Temperature Controller Replacement - Air
Contents
1. alf Vac eng CUT DRS24C amp R Series Temperature Controller Replacement Section 6 0 Replacing your Athena or Cal 9300 temperature controller Also upgrading from Athena to Cal 9300 CONTENTS wa 6 01 Athena amp Cal 9300 replacement 2 3 6 02 Cal 9300 upgrade ccccccesscceessees 4 8 a BEFORE YOU START J CHECKLIST Read instructions thoroughly before beginning The following items will be needed in this section _ Athena temperature controller part no 9002 11 000 ELECTRICAL WARNING _ Cal 9300 temperature controller POWER DOWN DRS24 AND DISCONNECT part no 9002 11 015 FROM POWER SOURCE For Upgrading only __ Phillips screwdriver C Small straight blade screwdriver Metric amp American Allen wrenches __ Metal file For technical problems please contact the Air Vac technical service department at Air Vac Engineering Company Inc 30 Progress Avenue Seymour CT 06483 Phone 203 888 9900 Fax 203 888 1145 e mail solder tech air vac eng com www air vac eng com 03 26 01 DRS24 Technical Service Manual Section 6 0 Temperature Controller Replacement 6 01 Athena amp Cal 9300 Replacement A important VERIFY DRS24 IS DISCONNECTED FROM THE POWER SOURCE NOTE p The temperature controllers are located in the DRS24 right box A fig 1 V steps 1 Remove the 10 32 button head screw B fig 1 and swing right box open B Fig 1 SRE2. NOTE pa The remaining steps will be performed assuming you are located behind the DRS24 2 Determine if you have Athena controllers C fig 2 or Cal 9300 controllers D Fig 2 C Athena D Cal 9300 DRS24 Technical Service Manual Section 6 0 Temperature Controller Replacement Each type of controller has a removable bezel and circuit board assembly E fig 3 NOTE pa The controller sleeve F stays in the machine during controller removal ELECTROSTATIC PRECAUTIONS SHOULD BE OBSERVED WHEN HANDLING THE Ax eortant CONTROLLER OUTSIDE OF THE SLEEVE 3 Grasp left and right side controller face grips G fig 3 and firmly squeeze in and slide controller out of the sleeve Ke TIP While pulling out the controller a gentle side to side rocking motion will make re moval easier Fig 3 4 Remove your new controller from its anti static packaging and carefully install into the sleeve It should snap in when fully seated Place old controller into anti static packaging 2 6 Please refer to the instructions included with your new temperature controller for programming details DRS24 Technical Service Manual Section 6 0 Temperature Controller Replacement 6 02 Cal 9300 Upgrade A important VERIFY DRS24 IS DISCONNECTED FROM THE POWER SOURCE NOTE pe The temperature controllers are located in the DRS24 right box A fig 1 V steps 1 Remove the 10 32 button head sc
3. amp 6 may be different than indicated in figure 4 make a note if they are different Red Black f CJ POS White Red ae ie kn a Fig 4 NEG White Black P pA ane ant eps bax Black Light Blue DRS24 Technical Service Manual Section 6 0 Temperature Controller Replacement Gently slide a thin straight blade screwdriver behind the locking tabs of the Athena retaining ring 1 fig 5 pry up and slide the ring down several clicks Repeat alternating sides until the retaining ring slides off Remove Athena J from cutout Insert the new Cal 9300 controller into the same cutout making sure that the face is orien tated properly fig 6 NOTE pa You made need to use a file to make the cutout larger 9 Slip the retaining ring I back over the Cal 9300 sleeve and lock against the riser plate K Fig 5 Fig 6 DRS24 Technical Service Manual Section 6 0 Temperature Controller Replacement NOTE e NOTE pe Ee Ww G Bb H amp amp G For wire connection steps 10 17 refer to figure 7 on page 8 If the wire lengths are too short it may be necessary to splice on additional wire lengths by soldering and adding heat shrink tubing over the splice Remove spade lugsfrom the end of wires and strip insulation back approximately 3 16 Connect white red wire Athena terminal 1 to Cal 9300 terminal 3 Connect white black wire Athena terminal 2 to Cal 9300 terminal 4 Connect yellow wire Athe
