1.1. Tool and Supply List

List of tools and supplies needed to complete the retrofit

- Radiometer Retrofit Kit (includes ILT1000, USB cable, mounting bracket, radiometer arm, cover, and USB hub)

- Keyboard and mouse

- Ladder (you will need to work on top of the machine)

- Standard Allen Wrenches

- Side Cutter (for clipping cable ties)

- Adjustable Wrench

- Cable ties

- Small flathead screwdriver

-  #1 Phillips screwdriver

- These instructions

1.2. Machine Preparation

Before moving on, make sure everything here has been completed.

1. Remove any solution from the machine
2. Remove funnels or C-Tubes from machine (depending on configuration)
3. Make sure you have plenty of space to work around the machine
4. Manually move the radiometer arm to Position 4
   • Log into the machine as an Engineer
   • Go to the Radiometer screen
   • Under 'Radiometer Controls', select 'Mode: Jog to Sensor'
   • Press 'Jog Up' until you get to position 4
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5. Once the arm is in position 4, go to the Main screen
6. Press the 'About' button
7. Press the 'Quit' button to exit the software
8. From the Start menu, shut down the PC
9. Turn off power to the machine by turning the main disconnect handle off

2.1. Remove Roof Skins

1. Using a 5/32” Allen key, remove the fasteners from the 4 corners of the front roof skin panel

2. Remove the front roof skin and set aside

3. Using a 5/32” Allen key, remove the fasteners from the 4 corners of the rear roof skin panel

4. Disconnect the upper fans by unplugging the connectors on the roof of the machine near the fans

5. Push the fan cables through the opening in the roof skin

6. Remove the rear roof skin containing the fans and set aside

2.2. Remove Side Window and Brackets

1. Remove the upper radiometer window bracket by using a 1/8” Allen key to remove the 5 bolts shown below (make sure to reach into the machine to hold the bracket when removing the last bolt)

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2. Remove the lower radiometer window bracket by using a 1/8” Allen key to remove the 5 bolts indicated below (make sure to reach into the machine to hold the bracket when removing the last bolt)

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3. LOOSEN the remaining 12 window bracket bolts using a 1/8” Allen key (do not remove them) – This will free up the window panels inside to allow for removal

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4. Remove the four window panels from the machine and set aside (1 clear UV pane, 3 tinted panes)

2.3. Remove Side Skins

1. Using a 1/8” Allen key, remove the four bolts securing the UV Bank Shield (this runs from the ceiling to the floor inside the rear door – see blue square and green highlight below) and set this piece aside.

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2. Using a 5/32” and a 1/8” Allen key, remove the 2 black strips on the side of the machine and set aside.

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3. Using a 5/32” Allen key, remove the bolts securing the upper side skin to the frame (indicated below) and remove the skin (You may want to have a second person assist with the skin removal)

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4. Set the skin aside

2.4. Remove Radiometer Stage Skins

1. Using a 1/8” Allen key, remove the three bolts securing the radiometer motor cover, set the cover aside.

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2. Using a 1/8” Allen key, remove the four bolts securing the radiometer stage cover skin to the machine. Set the skin aside.

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3.1. Begin Existing Probe Cable Removal

1. Disconnect probe cables from probes

2. Cut all zip ties on radiometer carriage

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3. Unfasten both ends of Igus bracket using a 1/16" Allen key

4. Remove the Igus chain cover by ‘unzipping’ the entire length of the chain. Set cover aside.

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5. Ends of Igus will need to be removed to get radiometer cables through (use a flathead screwdriver to pry the ends apart)

6. Cut all cable ties from the end of the Igus chain up to the roof of the machine

7. Undo any zip ties around cable bundles secured to frame (path shown below)

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8. Remove radiometer cables back to the top of the stack light

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9. Remove inside front door skin (with buttons)

10. Remove bulkhead on cable opening

11. Cut any zip ties between radiometer and bulkhead on front button panel (be sure to pull back sleeving over cable bundle and cut any zip ties found inside sleeving

3.2. Front Panel, HMI, and Top of Machine

1. Unplug serial cable from radiometer

2. Unplug power cable from radiometer (G&R Model 204)

3. Unplug probe cable(s) from radiometer

4. Remove radiometer from bracket

5. Remove battery box (if installed)

6. Uninstall any brackets for radiometer or battery box and set aside

7. Pull probe cables, serial cable and power cable through the bulkhead in the front panel

8. Pull cables through the back of front button panel through the circular opening in the stainless bracket shown below

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9. From above the stacklight, remove probe cables completely

