Home

Orion 104B Users Manual

1. FLEXSTAR TECHNOLOGY INC 7 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 8 PEGASUS 104B Rev 6 2156 1 7 Rear EMO Switch Installation WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing To install the EPO switch on the back of the 104B locate the EMO knock out on the rear left side panel and remove with a flat head screw drive The EMO switch must meet all EMO safety standards and can be ordered from Flexstar Technology see part list below Refer to the 104B wiring diagram for recommended wiring procedure For easy access to the inside of the left side panel remove the intake fan assemblies ITEM DESCRIPTION 35 38650 00 FLANGE NARROW 2 38 38649 00 BUTTON EMO a M 3 38 38651 00 CONTACT BLOCK Intake fan assembly eee Rear EMO Switch Knock out Rear EMO Switch FLEXSTAR TECHNOLOGY INC 8 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 9 PEGASUS 104B Rev 6 ECO2156 1 8 Control Panel Identification To access the control wiring remove control panel cover CONTROL PANEL Set Point Overtemp Alarm Audible WATLOW 984C Set Point Overtemp Controller Alarm Visual 24VAC Lamp To replace the indicator lamp unscrew the lens and remove the 100 BASE T Hub lamp Port 45 Thermal Overload 24VAC Lamp To replace the indicator lamp am et Point Overtemp
2. OO UU CUR TN ERE no no 8 CD 7 5 7 100 5 DCD 6 D PS 6 P Ps s 2 3 2CD 3 102 4 PS 3 5 4 PS PS 104B PORT N 182 45 EEND LUN 1 1 65 PRT PSL COLUMN 121 43 ener ENS LUN 12142 PORT oo DSN ER NIAE VI COLUMN 1 20 132 PURI m PSI RET ILUMN 1 PURT 919 788 LUN 1 PIRT 5 eL COLUMN 1 PIRT ool 79W PSI UN 1 PORT 99 00 COLUMN 1 PORT 10102 o4H anu LUN 1 PIRT 934 80 POWER WODULE VI Em E PSL RET TLUN 1 PURI 99 100 9480810 TLUN 1 PORT 101102 eL LUN 1 PORT 103 T 951 821 4 951 828 o b Pe kai 9 969 83 x 10A CLIENT COLUMN 2 PRT eL 1506 ee CLIENT COLUMN 2 PORT 97H 940 A acne CLIENT COLUMN 2 PORT 2 VDC POWER MODULE V2 Dene a PORT id cM RET s 2 1 988 858 ror a PORT 1 JA 002 7 2 PORT 994 86 Pse 5V2C eer a CLIENT COLUMN 2 Port d De 002 9 2 eer 1100 9 871 nana ee 87 DCD2 11 t PORT nt ol T Ir Qi Jcle l2 CLIENT COLUMN PORT 7101 9 88 CLIENT COLUMN 2 PORT Iran 1 14 CLIENT COLUMN 2 PORT 91021 898 FAN 1 RET s 5 oL and 41038 906 PORT 65 66 PS3 15v PIRT 6768 DCD 1 060 2 rm RET PIRT 6758 LUN PIRT 69 70 T COLUMN PORT Ps3 1505
3. 5 Watlow 892 Temperature Controller Rack Installation 4 Setup Modifying 5 7 Rack Power Up Power Down 4 Watlow 982 Temperature Controller 7 Rack 9 Wiring Diagrams seseris 22 m 13 Control Wiring 24 Cabinet 9 Rack Wiring 22 Circulation Baffle Assembly 17 FLEXSTAR TECHNOLOGY INC 34 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0
4. 27 70000 00 SCREW 6 32 1 4 PH PHIL STZN 32 50103 00 COUPLER RJ45 RJ45 FLEXSTAR TECHNOLOGY INC 23 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 24 505 104B Rev 6 2156 3 11 Hub Assembly WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING Lifting hazard Single person lift could cause injury Use assistance when moving or lifting Cap Weight 6416 2 9kg Warning When power cycling the 104B the power must remain off for 60 seconds and the controller must be in the exhaust mode to allow the frequency converter to reset To replace the Ethernet Hubs remove the 6 10 32 screws in the top cap and lift the top cap off the rack Unplug the Ethernet and power cables remove the 4 8 32 screws in the hub bracket and lift the hub assembly off the rack Remove the two hub brackets mounted to the hub Reverse process to install a hub ITEM PART NUMBER DESCRIPTION 1 01 37710 00 32 PORT 100 BASE T HUB 2 01 50367 00 CAP 104B 3 19 38355 00 HUB BRACKET 4 03 38532 36 36 ETHERNET CABLE 5 27 50311 00 10 32 X 3 1 2 SCREW Not shown 6 27 34308 00 8 32 X 1 4 SCREW Not shown 7 36 30275 00 ETHERNET POWER CABLE Not shown 8 38 37709 00 5 PORT HUB SWITCH if necessary RJ45 8 Position Ethernet
5. PORT COLUMN PORT 75 76 POWER MODULE V2 PORT TP PS3 RET COLUMN 3 J2 12 11 PORT 7374 CLIENT COLUMN 3 42 109 PIRT 75 76 1 13 14 COLUMN 42 8 PORT 77 n UP 2 Rt m XA mener CLIENT COLUMN 4 PORT PS4 ISVDC Dene CLIENT COLUMN 4 PORT 15 VIC POWER MODULE V3 QUA 0 ED D UMN 4 PORT Tee LUN 4 PORT ps4 RET 4 PORT 1014 6 COLUMN 4 PORT ii PU NES D 4 54 1505 CLIENT COLUMN 4 PORT CLIENT COLUMN 4 PORT CLIENT RT 15 VIC POWER MODULE VI eal PS4 RET CLIENT COLUMN 4 PORT CLIENT COLUMN 4 PRT PORT LUN 5 PIRT 3940 55 PORT 4142 COLUMN 5 PORT 43 44 LUN 5 PIRT 3940 PSS COLUMN 5 PORT DUM S PORT 4344 MA DCDS 7 COLUMN 5 PORT 45 45 PSS 1506 10A Dcns 8 ILUN 5 PORT 47 48 EN 5 PORT 4950 VIC POWER MODULE va UN 5 51 E LUN PORT 4346 55 RET PORT 4748 LIENT 5 PIRT 49 CLIENT COLUMN 5 42 8 PORT 5t FAN GROUP 3 RET T enu PORT Ps6 vac CLIENT COLUMN 15 VIC POWER MODULE m PS6 RET PORT UMN 6 PORT o ENT COLUMN PIRT PS6 15VDC LUN PORT PERT i 15 VIC POWER MODULE v2 on id PS6 RET ILUMN PORT rar CLIENT COLUMN PORT LIENT COLUMN 6 PORT AN CROP 4 RET PIRT PS TLUN 7 PRT UMN 7 PORT 15 VIC POMER HOLE v3 ys pd n RET 1007 2 CLIENT COLUMN 7 PRT 007 6 7 PORT 0077 7 PORT PS HSVDC 7 PORT C
6. 2156 3 10 Pallet Ladder Assembly ass y P N 01 36279 00 WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING Lifting hazard Single person lift could cause injury Use assistance when moving or lifting SBC Panel Weight 33lb 19kg To replace a damaged power or Ethernet cable in the power ladder remove all the SBC pallets on both sides of the column with the damaged cable Unscrew the Left Hand Tray Guide from Right Hand Tray Guide carefully clip the zip ties and remove the damaged cable Reverse the process to replace the cable carefully zip tying the cable back into place To access the Ethernet cables and RJ45 couplers in the top of the rack remove the access panel on the top of the rack Warning Do Not Operate the Rack For More then 10 Minutes with the SBC Panels Removed PART NUMBER DESCRIPTION 03 38532 24 CABLE RJ45 RJ45 24 03 38532 36 CABLE RJ45 RJ45 36 03 38532 48 CABLE RJ45 RJA5 48 03 38532 60 CABLE RJ45 RJ45 60 03 38702 00 CABLE LADDER PWR SHORT 104B 03 38703 00 CABLE LADDER POWER 104B 19 38011 00 TRAY GUIDE RIGHT HAND 104B 19 38012 00 TRAY GUIDE LEFT HAND 104B SHOWN 2 3 4 5 6 7 8 9 25 30777 00 TIE WRAP 6 25 31695 00 TIE WRAP 3 25 50542 00 WIRE TIE MOUNT 1 N 27 30359 00 CABLE TIE MOUNT
