Attachment 4 - Appendix B Assembly Instructions Rev2.docx

AJW-143-026-001

Appendix B

Appendix B Universal Pedestal Electronic Control Assembly Instructions

1) It is up to the successful bidder to decide how to manufacture, build, or assemble these units according to the supplied drawings, parts list, and suggested manufacturing guide. All CAD drawings/files will be supplied. The order of manufacture and assembly below is only one method, assemblies /kits/component(s) may be completed in any reasonable manner and order.

2) Build wires according to the following drawings:

3) Get enclosure silkscreened/labeled/laser engraved as applicable for proper labeling.

4) Ensure each enclosure has a serial number labeled somewhere on the front of the enclosure.

a. Use ¼” lettering in the format SN:XXXX

5) Place precut enclosure on work bench.

6) The following steps provide the suggested assembly procedures for the Universal Pedestal Electronic Control.

7) Install rivet-nuts in in correct locations on the inner panel.

NOTE: Flush mount Rivet-nuts require 90-degree countersink.

8) Install din rail in correct locations using appropriate hardware.

a. Install Surge rail

i. Install 3 1201140 terminal block supports using 3 of each:

1. 90272A829 10-32 ½” screws.

2. 92146A550 #10 lock washer.

3. 92141A011 #10 flat washer.

ii. Install 20” din rail using terminal block support supplied screws.

iii. Install 15 2800982 Surge suppressors and 1 2800768 supply and remote module.

1. Each module comes with an included din rail bus connector that must be connected to the din rail before assembly. Install 16 of these in the correct location.

2. Snap Supply and remote module to the left din rail bus connector.

3. Snap 15 surge suppressors to each of the remaining bus connectors.

4. Connect cable 868610-265 to the right side of the bus connectors.

5. Install 2713780 end bracket on left side of surge arrestors.

6. Install 2713780 end bracket on right side of surge arrestors.

7. Install relay base PTF11PC with relay MJN2CK-DC24 and spring hold down PYMJN-S.

8. Install 2713780 end bracket on right side of surge on right side of relay.

9. Install relay base PTF11PC with relay MJN2CK-DC24 and spring hold down PYMJN-S.

10. Install 2713780 end bracket on right side of surge on right side of relay.

b. Install Power supply terminal rail

i. 12” Din rail is mounted using 5 of each:

1. 90272A194 8-32 ½” screws.

ii. Install 2 1421659 end brackets on rail. (these will not slide over screw heads)

iii. Install 35 3100305 MT 1,5 micro terminals on rail.

iv. Install 1 3100321 end cover on last micro terminal.

v. Slide end brackets tightly against the terminals and secure sing integrated screw.

vi. Install 0800268 label strip to micro terminals. (cut out 1-35)

vii. Carefully remove center divider from middle of micro terminals to allow installation of jumpers. (this may be easier before installing terminal on din rail)

viii. Install 3001608 jumper in position 28-35.

ix. Install 3001637 jumper in position 1-20.

x. Install 3001572 jumper in position 21-24.

c. Install power supply and comm Din Rail

i. Attach 18” Din rail to panel using 5 of each:

1. 90272A194 8-32 ½” screw

2. 92146A545 #8 split lock washer

3. 92141A009 #8 flat washer

ii. Using drawing as a guide install the following components on the Din rail:

1. 1 2866789 Quint 24VDC power supply

2. 4 DDA325N-D2PN-1212-001 DC power supplies

3. 1 2966841 Separator

4. 2 2967125 24V Relays

5. 1 2966841 Separator

6. 1 SE-SW5U Ethernet Switch

7. 2 2909511 120V Relays

8. 1 2966841 Separator

9. 1 7218K24 Din Rail Mounted Toggle Switch

10. 1 2713780 End Bracket

d. Install PLC chassis

i. To install PLC chassis GRV-EPIC-CHS4 to panel you have to first remove the backplane.

