5550 w/omniscan Service Kit 4-1 Electrical Service Kit Installation for the Model 5550 Drum Melter with OmniScan Controller 1. introduction This document provides the required information necessary to install the Nordson Model 51550 Drum Melter with OmniScan Controller Electrical Service Kit on the following units: Hard-wired IEC-type (415Y) units (grab handles on each side of the OmniScan controller) - service kit P/N I59 370 Hard-wired NEC-type (460Delta) units (grab handles on each side of the OmniScan controller) - service kit P/N I59 370 Soft-wired IEC-type (415Y) units (no grab handles on each side of the OmniScan controller) - service kit P/N I59 366A Part item, name and number information Nordson engineering drawings: in this document refers to P/N I59 364 (2 sheets) P/N 159 362 (3 sheets) P/N 159 367 (I sheet) P/N I57 856 (wire list) A WARNING: When performing these procedures, read, observe and follow the Safety Instructions (Section I) in the full-length manual (P/N 106 572A) that accompanies this unit. Failure to do so may result in equipment damage, personal injury or death. The steps in this document are grouped into the following general categories: Replacement of the OmniScan Controller Assembly (soft-wired, IEC units only) Installation of the IEC Fuse Holders and Fuses (soft-wired, IEC units only) Modification of the Grounding Scheme (soft-wired, IEC units only) Noise Filter Relocation (soft-wired, IEC units only) Removal of the Seven-Day Digital Timer (soft-wired, IEC units only) DIN Rail Assembly Replacements (soft-wired, IEC units only) Modification of the Pump Lockout Switch and Label (all units) Modification of the Light Tower Mounting (all units) Miscellaneous If problems occur during this installation, representative immediately. contact your Nordson 0 Nordson Corporation 1993 Publlcatlon No 108 737A (S) 47.52 - Issued 6/93
5550 w/omniscan Service Kit Service Kit, Model 5550 Drum Melter with OmniScan Controller Item No. Part No. Description Req d 1 2 3 4 5 6 7 a 9 10 11 12 13 14 15 16 17 ia 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 159 366 984 120 983 120 150 301 981 139 983 112 151 759 939 091 157 779 981 159 983 124 981 731 157 780 983 123 151 757 151 758 159 324 159 325 161 la9 161 191 151 760 983 102 133 660 157 a57 157 865 933 315 933 569 933 375 933 541 933 570 900 71 a 981 778 157 793 984 101 133 962 157 a27 Service Kit, Electrical, Model 5550 w/omniscan, Soft-Wired IEC Nut, Hex, Machine, #lo-32 Lockwasher, Split, External, No. 10. Block Assembly, Terminal, TBl9 Screw, Pan Head, 8-32 x 0.625 in. Washer, Flat, 0.188 x 0.625 in. Block Assembly, Model 5550, TB5-TB8,415Y IEC Fuse, 25OV, 5 Amp Plate, Ground, Copper Screw, Pan Head, #IO-32 x 0.50 in.. Lockwasher, Internal, #IO Screw, Hex Head, #lo-32 x 1.OO in. Spacer, 0.75 in. Diameter x 5.00 in. Long Washer, Flat, 0.219 x 0.50 x 0.049 in. Block Assembly, Model 5550, TBl6, NEC/IEC Block Assembly, Model 5550, TBS-TBl5,415Y IEC Plate, ID, Pump Enable Plate, ID, Pump Disable. Plate, Escutcheon. Knob, Single-Handle Block Assembly, Model 5550, TBl -TB4 Lockwasher, Split, #6 Holder w/adapter, Fuse, 63 Amp Wire Assembly, Model 5550 with OmniScan, IEC Panel, Control Assembly Plug, Electrical Connector, g-pin, Std. Plug, Electrical Connector, 16-Pin, Std Plug, Electrical Connector, 24-Pin, Std Plug, Electrical Connector, 37-Pin, Std Plug, Keying, Series 1 & 4 Connector Bushing, Snap, It/16 in. ID Screw, Pan Head, #lo-32 x 0.62 in. Fuse, Link, Fast-Acting, 40-Amp, GE Nut, Hex, Machine, #6-32 Board with Bracket, Filter, 380Y Kit, Label Ref a a 1 a 2 1 1 10 20 4 4 4 16 17 la 19 30 31 159 370 Service Kit, Electrical, Model 5550 w/omniscan, Hard-Wired IEC and NEC Ref 159 324 Plate, ID, Pump Enable 1 159 325 Plate, ID, Pump Disable 1 161 la9 9 Plate, Escutcheon 1 161 191 Knob, Single-Handle 1 900 71 a Bushing, Snap, 11/16 in. ID 1 981 778 Screw, Pan Head, #lo-32 x 0.62 in. 4 Pubkatlon (S) 47 52 - No Issued 108 737A 6/93 0 Nordson Corporation 1993
