Sprint EPROM and Controller Replacement Instructions Page 1 EPROM Replacement Instructions for Sprint ; Controller Assembly Service Kit P/N 157 151 and Replacement Instructions for Sprint Controller Assembly Service Kit P/N 151 486 1. Introduction This publication contains instructions for the following two service kits: Sprint Controller IReplacement Kit, which contains one complete Sprint Controller Assembly, P/N 101 940. Controller Assembly Reference Drawing: P/N 154 004 Sprint Controller EPROM Replacement Kit, which contains: Six EPROMs, labeled1 as follows: MEDIA NUMBER l MEDIA NUMBER 2 MEDIA NUMBER 3 MEDIA NUMBER 4 MEDIA NUMBER 5 MEDIA NUMBER 7 One Electrostatic Discharge (ESD) wrist strap, One EPROM insertion tool, and One EPROM extraction tool Controller Assembly Reference Drawings: P/N 151 491 and P/N 125 214 Tools Required The tools required to install these kits are: l/4-in. open-end vvrench small flathead screwdriver CQ No&on Corporation 1994 4&212 Issued 2l94 P/N 108 711A
Page 2 Sprint EPROM and Controller Replacement Instructions 2. Safety Precautions Before performing either replacement procedure, remove all power from the system and lock out external power to the electrical cabinet. ; WARNING: Failure to lock out external power to the electrical cabinet may present a serious shock hazard. The input terminal block remains energized with the power OFF. CAUTION: Static electricity can damage EPROMs and boards. Before handling or transporting any board or EPROM, put on the grounded electrostatic discharge (ESD) wrist strap supplied with this kit. For maximum protection, work on a grounded ESD surface. 3. Recording Your Controller User Settings If when you replace the existing controller or option board EPROMs, the user settings will be lost ancl reset to the Nordson defaults. Therefore, after replacing either the controller or the EPROMs, you will need to have available the Table 4.1 Default Settings for OmniScan Control System from section 4 of your applicator system manual so that you can re-enter this data. These are the pages where you entered data on your initial setup. Note: If you did not previously record your user settings, you must go through the menus to get this information. This time make sure that you record these settings for future use. Refer to the part of these instructions that apply to your kit. 4. Replacing the Controller Assembly The following two procedures describe how to remove the existing controller assembly and install a new controller assembly. If you are just replacing EPROMs in an existing controller, go to the EPROM Replacement procedure described later in this document. Once the new assembly is installed, you are then referred to a procedure describing how to check installation and configure software. Removing the Old Con troller Assembly 1. Move the melter circuit breaker to the OFF position. 2. Disconnect and lock out the input power to the melter main circuit breaker. Refer to Figure 1. Figure 1. Locking out powor PIN 108 711A 46-212 8 Nordson Corporation 1994 Issued 2fQ4
Sprint EPROM and Controller Replacement Instructions Page 3 Removing the Old Controller Assembly (contd.) 3. Open the melter cabinet door and locate the controller. A t CAUTION: Wear the grounded wrist strap during this procedure. F:ailure to wear the grounded wrist strap may result in damage to the boards. 4. Ground the wrist strap and put it on your wrist. 5. Refer to Figure 2 and loosen the two lower screws (1) at the bottom sides of the protective cover (3). Figure 2. Removing protective cover 1. Lower Screws 2. Upper Screws 3. Protective Cover 6. While holding the protective cover (3), remove the two upper screws (2), and pull the cover off, clearing all boards. Then set it aside until you install the new controller assembly. 0 Nordson Corporation 1994 46-212 P/N 108 711A All Riqhts Reserved Issued 2l94
