Control. Part B, Section 2. This section covers the following unit configurations. 3400V 3500V. Voltage 4. Pump Piston (E, F, G)

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1 Part B, Section 2 Model This section covers the following unit configurations. Voltage V 3400V 3500V Pump Piston (E, F, G) Manifold 4-Port (A) 6-Port (B, C) 2-Port (S, T) Vista Standard (V)

2 B 2-0

3 B 2-1 Section B 2 WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This section includes control system troubleshooting and repair procedures. Refer to the parts lists for the part number of any component that needs to be replaced. If you try all the troubleshooting suggestions in this section and still need assistance solving control system problems, call your Nordson representative. The following sections of this manual contain additional information on the control system: Description includes an overview of each of the functional areas of the operator panel. Installation includes procedures for connecting output contacts, connecting electrical service, and programming your unit. Wiring Diagrams includes a set of wiring diagrams for your system. If your unit has any special options, such as an input/output (I/O) board or a low-level indicator, refer to the Options section at the end of this manual for troubleshooting and repair procedures. Refer to the Hydraulics section for troubleshooting procedures, repair procedures, and parts lists for the unit s pump and manifold assemblies.

4 B Overview of the System The Vista control system controls how your unit operates. The control system includes a variety of printed circuit boards (hereafter referred to as boards) and other components that you should be familiar with to safely troubleshoot and repair your unit. Assembly See Figure B 2-1. The main components of the control system are the control-end frame, the control assembly, and the operator panel. The control assembly is mounted on the inside of the control-end frame. The operator panel is mounted on the front of the control-end frame. The control assembly is made up of three boards that are required for your unit to function properly. Refer to the following table. Table B 2-1 Assembly Boards Assembly Board Function Power board board Display board Provides power to the unit and supplies the heater power for most of the unit s heated components Contains the Vista software chip and controls how the unit operates Allows the displays to function Fig. B 2-1 Assembly Components 1. Power board 4. -end frame 2. board 5. Operator panel 3. Display board

5 B 2-3 Unit-Specific Boards See Figure B 2-2. The control system also includes any unit-specific boards that are required for your unit to function properly. The presence of these boards varies depending on the configuration of the unit. Refer to the following table. Unit-Specific Board 480 VAC distribution board 5/6 hose/gun board Table B 2-2 Unit-Specific Boards Function Distributes incoming power to the power board Expands a unit s temperature-control capacity from four hoses/guns to six hoses/guns, supplying the heater power for hoses 5 6 and guns 5 6 Optional Input/Output Board See Figure B 2-2. Your unit may have an optional input/output (I/O) board. The I/O board is not required for a unit to function properly. Refer to Series 3000V Input/Output Board in the Options section at the end of this manual for information about the I/O board, including troubleshooting procedures, repair procedures, and a parts list A Fig. B 2-2 Unit-Specific Boards and I/O Board VAC distribution board 2. 5/6 hose/gun board 3. I/O board

6 B 2-4 System on 480 Vac Three-Phase Units Your hot melt unit operates on 480 VAC three-phase (3 ) incoming power, which you connected to a terminal block on the 480 VAC distribution board. A 480 VAC/230 VAC 1 isolation transformer provides 230 VAC power to the control assembly. The tank heaters operate on 480 VAC power. A solid-state relay controls the heater power to the tank heaters through the control board. Fuses F1, F2, and F3 on the 480 VAC distribution board provide protection for the 480 VAC power section, which includes the transformer and the tank heaters. Gun and hose heaters are powered by the power board and operate at 230 VAC. The tank heater circuit on the power board is not used on 480 VAC units. 3. Troubleshooting Tables The following troubleshooting tables describe the kinds of control system problems you may encounter and provide corrective actions for handling those problems. When necessary, the tables refer to more detailed troubleshooting procedures. Refer to the appropriate troubleshooting table for the type of problem you are experiencing: Internal, Hose, or Gun Zone Not Heating Settings Changed or Lost Unit Not Powering On System Indicating a Warning - Out-of-Band Warning - Under-Temperature (UT) Warning System Indicating a Fault - Over-Temperature (OT) Fault - Resistance Temperature Detector (RTD) Fault - Fault-Code Fault (F1 F7)

7 B 2-5 Electrical Safety During Troubleshooting Before performing troubleshooting activities inside the unit s electrical enclosure, you should exhaust all methods of troubleshooting the problem with the electrical enclosure closed or with the power off. The troubleshooting tables and procedures in this section are organized using this methodology. In general, you should perform troubleshooting activities as follows: Check the displays and lights for warnings, faults, and other status information. Check your programmed settings to make sure they haven t been changed. Refer to Records of System Settings in the Installation section. Check for continuity and grounding between system components (unit, guns, hoses, and other equipment). Make sure your branch circuit disconnect switch is properly installed. Make sure your power supply is supplying the proper voltage. Prioritize troubleshooting activities to limit exposure to live power. Perform troubleshooting activities involving live power last. Understand your system electrically and mechanically before opening the electrical enclosure. Pay special attention to system power distribution and to I/O interfaces with other equipment. Identify and eliminate potential electrical shock hazards in the environment surrounding your unit. Opening and Closing the Electrical Enclosure To troubleshoot control system problems or to make any repairs, you may need to access the electrical enclosure. Use these procedures as directed to safely access the electrical enclosure.

