replacement instructions for omniscan controller assembly...

MC0 Option Board Replacement Instructions

Replacement Instructions for lOmniScan@ Controller Assembly MC0 Option Board

Service Kit P/N 166 773

1. Introduction This publication contains instructions for replacing the MC0 Option Board. The service k.it contains:

l one MC0 Board Assembly

l one Electrostatic Discharge (ESD) wrist strap

l one set of replacement EPROMs (for use only if necessary)

Tools Required

The tools required to install this kit are:

l l/4-in. open-end vvrench l small flathead screwdriver

Replacing the MC0 option board in the OmniScan Controller is done to either replace a defective board or replace an existing board with a newer version. The procedure involves hardware steps that are primarily physical (switch settings, wiring, and fasteners), and software considerations in which the EPROMs on all controller boards form a matched set. Thus the software and/or the board version may have changed since the controller was first placed in operation.

To minimize both downtime and inconvenience, perform the detailed steps in these instructions exactly as described. The following is a brief overview of the procedures covered in this document:

l comparing software versions of the old and replacement boards

l recording current software settings (if required)

l removing the controller from applicator

l replacing the MC0 option board

l replacing the EPFlOMs (if required)

l reinstalling the controller into applicator

l checking installation and configuring software

2. Safety Precautions Before performing thle replacement procedure described in this document, remove allI power from the system and lock out external power to the applicator.

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A !i

WARNING: Failure to lock out external power to the applicator may present a serious shock hazard. The input terminal block remains energized with the power OFF.

_ A CAUTION: Static electricity can damage EPROMs and reduce

I board life. Before handling or transporting any board or 0 EPROM, put on the grounded electrostatic discharge (ESD)

wrist strap supplied with this kit. For maximum protection, also work on a grounded ESD surface.

3. Confirming Current Software Verslon

This procedure is used to compare the existing controller software version against that installed on the replacement MC0 option board. The results of this comparison determine whether you will need to install new EPROMs on all boards or just install the replacement MC0 option board.

NOTE: If the controller is inoperative, you will not be able to check the software version as outlined below. You will have to physically look at the label on each EPROM of the controller boards. If this is the case, skip the following steps and go directly to Replacing the Option Board described next.

1. Turn the applicator om.

2. On the OnmiScan Controller display, press PROGRAM, then INFO, then VERSION. This will give you the current software version in your controller.

3. Inspect the labels on the EPROMs included with your service kit as well as the EPROM installed on the replacement MC0 board. The label format is “SW# x.yyy/n.”

4. If the software version in your controller is the same as the new board, you do not have to replace the EPROMs on your existing controller boards. If the software version of the replacement MC0 board EPROM is newer, you must replace the EPROMs on all existing boards in order for your controller to function properly. Later in this document you will be given instructions on how to replace the EPROMs.

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MC0 Option Hoard Replacement Instructions

. 4. Replacing the Option Board

Recording Your Con troller User Settings

If when you replace the existing MC0 option board with a new one, you determined that you also need to replace the board EPROMs, the user settings will be lost and reset to the Nordson defaults. Therefore, after replacing the EPROMs, you will need to have available the Menu Defaults, Part 7from section 4 of your applicator manual (usually printed as yellow pages) 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.

In addition, record the configuration code stamped on the hose-end panel of your applicator.

Proceed with Gaining Access to Controller Boards described next.

Gaining Access to Controller 1. Disconnect and lock out the input power to the applicator’s main

Boards circuit breaker. Flefer to figure 1.

Figure 7. locking Out Power

To replace a controller option board you must first record your controller user settings. Next, remove the controller from the applicator and then remove the option boards from the controller assembly. You must then reinstall the option boards and controller into the applicator This section describes how to perform each of these operations.

2. Refer to figure 2 and switch the applicator (1) circuit breaker to the OFF position.

A

WARNING: Parts of the applicator may still be hot. Use

I caution when removing panels or covers to prevent getting 0 burned.

3. Remove the applicator’s electrical cabinet top cover (2) by unscrewing the captive screws on top of the cabinet and disconnecting the ground wire.

.

4. Loosen the captiive screws on the front and rear covers (3) that attach the covers to the controller frame and the center frame.

NOTE: During the next step you may need to slightly pull out on the top edge of the front panel so that the captive nuts will clear the heat sink as the frame assembly is pulled out.

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5. Loosen the two nuts (4) located under the controller frame. Carefully slide the controller frame assembly out until it comes to a stop. See figure 2.

