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10 Si plac e G au tom atic g lue ap plic ator SIPLA CE 80 S/80 F/G Servi ce Ma nua l Ed itio n 06 /98 10 - 32 10.3.4 Electrical adjustments PLEASE NOTE Always che ck the set values be fore you carr y out any elec trical …
10 Siplace G automatic glue applicator SIPLACE 80S/80F/G Service Manual
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● Enter the new zero point correction in the machine data. To do this, select the "Change axis data" menu,
followed by "Positions" and then "Zero point correction".
● Carry out a reference point run with the z axis.
PLEASE NOTE
The zero point correction must not exceed ± 50 digits, otherwise the axis will not find the zero pulse or will
move down too far during the reference run.
● Switch off the z axis and turn the cam disc until it reaches the end stop. If the cam disc is adjusted correctly
and if the zero point correction has been determined correctly, the following value will be obtained:
maximum travel distance: 680 digits ± 1 digit.
● Switch the z axis on again.
● Save the machine data.
● Check: the z axis must not drop after the machine is switched off.
● If necessary, carry out the zero point correction for the other two z axes.
10.3.3.2 Zero point correction for the X2/Y2 axis
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● Switch the machine control.
● Carry out a reference run for the three z axes.
● To do this, select the "Axes" menu followed by "Z axis ..." and then "Run axis reference".
● Select the "Gantry positions" menu.
● Select the "Calibrate" menu and then "Calibrate CP". The zero point correction and the maximum and min-
imum positions for the X2 and Y2 axes will then be calculated automatically.
● Check the maximum position of the X2 and Y2 axes. The maximum position must always be larger than
2856 digits (= travel distance 50 mm). To do this, select the "Axes" menu, followed by "X2/Y2 axis", then
"Change axis data" and "Positions".
● Save the machine data.
10.3.3.3 Calibrating the PCB camera
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● Carry out the full reference sequence.
● Select the "Gantry positions" menu from the SIKLEBER test program.
● Select the "Move to position" menu.
● Select the "Pos. calibration tool" menu. The camera is positioned over the position calibration tool.
● Press the ESC key to return to the main menu.
● Select the "Camera system" menu.
● Select the "Camera functions" menu.
● Select the "Calibrate camera" menu. The camera calibration routine will then run.
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● Once the measuring procedure has ended, you can use the "Display coefficients" function to check the cal-
culated values.
● Save the calculated values to the MA data via the main menu. To do this, select the "MA data" → "Store
file" option.
● Press OK to confirm the "Save REAL.MA?" prompt.
10.3.3.4 Calibrating the offset between glue application head 3 and the PCB camera
● Set up a full glue cartridge with a 0.44 nozzle and a 0.10 spacer. Insert a glue cartridge in glue application
head 3.
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● Carry out the entire reference sequence.
● Select glue application head 3 by selecting the "Select head" menu and then the "Gluing head 3" option.
● Then fill the glue nozzle with adhesive. To do this, select the "Dispens. control" menu and then "Dispens.
indefinitely (apply as required)". Hold a cloth beneath the glue application head 3 and press the spacebar.
The adhesive will then be pumped out. Press the spacebar again to stop dispensing.
● After the reference run, initialize glue application head 3 with a glue characteristic curve using the "Dis-
pens. control" menu. To do this, select the "Initialize glue head" menu and then "Enter name". Enter the file
name (without an extension) of the characteristic curve of the adhesive used (e.g. H_PD86L for Heraeus
PD 86002). Then select the "Start initializing" menu.
● Introduce an aluminum test PCB crosswise into the center conveyor. To do this, select the "Functions"
menu and then "PCB transport". Use the "PCB onto input conveyor" function to move the PCB over the
sensor of the input belt and then the "PCB in - to stopper" function to move onto the center conveyor.
● Select the "Camera system" menu, followed by "Camera functions" and then offset "Camera D3".