7. Hit Exit Hit Enter Hit Exit 0 0 4 PAr L MENU FWD aq 99 If unit is new out of the box it will be in local mode thus will not start Rev 6 ECO2156 LOC 9 9 0 2 Loc 1 Hit Enter to enter Parameters Hold Enter Use OO to set Parameter Hit Enter to exit PAR FWD PAR Sag FWD Loc 9 9 0 5 Loc 2 3 0 Use to select next Parameter Hold Enter Use to set Parameter Hit Enter to exit PAR FWD PAR FWD LOC 7 5 Use to select next Parameter Hold Enter Use to set Parameter Hit Enter to exit PAR FWD LOC 9 9 0 7 LOC 6 0 0 Use to select next Parameter Hold Enter Use to set Parameter Hit Enter to exit PAR FWD PAR Sag FWD Loc 9 9 PAR FWD LOC 1 0 Use to select next Parameter p PAR FWD LOC 1 0 0 1 LOC 1 Hold Enter Use to set Parameter Hit Enter to exit PAR FWD PAR Er wb LOC 1 0 0 3 LOC 1 Use to select next Parameter Hold Enter Use to set Parameter Hit Enter to exit PAR FWD PAR FWD LOC 0 Use to select next Parameter Hold Enter Use to set Parameter Hit Enter to exit PAR FWD LOC 1 1 PAR FWD LOC 1 6 Use to select next Parameter PAR FWD FLEXSTAR TECHNOLOGY INC 28 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 29 505 104B Rev 6 2156 Hit Enter Hit Exit Use to select next Parameter Hit Enter Use to select next Parameter Use
8. Roll the rack back into position and bolt the plates to the floor To secure the rack to the ceiling use strut channel bolted to the rack and the ceiling with a or 5 16 nut and bolt See diagram below for mounting hole location For ease of installation remove the Top Cap after marking and drilling mounting holes Strut Channel with ceiling mounting plate not provided 1 Right side of 104b showing the ZA EEP mounting hole for the strut channel sss Fr j Earthquake Lock Down Plate e 7 1 9 3861 5 00 3 8 Drive Anchor n not provided FLEXSTAR TECHNOLOGY INC 4 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 5 PEGASUS 104B Rev 6 ECO2156 1 3 Main AC Power Hook up Power Requirements 230VAC 40 AMP 50 60hz Three Phase unless otherwise stated on the machine Insure customer supplied power meets this requirement The Orion Series is high performance test equipment In order to ensure proper operation care must be taken to supply computer grade AC power This includes a low impedance ground Failure to do so may cause unexpected operation or other errors The 104B main power switch is a UL listed 1077 circuit protector Customer supplied power must use a UL 489 or IEC 947 2 10k AIC listed breaker for proper 104B protection The 104B is not supplied with a main power disconnect The customer must supply a m
9. CE INDICATE THE PART IS USED IN THE 104B 400VAC CE UNIT ONLY ALL OTHER PARTS ARE IDENTICAL aS memmas L1 mem 1 A E C FLEXSTAR TECHNOLOGY INC 33 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 34 505 104B Rev 6 ECO2156 8 0 104B Decommissioning Procedure The total weight of the 104B is 2100 Ibs 104B is made up of 1425lb sheet steel 325lb electronics 22516 wire and cable assemblies 1001 aluminum and 2516 plastic Separate the 104B into the above categories and recycle or dispose components according to local ordinances 9 0 Technical Support Flexstar Technology 47323 Warm Springs Boulevard Fremont CA 94539 510 440 0170 Fax 510 440 0177 Email sales flexstar com www flexstar com Flexstar Technology 1871 Lefthand Circle Suite A Longmont CO 80501 303 776 8030 Fax 303 776 8086 104B Replacement Pans 28 Circulation Blower Housing 15 Drive Fixtures Drive FITUES 10 Fixture Assembly 10 Exhaust Blower Assembly 18 Fixture Shelf Removal and Installation 11 Heater 16 Operation Procedures 4 SBC Rear TE aso tona nca ix b odd 12 Control Panel Identification 6 Technical Support 29 Emergency Shut
10. Check the Watlow controller to ensure it is properly programmed See page 7 If the rack does not reach the desired elevated temperature insure the intake baffle is completely closed If the baffle does not close remove the intake panel and insure the assembly is property adjusted and does not bind insure the thermal actuators are fully functional replace parts that exhibit excessive wear or do not function See pages 13 14 If the rack does not reach the desired elevated temperature insure the circulation baffle is completely open Remove the intake panel and insure the assembly is property adjusted and does not bind insure the thermal actuator is fully functional replace parts that exhibit excessive wear or do not function See page 17 If the rack does not reach the desired elevated temperature insure the exhaust stack baffle is fully closed See page 18 If the rack does not reach the desired elevated temperature insure the heaters are fully functioning Each heater should produce 1500 watts of heat See page 16 The intake panel is hot to the touch Check the Watlow controller to insure it is properly programmed See page 7 Insure the circulation baffle is completely open during the heat mode Remove the intake panel and insure the assembly is property adjusted and does not bind insure the thermal actuator is fully functional replace parts that exhibit excessive wear or do not function See page 17 The blowers do not come on or the hav
11. unscrew the lens and Alarm Manual Override remove the lamp ESD Ground ML BES Jacks Start Switch E Push to turn HO machine ON s E Stop Switch p 2i Push to turn machine OFF Frequency Converter Bypass Alarm 24VAC Lamp To replace the indicator lamp unscrew the lens and remove the lamp Control Panel Cover WATLOW Com Port Warning When power cycling the 104B the power must remain off for 60 seconds and the controller must be in the exhaust mode to allow the frequency converter to reset Control Panel functions Start Switch Starts machine Green LED unit energized The main circuit protector must be on the start machine Stop Switch Stops machine Red LED unit de energized Thermal Overload When the Thermal Overload light is energized either the heater bay or the DUT bay has gone into an over temp condition and the unit the main power has shut off See section 3 13 Frequency Converter Bypass When the frequency converter bypass light is energized the motor drive has failed and the blowers are now operating on house power If the control panel does not have a Fequency Converter bypass light installed then the 104B does not have the Frequency Converter circuitry installed See section 4 0 Set Point Overtemp Alarm visual Audible Alarm When the Set Point Overtemp alarm is energized the DUT bay has exceeded the high temp set point To silence the alarm turn the Set Point Overtemp alarm Manual Overrid
