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Table of contents 4 Serv ice Manual SIPLACE D4 3.4.1 Changeover Table . ............. ................ ............. ............. ................ ............. ............. ........ .................. ..... 36 3.4.1.1…

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Table of contents
Service Manual SIPLACE D4
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Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.1 Safety Instructions................................................................................................................................ 9
1.1.1 Serial Number of D4 Module................................................................................................................... 9
1.1.2 Environmentally-Friendly Disposal of Materials and Components.......................................................... 9
1.1.3 Use of Original SIPLACE Accessories and Spare Parts......................................................................... 9
1.2 Key Information................................................................................................................................... 10
1.2.1 Information About This Service Manual (Customer Version)................................................................ 10
1.2.2 Validity of Document ............................................................................................................................. 10
1.2.3 Release History..................................................................................................................................... 10
1.2.4 Further Information ............................................................................................................................... 10
1.2.5 SIPLACE on the World Wide Web (WWW) .......................................................................................... 11
1.2.6 Abbreviations ........................................................................................................................................ 12
1.3 Staff Qualifications and Training....................................................................................................... 12
2 Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.1 Safety Instructions.............................................................................................................................. 13
2.1.1 Conventions for the Use of Hazard Symbols ........................................................................................ 13
2.1.2 Safety Instructions for Working with Strong Magnetic Fields................................................................14
2.1.3 Safety Instructions for the Power Supply .............................................................................................. 14
2.1.4 Safety Instructions for Work on the Cutting Device .............................................................................. 15
2.1.5 Safety Instructions for the Compressed Air Supply .............................................................................. 15
2.2 Preparations for Service Work .......................................................................................................... 16
3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.1 D-Series - General............................................................................................................................... 17
3.1.1 SIPLACE D1 ......................................................................................................................................... 17
3.1.2 SIPLACE D2 ......................................................................................................................................... 18
3.1.3 SIPLACE D3 ......................................................................................................................................... 18
3.1.4 SIPLACE D4 ......................................................................................................................................... 19
3.2 Electrical System................................................................................................................................ 20
3.2.1 Position of the modules......................................................................................................................... 20
3.2.2 Power Supply Unit ................................................................................................................................ 21
3.2.2.1 Supply Voltages .................................................................................................................................. 21
3.2.2.2 Description of the power supply functions .......................................................................................... 22
3.2.3 Distributors in Sectors 1-4..................................................................................................................... 26
3.2.3.1 Distributors in Sector 1 ....................................................................................................................... 26
3.2.3.2 Distributors in Sector 2 ....................................................................................................................... 27
3.2.3.3 Distributors in Sector 3 ....................................................................................................................... 28
3.2.3.4 Distributors in Sector 4 ....................................................................................................................... 29
3.2.3.5 Overview of Settings ........................................................................................................................... 30
3.2.4 Computer Unit....................................................................................................................................... 31
3.2.4.1 Overview of Settings ........................................................................................................................... 31
3.2.5 Axis Unit................................................................................................................................................ 32
3.2.5.1 Overview of Settings ........................................................................................................................... 32
3.3 Gantry .................................................................................................................................................. 33
3.3.1 Parts Overview...................................................................................................................................... 34
3.4 Component Handling.......................................................................................................................... 36
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4 Service Manual SIPLACE D4
3.4.1 Changeover Table................................................................................................................................. 36
3.4.1.1 Structure of Changeover Table (S Table) ........................................................................................... 36
3.4.2 Cutter .................................................................................................................................................... 37
3.4.2.1 Safety Instructions............................................................................................................................... 37
3.4.2.2 Overview: Mechanical Construction.................................................................................................... 38
3.4.2.3 Diagrams of Pneumatic System and Functional Sequence ................................................................ 39
