Service Manual - Honeyville Metal, Inc.
Contents
1. i YOOO000000006090 0 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 20 21 22 23 x0909090000000000000090 INPUT 12 24 2 3 15mA 21 23 T ii Ls D X22 ne SSSSSSSSSSSSSS ele vss lololol olololol olololol olololol olololo 910910 DC Pulse Outputs YO Y1 High Speed Inputs X0 X3 B Internal module circuitry yy V gt 1 Optical me Input isolator Optical i OUTPUT To LED Derating Chart for DC Outputs Y Common Points l 15 LED zi 0 75 YO Y17 COM B 1 0 8 Standard Input Circuit X4 X23 standard ET ir 0 1 Qo circuitry 0 10 20 30 40 50 55 C 1 32 50 68 86 104 1221312. AYNSOTONA OV ASVHd NOISS3A 993 30118181914 9 Z 12 12 WVYOVIG AYNSOTONA TVOTH L03 TH 103109 9892 6686 092 9922 666 092 1189 VNVIGNI VAIO M 006 5 0027 SWALSAS TOHLNOO LSNA 9NFIONVH TVIHALVIN 1812W anvos 330 uno NOLLONHLSNO OL NOLLNALLV OL N338 LON 3AVH HOIHM 5310 9 510 TYNOISNAMIG ANY HO 318 5NOdS3H 38 LON TIVHS HOIOVHINOO A8 38 15 SNOISNAMIG TIV 40 JHLLNOHLIM OL LON SI ANY VLAN STHAASNOH 30 ALHAdOld SI G3NIVINOD NOLLVNHO ANI SIHL PANEL LEGEND ajoj nji ya vs ve vv c2 vu vio vo ve vie D0 06 PLC t x pe x po e beoporpoz xe pae xn 2223 to vo v v
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6. 24V DC POWER SUPPLY CO XO X1 X2 5 000 TRANSFORMER 120 VAC OUTPUT 5 amp l o 8 al 8 5 M HEATER ups amp CONTACTOR 5 220 240 VAC INPUT TRANSFORMER 120 VAC OUTPUT 440 480 VAC INPUT B 11112113 HIGH VOLTAGE OPTION 2 11 12 13 6 4 mzomaorom NOISS3A 993 30118181914 9 WVHOVIG al o 9892 666 092 9922 68 092 3NOHd FYNSOTONA TVOLMLOTTA 14899 WNVIGNI 340 006 5 002 SWALSAS 1081109 LSNA TVIHALVIN te 209 33a 3AVH S3ION3d3HOSIQ TYNOISNAMIG 3 18 5NOdS3H 38 LON TIVHS HOIOVHINOO 3H1 38 SNIN SNOISNAMIG TIV peso 2 20 BI 1810 0028 ALH3dOHd SI G3NIVINOD SIHL LEGEND 7 849
7. ler or wamng nano or wamo ono ayiaAauopy sm mou coeno 7j 3ueuno ind 63ueun indino e queung wa wier uonounj uomounj ad j fuel uonounj SNOLLO3NNOO a NE PEROT oF E dur zz ouma Fez 16 er wema inano er indno Fez Jew memo oz z spon 61 1 wema ro s ER 8 9 EN 51311010 GASANN 303 SI di 0r 1897 TZ 41872 2 ISN ALON FINGON FINGON 21490 00 104110 1034 0 5131008 0140 81935554 Q 1914
8. slang dno 209119 SNOLOENNOO 2 5181110 303 933033 SI ON 41 08189 12 31875 ISN LON 31 008 on 31aon on VW LYND 2000846 e m m m ex x 1NdNI 514 90 00 E 21524423 LA 83 s Jea za LA Joa foa afen NOISSINH3d WVYOVIG 1 TWNYALXA 12340 5131100 tZ OL dN enfer os 08919 12 Le se se ve ee 62 82 12 92 05 6 ev ev sm NOLLODHISNOO OL OL LON SJIONJAAHOSIG TYNOISNAINIG 31815 0453 38 LON TIVHS IWH HOIOVHINOO 8 SNN SNOISNANIG TIV 1 ALH3dOHd SI Q3NIVINOO SIHL 9872 69 092 Xv 3 9922 666 092 11499 WNVIGNI M 006 5 0027 SWALSAS 108109 LSNA ANY LNAWdINOA ONITGNVH IVINILYW asfiAAauopy 103410 SL31100 vc OL dN 743554 WVYSVIC TIVNH3LX3
9. 1 _ LR 1P0 460V AC Line Reactor 1 Endosure Heater 60 Watr S040 TSt 00 7 1 Block Gray DSECEE02L Low Voltage 220 240 VAC em Fat oy ___ _______ 6 oswa 1 17 Book 7 9 880001 Canada Only 1 1 1 1 1 1 5 24 2012 Parts List DRIVE ELECTRICAL ENCLOSURE 5 24 2012 3 5 Honeyville EPC 3 6 CONTROL ELECTRICAL ENCLOSURE DSECCEO2H High Voltage 440 480 VAC 5 DSHW1019 1 PS24 075D 24VDC Power Supply 6 DSHW1018 1 D0 06DD1 D Direct Logic PLC 8 09 4 20 TemhalBokBue 1 EZ2OBLEZPedCale DSECCE02L Low Voltage 220 240 lem Description 2 DSHW1 118 1 GS 21P0 FKIT 3P Fuse Kit 3 DSEC1002 1 240 480V to 120 Transformer 6 owo 0000010 8 084 1010 14 TerminalBockG ay 9 owo 2 TemmalBkBue 3 5 24 2012 Parts List CONTROL ELECTRICAL ENCLOSURE 22477 i 2 i 4 ISS SIAR oa 5 24 2012 3 7 Honeyville EPC 3 8 This page intentionally left blank 5 24 2012 Installation INSTALLATION Transportation Do not put excessive stress on the drive enclosure
10. finding WVYOVIC 9NISIM 86 0 eno mdu cO eno __ nding 39vMOVd TOMLNOO 1 Od3 16 6 0 camo emm 96 80194 du 92 3dmo oz zr queuing m no v3ueuno dno 9875 66 092 9922 t65 092 aNoHd yp zi 1 0 9 ow apon ndino queuing p mdno 6 _ indui VN CL KEETE omamo mino or ceo mono 2 yew iso Lee soson owe Uonounj uonounj uonounj uonouny SNOLLOSNNOO LO lt gt gt NIN NIN 51311010 GASANN 303 SI di 0r 1897 TZ 41872 2 ISN ALON 90980 04 INON 2149000 1034 5100 2 OL dN T vod zi yndur 26 incur 92 eng
11. NN id Ambient Temperature T Optical m nput TT OUTPUT GRO 24 T 5 4 1 2 38 DLO06 Micro PLC User Manual 3rd Edition Rev Chapter 2 Installation Wiring and Specifications 00 06001 0 General Specifications External Power Requirements 12 24 VDC 20 W maximum Communication Port 1 9600 baud Fixed K Sequence Slave DirectNET Slave 8 data hits 1 stop bit odd parity MODBUS Slave Communication Port 2 9600 baud default K Sequence Slave DirectNET Master Slave 8 data bits 1 stop bit odd parity MODBUS Master Slave Non sequence print ASCII in out Programming cable type D2 DSCBL Operating Temperature 32 to 131 0 to 55 C Storage Temperature 4 to 158 F 20 to 70 C Relative Humidity 5 to 9596 non condensing Environmental air No corrosive gases permitted Vibration MIL STD 8106 514 2 Shock MIL STD 810 516 2 Noise Immunity NEMA 1053 304 Terminal Type Removable Wire Gauge DC Input Specifications One 16 AWG or two 18 AWG 24 AWG minimum Parameter High Speed Inputs X0 X3 Standard DC Inputs X4 X23 Min Max Voltage Range 10 8 26 4 VDC 10 8 26 4 VDC Operating Voltage Range 12 24 VDC 12 24 VDC Peak Voltage 30 VDC 7 kHz maximum frequency 30
12. 3349 1H9l 9 ama 3349 035 NMOMG 1 00 dU 0p 82 12 02 61 81 21 9 GL vl NN 21 0 wwe 8201 415 LO3SIQNOLLVINOLOV 91905 5 ANNdIZ Ov6e0 025 spun 1102 20 eoq 06182 17 uzez 9 QN38 WNNWININ 000 0122 0520 GOOH 230009 06101 N d YOLOSNNOO WE MOLIO3NNOO 14 4091 2425 0 09 0 3g 2v Avz 20 2 AOVIIOA 72 3 941 2 08 OMY 80 OG 37870 5410 GANNIL 201 91415 81 0 18 7 84 40005 0 180 17 Lesc 41420001 41 0 189 17 H19N31 ON Molla enjg uesi9 34511 19 5119755259 59 77 2 MO ISA ADID E ueeJ5 fDJ49 vl Ld opow V 3181 33S PIIA UIE Aid 2 SI SUM E SHUM
13. 6 1 6 1 ENY ter 6 1 Galibratiom ab a 6 1 6 1 PLC Not Running 6 2 Emergency Procedures 6 2 5 24 2012 1 1 Honeyville EPC aue Em Preparing for External Control eg a Selecting the Correct Remote Starting the Remote PURCHOLT dehet Reading th retia b Setting MS PG External Control Accessory 2 200044204 ao Ub dut a CemmniGate Of RR Field Wiring Diagram Control Enclosure Wiring Diagram Drive Enclosure Wiring Diagram External Control Wiring Diagram External Control Accessory Package Wiring Diagrams External Control Accessory Package Field Wiring Diagrams Ziplink Cable Diagrams Supplemental Data Sheets Publication History Issue Dae Description of Changes First Edition 8 12 2009 Original Manual for EPC GR3 with software version 3 0 Second Edition 3 19 2010 Updated wiring diagrams for software version 3 1 Third Edition 5 2 2011 Fixed s