8 B 2-6 Opening WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. See Figure B 2-3. Loosen the captive screws on the electrical enclosure lid, lift the lid from the unit, and prop it against the pump cover. Take care not to disconnect the ground wire. 3. Make sure the support strap is not wrapped around any board components. Untangle the strap if necessary. 4. Loosen the two captive screws on either side of the control-end frame and lower the frame. You may need to pull the front and rear covers apart to release the frame. 5. Avoid direct contact with internal electrical connections, components, or wiring. 6. Make sure all ground wires are securely connected. Î Î Î Î A Fig. B 2-3 Opening the Electrical Enclosure

9 B 2-7 Closing 1. Reconnect any ground wires that were disconnected during troubleshooting or repair activities. 2. Raise the control-end frame into place and tighten the captive screws on each side of the frame. You may need to pull the front and rear covers apart to position the frame. 3. Position the electrical enclosure lid on top of the unit and secure it with the captive screws. 4. Remove the lock-out and restore power to the system. Internal, Hose, or Gun Zone Not Heating If a tank, hose, or gun will not heat, use this troubleshooting table. Problem Possible Cause Corrective Action Internal, hose, or gun zone not heating Zone setpoint temperature below 38 C (100 F) Check the setpoint temperature for the zone. The setpoint temperature must be 38 C (100 F) or above for the zone to heat. Refer to Programming TEMPERATURE s in the Installation section to program setpoint temperatures.

10 B 2-8 Settings Changed or Lost Use the following table to troubleshoot changed or lost settings (memory). Because the control system memory is stored on the microprocessor chip and does not require the protection of a battery backup, your settings cannot be lost during a brownout or a power failure. Problem Possible Cause Corrective Action 1. One or more settings changed Someone entered programming mode and changed one or more settings Use the password-enable feature to protect your settings. Refer to System Programming Procedures in the Installation section. Be sure to record your settings in the Records of System Settings at the end of the Installation section. 2. All settings lost Software upgraded to latest version by replacing software chip (all custom settings are lost during this procedure and are replaced by the factory default settings) Defective microprocessor chip Reprogram your unit. Refer to System Programming Procedures in the Installation section. Replace the control board. Refer to Replacing a Assembly Board in Repair Procedures. Unit Not Powering On If your unit will not power on, use this troubleshooting table. WARNING: Risk of equipment damage, personal injury, or death. Some troubleshooting procedures require you to perform work inside the electrical enclosure with the power on. Follow electrical safety procedures and observe all high-voltage indicators. Refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure before performing any troubleshooting procedure.

11 B 2-9 Problem Possible Cause Corrective Action Displays do not illuminate or displays illuminate but unit will not power on and no faults are displayed No input power Defective POWER switch Incorrect voltage plug at X3 on power board or plug not connected Blown fuse or fuses on 480 VAC distribution board Blown fuse or fuses on power board Defective harness on 480 VAC distribution board or defective transformer Contactor K1 on 480 VAC distribution board or power board not engaging Power board not properly connected to control board Defective power board or control board Make sure the power is turned on at your branch circuit disconnect switch and that your power supply is supplying 480 VAC to the unit. Make sure the voltage measures 480 VAC at TB1 on the 480 VAC distribution board. If necessary, check your electrical connections at TB1. Refer to Connecting Electrical Service in the Installation section. Check the POWER switch. Refer to Checking the POWER Switch in Troubleshooting Procedures. Make sure the voltage plug at X3 on the power board is part and that the plug is securely connected. See the illustration in the Parts section for the location of the voltage plug. Use an ohmmeter to check fuses F1 through F4 on the 480 VAC distribution board. Replace blown fuses. Refer to Replacing a Fuse in Repair Procedures. Use an ohmmeter to check fuses F9 and F10 on the power board. Replace blown fuses. Refer to Replacing a Fuse in Repair Procedures. Check the harnesses and transformer. Refer to Checking the 480 VAC Distribution Board Harnesses and the Transformer in Troubleshooting Procedures. While pressing the unit s HEATERS key on and off, listen for the K1 contactors to engage. You can also open the unit and visually examine the contactors to see if they are engaging. See Figure B 2-4 for the location of K1 on each board. If K1 is not engaging, replace the 480 VAC distribution board or the power board as appropriate. Refer to Replacing a Unit-Specific Board or Replacing a Assembly Board in Repair Procedures. Make sure the power board is properly connected to the control board at XP1. The pins from the control board should extend through XP1 on the power board. Replace the control assembly. Refer to Replacing the Assembly in Repair Procedures.

12 B 2-10 Unit Not Powering On (contd.) X1 X3H XP6 XS2H XP1 XP1 K1 X3 XP3 X2 X4 XP5 XP4A XS3 XS4 X2H Q17 TB1 XS1H TB J9 J4 XS2 J2 XS1 L1 L2 L3 N XP2 X1H A Fig. B 2-4 Location of Connectors on Boards 1. Power board 3. 5/6 hose/gun board VAC distribution board 2. board System Indicating a Warning During a warning condition, the unit continues to function normally. The control system indicates a warning as follows: The FAULT light flashes and turns off or flashes continuously. The Selector display shows a zone number. NOTE: Each heated component (each hose, each gun, and the tank) is referred to as a zone. When the Selector display shows a zone number, the INTERNAL, HOSE, or GUN light turns on. In combination, these indications identify which zone is affected. Refer to Table B 2-3. The Multipurpose display shows either a temperature reading or a flashing UT for the affected zone.

