Document number RS-PRD Revision 05 Date 20/10/2009 Page 1/30

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1 Date 20/10/2009 Page 1/30 1. Purpose This document describes the field replacement of the footscan plate cable for these models: 2m hi-end plate SN 11/5/xxx 2m pro plate SN 7/5/xxx 0.5m 2003 hi-end plate SN 9/3/xxx 0.5m 2004 hi-end plate SN 11/3/xxx 1m 2004 XL hi-end plate SN 11/4/xxx 0.5m USB1 SN 3/9/xxxx 0.5m USB2 SN 4/9/xxxx 1m USB2 SN Verify the serial number of the plate and follow the instructions in the appropriate paragraph! Notes: RoHS compliant (lead free) plates have the following marking on the name plate: For RoHS complaint plates: use SACX solder with the appropriate solder equipment, temperature setting and tips. For non RoHS complaint plates: use 60/40 sn/pb solder with the appropriate solder equipment, temperature setting and tips. Do not mix lead containing and lead free solder and tips. Set the tip temperature to C. Replace the cable before the PSL is replaced (the sticker might be damaged by the heat of the soldering iron). If the PSL is to be replaced: remove the PSL before replacing the cable, this will provide access to the reverse side of the PCB for inspection and touch up.

2 Date 20/10/2009 Page 2/ m hi-end plate SN 11/5/xxx There are several versions: Rubber grommet, cable tie strain relief Rubber grommet, P-clip strain relief PVC grommet, P-clip strain relief (latest version) When possible, upgrade the plate to the latest version. The instructions will show all steps, some steps can be skipped if the plate already has the modifications. Order the correct replacement cable: Rsscan catalog number for Replacement cable 2m type 2004 plate, rubber grommet (length 1.8m) : Rsscan catalog number for Replacement cable 2m type 2004 plate, plastic grommet (length 0,5m) : Mark the U-profiles at each corner with matching symbols.

3 Date 20/10/2009 Page 3/30 Remove the screws from all U-profiles except the U-profile on the cable side. (OPTIONAL) if the plate will be modified to use the PVC grommet instead of the rubber grommet: remove all screws. Pull and remove the 3 U-profiles. (OPTIONAL) if the plate will be modified to use the PVC grommet instead of the rubber grommet: remove all U-profiles. Slowly and gently remove the rubber top cover at the 3 sides where the U-profile has been removed. (OPTIONAL) if the plate will be modified to use the PVC grommet instead of the rubber grommet: remove the rubber top cover on all sides.

4 Date 20/10/2009 Page 4/30 Flip the rubber top cover as pictured. (OPTIONAL) if the plate will be modified to use the PVC grommet instead of the rubber grommet: remove the rubber top cover entirely and put it aside on a clean surface. Carefully lift the printed circuit board until there is enough clearance to grab the printed circuit board. Support the printed circuit board in the middle and gently lift up the printed circuit board (the printed circuit board is stuck to the housing at the middle with double sided tape). Avoid bending the printed circuit board.

5 Date 20/10/2009 Page 5/30 Remove the strain relief, either the cable tie or P-clip. Flip the printed circuit board as pictured. De-solder the cable wires from the printed circuit board. Be careful not to remove the red wire that runs across the printed circuit board. Remove the printed circuit board, support it as much as possible so it does not bend when handling. Flip the rubber top cover as pictured.

6 Date 20/10/2009 Page 6/30 Remove the old cable. (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: remove the rubber grommet and enlarge the hole in the U- profile on the cable side, use a 10mm drill. (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: enlarge the cable entry to 10mm. Drill carefully with and 10mm. Clean the cable entry and void.

7 Date 20/10/2009 Page 7/30 (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: flip the plate over. (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: remove the metal cover. (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: flip the plate over again and mark a drill hole for the P-clip strain relief. (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: use a 3mm drill to drill a hole at the marked spot.

8 Date 20/10/2009 Page 8/30 (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: thread the hole with M4 thread. (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: place the metal cover. (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: fix the rubber top cover on the cable side of the plate.

