00195346-0302_SM_WPC4_EN - 第4页

Table of contents 4 Ser vice Manual SIPLACE WPC4 3.5.2.2 Replacing the Inrush current Limitation Board [03047752-xx] ................... .......................... ............... 3 9 3.5.2.3 Removing the Front Cover Pla…

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Table of contents
Service Manual SIPLACE WPC4
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Table of contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Notes on this documentation .............................................................................................................. 7
1.2 Document History ................................................................................................................................. 7
1.3 SIPLACE on the World Wide Web (WWW)..........................................................................................7
2 Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Conventions for the Use of Safety Instructions................................................................................. 9
2.2 Safety Instructions.............................................................................................................................. 10
2.2.1 Qualified Personnel............................................................................................................................... 10
2.2.2 Safety Instructions for the Power Supply .............................................................................................. 10
2.2.2.1 Safety Instructions for Work on the Cutting Device ............................................................................ 11
2.2.3 Safety Instructions for the Compressed Air Supply .............................................................................. 11
2.2.4 Safety Instructions for Working with Strong Magnetic Fields................................................................11
2.2.5 Correct Usage....................................................................................................................................... 12
2.2.6 Incorrect Usage..................................................................................................................................... 12
2.2.7 Warning labels ...................................................................................................................................... 13
2.2.7.1 Laser note at the 1D PCB barcode reader ......................................................................................... 13
2.2.8 ESD Guidelines..................................................................................................................................... 14
2.2.8.1 Handling ESD Modules....................................................................................................................... 14
2.2.8.2 Measurements and Modifications to ESD Modules ............................................................................14
2.2.8.3 Dispatching ESD Modules .................................................................................................................. 14
3 Replacing Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Safety Instructions.............................................................................................................................. 15
3.2 Overview of Main Assemblies ........................................................................................................... 16
3.3 Drive Unit – Lifting Axis ..................................................................................................................... 17
3.3.1 Preparations.......................................................................................................................................... 17
3.3.2 Replacing the Lifting Axis Drive Motor [03047846-xx] .......................................................................... 18
3.3.3 Replacing the Lifting Axis Toothed Belt [03046971-xx] ........................................................................ 21
3.4 Drive Unit – Feed Axis ........................................................................................................................ 22
3.4.1 Preparations.......................................................................................................................................... 22
3.4.2 Replacing the Feed Axis Drive Motor [03047364-xx]............................................................................ 23
3.4.3 Replacing the Drive Toothed Belt [03047689-xx] ................................................................................. 25
3.4.4 Replacing the Feed Axis Toothed Belt [03047690-xx].......................................................................... 26
3.4.5 Setting the Feed Axis Belt Tension....................................................................................................... 29
3.5 Control Unit and Power Supply Unit ................................................................................................. 30
3.5.1 Control Unit ........................................................................................................................................... 31
3.5.1.1 Instructions for Working with Control Units......................................................................................... 31
3.5.1.2 Replacing the Power Supply Board [03047225-xx] ............................................................................ 32
3.5.1.3 Replacing the Controller Board [03047223-xx] ................................................................................... 33
3.5.1.4 Replacing the Axis Controller Board [03041865-xx] ........................................................................... 33
3.5.1.5 Replacing the Servo Amplifier [03048005-xx]..................................................................................... 34
3.5.1.6 Replacing the Ballast Circuit [00344207-xx] ....................................................................................... 34
3.5.1.7 Replacing the Complete Control Unit [03047226-xx].......................................................................... 35
3.5.1.8 Replacing the Fan [03051368-xx]....................................................................................................... 37
3.5.2 Power Supply Unit ................................................................................................................................ 38
3.5.2.1 Replacing the Protective Contactor Combination (SSK) [00372649-xx]............................................. 38
Table of contents
4 Service Manual SIPLACE WPC4
3.5.2.2 Replacing the Inrush current Limitation Board [03047752-xx] ............................................................ 39
3.5.2.3 Removing the Front Cover Plate with Main Switch and the Emergency Stop Button ......................... 40
3.5.2.4 Replacing the Complete Power Supply Unit [03047298-xx] ............................................................... 41
3.6 Limit Switches, Sensors and Light Barriers..................................................................................... 42
3.6.1 Introduction ........................................................................................................................................... 42
3.6.1.1 Overview ............................................................................................................................................. 42
3.6.1.2 General Installation/Removal Instructions........................................................................................... 43
3.6.1.3 Requirements for Settings................................................................................................................... 44
3.6.2 Replacing the WPTC Available Sensor [03047283-xx].........................................................................46
3.6.3 Replacing the WPTC Lock Sensor Closed [03047285-xx].................................................................... 47
3.6.4 Replacing the WPTC Present in Tower Sensor [03047284-xx] ............................................................ 48
3.6.5 Replacing the Reference Sensor, Feed Axis [03047273-xx] ................................................................ 49
3.6.6 Replacing the Feed Axis Limit Switch on Transfer Side [03047277-xx]................................................ 52
3.6.7 Replacing the Feed Axis Limit Switch on Tower Side [03047276-xx] ................................................... 53
3.6.8 Replacing the Collision Light Barriers [03047281-xx] ........................................................................... 54
3.6.8.1 Adjusting the Collision Light Barriers .................................................................................................. 55
3.6.9 Replacing the Reference Sensor, Lifting Axis [03047278-xx] ............................................................... 57
3.6.10 Replacing the Top Lifting Axis Limit Switch [03047279-xx]................................................................... 59