12. DD 7 PORT ncn LUN 7 PORT 25 CLIENT cun 7 PRI 1920 57 RET 0007 12 LUN 7 PORT 2122 007 13 CLIENT TOLUN 7 PURI 2324 2007 4 CLIENT COLUMN PORT 25 CLIENT COLUMN 11 65 PSB CNET 23 10 1 8 3 PORT 45 15 VIC POWER MODULE ve PSB RET CLIENT COLUMN PRI 23 CLIENT COLUMN PORT 45 CLIENT COLUMN PIRT 67 PSB CLIENT COLUMN PORT 8 9 NK MUN PORT z LUMN PORT 12 a pena COLUMN 42 1413 PORT 6 7 PSB Hl IT COLUMN 8 PORT 8 9 1 18 13 ENT COLUMN 8 22 09 PORT id CLIENT COLUMN B PORT 12 ne ESIODING CABLE REAR VIEW FLEXSTAR TECHNOLOGY INC 30 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 31 505 104B Rev 6 ECO2156 5 2 Control Wiring Diagram To access the control wiring remove control panel cover See diagram 104B Fused Control Panel Wiring Diagram 89 38602 00 5 3 Rack Wiring Diagram To access the fused wiring base remove the power panel at the rear lower left of the rack See diagram 104B Pegasus 208V 50 60Hz Fused Wiring Diagram 96 39632 00 and 96 39634 00 FLEXSTAR TECHNOLOGY INC 31 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 32 PEGASUS 104B Rev 6 ECO2156 6 0 104B Trouble Shooting The rack does not reach desired temperature
13. From the rear of the rack disconnect the Power and Ethernet Cables unscrew the panel fastener on the rear of the tray and slide the tray out If the rack is configured with IDE or Fibre or SATA cables carefully slide the pallet out to insure the cables do not chafe on the bulkhead To replace the tray reverse the process Warning Do Not Operate the Rack For More then 10 Minutes with the SBC Panels Removed 02 37183 00 PWA TWO SLOT RISER 02 37177 PWA PEGASUS SBC CONTACT FLEXTAR FOR PART NUMBER 02 37351 00 PWA 1 CH NWK POWER MARGIN HOST BUS ADAPTER CONTACT FLEXSTAR FOR PART NUMBER EXEL O FLEXSTAR FOR PART NUMBER s 2950587 case VGA KEVEOARD 9 19 50204 00 PALLET NOSE seres osemsumon TIE WRAP 6 s 49506746 GASKETPALLET 21 53 37977 00 CPU CELERON 733MHZ MRAM POCO To order replacement parts please use the above part numbers and description 11 FLEXSTAR TECHNOLOGY INC 15 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 16 5 5 104B Rev 6 ECO2156 3 4 Air Handler The 104B air handler consists of the intake baffle circulation blower circulation baffle and the exhaust blower When the rack calls for cooling the circulation blower draws air into the rack through the intake baffle The circulation blower then pushes the air into the right side plenum over the DUT and to the left side plenum where it is picked up by the exhaust blower and rem
14. Value in the upper display PROMPT VALUE NEW VALUE Degrees of process units or of span Pb1 1 Eliminates offset between set point and actual process temperature rE1 0 00 Eliminate overshoot on start up after the set point changes rA1 0 00 Time for the controller to complete one on off cycle Expressed in seconds Ct1 5 0 Degrees of process units or 96 of span Pb2 0 The area between output 1 and output 2 where no heating or cooling takes place in a heat cool proportional control db 0 10 Push the DISPLAY KEY Adjust the set points with the 4 and Down W ARROW Keys The alarm will follow the set point 5 The alarm will not be on when first powered up It will wait until the temperature is in the set point before it is enabled FLEXSTAR TECHNOLOGY INC 11 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 12 5 5 104B Rev 6 2156 3 0 Rack Maintenance 3 1 Cabinet Cleaning Exterior Keep Cabinet free of dust and dirt Clean the exterior of the Cabinet with a soft damp cloth Do NoT USE ABRASIVE CLEANSER Interior To PREVENT ELECTRICAL SHOCK DISCONNECT CABINET POWER BEFORE PERFORMING MAINTENANCE SERVICE OR CLEANING Inspect the Cabinets interior compartments frequently If needed clean with an ESD safe cloth Door Operation Inspect the two sliding doors rollers periodically If the doors begin to move with difficulty lubricate the roller bearings with a
15. WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING Rotating fan blades Can cause serious injury or cut Keep hands clear Turn off and lockout unit before servicing FLEXSTAR TECHNOLOGY INC 26 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 27 PEGASUS 104B Rev 6 ECO2156 The 104B has been equipped with an ABB Frequency Converter that powers the circulation and exhaust blowers This was done to provide a constant frequency of 60Hz to the blowers regardless of the input frequency and to provide the customer with the flexibility of shipping the 104B to sites that have 50Hz frequency The ABB Frequency Converter is located in the power bay next to the main circuit breaker See the ABB Frequency Converter User s Manual for more information t Frequency Converter 4 1 Frequency Converter Power On The ABB Frequency Converter has been factory set to automatically start when the 104B is powered up A green LED on the converter will indicate proper function 4 2 Frequency Converter Power Reset The Frequency Converter will shut down in an over current and over heat condition When this occurs the circulation and exhaust blowers will automatically switch to house power and continue running at a lower CFM The 104B will continue to safely operate in this condition until test tests are complete and the operator can safely power down the sy
16. small amount of Lithium grease Properly dispose Lithium grease applicator according to MFG recommended process and local ordinances Plexiglas Care Clean when required with soft damp cloth to remove smudges and dirt Do USE ABRASIVE CLEANSER Cable Connection Care TO PREVENT ELECTRICAL SHOCK DISCONNECT THE CABINET FROM POWER BEFORE MAINTENANCE amp SERVICE Frequently inspect the Cabinet s AC DC Power cabling and connections insuring good contact Insure Ethernet cabling is kink free SBC Cooling Intake and Exhaust Fans For optimal SBC performance frequently inspect and clean the SBC intake and exhaust cooling fans FLEXSTAR TECHNOLOGY INC 12 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 13 5 5 104B Rev 6 2156 3 2 Drive Fixture 2 1 Drive Installation To install a drive into the fixture grasp the black ball knob and rotate the lever handle then pull the slider out until it stops on the hinge pin Carefully place the drive into the fixture then push the slider in until it stops against the hinge pin then rotate the black ball knob closed The drive has fully engaged the sub adapter when the lever has stopped against the right side of the fixture 3 2 2 Sub Adapter Removal To remove the slider and sub adapter rotate the lever handle and pull out the slider until it stops on the hinge pin Unsnap the left card guide and rotate up tilting the slider up and out Disconnect the cab
