Industrial Monitor Update Kit (Bulletin Number 6157) Installation Instructions
2 Table of Contents Table of Contents Industrial Monitor Update Kit... 3 Overview... 3 Part 1 - Initial Preparation... 5 Part 2 - Replacing Analog Board Components... 5 Part 3 - Installing the Fan Assembly... 13 Contacting Technical Support... 14 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. "Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls" (Publication SGI-1.1) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation with respect to use of the information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation is prohibited. Throughout this manual, we use notes to make you aware of safety considerations. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Important: Identifies information that is especially important for successful application and understanding of the product.
Industrial Monitor Update Kit 3 Industrial Monitor Update Kit Overview The Bulletin 6157 Update Kit resolves problems with thermal stress failures due to poor air circulation around some components of specific models of the Industrial 20 Monitor. Historical failure data for these monitors revealed a pattern of premature thermal stress failures of some components. The cause of the thermal failures was linked to an area of poor air circulation on the main monitor analog board. Stagnant air can allow higher temperature power devices to overheat transistors and electrolytic capacitors located nearby. This Update Kit provides the necessary parts to update an Industrial 20 Monitor to improve long-term reliability. This kit includes the following updates: Replacement and relocation of components on the monitor analog board assembly Addition of a fan assembly Products Affected Industrial 20 panel mount monitors with the following catalog numbers are affected: 2711-MT20 products. 2711-M20 products. 6157-AAxxxxxxxx products (where x denotes an option that is not relevant to this update). Note: If your monitor is not functioning, do not perform these procedures. The unit must be returned for service.
4 Industrial Monitor Update Kit Parts Required The following table lists the parts that are included in the Update Kit: Table A Parts Required for Update Part Number Description Quantity 77189-310-51 Fan Bracket Assembly 1 21509-356-01 2.2 ufd 200 vdc capacitor (C208) 1 21509-436-01 10uF/250V capacitor (C108) 1 21509-437-01 120uF/250V capacitor (C301) 1 24815-340-01 BYM26E diode (CR301, 110) 2 24851-230-01 2SC3598 transistor (Q503, Q603, Q703) 3 Equipment and Tools To perform the procedure, the following tools and equipment are required: 7 mm hex socket #2 Phillips screwdriver 5/16 nut driver Solder and soldering iron Lead cutter Small needle-nosed pliers Skills Required The personnel performing these procedures should have familiarity with the following tasks: Disassembling and assembling computer products Working with equipment that presents high voltages Desoldering and soldering on PC board assemblies
Industrial Monitor Update Kit 5 Part 1 - Initial Preparation Before you begin installing the Update Kit, do the following initial preparation steps: 1. Remove the power and video cables from the unit. ATTENTION: You must be sure to disconnect power from the unit before beginning this procedure. Failure to disconnect power could lead to personal injury or death, property damage, or economic loss. 2. Remove the monitor from the enclosure or cabinet. 3. Remove the six screws that hold the unit s cover in place (two on each side and two on the back) and remove the cover. Part 2 - Replacing Analog Board Components Use these instructions to replace components on the monitor s analog board assembly. Important: If you are updating a 6157-AAxxxxxxxx product: Check the serial number on your unit. If the serial number is above 684000, you do not need to complete this part of the instructions. Skip to the section Part 3 - Installing the Fan Assembly on Page 13. The serial number is located on the product s nameplate label which is on the rear of the unit. The serial number is a six-digit number starting with a 6 or 7. Removing the Board from the CRT After you have removed the cover of the unit, the first step in replacing components on the monitor analog board assembly is to remove the analog board from the CRT. This involves the following tasks: Disconnecting the video interface board Disconnecting cables from the analog board Removing the analog board
6 Industrial Monitor Update Kit Figure 1 6157 Industrial Monitor Parts Identification CRT Anode Cap CRT Connector AC Filter Touchscreen Control Board (Optional) Analog Board Video Interface Board 1. Lift the unit and use a #2 Phillips screwdriver to remove the screw from the center of the bottom of the unit. 2. Using the 7mm hex socket, remove the four screws on the video interface board. 3. Remove the screw on the AC filter and slide it out of the bracket. 4. If the unit is equipped with a touchscreen, you must disconnect the following connectors: Disconnect the touchscreen controller ribbon cable from the touchscreen control board. You must break the glue seal on the connector to remove it. Disconnect the touchscreen power connector at J7 on the analog board. Refer to Figure 2. 5. On the rear of the CRT, gently pull on the small CRT connector or connector board to detach it from the point of the CRT.
Industrial Monitor Update Kit 7 6. Remove the two screws located on the back corners of the analog board. 7. Partially remove the analog board by pushing the board towards the front of the unit about 1/4 inch and lifting it up and out. Pulling the board out partially allows you easier access to cables which must be disconnected. 8. Disconnect the following cables from the analog board in this order: P2 degauss cable at J2 AC Power at J1 Vertical yoke at J4 Horizontal yoke at J3 Figure 2 Analog Board Connectors J3 J4 J1 J2 J8 J7
8 Industrial Monitor Update Kit 9. Identify the anode cap, a black rubber cup with red wire leading to the CRT. Figure 3 CRT Anode Cap Parts Identification Anode Boot Anode Clip CRT Anode Socket ATTENTION: When removing the anode cap from the CRT, do not touch any exposed metal, either on the clip or around the socket on the CRT. This metal retains a residual charge even when not powered, and touching it may result in a severe shock. 10. Remove the anode cap from the CRT by grasping only the rubber boot. Push to one side to release one pin on the clip from the socket on the CRT, and then push to the other side to release the second pin. 11. Lift the analog board out of the unit.
