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Milnor MP1540 Series, Manual

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Milnor MP1540 Series Manual Download Page 5

C O M P O N E N T   P A R T S   L I S T 

W6PM1SPL/2015184N

COMPONENT

FUNCTION OF THIS

WHERE TO FIND

NUMBER

COMPONENT NUMBER

THIS COMPONENT

MILNOR P/N

DESCRIPTION

LOCATION

>>>COMPONENT LOCATION DETAILS

 01

DETAIL-INPUTS AND OUTPUTS

W6PM1STG1

B2TAG98010

SINGLE STAGE PRESS IN/OUTPUTS

CONTROL BOX

 02

DETAIL-AIR VALVES

W6PM1STG1

B2TAG98011

SINGLE STAGE PRESS AIR VALVES

VALVE BOX

 03

DETAIL-PROCESSOR BOX

W6PM1STG1

B2TAG98002

SINGLE STAGE PRESS PROCESSOR

PROCESSOR BOX

 04

DETAIL-CONTROL BOX

W6PM1STG1

B2TAG98001

SINGLE STAGE PRESS CONTROL TAG

CONTROL BOX

BA

>>>PRINTED CIRCUIT BOARDS

BAD-1

BOARD- A TO D CONVERTER

W6PM1SBW

08BSADCT

BD:SERIAL A-D CONVERT->TEST

CONTROL BOX

BAD-1

BOARD- A TO D CONVERTER

W6PM1SBWA

08BSADCT

BD:SERIAL A-D CONVERT->TEST

CONTROL BOX

BBB-1

BOARD-RAM BATTERY BACKUP

W6PM1SBW

08BSBB1T

BOARD: SER BATT BACKUP-TEST

PROCESSOR BX

BBB-1

BOARD-RAM BATTERY BACKUP

W6PM1SBWA

08BSBB1T

BOARD: SER BATT BACKUP-TEST

PROCESSOR BX

BDA-1

BOARD-HI RES D TO A #1

W6PM1SBW

08BSDACHT

BD:HI-RES SERIAL D-A->TEST

CONTROL BOX

BDA-1

BOARD-HI RES D TO A #1

W6PM1SBWA

08BSDACHT

BD:HI-RES SERIAL D-A->TEST

CONTROL BOX

BDFP

DISPLAY-10.4 FLAT PANEL

W6PM1SEC

08EFD320C

DISPLAY 10.4FP/DCUL7/INVERTER

BDVFD

DISPLAY-MICROPROCESSOR  IF 8088 PROC.

W6PM1SD

08BSEVFD5U

SERIAL VFD 2LINE 9600B-TEST

SWITCH PANEL

BDVFD

DISPLAY-MICROPROCESSOR IF 186 PROC.

W6PM1SD

08BSEVFD5V

BD:SER VFD.2LINE-19200B-TEST

SWITCH PANEL

BFPC

BOARD-COLOR FLAT PANEL CONTROLLER

W6PM1SEC

08EFD320C

DISPLAY 10.4FP/DCUL7/INVERTER

SWITCH PANEL

BFPI

BOARD-COLOR FLAT PANEL INTERFACE

W6PM1SEC

08BSEDIFAT

BD:FP LCD DRVR/INV INTERFACE>TEST

SWITCH PANEL

BIO-1

BOARD-8 OUTPUT/16INPUT #1

W6PM1SBW

08BS816CT

BD:SERIAL 8OUT-16INPUT-TEST

CONTROL BOX

BIO-1

BOARD-8 OUTPUT/16INPUT #1

W6PM1SBWA

08BS816CT

BD:SERIAL 8OUT-16INPUT-TEST

CONTROL BOX

BIO-2

BOARD-8 OUT/16IN #2 (DATA PASS)

W6PM1SBW

08BS816CT

BD:SERIAL 8OUT-16INPUT-TEST

CONTROL BOX

BIO-2

BOARD-8 OUT/16IN #2 (DATA PASS)

W6PM1SBWA

08BS816CT

BD:SERIAL 8OUT-16INPUT-TEST

CONTROL BOX

BIO-3

BOARD-8OUT/16IN #3 (DATA PASS)

