WPW_type3%20service-F5 WPW for Eduardo
Contents
1. r 25 Servo ES Bl xlx 2 a power supply aya o g E p i S c o x E ee Xx 2 o lt lt 9 x a U oF u S0 1 S w gt gt E M 3 5 Z umm M Feed axis s se e motor P h s br Sx XxXxX Pi E NIN k j s o o gt SBF E E xx lt 7 aS a i c o X a a a s L3 s S L4 m M X S 2 k s i M P 2 R Y wh Lift axis sell as br s r g X gt lt moto J l A S S 1 ya i amp E o 9 E gja ols a gt Ell X6 X8 x6 X8 k bk a X3 IL Disable brake F x x gt v u an oles o Q i Axis card a gt ala 8x Byposs lift axis inputs 9 0 x n 96 a end position Q Lift axis sel sz Sa encoder ud ai S a Feed axis gt gt lt x x x E encoder C C l ms d X Axis card F lo lo gt la g measurement socket y 8 Ie mi lo lo gt les o o 3 U o l o 9 gt i zm ale x o X gt lt 2528 E x e B A o Star poinjt m a gt 15V grbi 15 z D N 15V whbI us 8 ES Input byte 1 bl V 5 Ground 5V sele p T5V i 0V a X15V 24V NIN 5V o x Y 8 a m Input byte 2 a u ze f So Gi v o Ax s 5 Fe Ras Z z Output byte x 2 vobec Ql ols alx x x x x o wo SISIS sas 99992 g2. C BA6 60025 length 250 o E length 500 9 FH lel e M E211 XI Ms Inputs e does e e e 7 Distributor a BAG 60075 length 250 C E o o o E ki o o e e BAG 60025 length 245 6 length 50000 m pi pi PE o PE rail Fig 3 3 Mounting plate Y2 The mounting plate accommodates the following modules 24V rectifier Grounding terminal strip 24V distributor inputs Diagram 3 3 shows the layout of control unit Y2 The incoming unit accommodates the following modules Main fuse F1 Grounding terminal strip 3x 380 V or 3 x 230 V transformers the USA version is connected differently Emergency stop circuit contactor safety protection unit or two AC contactors F2 fuse for the power supply to the servo boards 90 100 V WPC 80F Type 3 Service Manual Edition 09 97 3 Design and Method of Operation E o a E amp 5 m S8 t z 552258 x 92558 xm 8 2 4 6 2 z o 88865 Sew bp POS o d SEEEESS SESE oN ee Da
3. Axis board Controller Feed axis LT LT LT LT J Peed Lifting axis Sea Hs k E 5 limit switch CO oo S s S CO 5 Output byte 2 o G1 Lifting axis WMer ht E Disable ao x brake Input byte 2 Z 3 e CO 2 lt a p 4 Input byte 1 x oo Ballast Lifting axis oo LI LT J 5 lt E C V24 console o s Discharge time z 9 2 minutes B o 5 2 5 o SIPLACE V24 ee 8 s D amp 5 c e 10 2 lt lt lt lt E L1 L1 p os id 1T T SU NU Motor feed axis 9900999P999PPP PP PPP OP POD PP OPPP PPP P PPP OPPP O9 E i r IO gt x6 2 CO g M x lt R SE s Power supply for servo vround 8 Li L4 x amp 5 x7 2 e PES z O Motor lift_axis ag 2 5 x O Y EG 8 5 X8 xt J U o o606000600006000000000000000000000000000000090 Main meni etr gt a O e gt o SS s s z z MES 8 a i OV 2 2 2 2 2 TI5V c lt c gt zi dE s O 15v s i 5 3 a o o o o o i o o 5 E 3 E 3 o o o o lt 5 o c H 14 POD BOP YGKHHPOGHK Pe LOHSHHSHSSHHSHSSHSSSHHS OH
4. Setting on the WPC 80 F type 3 Select the Transfer position option from the Feed axis column Approach the transfer position without a magazine plate after inserting a 4 mm pin into the hole at the transfer position to act as a stop PLEASE NOTE Check the transfer position When making the setting move the pusher against the 4 mm pin manually if necessary and accept the position PLEASE NOTE The transfer position MUST be set before setting the limit switch feed axis since the switch position is cal culated from the transfer position Setting the feed axis limit switch AY S2 First remove the magazine plate Select the Limit switch option from the Feed axis column and then set the limit switch using the testing program Setting the feed axis limit switch AY S1 Select the Limit switch option from the Feed axis column and then set the limit switch using the program 4 1 3 Electrical Adjustment Tools and auxiliary materials Multimeter Oscilloscope Axis tester Size 0 screwdriver WPC 80F test program version V100 05 and later WPC 80F Type 3 Service Manual Edition 09 97 4 Feed Axis Electrical adjustments to the axis board and the servo board are carried out analogously to those for the x axis of the SIPLACE 80F Adjustment work Zero adjustment of the axis controller do this only when you change the board Servo amplifier offset do this only
