INSTALLATION INSTRUCTIONS

Transcription

1 INSTALLATION INSTRUCTIONS for SUNNEN PED3198 PC OPERATOR STATION RETROFIT KIT For Use on Sunnen SV Series Vertical Honing Machines I-PED-319A INTRODUCTION Sunnen PED3198 PC Operator Station Retrofit Kit is designed to replace the PED3137 & PED3159 PC Operator Stations on Sunnen SV Series Vertical Honing Machines (see Figure 1). TOOLS & MATERIALS The following tools and materials are required for unpacking and installing the new parts: Knife Allen Wrench Set Screwdriver, Std. Screwdriver, Phillips INSTALLATION Read the following instructions carefully and thoroughly before unpacking, inspecting and installing the Kit. To install Kit, proceed as follows: All wiring is to be performed by a competent, Licensed Electrician in accordance with all local, FIGURE 1a, Old PC PED3137 state, and federal codes and regulations; along with any special information provided on machine nameplate or electrical specification plate. WARNING All wiring and electrical equipment service should be performed by authorized personnel ONLY. 1. Create a diagnostic archive of current PC. Go to Main Menu <F1>. Go to Diagnostic Menu. NOTE: If greyed-out, please contact your appropriate supervisor. Go to Diagnostic Archive <F12>. Software will ask where to save file. Please pick an appropriate directory (the default is the Desktop), and then click OK Button. The file generated from a Diagnostic Archive is named SendToSunnen.cab this is the file that should be sent to Sunnen Products Company personnel. 2. Turn off main electrical power switch. 3. Remove eight (8) capscrews from back panel of operator station enclosure and set back panel aside (see Figure 2). 4. Disconnect all wires and cables from contacts and PC in operator station box. Cables will be reused to wire in new enclosure. 5. Remove mounting hardware for your machine (see Figure 3a for SV1010/15;2010/15 or 3b for SV410/60/90;510/60;1052;2410/60/90/2510/60; 2052). Retain hardware to mount new Operator Station enclosure. FIGURE 1b, New PC PED3198 FIGURE 2, Rear Panel SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST. LOUIS, MO 63143, U.S.A. PHONE:

2 CABLE TIE BRACKET - Wire Cables To Bracket So That Cables Move Freely When Enclosure Is Rotated SPRING COMPRESSOR WAVE SPRING - Lightly Grease CAPSCREWS LOCKWASHER BUSHING CAPSCREWS STIFFENER PLATE LOCKWASHER Position Enclosure Between Stiffener Plate and Enclosure Base As Shown CAPSCREWS ENCLOSURE BASE SLIDE WASHER - Lightly Grease PLATE FLATWASHER LOCKWASHER HANDLE LEVER FIGURE 3a, Enclosures NUT NUT LOCKWASHER RUBBER BUMPER CAPSCREW CONDUIT CONNECTOR ENCLOSURE CAPSCREW FIGURE 3b, Enclosures 2

3 OPTIONAL GAGING 6. Remove Operator Station Enclosure and feed cables through as not to damage any of the conductors or insulation. Set old operator station enclosure aside. WARNING Use care when installing the new Operator Station Enclosure it weighs more than the older Enclosure. 7. Mount new Operator Station Enclosure using hardware removed in step 5. Assemble in reverse order to disassembly of old Enclosure (see Figures 3a & 3b). New enclosure comes with electrical components already installed. 8. Feed cables to new enclosure being cautious as to not smash or crimp any of cables or conductors going to operator station (see Figure 4). 9. Wire cables to appropriate components using wire diagram provided (Figures are for reference only). Wire CBL1038 Cable to Surge Suppressor 2SS as shown (see Figure 5). Wire Handwheel Cable as shown (see Figure 6). Wire Operator Station Control Cable as shown (see Figure 7). FIGURE 4, Enclosure Wiring (refer to Wiring Diagram) FIGURE 5, CBL1038 FIGURE 6, Handwheel FIGURE 7, Operator Station Cable 3