17. 104B 24 32 30397 00 TERM FEMALE AMP ACTUATOR THERMAL SERIES 700 25 32 50462 00 CONN 4 POS MATE N LOC HSG 9 39 37953 00 THERMAL ACTUATOR 24V 10 27 34474 00 WASHER 6 FLAT STAINLESS 11 27 34106 00 SCREW 6 32x1 4 PH PHIL SS 12 27 50636 00 12 24 HEX STZN 13 27 50637 00 WASHER 6 FENDER 5 8 OD SZ 14 27 70106 00 6 32 KEP 1 4 STZN 15 27 70064 00 SCREW 10 32x3 8 PH PHIL STZN 16 27 70048 00 SCREW 4 40x1 2 PH PHIL BLACK To order replacement parts please use the above part numbers and description 26 32 50463 00 CRIMP MATE N LOC 14 20 GA 27 33 36092 00 0 187 FASTON AMP 28 41 35378 00 WIRE 18 AWG BLACK UL1061 29 41 35409 00 WIRE 14 AWG SF 2 30 25 31695 00 WRAP 3 31 43 50043 00 1 CLOSED CELL INSULATION 32 43 50008 00 1 4 LYTHERM INSULATION FLEXSTAR TECHNOLOGY INC 16 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 17 PEGAsus 104B Rev 6 ECO2156 6 10 11 bt s 5 11 10 11 20 28 29 ACTUATOR OPEN ACTUATOR No 1 THIS ACTUATOR CONTROLS THE BAFFLE IN THE RAMP DOWN CYCLE THE BAFFLE IS MOVED TO EXPOSE THE OPENINGS IN THE INTAKE BASE PANEL ADJUSTMENT SCREW 1 MICRO SWITCH No 1 THIS MICRO SWITCH IS USED TO FINE TUNE THE LOCATION OF THE BAFFLE BY TURNING THE ADJUSTMENT SCREW 1 IN OR OUT THE BAFFLE CAN BE ADJUSTED TO ENSURE THE AIR
18. 4 VDC Control Circuit Supply Power Supply Power Supply Base FLEXSTAR TECHNOLOGY INC 25 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 26 PEGASUS 104B Rev 6 ECO2156 3 13 Thermal Over Temperature Shut Down WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING burn hazard Hot surface inside Allow this area to cool before servicing The 104B has two thermal fuses that shut down the system when it goes into an over temperature condition The first fuse is in the center of the DUT bay It will shut down the system when the air temperature reaches 71 degrees Celsius The second thermal fuse is in the heater bay and will shut down the system when the heater bay reaches 140 degrees Celsius When either fuse is blown the machine shuts off and activates an amber light located on the control panel indicating one of the fuses has blown and needs to be replaced To replace the fuse in the DUT bay locate the fuse holder in the center of the bay and unplug it from the terminal block To replace the fuse in the heater bay remove the intake panel locate the fuse assembly above heater and remove the two 8 32 nuts Reverse process to install fuse Heater Bay Thermal Fuse Replace Fuse with part 01 38456 00 Some parts in this view not shown DUT Bay Thermal Fuse Replace Fuse with part 01 38457 00 4 0 ABB Frequency Converter
19. 8181 00 98 38181 00 104B PEGASUS MANUAL 6_0 19 5 5 104 6 2156 3 6 Heater Assembly WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING burn hazard Hot surface inside Allow this area to cool before servicing To access the heater assembly remove the lower front intake panel and disconnect the intake actuator power To replace a heater disconnect the power unscrew the 8 32 nuts that secure the heaters to the mounts 19 50362 00 HEATER MOUNT 2 34 37663 00 FINNED STRIP HEATER 3 27 50141 00 8 32 X 3 8 SCREWS To order replacement parts please use the above part numbers and description FLEXSTAR TECHNOLOGY INC 19 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 20 505 104B Rev 6 ECO2156 3 7 Circulation Damper Assembly Ass y P N 01 38464 00 WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING burn hazard Hot surface inside Allow this area to cool before servicing Warning When power cycling the 104B the power must remain off for 60 seconds and the controller must be in the exhaust mode to allow the frequency converter to reset To access the circulation baffle remove the lower front intake panel and disconnect the intake actuator power To remove the circulation baffle unscrew the six 8 32 screws that secure the
20. 8609 00 ITEM PART NUMBER DESCRIPTION 1 35 31015 00 FAN GUARD 4 5 19 50588 00 FAN PLATE 2 19 37653 00 CE FAN PLATE 3 27 70106 00 46 32 STZN 4 35 38555 00 4 5 130CFM 24VDC 5 25 50181 00 GROMMET 150 DAMP 6 27 50168 00 ISCR 6 32 X 2 5 PH SLOT STZN 7 27 50637 00 WASHER 6 FENDER 5 8 OD 8 32 36096 00 ICONN 156 2 POSITION RECEPTACLE rows nelcale direction of airflow 9 33 35841 00 MINI FIT FEMALE 18 22 AWG GOLD To order replacement parts please use the above part numbers and description 2 2 1 x 89 6 6 4 4 77 5 Exhaust Ass y 01 38608 00 ITEM PART NUMBER DESCRIPTION 1 35 31015 00 FAN GUARD 4 5 19 50588 00 FAN PLATE 2 19 37653 00 CE FAN PLATE 3 27 70106 00 NUT 6 32 KEP STZN 4 35 38555 00 FAN 4 5 130CFM 24VDC 5 25 50181 00 IGROMMET 150 DAMP 6 27 50168 00 ISCR 6 32 X 2 5 PH SLOT STZN 7 27 50637 00 WASHER 6 FENDER 5 8 OD 8 19 37722 00 PEGASUS 104B AIR DEFLECTOR 9 32 36096 00 CONN 156 2 POSITION RECEPTACLE 10 33 35841 00 MINI FIT FEMALE 18 22 AWG GOLD Arrows indicate To order replacemen order replacement parts please use direction pf airflow the above part numbers and description mad y 4 Intake Ass y 01 38609 00 FLEXSTAR TECHNOLOGY INC 22 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 23 PEGASUS 104B Rev 6
21. INTAKE OPENINGS IN THE INTAKE BASE PANEL ARE COMPLETELY EXPOSED 14 17 ACTUATOR CLOSED ADJUSTMENT SCREW 2 MICRO SWITCH No 2 THIS MICRO SWITCH IS USED TO FINE TUNE THE LOCATION OF THE BAFFLE BY TURNING THE ADJUSTMENT SCREW 2 IN OR OUT THE BAFFLE CAN BE ADJUSTED TO ENSURE THE AIR INTAKE OPENINGS IN THE INTAKE BASE PANEL ARE COMPLETELY SEALED OFF ACTUATOR No 2 THIS ACTUATOR CONTROLS THE BAFFLE IN THE RAMP UP CYCLE THE BAFFLE IS MOVED TO CLOSE OFF THE OPENINGS IN THE INTAKE BASE PANEL L FLEXSTAR TECHNOLOGY INC 17 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 18 5 5 104 Rev 6 ECO2156 3 5 Circulation Blower Housing Ass y P N 01 37681 00 WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING Lifting hazard Single person lift could cause injury Use assistance when moving or lifting Circulation Blower Weight 5516 25kg WARNING Rotating fan blades Can cause serious injury or cut Keep hands clear Turn off and lockout unit before servicing Warning When power cycling the 104B the power must remain off for 60 seconds and the controller must be set in the exhaust mode to allow the frequency converter to reset To access the circulation blower housing remove the lower front panel and disconnect the intake actuator power To remove the blower housing disconnect the blower power at the termi