14. Fuses None external recommended DL06 Micro PLC User Manual 3rd Edition Rev 2 39 ENGINEERING SERVICE BULLETIN IW WINSMITH ILD 99 PEERLESS WINSMITH INC 0 90 7125 SPEED REDUCERS Installation Operation and Lubrication Instructions This Engineering Service Bulletin is designed to enable users to obtain the best possible performance from their WINSMITH Speed Reducers SELECTION The selection of the appropriate speed reducer for a given application requires that all factors affecting the operation of the unit be given careful consideration Service factors must be applied to catalog ratings depending on the type of prime mover used severity of the application and duration of daily service If you have any questions relative to the suitability of your WINSMITH speed reducer for your particular appli cation refer to the selection section of the appropriate WINSMITH catalog or contact your WINSMITH representative or distributor Il INSTALLATION 1 Shaft Alignment A The various drive members motor speed reducer couplings sprockets sheaves gears etc should be aligned as accurately as possible to guard against unusual stresses and overloads imposed by misalignment B If a prime mover shaft is to be directly connected to the high speed input shaft or if the slow speed output shaft is to be directly connected to the driven shaft flexible couplings should be used It should
15. PT dur oc 2090 2 3ovXOVd TOHINOO Od3 paus wa Far Tena euena or auem dno z3vemo firno z i rano 6 Tino SNOLLO3NNOO PINI IdIZ SEEM apon away 9872 65 092 Xv 99227668 092 INOHd 1489 840 006 0029 3 __ 9 9 9 ow 92 0 yezayy ye no acus hee 52 A8 E 0 6 8 1 3 0 6 8c 14 110 10 511100 GASANN 303 SI ON ALON HELIN KE 11 01 ov orenow oan L o mdu 0 6 orenow 8 0 sron se ap eno 4 WVYSVIC 9NISIM ar I VMIVd 9d3 HEUS ano mdu waans _ 9 Mdu oc 9 ore oW 989256 092 Xv 9922565 092 INOHd 0 e o ynduj 0
16. 11 meer E 13 Moenia 10 15 1 1 16 010101011 Move T7 18 011101011 19 1 1 0 0 f Moveta20 0 0 1 0 0221 1 1 0 1 Mowt 22 0 1 1 0 7 Moez 1 1 1 0 4 Moveta 24 0 0 0 1 0 1 On 1 3 Honeyville EPC EXTERNAL CONTROL ACCESSORY PACKAGE Note this section is applicable to your EPC only if the optional EPC External Control Accessory Package has been installed e Simplifies the wiring for all External Control Applications e Allows you to use direct remote control type on distributors of any size e See Field Wiring Diagram for each package later in this manual for wiring details Packages Number Binary Remote Type 0 Direct Remote Type 1 Compatibility DSECEP08 DSECEP12 DSECEP18 Up to 8 outlets Version 2 2 and higher Up to 12 outlets Version 3 4 and higher Up to 18 outlets Version 3 4 and higher DSECEP24 Up to 24 outlets Version 3 4 and higher DSECEP08 EPC External Control Package for up to 8 Outlets Direct All Binary Fanon Tem Type Function Curent 6 ouput 9 Poner 5 24 2012 External Control DSECEP1
17. 8 a 75518 748519 2 e 9 19 14511 205 19 1457 3467 uncug 284 18 X95i8 P9u 6 5518 MOII A 8 LNO NId ld Chapter 2 Installation Wiring and Specifications i M D D0 06DD1 D Wiring Diagram These micro PLCs feature twenty DC inputs and sixteen sinking DC outputs The following diagram shows a typical field wiring example The DC external power connection uses four terminals at the left as shown Inputs are organized into five banks of four Each bank has an isolated common terminal and may be wired as either sinking or sourcing inputs The wiring example below shows all commons connected together but separate supplies and common circuits may be used All outputs actually share the same common Note the requirement for external power 12 24 VDC LJ L L L LJ L L L 1 ee YO Y2 55 10 12 C3 15 Y17 1 Y4 C2 vti 14 16 OUTPUT Sinking Output 6 27 1 0A PWR 12 24 20W 00 06001 0 24
18. oe 1 Description ve Yr 110 vio vii v3 via vie Rme IT 1 A e uenti 1 1 1 010101011110101010 01010 2 1 0111010101 oti 01010 01010 Cuent3 01011 010 01010 uen 010101011 01010 0 010101010101011 9 Curent 10 4 12 117051 21 1 0 1 1 1202 Current 172 Current qo Current 15 1 1 1 1 0 Curent 6 Current 17 1 050 0 1 Current 8 Current Current 20 Current 21 1 0 1 0 1 Current 22 Current 23 1 1 1 0 1 Current 0 Off 1 On 7 2 5 24 2012 External Control Setting the Inputs When the EPC is in the Remote Function output Y6 will be turned on You can send a position command by turning on the corresponding inputs X10 X14 After a one second de
19. 5 the control enclosure and to the left AC LINES side of the drive enclosure 6 14 GA WIRES NOT EXCEED RECOMMEND WIRE SIZES 5 24 2012 4 1 Honeyville EPC Connect the DC Lines 12 conductors of 18 AWG wire are required For best results use Belden 9556 or equivalent 18 AWG 6 twisted pair shielded control cable Always take the shortest distance between the control enclosure and the drive enclosure Run the DC cable in its own conduit If possible keep 12 away from AC lines Do not allow DC lines to cross AC lines Connect wires to the blue terminals labeled 1 to 12 in the control enclosure connect the other end to the corresponding blue terminals in the drive enclosure Use a twisted pair for connections 1 8 2 3 amp 4 5 amp 6 7 amp 8 9 amp 10 11 amp 12 Connect the shield to ground in the control enclosure only Do not connect the shield to ground in the drive enclosure Keep DC wiring to the lower right side of the control enclosure and to the right side of the drive enclosure Test the Rotation When the wiring is complete you must test the rotation of the motor Press the Manual button on the Operator Panel to enter the Manual Mode While pressing the Up arrow on the keypad verify the following 1 2 T1 and wires in the control enclosure and repeat steps 1 2 The number showing on the display should be increasing The spout should be rotating c
20. 5 24 2012 Operation OPERATION Direction of Travel In this documentation forward means the spout is moving up to a higher outlet number toward the last outlet or counterclockwise when looking at the Distributor from above On a Flatback Honeyville Distributor forward is moving away from the door Reverse means the spout is moving down to a lower outlet number toward the first outlet or clockwise when looking at the Distributor from above On a Flatback Honeyville Distributor reverse is moving toward the door TOP VIEW READY B MOVING E ERROR Light Description Spout is in position Distributor is ready to be used Red Spout is not in position Do not use distributor Status Lights Spout is in motion Action required Follow on screen instructions Red See Troubleshooting chapter Functions won SETUP There are five function buttons on the operator panel Press a function button to enter mode of operation If an error is generated you will need to restart the function that you were in Example If you are in the Run Function and enter the number 0 as the outlet to move to an Invalid Entry message will appear in the display Press the Run button to return to the Run Function 5 24 2012 5 1 Honeyville EPC Manual Function Setup Function e Enter the Setup Function by pressing the Setup button on the Operator Panel then pr
21. ips 9872 65 092 9952 566 092 3NOHd YP Buu 10599 WNVIGNI 401 006 5 0027 vu dad ayiaAauoy 21028818 YZ 0 9 0 0 910 ZZ 0 9 0 220 OZ 0 9 0 61 0 9 0 Z 0 9 0 1100 ndu 5 e c 5 e c 08 9y W ue N Qc 3ueun 0 uung n qn yn jn n yn yn 9 9 Lincino Lincino Lincino nano Lindino dino dino dino dino dino dino dino dino dino dino ed 0c l 81 9 EN amp 2 9 90 OL 1 reno 941 941 juer SNOLLO3NNOO MNITdIZ 5131100 GASANN 304 SI ON ALON i LO3HIQNOLLVAOLO V A 91402 4031299uu02 YNIMdIZ 46607 5 59420 syuf 6002 40 e1od