W6PM1SBW

08BS816CT

BD:SERIAL 8OUT-16INPUT-TEST

CONTROL BOX

BIO-3

BOARD-8OUT/16IN #3 (DATA PASS)

W6PM1SBWA

08BS816CT

BD:SERIAL 8OUT-16INPUT-TEST

CONTROL BOX

BIO-4

BOARD-8OUT/16IN #4 (DATA PASS)

W6PM1SBWA

08BS816CT

BD:SERIAL 8OUT-16INPUT-TEST

CONTROL BOX

BMTH

BOARD-5 CARD MOTHER 

W6PM1SBW

08BS5MTHAT

BD:SERIAL 5 CARD MOTHER-TEST 

CONTROL BOX

BMTH

BOARD-8 CARD MOTHER 

W6PM1SBWA

08BS8MTHAT

BD:SERIAL 8 CARD MOTHER-TEST 

CONTROL BOX

BO24-1

BOARD-24 OUTPUT #1

W6PM1SBW

08BSO24AT

BD:SERIAL 24 OUTPUT->TEST

CONTROL BOX

BO24-1

BOARD-24 OUTPUT #1

W6PM1SBWA

08BSO24AT

BD:SERIAL 24 OUTPUT->TEST

CONTROL BOX

BPB

BOARD-8088 PROCESSOR

W6PM1SBW

08BSPDT

8088 PROCESSOR  ->TESTED

PROCESSOR BX

BPB

BOARD-186 PROCESSOR

W6PM1SBWA

08BSPE2T

PROC BD+FP->TEST

PROCESSOR BX

BPC-1

BOARD-PROPORTIONAL VALVE CONTRL

W6PM1SBW

96RH708A3T

ELE AMPLIFIER CARD-PRESS+TAG

CONTROL BOX

BPC-1

BOARD-PROPORTIONAL VALVE CONTRL

W6PM1SBWA

96RH708A3T

ELE AMPLIFIER CARD-PRESS+TAG

CONTROL BOX

BWPS

BOARD:WATER SENSOR PROBES

W6PM1SI2

08BNWPST

WATER PROBE SENSOR BD-TEST

CONTROL BOX

Page 1 of 8

1

Summary of Contents for MP1540 Series

Page 1: ...hing System TPAS2 Access date 08 24 2015 Document ECNs Latest Schematic Electrical Parts SINGLE STAGE PRESS MP1540 MP1550 MP1601 MP1602 MP1603 MP1604 MP1650 MP1A50 and MP1A03 PELLERIN MILNOR CORPORATION POST OFFICE BOX 400 KENNER LOUISIANA 70063 0400 U S A ...

Page 2: ......

Page 3: ...for 08BSPE3T W6PM1SBWB 2015352B 52 Serial Display W6PM1SD 1997311B 54 Press Dry Contact Data Pass W6PM1SDP2 1998101B 56 Press Dry Contact Data Pass 8088 Processor W6PM1SDP3 1998101B 58 Press Dry Contact Data Pass 186 Processor W6PM1SDP3A 2003174B 60 Press Dry Contact Data Pass Weight W6PM1SDP4 2004492B 62 Flat Panel Graphic Display W6PM1SEC 2007285B 64 Control Circuit Transformer W6PM1SHV 1999526B...

Page 4: ...1AE 15352A Page Description Document 96 Soft Squeeze W6PM1SSQ 2011452B 98 Electrical Valves MkV only W6PM1SVS 2014252B 100 Electrical Valves Mk VI Spray Ring W6PM1SVSA 2014252B 102 Electrical Valves Mk VI Soft Squeeze W6PM1SVSB 2014252B ...

Page 5: ...LLER W6PM1SEC 08EFD320C DISPLAY 10 4FP DCUL7 INVERTER SWITCH PANEL BFPI BOARD COLOR FLAT PANEL INTERFACE W6PM1SEC 08BSEDIFAT BD FP LCD DRVR INV INTERFACE TEST SWITCH PANEL BIO 1 BOARD 8 OUTPUT 16INPUT 1 W6PM1SBW 08BS816CT BD SERIAL 8OUT 16INPUT TEST CONTROL BOX BIO 1 BOARD 8 OUTPUT 16INPUT 1 W6PM1SBWA 08BS816CT BD SERIAL 8OUT 16INPUT TEST CONTROL BOX BIO 2 BOARD 8 OUT 16IN 2 DATA PASS W6PM1SBW 08B...