Figure 2. Applicator with Frame Extended for Removing Controller

1 =Circuit Breaker 2=Top Cover 3=Front and Rear Cover Captive Screws 4=Nuts Securing Controller Frame to Unit Base

A t

CAUTION: Wear the grounded ESD wrist strap during this procedure. Failure to wear the grounded wrist strap may result in electrostatic damage and/or reduce board life.

6. Ground the wrist strap to the frame of the applicator and put it on your wrist.

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7. Record or tag all cables and/or connectors going to the controller. This will assist you with the reassembly. Then refer to figure 3 and disconnect all external cables and connectors from the controller.

4103126

Figure 3. Disconnecting Controller’s External Cables and Connectors

1 =Front Display Panel 2=Ground Wire

8. Disconnect the ground wire from the quick connector lug at the bottom of the display panel.

NOTE: If the controller assembly being removed includes an l/O option board, check to see if connectors TBl through TB6 (along the left and right board edge) are unused (no cables attached). If these connectors are unused, you musIt also remove these six connectors to provide clearance to remove the controller assembly.

9. Remove the screws from the front of the display panel. Note that two of the screws also secure the door latch bracket, which will also come loose. Set the bracket and screws aside.

A Is

CAUTION: Be sure to wear the grounded ESD wrist strap for the followinlg procedure. Failure to wear the grounded wrist strap may result in electrostatic damage and/or reduce board life. In addition, if possible, use a grounded ESD surface mat to set the controller on when placing on work area.

10. Remove the controller assembly from the control frame and lay the unit face down on a clean, flat, electrically grounded surface (ESD work mat). This will help avoid scratching the display panel and prevent damage from electrostatic discharge during the following steps. Proceed with Removing Controller Option Boa& described next.

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Removing Con troller Option Boards

1. Refer to figure 4 and remove the outer option boards one at a time by removing the screws and standoffs between them using a screwdriver and a l/41-in. wrench.

Figure 4. Removing Boards

1 =Front Display Panel 2=ACU (main) Board 3=1/O Board (shown here in positionl) 4=MCO Board (shown here in position 2)

NOTE: Figure 4 shows the controller with two option boards installed, the MC0 board (4) is in position 2 and the I/O board (3) is in position 1. The position in which any option board is located is arbitrary, but the address switch on each board must be set to a different position.

2. If you determined that the replacement board has newer software than your existing controller, go to c. below. However, if you were unable to check the current software version because the controller was inoperative, do so now by physically looking at the EPROM label on each board, continue with a. below.

a. Inspect the labels on the EPROMs on your controller boards. The label format ir; “SW# xyyyln.”

b. If the software version on your existing controller boards is the same as the replacement board, you do not have to replace the EPROMs on your existing controller boards. In this case, place the option boards on the grounded ESD surface, and continue with Checking Option Board Switch Settings described later in this document.

c. If the software version of the replacement board EPROMs is newer (or higher number), you must replace the EPROMs on all

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boards for your controller to function properly. In this case, go to Replacing Board EPROMs described next and replace the EPROMs.

Replacing Board EPROMS

A Il

CAUTlON:ESe sure to wear the grounded wrist strap during this procedure. Failure to wear the grounded wrist strap may result in electrostatic damage to the EPROMs and/or reduce board’s life.

NOTE: This procedure describes how to replace EPROMs on all boards within the controller. You must replace at least one EPROM on each board present in your controller. Therefore, just use the portion of this procedure that applies to your situation.

According to your needs, install the EPROMs on the boards as noted below:

ACU (main) board MEDIA NUMBER 1 MEDIA NUMBER 2 MEDIA NUMBER 3

I/O board MEDIA NUMBER 4

MC0 board MEDIA NUMBER 6

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1. Refer to figure 5 and locate the EPROMs labeled MEDIA NUMBER 1,2, and 3 on the ACU board.

Figure 5. ACU Board EPROM Locations

1 =Media Number 1 2=Media Number 2 3=Media Number 3 4=Notch Location

57

2. Refer to figure 6 and locate the EPROM labeled MEDIA NUMBER 4 on the I/O board if your controller contains an I/O board.

