D-Drive Controller Retrofit Instructions

Transcription

1 D-Drive Controller Retrofit Instructions These instructions will outline the procedure for replacing the circuitry within a Movotec D-Drive lift system. The circuit board is located within the black, metallic motor housing and is responsible for processing the main functions of the motor-drive.

2 I. Circuit Board replacement requirements: Retrofit Kit (p/n: D ), including: a.) D-Drive Logic-S Cable (p/n: ) b.) Controller (p/n: D ) c.) Surface Switch (p/n: ) d.) Installation Instructions (p/n: ) 4mm and 5mm Allen wrenches (not included) (4) Controller Mounting Screws (not included) Recommended Controller Mounting Fastener Sizes Metric English Machine M4x0.7 #6-32 Wood ST 3.5 #6 Sheet Metal ST 3.5 #6 Note: due to height restrictions, Round Head (standard) and Pan Head caps are recommended

3 II. Installation Procedure It is recommended that the system be completely lowered before attempting installation. Further, the hydraulic fittings should not be disconnected at any point during this procedure. For the instructions described below, please reference the following figure for component identification. Also note, for the components to become visible, it may be required to slide the black, plastic cover off of the pump track. Figure 1: Component Identification - 3 -

4 REMOVE POWER CONNECTION TO THE SYSTEM BEFORE ATTEMPTING THE PROCEDURE. FAILURE REMOVE POWER SOURCE MAY RESULT IN FIRE, PROPERTY DAMAGE, ELECTRIC SHOCK, PERSONAL INJURY OR DEATH. Step 1: Before removing the motor drive from the pump, mark the location of the magnetic reed switches on the pump. NOTE: The magnetic reed switches are responsible for starting and stopping the motor (preventing internal damage to the system); ensure their locations are carefully marked! Also, it is important to note the direction of the wires attached to the reed switches. The wires should exit the magnetic reed switches in the outward direction; that is, the red wire should exit the reed switch towards to the motor drive, and the black wire should exit towards the hydraulic lines. Figure 2: Reed Switch Orientation - 4 -

5 Step 2: With their locations marked, remove the reed switches from the pump track, and unplug the switch and transformer from the motor. Remove the motor assembly (shown at left) from the pump by removing the pump screws using a 4mm Allen wrench. Step 3: Using a 5mm Allen wrench, carefully remove the front cover of the motor housing. The circuit board will become visible after removing the cover. Step 4: Slide the circuit board out of the motor enclosure. Carefully disconnect the power (green and brown wire) and reed switch (red and black wires) from the circuit board. Step 5: Carefully connect the power and sensor cord into the new, D-Drive Logic-S cable. NOTE: Ensure that the sensor cord mates properly with the new cable; the white tab on the new cable connector should fit securely into the slots of the red sensor cable connector

6 Step 6: Slide the black, circular end of the cable through the round slot of the motor housing cover. Continue feeding the cable, and secure the rubber strain relief into the housing. Step 7: With the cable strain-relieved, place the motor cover back onto the housing, and secure using a 5mm Allen wrench. Carefully press the reed switches into their marked locations (from step 1) in the pump track. NOTE: As described in step 1, the wiring orientation is also essential for the system to start and stop properly; ensure the reed switches are installed as shown in Figure 2. Step 8: Plug the cable into the control box, into the port labeled M1. Plug the new switch (with the blue connector) into the port labeled HS on the controller. Finally, plug the power cord into controller. NOTE: The old switch is incompatible with the new controller; be sure to use the new, 7-pin switch with the circular, blue plug. Secure the new switch to the structure using the screws and mounting holes from the old switch

7 III. Post-Installation Notes After finishing the installation, a few components will no longer be required. As noted in Step 8, the old switch (containing the black, 4-pin plug) is not compatible with the new system. Also, the oldstyle transformer (shown below) will no longer be used the new controller replaces its functionality. Figure 3: D-Drive Transformer Before operating the system, ensure that all connections are secure. Also, to avoid damaging the system, check that the magnetic reed switches are in the locations marked in during step 1. For questions or concerns with any of the procedures outlined above, please contact Suspa, Inc before operating the unit, at (616) (and ask for Movotec Technical Support). For assistance mounting the control box, please reference the following controller mounting instructions

8 IV. Controller Mounting Procedure Mark the edge of the controller with a pencil. Detach the mounting plate from the bottom of the controller. Align the mounting plate with the pencil line. Mark and prepare two mounting holes in the locations provided by the mounting plate. Fasten the mounting plate, tapered side down, using mounting screws with screw heads that clear the openings in the motor controller. To prevent breakage, do not over tighten the mounting screws. Please note that mounting screws are not provided with system

9 Slide the motor controller onto the mounting plate tabs so that they are fully engaged with motor controller enclosure slots. Mark two mounting holes in the motor controller keyway slots provided. Detach the controller from the mounting plate and prepare the two marked holes for mounting screws. Install two mounting screws halfway into the prepared holes

10 Slide the controller onto the mounting plate so it is fully engaged with the motor controller housing. Tighten the two front side screws. To prevent breakage, do not over tighten the mounting screws. Check mounting screws to ensure that the unit is secured