Page 6: ...RH RELAY COINC AT HOME POSITION W6PM1SPC1 09C024D37 4PDT KH 110 120V CONTROL BOX CRN RELAY NORMAL RAM PRESSURE W6PM1SSQ 09C024D37 4PDT KH 110 120V SOFT SQUEEEZE BX CRPRB RELAY RUN PIVOTING COINC BELT W6PM1SPC1 09C024D37 4PDT KH 110 120V CONTROL BOX CRRB RELAY RUN PIVOTING COINC BELT W6PM1SPC1 09C024D37 4PDT KH 110 120V CONTROL BOX CRS RELAY START W6PM1SS 09C024D37 4PDT KH 110 120V CONTROL BOX CS C...

Page 7: ...PM1SHV 09FF006AMA FUSE BK ABC 6 AMP 250V BUSS CONTROL BOX EFF1 FUSE DOOR FAN L1 W6PM1SMTR 09FF002AWN FUSE BUSS KTK 2 1 2 AMP 600V CONTROL BOX EFF2 FUSE DOOR FAN L2 W6PM1SMTR 09FF002AWN FUSE BUSS KTK 2 1 2 AMP 600V CONTROL BOX EL LIGHT PILOT OR INDICATOR ELM LIGHT ROTATING BEACON W6PM1SPC1 09H025V37 BEACON ROTARY 5 5 DIA AMBER TOP OF PRESS ELPRP LIGHT PRESS RETURN PUMP RUNNING W6PM1SPP 09J060A37 LA...

Page 8: ...TCRB MOTOR COINC BELT W6PM1SMTR MESSAGE SN SEE SPECIFIC MACHINE NAMEPLATE ON COINC MTDF MOTOR DOOR FAN W6PM1SMTR 13AF210071 FAN 2100 CFM 240V 60HZ ON DOOR MTHF1 MOTOR HOOD FAN 1 W6PM1SMTR MESSAGE SN SEE SPECIFIC MACHINE NAMEPLATE TOP OF PRESS MTHF2 MOTOR HOOD FAN 2 W6PM1SMTR MESSAGE SN SEE SPECIFIC MACHINE NAMEPLATE TOP OF PRESS MTHP MOTOR HYDRAULIC PUMP W6PM1SMTR MESSAGE SN SEE SPECIFIC MACHINE N...

Page 9: ...PS30ADS PRXSW QK CONN 30M NO DC SHLD LOAD CHUTE PXLCU PROX SW LOAD CHUTE FULL UP W6PM1SI2A 09RPS30ADS PRXSW QK CONN 30M NO DC SHLD LOAD CHUTE PXSB PROX SW RAM AT BOTTOM W6PM1SI1 09RPS18ADS PRXSW QK CONN 18M NO DC SHLD TOP OF RAM PXSB PROX SW RAM AT BOTTOM W6PM1SI1A 09RPS18ADS PRXSW QK CONN 18M NO DC SHLD TOP OF RAM PXSB PROX SW RAM AT BOTTOM W6PM1SI1B 09RPS18ADS PRXSW QK CONN 18M NO DC SHLD TOP OF...

Page 10: ...405PB10 SWASS PBBK 1NO NON SWPNL SIDE SHSC SWITCH SIGNAL CANCEL W6PM1SI1 09N405PY10 SWASS PB YELLOW 1NO SWITCH PANEL SHSC SWITCH SIGNAL CANCEL W6PM1SI1A 09N405PY10 SWASS PB YELLOW 1NO SWITCH PANEL SHSC SWITCH SIGNAL CANCEL W6PM1SI1B 09N405PY10 SWASS PB YELLOW 1NO SWITCH PANEL SHSMA SWITCH MASTER W6PM1SS 09N405M220 SWASS M2W 2NO SWITCH PANEL SHSO SWITCH STOP W6PM1SS 09N404PR01 SWASS PBRD 1NC SWITCH...