I r

b 184 3

l81

rB5 1 TB2 786

Li-

1 m I ” TB7 TM

4105129

Figure 6. I/o Board EPROM Location

1 =Media Number 4 2=Notch Location

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4103131

Figure 8. EPROM Locking Tab (Pictured in locked (ACT) Position)

4103132

Figure 9. Grasping EPROM Chip Using Extracting Tool

3. Refer to figure 7 ‘and locate the EPROM labeled MEDIA NUMBER 6 on the MC0 board.

I- OC O

Jl J2 53

Figure.?. MC0 Board EPROM Location

l=Media Number 6 2=Notch Location

4. Except for MEDIA NUMBER 3 (on the ACU board), remove all the other EPROMs as follows:

d. Push the locking tab down in the direction of the arrow labeled OPEN to release the EPROM from its socket. Refer to figure 8.

8. As shown in figure 9, remove the EPROM by grasping it with the extraction tool, then gently pull from the board at a 90” angle.

5. MEDIA NUMBER 3 does not have a locking tab. Just use the chip extraction tool as follows to remove it: -

a. As shown in figure 9, align the extraction tool above the EPROM and firmly grasp the ends of the chip.

b. Gently pull the EPROM from the board at a 90” angle.

6. Remove the new EPROMs from their protective bags.

NOTE: Be sure to obs#erve the MEDIA NUMBER of each chip. The EPROMs must be inserted in the correct location on the boards for proper equipment operation. Refer to figures 5, 6, and 7.

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Page IO MC0 Option Board Replacement Instructions

_j 410301

Figure 7 0. Correct orientation of EPROM chip placement in socket (Notch is closest to top of board.)

Figure il. Aligning MEDIA NUMBER 3 With Socket Using insertion Tool

7. Insert each EPROM (except MEDIA NUMBER 3) in its correct socket as follows:

A

CAUTION: Be sure that you insert the EPROMs correctly in 1 their respective sockets, see figure 10. If they are Installed 0 incorrectly they will be damaged when power is applied to the

controller.

l=Pin 1 2=Top of board 3=Notch Location

a. Holding the EPROM in the insertion tool, position the chip above the socket, making sure that each pin lines up correctly with the corresponding socket hole.

b. Align the notch of the socket with the notch in the EPROM. Misalignment could cause one of the pins to bend. Refer to figure 11. Insert the EPROM into the socket with insertion tool.

c. Press the EPROM firmly and evenly into the socket.

d. Ensure that the pins are fully bottomed in the socket.

e. Lock the EPROM in its socket by pushing the tab up in the direction of the arrow marked ACT.

.

8. Insert MEDIA NUMBER 3 as follows:

A

CAUTION: Match the notched end of the EPROM with the

I notched end of its socket. The notch is near top of the board 0 just as with MEDIA NUMBER 1 and 2.

a. Holding the EPROM in the insertion tool, position the chip above the socket, making sure that each pin lines up correctly with the corresponding socket hole. Misalignment could cause one of the pins to bend. Refer to figure 11.

b. Insert the EPROhIl into the socket with the insertion tool.

c. Press the EPROM firmly and evenly into the socket.

9. This completes EPROM installation. Continue with Checking Option Board Switch &flings described next.

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MC0 Option Board Replacement Instructions .

Checking Opifon Board Switch Seffings

Whether you are installing option boards on a controller assembly or just installing a complete controller assembly that includes previously installed option boards, you should perform this procedure to either correctly set the board switches or verify that they were correctly set when the assembly was shipped from the factory.

.

A CAUTION: E3e sure to wear the grounded wrist strap for the

1 following procedure. Failure to wear the grounded wrist strap 0 may result in electrostatic damage and/or reduce board life. In

addition, if possible, use a grounded ESD surface mat to set the controller on when placing on work area.

For simplicity, it is recommended that the switch settings on each option board correspond to the physical position that the board occupies. (Incidentally, the controller will work as long as no two boards are selecting the same position.)

\ 3

7

1 =Front Display Panel 2=ACU (main) Board 3=Option Boards 4=Physical Position 1 5=Physical Position 2 6=Physical Position 3 7=Physical Position 4

Figure 12. Option Board Positions in Relation to the ACU (main) Board

1. Refer to figure 12 for the board positions, and figures 13 and 14 for the switch settings.

2. After verifying the correct switch settings, Go to Reinstalling Controller 0ptior;r Boards described next.

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0 II

~

0 0

SW1

Oh0 0

41OJlJ6

Figure 13. I/O Board Swit’ch Settings

1 =Switch setting for board in position 1 (1 is ON and 2,3, and 4 are OFF) Note: Some boards may have their switches labeled OPEN for OFF and CLOSED for ON. 2=Switch setting for board in position 2 3=Switch setting for board in position 3 4=Switch setting for board in position 4

ON OFF I

Figure 74. MC0 Board Switch Settings

l&witch setting for board in position 1 (1 and 2 are both ON) 2=Switch setting for board in position 2 3=Switch setting for board in position 3 4=Switch setting for board in position 4

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Reinstalling Con troller Op tlon Boards

1, Replace the MC0 option board (and any others) by referring back to figure 3 and performing its associated procedural steps in reverse order.