13 B 2-11 Table B 2-3 Determining the Affected Zone Zone Number in Selector Display (See Note A) Affected Zone INTERNAL Light On HOSE Light On GUN Light On 1 Tank Hose 1 Gun 1 2 Hose 2 Gun 2 3 Hose 3 Gun 3 4 Hose 4 Gun 4 5 (See Note B) 6 (See Note B) Hose 5 Gun 5 Hose 6 Gun 6 NOTE A: For example, if the Selector display shows the number 3 and the GUN light is on, then the affected zone is gun 3. B: Some units can accept only four hoses and four guns. Out-of-Band Warning When the FAULT light. And the Selector display And the Multipurpose display It means Do this is OFF (See Note A) Shows a zone number (refer to Table B 2-3) Shows the setpoint temperature of the affected zone The actual temperature of the indicated zone is out-of-band. Wait to see if the temperature stabilizes at the setpoint. You may want to change your out-of-band temperature setpoints. See Note B. NOTE A: The warning output contact is open and the fault output contact is closed. For more information on these output contacts, refer to Connecting Output Contacts in the Installation section. B: You can choose the degree to which a zone s temperature may deviate from its temperature setpoint (Features 5 19) and still stay within the temperature setpoint band. You should base your out-of-band temperature setpoints on your adhesive application requirements. Refer to System Programming Procedures in the Installation section to program out-of-band temperature setpoints.

14 B 2-12 Under-Temperature (UT) Warning WARNING: Risk of equipment damage, personal injury, or death. Some troubleshooting procedures require you to perform work inside the electrical enclosure with the power on. Follow electrical safety procedures and observe all high-voltage indicators. Refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure before performing any troubleshooting procedure. Table B 2-4 Identifying and Correcting UT Faults FAULT Light Selector Display Shows... Multipurpose Display Shows... Problem Solution OFF (See Note A) Zone number of the affected zone. Setpoint temperature of the faulted zone. The zone is out of band. Wait for 5 minutes to see if the temperature stabilizes at the setpoint. Zone number of the affected zone. UT flashing (See Note B) The system is under temperature because: No or insufficient power is being applied to the unit. The heater connection of the faulted zone is not secure. Zone fuses are bad. The heater of the faulted zone is bad. The power board or control board is defective. Check that the applicator is connected to the main power supply. If it is connected, check that electrical service connections are correct. Check the XS1 and XS2 heater connections on the main power board for the corresponding zone. Replace appropriate fuses. Replace the heater of the faulted zone. For a hose or gun fault, refer to the manual that came with your hose or gun. For an internal (tank) fault, the cast-in heaters of the tank require that you replace the tank. Replace the power board or control board. NOTE A: UT (undertemperature) occurs when a heater zone is more than 19.5 C (35 F) under the setpoint temperature. B: A UT warning can appear as a result of a zone that is either heating too slowly or not heating at all. The minimum time it takes for Vista to show a UT warning time as a result of a zone heating too slowly or not heating at all is 15 minutes.

15 B Press the CLEAR FAULTS key and wait for the system to return to the system-ready state. 2. If the warning disappears and the unit appears to be working again, the voltage to the unit may have temporarily sagged or you may have an intermittent problem. Repetitive warnings in the same zone indicate a problem with the circuitry in that zone or an intermittent RTD failure. Take the following steps to troubleshoot intermittent under-temperature warnings: a. Check for a change in environmental conditions, such as added ventilation or sources of drafts. A cold draft can keep your unit, hoses, and guns from heating. b. Make sure the power is turned on at your branch circuit disconnect switch and that your power supply is supplying the proper voltage to the unit. c. Check all hose and gun electrical plugs. Make sure the connections are tight and free of corrosion. d. Check your operating temperature setpoints to make sure they haven t been changed. Refer to Records of System Settings in the Installation section. e. If the affected zone is a hose or gun, replace the hose or gun with a hose or gun that is known to be good. If the warning disappears, replace the defective hose or gun. If the warning still appears, continue to the next step. 3. If the warning still appears after you press the CLEAR FAULTS key and after you have taken the actions in step 2, take the following steps. a. Check for loose heater connections on the board that supplies the heater power for the affected zone. Refer to Table B 2-6 for heater connector locations. For example, check the harnesses connected to X1 and X2 on the power board to check the heater connections for hoses 1 4 or guns 1 4. See Figure B 2-4 for the location of connectors on boards.