● Select the "Start position D3" menu". Then press the arrow keys to position glue application head 3 over
the aluminum test PCB. Then press the ESC key.
● Select the "Measure offset" menu. Glue application head 3 will then apply a glue point to the test PCB. The
PCB camera will then be positioned over this glue point. The offset between the PCB camera and glue
application head 3 will be measured and calculated automatically.
● Select the "Display offset" menu. This menu lists the calculated values.
● Save the calculated values to the MA data via the main menu. To do this, select the "MA data" → "Save
file" option.
● Press OK to confirm the "Save REAL.MA?" prompt.
10.3.3.5 Calibrating the offset between glue application heads 1 and 2
and glue application head 3
● Set up three full glue cartridges, each with a 0.44 nozzle and a 0.10 spacer. Insert the glue cartridges in
glue application heads 1, 2 and 3.
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● Switch the control.
● Carry out the entire reference sequence.
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● Select the glue application heads. To do this, select the "Dispens. control" menu, followed by "Select head"
and then the "Gluing head 1" or "Gluing head 2" or "Gluing head 3" option.
● Then fill the glue nozzles of head 1, 2 and 3 with adhesive. To do this, select the "Dispens. control" menu,
followed by "Dispens. indefinitely (apply as required)". Hold a cloth beneath the glue application head and
press the spacebar. The adhesive is then pumped out. Press the spacebar again to stop dispensing.
● Initialize the three glue application heads with a glue characteristic curve using the "Dispens. control"
menu. To do this, select the "Initialize glue head" menu from the “Dispens. control” menu and then the
"Enter name" menu. Enter the file name (without an extension) of the characteristic curve of the adhesive
used (e.g. H_PD86L for Heraeus PD 86002). Then select the "Start initializing" menu.
● Run an aluminum test PCB (approximately 250mm x 350mm x 2mm) crosswise onto the center conveyor.
To do this, select the "Functions" menu then "PCB transport". Use the "PCB onto input conveyor" function
to move the PCB over the sensor of the input belt and then the "PCB in - to stopper" function to move it
onto the center conveyor.
● Select the "Gantry positions" menu and then "Head offset D31 - D32".
● Select the "Start position D3" menu". Then press the arrow keys to position the gantry until all three glue
application heads are over the aluminum test PCB.
● Select the "Start" menu. Glue application head 3 will then apply a glue point to the test PCB. Glue applica-
tion heads 1 and 2 will each apply two glue points (one at the minimum position and one at he maximum
position of the X2/Y2 axis).
● The PCB camera will move these glue points in order and determine the precise coordinates in relation to
DE3.
● Save the calculated values to the MA data via the main menu. To do this, select the "MA data" → "Save
file" option.
● Press OK to confirm the "Save REAL.MA?" prompt.
10.3.3.6 Mapping the X2/Y2 axes (mini-gantry mapping)
● Set up two full glue cartridges, each with a 0.44 nozzle and a 0.10 spacer. Place these glue cartridges in
glue application heads 1 and 2.
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● Switch the control.
● Carry out the entire reference sequence.
● Select the glue application heads by selecting "Dispens. control", "Select head" and then the "Gluing
head 1" or "Gluing head 2" option.
● Then fill the glue nozzles of heads 1 and 2 with adhesive. To do this, select the "Dispens. control" menu
and then "Dispens. indefinitely (apply as required)". Hold a cloth beneath the glue application head and
press the spacebar. The adhesive is then pumped out. Press the spacebar again to stop dispensing.
● Initialize the two glue application heads with a characteristic curve in the "Dispens. control" menu . To do
this, select the "Initialize glue head" menu and then "Enter name". Enter the file name (without an exten-
sion) of the characteristic curve of the adhesive used (e.g. H_PD86L for Heraeus PD 86002). Then select
the "Start initializing" menu.