4 OPTIONAL GAGING FIGURE 8, Optional PS50 Gaging Transducer (refer to Wiring Diagram) Connect the purple Profibus cable and the yellow Ethernet cable to 1PC. 10. OPTIONAL: If machine includes gaging, additional cables and gaging transducer will be included in operator station. Refer to wire diagram provided for wiring (Figures are for reference only). Connect CBL1176 to CBL579 for PS50 Gaging Transducer as shown (see Figure 8). REFER TO THE FOLLOWING PAGES FOR PARTS LIST RELATED TO YOUR MACHINE AND TO THE WIRING DIAGRAM INCLUDED IN THE KIT. 4

5 ITEM NO. PARTS LIST COVERING SV4xx/SV5xx/SV1410/SV1052/SV24xx/SV25xx ORDER BY PART NUMBER QTY. DESCRIPTION - - SV245X0 Ref....IPC Retrofit Kit (SV4xx/SV5xx/SV1410/SV1052/SV24xx/SV25xx), includes 1 SV Common Parts (SV4xx/SV5xx/SV1410/SV1052/SV24xx/SV25xx) Blue #18 AWG TEW Wire Red #16 AWG TEW Wire Green #14 AWG TEW Wire Blue #14 AWG TEW Wire Gasket 10 DRB Din Rail (200mm) 11 F Small End Fuse GY Cover Section 12 HL Screw (M6 X 1,0 X 10mm BSHCS) 13 PEC Profibus Connector w/pg Port 14 PED Manual Pulse Generator, Hand Wheel 15 PED Profibus Card 16 PED Phoenix Quint 10A 1pH Power Supply 18 PED Phoenix Valueline 19 Inch IPC 20 PEF Fuse 22 PEM End Section 23 PEM VDC Enclosure Fan 24 PEM Fan Outlet Grill 25 PEM Usb Connector 27 PEM Phoenix 1 Phase Surge Suppressor 28 PEM Wire & Cable Marking Label; 500 Labels Per Roll 29 PEM Cable Tie Mounting Base 30 PEM Fuseholder 31 PEM Knockout Plug 22,5mm 32 PEM Pole 6mm Ground Block 33 PEM Pole 6mm Block 34 PEM Mounting Collar, Die Cast 35 PEM Push Button Cap, Flush Green 36 PEM Push Button Cap, Flush Blue 37 PEM Push Button Cap, Extended Red 38 PEM Light Block, Led White, Screw Clamp Terminals 39 PES Contact, N.O. Screw Terminal 40 PES Contact, N.C. Screw Terminal 41 PES Selector Switch, 3 Position, Rtc 42 PES Pushbutton Head Without Cap 43 PES Pushbutton, Red Mushroom 44 PES Pushbutton, Illuminated, White 45 PET Wire Pin 20 To 18 AWG 46 PET Wago 2 Pin Lever-Nut 47 PHM Locking Hinge 48 PHM Hinge 49 PHNM Nut, Hex (M8 X 1,25) 50 PHNM Nut, Hex (M5 X 0,8) 51 PHNM Nut, Self Clinching (M6 X 1,0) 52 PHSM Screw (M8 X 1,25 X 20mm HHCS) 53 PHSM Screw (M3 X 0,5 X 8mm SHCS) 55 PHSM Screw (M8 X 1,25 X 30mm FSHCS) 56 PHWM Lockwasher (M5) 57 PHWM Lockwasher (M8) 58 PHWM Flatwasher (M8) 60 PHWM Washer, Fender (M5) 61 PHWM Lockwasher (M3) 62 PNP Electrical Decal 63 PNP Control Panel Overlay 64 PSW RTX License 65 SV Operator Station Hinge Plate 66 SV Operator Station Enclosure Assembly 67 SV SV Machine Software Disc 68 SV Back Plate 70 PNP Electrical Specification Plate With Ce Mark Adhesive Transfer Tape, 3m 468mp, 3 Inch Wide X 60yards Roll 72 IPED Retrofit Kit Installation Instruction A 1...Corrugated Tube; Half Pack B 2...Corrugated Cap 75 MSP Wooden Pallet, ISPM15 Certified & Stamped N/S indicates Not Shown 5