Page 4 Sprint EPROM and Con troller Replacement Instructions Removing the Old Controller Assembly (contd.) 7. Kefer to Figure 3 and diisconnect all external cables and connectors from the controller. ; Figure 3. Disconnecting controller s external cables and connectors 8. Move to the front of the cabinet door and, while supporting the entire controller assembly, remove the six screws that secure the controller s front panel to the door. 9. With all the screws removed, tilt the assembly slightly forward so that you can grasp the front panel, then carefully remove it from the cabinet door. IO. Set the entire assembly aside and, when time permits, contact your NordsonB representative or customer service for return procedures. 11. This completes removal of the old controller assembly. Proceed with lnsfalling the New Controller Assembly described next. Ins tailing the New Con troller Assembly 1. Remove the new controller from its packing material and inspect it for loose or broken items, etc. If damage is evident, contact your NordsonB representative or customer service before proceeding. 2. Move to the front of the cabinet door and, while supporting the entire controller assembly, insert the rear portion through the door opening. While holding the front panel against the supporting edge, install the six screws that secure the controller s front panel to the door. 3. Move to the rear of the cabinet door and connect all external cables and connectors to the controller (figure 3) that were removed from the original assembly. 4. Mount the old protective cover onto the new controller assembly as shown in figure 2 using four screws. 5. This completes installation of the new controller assembly. Proceed with Checking Installation and Configuring Software described later in this document. P/N 108 711A 46-212 Issued 2/94 Q Nordson Corporation 1994
Sprint EPROM and Con troller Replacement Instructions Page 5 5. EPROM Replacement If you are installing a complete Sprint Controller Assembly (Kit P/N 151 486), skip these instructions. This procedure is only for replacing the EPROMs on boards of an existing controller, and involves: gaining access to the controller boards, removing the boardls from the controller, replacing the board EPROMs, and reinstalling the boalrds Gaining Access to Con troller Boards 1. Move the melter circuit breaker to the OFF position. 2. Disconnect and lock out the input power to the melter main circuit breaker. Refer to Figure 4. Figure 4. Locking out power 3. Open the melter cabinet door and locate the controller. A t CAUTION: Wear the grounded wrist strap during this procedure. Failure to wear the grounded wrist strap may result in damage to the boards. 4. Ground the wrist strap and put it on your wrist. 6 Nordson Corporation 1994 All Rinhts Resewed 46-212 Issued 2l94 P/N 108 711A
Page 6 Sprint EPROM and Con troller Replacement Instructions Gaining Access to Controller Boards (contd.) 5. Refer to figure 5 and loosen the two lower screws (1) at the bottom sides of the protective cover (3). Figure 5. Removing protective cover 1. Lower Screws 2. Upper Screws 3. Protective Cover 6. While holding the protective cover (3), remove the two upper screws (2), and pull the cover off, clearing all boards. Then set it aside. 7. Refer to Figure 6 and disconnect all external cables and connectors from the controller. Figure 6. Disconnecting controller s external cables and connectors P/N 108 711A 46-212 0 Nordson Corporation 1994 Issued 2194
Sprint EPROM and Con troller Replacement Instructions Page 7 Rem0 ving Con troller Option Boards 1 Refer to Figure 7 and remove the outer three circuit boards by removing the screws and standoffs between them using a screwdriver and a l/4-in. wrench. Figure 7. Removing boards 1. l/o Option Board 2. Analog Option Board 3. RS23;? Option Board 4. ACU (main) Board Note: Referring to Figure 7, remove the circuit boards in the following order: the I/O (1), the analog input board (2), and the RS-232 (3). The ACU board (4) does not have to be removed. 2. Place the three boards on the grounded ESD surface, and continue with Replacing Board EPROMs described next. Replacing Board EPROMs A CAUTlONWear t the grounded wrist strap during this procedure. Failure to wear the grounded wrist strap may result in damage to the boards. This kit contains six EiPROMs. Install them on the following boards: ACU board MEDIA NUMBER 1 MEDIA NUMBER 2 MEDIA NUMBER 3 I/O board RS-232 board MEDIA NUMBER 4 MEDIA NUMBER 5 Analog board MEDIA NUMBER 7 1. Refer to drawing 125 214 sheet 1 and locate the EPROMs labeled MEDIA NUMBEFt 1,2, and 3 on the ACU board. 2. Refer to drawing 125 214 sheet 1 and locate the EPROM labeled MEDIA NUMBEFl4 on the I/O board. Q Nordson Corporation 1994 All Riqhts Reserved 46-212 issued 2/94 P/N 108711A