● Introduce an aluminum test PCB onto the center conveyor by selecting the "Functions" menu, followed by
"PCB transport" and then "PCB in - to stopper". Use the "PCB onto input conveyor" function to move the
PCB over the sensor of the input belt and then use "PCB in - to stopper" to move it onto the center con-
veyor.
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● Select the "Mapping" menu, followed by "X2/Y2 axes".
● Select the "Start position D3" menu". Then press the arrow keys to position the gantry until glue application
heads 1 and 2 are over the aluminum test PCB.
● Select the "Head 1 mapping" or "Head 2 mapping" menu.
● The selected glue application head will apply 22 glue points to the test PCB. These glue points will then be
measured by the PCB camera.
● Repeat the mapping for the other glue application head, as described above.
● Save the test points after mapping using the "Save RASTER.K1" option.
10.3.3.7 Measuring the machine zero point
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● Carry out the entire reference sequence.
● Lower the lifting table. Attach the machine zero point gauge (clip-on bracket) to the lifting table.
DANGER
Risk of collision! If the lifting table is raised, the mini-gantry will collide with the machine zero point gauge
when it is approached. The lifting table must therefore always be lowered when the following work is carried
out.
The machine zero point gauge must be removed after the machine zero point has been determined.
● Select the "Gantry positions" menu.
● Select the "Move to position" menu.
● Select the "Machine zero point" menu.
● Press "ALT+9" to check that the screen is in the camera scanning range.
● Press "ALT+0" to return to the menu.
● Select the "Calibrate" menu.
● Select the "Machine zero point" menu. The test program will then calculate the correct zero point correc-
tions for the X1 and Y1 axes (main axes).
● Save the calculated values to the MA data via the main menu. To do this, select the "MA data" → "Save
file" option.
● Press OK to confirm the "Save REAL.MA?" prompt.
● Remove the machine zero point gauge from the lifting table.
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10.3.4 Electrical adjustments
PLEASE NOTE
Always check the set values before you carry out any electrical adjustments. The potentiometers are preset
and only have to be adjusted if the set values are outside the tolerances.
Switch the machine off for at least 30 minutes before making any adjustments (particularly when changing the
temperature).
10.3.4.1 Adjusting the room temperature sensor
Fig. 10.3.2 Overview: Y0055 conversion board
Key to Fig. 10.3.2
1 Test point TP1 for temperature sensor PT 500
2 Potentiometer R74 for 0V adjustment ( 15
o
C)
3 Potentiometer R73 for 5V adjustment ( 40
o
C)
4 Jumper block X27
X9 X1 3
X1 1
X2 8
X2 9
1
IC1
IC19
X15
X16
X17
R71
R69
R72
R70
R1
R2
R3
IC20
R73
R74
X8 X1 0 X12
X27 X14 X2 3
X24 X25 X2 6
X22 X21 X20 X19 X18
TP1
1
Amplitude
Offset
Amplitude
Offset
Spur A
Spur B
1
3
2
1
4
Amplitude
Offset
Amplitude
Offset
Track A
Track B
^
=
^
=
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Preparation:
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● A digital voltmeter is used to adjust the room temperature sensor. Set the voltmeter to a measuring range
of 20 V DC.
● Connect the test cable of the voltmeter as follows:
Connect the positive cable to TP1 on the small axis conversion board Y0055 (= board at the top of the gan-
try, see Fig. 10.3.2). Test point 1 is used for temperature sensor PT 500.
Connect the negative cable to TP 3 on board Y0052 (= glue head board, see Fig. 10.3.3). Test point 3 is
the ground terminal.
Adjustment:
● Connect the jumper of jumper block X27 to pin 1/2. Jumper block JP 1 is located on conversion board
Y0055 (see Fig. 10.3.2).
● Select the "Dispens. control" menu, followed by "Peltier functions" and then "Environm. temperature (ambi-
ent temperature)" to display the ambient temperature. Press Return to read the ambient temperature on
the right of the monitor.