9 Date 20/10/2009 Page 9/30 (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: place the U-profile at the cable side of the plate. Secure the U- profile with the screws. When placing a cable with a rubber grommet, put the grommet over the cable first. Insert the new cable through the hole in the U-profile. Be careful not to bend the individual wires when pushing the cable through. (OPTIONAL ) if the plate will not be modified to use the P-clip strain relief: pull the cable through at the length pictured. Place the cable tie.

10 Date 20/10/2009 Page 10/30 (OPTIONAL ) if the plate will not be modified to use the P-clip strain relief: cut the excess of the cable tie. Pull the cable further through to allow easy soldering to the printed circuit board.

11 Date 20/10/2009 Page 11/30 Solder the wires to the printed circuit board according to the color scheme. Do not use excessive solder, the solder should not flow through to the reverse side of the printed circuit board. Verify all connections and colors. Position the printed circuit board vertical. Pull the cable back. Route the cable in the void.

12 Date 20/10/2009 Page 12/30 (OPTIONAL ) if the plate will be modified to use the P-clip strain relief: secure the cable with the P-clip strain relief and an M4 screw with washer. Place the printed circuit board in the housing. The printed circuit board should be flat and recessed in the housing.

13 Date 20/10/2009 Page 13/30 Carefully lift the edge of the transparent sticker at the cable side and check the soldering. If the solder is protruding too much, touch up to remove excess solder. Place the sticker back on the plate.

14 Date 20/10/2009 Page 14/30 Place the rubber top cover on the plate. Rub firmly around the edges. Test the plate for other defects before closing. (OPTIONAL ) if the plate will be modified to use the PVC grommet instead of the rubber grommet: place the PVC grommet over the cable and press into the U-profile until it latches into place.

15 Date 20/10/2009 Page 15/30 Slide the U-profiles back on the plate. Make sure the symbols on the edges match. Secure the U-profiles with the screws.

16 Date 20/10/2009 Page 16/ m pro plate SN 7/5/xxx Disassemble the plate and remove the old plate cable. Slide the new cable trough the cable entry. Put the large heat shrink around the cable.

17 Date 20/10/2009 Page 17/30 Put the 3 smallest heat shrinks around the individual wires: green, red and orange. Place the red heat shrink around the twisted blue & purple wire. Place the 2 remaining black heat shrinks around the twisted black & yellow wire and the brown & shield wire. Solder the wires to the pins of the header as shown in the picture. Soldering the wires on the wrong pins will cause plate and/or box damage when the plate is connected to the box!

18 Date 20/10/2009 Page 18/30 Slide the heat shrinks over the solder connections and shrink them with a hot air gun. Slide the large heat shrink over the wires as shown in the picture and shrink it with the hot air gun. The red heat shrink should stay visible for the positioning of the connector later. Fix the cable tie for strain relief. Cut the excess of the cable tie. Put the rubber grommet in the hole of the U-profile.

19 Date 20/10/2009 Page 19/30 Plug the header into the plate, the red heat shrink towards the edge of the plate. Use a piece of double-sided tape between the cable and the printed circuit board to fix the cable to the printed circuit board. Make sure the red heat shrink is in the correct position. Test the plate for other defects before closing. Close and final test the plate.

20 Date 20/10/2009 Page 20/ m 2003 hi-end plate SN 9/3/xxx & 0.5m 2004 hi-end plate SN 11/3/xxx & 1m 2004 XL hi-end plate SN 11/4/xxx The instructions for these plate models are identical. Order the correct replacement cable: Rsscan catalog number for Replacement cable 0,5m type 2004 plate (length 1.8m) : Rsscan catalog number for Replacement cable 0,5m type 2004 plate (length 0,5m) : Rsscan catalog number for Replacement cable 1m type 2004 plate (length 1.8m) : Rsscan catalog number for Replacement cable 1m type 2004 plate (length 0,5m) : Turn the plate over, the name plate facing towards you. Locate the metal cover underneath the rubber mat. When available, use a metal template to cut through the rubber. Use a sharp cutter and carefully cut through the rubber around the edges of the metal cover, cut about 5mm larger then the size of the metal cover. Alternatively you can peel off the rubber and

21 Date 20/10/2009 Page 21/30 re-stick later. Peel the cut rubber off the metal cover. Remove the 3 (or 6 on later revisions) M3 screws. The screw head can be hex (2mm metric) or Phillips (NR 1). Be very careful because the head of the stainless steel screws can be damaged easily! Use a proper matching screwdriver or bit! Lift the metal plate and remove the double sided tape on the back. Note: Newer plates have 6 screws and no tape. Clean the top of the metal plate, do not damage the name plate.

