Widen And Reshape The Range Selector Switch Holes; Applicability; Requirements; Safety Precautions - Abb Ak100 Upgrade Instruction Manual

12 A K 1 0 T O G A H | U P G R A D E I N S T R U C T I O N | I N/A K 1 0 -TO - G A H - E N R E V. A
...5 Upgrade procedure

5 .5 Widen and reshape the range selector switch holes

5.5.1 Applicability

This section applies to:
• AK101
• AK102
• AK103
For AK104, go to: Section "5.7 Install the CM30s" on page 14.

5.5.2 Requirements

Table 5 Tools required
Part number Description
Cone cutter/step drill
—
22 mm
— Manual file
— Vice
Table 6 PPE required
Part number Description
— Safety glasses
— Gloves

5.5.3 Safety precautions

This procedure will create a lot of mess and swarf. It is
recommended to do this procedure in a location where the this
swarf will not be a problem and where it can be easily cleaned
and swept.
There are many small screws in the terminal rails. These can
loosen during drilling. Therefore, perform this on a work bench
where you can easily find loose screws.
We recommend to gently tighten all terminal rail screws to hold
them in position, particularly those on TB1 and TB2 (power
connections).
In order to receive the new swich(es), the resulting hole should
be 22.5 mm in diameter, with a small notch vertically up of
12.9 mm from the center that stops the switch from rotating.
Figure 21 Hole profile
You need a cone cutter/step drill that gives you as close to
22.5 mm as possible, without being larger. We have found that
22 mm step drill to drill the central hole, followed by a manual
file to remove swarf and to file back the notch should provide
the perfect sized hole. The drilling of the new hole should be
centered around the larger of the two existing switch holes.
Quantity
1
1
Quantity
1
Figure 22 Cone cutter
1
The panel will turn with the drill. If you are unable to place the
device in a vice, it may be advisable to have one person operate
the drill while a second person holds the panel still.

5.5.4 Procedure

1 Drill from the front and lay the panel such that any remaining
cables attached to the panel are not going to get caught by
the drill.
Note:
Vibration from drilling may cause smaller pieces, particularly
screws from the terminal rails, to fall from the panel. Therefore
drill over a surface where such pieces can be retrieved after
drilling.
2 Drill using the existing hole (the larger of the two) as the
center point of your drill.
3 AK102 only:
Repeat for the 2nd hole.
4 Your panel should now look like Figure 23 (AK102 shown).
Note:
AK101 and AK103 will only have one hole.