● If the jumper setting is correct, the ambient temperature reading will be 15 °C.
● Use potentiometer R 74 to set TP1 to 0V (tolerance ± 20 mV). Potentiometer R 74 is located on conver-
sion board Y0055 (see Fig. 10.3.2).
● The set 0 V voltage corresponds to a temperature of 15 °C (tolerance ± 0.3 °C).
● Then connect the jumper of jumper block X27 to pin 3/4.
● Read the ambient temperature. If the jumper is set correctly the ambient temperature will be 40 °C.
● Use potentiometer R 73 to set TP1 to 5 V (tolerance ± 20 mV). Potentiometer R 73 is located on conver-
sion board Y0055 (see Fig. 10.3.2).
● The adjusted 5 V voltage corresponds to a temperature of 40 °C (tolerance ± 0.3 °C).
PLEASE NOTE
After adjustment, you must replace the jumper on pin 5/6, otherwise the temperature cannot be measured.
● Display the ambient temperature, which should now be approximately the same as the actual room tem-
perature.
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10.3.4.2 Adjusting the temperature sensor
Fig. 10.3.3 Overview: glue head conversion board (glue head board) Y0052
Key to Fig. 10.3.3
1 Potentiometer R26 (-5V temperature sensor setting 40
o
C)
2 Potentiometer R27 (0V temperature sensor setting 15
o
C)
3 Jumper block JP1 (return jumper to pin 5/6 after adjustment)
4 Test point TP1 (heat exchanger signal)
5 Test point TP3 ⊥ (ground)
6 Test point TP2 (dispensing pressure sensor signal)
7 Potentiometer R37 (dispensing pressure sensor setting for Pmax)
8 Potentiometer R38 (0V adjustment ambient pressure)
Preparation:
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● A digital voltmeter is used to adjust the temperature sensor. Set the voltmeter to a measuring range of 20
V DC.
● Connect the test cable of the voltmeter as follows:
Connect the positive cable to TP1 on board Y0052 (= glue head board of the glue application head to be
adjusted, see Fig. 10.3.3). Test point 1 is used for the PT 500 temperature sensor on the heat exchanger.
Connect the negative cable to TP 3 on board Y0052. Test point 3 is the ground terminal.
^
=
^
=
^
=
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Adjustment:
● Select the "Dispens. control" menu and then "Gluing head 1" (or "2" or "3"), i.e. the glue application head
with the temperature sensor to be adjusted.
● Connect the jumper of jumper block JP 1 to pin 1/2. Jumper block JP 1 is located on glue head board
Y0052 (see Fig. 10.3.3).
● Select the "Dispens. control" menu, followed by "Peltier functions" and then "Actual temperature" to display
the actual temperature on screen. Press the Return key to read the actual temperature on the right of the
monitor.
● If the jumper is set correctly, the actual temperature will read 15 °C.
● Use potentiometer R 27 to set TP1 to 0 V (tolerance ± 20 mV). Potentiometer R 27 is also located on
board Y0052.
● The adjusted 0 V voltage corresponds to a temperature of 15 °C (tolerance ± 0.3 °C).
● Now connect the jumper of jumper block JP 1 to pin 3/4.
● Select the "Dispens. control" menu, followed by "Peltier functions" and then "Actual temperature" to display
the actual temperature on screen. Press the Return key to read the actual temperature on the right of the
monitor.
● If the jumper is set correctly, the actual temperature will read 40 °C.
● Use potentiometer R 26 to set TP1 to 5 V (tolerance ± 20 mV). Potentiometer R 26 is also located on
board Y0052.
● The adjusted 5 V voltage corresponds to a temperature of 40 °C (tolerance ± 0.3 °C).
● Adjust the temperature sensors of the other glue application heads, if necessary.
PLEASE NOTE
After adjustment, you must replace the jumper on pin 5/6, otherwise the temperature cannot be regulated.
