Installing A New Proportional Valve; Removing The Control Pcb; Installing A New Control Pcb - ABB PGC5000 Series Service Instructions Manual

PGC5000
PGC5000 Series Service Instructions
You may need to remove the Sensor PCB cable from the Control PCB to allow access to the connector of
some zones.
7. Using 3 mm hex socket wrench ABB Tool TL1009, remove the screws and washers that secure the valve in place.
8. Firmly grasp the valve and remove it from the enclosure.

6.6.7 Installing a new proportional valve

1. Before inserting the new valve, check the position of the o-ring on the valve.
2. If the o-ring is positioned at top of groove, use a solder aid or non-metal pick to roll the o-ring down to the bottom of the
groove. The o-ring must not be twisted.
3. Insert the new valve into its position in the enclosure. The wires coming out of the coil should face the Control PCB (See
Figure 6.7).
4. Assemble the spring or Belleville washer and hex socket head screw, ensuring that the concave side of the washer is facing
away from the head of the screw.
5. Start the screw with the spring washer in the hole next to the valve.
6. Press down on the center of the valve and finish tightening the screw.
7. Insert and tighten the second screw and washer, if applicable.
8. Plug all cables back into their corresponding connectors on the Control PCB.
9. If another proportional valve needs to be replaced, repeat the appropriate steps to remove the old valve and install a new
one.
10. Reinstall the EPC Control Assembly cover and insert the ten screws and tighten them to 16 in.-lb, using ABB Tool
TL1000/TL1002. Ensure that the flame-proof or explosion-proof surfaces of the cover or the body of the Control Assembly
are not damaged.
11. Reinstall the top panel and tighten the four screws.

6.6.8 Removing the control pcb

1. Perform the "Preparation" procedure.
2. Remove the four screws holding the top panel on the front of the ovenl.
3. Remove the ten screws holding the EPC Control Assembly cover using ABB Tool TL1009 and remove the cover. Be careful
not to damage the flame-proof or explosion-proof surfaces of the cover or the body of the Control Assembly.
4. Unplug the large ribbon cable from the Control PCB and fold it back to the left and out of the way (see Figure 6.9).
5. Unplug all valve, sensor PCB, and heater cables.
6. Using 2.5 mm hex socket wrench ABB Tool TL1007, remove three screws and washers (two from the triacs and one from
the PCB mounting bracket at the right side of the PCB).
7. Pull the Control PCB straight out of the enclosure toward you.
8. Remove fish paper isolator (do not throw away).
9. With a clean cloth, clean thermal joint compound off the enclosure.

6.6.9 Installing a new control pcb

1. On the new Control PCB, place a thin layer of thermal joint compound on all sides and the bottom of each RTD, and on the
back of each triac.
2. Insert the Control PCB into enclosure with components and connectors facing up.
3. Align RTDs with the holes in the enclosure and ensure the RTDs are inserted in the holes flush with the enclosure.
4. Using 2.5 mm hex socket wrench ABB Tool TL1007, attach the Control PCB to the enclosure with three screws and washers
(or four screws and washers if this is an older version of the Control PCB).
5. Insert the fish paper insulator between the enclosure and the back side (solder side) of the Control PCB.
6. Plug all cables back into their corresponding connectors on the Control PCB.
7. Reinstall the EPC Control Assembly cover and then insert the ten screws and tighten them to 16 in.-lb, using
ABBToolTL1000/TL1002. Ensure that the flame-proof or explosion-proof surfaces of the cover or the body of the Control
Assembly are not damaged.
8. Reinstall the top panel and tighten the four screws.
SI/PGC5000-EN, rev B
6 Component repair
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