22. 10 11 12 3 4 5 1 2 au 1 2111117112 18113119 15 16 _ __ LOWVOLTAGEOPTION _ RF FILTER RF FILTER E a a gu wt 25 S _ E Eg zo 2 oS a ES2 295 mi 77 15 18 re 79 _ HIGHVOLTAGEOPTION __ _ HEATER BLACK WHITE ORANGE BLUE PURPLE GREEN YELLOW GRAY BROWN 043 YOLNEIYLSIG 68 9 WVYSVIC 133HS 092 9922 265 092 3NOHd 03 14899 VNVIQNI V3dO L M 006 5 0027 J812 aypiAAauoy 2102085 21490 04 N ILLA 93184196 8 1 01A ZI LA 94 S 1 ATddNS 2 ANNIE SLFUNO 1 oc sen nano or s3wuro WWYOVIC er er nano s amp xeuno e TOMLNOO TWNYSLXS Od3 ma
23. 422 WINSMITH PEERLESS WINSMITH INC SPRINGVILLE OPERATIONS 172 EATON STREET BOX 530 SPRINGVILLE NY 14141 0530 PHONE 716 592 9310 FAX 716 592 9546 http www winsmith com e mail winsmith winsmith com E CERTIFIED 9 E 90 MOTORS 3 and GEARING 52 PWS 18560 August 1999 10M Printed in U S A
24. If this occurs shut down the drive remove the oil level plug and allow oil to drain until oil ceases to drain from the level hole reinstall the oil level plug and restart the drive If the speed reducer is underfilled the resultant friction can cause overheating and possible damage If this occurs fill the speed reducer to the oil level plug hole and check the gearing for excessive wear C Inadequate Cooling In order to dissipate internally generated heat the speed reducer must be installed in such a way that air can circulate freely Tightly confined areas inside cabinets etc should be avoided If this is not possible forced air cooling by means of a separate blower should be used 8 Oil Seals Although WINSMITH uses high quality oil seals and precision ground shafts to provide a superior seal contact surface it is possible that circum stances beyond WINSMITH s control can cause oil seal leakage damage during shipment or installation etc When replacing a shaft oil seal using the following suggestions will help to insure leak free operation and long seal life A When installing a new seal cover the keyway and any other surface discontinuity with smooth tape to protect the seal lip from being damaged B A sealant should be used between the O D of the seal and the 1 0 of the bore into which the seal is installed The seal bore should also be free of any burrs nicks or scratches C Be sure that the seal
25. N3349 N3349 LHOM 95 N33N9 AvNH9 N3349 3n19 9 og QN38 WNNWININ 79 x9v18 31n 8 26 0 0 9 19205 JOVIB NId Jeppeu s 4019euuo2 06 201 seues COOKS WE 0 14 lt 62 4 0b1 ZE 2 09 0 ONILVYSdO 7 8C 20 2 AOS 1 49 90 04 jueuino yzg INAYYND Z 394251 OMY 318VO 9 9 940002 42 02180 17 5 oe 840001 41 0 189 12 u 911 4 0 189 127 HI9N3I ON 18 1 31 92 3IHM N33439 9 vZ 3lHM Q3H4 4 9Z1 2 08 x lt 1 ld 18 03 xov18 31dM nd Q3H N3349 LHON 3 Q3M 3n1l8 LHON 30118 MOTI3A
26. Timeout displayed on Operator Panel Run light off on the PLC Follow these steps to restart the PLC Use extreme caution these steps must be performed with the power on 1 Open the door of the Control Enclosure 2 Look for a light labeled Run on the face of the PLC If the light is off continue to the next step 3 Find the small silver switch on the front of the PLC This is a three position switch that should be in the center position 4 Move the switch to the left the back to the center position 5 The Run light should be on 6 Close the door of the Control Enclosure Emergency Procedures If the Motor is not working disconnect the power and then loosen the four bolts to drop the Motor and Encoder to the floor of the Drive Enclosure Insert the Emergency Handle into the Speed Reducer Each revolution of the Emergency Handle will turn the distributor spout 1 300 of a circle 6 2 5 24 2012 External Control EXTERNAL CONTROL Preparing for External Control 1 Your EPC be controlled from external system by using the inputs and outputs on the PLC as described in this chapter The inputs are 12 24 VDC sinking or sourcing The outputs are 12 24 VDC sinking You can use power from the 24 VDC power supply in the Control Enclosure See the External Control Wiring Diagram for additional information An optional External Control Accessory Package is available to assist you in
27. VDC Minimum Pulse Width 70 us N A ON Voltage Level 210 0 VDC 10 0 VDC OFF Voltage Level 2 0 VDC 2 0 VDC Max Input Current 6mA 12 0 13mA 24VDC 4mA Q12VDC 8 5mA 24VDC Input Impedance 1 8 12 24 VDC 2 8 12 24 VDC Minimum ON Current 5 mA 54 Maximum OFF Current lt 0 5 mA lt 0 5 mA OFF to ON Response lt 70 us 2 8 ms 4 ms typical ON to OFF Response lt 70 us 2 8 ms 4 ms typical Status Indicators Logic side Logic side Commons DC Output Specifications 4 channels common x 5 banks isolated Parameter Pulse Outputs YO Y1 Standard Outputs Y2 Y17 Min Max Voltage Range 5 30 VDC 5 30 VDC Operating Voltage 6 27 VDC 6 27 VDC Peak Voltage 50 VDC 10 kHz max frequency 50 VDC On Voltage Drop 0 3 VDC 1A 0 3 VDC 1A Max Current resistive 0 5 A pt 1A pt as standard pt 1 0 point Max leakage current 15 uA 30 VDC 15 uA 30 VDC Max inrush current 2 A for 100 ms 2 A for 100 ms External DC power required 20 28 VDC Max 150mA 20 28 VDC Max 150mA OFF to ON Response lt 10 us 10 us ON to OFF Response 20 us 60 us Status Indicators Logic Side Logic Side Commons 4 channels common x 4 banks non isolated
28. be remembered that even flexible couplings have limited ability to accommodate misalignment Care must be taken at installation to insure that shaft alignments are within the limits recommended by the coupling manufacturer Use of a rigid coupling to connect speed reducer shafts to other drive components is not recom mended as it is almost impossible to obtain exact alignment between two shafts C A common base plate supporting the motor and reducer will help preserve the original alignment between reducer and motor shafts If a structural steel base is used the plate should be at least equal in thickness to the diameter of the bolts used to fasten the speed reducer to the base plate Also for sufficient rigidity the design in general including angle or channel members should be substantial enough to prevent flexing under vibration After the first week or two of operation all of the bolts and nuts used to fasten the reducer and motor pedestal etc to the base plate should be retightened Vibration tends to loosen the nuts even if tight initially Dowelling the motor and speed reducer to the base plate will help insure that alignment is maintained 2 Mounting Positions A Single reduction units are designed to accom modate most standard mounting positions Figure 1 illustrates the utility plug locations for each based on model All standard single reduction models are equipped with an internal splash shield located near the w
