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Table of contents 6 Serv ice Manual SIPLACE D4 4.4.18.5 Extension Controller Board TSP 301E for Dual Conveyors [ 00370398] .... ................ ................ ....... 146 4.5 C&P12 Placement Head ................ …

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Table of contents
Service Manual SIPLACE D4
5
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
Table of contents
6 Service Manual SIPLACE D4
4.4.18.5 Extension Controller Board TSP 301E for Dual Conveyors [00370398] ........................................... 146
4.5 C&P12 Placement Head....................................................................................................................147
4.5.1 Replacing the C&P12 Head (D4) ........................................................................................................ 147
4.5.2 Removal/Installation of Head Front Part ............................................................................................. 149
4.5.3 Replacing the Component Camera (D Series) [03014449-xx]............................................................ 151
4.5.4 Replacing the Intermediate Distributor [00330648]............................................................................. 153
4.5.5 Replacing the Turning Station (D Series) [00341780-xx].................................................................... 155
4.5.6 Replacing the DP Rocker.................................................................................................................... 156
4.5.7 Replacing the Toothed Belt for the DLM Turning Station (from version 07) [00320041-xx]................ 158
4.5.8 Replacing the Valve Positioning Drive for the Placement Circuit [00368075]..................................... 159
4.5.8.1 New Valve Positioning Drives (From Version 03) ............................................................................. 161
4.5.8.2 Mechanical Adjustment (Up To Version 02)...................................................................................... 161
4.5.8.3 Mechanical Adjustment (All Versions)............................................................................................... 163
4.5.9 Replacing the Valve Positioning Drive for the Reject Circuit [00367768]............................................ 165
4.5.9.1 New Valve Positioning Drives (From Version 03) ............................................................................. 167
4.5.9.2 Mechanical Adjustment (Up To Version 02)...................................................................................... 167
4.5.9.3 Mechanical Adjustment (From Version 03) ....................................................................................... 169
4.5.10 Replacing the Light Barrier "Z Axis Up" [03053294-xx]....................................................................... 171
4.5.11 Replacing the Z Axis Drive [00341011]............................................................................................... 172
4.5.12 Replacing the Z Axis Toothed Belt [00334936]................................................................................... 173
4.5.13 Replacing the "Z Axis Down" Sensor [00321524-xx] ..........................................................................176
4.5.14 Replacing the Complete Z Axis [03001959]........................................................................................ 177
4.5.15 Replacing the Forced Air Unit [00367793-xx] ..................................................................................... 179
4.5.16 Replacing the Silencer [03003134] ..................................................................................................... 180
4.5.17 Replacing the Star [00341181]............................................................................................................ 181
4.5.17.1 Adjusting the Star to the Star's Magnetic Neutral Position................................................................ 182
4.5.17.2 Replacing the Air Blast Supply to the Star [03000896-xx] ................................................................184
4.5.17.3 Replacing the Silicone Hoses on the Star [00341183S01] ............................................................... 184
4.5.18 Replacing the Star Drive [03020626-xx] ............................................................................................. 186
4.5.19 Replacing the RSF Digital Rotary Encoder (DP Axis) [00335990-xx] ................................................. 187
4.5.20 Replacing the Control Board for the Nozzle Changer 6/12 [00317353] .............................................. 189
4.5.21 Checking the Cable Routing ............................................................................................................... 190
4.5.21.1 Cable Routing for Gantry Head Distributor Board............................................................................. 191
4.5.21.2 X Gantry Cable Routing .................................................................................................................... 194
4.5.21.3 Component Sensor Cable Routing ................................................................................................... 194
4.5.21.4 Running the Valve Positioning Drive Cables..................................................................................... 195
4.5.22 Press Fit Connections with Fixture Clips on the Vision Board (D Series) ........................................... 196
4.5.23 Replacing the Raceway (Circular Arc Guide)...................................................................................... 196
4.5.24 Replacing the Membrane (Vacuum Plate) on the Sleeve [00354244-xx] ........................................... 197
4.5.25 Replacing the Vacuum Hoses on the C&P Head................................................................................198