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10.3.4.3 Adjusting the dispensing pressure sensor
Fig. 10.3.4 Test set-up: Adjusting the dispensing pressure sensor
Key to Fig. 10.3.4
1 Dispensing pressure line
2 Quick-release coupling for the pressure chamber
3 Glue head conversion board Y0052
4 Adapter hose (prepare as shown in drawing)
a Test point TP1 (heat exchanger signal)
b Potentiometer R27 (0V temperature sensor setting; 15
o
C)
c Potentiometer R26 (5V- temperature sensor setting; 40
o
C)
d Potentiometer R38 (0V setting; ambient pressure)
e Potentiometer R37 (dispensing pressure sensor setting for Pmax)
f Test point TP2 (dispensing pressure sensor signal)
g Test point TP3 ⊥ (ground)
h Jumper block JP1 (replace jumper on pin 5/6 after adjustment)
^
=
^
=
^
=
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PLEASE NOTE
Prepare an adapter hose made of a ∅ 3 mm PU hose approximately 70 mm long, a ∅ 3 mm to ∅ 4 mm reduc-
ing adapter (metal) and a ∅ 4 mm PU hose approximately 70mm long (see Fig. 10.3.4, item 4).
Preparation:
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● Switch the control on.
● Detach the dispensing pressure line (Fig. 10.3.4, item 1) from the quick-release coupling of the pressure
chamber (Fig. 10.3.4 item 2). Insert the ∅ 3 mm end of the adapter hose into the quick-release coupling of
the pressure chamber.
PLEASE NOTE
When you insert air hoses into quick-release connections, ensure that you push them in as far as the sec-
ond perceptible stop.
● A digital voltmeter is used to adjust the dispensing pressure sensor. Set the voltmeter to a measuring
range of 20 V DC.
● Connect the test cable of the voltmeter as follows:
Connect the positive cable to TP2 on board Y0052 (= gluing head board of the glue application head to be
adjusted, see Fig. 10.3.4). Test point 2 is used for the dispensing pressure sensor IC 5.
Connect the negative cable to TP 3 on the same board (Y0052). (Test point 3 is the ground terminal).
● Select the "Dispens. control" menu, followed by "Gluing dots" and then "Adjust pressure" to set the dis-
pensing pressure. Use the arrow keys ↑ and ↓ to change the pressure. Set the pressure to 5.115 bar and
then press the ESC key to accept the setting.
● Select the "Dispens. control" followed by "Gluing head 1" or 2/3 to select the glue application head with the
dispensing pressure sensor to be adjusted.
Adjustment:
● Do not close the open end of the adapter hose (= ambient pressure of 0 bar).
● Use potentiometer R38 (left potentiometer) on board Y0052 to set the signal at TP2 to 0 V (tolerance ± 20
mV). The adjusted 0 V voltage corresponds to a pressure of 0 bar.
● Connect the ∅ 4 mm side of the adapter hose to connector B (overpressure) of the compressed air testing
device.
● Select the "Dispens. indefinitely (apply as required)" menu to switch on the pressure in the dispensing
chamber (5.115 bar). Press the spacebar once to pressurize the pressure chamber. Press the spacebar
again to depressurize.
● Calculate the voltage using the following formula:
5.0 V
x measured pressure in bar = voltage to be set
5.115 bar
● Use potentiometer R37 (right potentiometer) on board Y0052 to set the signal at TP2 to the calculated volt-
age. Press the spacebar to depressurize the valve chamber.
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● Remove the adapter hose from the quick-release coupling in the pressure chamber (Fig. 10.3.4 item 2)
and reconnect the original hose (Fig. 10.3.4 item 1).
● Adjust the dispensing pressure sensors on the other glue application heads if necessary.
10.3.4.4 Checking the seals of the dispensing pressure unit
PLEASE NOTE
It is only necessary to check the seals if the dispensing pressure unit has been dismantled (e.g. after replac-
ing the dispensing valve or air relief valve). During the seal test, a constant pressure must be measured in the
pressure chamber over a period of five minutes. After five minutes, the maximum pressure loss must not
exceed 10 % of the initial value.