6 ITEM NO. PARTS LIST COVERING SV4xx/SV5xx/SV1410/SV1052/SV24xx/SV25xx w/gaging ORDER BY PART NUMBER QTY. DESCRIPTION - - SV245X5 Ref....IPC Retrofit Kit (SV4xx/SV5xx/SV1410/SV1052/SV24xx/SV25xx w/gaging), includes 1 SV Common Parts (SV4xx/SV5xx/SV1410/SV1052/SV24xx/SV25xx w/gaging) Blue #18 AWG TEW Wire Red #16 AWG TEW Wire Green #14 AWG TEW Wire Blue #14 AWG TEW Wire Gasket 7 CBL PS50 Shielded Ethernet Cable 3m Long 8 CBL PS50 Power Cable 24V 9 CBL TPE99 Adapter To Analog PS50 Cable 10 DRB Din Rail (200mm) 11 F Small End Fuse GY Cover Section 12 HL Screw (M6 X 1,0 X 10mm BSHCS) 13 PEC Profibus Connector w/pg Port 14 PED Manual Pulse Generator, Hand Wheel 15 PED Profibus Card 16 PED Phoenix Quint 10A 1pH Power Supply 17 PED Etamic Ps-50 Signal Conditioner 18 PED Phoenix Valueline 19 Inch IPC 19 PED Ethernet Pci Network Adapter Card 20 PEF Fuse 21 PEF A Type 218 Fuse 22 PEM End Section 23 PEM VDC Enclosure Fan 24 PEM Fan Outlet Grill 25 PEM Usb Connector 26 PEM Rj-45 Ethernet Connector 27 PEM Phoenix 1 Phase Surge Suppressor 28 PEM Wire & Cable Marking Label; 500 Labels Per Roll 29 PEM Cable Tie Mounting Base 30 PEM Fuseholder 32 PEM Pole 6mm Ground Block 33 PEM Pole 6mm Block 34 PEM Mounting Collar, Die Cast 35 PEM Push Button Cap, Flush Green 36 PEM Push Button Cap, Flush Blue 37 PEM Push Button Cap, Extended Red 38 PEM Light Block, Led White, Screw Clamp Terminals 39 PES Contact, N.O. Screw Terminal 40 PES Contact, N.C. Screw Terminal 41 PES Selector Switch, 3 Position, Rtc 42 PES Pushbutton Head Without Cap 43 PES Pushbutton, Red Mushroom 44 PES Pushbutton, Illuminated, White 45 PET Wire Pin 20 To 18 AWG 46 PET Wago 2 Pin Lever-Nut 47 PHM Locking Hinge 48 PHM Hinge 49 PHNM Nut, Hex (M8 X 1,25) 50 PHNM Nut, Hex (M5 X 0,8) 51 PHNM Nut, Self Clinching (M6 X 1,0) 52 PHSM Screw (M8 X 1,25 X 20mm HHCS) 53 PHSM Screw (M3 X 0.5 X 8mm SHCS) 54 PHSM Screw (M4 X 0,7 X 8mm BSHCS) 55 PHSM Screw (M8 X 1,25 X 30mm FSHCS) 56 PHWM Lockwasher (M5) 57 PHWM Lockwasher (M8) 58 PHWM Flatwasher (M8) 59 PHWM Flatwasher (M4) 60 PHWM Washer, Fender (M5) 61 PHWM Lockwasher (M3) 62 PNP Electrical Decal 63 PNP Control Panel Overlay 64 PSW RTX License 65 SV Operator Station Hinge Plate 66 SV Operator Station Enclosure Assembly 67 SV SV Machine Software Disc 68 SV Back Plate 69 PES Phoenix 8 Port Ethernet Switch 70 PNP Electrical Specification Plate With Ce Mark Adhesive Transfer Tape, 3m 468mp, 3 Inch Wide X 60yards Roll 72 IPED Retrofit Kit Installation Instruction A 1...Corrugated Tube; Half Pack B 2...Corrugated Cap 75 MSP Wooden Pallet, ISPM15 Certified & Stamped N/S indicates Not Shown 6