5550 w/omniscan Service Kit 4-3 2. Replacement of the OmniScan controller assembly A I WARNING: Disconnect and lockout input power from this equipment before proceeding. Failure to do so may result in equipment damage, personal injury or death. (soft-wired, IEC units only) I. Open the electrical enclosure door, then put on the ESD (electrostatic discharge) wrist strap that hangs from the back panel of the enclosure. The strap should be attached to a coiled wire connected to a ground stud. 2. Loosen the four slotted screws that secure the inside protective bracket in place, then lift the bracket free of the assembly. 3. Disconnect, remove and discard all electrical enclosure wires. The new wiring assemlbly will be used instead. 4. Open the hinged protective cover on the outside of the unit, then remove the four screws from the front of the OmniScan membrane. 5. Support the OmniScan controller assembly, then remove the two remaining screws from the exterior latch. 6. Carefully remove the controller assembly through the front of the enclosure door. Place the controller assembly on an ESD protective surface. 7. Remove the remaining OmniScan framework and mounting hardware from the enclosure door. 8. Drill eight new holes for mounting the replacement OmniScan controller assembly. See drawing P/N I59 362, sheet I, for exact locations. 9. Drill/cut four new htoles to accommodate the new OmniScan mounting hardwarle. See drawing P/N I59 362, sheet I, for exact locations. IO. Drill and tap two new holes in the power supply bracket (underneath the OmniScan controller) to accommodate TBI9. See drawing P/N I59 367 for exact Ilocations. I I, Remove and shorten wireway WWI 0 as needed to accommodate TBI9. 12. Install TBI9 (item 3) to the power supply bracket and secure it in place using two of the pan head screws and flat washers (items 4 and 5) from this kit. 13. Install the new OmniScan controller assembly (item 24) and secure it in place using the eight machine hex nuts and split lockwashers (items I and 2) frolm this kit. 14. Package the old OmniScan controller assembly and mounting hardware for return to Nordson. 0 Nordson Corporabon 1993 Pubkabon No.108 737A (S) 47.52 - issued 6/93
4-4 5550 w/omniscan Service Kit 3. Installation of the /EC fuse holders and fuses (soft-wired, EC units only) 1. Remove and discard the old fuse cover and standoffs from the backplate. 2. Remove and discard the old fuseblock. 3. Drill and tap six new holes in the backplate to accommodate the new fuse holders. See drawing P/N 159 362, sheet 2, detail A, for exact locations and pattern. 4. Mount the new IEC fuse holders (item 22) in place and secure them with four pan head screws (item 4) from this kit. 5. Install the fuses (item 32) from this kit. Publicahon No 108 737A (S) 47.52 - Issued 6193 Q Nordson Corporation 1993
5550 w/omniscan Service Kit 4-5 4. Modification of the grounding scheme 1. Disconnect the ground wires from the ground stud assembly (GSl at upper left corner of cabinet). (soft-wired, /EC units only) 2. Remove but do not discard the ESD strap and lug. 3. Remove and discard the old ground stud assembly. 4. Drill and tap three new holes in the backplate to accommodate the new grounding plate. See drawing P/N 159 362, sheet 2, for exact locations. 5. Remove paint on the backplate to a 0.75 in. radius around the new holes and existing fourth hole. 6. Drill and tap a new hole in the backplate for the ESD strap. See drawing P/N 159 362, sheet 2, for exact location. 7. Remove paint on the backplate to a 0.75 in. radius around the new hole. 8. Mount the ESD strap and grounding lug in place. 9. Secure the copper grounding plate (item 8) from this kit in place using the mounting hardware (items 11, 12 and 13) from this kit. 10. Install the ground bar hardware (items 9 and 10) from this kit. 0 Nordson Corporation 1993 Publlcahon No 108 737A (S) 47.52 - Issued 6/93
4-6 5550 w/omniscan Service Kit 5. Noise filter relocation (soft-wired, IEC units only) 1. Electrically disconnect the noise filter (NFl). 2. Remove the mounting screws for NFl. 3. Remove the mounting screws for the NFl bracket. 4. Drill and tap two new holes in the backplate for the relocated NFl bracket. See drawing P/N 159 362, sheet 2, for exact location. 5. Secure the old bracket in place using the existing screws. 6. Mount the new NFl (item 34) in place. 7. Connect NFl to the input side of the main power contactor. Refer to the wire list (P/N 157 656) for specific electrical connection information. Pubkation No.1 08 737A (S) 47.52 - Issued 6/93 0 Nordson Corporahon 1993 All Fhghts Reserved