22 Date 20/10/2009 Page 22/30 De-solder the cable wires from the printed circuit board. Note: There are 2 types of printed circuit boards. One with through-hole pads to solder the wires (older versions) and one with SMD pads (newer version). Clean the pads, use solder wick or a desoldering iron. Note: The SMD type of pads should be cleaned and pre-tinned. Tin and trim the ends of the wires to match the pads. Solder the wires to the printed circuit board according to the color scheme. Check the other side of the PCB, if the solder is protruding too much, touch up to remove excess solder.

23 Date 20/10/2009 Page 23/30 Route the wire in the cable guide. Place a piece of double sided tape as depicted. Note: plates with 6 screws do not need this tape. Remove the cover of the double sided tape and place the metal cover plate. Use the screws to attach the cover plate. If the screw heads are damaged during removal: use new screws. Replace the hex head screws by Phillips head screws.

24 Date 20/10/2009 Page 24/30 Replace the cut-out rubber, use a new piece of rubber matching the removed piece if possible.

25 Date 20/10/2009 Page 25/ m USB2 plate SN 4/9/xxxx & 0.5m USB1 plate SN 3/9/xxxx & 1m USB2 plate SN x/x/xxxx The instructions for these plate models are nearly identical. Order the correct replacement cable: Rsscan catalog number for Replacement cable footscan USB1 plate : Rsscan catalog number for Replacement cable footscan USB2 plate : Turn the plate over, the name plate facing towards you. Locate the metal cover underneath the rubber mat. When available, use a metal template to cut through the rubber. Use a sharp cutter and carefully cut through the rubber around the edges of the metal cover, cut about 5mm larger then the size of the metal cover. Alternatively you can peel off the rubber and re-stick later. Peel the cut rubber off the metal cover.

26 Date 20/10/2009 Page 26/30 Remove the 3 (or 6 on later revisions) M3 screws. The screw head can be hex (2mm metric) or Phillips (NR 1). Be very careful because the head of the stainless steel screws can be damaged easily! Use a proper matching screwdriver or bit! Lift the metal plate and remove the double sided tape on the back. Note: Newer plates have 6 screws and no tape. Clean the top of the metal plate, do not damage the name plate. De-solder the cable wires from the printed circuit board. Note: There are 2 types of printed circuit boards. One with through-hole pads to solder the wires (USB1 version) and one with SMD pads (USB2 version).

27 Date 20/10/2009 Page 27/30 Clean the pads, use solder wick or a desoldering iron. Note: The SMD type of pads should be cleaned and pre-tinned.

28 Date 20/10/2009 Page 28/30 USB 1: Tin and trim the ends of the wires to match the pads. Solder the wires to the printed circuit board according to the color scheme. Check the other side of the PCB, if the solder is protruding too much, touch up to remove excess solder. USB 2:

29 Date 20/10/2009 Page 29/30 USB1: Route the wire in the cable guide. USB2: Place a piece of double sided tape as depicted. Note: plates with 6 screws do not need this tape. Remove the cover of the double sided tape and place the metal cover plate. Use the screws to attach the cover plate. If the screw heads are damaged during removal: use new screws. Replace the hex head screws by Phillips head screws.

30 Date 20/10/2009 Page 30/30 Replace the cut-out rubber, use a new piece of rubber matching the removed piece if possible. Revision history Revision Originator Date Changes 01 Jonas Vos 31/03/2008 First revision 02 Jonas Vos 15/10/2008 Added instructions for 2m plates with SN 11/5/xxx 03 Jonas Vos 7/1/2009 Color scheme on page 10 corrected Instructions added for 0.5m and 1m plates 04 Jonas Vos 12/10/2009 Instructions added for USB plates 05 Jonas Vos 20/10/2009 Color scheme USB plates added.

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