4. 00 terminals 9 10 and 11 to make sure they are wired correctly Usually terminals 10 amp 11 red amp black are reversed If your controller has difficulty reaching or stabilizing its setpoint you will need to again check the controller programming Open Profile ES NotePad Files Diffuser test profile Heater Burn In Profile Motion Offset Test Nozzle flow sensor adjust Nozzle Vacuum Removal Retry Test post power up voltage and pressure verification gfp 208 align and force place testing site Clean Yacuum Sensor Test Temp File Last changes made using the TEACH screen Temperature Scale Testing Thermocouple Channel Test Vision Alignment Offset Test Use QFP206 Customer Group system Files Board Group system Files Device Group oystem Files E H H
5. BIk Blk Red Yel l 10 11 12 13 14 15 16 E0606666 Thick Thick Blk Lt Blue l Wht Red A aod Wht BIk 120 119 Blk Red Yel f 10 11 12 13 14 15 16 CO606666 Thick Thick Blk Lt Blue l Wht Red i acd Wht BIk DRS24 Technical Service Manual Section 6 0 Temperature Controller Replacement A IMPORTANT NOTE Fe Fig 8 After all wire connections have been made reverse steps 1 5 earlier in this section to re install the riser plate and sub plate assemblies back into the DRS24 right box Reconnect power to the DRS24 and power up module At DRS24 software DO NO LOG ON Verify that your new Cal 9300 controllers have power the front display should be green and program them according to the instructions in section PROGRAMMING IS VERY IMPORTANT IF THE CONTROLLERS ARE NOT PRO GRAMMED THE DRS24 AND ITS SOFTWARE WILL NOT WORK Once the controllers are programmed log into the DRS24 software with a High level opera tor password and then right mouse click the spinning chip in the bottom right corner to access the hidden menu Under Options Open run the Heater Burn in Profile figure 8 to make sure the controllers reach their setpoint temperature and appear to be stable If you get a Temp Communication Link error message you will need to check the controller programming first If that appears okay you then need to check your com munication wires on the Cal 93
6. na terminal 9 to Cal 9300 terminal 1 Connect red wire Athena terminal 10 to Cal 9300 terminal 2 Connee6 thick black wire Athena terminal 11 to Cal 9300 terminal 7 Connect thick light blue wire Athena terminal 12 to Cal 9300 terminal 8 Connect red wire Athena terminal 13 to Cal 9300 terminal 10 Connect black wire Athena terminal 14 to Cal 9300 terminal 11 Repeat steps 10 17 for the remaining Athena controller s to be upgraded See complete diagram for all wire colors and numbers fig 7 page 8 If you have a single diffuser with only two controllers make sure the wires for the center left diffuser Athena are secured and the ends are shrink wrapped to prevent grounding or shorting DRS24 Technical Service Manual Section 6 0 Temperature Controller Replacement Fig 7 Athena amp Cal 9300 Temperature Controller Hookup rear view Athena 3 Athena 2 Red Black Red Black P vy vey i a 80 aa an Yel ee 81 White T nA White vw vu NEG 77 as 2 jan NEG 76 W White a SS White AA i SI RA A v V a gf N gy N A 128 A wE wE Athena 1 122 amp 120 119 amp 121 Red Black Thick Light Blue POS 2 yw yu rr 7 Rt EE PKA AIT DEK KA NEG 78 2 i White AA DA ee s DRA xe iat RA as eS 120 amp 68 66 amp 119 Cal 9300 3 Cal 9300 2 Cal 9300 1 Blk Red Yel 10 11 12 13 14 15 16 E0606666 Thick Thick Blk Lt Blue l Wht Red w ao Wht
7. rew B fig 1 and swing left box open Fig 1 Z lt 3 NOTE pa The remaining steps will be performed assuming you are located behind the DRS24 2 Remove the four 10 32 low head screws C fig 2 with a 3 32 Allen wrench 3 Carefully lift the sub plate assembly D out of the right box and rest on top of power panel 4 Squeeze the hinge pins E together to release the left box and then lower box to bench Remove lid support pin F to allow box to sit flat on bench 5 With the left box cover sitting on the bench next to the machine flip the entire sub plate assembly D back over and rest on top of cover fig 3 page 5 Fig 2 DRS24 Technical Service Manual Section 6 0 Temperature Controller Replacement 4 Remove the four M4 screws G fig 3 with a 3mm Allen wrench and then remove the wire ties holding the harness 5 Carefully lift the riser plate assembly H off of the sub plate assembly and flip over for access to the Athena controller rear wire connections NOTE pam You can re install two M4 screws G into the sub plate to hold the riser plate upside down in place NOTE pe Remove and replace one controller at a time so you do not get the wire connections mixed up Fig 3 So _ _ Cover 6 Remove the wires from the Athena controller figure 4 with a phillips head screwdriver NOTE he The wire colors on terminals 13 14
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