5. The voltages can all be readjusted this should only be done after a warming up period of 30 minutes The power supply unit is supplied with alternating current at 220 V or 110 V It will function correctly with either voltage and no switchover is necessary g Feed axis One full revolution of the motor corresponds to 4000 increments One millimeter of travel path corresponds to 53 333 increments The travel speed at stage 1 0 43 m s 10 4 3 m s The current limit is r m s current 4 3A peak current 8 0A h Lifting axis One full revolution of the motor corresponds to 4000 increments One millimeter of travel path corresponds to 520 increments The acceleration deceleration should not be set to more than 50 2 0 5 g The travel speed at stage 1 0 04 m s stage 10 0 4 m s The current limit is r m s current 7A peak current 16A i Emergency stop circuit The emergency stop button make contact is integrated in the emergency stop circuit of the Siplace 80F A check back signal is returned from this emergency stop circuit in the form of an alternating voltage of 24 V which switches on the control unit in the wafflepack changer The contactors switch off the servo voltage 90 100 V off In addition the power supply to the brake is swit ched off after a brief delay The emergency stop button is integrated into the safety circuitry of the 80F j Control unit start up The control unit can be tested independently of the
6. gt Replace the bearing Drive unit or servo board is defective Replace the drive unit or servo board and carry out adjustment of the axis The axis controller board in the wafflepack changer is not properly plugged in Plug it in properly The axis controller board in the wafflepack changer is defective Insert a new board to test gt ATTENTION Set the addresses correctly first Intermittent electrical contact in the motor circuit Notify Siemens SMD Service department With Situation 2 Motor can be activated but is switched off again NOTE The yellow LED is on the r m s current sensor responds stiffness of running The axis runs stiffly e Noor incorrect maintenance gt maintain the axis see user s manual e The tension of the toothed belt is too high Setpoint values Lifting axis 260 10 Hz feed axis drive belt 230 5 Hz Conveyor belt long belt 85 2 Hz e Other mechanical obstacle mechanism is jamming If applicable notify Siemens SMD Service depart ment Only with no 530 Error Lifting axis fault occurs always during downward travel Ballast circuit is defec tive NOTE During downward travel the ballast circuit LED flashes if the storage unit is full 26 WPC 80F Type 3 Service Manual Edition 09 97 a li 6 Fault Description With Situation 3 Motor cannot be activated DANGER A A A During all work you should comply with the DANGER texts particu
7. 2 1 2 380 V Power Supply us eed oe eee RR EE rS peters QE bs Ep E EET 2 2 1 3 EMERGENCY STOP Interface ee ANA srN ANENA EEEE NERA 2 2 2 Machine Data sss esser owes eei E ew oe De nw Row do ne Re db d 3 3 Design and Method of Operation lt lt lt lt lt lt RR un 4 3 1 Reference POM RUM iussu sss os tepadi ki e nae A AE E DERE TR 4 don bb ba be eb 6 3 2 Modules of the Control System lisse 7 3 9 Control Unit Yi essersi sa 8 drui seems RE DER des eee a eS v a 8 3 9 1 Machine Controller 2c vetdu cele 8 DE p EE ey ede ote beeen bed es EDS 8 3 3 Z AXIS BOIA ss bem nay pu ba BY Miele RE Heke RR RE HER ewes urhe 4 8 3 8 3 5 V 15 V 24 V Power Supply Unit 9 3 93 4 Servo Bo rdS esa ce ge babe Bom eene ER Bae dor Renee E RO og z vd 9 3 3 5 Ballast CIrCUIt s es Hoe dined sadech s Be Seda d nbs d auem ma du i zem AL RUN RS 9 3 4 Mounino PIME YZ 453 sq eed bod ky p REX ee i ee eee Ee ER NS 10 A Feed AXIS srci sce ne a ee o Rabe manm LAE mde Ieee NE M dd M 13 4 1 Adjusting and Testing lt lt I i 14 4 1 1 Zero Point Correction lt hh 14 4 1 2 Adjusting the Beros and Limit Switches lt aaaea 15 4 1 3 Electrical Adjustment ee e 16 4 1 4 Setting the crash light barrier 19 5 Lif ing AXIS lt 2 din ienna sate teste elu a Ru ade Gide Raed uie rae E m le ee wee 20 5 1 Adjusting and Testing lt Hu 21 5 1 1 Z ro Point COMmectonl z 654343 Bon Wed Ee eda E ate HER QS pele Bete ee