7 ITEM NO. ORDER BY PART NUMBER QTY. PARTS LIST COVERING SV10xx/SV20xx DESCRIPTION - - SV247X0 Ref....IPC Retrofit Kit (SV10xx/SV20xx), includes 1 SV Common Parts (SV10xx/SV20xx) Blue #18 AWG TEW Wire Red #16 AWG TEW Wire Green #14 AWG TEW Wire Blue #14 AWG TEW Wire Gasket 10 DRB Din Rail (200mm) 11 F Small End Fuse GY Cover Section 12 HL Screw (M6 X 1,0 X 10mm BSHCS) 13 PEC Profibus Connector w/pg Port 14 PED Manual Pulse Generator, Hand Wheel 15 PED Profibus Card 16 PED Phoenix Quint 10A 1pH Power Supply 18 PED Phoenix Valueline 19 Inch IPC 20 PEF Fuse 22 PEM End Section 23 PEM VDC Enclosure Fan 24 PEM Fan Outlet Grill 25 PEM Usb Connector 27 PEM Phoenix 1 Phase Surge Suppressor 28 PEM Wire & Cable Marking Label; 500 Labels Per Roll 29 PEM Cable Tie Mounting Base 30 PEM Fuseholder 31 PEM Knockout Plug 22,5mm 32 PEM Pole 6mm Ground Block 33 PEM Pole 6mm Block 34 PEM Mounting Collar, Die Cast 35 PEM Push Button Cap, Flush Green 36 PEM Push Button Cap, Flush Blue 37 PEM Push Button Cap, Extended Red 38 PEM Light Block, Led White, Screw Clamp Terminals 39 PES Contact, N.O. Screw Terminal 40 PES Contact, N.C. Screw Terminal 41 PES Selector Switch, 3 Position, Rtc 42 PES Pushbutton Head Without Cap 43 PES Pushbutton, Red Mushroom 44 PES Pushbutton, Illuminated, White 45 PET Wire Pin 20 To 18 AWG 46 PET Wago 2 Pin Lever-Nut 47 PHM Locking Hinge 48 PHM Hinge 49 PHNM Nut, Hex (M8 X 1,25) 50 PHNM Nut, Hex (M5 X 0,8) 51 PHNM Nut, Self Clinching (M6 X 1,0) 52 PHSM Screw (M8 X 1,25 X 20mm HHCS) 53 PHSM Screw (M3 X 0,5 X 8mm SHCS) 55 PHSM Screw (M8 X 1,25 X 30mm FSHCS) 56 PHWM Lockwasher (M5) 57 PHWM Lockwasher (M8) 58 PHWM Flatwasher (M8) 60 PHWM Washer, Fender (M5) 61 PHWM Lockwasher (M3) 62 PNP Electrical Decal 63 PNP Control Panel Overlay 64 PSW RTX License 65 SV Operator Station Hinge Plate 66 SV Operator Station Enclosure Assembly 67 SV SV Machine Software Disc 68 SV Back Plate 70 PNP Electrical Specification Plate With Ce Mark Adhesive Transfer Tape, 3m 468mp, 3 Inch Wide X 60yards Roll 72 IPED Retrofit Kit Installation Instruction A 1...Corrugated Tube; Half Pack B 2...Corrugated Cap 75 MSP Wooden Pallet, ISPM15 Certified & Stamped N/S indicates Not Shown 7