29. connecting and controlling your EPC from an external system See page 7 4 for details Selecting the Correct Remote Type 1 2 Use the following chart to determine which remote type is best suited for your application Without External Control Accessory Package Setting Description Number of Outlets 4 to 24 220222 With External Control Accessory Package Setting Description Number of Outlets 408 424 See page 7 4 for details The remote type needs to be set using the setup function See the Setup Function of the Operations chapter of this manual for more details Starting the Remote Function 1 5 24 2012 Every time you power up the EPC you must calibrate before entering the Remote Function Enter the Remote Function by pressing the Remote button on the Operator Panel The Run Function and the Remote Function operate exclusively of each other You cannot operate them both at the same time 7 1 Honeyville EPC Reading the Outputs e When the EPC is in the Remote Function output Y6 will be turned on This indicates that it is ready to accept a command from the inputs e When the spout is in position and the Ready light is green output Y7 will be turned on The corresponding value of the current outlet will be turned on in outputs Y10 Y14 This happens whether the EPC is in Remote Function or not PLC Outputs Binary Remote Type Drect Remote Type
30. from medium speed to slow speed Increase this number to have the motor slow down earlier decrease this number to have the motor slow down later Green Range e This number determines the distance the spout is allowed to move off of its target before the Ready light changes from green to yellow e Adjust this number only if the spout tends to coast past its target position and changes the Ready light to yellow e Possible values are 0 to 3 Safety Timer f power is being sent to the motor but there is no motion being detected by the encoder a Motion Error will occur after a certain length of time This number determines that length of time Each number represents 1 100 of a second i e 50 5 seconds 200 2 0 seconds 5 24 2012 12 19 14 15 16 17 18 5 24 2012 Operation Remote Type e Use the following chart to determine which remote type is best suited for your application Without External Control Accessory Package Setting Description Number of Outlets 0 4to 24 With Extemal Control Accessory Package Setting Description Number of Outlets Ato 24 1 4024 See page 7 4 for details e See the External Control chapter in this manual for information on implementing each remote type If you are not using external control leave this setting at 0 Calibration Type e Set this number to 0 when the encoder is attached to t
31. 2 EPC External Control Package for up to 12 Outlets Direct Type Fumo Tem 8 E m mar 4 Pover 266 5 24 2012 7 5 Honeyville EPC DSECEP18 EPC External Control Package for up to 18 Outlets Direct Type Function Tem Type Function 2 1 5 24 2012 External Control DSECEP24 EPC External Control Package for up to 24 Outlets Direct zeoo00900000000000000000000 5 24 2012 Type Fumo Type Function 48 25 50 7 7 Honeyville EPC This page intentionally left blank 5 24 2012 Warranty WARRANTY The full extent of the warranty supplied by Honeyville Metal Inc is to correct any defects in material and or workmanship on the products manufactured only by Honeyville Metal Inc This warranty period extends for one y
32. Honeyville METAL INC TOPEKA IN HONEYVILLE DISTRIBUTOR ELECTRONIC POSITION CONTROL SERVICE MANUAL Model No Serial No Software Version Honeyville Metal Inc Phone 800 593 8377 4200 S 900 W Fax 260 593 2486 Topeka IN 46571 www HoneyvilleMetal com Specifications General Model No EPC GR3 EO 24 Dealer Name Odin Distributor Model No Distributor Serial No AC Drive Parameters Factory Setting Motor Parameters PO 00 Motor Nameplate Voltage P0 01 Motor Nameplate P003 MotorBase RPM Ramp Parameters P101 P102 _________ Time _____ Voltz Hertz Parameters Volts Hertz Settings Slip Compression Control Mode Digital Parameters Source of Operation Comman Multi Function Input DI Multi Function Input DI Presets Parameters P5 01 Multi Speed P5 02 Multi Speed P5 03 Multi Speed All Parameters not listed above are at default setting P3 04 must be set before P3 02 2 00 2 01 2 10 00 02 04 PLC Settings Factory Setting L1 220 240 VAC 3 Phase 60 Hz Setup Password Power Requirements Ll 440 480 3 Phase 60 Hz Alignment Factor Outlets Spacing Checkpoint Precision Resoltion Ratio MedumRange SlowRange Green Range Safety Timer Remote Type Calibration Type En
33. If the electric control is attached to a distributor transport the distributor on its back Environment Mount the control enclosure in a clean dry indoor environment Please observe these operating temperatures Operating Temperatures Minimum Maximum Control Enclosure Drive Enclosure 40 F If the control enclosure needs to be mounted in a location where the temperature could drop below 40 there is an optional enclosure heater available HMI item DSHW1039 Wiring See diagram at right and the Field Wiring Diagram DRIVE in the back of this manual for conduit and wiring details ENCLOSURE Incoming Power is the responsibility of the end user to install the appropriate power disconnect between the incoming power supply and the controller e Do not apply power until all other wiring is complete CONDUITS e Connect incoming 3 phase AC power lines to the blue terminals labeled L1 L2 L3 and Connect the AC Lines 6conductors of 14 AWG wire are required 12118 e Always take the shortest distance between the control enclosure and the drive enclosure e Run the AC wire in its own conduit If possible keep 12 away from the DC lines not allow DC lines to cross AC lines e Connect wires to the blue terminals labeled T1 T2 T3 G 51 and 52 in the control enclosure connect CONTROL ENCLOSURE the drive enclosure COMI Keep AC wiring to the lower left side of 3
34. Valvata J 460 Omala RL 680 Omala RL 460 Texaco Pinnacle 220 Vanguard 460 Vanguard 680 Vanguard 460 Pinnacle 680 Pinnacle 460 synthetic oil 3 to 10 fatty or synthetic oils or mild EP additives Lubricant selections are provided by the lubricant manufacturer based on AGMA recommended viscosity grades Viscosity grades are based on Lubrication Standard ANSI AGMA 9005 D94 The sliding velocity in feet per minute FPM for standard ratios is determined by multiplying the speed of the worm in RPM by the factor from the following table For selecting the proper lubricant use the speed of the worm in the final stage input RPM divided by the first stage ratio Nominal Ratio SIZE 5 7 5 10 15 20 25 30 40 50 60 80 100 910 0 153 0 137 0 133 0 122 0 116 0 132 0 121 0 115 913 0 231 0 189 0 183 0 179 0 171 0 165 0 178 0 169 0 164 0 161 917 0 303 0 229 0 201 0 193 0 180 0 172 0 189 0 176 0 170 0 166 0 161 0 133 920 0 347 0 263 0 225 0 216 0 202 0 191 0 215 0 200 0 188 0 182 0 164 0 161 924 0 412 0 312 0 261 0 256 0 236 0 223 0 249 0 231 0 216 0 210 0 201 0 196 926 0 455 0 345 0 283 0 276 0 254 0 238 0 269 0 249 0 234 0 225 0 215 0 210 930 0 520 0 395 0 327 0 317 0 291 0 273 0 307 0 285 0 269 0 258 0 246 0 241 935 0 607 0 461 0 427 0 412 0 373 0 349 0 403 0 367 0 345 0 330 0 311 0 299 943 0 633 0 588 0 568 0 553 0 507 0 558 0 544 0 501 0 475 0 457 0 435 0