Page 11: ...7 1 8 AIRPILOT 3W NC 120V50 60 AIR VALVE BOX VECU VALVE LOAD CHUTE UP W6PM1SVSA 96R301B37 1 8 AIRPILOT 3W NC 120V50 60 AIR VALVE BOX VEDDD VALVE DISCHARGE DOOR DOWN W6PM1SVS 96R301B37 1 8 AIRPILOT 3W NC 120V50 60 AIR VALVE BOX VEDDD VALVE DISCHARGE DOOR DOWN W6PM1SVSA 96R301B37 1 8 AIRPILOT 3W NC 120V50 60 AIR VALVE BOX VEDDD VALVE DISCHARGE DOOR DOWN W6PM1SVSB 96R301B37 1 8 AIRPILOT 3W NC 120V50 ...

Page 12: ... 24VDC HYDRAULIC UNIT VERS VALVE PREFILL W6PM1SVS 09RH712E37 PREFILL VALVE HYDRAULIC UNIT VERS VALVE PREFILL W6PM1SVSA 09RH712E37 PREFILL VALVE HYDRAULIC UNIT VERS VALVE PREFILL W6PM1SVSB 96RH712E37 PREFILL VALVE REXROTH ZSFW100 HYDRAULIC UNIT VESR VALVE SPRAY RING W6PM1SVSA 96R301B37 1 8 AIRPILOT 3W NC 120V50 60 AIR VALVE BOX VESR VALVE SPRAY RING W6PM1SVSB 96R301B37 1 8 AIRPILOT 3W NC 120V50 60 ...

Page 13: ...is warranty For parts which require routine replacement due to normal wear such as gaskets contact points brake and clutch linings belts hoses and similar parts the warranty time period is 90 days We reserve the right to make changes in the design and or construction of our equipment including purchasedcomponents withoutobligationtochangeanyequipmentpreviouslysupplied ANY SALE OR FURNISHING OF ANY...

Page 14: ...ou can also get components from the Milnor factory Tell the supplier the machine model and serial number and this data for each necessary component The component number from this manual The component name if known The necessary quantity The necessary transportation requirements If the component is an electrical component give the schematic number if known If the component is a motor or an electric...

Page 15: ...ltage will electrocute or burn you Power switches on the machine and the control box do not eliminate these hazards High voltage is present at the machine unless the main machine power disconnect is off Do not service machine unless qualified and authorized Lock out and tag out power at the main machine disconnect before opening electric boxes and accessing electrical components For inputs from Mi...

Page 16: ...ic signals during this time 2 For numeric signals from Milnor to allied allied discharge interface allied must not read signals until the data valid or other operational signal indicating data is valid occurs see Discharge Interface non Numeric Signals 3 Although not all the operational signals listed in the tables are necessarily required the signals used will vary with specific machine models an...

Page 17: ...umn provides pertinent information for that signal Generally these signals must be exchanged by the interfaced devices in the order listed The labels given to operational signals in the schematics can vary from device to device However the document Summary of Milnor Allied Interface Capability provides generic names for these The right hand column of this table provides both the generic function n...

Page 18: ...7 338 339 330 Display code Not available i2 T i2 S i2 R 64 Goods Codes 00 63 Board code io3 5 io3 4 io3 3 io3 2 io3 1 io3 0 Multi terminal TBA WC2 WC2 WC2 WC2 Pin Number 7 4 3 2 1 Wire Number 7 237 238 239 230 Display code i1 t i1 s i1 r i1 q 16 Extract Press Codes 00 15 Board code io2 3 io2 2 io2 1 io2 0 Customer codes G and H use direct inputs on the processor board not inputs on the peripheral ...

Page 19: ...or outputs from Milnor Milnor does not normally assign either pin of the potential free contact as the common Hence both pins have unique pin and wire numbers In this table these are listed together in the same cell with a dot between e g C D To provide eight customer code signals with limited available terminals Customer codes A through H had to share pin 1 Table 4 Discharge Interface non Numeric...

Page 20: ...r doing so are explained in the reference manual The Display code values listed in the tables herein tell you which display page and character represent the indicated signal as shown in the following example i2 H Where i input display page o output display page 2 the second in a series of input display pages See the reference manual for the keystrokes used to access each display page in the series...