8 ITEM NO. ORDER BY PART NUMBER PARTS LIST COVERING SV10xx/SV20xx w/gaging QTY. DESCRIPTION - - SV247X5 Ref....IPC Retrofit Kit (SV10xx/SV20xx w/gaging), includes 1 SV Common Parts (SV10xx/SV20xx w/gaging) Blue #18 AWG TEW Wire Red #16 AWG TEW Wire Green #14 AWG TEW Wire Blue #14 AWG TEW Wire Gasket 7 CBL PS50 Shielded Ethernet Cable 3m Long 8 CBL PS50 Power Cable 24V 9 CBL TPE99 Adapter To Analog PS50 Cable 10 DRB Din Rail (200mm) 11 F Small End Fuse GY Cover Section 12 HL Screw (M6 X 1,0 X 10mm BSHCS) 13 PEC Profibus Connector w/pg Port 14 PED Manual Pulse Generator, Hand Wheel 15 PED Profibus Card 16 PED Phoenix Quint 10A 1pH Power Supply 17 PED Etamic Ps-50 Signal Conditioner 18 PED Phoenix Valueline 19 Inch IPC 19 PED Ethernet Pci Network Adapter Card 20 PEF Fuse 21 PEF A Type 218 Fuse 22 PEM End Section 23 PEM VDC Enclosure Fan 24 PEM Fan Outlet Grill 25 PEM Usb Connector 26 PEM Rj-45 Ethernet Connector 27 PEM Phoenix 1 Phase Surge Suppressor 28 PEM Wire & Cable Marking Label; 500 Labels Per Roll 29 PEM Cable Tie Mounting Base 30 PEM Fuseholder 32 PEM Pole 6mm Ground Block 33 PEM Pole 6mm Block 34 PEM Mounting Collar, Die Cast 35 PEM Push Button Cap, Flush Green 36 PEM Push Button Cap, Flush Blue 37 PEM Push Button Cap, Extended Red 38 PEM Light Block, Led White, Screw Clamp Terminals 39 PES Contact, N.O. Screw Terminal 40 PES Contact, N.C. Screw Terminal 41 PES Selector Switch, 3 Position, Rtc 42 PES Pushbutton Head Without Cap 43 PES Pushbutton, Red Mushroom 44 PES Pushbutton, Illuminated, White 45 PET Wire Pin 20 To 18 AWG 46 PET Wago 2 Pin Lever-Nut 47 PHM Locking Hinge 48 PHM Hinge 49 PHNM Nut, Hex (M8 X 1,25) 50 PHNM Nut, Hex (M5 X 0,8) 51 PHNM Nut, Self Clinching (M6 X 1,0) 52 PHSM Screw (M8 X 1,25 X 20mm HHCS) 53 PHSM Screw (M3 X 0.5 X 8mm SHCS) 54 PHSM Screw (M4 X 0,7 X 8mm BSHCS) 55 PHSM Screw (M8 X 1,25 X 30mm FSHCS) 56 PHWM Lockwasher (M5) 57 PHWM Lockwasher (M8) 58 PHWM Flatwasher (M8) 59 PHWM Flatwasher (M4) 60 PHWM Washer, Fender (M5) 61 PHWM Lockwasher (M3) 62 PNP Electrical Decal 63 PNP Control Panel Overlay 64 PSW RTX License 65 SV Operator Station Hinge Plate 66 SV Operator Station Enclosure Assembly 67 SV SV Machine Software Disc 68 SV Back Plate 69 PES Phoenix 8 Port Ethernet Switch 70 PNP Electrical Specification Plate With Ce Mark Adhesive Transfer Tape, 3m 468mp, 3 Inch Wide X 60yards Roll 72 IPED Retrofit Kit Installation Instruction A 1...Corrugated Tube; Half Pack B 2...Corrugated Cap 75 MSP Wooden Pallet, ISPM15 Certified & Stamped N/S indicates Not Shown