8. Edition 09 97 a li 6 Fault Description Error 542 WPC Lifting axis servo released See Error 537 Error 543 WPC Control switched off Wafflepack changer control is switched off 24 V voltage not present in the wafflepack changer check power supply of the wafflepack changer The circuit breaker is not working properly gt Notify Siemens SMD Service department Error 544 WPC Protection at WPC open If itis possible to close the guard If you can close the guard this is all that needs to be done If itis not possible to close the guard There is a mechanical obstacle for example a component jammed between the circuit breaker and the guard Remove the obstacle Error 545 WPC Error while transporting tray The tray has been removed Replace the tray which was previously removed back in its correct position at the front of the feed axis Make sure this is the correct tray You must ensure that the tray has the correct contents The pusher of the feed axis must engage once more with the cutout in the tray The magazine of the tray must not be the wrong way round 180 positioning error as this will spoil the assignment of component and division which in turn can lead to pick up error 43 101 during operation a division registered as full is in fact empty You can obtain information on the method used for counting the divisions of the trays by clicking on the right arrow button on the symbols bar beneath this text Reset
9. RISK OF INJURY When in operation the lifting axis is isolated after reaching this position and the brake is activated The brake 20 WPC 80F Type 3 Service Manual Edition 09 97 FE ij a fil 5 Lifting Axis is operated at the axis board via a relay servo controller release brake on The servo release signal is given with an OFF delay C2 R4 in order to bridge the response time of the brake Function of the two buttons on the control servo unit Bridge the limit switches Disables the limit switches Isolate brake WARNING A A If the brake is disabled the axis will drop there may be a collision of the wafflepack tray and the pusher 5 1 Adjusting and Testing CAUTION A Remove the wafflepack tray from the storage unit before making any adjustments 5 1 1 Zero Point Correction The reference point of the lifting axis is the transfer position of the lowest wafflepack tray The lower edge of the first wafflepack tray is at the same height as the slide guideway of the feed axis CAUTION A An incorrectly set reference point can result in the wafflepack tray jamming in the feed axis or the guide rails If necessary modify the zero point correction After modifying the zero point correction you must check the minimum and maximum travel paths 21 WPC 80F Type 3 Service Manual 5 Lifting Axis RE a Edition 09 97 Recording the lifting axis zero point Select the menu item Zero point cor
10. V x S S o i 3 V24 interface x Erb RE PRR ERE Lii o So o p a x PRE BBE PREEEE o x o A3 V24 interface s BA M o o o P a z z Z o s E o A L Se 509 3 E20 5 V x S7 p S g Battery 8 U N U o S285 gt a o 5 lt o Fig 3 5 Control and servo unit 12 WPC 80F Type 3 Service Manual Edition 09 97 4 Feed Axis 4 Feed Axis The feed axis consists of a direct current servo system with belt drive The wafflepack trays are transported by the pushers from the storage unit into the pick up area of the SIPLACE 80F For this purpose two lateral grooves are provided in the wafflepack trays Fig 4 1 Feed axis viewed from above Key 1 AY B2 tray supplied 2 AY S2 limit switch 3 AY B6 transmitter for crash light barrier 4 AY B1feed axis reference point 5 AY S1 feed axis limit switch 6 AY B3 tray in magazine 7 AY B5 receiver for crash light barrier 8 Fast slow switch 9 EMERGENCY STOP switch The pusher drive consists of one belt which is driven via a connecting shaft The pusher is attached to the end of the belt The connecting shaft is driven by an endless belt running off the motor WPC 80F Type 3 Service Manual 4 Feed Axis a li Edition 09 97 The belt can be tensioned by means of slots in the motor bracket or in the rear deflection bearing The reference point bero monitors the position of the pusher when the storage unit moves lifting axis The zero pulse o