5550 w/qmniscan Service Kit 4-7 6. Removal of the seven-day digital timer 1. Remove and disclard the pan head screws and split lo&washers that secure the timer (item 107 in original manual) in place. (soft-wired, EC units on/y) 2. Remove and discard the pan head screws and split lockwashers that secure the timer bracket (item 108 in original manual) in place. 3. Discard the old timer and bracket. 0 Nordson Corporation 1993 Pubkabon No 108 737A (S) 47.52 - Issued 6/93
4-8 5550 w/omniscan Service Kit 7. DIN rail assembly replacements (soft-wired, /EC units only) 1. Remove both pan heald screws and flat washers that secure the TB5-TB8 DIN rail assembly (item 64 in original manual) in place. 2. Remove the solid state relay (SSRl) from the old DIN rail assembly, then discard the old rail assembly. 3. Install the new DIN rail assembly (item 6) from this kit using the existing pan head screws and flat washers. 4. Install SSRl to the new DIN rail assembly at the same location it was removed from the old rail assembly. 5. Install fuse Fl (item 7) into the Fl fuse holder on the DIN rail assembly. 6. Replace the old TBl-TB4 DIN rail assembly (item 65 in original manual) with the new one (item 20) from this kit. Discard the old rail assembly. 7. Replace the old TBS-TB15 DIN rail assembly (item 63 in original manual) with the new one (item 15) from this kit. Discard the old rail assembly. 8. Replace the old TB16 DIN rail assembly (item 62 in original manual) with the new one (item1 14) from this kit. 9. Remove relays CR2, CR4 and CR5 from the old TB16 rail assembly and install them in their same positions on the new TB16 rail assembly. 10. Remove power supplies PSl and PS2 from the old TB16 rail assembly and install them in their same positions on the new TB16 rail assembly. Discard the old TB16 rail assembly. (S) Publication 47 52 - No.1 lssued 08 737A 6/93 0 Nordson Corporation 1993
5550 w/omniscan Service Kit 4-9 8. Modification of the pump lockout switch and labels (all units) 1. Remove the Pump Lockout label from the outside of the electrical enclosure side panel, and replace it with the Pump Enable label (item 16) from this kit. 2. Remove the old switch knob and indicator plate. 3. Remove the old switch housing and mounting screws, 4. Drill two new holes for the new switch mounting plate. See drawing P/N 159 362, sheet 2, detail B, for exact location and pattern. 5. Drill two new holes for the Pump Disable label. See drawing P/N 159 362, sheet 2, for exact location. 6. Secure the old switch in place using the existing mounting hardware. 7. Secure the new switch plate (item 18) in place with the two screws that accompany it. 8. Place the clear plastic cover plate (accompanies the new switch plate) over the new switch plate 9. Install the new switch knob (item 19). 10. Secure the Pump Disable label (item 17) in place using two machine hex nuts and split lockwashers (items 33 and 21) from this kit. 0 Nordson Corporation 1993 All Rtghts Reserved Publlcatron No.108 737A (S) 47.52 - Issued 6/93
4-10 5550 w/omniscan Service Kit 9. Modification of the light tower mounting (all units) 1. Disconnect the light tower electrical wiring. 2. Remove the four existing mounting screws, nuts and lockwashers, then lift the light tower from the enclosure. 3. Enlarge the existing wire feedthrough hole to Vs in. diameter to accommodate the new bushing. 4. Insert the new snap bushing (item 30) in the feedthrough hole. 5. Install the light tower using the new pan head screws (item 31) from this kit, but with the old nuts and washers. 6. Reconnect the light tower electrical wiring. Refer to the wire list (P/N 157 856) for specific electrical connection information. Pubkatlon No.i 08 737A (S) 47.52 - Issued 6/93 0 Nordson Corporation 1993
5550 w/omniscan Service Kit 4-11 IO. Miscellaneous 1. (Soft-wired, IEC units only) Rewire the electrical enclosure using the wire assembly (item 23) from this kit. Use the accompanying wire list for reference when performing this step. NOTE: Use the five plugs from this kit (items 25, 26, 27, 28 and 29) to connect the wiring harness to the new OmniScan controller. 2. (Soft-wired, IEC units only) Apply new labels from the label kit (item 35) in this service kit. 3. (All units) Close and latch the electrical enclosure door. 4. (All units) Reconnect and apply input power. 5. (All units) Refer to your original manual for startup and operating procedures. 0 Nordson Corporation 1993 Pubkatlon No.108 737A (S) 47 52 - Issued 6/93
4-12 5550 w/omniscan Service Kit This Page Intentionally Left Blank Publication No 108 737A (S) 47 52 - Issued 6/?33 Q Nordson Corporahon 1993