Page 8 Sprint EPROM and Controller Replacement Instructions Replacing Board EPROMs 3. Refer to drawing 125 214 sheet 2 and locate the EPROM labeled (con td.) MEDIA NUMBER 5 on the RS-232 board. ; 4. Refer to drawing 125 214 sheet 2 and locate the EPROM labeled MEDIA NUMBER 7 on the Analog board. 5. Except for MEDIA NUMBER 3 (on the ACU board), remove all the other EPROMs as follows: a. Push the locking tab in the direction of the arrow labeled OPEN to release the EPROM from its socket. Refer to Figure 8. Figure 8. EPROM locking tab (pictured in locked (ACT) position) b. Remove the EPROM by grasping it with the extraction tool. Pull gently from the board at a 90 angle. See Figure 9. Figure 9. Grasping EPROM chip using extracting tool 6. MEDIA NUMBER 3 dosle not have a locking tab. Just use the chip extraction as follows to remove it: P/N 108711A 46-212 Issued 2194 0 Nordson Corporation 1994 All Riqhts Reserved
Sprint EPROM and Controller Replacement Instructions Page 9 Replacing Board EPROMs (con td.) - a. As shown in Figure 9, align the tool above the EPROM and firmly grasp the ends of the chip. ; b. Pull the EPROM gently from the board at a 90 angle. 7. Remove the new EPROMs from their protective bags. Note: Observe the MIEDIA NUMBER of each chip. The EPROMs must be inserted in the correct location on the boards for proper equipment operation. Refer to dr awing 125 214 sheets 1 and 2. 8. Insert each EPROM (except MEDIA NUMBER 3) in its correct socket as follows: a CAUTION: l3e sure that you insert the EPROMs correctly in I their respective socket, see Figure 10. If they are installed 0 wrong they will be damaged when power is applied to the controller. Figure 10. Correct orientation of EPROM chip placement in socket (Notch is closed to top of board.) 7. Pin 7 2. Top of board 3. Notch Location a. Align the notch of the socket with the notch in the EPROM. b. Make sure that each of the pins lines up correctly with the socket holes. Misalignment could cause one of the pins to bend. c. Ensure that the pins are fully bottomed in the socket. d. Lock the EPROM in its socket by pushing the tab in the direction of the arrow marked ACT. 0 Nordson Corporation 1994 46-212 Issued 2/94 P/N 108 711A
Page 10 Sprint EPROM and Controller Replacement Instructions Replacing Board EPROMs (con td.) 9. Insert MEDIA NUMBER 3 as follows: a. Holding the EPROM in the insertion tool, alignthe chip above the socket, making sure thlat each of the pins line up correctly with the socket holes. Misalignment could cause one of the pins to bend. Refer to Figure 11. Figure II. Aligning MEDIA NUMBER 3 with socket using insertion too/ b. Insert the EPROM into the socket with insertion tool. c. Press the EPROM firmly and evenly into the socket. 10. This completes EPROM installation. Continue with Checking the Board Switch Settings described next. Checking Option Board Switch Settings Check the switch settings on the I/O, Analog, and RS-232 boards before installing them. The switches should be set as shown in drawing 151 491. After verifying for correct switch settings, go to Reinstalling Controller Boards described next. Reins tailing Con troller Option Boards 1. Replace the I/O, Analog, and RS-232 boards as shown in Figure 7. CAUTION: SometiImes the standoffs used for mounting the boards have been shipped with washers for use between the standoff and the board; however, it has been found that this slight spacing distance that the washer adds can cause problems with proper mating of the board s 64-pin connector Jl. Therefore, be sure not to use any washers between the board and standoff when reinstalling boards. Inspect the 64-pin connector Jl to ensure that all pins mate correctly with the corresponding socket. View the mated connector from several angles to ensure correct mating. 2. Reconnect all ribbon cables and connectors as shown in Figure 6. PM 108 711A 46-212 0 Nordson Corporation 1994 Issued 2l94 All Rights Resewed
Sprint EPROM and Con troller Replacement Instructions Page 11 Reins tailing Con troller Option Boards (con td.) 3. Remount the protective cover as shown in Figure 5. 4. This completes installation of the boards. Proceed with Checking installation and CcvViguring Software described next. 6. Checking Ins talla tion and Configuring Software This procedure serves as a final operational check for the controller and should be performed after either installing a new option board and/or new EPROMs, or a new complete controller assembly. I. Restore external plower. The unit will now automatically perform power up self-test.. When the self test is finished and if no problems were encountered, the controller display begins monitoring the configured parameters, or displays the default present configuration code menu. Service Activity Performed and Software Version Option board replaced and its software version is same as that on old controller. Option board replaced and its software version is newer than that on old controller. Thus, controller software (EPROM) was replaced to match new board. Entire controller was replaced. 