EMC 10T "CE" Mechanical Upgrade Procedure Kit Part Number: 009866-01 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 EN292-2. This upgrade requires replacing the entire Keyboard Assembly and installing a new programmed IC in the CPU PCB. The estimated time for a trained technician to complete this upgrade is 30 minutes. When the machine upgrade is completed, various labels are placed on the machine, and a new RSA file must be loaded into the EDS computer. Upgrade Kit Parts List: Tools Required: Procedure: 1. Turn the EMC 10 power switch OFF. 1 ea Assembly, Keyboard (009313-01S) 1 ea IC, Programmed, Disk BIOS, Firmware (CE) (009592-01S) 2 ea Warning Label (009113-01) 1 ea Warning Label (009114-01) 1 ea Warning Label (009115-01) 1 set RSA File Disk (2ea) (005917-01) 1 ea Disposable Wrist Grounding Strap (001268-01) 1 ea IC Extractor Tool (010311-01) 1 ea Upgrade Instructions (110286-01) Medium Phillips Screw Driver Static Grounding Strap from kit (or equivalent) IC Extractor Tool 2. Install a static grounding strap between yourself and a good earth ground location on the embroidery peripheral such as the metal base at the bottom rear of the embroidery peripheral (see Figure 1). 3. Remove the current Keyboard Assembly and disconnect the keyboard ribbon cable. 4. Put the new Keyboard Assembly from the upgrade kit in position for installation. Attach static grounding strap here Figure 1 110286-01, Rev. B 1 of 5
Kit Number 009866-01 5. Locate the existing black ground wire attached to the screw in the rear Y-rail retainer block inside the area under where the Keyboard Assembly installs. 6. Attach the green with yellow strip ground wire from the new Keyboard Assembly to the screw identified in the previous step. 7. Attach the keyboard ribbon cable to the keyboard on the new Keyboard Assembly from the upgrade kit. Install the Keyboard Assembly. 8. Place the old Keyboard Assembly into the same packaging in which the new one was shipped. 9. Remove the Electronics cover and set it aside. 10. After removing the electronics cover you must install the static grounding strap between yourself and a good earth ground location inside the electronics opening. Locate the ground wire stud on the Z drive motor mounting bracket. This bracket is located directly behind the rear of the embroidery head. Attach the grounding strap to this ground wire stud (or any other metal which is proven to have chassis electrical ground level). 11.Refer to Figure 2, then remove the ground cable and associated hardware from the middle front of the RFI shielding panel located inside the electronics opening just in front of the 4 axis driver board. 4 Axis Driver PCB CPU PCB RFI Shielding Panel Z Encoder Cable Z Motor Harness 26 pin interface cable card edge mounting screws CONTROLLER SECTION TOP VIEW (Cover Removed) Figure 2 12. Grasp the RFI shielding panel at the top and pull it out of the electronics opening. 13. Disconnect the Z motor harness at the top right hand corner of board 4 axis driver board. 14. Disconnect the Z encoder cable at the top right hand corner of the CPU. 2 of 5 Melco Embroidery Systems
15. Disconnect the network cable, and terminator (if present) from the rear of the peripheral at the CPU card edge mounting bracket. Disconnect the 18 color interface harness from the rear of the peripheral at the 4 axis driver card edge mounting bracket. 16. Disconnect the 26 pin interface cable connected at the bottom left of the 4 axis driver board. 17. Remove the screws and washers at the card edge mounting brackets (near the embroidery head) for the CPU and 4 axis driver board. 18. Grasp the 4 axis driver board at the top corners and gently rock it up and out of its card edge connectors in the bottom backplane board. Do not attempt to remove the 4 axis driver board at this time. 19. Grasp the CPU at the top corners and gently rock it out of its connectors in the backplane board. 20. Remove the CPU from the electronics section, using care not to catch the 26 pin interface ribbon cable on any 4 axis driver board components. 21. Place the CPU on an ESD static bag as a static control mat. 22. If the CPU is part number 005106-01, locate the IC socket labeled U19. If the CPU is part number 007192-01, locate the IC socket labeled U12. 23. With the static grounding strap still installed between yourself and the EMC 10 remove the existing IC using the following method: IC Extractor a. Using the IC extractor tool from the kit (see Figure 3), attach the extractor to the IC. b. While slightly rocking it loose from the socket, lift it out of the socket. Figure 3 24. After the old IC is removed, orient the new IC from the upgrade kit over the empty socket with the end that has the notch facing the same as the other socketed ICs on the PCB (see Figure 4). IC notch U19 or U12 IC 25. Align the IC pins above the associated socket pin locations, then press the IC fully into the socket using care to insert the pins evenly. notch orientation socket Figure 4 110286-01, Rev. B 3 of 5
Kit Number 009866-01 26. Replace the CPU PCB by reversing the steps used to remove it. a) Insure the 26 pin interface cable is securely connected to the bottom left of the CPU PCB. b) Lift the 4 axis driver board slightly, then carefully lower the CPU into the card edge connectors of the backplane board. Make sure the 26 pin interface cable routes under the 4 axis driver board. c) Insert the 4 axis driver board into the card edge connectors of the backplane board. 27. Install the screws and washers at the card edge mounting brackets to secure the CPU PCB and 4 axis driver board. Caution! It is very important to be certain the connector is not offset to one side or the other in the next step. 28. Connect the 26 pin interface cable connection to the bottom left of the 4 axis driver board. 29. Reconnect the Z motor harness at the top right corner of the 4 axis driver board. 30. Reconnect the Z encoder cable at the top right corner of the CPU. 31. Reinstall the network cable, terminator (if present), and 18 color interface harness to the rear of the peripheral at the CPU and 4 axis driver board card edge mounting brackets. 32. Reinstall the RFI shielding panel in front of the 4 axis driver board in the electronics section. 33. Reinstall the ground cable and associated hardware at the middle front of the RFI shielding panel. 34. Replace the electronics cover. 35. Attach the labels per Figures 5 and 6. 36. Install the new RSA file to the EDS computer. 37. The CPU BIOS IC was changed so you must "reconfigure" the EMC 10 embroidery peripheral. Refer to Section 1 of the manual for information regarding the configuration process. The new Peripheral Programs are EMC 10 CE and EMC 10T CE. 38. Carefully package the old Keyboard Assembly in the same packaging the new Keyboard Assembly was shipped in and return it to Melco. Place RA number RA03333-03 on the box for Melco to know that the assembly was replaced by this kit. 4 of 5 Melco Embroidery Systems
Label onto back wall under table insert Figure 5 Figure 6 110286-01, Rev. B 5 of 5