3.5 Modular Conveyor...............................................................................................................................40
3.5.1 Module Overview .................................................................................................................................. 40
3.6 C&P12...................................................................................................................................................41
3.6.1 Overview ............................................................................................................................................... 41
3.6.1.1 Technical Data C&P12........................................................................................................................ 41
3.6.1.2 Camera Modularity on C&P 12 Head.................................................................................................. 42
3.6.1.3 Position and Function of Individual Star Stations................................................................................ 42
3.6.1.4 Overview of C&P6/12 Head Parts....................................................................................................... 43
3.6.1.5 Compressed Air Supply - C&P Head .................................................................................................. 45
3.6.1.6 Overview of Blast Air Supply............................................................................................................... 46
3.6.1.7 Overview of Vacuum Supply ............................................................................................................... 47
3.7 Pneumatic Unit....................................................................................................................................48
3.7.1 Overview of Pneumatic Unit.................................................................................................................. 48
3.7.1.1 Manometer Arrangement .................................................................................................................... 48
4 Service Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.1 Electrical System ................................................................................................................................49
4.1.1 Measuring Voltages on the Power Supply Unit..................................................................................... 49
4.1.1.1 Safety Instructions............................................................................................................................... 49
4.1.1.2 Tools and equipment required ............................................................................................................ 49
4.1.1.3 Preparing the power supply unit for measurement ............................................................................. 50
4.1.1.4 What To Do After Completing Service Work....................................................................................... 50
4.1.2 Measuring the Power Supply Unit......................................................................................................... 51
4.1.2.1 Front View ........................................................................................................................................... 52
4.1.2.2 Side View ............................................................................................................................................ 54
4.1.2.3 Measuring voltages at transformer T1 ................................................................................................ 56
4.1.3 Distributors in Sectors 1-4..................................................................................................................... 59
4.1.3.1 Replacing parts ................................................................................................................................... 59
4.1.4 Axis Unit ................................................................................................................................................ 59
4.1.4.1 Replacing parts ................................................................................................................................... 59
4.2 Gantry...................................................................................................................................................62
4.2.1 Preparations for Service Work .............................................................................................................. 62
4.2.2 Replacing the Elastomeric Spring [00301040-01]................................................................................. 62
4.2.2.1 Tools and Equipment .......................................................................................................................... 62
4.2.2.2 Parts.................................................................................................................................................... 62
4.2.2.3 Removing the elastomeric spring........................................................................................................ 63
4.2.2.4 Installing the elastomeric spring.......................................................................................................... 63
4.2.2.5 Settings ............................................................................................................................................... 63
4.2.3 Replacing the X Axis Scale [00329316-01]........................................................................................... 63
4.2.4 Replacing the Y-Axis Scale................................................................................................................... 64
4.2.5 Replacing the Tensioning Keys [00329478-01, 00329485-01] ............................................................. 64
4.2.5.1 Tools and Equipment .......................................................................................................................... 64
4.2.5.2 Parts.................................................................................................................................................... 64
4.2.5.3 Removing the tensioning keys ............................................................................................................ 64
4.2.5.4 Installing the tensioning keys .............................................................................................................. 66
4.2.5.5 Settings ............................................................................................................................................... 66
4.2.6 Replacing the Deflection Unit [00330938-02]........................................................................................ 67
4.2.6.1 Tools and Equipment .......................................................................................................................... 67
4.2.6.2 Parts.................................................................................................................................................... 67
4.2.6.3 Removing the deflection unit............................................................................................................... 67
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Service Manual SIPLACE D4
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4.2.6.4 Installing the deflection unit ’X’ ........................................................................................................... 69
4.2.6.5 Settings ............................................................................................................................................... 70
4.2.7 Replacing the X Axis Toothed Belt [00331076-02] ............................................................................... 70
