INTERNATIONAL CUSTOMER SUPPORT

Field Change Order

Classification: Company Confidential Product: Fresco HiQ

Part/Assembly: Baldor –Motor 6.5Nm Kit FCO Kit P/N: 10-0399

Date: 12-Jun-02 Prepared By: Alex Davidson

Subject: Replacing the X Baldor Motor 4.3 Nm to 6.5 Nm

X Motor Baldor Replacement.doc FC10-0399 Page 1 of 11

FF IIEE LL

DD CC

HHAA N

N GG E

E OO

RR DD EE

RR

SOFTWARE AFFECTED: YES NO

IMPLEMENTATION: ON REQUEST IMMEDIATE NEXT CALL ON FAILURE

TYPE OF CHANGE:

MANDATORY CONDITIONAL

COST RELIABILITY

PRODUCTION FUNCTIONALITY

MAINTENANCE

MATERIAL DISPOSITION:

N/A

USE AS SPARE

DISCARD ALL

DISCARD SELECTIVELY (refer to Mat’l Disposition)

SEND BACK FOR REWORK PROJECT MANAGER: SIGNATURE/DATE

ENGINEERING MANAGER: SIGNATURE/DATE

ICS MANAGER: SIGNATURE/DATE

Read this document in its entirety before implementing the changes!

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 2 of 11

Table Of Contents

1. GENERAL.......................................................................................................................................................................... 3 2. REASON FOR CHANGE ............................................................................................................................................ 3 3. SYMPTOMS ..................................................................................................................................................................... 3 4. ESTIMATED INSTALLATION TIME................................................................................................................... 3 5. IMPLEMENTATION..................................................................................................................................................... 3 6. INSTALLATION PROCEDURE: ............................................................................................................................. 4 7. INITIALIZING THE DRIVER ................................................................................................................................... 7 8. TEST...................................................................................................................................................................................11 9. LOGISTICS .....................................................................................................................................................................11 10. MATERIAL DISPOSITION......................................................................................................................................11

List of Figures

Figure 1: X-Motor.......................................................................................................................4

Figure 2: Cables W37 And W41 (Wires Inside Connection Box)..............................................5

Figure 3: Screw Inside Gear To Motor Coupling (On Both Sides)............................................5

Figure 4: Baldor Driver Schematic.............................................................................................8

Figure 5: Flex Set Up Wizard Screen.........................................................................................9

Figure 6: Com Port Settings Window.........................................................................................9

Figure 7: Set Up Drop Down Menu For Motor And Control.....................................................10

Figure 8: Motor Tab Screen In Motor And Control Window.....................................................10

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 3 of 11

1. General This Field Change Order details the replacement of the current 4.3Nm X Baldor Motor

with a new 6.7Nm motor.

2. Reason for Change The X motor may be damaged when, performing under strenuous circumstances, it will

suffer from current overload and thus overheat. Therefore, the X motor (4.3Nm) is

strained during sustained lengthy continuous motion, mainly on narrow substrate, and

needs to be replaced, if damaged, with a more efficient and powerful X motor (6.7Nm)

that will prevent similar failure from reoccurring.

3. Symptoms Use the following symptoms to diagnose the problem:

��Unstable acceleration and deceleration of the print head carriage, that

eventually led to the PH carriage to stop during printing.

��The X Baldor driver's LED will turn red and the status panel will display first

"7" then "6" fault code, which means "over current."

��The motor surface will reach a high temperature of ~ 80º C (~170º F).

4. Estimated Installation Time Forty-five minutes.

5. Implementation ��NUR Fresco HiQ 1800 Up to # 10201.

��NUR Fresco HiQ 3200 Up to # 14183.

Note: In order to maintain a common platform configuration, both X and Z-

axis will be equipped with the 6.7Nm motor at the manufacturing stage, as of

printer's serial numbers above.

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 4 of 11

6. Installation Procedure:

6.1 Removing the current X-motor

1. Power down the printer.

2. Locate the X motor in the Motor Cabinet.

3. Use a Phillips screwdriver to remove the four screws that secure the cover of the AC connection box (refer to Figure 1).

Note: Make sure to label all cable W41 wires inside the AC connection box.

4. Disconnect all the wires locate inside the connection box (refer to Figure 2).

5. Use a wrench to disconnect the W41 cable from the connection box (refer to Figure 2).

6. Manually disconnect the W37 cable from the connection box (refer to Figure 2).

7. Move the PH carriage slowly across the X-axis to align the coupling screw inside the gear with the hole (refer to Figure 3).

8. Use a 6 mm Allen key to loosen the coupling on both sides of the gear.

9. Use the 6 mm Allen key to unscrew the four M4 screws that secure the motor to the gear (refer to Figure 3). Remove the screw cap if necessary.