11. any work on the electrical systems switch the machine off and pull out the power supply plug You must comply with the accident prevention regulations applicable to working with the machine and also with the relevant user s manuals User s Manual SMD Placement Machine SIPLACE 80S F G This applies particularly to the travel ranges of the two axis positioning systems of the machine It is essential that you carry out the work in the same order as is specified here if injury and or damage to property is to be avoided WPC 80F Type 3 Service Manual 2 Integration into the SIPLACE Placement Machine ia a Edition 09 97 2 Integration into the SIPLACE Placement Machine The wafflepack changer expands the component feed capacity of a SIPLACE 80Fplacement machine by 28 wafflepack trays Programming the Type 3 WPC 80F is also integrated into the line computer software of a SIPLACE line The Type 3 WPC 80F is activated in the line computer software via the configuration editor Note that a des cription of using each software version is provided in the corresponding line computer user s manual The components are assigned to the wafflepack trays at location 1 of the conveyor editor Here too the software versions vary in how they are used and you should refer to the corresponding line com puter user s manual The Type 3 WPC 80F is operated via the SIPLACE 80F by means of an extended single functions menu The precise position of the Typ
12. d 21 5 1 2 Adjusting the Beros and Limit Switches sasaaa 00 cece lt lt lt 22 5 1 3 Electrical Adjustment 0 0 0 0c eee tee eee 22 6 Fault Description orire ri erneer ANENE eee dena ea eee et eee dia RR SR edhe eee ey 24 6 1 Errors with Error Messages 00 00 eee teas 24 6 1 1 General ErTOIS 5 osos ciegos wea eek ska 0 ERR Soa Xu ERG eG ea 24 6 1 2 Feed Axis Errors zsz osos eed ise nga nde dome Reg de dde d dod ds 26 6 123 Lir ng AxiS EITOIS 2 cance beet e Eee a E D DRE A PAS UETTE PSU ET 29 6 2 Menu Items in the Version 100 04 Test Program lt 33 WPC 80F Type 3 Service Manual Edition 09 97 a n 1 Introduction 1 Introduction 1 1 General Comments The layout of the control system of the wafflepack changer is for the most part identical to that of the SIPLACE 80F machines Modules which are also found in the SIPLACE 80F machine will not be described in more detail here If adjustment work is analogous to that for the SIPLACE 80F it will only be described in broad outline 1 2 Safety Instructions WARNING A A The SIPLACE 80F placement machine and the wafflepack changer are supplied with heavy current 3x 380 V main power voltage Parts of this machine will therefore be conducting dangerous voltages even when the main switch is switched off You must comply with the relevant VDE VDI VGB regulations and all applicable provisions of federal state and local safety laws Before you carry out
13. defective If necessary replace the bero and adjust the sensing distance e Input at the controller wafflepack changer control unit is defective gt Measure the voltage to check the input If necessary replace controller A18 Zero point correction of the feed axis is incorrect gt Load the WPC test program and record the zero point correction Counting error of the feed axis gt WPC test program gt Check counting error gt gt Counting errors are displayed If necessary check the tracks using the oscilloscope track missing A and B pulse edges off set Constant counting error e The drive unit incremental encoder of the feed axis is defective e The axis controller board in the wafflepack changer control unit is defective To test insert a new board gt ATTENTION Set the addresses correctly first Sporadic counting error e Check the screening of the motor cable track signals 6 2 Menu Items in the Version 100 04 Test Program NOTE To set the machine you will require the WPC 80F test program item no 00325907 04 with the corresponding user s manual item no 00190799 01 The help menu of the version 100 04 test program supports fault location or adjustment instructions for the WPC 80F in all of the following sub menus Overview Menu HELP SELECTION a Axis board g Feed axis b Machine controller h Lifting axis c Servo board i Emergency stop circuit d Ballast circuit j