4.2.7.1 Tools and Equipment .......................................................................................................................... 70
4.2.7.2 Parts ................................................................................................................................................... 70
4.2.7.3 Removing the X-axis toothed belt ....................................................................................................... 71
4.2.7.4 Installing the X-axis toothed belt ......................................................................................................... 72
4.2.7.5 Settings ............................................................................................................................................... 73
4.2.8 Replacing the X Motor Unit [00333167-03]........................................................................................... 74
4.3 Component Handling.......................................................................................................................... 78
4.3.1 Changeover Table ................................................................................................................................ 78
4.3.1.1 Safety Instructions .............................................................................................................................. 78
4.3.1.2 Preparations for Service Work ............................................................................................................ 79
4.3.1.3 Replacing the Fixed and/or Guide Castors ......................................................................................... 80
4.3.1.4 Replacing the Communication Unit (Feeder Control Unit) [03002179-xx] .......................................... 81
4.3.1.5 Replacing the Changeover Table Connection Cable..........................................................................82
4.3.1.6 Final Steps.......................................................................................................................................... 83
4.3.2 Cutter .................................................................................................................................................... 84
4.3.2.1 Safety Instructions .............................................................................................................................. 84
4.3.2.2 Parts ................................................................................................................................................... 84
4.3.2.3 Tools, Expendable Materials, Documentation .................................................................................... 85
4.3.2.4 Overview of Cutter .............................................................................................................................. 86
4.3.2.5 Exchanging the Pneumatic Cutter ...................................................................................................... 87
4.3.2.6 Turning the Stationary and Moveable Blade by 180 ° ........................................................................ 92
4.3.2.7 Replacing the Stationary Blade and Movable Blade incl. Spacers ..................................................... 95
4.3.2.8 Replacing the Articulated Joint on the Short-Stroke Cylinder [00348579-xx] ................................... 101
4.3.2.9 Exchanging the Control Unit ............................................................................................................. 106
4.3.2.10 Exchanging the Solenoid Valve on Left or Right (and/or Cable)....................................................... 108
4.3.2.11 Exchanging the Inductive Proximity Switch ...................................................................................... 110
4.3.2.12 Exchanging the Empty-Tape Duct Assembly.................................................................................... 112
4.3.2.13 Exchanging Baffles and / or Reject Box (Profile).............................................................................. 113
4.3.2.14 Final Steps........................................................................................................................................ 114
4.4 Modular Conveyor ............................................................................................................................ 115
4.4.1 Tools ................................................................................................................................................... 115
4.4.2 Replacing the Complete Drive Unit [00359284].................................................................................. 116
4.4.3 Replacing the DC Geared Motor [03009269]...................................................................................... 118
4.4.4 Replacing the Toothed Belt of the Drive Unit [00355553]................................................................... 120
4.4.5 Replacing the Conveyor Toothed Belt [00359917-xx] ........................................................................ 122
4.4.5.1 Adjusting the Tension of the Conveyor Toothed Belt........................................................................ 124
4.4.6 Replacing the Lifting Table Unit [00358653] ....................................................................................... 124
4.4.7 Replacing the Lifting Table Solenoid Valve [00358663] ..................................................................... 126
4.4.8 Replacing the Lifting Table Fork Light Barrier [00363079].................................................................. 127
4.4.9 Replacing the Complete Lifting Table Cylinder [00358703]................................................................ 12
8
4.4.10 Replacing the Lift
ing Table Stabilizer (Stabilizer Unit) [00358684-xx] ................................................ 129
4.4.11 Replacing the Stepping Motor of the Width Adjustment System [00367174] ..................................... 131
4.4.12 Replacing the Limit Switch for the End Position Width Adjustment System [00365108-xx] ............... 133
4.4.13 Replacing the Solenoid Valve for the Adjustment Unit [00369014-xx]................................................ 135
4.4.14 Replacing the Cylinder Switch for the Adjustment Unit [00369016].................................................... 136
4.4.15 Replacing the Proximity Switch for the Adjustment System [00363268] ............................................ 137
4.4.16 Replacing the Light Barriers for Transmitter and Receiver Modules [00370063] ............................... 138
4.4.16.1 Replacing the Transmitter or Receiver for Placement Areas 1 + 2................................................... 139
4.4.16.2 Replacing the Transmitter or Receiver for the Input or Output Conveyor......................................... 140
4.4.16.3 Replacing the Light Barriers for the Intermediate Conveyor ............................................................. 141
4.4.17 Replacing the Laser Light Barriers for Stopper Positions [00370385] ................................................ 142
4.4.18 Overview of the Electrical Components .............................................................................................. 144
4.4.18.1 Conveyor Side Conversion Board [00359424].................................................................................. 144
4.4.18.2 Conveyor Conversion Board [00359425].......................................................................................... 144
4.4.18.3 Lifting Table Conversion Board [00362766] ..................................................................................... 145
4.4.18.4 Conveyor Control TSP 301 [00370397] ............................................................................................ 145