35. and mounting position Before putting the unit into service review Figures 1 and 2 and relocate the vent plug if necessary as shown for the appropriate model and mounting position Double reduction models Figure 2 are vented in the main housing only To prevent loss of oil during shipment the vent plug includes a brass pin which must be removed prior to operation If a speed reducer is installed in an atmosphere containing excep tional amounts of moisture or dust a shielded or hooded vent plug should be used For inter mittent duty applications where the operating temperature does not rise more than about 20 degrees F internal pressure build up is minimal and venting is not necessary Some models are available with an optional internal expansion chamber allowing units to be totally sealed Contact us for more details 4 C Flange Motor Mounting Procedures A Mounting Motor to C Flange Reducer With Hollow Input Shaft Check motor and reducer mounting registers for nicks that would interfere with assembly Remove if necessary Remove protective plastic plug from reducer input shaft The bore has been coated with an anti seize compound Align the motor shaft and key with keyway in bore and slide motor up to flange Position the motor conduit box as desired Using the fasteners supplied secure the motor to the reducer Draw down evenly so as not to bend the motor shaft Tighten fasteners to 200 inch pounds B Mounti
36. coder Direction Use Nicknames Factory Setting Skip Outlets Skip Outlet SkipOutet2 5 Skip Outlet 5 5 5 5 8 __ SkpOult9 Outlet 10 Skip Outlet14 SkpOuleti2 SkpOulet 3 Outlet 14 Skip Outlet 15 Skip Outlet 16 Skip Outlet17 _ 0 Skip Outlet 18 Skip Outlet19 Skip Outlet 20 0 Skip Outlet 2 Skip Outlet 22 0 Skip Outlet 2 Skip Outlet 2 Skip Outlet 21 Nickname Nickname Nickname Nickname 4 Nikname5 O Nikname7 Nickname 8 Nikname9 O Nickname10 Nickname 11 Nickname12 Nickname 13 Nickname14 Nickname 15 Nickname16 17 18 19 20 21 Nickname22 Nickname 2 Nickname 24 Honeyville EPC Table of Contents TABLE OF CONTENTS Table of 1 1 Introduction os sa Si 2 1 Pants on boo teen e 3 1 Drnye OM
37. do not save your settings after you make a change they will be lost when the power is shut off e After saving settings you will be required to calibrate before continuing in run mode Calibrate Function Enter the Calibrate Function by pressing the Calib button on the Operator Panel You must calibrate 1 Every time you power up 2 Every time you Save Settings If the power is always on it is recommended that you calibrate daily to verify that the equipment is functioning properly If any errors are encountered during the Calibration process a Calibration Error is displayed See Troubleshooting for more information Process 1 2 3 The Motor runs in reverse until the leading edge of the Calibration Arm passes over Proximity Switch A This sets the zero reference point The Motor runs forward until the Calibration Arm reaches Proximity Switch B then compares it position with the Checkpoint setting The Motor continues forward until the spout reaches the last usable outlet then automatically switches to the Run Function Run Function Enter the Run Function by pressing the Run button on the Operator Panel The Setup Function and the Calibrate Function need to be completed before you can start the Run Function Process gt 5 6 Press Enter to begin input Use the keypad to enter the number or nickname of the outlet that you want to move to Press Enter again The spout will mo
38. e unit will help establish the appropriate interval C Synthetic Oils Synthetic lubricants can be advantageous over mineral oils in that they generally are more stable have a longer life and operate over a wider temperature range These oils are appropriate for any application but are especially useful when units are subjected to low start up temperatures or high operating temperatures However continuous operation above 225 F may cause damage to seals or other components It is recommended that the initial oil be changed or filtered after the first 1500 hours of operation to remove metal particles that accumulate during break in Subsequent oil STANDARD MOUNTING POSITIONS D 9 0 TRADITIONAL MOUNTING TYPE SE INVERTED ADDITIONAL MOUNTING POSITIONS MOUNTING INPUT SHAFT HORIZONTAL INPUT SHAFT VERTICAL DL SPECIAL Contact the Factory DSF SPECIAL Contact the Factory DSN DSR DSU Figure 1 Single Reduction Models DOUBLE REDUCTION WORM WORM DOUBLE REDUCTION HELICAL WORM Double Reduction units are not universal mounting Mountings other than standard require a special outline Figure 2 Double Reduction Models Note Single Reduction 935 and 943 standard models are supplied with grease fi
39. ear from the date the product arrives on the site where installation will take place Honeyville Metal Inc retains the right to review and or adjust the time period for those products that may be held in inventory at a dealer s warehouse Honeyville Metal Inc retains the final authority on determining if a product is within the warranty period and if full replacement of that product is required to retain the integrity of our products reputation and meet the customer s expectations Honeyville Metal Inc will not furnish labor for replacement of any defective product or components of a product Any product that is determined defective by both Honeyville Metal Inc and the end user who purchased the product may not be returned to Honeyville Metal Inc without the receipt of Return Authorization Returned products must be shipped to Honeyville Metal Inc prepaid unless instructed otherwise and must be clearly marked with a Return Merchandise Authorization RMA number that needs to be obtained prior to the return shipment This warranty supplied by Honeyville Metal Inc excludes damage to products while in transit to the destination on all public forms of transportation except the trucking equipment owned and operated by Honeyville Metal Inc This warranty does not cover performance guarantees on products only defects in material and or workmanship as prior statement Metal Inc does honor vendor warranties that extend beyond the
40. essing the Esc button Honeyville EPC 5 2 wall of a Flatback Distributor Process 1 Press the Up arrow on the Operator Panel to move the spout forward 2 Press the Down arrow to move the spout in reverse Skip Outlet 24 Nickname 24 Skip Outlet 2 Target Pos Skip Outlet 1 Enter the Manual Function by pressing the Manual button on the Operator Panel The Manual Function is primarily for diagnostic and maintenance purposes The number displayed is the distance from the zero reference point Use caution when using the Manual Function it is possible to run the spout into the back 5 24 2012 Operation e The Setup Function needs to be run at least once before you can start the Calibrate or Run Functions e Changes to settings are effective immediately however they will not be retained if the power is shut off unless you change the value of Save Settings to 1 f your Electronic Control was purchased with a new Honeyville Distributor the settings have been pre set at the factory You should go through the Setup Function to verify the settings e The Setup menu is arranged in a hierarchy with folders and messages A plus is displayed in front of a folder s name if it is closed Press the Enter button to open a folder If a folder is open a minus is placed in front of the name Any messages within that folder will be displayed below it You may use the UP DOWN arrow buttons to scroll dow