14. is at the stack bero activated the lifting axis will start first if the feed axis is outside the stack it will carry out its reference run first The actual reference run of an individual servo axis takes this form Travel in the negative direction until the reference point switch or the reference point bero is activated Travel inthe positive direction until the first zero pulse rotary encoder is found Load the current zero point correction into the position counter Travel to the reference point equal to zero on the position counter The procedure with the reference point switch is required due to the fact that the zero pulses ofthe incremental shaft encoder repeat with every revolution and thus appear repeatedly within the possible travel range Once both reference points have been found a search will also be made for the position of the tray in the SI PLACE 80F Here the first tray will be moved to the position for transfer to the SIPLACE 80F The SIPACE 80F then looks for the fiducial which is to be found on the right hand pusher The fiducial position found is used later in determining the pick up position of the components Of course this fiducial must be included in the line com puter s MVS file WPC 80F Type 3 Service Manual Edition 09 97 3 Design and Method of Operation 3 2 Modules of the Control System
15. of between several hours to several days Sensors The reference point bero and the limit switches are wired into the machine controller and into the axis board 3 3 2 Axis Board The axis controller of the Type 3 WPC 80F has the same design as the axis boards of the SIPLACE machines The Type 3 WPC 80F will only function with EPROMs of version 3 4 or later WPC 80F Type 3 Service Manual Edition 09 97 a a 3 Design and Method of Operation 3 3 3 5 V 15 V 24 V Power Supply Unit The voltages are routed to the modules in the control unit via the SMP bus on the rear panel of the control unit The following modules require 5 V direct current Incremental shaft encoders Machine controllers Axis board The following modules require 15 V direct current Machine controller RS232 Axis board Servo cards The voltages can be checked at the back of the control unit see Fig 3 2 3 3 4 Servo Boards The servo boards for the lifting and feed axes have the same design as the x axis servo of the SIPLACE 80F differing only in the dimensioning of the PI controller 3 3 5 Ballast Circuit The task of the ballast circuit is to compensate for the energy created during the downward movement of the lifting axis At approximately 140 V it switches ballast resistors into the power supply to the servo board WPC 80F Type 3 Service Manual 3 Design and Method of Operation a ali Edition 09 97 3 4 Mounting Plate Y2
16. the error and continue with the sequence Situation 1 The tray moves up as far as the bero The sensing distance of the bero Tray in the storage unit magazine Tray furnished is incorrect The corresponding bero or bero cable is defective If necessary replace the bero and adjust Situation 2 The tray does not move up as far as the bero The transfer position in the MA data is incorrect gt Load the WPC test program and record the transfer position Thecrash light barrier is not set correctly Thecrash light barrier or controller A18 in the wafflepack changer control unit is defective Error 546 WPC Error in saved set up Check the set up of the wafflepack changer in the station computer Where applicable continue with the sequence or if you cannot detect an error gt Notify Siemens SMD Service department Error 547 WPC One tray of saved set up missing Situation 1 All trays are present Load WPC test program gt Check inputs e The bero Tray in the storage unit magazine is not set correctly e The bero or bero cable is defective If necessary replace the bero and adjust the sensing distance 31 WPC 80F Type 3 Service Manual 6 Fault Description FE ij a fil Edition 09 97 e Input at the controller wafflepack changer control unit is defective gt Measure the voltage to check the input If necessary replace controller A18 Situation 2 Atray inthe saved set up is missing Insert the correct