16 B 2-14 Under-Temperature (UT) Warning (contd.) b. Use an ohmmeter to check the fuse or fuses on the board that supplies the heater power for the affected zone. Refer to Figure B 2 8 for fuse locations. Replace the appropriate fuse or fuses. Refer to Replacing a Fuse in Repair Procedures. If the fuse blows again, make sure the heater is not shorted to the ground. c. If the affected zone is the tank, make sure the harness connected to J2 on the power board is secure or check the thermostat. See Figure B 2-4 for the location of J2 on the power board. To check a thermostat, refer to Checking a Thermostat in Troubleshooting Procedures. d. Check the K1 contactors on the 480 VAC distribution board and the power board. While pressing the unit s HEATERS key on and off, listen for the K1 contactors to engage. You can also open the unit and visually examine the contactors to see if they are engaging. See Figure B 2-4 for the location of K1 on the 480 VAC distribution board and the power board. If K1 is not engaging, replace the 480 VAC distribution board or the power board as appropriate. Refer to Replacing a Unit-Specific Board or Replacing a Assembly Board in Repair Procedures. e. Check the heater or heater circuit of the affected zone. Refer to Checking a Heater or Heater Circuit in Troubleshooting Procedures. f. If the warning condition still appears after you have taken all the actions in this step, replace the control assembly. Refer to Replacing the Assembly in Repair Procedures.

17 B 2-15 System Indicating a Fault A fault condition causes the unit to shut down. The control system indicates a fault as follows: The FAULT light either turns on and stays on or flashes for two minutes and then stays on. The Selector display shows either a zone number or the letter F. NOTE: Each heated component (each hose, each gun, and the tank) is referred to as a zone. If the Selector display shows a zone number, the INTERNAL, HOSE, or GUN light turns on. In combination, these indications identify the faulted zone. Refer to Table B 2-5. The Multipurpose display shows either a flashing OT or RTD for the faulted zone or a fault code (F1 F7). The heaters turn off. Whenever the heaters turn off, the pump stops. Table B 2-5 Determining the Faulted Zone Zone Faulted Zone Number in Selector Display (See Note A) INTERNAL Light On HOSE Light On GUN Light On 1 Tank Hose 1 Gun 1 2 Hose 2 Gun 2 3 Hose 3 Gun 3 4 Hose 4 Gun 4 5 (See Note B) 6 (See Note B) Hose 5 Gun 5 Hose 6 Gun 6 NOTE A: For example, if the Selector display shows the number 3 and the GUN light is on, then the faulted zone is gun 3. B: Some units can accept only four hoses and four guns.

18 B 2-16 Over-Temperature (OT) Fault WARNING: Risk of equipment damage, personal injury, or death. Some troubleshooting procedures require you to perform work inside the electrical enclosure with the power on. Follow electrical safety procedures and observe all high-voltage indicators. Refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure before performing any troubleshooting procedure. When the FAULT light And the Selector display And the Multipurpose display It means Do this Turns on (See Note A) Shows a zone number (refer to Table B 2-5) Flashes OT (See Note B) A zone s actual temperature has reached the over-temperature setpoint entered in Feature 3. The default setting is 218 C (425 F). Refer to the following procedure. NOTE A: When the FAULT light turns on, the warning output contact is closed and the fault output contact is open. When the FAULT light is off, both output contacts are closed. For more information on these output contacts, refer to Connecting Output Contacts in the Installation section. B: You should base your over-temperature setpoints on your adhesive application requirements. Refer to System Programming Procedures in the Installation section to program over-temperature setpoints. 1. Press the CLEAR FAULTS key. 2. If the fault disappears and the unit appears to be working again, you may have an intermittent problem. Repetitive faults in the same zone indicate a problem with the circuitry in that zone or an intermittent RTD failure. Electrical noise from DC-drive motors may cause the triacs that control heater power on the power board to close independent of the control system. Take the following steps to troubleshoot intermittent over-temperature faults: a. Check your operating temperature setpoints to make sure they haven t been changed. Refer to Records of System Settings in the Installation section.

19 B 2-17 b. To verify that something other than the control system is affecting a heated zone, turn on the Display Heater Proportioning feature (Feature No. 21) for the affected zone. When the display blinks on and off, it means the control system is proportioning heat control to the heater. During proportioning, the temperature displayed for the zone should stay fairly constant, within +/ 1 F. If the temperature continues to rise during proportioning, then something other than the control system is closing the triacs on the power board and causing the heaters to heat. If electrical noise from DC drives is causing the overheating problem, then you may be experiencing problems with other equipment in your facility. Take the following steps to solve electrical noise problems: Install the proper line reactor. Consult with the DC drive manufacturer for the appropriate line reactor size. Electrically ground the hot melt unit to the parent machine using as short a length of twisted cable as possible. If the triacs continue to close after the hot melt unit is grounded to the parent machine, install a line filter on each input power line to the hot melt unit. Connect the filter line-to-line. Refer to Parts for the line filter part number. For a three-phase system, order three filters. c. If the faulted zone is a hose or gun, replace the hose or gun with a hose or gun that is known to be good. If the fault disappears, replace the defective hose or gun. If the fault remains, continue to the next step. 3. If the fault remains after you press the CLEAR FAULTS key and after you have taken the actions in step 2, check the heater or heater circuit of the faulted zone. Refer to Checking a Heater or Heater Circuit in Troubleshooting Procedures. 4. If the fault remains after you have taken all the actions in this procedure, replace the control assembly. Refer to Replacing the Assembly in Repair Procedures.