Page 21: ... input or output 5 if this signal is an output 5 Decimal Binary Conversion and How It Applies to Allied Interfaces Batch codes decimal numbers are converted to binary by the sending controller then passed via the numeric signals to the receiving controller where they must be converted back to decimal numbers For example if an interface provides for passing 16 drycodes then to pass drycode 14 binar...

Page 22: ... J or K 13 1 1 0 1 14 See explanations of decimal binary conversion herein 1 1 1 0 15 1 1 1 1 For convenience an example and explanations of converting between decimal and binary follow Many other examples and explanations can be found in mathematics texts on the Internet etc Also some pocket calculators and many computer programs are available for converting between decimal and binary Note 5 In T...

Page 23: ...elds 1001011010 Hence decimal 602 binary 1001011010 5 2 Converting Binary to Decimal Referring to Table 6 if you want to convert binary to decimal simply sum the decimal values corresponding to the 1 s in each position of the binary number Keep in mind that while a 1 in any position has a certain positive decimal value a 0 zero in any position has the decimal value 0 zero The conversion for binary...

Page 24: ...lies to a subset of machines will normally state in the title which models and or options it covers Compare this with the nameplate on your machine and with your purchase records Each schematic is devoted to circuits with common functions e g microprocessor inputs motor contactors Schematics appear in the manual in alphanumeric order 1 Component Prefix Classifications and Descriptions Component it...

Page 25: ...whose contacts switch immediately when voltage is applied to its coil and revert to normal when the voltage is removed Figure 4 Standard Relay CR Coils and Contacts Legend A Coil B Contacts CP Control Photo Eye Figure 5 Photo eyes sense the presence of an object without direct physical contact Photo eyes consist of a transmitter receiver and output module These components may be housed in one asse...

Page 26: ... Fuse Figure 6 A fuse is an over current safety device with a circuit opening fusible member which is heated and severed by the passage of over current through it EL Electric Light Figure 6 Indicator lights may be either incandescent or fluorescent EM Electro Magnet Solenoid A device consisting of a core surrounded by a wire coil through which an electric current is passed While current is flowing...

Page 27: ...l energy Figure 8 Transformer EX Figure 9 Electric Motor MR MV Motor Variable Speed Inverter To vary the speed of an AC motor the volts to frequency ratio must be kept constant The motor will overheat if this ratio is not maintained The motor variable speed inverter converts three phase AC to DC The inverter then uses this DC voltage to generate AC at the proper voltage and frequency for the comma...

Page 28: ...y operated e g Start button Master switch etc Figure 11 Cam Switch SC Figure 12 Hand Operated Switch SH SK Switch Key Lock Figure 13 A switch that requires a key to operate This prevents unauthorized personnel from gaining access to certain functions e g the Program menu SL Switch Level Operated Figure 14 A switch connected to a float that causes the switch to open and close as the level changes F...

Page 29: ...ble set points e g Motometers or Combistats TB Terminal Board Figure 18 A strip or block for attaching or terminating wires Figure 17 Temperature Switch ST Figure 18 Terminal Board TB VE Valve Electric Operated Figure 19 A valve operated by an electric coil to control the flow of fluid The fluid can be air water or hydraulic Figure 19 Electrically Operated Valve VE ZF Rectifier Figure 20 A solid s...

Page 30: ...n electronic circuit or piece of equipment Connectors are male or female according to whether they plug into or receive the mating connector 2 Component Terminal Numbering CAUTION 1 Risk of Mis wiring Due to electrical component manufacturing inconsistencies the pin numbers imprinted on components such as connectors and relay bases used on Milnor machines often do not correspond to the pin numbers...

Page 31: ...RIN MILNOR CORPORATION Figure 22 Plug in Relays 11 pin Relay with Grey Base Legend 14 pin Relay with Grey Base older 14 pin Relay with Black Base newer 14 pin Relay with Beige Base rare Left View of relay and base Right Same view show ing pin num bers 27 ...

Page 32: ...ng with the letter M e g CRxxM are not discrete components but are a component of a printed circuit board They are usually not individually replaceable Figure 23 AMP Connector Pin Locations 36 pin Connector 18 pin Connector Legend A View of mating halves of connector B Same view showing assigned pin numbers 28 ...