41. he motor and two proximity switches are used for calibration If the encoder is attached directly to the distributor shaft and no proximity switches used set this number to 1 Encoder Direction e f the encoder is counting up when the spout is moving forward set this number to 0 e f the encoder is counting up when the spout is moving forward set this number to 1 Use Nicknames You can choose to use an alternative numbering system for your outlets e Set this number to 0 to disable nicknames Set this number to 1 to enable nicknames Skip Outlets f certain outlets are not being used you can choose to skip those outlets Setthis number to 0 to use an outlet Set this number to 1 to skip an outlet Nicknames e You can choose to use an alternative numbering system for your outlets e f you are using nicknames you may enter either the original number or the nickname e You may assign any number between 25 and 9999 to any outlet f you have duplicate nicknames the spout will stop at the highest outlet Example outlet 2 is nicknamed 100 and if outlet 5 is nicknamed 100 when 100 is entered as the outlet to move to the spout will go to outlet 5 Status e Lists the current values for several variables within the PLC e These values are used primarily for troubleshooting 9 5 Honeyville EPC 19 Save Settings e Change this number to 1 to permanently save your settings f you
42. is not cocked in the seal bore The outer face of the seal should be flush with the surface into which it is mounted Lubricants Worm Gear Reducers For special applications that involve severe ambient temperature extremes or a seasonal oil requirement WINSMITH based on extensive testing and field experience recommends the use of Mobil SHC synthetic lubricants Ambient Temperature 30 to 15 F 16 to 50 F 51 to 95 F 51 to 95 F 96 to 131 F 96 to 131 F Final Stage Worm Speed to 2000 FPM up to 2000 FPM up to 450 FPM above 450 FPM up to 450 FPM above 450 FPM ISO Viscosity Grade 220 460 680 460 680 460 AGMA Lubricant No 58 7 Compounded 8 Compounded 7 Compounded 8 S 75 SHC 630 600W Super Cylinder Extra Hecla Super 600W Super Cylinder SHC 636 SHC 634 American Lubricants SHC 90W AGMA 7 Gear Oil AGMA 8 Gear Oil AGMA 7 Gear Oil N A N A Castrol Tribol 800 220 Tribol 1105 7C Tribol 1105 8C Tribol 1105 7C Tribol 800 680 Tribol 800 460 Chevron Tegra 220 Cylinder Oil W460 Cylinder Oil W680 Cylinder Oil W460 Tregra 680 Tegra 460 Conoco amp 220 Inca Oil 460 Inca Oil 680 Inca Oil 460 N A Syncon amp 0460 Exxon Esso Teresstic SHP 220 Spartan EP 460 Spartan EP 680 Spartan EP 460 Teresstic SHP 680 Teresstic SHP 460 Fiske Brothers SPO MG SPO 277 288 277 N A Shell Omala RL 220 Valvata J 460 Valvata J 680
43. lay the spout will start turning and output Y7 will turn off You can turn off the inputs any time after output Y7 turns off When the spout stops turning and is in position output Y7 will turn back on If the position command you send is the current position output Y7 will turn off for one second then turn back on If the position command you send is higher then the number of outlets or is an outlet that is not used see Skip Outlets in the Setup Function section of the Operation Chapter outputs Y6 will turn off and the display on the operator panel will read Invalid Entry The operator will need to press the Remote button on the operator panel to restart the remote function All inputs must be turned off before sending another position command If the operator presses Run or any other function button on the operator panel or if an error occurs output Y6 will turn off PLC Inputs 5 24 2012 Binary Remote Typed DirectRemote Type Cc Description X10 X11 X12 X13 X14 X10 X12 X13 X14 X15 X16 X17 Moveto1 11010 10 01111010 10 0101 o 0 2 10111010 011011 3 1 1 5 0 5 0 0 010111010101010 4 01011 01 01 010101110101010 Moe 110111 10101 010101 1011101010 6 01111 1 0101 01 0101010111010 Moveto7 11111 0 01 010101010101110 ae to 10
44. n to the next message in that folder At the end of the messages for that folder you can press the Esc button to move to the previous level e The settings can be viewed without a password If you need to change a setting you are required to enter a password See enclosed Specifications Sheet for the password and the settings described below Process 1 Alignment Factor e These adjustments ensure that the spout will lock into position when centered on the outlet e You only need to set the alignment adjustments for one outlet Assuming that all of your other settings are correct if the alignment is set correctly for one outlet all other outlets will also be correct e If the spout is stopping to the right of center use a smaller number If the spout is stopping to the left of center use a larger number e These adjustment numbers are obtained through a trial and error process in which the spout is moved to an outlet and then visually inspected for centeredness e During the trail and error process described above if you have previously completed Setup and Calibration you can press and not be forced to calibrate You can move the outlet to a different outlet then back again if you wish then press Esc to return to setup and enter another number and repeat the process When you are satisfied with the position of the spout be sure to Save Settings as described below 2 Outlets e This number is equal to
45. ng Motor to C Flange Reducer With Coupling Adaptor Check motor and reducer mounting registers for nicks that would interfere with assembly Remove if necessary When assembling the motor and coupling the coupling halves should be equally spaced on each shaft to insure adequate engagement The following describes a method for doing this First determine the assembled shaft clearance by measuring the distance from the C Flange face to the reducer shaft end and subtracting the motor shaft length Mount and secure the motor shaft coupling half with the spider end extending one half the clearance distance beyond the motor shaft Mount the reducer coupling half and coupling spider on reducer shaft in its approximate position but do not secure Locate the motor conduit box in the desired position and secure the motor to the reducer flange using the fasteners provided Tighten to about 200 inch pounds Using the access hole in the flange slide the coupling together and tighten the set screw 5 Unit Assembly Disassembly Instructions Contact the factory for an instruction manual LUBRICATION amp MAINTENANCE 1 Factory Filling WINSMITH speed reducers are oil filled at the factory to the proper level for the standard mounting position as shown in Figures 1 or 2 The oil level should be checked and adjusted if necessary prior to operation using the oil level plug provided and while the unit is oriented in its operating po