20 B 2-18 Resistance Temperature Detector (RTD) Fault Nordson offers two test plugs that simplify the troubleshooting of RTD faults. These test plugs help you quickly and easily determine whether the problem is a gun, hose, or tank RTD problem or a control system problem. Refer to Parts for the kit part number. When the FAULT light And the Selector display And the Multipurpose display It means Do this Flashes for two minutes then stays on continuously (See Note A) Shows a zone number (refer to Table B 2-5) Flashes RTD (See Note B) The RTD or RTD circuit of the indicated zone is open or shorted. Refer to Checking an RTD or RTD Circuit in Troubleshooting Procedures. NOTE A: When the FAULT light flashes, the warning output contact is open and the fault output contact is closed. After a two-minute delay, the warning output contact closes and the fault output contact opens. When the FAULT light is off, both output contacts are closed. For more information on these output contacts, refer to Connecting Output Contacts in the Installation section. B: The actual-temperature display will show 260 C (500 F) if the RTD is open. It will show 0 C (0 F) if the RTD is shorted.

21 B 2-19 Fault-Code Fault (F1 F7) When the FAULT light And the Selector display And the Multipurpose display It means Do this Turns on (See Note A) Shows the letter F Shows the number 2 The power board screws are loose, causing a faulty ground connection. Tighten the power board screws. Shows the letter F Shows the number 1, 2, 3, 5, or 6 The control board is defective. Turn the unit off, then back on again to see if the problem recurs. If it recurs, replace the control board or replace the control assembly. Refer to Replacing a Assembly Board or Replacing the Assembly in Repair Procedures. Shows the letter F Shows the number 4 There is a brownout condition. (See Note B) Correct the cause of the brownout. Shows the letter F Shows the number 7 The seven-day clock battery is dead. (See Note C) Replace the control board or the control assembly. Refer to Replacing a Assembly Board or Replacing the Assembly in Repair Procedures. NOTE A: When the FAULT light turns on, the warning output contact is closed and the fault output contact is open. When the FAULT light is off, both output contacts are closed. For more information on these output contacts, refer to Connecting Output Contacts in the Installation section. B: A brownout occurs when the power supply voltage falls below the voltage needed to maintain system operation. When this happens, the control system stops normal operation. The system will resume normal operation once the brownout condition is corrected. C: If the unit and the seven-day clock feature are turned on and the clock battery dies, the CLOCK light will flash. If the unit is then subject to a power cycle or power interruption, the displays will indicate fault code 7. However, if the clock feature is not turned on and the clock battery dies, the unit will not indicate a fault. When the clock battery is dead, the unit will continue to operate normally except for clock-related functions.

22 B Troubleshooting Procedures Use these procedures as directed in Troubleshooting Tables to further troubleshoot control system problems. Checking the POWER Switch Follow this procedure to check the POWER switch. WARNING: Risk of equipment damage, personal injury, or death. This procedure requires you to perform electrical troubleshooting with the power on. Use extreme caution and refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure for instructions on safely working inside the electrical enclosure. 1. Turn on power to the unit at the branch circuit disconnect switch. 2. With the unit s POWER switch in the off position, measure the voltage across J4 positions 1 and 4 on the power board. Voltage does not measure 230 VAC: replace the POWER switch and harness. Voltage measures 230 VAC: normal indication. Continue to the next step. 3. With the unit s POWER switch in the on position, measure the voltage across J4 positions 2 and 5 on the power board. Voltage does not measure 230 VAC: replace the POWER switch and harness. Voltage measures 230 VAC: normal indication. Return to the Unit Not Powering On troubleshooting table.

23 B 2-21 Checking the 480 Vac Distribution Board Harnesses and the Transformer Follow this procedure to check the harnesses on the 480 VAC distribution board and the transformer. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. Use an ohmmeter to check the continuity of the harnesses connected to the following connectors on the 480 VAC distribution board and take action as directed. See Figure B 2-4 for the location of connectors on boards. Harness Connector Check continuity across harness pins 480 VAC distribution board to transformer primary winding 480 VAC distribution board to transformer secondary winding 480 VAC distribution board to TB1A and TB1B Continuity exists? Action X1D 1 and 3 No Replace the harness. Yes Go to the next step. X1D 6 and 8 No Replace the harness. Yes Go to the next step. X3D 2 and 4 No Replace the harness. Yes Go to the next step.

24 B 2-22 Checking the 480 Vac Distribution Board Harnesses and the Transformer (contd.) 4. Use an ohmmeter to measure the resistance of the harnesses connected to the following connectors on the 480 VAC distribution board and take action as directed. Harness Connector Measure resistance across harness pins 480 VAC distribution board to transformer primary winding 480 VAC distribution board to transformer secondary winding 480 VAC distribution board to TB1A and TB1B Reading Action X1D 1 and 3 High ohms Replace the transformer Low ohms Go to the next step. X1D 6 and 8 High ohms Replace the transformer Low ohms Go to the next step. X3D 2 and 4 High ohms Replace the harness. Low ohms Go to the next step. WARNING: Risk of equipment damage, personal injury, or death. This procedure requires you to perform electrical troubleshooting with the power on. Use extreme caution and refer to Electrical Safety During Troubleshooting and Opening and Closing the Electrical Enclosure for instructions on safely working inside the electrical enclosure. 5. Restore power to the unit at the branch circuit disconnect switch and turn the unit on. 6. Use a voltmeter to measure the voltage at pins 1, 2, and 3 of the harness connected to X1D on the 480 VAC distribution board. Voltage does not measure VAC: make sure the unit is connected to the input power supply and that 480 VAC is being supplied. Make sure the electrical connections at TB1 on the 480 VAC distribution board are correct. Refer to Connecting Electrical Service in the Installation section. Voltage measures VAC: normal indication. Go to the next step.