1. Remove 4 screws holding backplane to the chassis. Be careful not to drop the plastic insulating washers.

2. Mount chassis to the panel using 4 of each:

a. 90272A147 6-32 7/16” screw

b. 92146A540 #6 split lock washer

3. Replace backplane using screws and plastic insulating washers previously removed.

ii. Install GRV-EPIC-PSDC to chassis.

iii. Install GFRV-EPIC-PR2 to chassis around the power supply being careful to ensure connector pins are correctly aligned. Secure using captive screws on module.

iv. Install GRV-IACDCTTL24 to chassis by hooking upper tab and rotating into place. Secure using captive screw.

v. Install 2 GRV-OMRIS-8 to chassis by hooking upper tab and rotating into place. Secure using captive screw.

vi. Install GRV-IDC-24 8 to chassis by hooking upper tab and rotating into place. Secure using captive screw.

e. Install ground cable between A1A3 and A1A4 din rail.

i. Install ground on left side of A1A3 din rail and bottom of A1A4 din rail. Attach using ¼-20 hardware to each end.

1. 92620A539 ¼-20x5/8” screw

2. 94895A029 ¼-20 hex nut

3. 98023A115 ¼’ flat washer (one below the lock washer and one below the nut)

4. 91104A029 ¼” split lock washer

f. Install azimuth decoder board.

i. Install 12 93620A115 6-36 thread ¾” long standoffs.

ii. Attach board to standoffs using 8 of each:

1. 90272A147 6-32x7/16” screw

2. 92146A540 #6 split lock washer

3. 92141A008 #6 flat washer

iii. Finish attaching board using 4 93620A115 6-36 thread ¾” long standoffs to hold LM5013-Q1EVM above board.

iv. Mount LM5013-Q1EVM using 4 of each:

1. 90272A147 6-32x7/16” screw

2. 92146A540 #6 split lock washer

3. 92141A008 #6 flat washer

9) Place panel inside enclosure and attach using enclosure supplied hardware.

10) Install front panel hardware.

a. Install 4 Q22F1BXXG24E green LEDs, 2 Q22F1BXXR24E red LEDs, and 2 Q22F1BXXY24E yellow LEDs as shown in Figure 1. Terminals should be oriented towards the top of the panel.

Figure 1

b. Install 3 S2AL switches. Ensure all are oriented wit labeling away from the hinge.

c. Install Fuse holder in order from top down:

i. 1 03440125H Fuse holder with connection towards the top of the door.

ii. 1 03440024H Fuse holder with connection towards the top of the door.

iii. 4 03440012X Fuse holder with connection towards the top of the door.

d. Install Display bracket.

i. Mount CFA735 LCD display to 999100-1 Display Bracket using 5 of each:

1. 92010A802 M2x0.4 14mm screw

2. 93475A195 M2 flat washer

3. 93625A101 M2x0.4 Nylon locknut

ii. Mount display assembly to enclosure using 4 of each:

1. 90272A539 1/4-20 5/8” screw

2. 92141A029 1/4 flat washer

3. 90630A110 1/4-20 Nylon locknut

11) Mount Encoder Surge rail to left side of enclosure.

a. Modify 2 1201140 terminal block supports using drawing 120114-A and 2 95105A135 rivet nuts

b. Mount modified terminal block supports using 2 of each:

i. 90272A829 10-32 ½” screws.

ii. 92146A550 #10 lock washer.

iii. 92141A011 #10 flat washer.

c. Mount 6” din rail using terminal block support supplied screws.

d. Attach Surge arrestors to Din Rail. LED should be towards the top of the cabinet.

i. Each module comes with an included din rail bus connector that must be connected to the din rail before assembly. Install 4 of these in the correct location.

ii. Snap 4 9800982 Surge arrestors to each of the bus connectors. Attach cable 868610-265 to last bus connector at the bottom of din rail.

12) Mount connectors J1-J8 to enclosure using 4 of each:

a. 91290A117 M3x0.5 12mm socket head screw

b. 98269A420 M3 flat washer

c. 92148A150 M3 split lock washer

d. 90593A001 M3x0.5mm hex nut

13) Mount J9 and J10 using 2 09454521560. Ensure plastic collar is securely tightened.

14) Install all wires to their respective locations.

15) Proceed to test and evaluation in Appendix G (issued at SIR release).

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