WPC4 services manual - 第4页

Contents 4 Service Manual SIPLACE WPC4 3.6.1.3 Requirements for Settings .......... ................ ............. ................ ............. ................ ........... ........... ......... 42 3.6.2 Replacing the …

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Contents
Service Manual SIPLACE WPC4
3
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)..........................................................................................8
2 Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.1 Conventions for the use of hazard symbols...................................................................................... 9
2.2 Safety Instructions................................................................................................................................ 9
2.2.1 Qualified Personnel................................................................................................................................. 9
2.2.2 Safety Instructions for the Power Supply.............................................................................................. 10
2.2.2.1 Safety Instructions for Work on the Cutting Device ............................................................................ 10
2.2.3 Safety Instructions for the Compressed Air Supply .............................................................................. 11
2.2.4 Safety Instructions for Working with Strong Magnetic Fields................................................................11
3 Replacing Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.1 Safety Instructions.............................................................................................................................. 13
3.2 Overview of Main Assemblies ........................................................................................................... 14
3.3 Drive Unit – Lifting Axis ..................................................................................................................... 15
3.3.1 Preparations.......................................................................................................................................... 15
3.3.2 Replacing the Lifting Axis Drive Motor [03047846-xx].......................................................................... 16
3.3.3 Replacing the Lifting Axis Toothed Belt [03046971-xx] ........................................................................ 19
3.4 Drive Unit – Feed Axis........................................................................................................................ 20
3.4.1 Preparations.......................................................................................................................................... 20
3.4.2 Replacing the Feed Axis Drive Motor [03047364-xx]............................................................................ 21
3.4.3 Replacing the Drive Toothed Belt [03047689-xx] ................................................................................. 23
3.4.4 Replacing the Feed Axis Toothed Belt [03047690-xx].......................................................................... 24
3.4.5 Setting the Feed Axis Belt Tension....................................................................................................... 27
3.5 Control Unit and Power Supply Unit................................................................................................. 28
3.5.1 Control Unit........................................................................................................................................... 29
3.5.1.1 Instructions for Working with Control Units......................................................................................... 29
3.5.1.2 Replacing the Power Supply Board [03047225-xx] ............................................................................ 30
3.5.1.3 Replacing the Controller Board [03047223-xx]................................................................................... 30
3.5.1.4 Replacing the Axis Controller Board [03041865-xx]........................................................................... 31
3.5.1.5 Replacing the Servo Amplifier [03048005-xx]..................................................................................... 31
3.5.1.6 Replacing the Ballast Circuit [00344207-xx]....................................................................................... 32
3.5.1.7 Replacing the Complete Control Unit [03047226-xx].......................................................................... 33
3.5.1.8 Replacing the Fan [03051368-xx]....................................................................................................... 35
3.5.2 Power Supply Unit ................................................................................................................................ 36
3.5.2.1 Replacing the Protective Contactor Combination (SSK) [00372649-xx]............................................. 37
3.5.2.2 Replacing the Inrush current Limitation Board [03047752-xx]............................................................ 37
3.5.2.3 Removing the Front Cover Plate with Main Switch and the Emergency Stop Button......................... 38
3.5.2.4 Replacing the Complete Power Supply Unit [03047298-xx]............................................................... 39
3.6 Limit Switches, Sensors and Light Barriers..................................................................................... 40
3.6.1 Introduction........................................................................................................................................... 40
3.6.1.1 Overview............................................................................................................................................. 40
3.6.1.2 General Installation/Removal Instructions .......................................................................................... 41
Contents
4 Service Manual SIPLACE WPC4
3.6.1.3 Requirements for Settings...................................................................................................................42
3.6.2 Replacing the WPTC Available Sensor [03047283-xx].........................................................................44
3.6.3 Replacing the WPTC Lock Sensor Closed [03047285-xx]....................................................................45
3.6.4 Replacing the WPTC Present in Tower Sensor [03047284-xx] ............................................................46
3.6.5 Replacing the Reference Sensor, Feed Axis [03047273-xx] ................................................................47
3.6.6 Replacing the Feed Axis Limit Switch on Transfer Side [03047277-xx]...............................................50
3.6.7 Replacing the Feed Axis Limit Switch on Tower Side [03047276-xx]...................................................51
3.6.8 Replacing the Collision Light Barriers [03047281-xx] ...........................................................................53
3.6.8.1
Adjusting the Collision Light Barriers..................................................................................................54
3.6.9 Replacing the Reference Sensor, Lifting Axis [03047278-xx]...............................................................55
3.6.10 Replacing the Top Lifting Axis Limit Switch [03047279-xx]...................................................................57
3.6.11 Replacing the Bottom Lifting Axis Limit Switch [03047280-01-xx] ........................................................58
3.6.12 Replacing the Safety Switch [03048181-xx]..........................................................................................59
4 Calibration and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
4.1 Lifting Axis...........................................................................................................................................61
4.1.1 Procedure - Calibrating the Lifting Axis.................................................................................................61
4.1.1.1 Troubleshooting for "Teach Zero Point Correction" ............................................................................62