25 B Repeat the voltage measurement at pins 6 and 8 of the harness connected to X1D. Voltage does not measure VAC: defective harness or transformer. Replace the harness. If replacing the harness does not solve the problem, replace the transformer. Voltage measures VAC: normal indication. Go to the next step. 8. Measure the voltage at pins 2 and 4 of the harness connected to X3D on the 480 VAC distribution board and at TB1 positions A and B on the power board. Voltage does not measure 230 VAC: defective harness or transformer. Replace the harness. If replacing the harness does not solve the problem, replace the transformer. Voltage measures 230 VAC: normal indication. Return to the Unit Not Powering On troubleshooting table. Checking a Heater or Heater Circuit Follow this procedure to check a heater or heater circuit. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. Check the heater by measuring its resistance at the heater connector harness pins. Refer to Table B 2-6 to determine which board the zone s heater connectors are located on. See Figure B 2-4 for the location of the connectors on the boards. Remove the harness from the connector and measure the resistance across the harness pins identified in Table B 2-6. Resistance reading of zero (0): heater short circuit. Check for a short in the heater circuit and repair the short. Infinite resistance reading: open heater circuit or heater. Go to the next step.

26 B 2-24 Checking a Heater or Heater Circuit (contd.) Table B 2-6 Heater Connector Locations and Harness Pins for Measuring Resistance Problem Zone Connector Location Connector: Pin Resistance Range Hose 1 Power board X1: 1 and X2: ohms Hose 2 Power board X1: 3 and X2: ohms Hose 3 Power board X1: 5 and X2: ohms Hose 4 Power board X1: 7 and X2: ohms Hose 5 (See Note A) 5/6 hose/gun board X1H: 4 and X2H: ohms Hose 6 (See Note A) 5/6 hose/gun board X1H: 2 and X2H: ohms Gun 1 Power board X1: 2 and X2: ohms Gun 2 Power board X1: 4 and X2: ohms Gun 3 Power board X1: 6 and X2: ohms Gun 4 Power board X1: 8 and X2: ohms Gun 5 (See Note A) 5/6 hose/gun board X1H: 3 and X2H: ohms Gun 6 (See Note A) 5/6 hose/gun board X1H: 1 and X2H: ohms Tank 480 VAC distribution board NOTE A: Some units can accept only four hoses and four guns. X5DA and X5DB ohms 4. Check the continuity of the heater circuit by measuring the heater resistance at a point in the circuit that is closer to the heater. If the faulted zone is a hose or gun, measure the resistance at the hose or gun electrical plug. Refer to your hose or gun manual for a diagram of the electrical plug and for procedures for replacing the gun heater. If a hose heater is defective, replace the hose. If the faulted zone is the tank, measure the resistance at the tank heater connectors. If you measure infinite or zero (0) resistance at the tank heater connectors, you must install a new tank. Refer to the Tank section. 5. Replace the control board or the control assembly. Refer to Replacing a Assembly Board or Replacing the Assembly in Repair Procedures.

27 B 2-25 Checking a Thermostat Use this procedure to check a thermostat. WARNING: System or material pressurized. Relieve pressure. Failure to observe this warning may result in serious burns. 1. Relieve system pressure. Refer to Relieving System Pressure in the Maintenance section. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 2. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 3. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 4. Remove the thermostat. Refer to RTD or Thermostat Removal in Repair Procedures. 5. Connect an ohmmeter set on the lowest resistance scale across the thermostat; then heat the thermostat with a flameless electric heat gun. Short circuit before thermostat reaches temperature and open circuit when thermostat reaches temperature: normal indication. Return to the appropriate troubleshooting table. Short circuit or low resistance at high temperature: defective thermostat. Replace the thermostat. Refer to Replacing an RTD or a Thermostat in Repair Procedures.

28 B 2-26 Checking an RTD or RTD Circuit Follow this procedure to check an RTD or RTD circuit. NOTE: If the faulted zone is a hose or a gun, you can remove the hose or gun and replace it with a hose or gun that is known to be good. If the fault disappears, then the problem is in the hose or gun, not inside the unit. As an alternative to using this procedure, you can refer to your hose or gun manual for instructions on checking the hose or gun RTD and replacing the gun RTD. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. Check the RTD by measuring its resistance. Refer to Table B 2-7. If the RTD is defective, replace the RTD. If a hose RTD is defective, you must replace the hose. To replace a gun RTD, refer to your gun manual. To replace a tank RTD, refer to Replacing an RTD or a Thermostat in Repair Procedures. NOTE: Flex the hose when you are checking a hose RTD. Some hose RTDs exhibit problems intermittently. If the RTD is good, go to the next step.