The constant pressure may be measured using either a voltmeter or a manometer. Both methods are
described below.
● Initial situation: The dispensing pressure unit is connected to the air and power supplies, but is not yet
screwed to the glue application head.
● Load the SIKLEBER test program. Please read the warnings at the start of this chapter.
● Switch the control on.
● For the pressure measurement with a manometer only: Connect the manometer to the dispensing pres-
sure line of the dispensing pressure unit. The connection must be absolutely airtight.
The next two steps relate to pressure measurement with a voltmeter and may be skipped.
● Seal the dispensing pressure line on the dispensing pressure unit (the dispensing pressure line is the air
line leading to the cartridge). To do this, insert a dummy hose or similar into the quick-release coupling of
the pressure chamber. The connection must be absolutely airtight.
● Set a voltmeter to a measuring range of 20 V DC. Connect the test cable of the voltmeter as follows:
Connect the positive cable to TP2 on board Y0052 (= gluing head board of the dispensing pressure unit to
be tested, see Fig. 10.3.3). Connect the negative cable to TP 3 on the same board (Y0052).
● Select the "Dispens. control" menu and then "Gluing head 1" or 2/3 to select the glue application head of
the dispensing pressure unit to be tested.
● Select the "Valve functions" menu and then the "Release pressure" option to vent the dispensing pressure
unit. Press Return to vent the unit. The voltmeter or manometer must display the following value: 0 V (tol-
erance + 20 mV) or 0 bar (tolerance + 0.02 bar).
PLEASE NOTE
If the voltage is outside the tolerance specified above after venting the dispensing pressure unit, the dis-
pensing pressure sensor must be adjusted as described in the previous section.
● Select the "Dispens. control" menu, followed by "Gluing dots" and then "Adjust pressure" to set the dis-
pensing pressure to 5.115 bar (maximum dispensing pressure). Use the arrow keys ↑ and ↓ to change the
pressure. Then press the ESC key.
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● Switch on the dispensing valve of the dispensing pressure unit by activating the top manual control of the
dispensing valve. The pressure chamber will then be pressurized.
● Switch the dispensing valve over by activating the right manual control of the dispensing valve with a thin
steel plate. This will “enclose“ the pressure in the pressure chamber. Once you have done this, do NOT
aerate or vent the pressure chamber.
● The voltmeter or manometer must display the following value: 5 V (tolerance ± 20 mV) or 5.115 bar (toler-
ance ± 0.02 bar).
PLEASE NOTE
If the voltage is outside the tolerance specified above after venting the dispensing pressure unit, the dis-
pensing pressure sensor must be adjusted as described in the previous section.
● Wait five minutes. Then read the value from the voltmeter or manometer again. The pressure loss must not
exceed 10 % of the initial pressure.
Minimum value on the voltmeter: 4.50 Volt; minimum value on the manometer: 4.60 bar.
● If the values fall below the values specified above, the dispensing pressure unit must be sealed or
replaced. Then check the seals again.
● If the dispensing pressure unit is airtight, remove the dummy hose or manometer. You will hear any resid-
ual pressure dissipating from the pressure chamber.
● Check the seals of the other dispensing pressure units, if necessary.
10.3.5 Tensioning the toothed belt of the X2/Y2 axis
PLEASE NOTE
The correct belt tension of the toothed belt on the X2/Y2 axis is extremely important for precise positioning. It
is only necessary to set the belt tension if the angle bracket has been released. It is absolutely essential to set
the belt tension after replacing the X2/Y2 axis direct-drive motor.
● Open the protective cover and push the gantry into an easily accessible position. Press an emergency
stop button as well.
● You must dismantle the glue application head in order to tension the toothed belt. Read the instructions on
removing the gluing heads in Section 10.2.3.