]> 2026-04-28T11:52:36+02:00 Fitting Zx5 Crank Upgrade 0 en Draft Fitting the crank upgrade to Z065, Z066, Z067 Hard 2 day(s) This upgrade replaces the crank arm assemblies on Z065, Z066 and Z067 with a direct drive system to improve reliability This procedure involves mechanical fitting, electrical wiring and help from a TwinCAT3 competent engineer at HQ for software changes <div class="icon-instructions caution-icon"> <div class="icon-instructions-icon"><i class="fa fa-exclamation-triangle"></i></div> <div class="icon-instructions-text">...The drives must be programmed before parts sent out</div> </div><div class="icon-instructions caution-icon"> <div class="icon-instructions-icon"><i class="fa fa-exclamation-triangle"></i></div> <div class="icon-instructions-text">...Motors must be rewired for Delta and NOT Star</div> </div> <br/> false en Fitting_Zx5_Crank_Upgrade_DSC_0261.JPG none B0001166 <div class="icon-instructions idea-icon"> <div class="icon-instructions-icon"><i class="fa fa-lightbulb-o"></i></div> <div class="icon-instructions-text">...Line up with a straight edge</div> </div> Use idler to create tension Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes This one has an extension Sensor cables run to rear Module C cabinet - EtherCAT fieldbus boxes This one has an extension Sensor cables run to rear Module E cabinet - EtherCAT fieldbus boxes Sensor cables run to rear Module E cabinet - EtherCAT fieldbus boxes Tidy wires away for the spare 2 phases Module C and D cranks to back of Module C cabinet Module E crank to back of Module E cabinet 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 * Backup Old multi folder * Copy in new winMulti version to c:\multi overwriting what is there And restart in run mode when prompted <nowiki>Ask HQ to download a relevant IODef.mul file<br /><br /><br />Failing this, the following IO refs need to be added<div class="mw-highlight mw-content-ltr" dir="ltr"><pre>OuC_CrankFWD,273,2,0,0,False,False,3,8,-,False,0<br />OuC_CrankREV,274,2,0,0,False,False,3,9,-,False,0<br />OuD_CrankFWD,275,2,0,0,False,False,3,10,-,False,0<br />OuD_CrankREV,276,2,0,0,False,False,3,11,-,False,0<br />OuE_CrankFWD,277,2,0,0,False,True,64,0,-,False,0<br />OuE_CrankREV,278,2,0,0,False,True,64,1,-,False,0</pre></div><br /><br /><br />And these removed</nowiki> # Ensure all Out and home sensors are working and correctly oriented. Home is towards rear of machine, Fwd or Out is towards front. # Ensure the clutches are set to slip if the crank bottoms out # Test direction of all cranks (Fwd is towards front). Switch phases on motors if direction needs to change. The PLC has hard code to switch the outputs off when the sensors are covered 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 *The crank clutches should be set to slip before damage is done to the crank end stops in the event that the sensors do not work Overwrite existing links if any exist <br/>See the wiring for MC2C and MC2E in Step 22 for the link IORefs and locations Running frequency Control mode Accel time Decel time [[Programming Eaton DE Drive|https://stuga.dokit.app/wiki/Programming_Eaton_DE_Drive]]<br/> May need to move trunking or mount directly to side of enclosure. Drive can be WEG or EATON * Live wire * Neutral wire * Earth wire * 0v supply * FWD and REV Signals * Motor cables wire directly into bottom of the drive <br/> Follow link below for information on programming WEG drives: [[WEG Inverter Setup]] https://stuga-ltd.atlassian.net/wiki/x/s4CFAg Remove Link arm connecting to rack and pinion Undo clutch and remove Cam Remove pivot shaft and arm Add sprocket to clutch Fix idler plate to upright Fix split sprocket onto drive shaft Drill and pin split sprocket to shaft Add chain minimum length sprocket to sprocket Fit Module C Crank Home sensor plate to Arm 5 Fit Module C Crank Out sensor plate to Arm 5 Fit Module D Crank Home sensor plate to Arm 5 Fit Module D Crank Out sensor plate to Arm 5 Fit Module E Crank Home sensor plate to Arm 5 Fit Module E Crank Out sensor plate to Arm 5 Map new Links Wire Sensor Cables to EtherCAT boxes Latest Front End software installed Activate Configuration Add new IO Refs to IODef.mul Test Function *IF EATON DRIVES ONLY* Program Drives before they leave Remove 2 off motor breakers and contactors from Module C Add 2 off 10A single pole MCB's in Module C Add 2 off drives to Module C Remove breaker and contactor from Module E Add 10A single pole MCB in Module E Add 1 Off drive to Module E For each WEG drive Programme WEG drives 06/10/2025 Moved to Confluence Confluence 2025-10-07T15:11:59Z 2460956.1333218 Fitting Zx5 Crank Upgrade 0 false false 0 0 0 1 plainlist 3 [[:Dokit:DocOptions]] [[DokitEPIEnable::yes]] Fitting Zx5 Crank Upgrade# QUERYee7a61aae48f1c3f91d8e4d7736360be Notes 844 fr Notes Comment on 102 fr Comment on