22. Orion 104B poweRED Users Manual STANDARD AND CE ect am va 104B Burn In Peripheral Device Test Chamber Document 98 38181 00 Rev 6 0 11 29 2006 2 PEGASUS 104B Rev 6 ECO2156 ORION is a Trademark of FLEXSTAR TECHNOLOGY INc This document supersedes all previous releases and revisions to the Operation and Maintenance Manual for the ORION 104B 1 0 Operation Procedures 4 1 1 Rack Installation 4 1 2 Earth Quake Lock Down 4 1 3 Main AC Power Hook up 5 1 4 Rack Power Up Power Down 6 1 5 Hazardous Energy Identification 7 1 6 Emergency Machine Off 7 1 7 Rear EMO Switch Installation 8 1 8 Control Panel Identification 9 2 0 Watlow 984C Temperature Controller 10 2 1 Setup Modifying Settings 10 3 0 Rack Maintenance 12 3 1 Cabinet Cleaning 12 3 2 Drive Fixture 13 3 2 1 Drive Installation 13 3 2 2 Sub Adapter Removal 13 3 2 3 Fixture Adjustment 13 3 2 4 Fixture Shelf Removal and Installation 14 3 2 5 Shelf Duct Configuration 14 3 3 SBC Rear Tray 15 3 4 Air Handler 16 3 5 Circulation Blower Housing Ass y P N 01 37681 00 18 3 6 Heater Assembly 19 3 7 Circulation Damper Assembly Ass y P N 01 38464 00 20 3 8 Exhaust Blower Assembly Ass y P N 01 50670 01 21 3 9 SBC Cooling Fan Replacement Intake Ass y 01 38609 00 Exhaust Ass y 01 38608 00 22 3 10 Pallet Ladder Assembly Ass y P N 01 36279 00 23 3 11 Hub Assembly 24 3 12 15 VDC Power Supply Replacement 25 3 13 Thermal Ov
23. ain power disconnect It is acceptable to use a cord and plug as a disconnect device provided it is accessible and can be easily reached The main AC power can be installed through the top or bottom of the rack Locate and remove the AC breaker panel Remove the breaker cover and connect the AC power wires to the circuit breaker For easy access remove the power panel and the bottom intake fan assembly To insure proper circulation and exhaust blower rotation insure the power phases are in line This can be done by turning off the motor drive and visually inspecting the blower blade rotation Both blower blades spin clock wise when functioning properly If the blades are rotating backwards reverse two of the main power phases T Bottom Intake Fan e Rear Power panel Assembly AC Breaker Panel AC Breaker Cover FLEXSTAR TECHNOLOGY INC 5 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 6 PEGASUS 104B Rev 6 ECO2156 1 4 Rack Power Up Power Down To safely power the 104B insure the main AC power cable is connected Flip up the main circuit protector switch located at the back of the unit To safely turn on the 104B push the start button located on the front control panel A green LED will indicate unit powered To safely power down the 104B push the Stop Button located on the front panel A red LED will indicate power down Flip down the main power switch wait 60 seconds to allow stored energy to discharge disconnec
24. baffle to the cabinet rotate the base toward the heater assembly and slide out Reverse the above process to install the baffle assembly ITEM DESCRIPTION 19 38403 00 DOOR CIRCULATION DAMPER 2 19 38404 00 FRAME CIRCULATION DAMPER 3 275522500 SCREW HHOXTAPHHILSS 74 28840500 WASHER SHOULDER 20010 X 003 _ 75 273840509 WASHER SHOULDER 20010 X 250 _ To order replacement parts please use k the above part numbers and description 5 FLEXSTAR TECHNOLOGY 20 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 21 505 104B Rev 6 ECO2156 3 8 Exhaust Blower Assembly Ass y P N 01 50670 01 WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING Lifting hazard Single person lift could cause injury Use assistance when moving or lifting Exhaust Blower Assembly Weight 3916 18kg WARNING Rotating fan blades Can cause serious injury or cut Keep hands clear Turn off and lockout unit before servicing Warning When power cycling the 104B the power must remain off for 60 seconds and the controller must be in the exhaust mode to allow the frequency converter to reset To replace the exhaust blower remove the exhaust stack cover on the left side of the cabinet and disconnect the power Remove the four 6mm bolts that mount the blower to the panel 7 11 Exhaust Blower s S S The Exhaust Bl
25. connector AMP PT 088R 03 35613 36 ETHERNET CABLE 1 1 COLOR TO COLOR Category 5 8 conductor twisted pair Ethernet Cable FLEXSTAR TECHNOLOGY 24 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 25 PEGASUS 104B Rev 6 ECO2156 3 12 15 VDC Power Supply Replacement WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING Rotating fan blades Can cause serious injury or cut Keep hands clear Turn off and lockout unit before servicing The 104B is equipped with 8 1200 watt 15VDC power supplies Each power supply has two independent 600 watt outputs which provide 92 watts of DC power to each port The SBC assembly requires 35 watt which leaves 57 watts of margined power for each drive Remove the lower right rear power panel to access the 15VDC power supplies To replace a power supply remove all wiring unscrew the 10 32 holding the power supply tray in position and slide the assembly out Remove the two TY plates that are on the top of the assembly Turn the assembly over and remove the screws on the bottom and side of the assembly Replace the power supply and reverse the process When installing the power supply assembly ensure the tab at the rear of the tray engages the slot at the back of the power supply base TY Plate Power Supply Tray 15VDC 1200 Watt Power Supply Assembly 24 VDC SBC Cooling Fan 2
26. e MODE KEY to enter the current Value and advance to the next Prompt The Prompt appears in the lower display and the Value in the upper display PROMPT VALUE NEW VALUE Confirm heater is connected to output 1 OT1 HT Heater hysteresis setting HYS1 2 Exhaust fans are connected to output 2 OT2 CL Hysteresis setting for the exhaust fans HYS2 2 or degrees of temp setting Connect energized alarm on to output 3 OT3 AL3n Deviation reference alarm input 1 AL3 dE1 Hysteresis for the alarm HYS3 1 Non latching condition for the alarm LAT3 nLA Permit operator to reset the alarm output SIL3 on 5 At this point push the DISPLAY KEY Pressing the DISPLAY KEY returns the controller to the Home or operational state from any Prompt in any menu 6 Push the MODE KEY FLEXSTAR TECHNOLOGY INC 10 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 11 5 5 104B Rev 6 ECO2156 7 Press the UP ARROW KEY until SYS has been reached Push the MODE KEY and enter the following commands PROMPT VALUE NEW VALUE Degrees below setting for alarm warning A3Lo 5 Degrees above setting for alarm warning A3Hi Turns off the auto tune Aut off Press the MODE KEY to return or change menu 8 Push the UP 4 ARROW KEY until Pld appears 9 Press the MODE KEY to enter the current Value and advance to the next Prompt The Prompt appears in the lower display and the