46. one year period and will pass warranty coverage on to the purchaser of that vendor product 5 24 2012 8 1 Honeyville EPC CERTIFICATE OF QUALITY Every effort has been made to make this equipment the best value you can obtain for your money All the components have been inspected and assembled The complete system has been tested to insure proper operation We sincerely hope this equipment and our efforts meet with your approval The full extent of Honeyville Metal Inc warranty is to correct any defects in material or workmanship in those products manufactured by Honeyville Metal Inc Motors and drives and all electrical and air control parts carry a one year warranty READ INSTRUCTIONS CAREFULLY BEFORE OPERATING THIS UNIT WAS FINAL INSPECTED AND PACKED BY 8 2 5 24 2012 043 YOLNEIYLSIG 8 c 4 9 WVYSVIC 07914 9895 8656 092 9922 092 3NOHd 1299p WNVIGNI X3dO L M 006 5 002 1812 Heeus 133HS OL INN 37113 MAY 2004000 aiva AYNSOTONA JOHLNOO 340190 10N3 TOHLNOO NI OL G T3IHS LOANNOO ALON vo vl 38190 TONS OL SANIT OV VO 8 38190 10N3 OL SANIT 2
47. or too low Action e Press the Function button to restart the Function that you were performing Calibration Error Occurs when an error is encountered during the Calibration process Causes Calibration Errors 2221 Number e Faulty Encoder Speed Reducer Motor Starter or PLC Actions Check that all wiring is connected properly e Enter the Manual Function and press an arrow button If the displayed number changes the Motor and Encoder are working If the spout moves the Motor and Speed Reducer are working Stay in the Manual Function and open the Control Enclosure If you press the Down button the 1 light on the PLC should light up and the reverse side of the Starter should click in If you press the Up button the YO light on the PLC should light up and the forward side of the Starter should click in Motion Error Occurs when power is being sent to the Motor but the Encoder isn t registering motion Causes e Debris or ice in Distributor e Loose or faulty wiring e Faulty Encoder Motor Starter or PLC Actions e Run the Calibration Function The cause of the error might be cleared e Open the inspection door on the Distributor check for obstructions Check that all wiring is connected properly 5 24 2012 6 1 Honeyville EPC PLC not running Symptoms No lights on Operator Panel Noresponse when pushing buttons e Protocol Error or PLC Communication
48. orm This shield deflects the oil from the vent preventing leakage when the vent plug is adjacent to the worm as on the DT or DV standard mounting When this location is used as a drain as on the DV sidewall worm under drainage will be better facilitated if done at or near the operating temperature Filling from this location is not recommended as the shield will impede the oil flow rate Bearings are splash lubricated provided the input speed is 1160 RPM or greater Contact the factory when input speeds fall below this B Double reduction models are built to accom modate one mounting position as specified during order entry Standard mounting positions furnished unless otherwise specified are shown in Figure 2 which also illustrates the utility plug locations Note that the mounting position relates to the main housing orientation Standard units have an oil level common to both housings and do not use an intermediate oil seal The vent plug is located in the main housing where the slower worm speed eliminates the need for a vent shield Grease fittings not shown in Figure 2 are used to lubricate bearings when oil splash does not serve this purpose as with the DV or DL upper slow speed bearing 3 Venting During operation the heat generated by the gear box will cause the air and lubricant inside the unit to expand A vent plug is used to equalize the resulting pressure the location of which is dependent on the model
49. ounter clockwise when viewed from the top If the spout is rotating in the opposite direction switch the Adjust the Reference Point on the Encoder VIEW The reference point on the encoder has been preset at the factory Under normal circumstances you should not need to make any changes to the reference point on the encoder If the encoder has been removed please follow this procedure for setting the reference point 1 10 Replace the cover the bottom of the encoder 12 Use manual mode to turn the spout to outlet 1 which is the outlet to the left of the door Continue to use manual mode to align then left side of the spout with the left side of outlet 1 In the drive enclosure remove the encoder Rotate the collar to align the mark on the top collar of the encoder with the center of the cord Align the slot in the bracket with the hole on the encoder mount Slide the encoder onto the shaft Tighten the collar on the top of the encoder With the power on in the control enclosure check the X2 light on the PLC If it is lit continue to step 10 Loosen the bolt on the anchor tab on the encoder and rotate the encoder slightly until the X2 light on the PLC is lit Tighten the bolt Repeat steps 7 and 8 until the X2 light on the PLC is lit You will need to calibrate and then adjust the alignment factor See Alignment Factor in the Setup Function section of the Operation chapter
50. s 1 zxeuo 2 9872 66 092 XV 9922 65 092 yp Guu IM 80 uopunj uopunj uojunj 904 uojunj 1489 WNVIGNI 006 5 002 NEN E SNOLLO3NNOO 417 ejiAKouoH 21028 5131100 GASANN 303 SI ON 1 70185 17 318VO MNMdlZ ISN ALON m a pa 2149000 5131110 TIN 0380 51410080140 8032350 ONIYIM Q 1914 39VMOVd TVNH3LLX3 9872 65 092 9952 566 092 3NOHd yp BULA 80 10599 WNVIGNI 401 006 5 0027 21028 SNOLLO3NNOO Si3100 GASANN 304 SI ALON N 21430354 103410 5191070 l 01 dn 90 zi ore ow o 66 0
51. sition 2 Ambient Temperature If the operating ambient temperature is other than 51 95 F then refer to lubrication chart and refill the unit with the correct grade based on actual ambient temperatures and operating speed See item 3 for additional information regarding oil changes 3 Oil Changing When changing oil for any reason it should be remembered that oils of various types may no be compatible Therefore when changing to a different oil it is recommended that the housing be completely drained and thoroughly flushed with a light flushing oil prior to refilling with the appropriate lubricant The oil level should be rechecked after a short period of operation and adjusted if necessary When changing double reduction models each housing should be drained and filled independently even though there may be a common level A Initial Oil Change The oil in a new speed reducer should be changed at the end of 250 hours of operation 30 days for 8 hour per day service 15 days for 16 hour service 10 days for 24 hour service B Subsequent Oil Changes Under normal conditions after the initial oil change the oil should be changed after every 2500 hours of operation or every six months whichever occurs first Under severe conditions rapid temperature changes moist dirty or corrosive environment it may be necessary to change oil at intervals of one to three months Periodic examination of oil samples taken from th