29 B 2-27 Table B 2-7 Measuring RTD Resistance Quick Methods In-Depth Methods Using a surface-temperature sensing device, such as a thermocouple, measure the temperature of the RTD at or near the end of the RTD that is accessible. Then use an ohmmeter to measure its resistance (See Note A). See Figure B 2-6 and compare the resistance reading to the RTD s normal resistance at the known temperature. Roughly estimate the temperature of the RTD to the nearest 50 C (100 F). Use an ohmmeter to measure its resistance (See Note A). See Figure B 2-6 and compare the resistance reading to the RTD s normal resistance at the estimated temperature. Because RTDs usually fail open or closed, any resistance reading from approximately ohms strongly indicates that the RTD is good. Let the system cool down to room temperature. When the RTD has had time to reach room temperature, use an ohmmeter to measure its resistance (See Note A). See Figure B 2-6 and compare the resistance reading to the RTD s normal resistance at room temperature. Remove the RTD and heat it to a known temperature by using an oven or by placing it in boiling water (protect the wires and hold them above the water). Then use an ohmmeter to measure its resistance (See Note A). See Figure B 2-6 and compare the resistance reading to the RTD s normal resistance at the known temperature. NOTE A: If the faulted zone is a hose or gun, measure the RTD resistance at the hose or gun electrical plug. Refer to your hose or gun manual for a diagram of the electrical plug and for procedures for checking RTD resistance. Because the core elements of a hose are not accessible, you cannot use some of the methods described in this table to measure the temperature of a hose RTD. If the faulted zone is a tank, measure the resistance at pins 33 and 34 of the harness attached to connector XP2 on the control board.

30 B 2-28 Checking an RTD or RTD Circuit (contd.) 4. Check the continuity of the RTD circuit by measuring the RTD resistance at other points in the circuit. Refer to Table B 2-8 for the plug or harness pins for each check. For a gun RTD, you can check continuity at two points: first at the hose electrical plug and then at the harness connected to XP2 on the control board. For a hose RTD, you can check continuity at the hose electrical plug or at the harness connected to XP2 on the control board. See Figure B 2-4 for the location of XP2 on the control board. For the tank RTD, there are no further checks you can make: go to the next step. Zone with Faulted RTD Table B 2-8 Pins for Checking RTD Resistance Gun Electrical Plug Pins Hose Electrical Plug Pins Connector XP2 Harness Pins Gun 1 3 and 5 3 and 5 9 and 10 Hose 1 N/A 5 and 8 1 and 2 Gun 2 3 and 5 3 and 5 11 and 12 Hose 2 N/A 5 and 8 3 and 4 Gun 3 3 and 5 3 and 5 13 and 14 Hose 3 N/A 5 and 8 5 and 6 Gun 4 3 and 5 3 and 5 15 and 16 Hose 4 N/A 5 and 8 7 and 8 Gun 5 (See Note A) 3 and 5 3 and 5 25 and 26 Hose 5 (See Note A) N/A 5 and 8 29 and 30 Gun 6 (See Note A) 3 and 5 3 and 5 27 and 28 Hose 6 (See Note A) N/A 5 and 8 31 and 32 Tank N/A N/A 33 and 34 NOTE A: Some units can accept only four hoses and four guns. 5. If you find a continuity problem in the gun RTD circuit, replace the hose or replace the gun RTD harness inside the unit as appropriate. If you find a continuity problem in the hose RTD circuit, replace the hose RTD harness inside the unit. If you do not find a continuity problem, go to the next step. 6. Replace the control board or the control assembly. Refer to Replacing a Assembly Board or Replacing the Assembly in Repair Procedures.

31 B RESISTANCE IN OHMS C 32 C 54 C (50 F ) (90 F) (130 F ) 77C 99C 121C 143C 166C 188C 210C 232C (170 F ) (210 F ) (250 F ) (290 F ) (330 F ) (370 F ) (410 F ) (450 F ) Fig. B 2-5 RTD Resistance vs. Temperature

32 B Repair Procedures Use these procedures to replace control system components. You can use the parts list illustrations at the end of this section as a guide as you perform these procedures. Refer to the parts lists for the part numbers of any components to be replaced. WARNING: Risk of electrical shock. Failure to observe electrical safety procedures may result in personal injury or death. Allow only qualified personnel to perform these repair procedures. Observe all high-voltage indicators. Replacing a Fuse Follow this procedure to replace a fuse. A fuse may be secured by a vertical or horizontal fuse holder. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. See Figure B 2-7 and use the following table to locate the fuse to be replaced.