27. e shut down or seem to be producing lower airflow The ABB drive motor does not power up The ABB drive motor has been factory set to start up when power is applied Check the ABB jumper setting against the wiring diagram for the proper jumper settings The ABB drive motor has gone into current overload and the blowers are not running on house power Reset the drive motor by powering down the 104B waiting 60 seconds for the drive motor to reset and powering the 104B up in the cool mode If the 104B is equipped with a drive motor reset Switch use that to reset the drive motor See page 22 One of the blowers is wired backwards If one of the blowers are wired backwards it will draw more current sending the drive motor into current overload shutting down the drive motor Check the blower wiring against the wiring diagram When the exhaust blower is properly wired it will draw 1 5 amps when wired backwards it will draw 2 5 amps When the circulation blower is properly wired it will draw 1 8 amps when wired backwards it will draw 2 8 amps The SBC cooling fans have shut down If all the SBC cooling fans have stop running immediately turn off the machine DO NOT RUN THE MACHINE FOR MORE THEN 10 MINUTES WITH THE SBC COOLING FANS OFF Check all the fuses in line with the power supply and replace as necessary If the fuses are ok check the 600 watt 24 VDC power supply in the power bay See page 24 If one of the fans has failed power down the machine and r
28. e switch to off and manually decrease the racks set point See section 2 1 FLEXSTAR TECHNOLOGY INC 9 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 10 5 5 104 Rev 6 ECO2156 2 0 Watlow 984C Temperature Controller NOTE The Controller has been factory set prior to shipment Refer to Chapter 6 Section 6 7 Factory Calibration in the WATLOW 984C Controller Users Manual to modify settings A WATLOW 984C Manual is provided with the system Refer to the manual for all 984C lockouts 2 1 Setup Modifying Settings The following will setup Flexstar s preset controller parameters 1 Push the UP and Down ARROW KEYS simultaneously and hold for three Seconds SEt Setup will appear in the lower display Push the UP 4 ARROW KEY until InPt Input Menu appears in the upper display 2 Press the MODE KEY to enter the current Value and advance to the next prompt The Prompt appears in the lower display and the Value in the upper display Push the UP 4 and Down Vv ARROW KEYS to select the Value PROMPT VALUE NEW VALUE To set the thermocouple type enter IN 1 J To set the low temperature range enter RL1 0 To set the high temperature range enter RH1 60 To set the calibration offset enter CAL1 0 To set the software filter enter FTR1 0 Press the MODE KEY to return or change menu 3 Push the UP ARROW KEY until OtPt Output Menu has been reached 4 Press th
29. eplace the fan See page 20 The drive does not engage the sub adapter The fixture slider ball plungers are not adjusted Place the drive in the fixture and slowly close the fixture until it engages the sub adapter tighten the ball plungers on the side of the fixture until they contact the edge of the slider then turn the ball plungers out 1 turn See page 10 The sub adapter is out of alignment Place the drive in the fixture and slowly close the fixture until it engages the sub adapter Tighten the ball plungers in the PCB Rail Vib Fixture to lock the sub adapter in place See page 10 Excessive drive vibration The fixture is not tightened down Insure the four 6 32 screws that fasten the fixture to the shelf are completely tightened down See page 10 The drive shelf is not tightened down Insure the panel fasteners on the shelf guides are completely tightened down See page 10 The circulation blower is out of balance Remove the intake panel and check the circulation blower for proper alignment The blower should spin freely with little or not noticeable wobble Replace the blower if excessive wobble is present See page 15 Network Communication The port is not communicating with the hub Ensure all cables are connected Use an Ethernet tester to test each Ethernet cable Replace or re terminate any cable in question See page 20 If all cables test good replace the Ethernet couplers in the pallet ladder assembly See page 20 The hubs do
30. er Temperature Shut Down 26 4 0 ABB Frequency Converter 26 4 1 Frequency Converter Power On 27 FLEXSTAR TECHNOLOGY INC 2 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 3 PEGASUS 104 4 2 Frequency Converter Power Reset 4 3 Installing the Frequency Converter Circuit 4 4 Programming the ABB Frequency Converter 5 0 WIRING DIAGRAMS 5 1 Port Wiring 5 2 Control Wiring Diagram 5 3 Rack Wiring Diagram 6 0 104B Trouble Shooting 7 0 104B Replacement Parts 8 0 104B Decommissioning Procedure 9 0 Technical Support Manuals included with the 104B Host Software Manual Fboot Software Manual NPM 1 User s Manual Pegasus SBC User s Manual Watlow 984C 24 V Manual Watlow 988 Communication Manual ABB Frequency Converter User s Manual 100 Base T Hub Manual Rev 6 ECO2156 27 27 27 30 30 31 31 32 33 34 34 www watlo com literature prodtechinfo search cfm www watlo com literature prodtechinfo search cfm www ABB com FLEXSTAR TECHNOLOGY INC 3 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 4 PEGASUS 104B Rev 6 ECO2156 1 0 Operation Procedures Read and observe all WARNING labels before servicing See example below Caution Indicates a potentially hazardous situation which if not avoided may result in a minor or moderate injury Warning Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Danger Indicates an imminen
31. les and grasp the sub adapter pulling up and out Reverse process to install sub adapter and slider 3 2 3 Fixture Adjustment Fixture Adjustment place the drive in the fixture and slowly close the fixture until it engages the sub adapter Tighten the 10 32 spring plungers on the right side of the fixture until they contact the edge of the slider then turn the spring plungers out 1 turn 19 36245 00 OPEN VIB II FIX 2 19 37584 00 IBM ULTRASTAR SLIDER 3 19 34797 00 LEVER EJECTOR 3 5 VIB FIXT 4 19 37587 00 25 30136 00 BUMPON KNOB BALL 11 16 DIA A OS 25 34810 00 WEAR STRIP UHMW 9 22 34800 03 VIB FIXTURE BASERAIL 25 34812 00 CARD GUIDE 6 5 LT 25 34813 00 CARD GUIDE 6 6 RT cecar cument e e DIA 38 Er3451609 SCREW 63201 BTNSCREWS 1a 27 34816 00 SCREW SPRING PLUNGER o okay sre ar ra o eeen pven ___ SUB ADAPTER CONTACT FLEXSTAR 22 2 2 FOR PART NUMBER To order replacement parts please use the above part numbers and description 20 FLEXSTAR TECHNOLOGY INC 13 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 14 5 5 104 6 2156 3 2 4 Fixture Shelf Removal and Installation To remove the fixture shelf remove the air duct above and below the shelf to be removed and place aside Disconnect all cables from the bulkhead and remove with shelf If