10. Pull the serial and power cables out the same way

11. Pull serial/power cables all the way back to the electrical panel, cutting any remaining cable ties as you go

3.3. Electrical Enclosure

1. Remove raceway covers inside electrical enclosure (if applicable) - PIC HERE

2. If power cable is installed, remove power cables from terminal block  - WIRE NUMBERS

3. Remove power cable from machine

4. Unplug serial cable from PC

5. Follow serial cable through enclosure to the loose end, cutting any cable ties along the way

6. Remove serial cable from machine

4.1. New Arm Installation

1. Probe(s) should still be attached to the radiometer arm at this point

2. Remove radiometer arm from carriage (bolt locations indicated below)

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3. Place old arm on table next to new arm (with ILT1000s already installed) and match left-right positioning of probes – Use stage side of arm as your reference point (pic)

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4. Secure new probes to new arm

5. Fasten the new arm to the radiometer stage carriage using the same hardware removed in step 2

4.2. Cable Installation

1. Plug new USB cables into ILT1000 – CBL30013 closest to enclosure & CBL30014 closest to radiometer stage (include if only one probe used)

2. Secure cables to radiometer stage carriage

3. Run USB cable ends through arm side of radiometer Igus chain

4. Fasten Igus end to carriage

5. Lay radiometer sensor cables (PXS30220, 30224, 30226) and USB cables (CBL30013, 30014) through the Igus, making sure cables are not twisted inside the Igus chain

6. Re-install Igus chain cover

7. After cover has been fully installed, attach the other Igus end to the radiometer side skin

8. Add a cable tie every 12-18 inches up to the roof skin

9. Run USB cables through the hole in the roof skin

10. Secure cables to the bundle going across the machine to electrical enclosure

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11. Run cables down into electrical enclosure

5.1. USB Hub Installation

1. Fasten the DIN rail mounts to the USB hub - P/N here with pic

2. Find an open section of DIN rail to mount the USB hub

3. Run +24VDC power (305), DC common (304A) and GND wires from hub terminal to the correct terminal blocks 

4. Run USB cable that came with hub from the PC to the hub. Label this CBL30009

5.2. Connect USB Cables

1. Unplug CBL30008 and CBL30010 from the PC USB ports and move to the USB hub (USB cables from the radiometer must be landed in the PC, not the hub)

2. Plug the new USB cables (CBL30013 & CBL30014) into the PC

3. Make sure all cable bundles on top of the machine have been re-secured to the frame, confirm that there are no loose cables hanging down beneath the frame member, as this may cause problems when the carousel is rotating

6.1. Assigning COM Ports

1. On the PC, open Device Manager

2. Expand ‘Ports (COM & LPT), you should see several communication ports, as well as 2 USB serial ports.

3. Unplug CBL30013 from the PC, one of the serial ports should disappear, whichever one stays on the screen is CBL30014 – Radiometer A – record this somewhere

4. Plug CBL30013 back in and unplug CBL300014, whichever one stays on the screen is CBL30013 - Radiometer B - record this somewhere

5. Go to the C://DC/Source/Source/Data folder and open ‘Serial Radiometer.xml’

6. Change the COM ports for radiometer A and B to the COM ports just recorded

7. Save the SerialRadiometer.xml file

8. Open the DC200 software and log in as Engineer

9. Go to the Settings > Config page and find the ‘Radiometers Installed’ setting

10. Set this to ‘ILT x 1’ or ‘ILTx2’ based on the number of ILT1000s in use

11. Press Save

12. Exit the software

13. Restart the software

14. Confirm that there are numbers displaying in the ‘Live Readings’ window(s) on the Radiometer screen

7.1. Reinstall Radiometer Skins

1. Reinstall the radiometer cover

2. Reinstall the radiometer motor cover

7.2. Reinstall Side Skins and Window

1. ***Leave all hardware loose until instructed otherwise

2. Reinstall the upper side skin (You may want another person to assist with this)

3. Reinstall the UV glass (tinted panes towards the outside)

4. Reinstall the window brackets

5. Reinstall the black side strips

6. Once all fasteners have been started in the black side strips,  the hardware for the side skin can be tightened (leave the #10 bolts in the black strips loose)

7. Install the UV partition onto the window brackets.

8. Once the UV partition is installed, all window bracket hardware can be tightened