52. tatement and chart on 7 3 Fourth Edition 8 12 2011 Added Encoder Direction setting Fifth Edition 5 24 2012 Version 3 4 Added External Control Accessory Package 1 2 5 24 2012 Introduction INTRODUCTION Thank you for purchasing a Honeyville EPC Electronic Positioning Control for your distributor This manual will help you understand the operation of the control guide you through the installation process and give you a reference for ordering replacement parts for your control Honeyville Metal Inc 4200 S 900 W Topeka IN 46571 Phone 260 593 2266 Fax 260 593 2486 www HoneyvilleMetal com 5 24 2012 2 1 Honeyville EPC 2 2 This page intentionally left blank 5 24 2012 Parts List PARTS LIST 3 2 5 24 2012 3 1 Honeyville EPC 3 2 DRIVE COMPONENTS NUMEN NEM C MEM NNNM ser KT o3 0 f __ a 5 o9 f 6 2 58 18 56548 Threaded Rod x 1077 8 4 9 PTGRIZ21E 1 935 500 1 Gear Reducer t Insert Distributor Model DSSM160645FE 5 24 2012 Parts List DRIVE COMPONENTS 5 24 2012 3 3 Honeyville EPC 3 4 DRIVE ELECTRICAL ENCLOSURE DSECEEO2H High Voltage 440 480 Bi 1 DURAMIeGSAIPOACDNe
53. the number of outlets on your distributor 3 Spacing e This number is distance between outlets on the distributor e The number based on the precision setting e To calculate this number take the degrees between outlets and multiply by the precision setting and then divide the result by 360 5 24 2012 5 3 Honeyville EPC 5 4 10 11 Checkpoint e This number is the count between the two proximity switches in the drive enclosure e This setting is not used on EPC GR2 EPC GR3 Precision his is the number of counts for one complete revolution of the spout in the distributor This setting is 1440 on EPC GR1 2000 on EPC GR2 and EPC GR3 Resolution e This is the resolution of the encoder e This setting is 60 on EPC GR1 2000 EPC GR2 and Ratio e This is the ratio of the gearbox if the encoder is attached to the motor If the encoder is attached directly to the distributor shaft this setting will be 1 This setting is 500 on EPC GR1 1 on EPC GR2 and EPC GR3 Medium Range As the spout approaches the target position the motor begins to slow down This number determines the point at which it slows from high speed to medium speed Increase this number to have the motor slow down earlier decrease this number to have the motor slow down later Slow Range As the spout approaches the target position the motor begins to slow down This number determines the point at which it slows
54. thium base NLGI 2 bearing grease For synthetic oils use a synthetic bearing grease such as Mobil Synthetic Universal grease Mobilith SHC 100 or a suitable equivalent For food grade lubricants use Chevron FM grease NLGI 2 or equivalent Low Input Speeds Under 1160 RPM When input speeds are less than 1160 RPM grease fittings will be required to lubricate any bearings not partially covered by the normal oil level Such units are considered non standard and necessitate factory modification If this low speed operating condition exists and units are without the appropriate grease fittings please contact the factory Oil Temperature Speed reducers in normal operation can generate temperatures up to 200 F depending on the type of reducer and the severity of the application loading duration of service ambient temper atures Excessive oil temperatures may be the result of one or more of the following factors A Overloads Overloads may be due to the original unit selection being too small for the application or increased loads on the speed reducer to a point where its rating is exceeded after it has been in service for a period of time Always check the speed reducer rating when increasing driven loads or increasing the horsepower rating of the motor or other prime mover Overfilling or Underfilling If a speed reducer is overfilled with oil the energy used in churning the excessive oil can result in overheating
55. ttings on the input shaft to insure bearing lubrication for all mounting positions Drain Plug _ Grease Fitting Plug locations apply to motorized units also Contact the factory when input speeds are less than 1160 RPM to insure proper lubrication changes should be made after 5000 hours tion if units are operating in a clean environment This can be extended to 10 000 hours if using new reformulated Mobil SHC lubricants orange in color and the lubricant remains free of contami nation over this period See comments under 3B for more severe ambient conditions 4 Long Term Storage or Infrequent Operation If a speed reducer is to stand idle for an extended period of time either prior to installation or during use it is recommended that the unit be filled completely with oil to protect interior parts from rust corrosion due to internal condensation Be sure to drain the oil to the proper level before placing the speed reducer in service A long term storage option is available on new units Contact us for details 5 Grease Fittings 7 Some units are equipped with grease fittings to lubricate bearings not adequately lubricated by the oil splash These fittings must be lubricated every 3 6 months depending on operating conditions Bearing greases must be compatible with the type of gear lubricant being used ie mineral synthetic food grade etc For mineral oils use a high quality li
56. ve to that outlet When the spout reaches the outlet and is locked into position the green Ready light will turn on and the Distributor will be ready for operation 5 24 2012 Operation Remote Function Enter the Remote Function by pressing the Remote button on the Operator Panel The Setup Function and the Calibrate Function need to be completed before you can start the Remote Function While in the Remote Function the bottom line of the display will read Remote When the green light is on the top line shows the current outlet and the Distributor is ready for operation See the External Control chapter for more information PLC Message Lamp 5 24 2012 There are two types of messages on the operator panel Setup Messages and PLC Messages If the PLC Message lamp is off you are in the Setup Messages You can alternate between the two types of messages by pressing the Esc button It is possible to enter the Setup Messages without pressing the Setup button However it is advisable to press the Setup button before entering Setup to clear any functions that are running The panel locks out all key presses for 3 seconds after a PLC Message is displayed in order to ensure the operator has a chance to read the message 5 7 Honeyville EPC 5 8 This page intentionally left blank 5 24 2012 Troubleshooting TROUBLESHOOTING Errors Invalid Entry Cause e Entering a number on the keypad that is too high
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