33 B 2-31 Table B 2-9 Board Fuses Board Fuse for Fuse Numbers Power board Hose 1, gun 1 F1, F5 Hose 2, gun 2 Hose 3, gun 3 Hose 4, gun 4 power supply 480 VAC distribution board power, tank heater power 5/6 hose/gun board (5/6 hose/gun units only) Transformer (secondary winding) Hose 5, gun 5 Hose 6, gun 6 F2, F6 F3, F7 F4, F8 F9, F10 F1, F2, F3 F4 F1, F3 F2, F4 F1 F2 F1 F2 F3 F5 F6 F7 F8 F9 F10 F3 F4 F11 F12 2 F4 1 F1 F3 F4 F A Fig. B 2-6 Location of Fuses on Boards 1. Power board VAC distribution board 3. 5/6 hose/gun board

34 B 2-32 Replacing a Fuse (contd.) 4. See Figure B 2-7. Remove the fuse from the fuse holder and install the new fuse. Refer to the following table. Fuse Holder To Remove To Install Vertical 1. Press down on the fuse cap and turn it counterclockwise until you feel the cap release. Horizontal 2. Lift the cap and fuse from the connector. Lift the fuse from its two-station connector. 1. Pull the fuse from the cap and replace it with a new fuse. 2. Insert the cap and fuse into the fuse holder. Turn the fuse and cap clockwise and press down until you feel the cap lock into place. Press the replacement fuse into the two-station connector until the fuse snaps into place. 2 1 Fig. B 2-7 Fuse Holders 1. Vertical 2. Horizontal A 3. Close the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure.

35 B 2-33 Replacing a Assembly Board Use these procedures to replace the power board, control board, or display board. As an alternative, you can save time by replacing the entire control assembly. Refer to Replacing the Assembly. Preparation for Removal WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit, including input/output (I/O) lines. 1. Place the unit s POWER switch in the off position, disconnect and lock out electrical power to the unit at the branch circuit disconnect switch, and disconnect and lock out electrical power supplied through any I/O wiring. 2. Open the electrical enclosure. Refer to Opening and Closing the Electrical Enclosure. 3. Unscrew the support strap from the control-end frame and disconnect the electrical service from TB1 on the power board. Power Board Removal 1. If you have not already done so, complete Preparation for Removal. 2. Label or note all power board connections for later reference. NOTE: See the Parts section for an exploded drawing of the control assembly parts. The wiring diagram contained in the Wiring Diagrams section at the end of this manual may also be helpful. 3. Disconnect the voltage plug from X3 (and X4 if applicable) on the power board. NOTE: Replacement power boards do not have a voltage plug. You must keep the voltage plug from your old board. 4. Disconnect all harnesses, ribbon cables, and other connections from the power board.

36 1 B Remove the mounting hardware from the power board. CAUTION: Risk of equipment damage. Do not bend the XP1 connector pins. 6. Starting from the edge opposite the XP1 connector, carefully separate the power board from the control board. Take care not to bend the XP1 connector pins that join power board and control board. NOTE: The XP1 connector may remain attached to the power board. If it does, remove it and attach it to connector XP3 on the control board. NOTE: If the optional I/O board is connected to the control board on your unit, take care not to damage the I/O board as you remove the power board. Power Board Installation 1. Remove the new board from its static-safe container. Handle the board by its edges without touching any pins, wires, or circuitry. 2. See Figure B 2-8. Align XP1 on the new power board with the connector pins on the control board. Press the board into place, making sure the connector pins are properly inserted into their sockets Fig. B 2-8 Aligning the XP1 Connector Pins

37 B 2-35 Power Board Installation (contd.) 3. Install the mounting screws and lock washers you removed earlier. Be sure to use lock washers on the three screws located at the three ground pads on the power board. Tighten all screws to Nm (10 12 in.-lb). NOTE: See the Parts section for an exploded drawing of the control assembly parts. 4. Install the large triac (Q17) screw, which is to the left of TB1. Tighten the screw to Nm (7 8 in.-lb). 5. Install the two triac clamps and, starting with the center screw, tighten the securing screws to Nm (10 12 in.-lb). 6. Connect the voltage plug you kept from your old board to X3 (and X4 if applicable) on the power board. 7. Connect all other harnesses, ribbon cables, and other connections to the power board. 8. Go to System Restoration. Board Removal 1. If you have not already done so, complete Preparation for Removal. 2. Remove the power board. Refer to Power Board Removal. 3. Label or note all control board connections for later reference. NOTE: See the Parts section for an exploded drawing of the control assembly parts. The wiring diagram contained in the Wiring Diagrams section at the end of this manual may also be helpful. 4. Disconnect all harnesses, ribbon cables, and other connections from the control board. 5. Remove the mounting hardware from the control board. NOTE: If your unit has the optional I/O board, you must also disconnect this board from the control board. Refer to Series 3000V Input/Output Board in the Options section for instructions on I/O board removal. 6. Carefully separate the control board from the display board. Take care not to bend the XP4A connector pins that join the control and display boards. Retain the connector.

38 1 B 2-36 Board Installation 1. Remove the new board from its static-safe container. Handle the board by its edges without touching any pins, wires, or circuitry. 2. See Figure B 2-9. Align the XP4A connector pins (2) with the connector (1) on the display board, then carefully press the control board into place. 1 2 Fig. B 2-9 Aligning the XP4A Connector 1. XP4A connector 2. XP4A connector pins A 3. Reinstall the mounting hardware. Be sure to use lock washers on the two screws located at the two ground pads on the control board. Tighten all screws to Nm (10 12 in.-lb). NOTE: See the Parts section for an exploded drawing of the control assembly parts. 4. Connect all other harnesses, ribbon cables, and other connections to the control board. NOTE: If your unit has the optional I/O board, you must also connect this board to the control board. Refer to Series 3000V Input/Output Board in the Options section for instructions on I/O board installation. 5. Install the power board. Go to step 2 in Power Board Installation.