s Energy & Automation

Rocky PC Retrofit Installation

For
CIA MINERA Antamina
Huaraz – Peru
Section 1 – Detail of items supplied by Siemens, pg 2-4
Section 2 – Installation instructions, pg 5-33

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Section 1 - Detail of items supplied by Siemens

Detail 1. Hardware as provided by Siemens, Loc-Tite not supplied but recommended!

Detail 2. Box assembly & related peripherals as provided/shipped from Siemens.

**Note** the Rocky PC should be removed for the assembly!

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Detail 3. Rocky PC installed (as shipped).

Detail 4. Modules, brackets, supports supplied from Siemens.

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Detail 5. Module in box. **Note** Use all proper ESD precautions when handling these
modules

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Section 2 - Installation instructions

Pic. 1 Remove the old Host PC/UPS, serial A-B-C switch and related peripherals.
Installation details will start from this point. **Note** ET200 not shown here but should
remain installed in the field unit!

Pic. 2 This is the lower, right, box support. Notice the orientation note that points toward
the front of the cabinet.

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Pic. 3 This is the lower, left box support. Notice the orientation note that points toward
the front of the cabinet.

Pic. 4 Align the left support (Pic.. 3) with the lowest frame rail on the inner left wall.
Make certain the support is flush with the front of the rail as shown in Pic. 6. This is
where the UPS was previously mounted. Mark the holes for drilling now. (Pic. 12 depicts
the finished support mounting)

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Pic. 5 All holes are used, mark and drill for all holes.

Pic. 6

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Pic. 7 Now mark & drill for the right support as done for the left. Remember to align the
support to the front of the rail!

Pic. 8

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Pic. 9 Finished hole.

Pic. 10 Install hardware. Thru-bolt the support to the frame rail as shown. Assemble the
hardware connection in this sequence: M6x16 Combi Bolt->Support->Rail->Flat->Lock-
>Nut. Use a thread lock additive such as “service removable” Loc-Tite to ensure a
reliable connection!

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Pic. 11 Note the hardware orientation as mentioned at Pic. 10. Under the frame rail, you
should have a Flat->Lock->nut. Remember the “service removable” Loc-Tite!

Pic. 12 Your completed support assembly should look like this. ET200 rack not shown
here.

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Pic. 13 The box assembly starts from this point (Rocky PC not shown in this picture).

Pic. 14 Notice the cable entry hole (black grommet) for the touch-screen cable
interconnects and Profibus cable.

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Pic. 15 Slide the box into the cabinet on the lower supports. **NOTE** Be careful not to
damage the existing wiring bundles. Temporarily cut tie-wraps and maneuver the harness
if needed!

Pic. 16 Box installation in process. Ensure the mounting locations on the box line up to
the mounting holes on the lower supports.

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Pic. 17 Install the box side clamps to the box using the holes provided. Hardware
sequence: M6x16 Combi Bolt->Side clamps->Box->Flat->Lock->Nut. Remember the
“service removable” Loc-Tite!

Pic. 18 Rear side of the box side clamps, installed. Notice the hardware!

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Pic. 19 Insert the hardware into the holes as shown. Assemble the hardware connection in
this sequence to minimize vibration: M6x16 Combi Bolt->Box->Support. Remember the
“service removable” Loc-Tite to ensure a reliable connection

Pic. 20 Bolt the box to the supports using all four connection points provided!

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Pic. 21 Begin routing the pre-made harness supplied in the box behind the rails as shown
here. Use caution to avoid damage to the wiring. The loom tubing has been provided for
protection. Use Tie-wraps supplied to secure the wire bundle to the cable supports.

E01/-MTB3

E01/-HTB4

Pic. 22 box installed, wiring in progress. Replace E01/-HTB4 at this time (supplied),
connect wires as shown in schematics for rocky host PC page 1 section E01.
Also replace E01/-MTB3 at this time (supplied), disconnect existing wires from the
original E01/-MTB3 and re-connect them in the new terminal board, then connect
additional wires as per shown in schematics for rocky host PC page 2 section P01.
**Note** E01/-HTB4 is located at the bottom, right corner of the Sibas cabinet.
E01/-MTB3 is located at the bottom, left corner of the Sibas cabinet.

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Pic. 23 Route the Sibas ETH communication cable (P01/0201) through the pass-thru hole
provided in the box and terminate to X5 on the new ZR card per the schematics provided
(Pic. 26).

Pic. 24 Remove the existing ZR card from the rack. This card will be replaced with a
newer style (Pic. 25). **ESD precaution required**

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Pic. 25 Replace the ZR card with the newer style provided. Note the extra sub-D
connector (X5).

Pic. 26 Termination of the Sibas ETH communication cable to the new ZR card now
shown.

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Pic. 27 Continue to route the interconnection cables coming from the touch-screen.

Parallel port
(reserved to
connect external Video Cable
floppy drive) (from
touchscreen)

Serial Com 1 (for

Serial Com 2 SIBAS monitor
(from NOT
Touchscreen) CONNECTED)

Pic. 28 Detail of ports on the side of he Rocky PC.

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Pic. 29 Continue terminating all connections as per schematics.

Pic. 30 DC power supply connector for Rocky PC.

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Pic. 31 Make the connection as shown, referring to the schematics as needed. This
connection is a “twist-lock” type connector. Be certain to twist the connector clockwise
to secure the connection.

Pic. 32 Route the cables through the Rocky PC mounting clamp slot.

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Pic. 33 The Rocky PC can now be inserted between the clamps in preparation for the
final mounting. **Be careful not to damage any wiring!**

Pic. 34 Rocky PC in place.

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Pic. 35 Terminate the remaining communication and power wiring as shown, referring to
the schematic as needed (USB cable from hub & Ethernet communication cable shown).

Pic. 36 Remove the plugs for the ports located at the back of Rocky PC. Ports from right
to left: USB-1, USB-2, Ethernet port. Left-most port not used.

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Pic. 37 Make the connections as shown, again, referring to the schematics as needed.

Pic. 38 The top clamp for the Rocky PC may be installed at this time. Hardware
sequence: M6x16 Combi Bolt thru the top clamp and into the weld-nut on the lower
clamp. Remember the “service removable” Loc-Tite!

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Pic. 39 Close-up picture of the finished bolt connection securing the Rocky PC.

Pic. 40 Another close-up showing the hardware sequence.

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Pic. 41 The PLC rack base can now be installed onto the rear of the box as shown here
using the M6x16 Combi Bolts. Remember the “service removable” Loc-Tite!

Pic. 42 Now, start installing the modules. Start from left to right ensuring all modules are
FULLY seated and the retaining screws are tightened.
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Pic. 43 Close-up of module installation.

Pic. 44 Module, fully installed. Proceed with installing the remaining modules.

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Pic. 45 Terminate the PLC power supply connector per the schematic.

Pic. 46 Terminate the wiring per the schematic. Make certain the batteries are installed at
this point.

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Pic. 47 Make certain the dip switch is set to “2 BATT”. Note the location for the Profibus
connection as shown above.

Pic. 48 Connect ethernet Communication cable P01/0114 to port 4 as shown above.

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Pic. 49 Modules installed/wired and all wiring now secured.

Pic. 50 The box side clamps can now be mounted to the frame as shown to complete the
mechanical assembly. Hardware sequence: M6x30 Bolt->Lock->Flat. Remember the
“service removable” Loc-Tite.

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NOT
REQUIRED
FOR
ANTAMINA

Pic. 51 Overall view of the completed assembly, all hardware in place, connections
terminated. The mechanical installation is now complete.

Now connect all remaining wires not connected, as per shown in schematics.

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