Industrial Monitor Update Kit 9 Replacing Components on the Board After you have removed the analog board from the CRT, you must replace the appropriate components. To remove components from the analog board, you must first use a desoldering tool to loosen the existing component. Then you can remove it and replace it with the new component. Figure 4 Analog Board Components to Replace C208 CR301 C301 CR110 C108 Q503, Q603, Q703 Step 1 - Remove the insulator from the board The analog board has a black insulator protecting the back of the board. You must remove this before you can remove components. 1. Using the 5/16 nut driver, loosen the screw on the back of the analog board. 2. On the front of the board, carefully remove the bolt and the translucent nylon washer that are attached to the screw. 3. Remove the insulator from the board.
10 Industrial Monitor Update Kit Step 2 - Replace capacitor C208 Remove capacitor C208 and replace it with the capacitor provided in the Update Kit: C208 (2.2mfd 200vdc) - Part 21509-356-01. Step 3 - Replace capacitors C108 and C301 Important: When pulling these capacitors from the board, be careful that you do not also pull out a component located nearby. These capacitors are secured on the board with RTV glue that can contact other components. You may need to use a screwdriver to hold other components in place while you remove the appropriate component. 1. Remove capacitors C301 (120uF/120V) and C108 (10uF/250V). 2. Replace capacitor C301 with the new capacitor provided in the Update Kit: C301 - Part 21509-437-01. 3. Replace capacitor C108 with the new capacitor provided in the Update Kit: C108 - Part 21509-436-01 (same values and part numbers). Step 4 - Replace and relocate diodes CR301 and CR110 You may also need to replace diodes CR301 and CR110 if they are TO-220 style diodes. 1. Examine diodes CR301 and CR110 to determine if they are Integral Diode/Heatsink style or TO-220 style diodes. Refer to the following figure: Figure 5 Integral Diode/Heatsink Style Diode (left) and TO-220 Style Diode (right) 2. If either diode CR301 or CR110 is Integral Diode/Heatsink style or if either are already soldered to the bottom of the analog assembly, skip to Step 5 - Replacing Transistors Q503, Q603, and Q703. 3. Remove diodes CR301 and CR110 from the component side of the PCB.
Industrial Monitor Update Kit 11 4. Add two diodes (Part 24815-340-01) on the solder side of the board as shown in the following figure: Figure 6 Back Silkscreen of the Analog Board (Solder Side) Step 5 - Replace transistors Q503, Q603, and Q703 1. Remove transistors Q503, Q603 and Q703 (2SC3953) 2. Replace these transistors with Part 24851-230-01 (2SC3598) at Q503, Q603 and Q703. Step 6 - Trim excess leads You must trim off any excess leads from the components you installed to no more than 1/8. Failure to trim the leads could result in a short circuit. Step 7 - Install the insulator 1. Place the insulator on the back of the board. 2. Using the small needle-nosed pliers, place the translucent nylon washer and the bolt over the appropriate hole on the front of the analog board. 3. Using the 5/16 nut driver, replace the screw on the back of the analog board.
12 Industrial Monitor Update Kit Install the Board into the CRT Reverse the procedures for disconnecting and removing the analog board (starting on Page 5) to install the updated analog board into the unit. In general, do the following: Reconnect the anode cap. Pull on the anode cap after you reconnect it to ensure that it is securely in place. ATTENTION: When replacing the anode cap on the CRT, do not touch any exposed metal, either on the clip or around the socket on the CRT. This metal retains a residual charge even when not powered, and touching it may result in a severe shock. Reconnect cables and the CRT connector Note: Ensure that you plug the cables into the appropriate connectors on the board. Each plug is labeled with the same number as its connector (for example, P4 is plugged into connector J4). Reconnect the touchscreen connectors, if applicable. Note: If the unit is equipped with a touchscreen, you must be sure to reconnect the touchscreen cables correctly. If you do not attach the ribbon cable connector to the touchscreen board completely, the touchscreen may be damaged when you apply power. Secure the analog board in the unit Reconnect the AC filter Reconnect the video interface board Replace the screw in the bottom of the unit. Proceed to the section Part 3 - Installing the Fan Assembly to continue the update process.
Industrial Monitor Update Kit Part 3 - Installing the Fan Assembly 13 Use these instructions to install the fan assembly into the CRT. This part of the update applies to all affected Industrial 20 Monitors. Initial Preparation Before you begin installing the fan assembly, ensure that the monitor is turned off and power is disconnected. ATTENTION: You must be sure to disconnect power from the unit before beginning this procedure. Failure to disconnect power could lead to personal injury or death, property damage, or economic loss. To install the fan assembly: 1. Mount the fan bracket on the left support arm with two 4mm x 10mm screws and nuts in holes B as shown in figure below. Figure 7 Holes for Mounting the Fan Assembly 2. Position the fan wires so as not to obstruct airflow. 3. Route the fan wires around the gold heat sink toward the back of the analog board. 4. Plug the fan into the J-8 Connector on the analog board. J-8 is located on the back edge of the analog board next to the green LED. The red wire should be located next to the green LED. Refer to Figure 2 (Page 7).
14 Industrial Monitor Update Kit Contacting Technical Support For additional technical assistance with this update, do one of the following: Call Technical Support at 440-646-5800. Fax the request for assistance to 440-646-7701 (Attention: Technical Support) Please provide the serial number of the product and reference the A-B V54 Monitor Update Program with any correspondence. Spare Parts You can obtain a spare parts package through PASSPORT using Catalog # 6189-V54UPDT.
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