3.6.11 Replacing the Bottom Lifting Axis Limit Switch [03047280-01-xx] ........................................................ 60
3.6.12 Replacing the Safety Switch [03048181-xx].......................................................................................... 61
4 Calibration and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
4.1 Lifting Axis........................................................................................................................................... 63
4.1.1 Procedure - Calibrating the Lifting Axis................................................................................................. 63
4.1.1.1 Troubleshooting for "Teach Zero Point Correction" ............................................................................ 64
4.1.2 Calibrating the Reference Sensor, Lifting Axis...................................................................................... 64
4.1.3 Teaching the Zero Point Correction ...................................................................................................... 65
4.1.4 Calibrating the Top Lifting Axis Limit Switch ......................................................................................... 65
4.1.5 Calibrating the Bottom Lifting Axis Limit Switch .................................................................................... 65
4.2 Feed Axis ............................................................................................................................................. 66
4.2.1 Procedure - Calibrating the Feed Axis .................................................................................................. 66
4.2.2 Calibrating the Reference Sensor, Feed Axis ....................................................................................... 66
4.2.3 Calibrating the Feed Axis Limit Switch on Tower Side.......................................................................... 66
4.2.4 Calibrating the Feed Axis Limit Switch on Transfer Side ...................................................................... 66
4.2.5 Measuring the Transfer Position ........................................................................................................... 67
4.2.5.1 Calibrating the Feed Axis Limit Switch on Tower Side........................................................................ 67
4.2.6 Calibrating the Zero Point Correction.................................................................................................... 67
4.3 Machine Data ....................................................................................................................................... 68
4.3.1 Initialization ........................................................................................................................................... 68
4.3.2 Saving the Machine Data ...................................................................................................................... 68
4.3.3 Restoring Machine Data........................................................................................................................ 69
4.3.4 Standard Values.................................................................................................................................... 69
4.4 Other Functions .................................................................................................................................. 72
4.4.1 Performing a Reference Run ................................................................................................................ 72
4.4.2 Performing a Continuous Run............................................................................................................... 72
4.4.3 Positioning Axes.................................................................................................................................... 72
4.4.4 Releasing Axes ..................................................................................................................................... 72
4.4.5 Calibrating Reference Fiducials ............................................................................................................ 73
5 SITEST for WPC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
5.1 General................................................................................................................................................. 75
5.2 Safety Instructions.............................................................................................................................. 75
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Service Manual SIPLACE WPC4
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5.3 Opening the SITEST Interface ........................................................................................................... 75
5.4 Closing the SITEST Interface............................................................................................................. 76
5.5 Selecting Dialog Boxes ...................................................................................................................... 76
5.6 SITEST Functions ............................................................................................................................... 77
5.6.1 Approach............................................................................................................................................... 78
5.6.1.1 Calibrate ............................................................................................................................................. 79
5.6.2 Version Info........................................................................................................................................... 80
5.6.3 Changing WPTCs ................................................................................................................................. 81
5.6.4 Production Data .................................................................................................................................... 82
5.6.5 Continuous Run .................................................................................................................................... 82
5.6.6 Display Configuration............................................................................................................................ 84
5.7 SITEST Axes........................................................................................................................................ 85
5.7.1 Positioning ............................................................................................................................................ 86
5.7.2 Continuous Run .................................................................................................................................... 87
5.7.3 Feed Axis Positions .............................................................................................................................. 89
5.7.4 Lifting Axis Positions ............................................................................................................................. 90
5.7.5 Standard Values ................................................................................................................................... 91
5.7.6 Positioning Data.................................................................................................................................... 92
5.8 SITEST Feed Axis Settings ................................................................................................................ 94
5.8.1 Measuring the Transfer Position ........................................................................................................... 95
5.8.2 Zero Point Correction............................................................................................................................ 96
5.9 SITEST Lifting Axis Settings.............................................................................................................. 97
5.9.1 Stepping the Lifting Axis ....................................................................................................................... 99
5.9.2 Teaching the Zero Point...................................................................................................................... 100
5.10 SITEST Machine Data ....................................................................................................................... 101
5.10.1 Initialize............................................................................................................................................... 102
5.10.2 Saving WPC Machine Data ................................................................................................................ 103
5.10.3 Restoring WPC Machine Data ............................................................................................................ 104
5.11 SITEST Inputs/Outputs..................................................................................................................... 105