4.6 Pneumatic Unit.................................................
.................................................................................199
4.6.1 Safety Instructions for Replacing Parts ............................................................................................... 199
4.6.2 Preparing for Part Replacement.......................................................................................................... 199
5 Measuring Equipment and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
5.1 SIPLACE Axis Tester (SAT) [03002801-01].....................................................................................201
5.1.1 Scope of Delivery ................................................................................................................................ 203
5.2 SIPLACE Diagnosis Adapter A364 [03051220-01]..........................................................................204
5.3 Axis Tester (Old Version) and Adapter Board................................................................................205
5.4 Track Signal Tester [00343785-01] ..................................................................................................206
5.5 Track Signal Tester [00322510-01] ..................................................................................................206
5.6 Belt Tension Device [00326015-01] .................................................................................................207
5.7 SIPLACE Compressed Air Tester [00311487-01] ...........................................................................207
Table of contents
Service Manual SIPLACE D4
7
5.8 Location Tester................................................................................................................................. 208
5.9 Z End Stopper Star Gauge for C&P6/12 [03019865-01]................................................................. 208
5.10 Adjustment Aid for C&P DLM [00327005-01].................................................................................. 209
5.11 Calibration Tool [03010565-01]........................................................................................................ 210
5.12 Calibration Nozzle for Twin Head [03008862-xx] ........................................................................... 210
6 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
6.1 Electrical System.............................................................................................................................. 211
6.1.1 Checking the Firmware Function ........................................................................................................ 211
6.1.2 Firmware Download Note ................................................................................................................... 211
6.2 Gantry ................................................................................................................................................ 212
6.2.1 Travel Ranges and Speed Monitoring (A364)..................................................................................... 212
6.2.2 Anticrash Function for the A364 Axis Card ......................................................................................... 213
6.2.2.1 Anticrash Function for the A364 ....................................................................................................... 213
6.2.2.2 Anticrash Monitoring for the A364 .................................................................................................... 214
6.2.2.3 Error "Gantry Crash" ......................................................................................................................... 214
6.2.2.4 Count Error: ...................................................................................................................................... 214
6.2.2.5 Anticrash Function - Procedure ........................................................................................................ 215
6.2.3 Description of the PCB boards on the Gantry..................................................................................... 216
6.2.3.1 Gantry Head Distributor .................................................................................................................... 216
6.2.3.2 Vision Board (Digital) ........................................................................................................................ 219
6.2.3.3 CAN 16 bit processor board (TQ module) ........................................................................................ 219
6.2.4 Checking the DIP Switches................................................................................................................. 220
6.2.4.1 DIP Switch on Gantry Head Distributor............................................................................................. 220
6.2.4.2 DIP Switch on Vision Board.............................................................................................................. 220
6.2.5 Mechanical Adjustment of the Incremental Encoder........................................................................... 220
6.3 C&P12 ................................................................................................................................................ 221
6.3.1 Calibrating the C&P Head and Cameras ............................................................................................ 221
6.3.2 Boards at C&P12 ................................................................................................................................ 222
6.3.2.1 8-fold DIP Switch of the gantry head distributor (incl. switch S1) – C&P6/12 ................................... 222
6.3.2.2 LEDs on gantry head distributor ....................................................................................................... 223
6.3.2.3 SP_12 Digital Intermediate Distributor [00330648-05]...................................................................... 223
6.3.3 Overview of Settings on the C&P6/12................................................................................................. 225
6.3.4 Setting the Resolution on the Star Axis .............................................................................................. 226
6.3.5 Setting the Digital Rotary Encoder for the DP Axis............................................................................. 226
6.3.6 Setting the Z axis Belt Tension ........................................................................................................... 227
6.3.7 Adjusting the Stop for the Z Axis......................................................................................................... 227
6.3.7.1 Tools and Equipment ........................................................................................................................ 227
6.3.7.2 General ............................................................................................................................................. 228
6.3.7.3 Settings ............................................................................................................................................. 228
6.3.8 Setting the Light Barrier Down ............................................................................................................ 229
6.3.9 Determining the Zero Point Correction for the Star Axis of the C&P Head......................................... 230
6.3.10 Setting the Mechanical Position of the Valve Positioning Drives ........................................................ 231
6.3.11 Adjustment of air pressure values....................................................................................................... 232
6.3.11.1 Tools and Equipment ........................................................................................................................ 232
6.3.11.2 Setting the Air Blast Pressure Values ............................................................................................... 232
6.3.11.3 Setting the Air Blast Pressure Values with the Compressed Air Testing Device .............................. 233
6.3.12 Performing a Vacuum Test on the C&P 6/12 DLM Heads.................................................................. 234
6.3.13 Other Mechanical Settings on the Star ............................................................................................... 237
6.4 Component Handling........................................................................................................................ 238
6.4.1 Setting the COT Basic Height ..............................................................................................
............... 238
6.4.1.1 Tools
and Equipment........................................................................................................................ 238
6.4.1.2 Adjusting the Component Trolley to the Board Transport Height ..................................................... 238
6.4.1.3 Adjusting the Component Trolley Height .......................................................................................... 239