelerometer Box A. Detail of Jumper J1 B. Increment switch (SW1) C. Select switch (SW2 D. Release tab at connection MTA2 1. Remove the four screws that secure the top on the accelerometer box. 2. At connection MTA2, push the release tab toward the connector and separate the connector. 3. Remove the four screws that hold the accelerometer board in the box. 4. Replace the accelerometer board. 5. With machine power turned off, move the jumper labelled J1 to the position shown in Figure 14. Figure 14: Jumper J1 Program Position

17 . Accelerometer Kit KBTXACTEXT 6. Put the connector on the connection labelled MTA2. 7. Turn on power to the machine. 8. On the board shown in Figure 12, measure the direct current voltage output from the accelerometer. Use an accurate digital multimeter to measure the voltage (Figure 15). Figure 15: Measure Accelerometer Output Voltage 9. Set the value that the multimeter shows 2.49 volts to 2.51 volts DC. To set a lower voltage from the accelerometer, push and release the Increment button (SW1) on the accelerometer board. See Figure 16. To set a higher voltage from the accelerometer, push the Select button (SW2). Hold the Select button down while you push and release the Increment button (SW1). See Figure 16. Note 1: The voltage will change some millivolts each time that you release the Increment button. Continue to push the Increment button until you see a change on the multimeter. Figure 16: How to Identify the Accelerometer Buttons Important Parts A. Increment button SW1 B. Select button SW2 C. Connection MTA2 D. Jumper J1 10. To set the shown value, hold button SW1 down while you remove jumper J1. This action sets the voltage. 11. Move jumper J1 to the position shown in Figure 17.

18 Figure 17: Set Accelerometer Output Voltage 12. Cycle the power to the machine. 13. Verify the accelerometer voltage. If necessary, repeat the procedure from Item 5 in Section How to Test the Accelerometer System CAUTION 3 : You can be electrocuted You need to work on the energized machine to perform this test. 1. Start a formula. 2. Find the accelerometer analog-to-digital converter board (Figure 12) inside the control box. 3. Disconnect the plug from receptacle MTA83 on the converter board. 4. Connect pin 1 in receptacle MTA83 to an electrical ground. 5. If the system is correct, then output K0 will close to tell the microprocessor that the accelerometer signal is out of bounds. Output light number 0 on the analog-to-digital converter is on. 6. Start an extract step. 7. Verify that the inverter stops accelerating at the minimum extract speed. See Table 3. Table 3: Minimum Extract Speeds and Test Weights Model Inverter Frequency at Minimum Extract Speed Test Weight 30022V6J 110 Hertz 5.6 pounds (2.6 kilograms) 36021V7J 167 Hertz 8.0 pounds (3.63 kilograms) 36026V7J 167 Hertz 10.0 pounds (4.54 kilograms) 42026V6J 140 Hertz 13.8 pounds (6.26 kilograms) 42030V6J 110 Hertz 13.8 pounds (6.26 kilograms) 8. Connect the plug to receptacle MTA83 on the converter board. 9. Remove the plug from the MTA84 receptacle. 10. Start an extract step with the machine empty. 11. Check that the inverter accelerates to the maximum speed. 12. Stop the machine. 13. Connect the plug in the MTA84 receptacle. 14. Attach the correct test weight beside a rib about midway between the front and the rear of the basket. See Table Start an extract step.

19 16. Check that the output number 3 turns on and that the inverter does not accelerate more. End of BICJNR01