A CAUTION: Don’t use washers: sometimes the standoffs used

1 for mounting the boards have been shipped with washers for l 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.

2. 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.

3. This completes installation of the boards onto the controller assembly. Proceed with Reinstalling Controller /MO Applicator described next.

Reins tailing Con troller In to Applica for A

CAUTION:Be sure to wear the grounded wrist strap during

t this procedure. Failure to wear the grounded wrist strap may result in electrostatic damage to the EPROMs and/or reduce

1.

2.

3.

4.

5.

6.

7.

8.

board life.

Place the controller assembly into the applicator’s control frame, and reattach the ground wire to the quick connect lug at the bottom of the display panel. See figures 2 and 3.

Reinstall the screws from the front of the display panel along with the door latch.

Reconnect all external cables and connectors to the controller.

Push the control frame assembly back into place.

Tighten the two nuts on the bottom of the control frame.

Tighten the captiive screws on the front and rear covers.

Reconnect the ground wire to the electrical cabinet cover and secure the cover with the captive screws.

This completes installation of the controller into the applicator. Proceed to Checking Installation and Configuring Software described later in this document.

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5. Checking Installation 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.

1. Restore external power. 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 will begin monitoring the configured parameters, or will display the defautt present configuration code menu.

2. Depending on the software version and the service activity performed, the following chart describes what action you should take next:

Senrlce ActlvRy Performed apd So~,uyare~~e~lOn ,:.;_ .i’:.~.;::‘,::.::;.:.~.::ii i.j:/‘:: i:.;:.;:. $ey@e &$l$ty @ded,:“‘I.. .’ ” ._: ; :.

Option board replaced and its software version is same Unit will resume normal operation. No further action as that on old controller. required.

Option board replaced and its software version is newer than that on old controller. Thus, controller software

Memory will be cleared and you must re-enter configu-

was replaced to match new board. ration code and all user settings recorded prior to performing the replacement operation described in these instructions. Continue with Re-entering Configuration Code MetI~od 7 described below.

Entire controller was replaced. Memory will contain factory defautt 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 Confjguration Code Method 2 described below.

Re-enfering Conflguratlon 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.

I PRESENT CONFIG CODE: 3400-lAA52/

3400-l AA52/ I

The configuration code is stamped on the metal tag on the back (hose end) of the applicator. The configuration code is located above the serial number on the metall tag.

Option Codes: The portion of the configuration code following the slash (I) is reserved for applicator options. All codes for options which were installed when the unit was built In the factory are stamped on the metal tag at the rear of the applicator. Any option codes for options which were added after manufacturing will, of course, not be stamped on the metal identification ltag.

If no options have been adlded after the unit was manufactured, then the configuration code on the back of the applicator will include all of the

PIN108663B


Rem tering Conflgurafion Code Method 2

necessary option codes. If, however, you cannot access the metal tag or lf options have been added after manufacturing, then use the data listed in table 1 below.

Table 1. Possible Option Codes

1 trol (MPC)

T

J

Key-To-Line (KTL) No

t/C) Option Board Yes

IA 1 Low Level Indicator IYes

A option code letter corresponding to each option present in your applicator’should be included. Note that the ‘T’ and “Q” options cannot both be included in the same applicator. Also many applicators will have neither the ‘T’ nor the “Q” options. Table 1 also indicates that the “T” and “Q” options cannot be installed after the applicator is manufactured. Therefore, if either the motor pressure control option or the key-to-line option is present, the corresponding option code will be stamped on the applicator’s metal tag. Finally, note that these option code letters can be added in any order after the slash (/). For example, all of the following option codes are acceptable for a 3700 applicator with an I/O board, a low level indicator, and motor pressure control:

. 3700-l RL56/AJQ or 3700-l RL56/JAQ

. 3700-l RL56/QAJ or 3700-l RL56/QJA

The option code letters, which follow the slash, can be arranged in any order as shown above.

1. Enter the proper configuration code for your applicator, Including any new boards added during the steps of this instruction sheet. Then press ENTE:R 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 &-entering User Settings described at the end of this document.

NOTE: This method is only to be performed when you replaced the entire controller.