Page 33: ...agrams PELLERIN MILNOR CORPORATION Figure 24 Molex Connector Pin Locations 15 pin Connector 9 pin Connector 6 pin Connector 4 Pin Connector 2 pin Connector Legend A View of mating halves of connector B Same view showing assigned pin numbers 29 ...

Page 34: ...inal R if normally open terminal L if normally closed L Terminal S if normally open terminal M if normally closed 3 Features of Milnor Electrical Schematic Diagrams Document BMP010012 following this section is a sample schematic based on a schematic diagram for the Milnor gas dryer For the purposes of this exercise the schematic is shown gray and explanations of the items on the schematic are show...

Page 35: ...ain several different types of circuit boards and one or more boards of each type A numerical suffix identifies the board type and a numerical prefix identifies which one of several boards of a given type is being depicted For example the designation 1MTA5 identifies this as the first I O board 8 output 16 input board in the control system As shown on the drawing a pin number follows the board num...

Page 36: ...tion of the relay on the machine Row and column numbers are shown on the appropriate tag for each relay tray A B Position 2A1M Relay Tray Number Row Column Function M Main Air Any relay that ends with an M is located on an electronic board S 09 S 11 S 11 Normally open contacts Normally closed contacts 7 1 contact 8 2 contact 9 3 contact V Q contact 7 4 contact 8 5 contact 9 6 contact V K contact C...

Page 37: ...signation Mass termination assembly MTA designation on board An MTA is a connection on an electronic circuit board The notes and the tag page locate the appropriate board Page line numbers Major revision letter Page number S Machine type Gas fired dryer 6th generation of controls W Wiring Class of control system Title of this circuit Voltage of this circuit BMP010012 R 33 ...

Page 38: ... Wiring Guidelines As explained in BISUUI01 a gate interlock switch must have one pole per machine to be interlocked Each pole on the switch must be electrically isolated from any other poles on that switch The gate interlock circuit for a given machine is a series circuit that includes one pole per switch per gate This circuit is wired into and becomes part of the machine s three wire circuit see...

Page 39: ...arms c Close the gate so the next gate can be tested 3 2 Testing Three wire Circuit Components on Each Interlocked Machine Typically these include the components listed in Table 1 Table 1 Typical Three wire Circuit Components Found On Component Shuttle Press Centrifugal Extractor Stop 0 push button on control panel Emergency Stop switch es locking push button Manually lifted access door typically ...

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Page 44: ... BIO 4 OPTIONAL DATA PASS INPUTS OUTPUTS 0 WEIGHT 0 1 WEIGHT 1 2 WEIGHT 2 3 WEIGHT 3 4 WEIGHT 4 5 WEIGHT 5 6 WEIGHT 6 7 WEIGHT 7 8 WEIGHT 8 9 WEIGHT 9 10 WEIGHT 10 11 WEIGHT 11 12 GOODS CODE 6 13 GOODS CODE 7 14 NOT USED 15 NOT USED 0 NOT USED 1 NOT USED 2 NOT USED 3 NOT USED 4 NOT USED 5 NOT USED 6 NOT USED 7 NOT USED BIO 1 STANDARD INPUTS OUTPUT 0 THREE WIRE ON 1 RAM HALF UP 2 RAM FULL DOWN 3 CA...

Page 45: ...P ETHP SNUBBER BOARD PROPORTIONAL CARD CBBP G N D G N D G N D G N D G N D G N D G N D E F 1 E F 2 E F 3 7 CRS CRGC CRFLHCRFLL CDD CRD OPTIONAL FOR PIVOTING COINIC CRH CRPRB CD1 CRRB CRCBL L 1 INCOMING POWER T 1 T 1 T 1 T 1 T 1 L 2 T 2 T 2 T 2 T 2 T 2 L 3 T 3 T 3 T 3 T 3 T 3 1MTM1 BIO 1 8 OUTPUT 16 INPUT BOARD SW1 SW2 ADDRESS 0 1 B024 1 24 OUTPUT BOARD SW1 SW2 ADDRESS 1 1 BDA 1 DIGITAL TO ANALOG CO...

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