4.1.2 Calibrating the Reference Sensor, Lifting Axis......................................................................................62
4.1.3 Teaching the Zero Point Correction......................................................................................................63
4.1.4 Calibrating the Top Lifting Axis Limit Switch .........................................................................................63
4.1.5 Calibrating the Bottom Lifting Axis Limit Switch....................................................................................63
4.2 Feed Axis .............................................................................................................................................64
4.2.1 Procedure - Calibrating the Feed Axis..................................................................................................64
4.2.2 Calibrating the Reference Sensor, Feed Axis.......................................................................................64
4.2.3 Calibrating the Feed Axis Limit Switch on Tower Side..........................................................................64
4.2.4 Calibrating the Feed Axis Limit Switch on Transfer Side ......................................................................64
4.2.5 Measuring the Transfer Position...........................................................................................................65
4.2.6 Calibrating the Zero Point Correction....................................................................................................65
4.3 Machine Data.......................................................................................................................................65
4.3.1 Initialization ...........................................................................................................................................65
4.3.2 Saving the Machine Data......................................................................................................................66
4.3.3 Restoring Machine Data........................................................................................................................66
4.3.4 Standard Values....................................................................................................................................67
4.4 Other Functions ..................................................................................................................................69
4.4.1 Performing a Reference Run ................................................................................................................69
4.4.2 Performing a Continuous Run...............................................................................................................69
4.4.3 Positioning Axes....................................................................................................................................69
4.4.4 Releasing Axes.....................................................................................................................................70
4.4.5 Calibrating Reference Fiducials ............................................................................................................70
5 SITEST for WPC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
5.1 General.................................................................................................................................................71
5.2 Safety Instructions..............................................................................................................................71
5.3 Opening the SITEST Interface............................................................................................................71
5.4 Closing the SITEST Interface.............................................................................................................72
5.5 Selecting Dialog Boxes ......................................................................................................................72
5.6 SITEST Functions ...............................................................................................................................73
5.6.1 Approach...............................................................................................................................................74
5.6.1.1 Calibrate..............................................................................................................................................75
5.6.2 Version Info...........................................................................................................................................76
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Service Manual SIPLACE WPC4
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5.6.3 Changing WPTCs................................................................................................................................. 77
5.6.4 Production Data.................................................................................................................................... 78
5.6.5 Continuous Run.................................................................................................................................... 78
5.6.6 Display Configuration............................................................................................................................ 80
5.7 SITEST Axes........................................................................................................................................ 81
5.7.1 Positioning ............................................................................................................................................ 82
5.7.2 Continuous Run.................................................................................................................................... 83
5.7.3 Feed Axis Positions .............................................................................................................................. 84
5.7.4 Lifting Axis Positions............................................................................................................................. 85
5.7.5 Standard Values ................................................................................................................................... 86
5.7.6 Positioning Data.................................................................................................................................... 86
5.8 SITEST Feed Axis Settings ................................................................................................................ 88
5.8.1 Measuring the Transfer Position........................................................................................................... 89
5.8.2 Zero Point Correction............................................................................................................................ 90
5.9 SITEST Lifting Axis Settings.............................................................................................................. 91
5.9.1 Stepping the Lifting Axis ....................................................................................................................... 93
5.9.2 Teaching the Zero Point........................................................................................................................ 94
5.10 SITEST Machine Data......................................................................................................................... 95
5.10.1 Initialize................................................................................................................................................. 96
5.10.2 Saving WPC Machine Data .................................................................................................................. 97
5.10.3 Restoring WPC Machine Data.............................................................................................................. 98
5.11 SITEST Inputs/Outputs ,..................................................................................................................... 99