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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:

I ACCESS CODE: XXXX

CALL NORDSON FOR F’ASSWORD: +,+**

2. ‘XxXx” will be a four digit number. This number corresponds to the first of a pair of fourdigit numbers shown in the password list in table 2.

Table 2. Access Code, Password Pairs

8974-2843 89720 6567 8924-4381 4238-5874

3564-1255 7762-8376 3544-8981 3847-8931

8353-0543 8659-9931 7654-3480 8372-0903

4538-6443 0365-7542 5629-8463 8939-9837

0283-4456 5071-3859 3054-5485 9023-2371

3342-2963 9203-8445 5924-8264 8723-3842

1171 - 0893 1546-7632 80314464 9188-6847

,8008-4572 ,8907-0347 ,3018-9340 I7593 - 8732 ,

3. Match the four-digit nIumber on the LCD (access code) with the first four-digit number in tlhe table. Use the touchpad to key in the second four-digit number (password) from the pair. Then press the ENTER touchpad twice. The display will show the factory or “secret” menu shown below:

SELECT A PRIVILEGED OPERATION.

DFLT-PWD DFLT-TMP CLR-RAM

‘4.. Select the CLRJAM function using the touchpad. A warning message will appear and a YES/NO confirmation will be requested as shown below:

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NOTE: If you mistakenly choose the wrong function and do NOT want to change lt, 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. In addition, any stored information that may be useful for determining the cause of the problem will also be cleared.

I CLEAR ALL RAM VALUES: NO

ARE YOU SURE? NO I

5. Use the arrow ke!ys 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: 34000lAA52/

3400-l AA58 I

The configuration codle is stamped on the metal tag on the back (hose end) of the applicator,, The configuration code is located above the serial number on the Imetal tag.

Optlon Cocks: The portion of the configuration code following the slash (I) is reserved for applicator options. All options codes for options which were installed when the unit was built in the factory are stamped on the metal tag at the rear of the applicator. Any codes for options which were added after manufacturing will, of course, not be stamped on the metal identification tag.

If no options have been added after the unit was manufactured, then the configuration code on the back of the applicator will include all of the necessary option codes. If, however, you cannot access the metal tag or if options have been added after manufacturing, then use the data listed in table 3 below.

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Re-entering User Settings

Table 3. Possible Option Codes .

Option Code .,I; .__ :. Option Descript!on,j.. ].::,..I: Optlon Can Be installed _,:. : “” ,.:: .. :: .. .,_. .. :’ : ,, . .._ __ ., .,.,_.,_, :> .,:.:,, :. .:, : : ,: ,, _I,. . . _,: ‘, ,. ‘. _. .: ;. _..: :_, .‘..‘?. ” ‘. ‘., ,,, : .., .’ _: ::, :’ :: ._ ._ ~,,: ,:, After Manufacturing (In,.’

._ 1. : ,; : ,.,C>’ ,... ,. :._ ,.:. _:. ,,__ “.’ .: :‘. ;. ,: :_; :::.. : ..,..,;‘:‘. _, :. .. ,’ ihe field) ‘._ _. : ” :

Q Motor Pressure Con- No trol (MPC)

T Key-To-Line (KTL) No

J l/O Option Board Yes

A Low L.evel Indicator Yes

A option code letter corresponding to each option present in your applicator should be included. Note that the ‘T’ and “Q” options cannot both be included in the same applicator. Also many applicators will have neither the Y” nor the “Q” options. Table 1 also indicates that the yll and “Q” options cannot be installed after the applicator is manufactured. Therefore, if either the motor pressure control option or the key-to-line option is present, the corresponding option code will be stamped on the applicator’s metal tag. Finally, note that these option code letters can be added in any order after tlhe slash (/). For example, all of the following option codes are acceptable for a 3700 applicator with an I/O board, a low level indicator, and motor pressure control:

. 3700-l RL56/AJQ or 3700-l RL56/JAQ

. 3700-l RL56/QAJ or 3700-l RL56/QJA

The option code letters, which follow the slash, can be arranged in any order as shown above.

6. Enter the proper configuration code for your applicator, including any new boards added during the steps of this instruction sheet. Then press ENTER until the controller resumes normal operation. Note that the dash (0) 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.

Refer to the user setting clata Menu De&u&s, part lfrom section 4 of your applicator manual (usually printed as yellow pages) 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 the 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.

P/N 108 663 B 4MOl

bsud 12m @No&on Corporation 1993

All Rights Reserved

replacement instructions for omniscan controller assembly...

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