10. Pull the motor gently out of the gear and set aside.

AC Connection Box

X-Motor

Cable W41

Cable W37

Gear Motor to Coupling

Four Phillips Screws Circled

Coupling Screw Cap

Figure 1: X-motor.

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 5 of 11

Four Wires Inside Connection Box Circled

Cable W41Cable W37

Figure 2: Cables W37 and W41 (Wires Inside Connection Box).

Coupling Screw Gear to Motor Gear Motor

Four M4 Screws

Figure 3: Screw inside Gear to Motor Coupling (on both sides).

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 6 of 11

6.2 Installing the new X-motor from Kit

Note: When inserting the new motor (from kit) do not force it in but rather use

synthetic oil to facilitate the motor shaft insertion.

1. Install the new motor (from kit) into the gear gently.

2. Use the Allen key to secure the motor to gear with the four M4 screws removed in step 9.

3. Use a torque meter to tighten the coupling screws (39Nm each), on both sides of the gear, loosened in step 8.

4. Reconnect all the wires (disconnected in step 4) inside the connection box.

5. Use the Phillips screwdriver to tighten the four screws that secure the connection box cover removed in step 3.

6. Use the wrench to tighten the cable W41 back into place.

7. Manually reconnect cable W37 to its original location.

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 7 of 11

7. Initializing the Driver

7.1 Preparation

1. Switch ON circuit breakers F1&F2 (Emergency loop & Galil controller) located in the electrical cabinet.

Caution: Make sure that circuit breakers FX & FZ, in the electrical cabinet,

are switched OFF.

2. Open Galil Motion Servo Design Kit > Terminal> write MO and press Enter to

disable all drivers.

3. Verify that the driver display is d.

4. Connect the BALDOR initializing cable, from kit, (male end) to the X6 Port, on the Baldor driver (refer to Figure 4).

5. The distal end of the BALDOR initializing cable may be connected to:

Option A: Using the printer's work station

��Disconnect the Galil communication cable (W26) from the P.C COM Port 1

and connect the BALDOR initializing cable (from kit) to PC COM Port 1.

Option B: Using Laptop

��Connect the BALDOR initializing cable to the laptop COM Port.

6. Change the driver’s status to setting status by changing dipswitch no. 8, in the AS1 dipswitch group, to OFF (refer to Figure 4).

Note: Verify that all switches on the AS1 dipswitch group are in OFF

position (refer to Figure 4).

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 8 of 11

Driver’s Display

AS1 Dip-Switch Group

BALDOR Initializing cable Socket

Figure 4: Baldor Driver Schematic.

7.2 Change Motor and Control Data

Set the driver’s parameters using Flex Setup Software as follows:

Note: You might have the DBSC (Digital BALDOR Servo Controller)

version, which is compatible with this procedure.

Note: Before getting into SW, a "Flex Setup Wizard " may appear. If it does,

click "Finish" and than click OK (refer to Figure 5).

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 9 of 11

Figure 5: Flex Set Up Wizard Screen

1. Once you get into the software, change to COM port-1 and press OK to apply communication (refer to Figure 6).

Figure 6: COM Port Settings Window.

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 10 of 11

2. Select Setup > Motor And Control (refer to Figure 7).

Figure 7: Set up Drop Down Menu for Motor and Control.

3. In the Motor Tab select the following and than press "OK" (refer to Figure 8).

��Motor type: BSM90B.

��Motor ID: BSM90B-3150.

Figure 8: Motor Tab Screen in Motor and Control Window.

4. Press the Download button and check the new default on the menu bar.

Note: Once you press the Download button the window will be closed.

International Customer Support

X Motor Baldor Replacement.doc FC10-0399 Page 11 of 11

7.3 Finish

1. Enable the drivers by switching DIP SWITCH no. 8 to the ON position.

2. Disconnect the BALDOR initializing cable from the driver and the P.C.

3. Reconnect Galil communication cable (W26) for the P.C COM Port 1

4. Switch ON circuit breakers FX & FZ located in the electrical cabinet.

8. Test

1. Verify that cables W37 and W41 are connected.

2. Verify that all screws; motor to gear and couplings are tightened properly.

3. Verify that the PH carriage is moving quietly and smoothly when you manually move it.

4. Perform Initialize and verify normal operation of the X-axis.

9. Logistics

10-0399 Baldor 6.5Nm Motor Kit

P/N Description Qty

25-0020 Brushless Servo Motor 5.3A, 6.5Nm BSM90B-3150 1

23-0003 Baldor Initialization Cable FW 124 1

FC10-0399 FCO Baldor 6.5Nm Motor 1

10. Material Disposition

P/N Description Action 200-15-00-003 X Baldor Motor 4.3Nm Ship Back*

*Unless notified to undertake a different action.