32. nal block in the rear to the cabinet Unscrew the four 8 32 screws that secure the blower housing to the cabinet and slide out the blower housing out of the cabinet To replace the blower remove the 8 32 screws from the housing cover Turn the blower over and remove the four 6MM bolts from the blower motor Reverse the above process to install the blower To access the lower section of the right plenum and the inside of blower box without removing the intake panel remove the access panel on the left side of the rack The circulation blower assembly contains the following ITEM DESCRIPTION 1 19 38049 00 BLOWER BOX 19 38050 00 BLOWER BOX 104B mmu _ gt 19 38051 00 BLOWER MOUNT 27 34455 00 WASHER 8 FLAT 1 27 37104 00 SCREW 10 32 1 4 PH PHIL T STZN SS 0 27 38053 00 WASHER RUBBER 23 ID X ud o STZN oo a 27 50158 00 SCREW 8 32 X 1 4 PH PHIL FT STZN 4 10 M 5 35 37681 00 BACKWARD CURVED UM IMPELLER 3100CFM m 12 43 35795 00 312 ID RUBBER c 13 22 37692 00 DAMPENING RING 2 11 14 25 37098 00 CLAMP RETAINING 13 27 70001 00 SCREW 6 32x3 8 PH PHIL STZN X 16 27 70103 00 NUT 6 32 KEP STZN 5 een 12 To order replacement parts please use the above part numbers and description NET Jan 14 15 16 FLEXSTAR TECHNOLOGY INC 18 P N 98 3
33. not communicate with the hub switch Insure all cables are connected Insure the switch has power If the switch has power but no led indicators replace switch Use an Ethernet tester to test the cable between the hub and hub switch Replace cable if necessary Insure the Ethernet cross over coupler is present and connected Use an Ethernet tester to test the cross over coupler Replace the coupler if necessary See page 21 FLEXSTAR TECHNOLOGY INC 32 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 33 PEGASUS 104B Rev 6 2156 7 0 104B Replacement Parts ITEM PART NUMBER DESCRIPTION WHEREUSED 13 37659 00 984C WATLOW CONTROLLER CONTROL PANEL 2 13 38653 00 PWR SUP 24V DIN POWER BASE 32 50103 00 COUPLER RJ45 TO RJ45 CONTROL PANEL PALLET LADDER ASSEMBLY 5 32 50104 00 D SUB 25 PIN SOLDER TYPE PANEL MOUNT CONN CONTROL PANEL 13 38671 00 POWER SUPPLY 1200W 15VDC MPI POWER SUPPLY BAY 8 35 38650 00 FLANGE NARROW CONTROL PANEL 38 38649 00 BUTTON EMO CONTROL PANEL 5 sia EOCNUCTROXOE eem ms 38 37664 00 CE CIRCUIT BREAKER 25 serena as PRASE vA Aa VRE VOC OUTPUT T suum ae ORE OV ae ABE RESTART pera pee wem Wmenumwup 70000 pm mimm rie A ___ a 33 01 38457 00 DUT BAY OVER TEMP THERMAL FUSE DUT BAY PART IDENTIFIED WITH
34. o exit Hit Enter to exit Wait about 30 seconds and turn the 104B back on When the 104B is turned back on the fans will start to spin then shut down and the by pass lamp will come on The By pass lamp should stay on for about two to three seconds and then go out Once by pass lamp goes off the fans will restart If the lamp does not go off and fans restart the MD did not fully power down If it takes more than two to three seconds for the by pass lamp to go off then the time delay relay time is set too high readjust relay by turning time adjustment screw fully CCW then CW turn FLEXSTAR TECHNOLOGY INC 8 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 30 505 104B 5 0 WIRING DIAGRAMS 5 1 Port Wiring SH 1 SH 1 SH 1 SH 1 SH 1 Rev 6 2156 658 52 661 53 681 55 69g 56 70 a au amp SSE SSO SS 398 26 40H 275 41 ff 28 421 29 438 448 315 5 468 339 4 789 481 35 498 36 508 37 SIH 38
35. oved form the rack When the rack calls for heat the intake baffle closes the circulation baffle opens the exhaust blower turns off and the heaters turn on until the desired temperature is reached Intake Baffle Ass y P N 01 37895 01 WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing WARNING burn hazard Hot surface inside Allow this area to cool before servicing To access the intake baffle remove the lower front panel and disconnect the intake actuator power The intake baffle is on the inside of the lower front panel To replace the actuator remove the 12 24 nut actuator pivot 10 32 nuts and the actuator clamp Reverse the above process to install the baffle assembly See page 14 for baffle adjustment ITEM P N DESCRIPTION ITEM P N DESCRIPTION 1 19 50627 00 PANEL INTAKE BASE 104B 17 27 37901 00 SCREW 6 32 X 5 8 HEX HEAD 2 19 37724 00 INTAKE BAFFLE 104B 18 27 50136 00 NUT 8 32 KEP STZN 3 19 50633 00 SLIDER INTAKE BAFFLE 104B 19 27 70104 00 NUT 10 32 KEP 3 8 STZN 4 19 50631 00 PLATE INTAKE PUSH 104B 20 38 37892 00 SWITCH SWITCH BASIC 5 19 37825 00 ACTUATOR MOUNT 104B 21 43 37896 00 GASKET TEMP WEATHER STRIP 6 19 50630 00 PIVOT ACTUATOR 104B 22 43 37900 00 INSULATION INTAKE BAFFLE 104B 7 19 37826 00 PIVOT BRACKET INTAKE ACT 104B 23 32 30396 00 CONN 4 POS AMP 8 19 50635 00 NTAKE BAFFLE PERF
36. ower Assembly contains the following ITEM DESCRIPTION 19 50620 00 EXHAUST STACK COVER Edd 77 MI 3PH 230 460 3 T950619 00 EXHAUST STACK BOTTOM 4 2736461 00 32 1 172 PHIL PANSTZN 5 275013500 NUT SESEKEP STZN 6 27358000 SCREW M xiOmm PH PHIL STZN 27 70001 00 e eeo INSULATION INSULATION _ 5 0 10_ 27 50141 00 SCREW 8 3238 PH PHIL STZN m 273779400 WASHER 8STAINLESS 712 93778400 PVOTDAMPER 71 48 50088 07 STOP INSULATION zrasr oo 715 2770084500 SCREW 10 32531 PH PHIL STZN 716 zr79105 00 To order replacement parts please use a e the above part numbers and description 4 11 6 11 14 FLEXSTAR TECHNOLOGY INC 21 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 22 PEGASUS 104B Rev 6 ECO2156 3 9 SBC Cooling Fan Replacement intake Ass y 01 38609 00 Exhaust Ass y 01 38608 00 WARNING HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing To replace an SBC cooling fan carefully remove the fan assembly from the side of the rack and disconnect the power connector To insure proper airflow locate the airflow arrow on the frame of the fan and follow the assembly diagrams For optimal SBC performance frequently inspect and clean the SBC intake and exhaust cooling fans The fans are powered by 24VDC 600 watt power supply See 3 12 for replacement Intake Ass y 01 3
