Fitting Zx5 Crank Upgrade

Fitting the crank upgrade to Z065, Z066, Z067

Difficulté

Hard Difficile

Durée

2 day(s) jour(s)

ZX5, Crank Fitting_Zx5_Crank_Upgrade_DSC_0261.JPG

Introduction

This upgrade replaces the crank arm assemblies on Z065, Z066 and Z067 with a direct drive system to improve reliability

Étape 1 - Program Eaton Drives before they leave

Running frequency

Control mode

Accel time

Decel time

Étape 2 - Remove Link arm connecting to rack and pinion

Étape 3 - Remove pivot shaft and arm

Étape 4 - Undo clutch and remove Cam

Étape 5 - Add sprocket to clutch

B0001166

Étape 6 - Fix idler plate to upright

Étape 7 - Fix split sprocket onto drive shaft

...Line up with a straight edge

Étape 8 - Drill and pin split sprocket to shaft

Étape 9 - Add chain minimum length sprocket to sprocket

Use idler to create tension

Étape 10 - Fit Module C Crank Home sensor plate to Arm 5

Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes

Étape 11 - Fit Module C Crank Out sensor plate to Arm 5

This one has an extension that may or not be required. See Module D Crank Out Sensor for more info.

Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes

Étape 12 - Fit Module D Crank Home sensor plate to Arm 5

Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes

Étape 13 - Fit Module D Crank Out sensor plate to Arm 5

This one has an extension

Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes

Étape 14 - Fit Module E Crank Out sensor plate to Arm 5

Sensor cables run to rear Module E cabinet - EtherCAT fieldbus boxes

Étape 15 - Fit Module E Crank Home sensor plate to Arm 5

This one has an extension

Sensor cables run to rear Module E cabinet - EtherCAT fieldbus boxes

Étape 16 - Remove 2 off breaker and contactor Module C

Étape 17 - Add 2 off single pole breaker Module C

Tidy wires away for the spare 2 phases

Étape 18 - Add 2 off Eaton Drive to Module C

May need to move trunking or mount directly to side of enclosure.

Étape 19 - Add single pole breaker Module E

Étape 20 - Remove breaker and contactor Module E

Étape 21 - Add 1 Off Eaton drive to Module E

Étape 22 - For each Eaton Drive

• 1 phase
• Neutral
• Earth
• Fwd and Reverse signals
• Wire motor cables directly to bottom of drives

Étape 23 - Wire Sensor Cables to EtherCAT boxes

Module C and D cranks to back of Module C cabinet

Module E crank to back of Module E cabinet

Étape 24 - Latest Front End software installed

• Backup Old multi folder
• Copy in new winMulti version to c:\multi overwriting what is there

Étape 25 - Map new Links

Overwrite existing links if any exist

Output Ref	Name	EtherCAT Slice	Channel
273	Crank C Fwd	MC2C	9
275	Crank D Fwd	MC2C	10
274	Crank C Rev	MC2C	11
276	Crank D Rev	MC2C	12
277	Crank E Fwd	MC2E	10
278	Crank E Rev	MC2E	11

Étape 26 - Activate Configuration

And restart in run mode when prompted

Étape 27 - Add new IO Refs to IODef.mul

Ask HQ to download a relevant IODef.mul file

Failing this, the following IO refs need to be added

OuC_CrankFWD,273,2,0,0,False,False,3,8,-,False,0
OuC_CrankREV,274,2,0,0,False,False,3,9,-,False,0
OuD_CrankFWD,275,2,0,0,False,False,3,10,-,False,0
OuD_CrankREV,276,2,0,0,False,False,3,11,-,False,0
OuE_CrankFWD,277,2,0,0,False,True,64,0,-,False,0
OuE_CrankREV,278,2,0,0,False,True,64,1,-,False,0

And these removed

Étape 28 - Latest Front End software installed

• Backup Old multi folder
• Copy in new winMulti version to c:\multi overwriting what is there

Étape 29 - Test Function

Key Pointers

• End stops should be set so the rack can never run off the pinion - always a full tooth engaged
• Each crank motion stops when the input is seen, and then decelerates. Therefore, set the crank input position to allow for this deceleration before hitting end stop. Normally about 30mm

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