2. Depending on the software version and the service activity performed, Table I describes what action you should take next: Table 1. Action Required for Service Activity Performed Service Activity Needed Unit will resume normal operation. No further action required. Memory will be cleared and you must re-enter configuration code and all user settings recorded prior to performing the replacement operation described in these instructions. Continue with Re-entering Configuration Code Method 7 described below. Memory will contain factory default codes. You must re-enter configuration code and all user settings recorded prior to performing the replacement operation described in these instructions. Continue with Re-entering Configuration Code Method 2 described below. Re-en tering Configuration Code Method I After restoring power to the controller the default present configuration code menu shown below is displayed. This code is just a representation of the content of this [menu and is not your actual configuration code. PRESENT CONFIG CODE: 3400-lAA52/ 3400-l AA52/ 1. Enter 4011 as the! configuration code for your Sprint applicator. Then press ENTER until the controller resumes normal operation. Note that the dash (-) must be included in the configuration code. 2. The start-up software will run and the unit will resume normal operation using factory default parameters. You now need to re-enter your user settings, so go to Re-entering User Settings described at the end of this document. Q Nordson Corporation 1994 46-212 Issued 2/94 PIN 108 711A
Page 12 Sprint EPROM and Controller Replacement Instructions Re-en tering Configuration Code Method 2 Note: This method is only to be performed when you replaced the entire controller. Begin at the Run Mode with Operator Menu and access the Factory Menu as follows: 1. Press number 1, then 2, then 7. The display will show the following: ACCESS CODE: XXXX CALL NORDSON FOR PASSWORD: **** I 2. XxXx will be a four digit number. This number corresponds to the first of a pair of four-digit numbers shown in the password list in Table 2. Table 2. Access Code, Password Pairs 8353-0543 I 8659-9931 I 7654-3480 I 8372-0903 I 4538-6443 IO365-7542 i 5629-8483 I8939-9837 1 1:: 3054 5924-5485 8264 :;:i 1 ii:: 1171-0893 11546-7632 I8031-4464 19188-6847 1 8008-4572 18907-0:347 I3018-9340 I7593-8732 1 4. Select the CLR-RAM function using the touchpad. A warning message will appear and a YES/NO confirmation will be requested as shown below: Note: If you mistakenly choose the wrong function and do NOT want to change it, press the CANCEL touchpad. The factory menu will again be displayed. Either choose the function that you intend to change, or press CANCEL again if no changes are desired. The CLR-RAM function re-initializes the battery-backed RAM. When the battery-backed RAM is re-initialized, the configuration code and all user-defined values are reset to factory defaults. CLEAR ALL RAM VALUES: NO ARE YOU SURE? NO P/N 108711A 46-212 tssued 2194 8 Nordson Corporation 1994
Sprint EPROM and Controller Replacement Instructions Page 13 Re-en tering Configuration Code Method 2 (contd.) 5. Use the arrow keys to select YES and press ENTER. The CLEAR RAM function then displays the applicator s default present configuration code. This code is just a representation of the content of this menu and not your actual configuration code. PRESENT CONFIG CODE: 3400-I AA52/ 3400-l AA52l 6. Enter 4011 as the configuration code for your Sprint applicator. Then press ENTER until the controller resumes normal operation. Note that the dash (-) must be included in the configuration code. 7. The start-up software will run and the unit will resume normal operation using factory default parameters. You now need to re-enter your user settings as described next. Re-en tering User Settings Refer to the Tab/e 4. I Default Setfings for OnmiScan Control System from section 4 of your applicator system manual that you were told to record earlier and re-enter the respective parameters by selecting the appropriate menu item and changing the setting to those on your list. If necessary, refer to th,e Operating Instructions, Section 4 of your applicator manual for instructions on entering or changing settings. Once these data are entered the unit will start running from these new settings. 8 Nordson Corporation 1994 46-212 Issued 2l94 P/N 108 711A
Page 14 Sprint EPROM and Con troller Replacement Instructions P/N 108 711A 46-212 8 No&on Corporation 1994 issued 2i94