37. stem To reset the Frequency Converter power down the 104B waiting 60 seconds for the Frequency Converter to reset and power the 104B up in the cool mode 4 3 Installing the Frequency Converter Circuit If the Control Panel does not have a Frequency Converter bypass light installed then the 104B does not have the Frequency Converter circuitry installed To wire in the Frequency Converter circuit simply add the warning light change three wires and three jumpers See wiring diagram 104B Pegasus 208V 50 60Hz Fused Wiring Diagram 96 39634 00 4 4 Programming the ABB Frequency Converter PROGRAMMING PROCEDURE FOR ACS150 SERIES MOTOR DRIVE This procedure is to be done when the 104B has been produced or rewired with the ABB ACS150 series motor drive The ABB ACS150 Motor Drive needs to have parameters changed from the default settings to operate per Flexstar s requirements Below is a procedure and correct values required for proper motor drive operation Please review the PROGRAMMING section pages 43 through 54 of the ABB ACS150 user s manual before proceeding FLEXSTAR TECHNOLOGY INC 27 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 28 505 104B ABB ACS 150 Series Parameter Setup Apply AC power Immediately hit the REM LOC button to put the unit in LOC mode Set Watlow 984 to OFF Hit Enter button to enter Main Menu Use to select next Parameter Hit Enter to enter sub menu Use to select Parameter
38. t the main power cable and apply LOCK OUT DEVICE Main Power On Off Switch Rear Panel Gu CIS Cx n NU S WO S To apply power flip handle up To disconnect power flip handle down le p Machine Rear Power panel ON Button Main Circuit Protector Machine OFF Button M8 1 1 FLEXSTAR TECHNOLOGY 6 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6_0 7 PEGASUS 104B Rev 6 2156 1 5 Hazardous Energy Identification Main Circuit Protector Contactor 15VDC 1200 Watt Power Supply 24VDC 600 Watt Power Supply 1500 Watt Finned Strip heaters 24VDC 40 Watt Power Supply 40 AMP Lower rear left side panel 55 AMP Inside the electrical bay rear bottom left 80 AMP QTY 8 Inside the power supply bay rear bottom right behind the power panel 25 AMP QTY 1 Inside the power supply bay rear bottom right behind the power supply panel 7 2 AMP Qty 4 Inside the heater bay front lower left behind the intake panel 1 66 AMP QTY 1 Inside the power supply bay rear bottom right behind the power supply panel 1 6 Emergency Machine Off Location Control Panel Operation Push IN to activate Emergency Machine Twist clock wise to Re Set EMO Push main start BUTTON to power machine MAIN POWER ON BUTTON EMO SWITCH
39. the rack is configured with IDE Fibre or SATA cables disconnect them from the sub adapter and leave on the bulkhead Unscrew the panel fastener on the bottom of the shelf guides and slide the shelf out of the rack To remove the fixtures from the shelf unscrew four 6 32 screws from the bottom of the shelf Reverse process to install the fixture shelf and ducts xm Fixture 3 2 5 Shelf Duct Configuration The 104B drive shelves are equipped with air ducts that deliver an equal amount of conditioned air to each drive To remove an air duct grasp the bottom side of the duct and pull straight out The ducts are labeled LEFT DUCT and RIGHT DUCT and the 104B should never be operated with the ducts swapped To maintain optimal thermal performance the 104B should never be operated without the air ducts in position Left Air Duct FLEXSTAR TECHNOLOGY INC 14 P N 98 38181 00 98 38181 00 104B PEGASUS MANUAL 6 0 15 5 5 104B Rev 6 2156 3 3 SBC Rear Tray WARNING Lifting hazard Single person lift could cause injury Use assistance when moving or lifting SBC Panel Weight 33lb 19kg SBC Tray Assembly To access the SBC trays lift off the two SBC panels on the back of the machine Warning the removable SBC panels are a two person lift Single person lift could cause injury To remove the SBC tray disconnect the cables that run from the sub adapter to the bulkhead nose
40. tly hazardous situation which if not avoided will result in death or serous injury HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock out power before servicing Warning When power cycling the 104B the power must remain off for 60 seconds and the controller must be in the exhaust mode to allow the 9 AMP phase converter to reset and all components time to discharge stored energy 1 1 Rack Installation Roll the cabinet into the desired location NOTE 36 of working space should be provided on all sides with electrical enclosures and cooling fans If this clearance cannot be provided on the right side of the system no electrical enclosures then the second EMO switch should be provided on the back of the unit See section 1 5 Using an adjustable wrench tighten the six load locks against the floor Warning the load locks are intended to hold the cabinet in position and are NOT intended to support the weight of the cabinet 1 2 Earth Quake Lock Down To install the 104B in an Earthquake prone region follow instructions below to install the 6 Earthquake Lock Down Plates Complete Section 1 1 Rack Installation Slide Earthquake Lock Down Plate 19 38615 00 over the load lock and mark the locations of the 4 3 8 holes on the floor Once all Lock Down Plate holes have been marked roll the 104B aside and drill for 3 8 concrete drive anchors For all other floors use appropriate 3 8 hardware
41. to select next Parameter Use to select next Parameter Use to select next Parameter Use to select next Parameter Hit Exit Use to select next Parameter Hit Enter Use to select next Parameter Hit Exit Hit Exit Set POT to MAX Speed Hit Exit LOC 1601 Hold Enter PAR FWD LOC 1 6 PAR FWD LOC 3 1 PAR FWD LOC 3101 Hold Enter PAR FWD LOC 3103 Hold Enter PAR FWD p 3104 Hold Enter PAR FWD dis 3105 Hold Enter PAR FWD 3106 Hold Enter PAR FWD i 3107 Hold Enter PAR FWD LOC 3 1 PAR FWD LOC _ 1 6 PAR FWD 1601 FWD A 1 6 0 7 Hold Enter PAR FWD LOC 1 6 PAR FWD 95 MENU FWD Loc 0 0 1 HZ OUTPUT FWD Hit REM LOC button so that REM is displayed Display should ramp up to 60 0Hz LOC 1 PAR Sag FWD LOC 5 PAR FWD LOC 5 0 PAR LOC 1 PAR FWD LOC 1 PAR LOC 1 PAR FWD LOC 1 PAR FWD LOC 1 PAR Use 60 Use Use Use 0U Use 0U Use 0U Use 00 Use Programming is complete Scroll through the values to verify proper settings to set Parameter to set Parameter to set Parameter to set Parameter to set Paramete to set Paramete to set Parameter to set Parameter Hit Enter to exit Hit Enter to exit Hit Enter to exit Hit Enter to exit Hit Enter to exit Hit Enter to exit Hit Enter t

Orion 104B Users Manual

Contents

Download Pdf Manuals

Related Search

Related Contents