17. the lifting axis The electrical adjustment of the axis is incorrect or the servo board is defective Counting error with the lifting axis WPC test program Check counting error gt Counting errors will be displayed If necessary check the tracks using the oscilloscope track missing A and B pulse edges off set Constant counting error e The drive unit incremental encoder of the lifting axis is defective e The axis controller board in the wafflepack changer control unit is defective To test insert a new board ATTENTION Set the addresses correctly on the board first Sporadic counting error Check the screening of the motor cable track signals No counting error but the zero point of the axis has shifted e The pitch of the belt has been jumped Check the tension of the toothed belt Feed axis incremental enco der is defective toothed wheel is loose If necessary replace the drive unit and carry out electrical adjust ment of the axis NOTE The corresponding zero point correction will have to be readjusted after replacement of the motor drive unit or the toothed belt The machine data of the lifting axis are incorrect The zero point correction is not correct Record with WPC test program The limit switch has not been set correctly gt WPC test program Menu item Limit switch Other electrical causes gt Notify Siemens SMD Service department 30 WPC 80F Type 3 Service Manual
18. wafflepack changer data from the current MA data printout at the machine If not current MA data are available notify the service department The following data should be entered e Zero point correction of the feed axis and lifting axis e Minimum and maximum positions of the feed and lifting axes e Transfer position for the feed axis Other defects controller A18 gt Notify the SMD Service department 25 WPC 80F Type 3 Service Manual 6 Fault Description RE a fifi Edition 09 97 6 1 2 Feed Axis Errors Error 534 WPC Fault in feed axis servo or axis card Time out axis is not reaching the setpoint position DANGER AAA During all work you should comply with the DANGER texts particularly those concerning VDE 0113 gt gt Starting screen no 4 Further information on the error in question is provided in the WPC test program Possible causes depending on error situations 1 to 3 With Situation 1 The motor can be activated by means of a reference point run The axis is stiff gt Carry out maintenance see user s manual The axis adjustment has been carried out incorrectly or not at all gt Carry out adjustment The tension of the toothed belt is incorrect gt Check with the belt tension measurement device gt Nominal values Lifting axis 260 10 Hz feed axis drive belt 230 5 Hz conveyor belt long belt 85 2 Hz The mechanism is jamming for example the bearing is defective
19. when you change the servo board Tachometer adjustment Controller optimization via P gain 1mm along the feed axis corresponds to 53 33 increments Adjustment values Adjustment parameters Setting values r m s fixed 4 3 A Belt tension of motor drive belt 230 5 Hz Belt tension of conveyor belt long belt 85 2 Hz at alength of 360 mm see Fig 4 2 Speed V 2 track signals period 100 us 2 us Positioning time 0 30000 dig V 10 approx 1150 ms guideline value Tab 4 1 OO8S a 560 Gauge block 12mm Be Gauge block 12mm Buffer Belt for the feeding axis THK guide Motor pinion Driving belt Fig 4 2 Adjusting the belt tension WPC 80F Type 3 Service Manual 4 Feed Axis a ili Edition 09 97 Zero adjustment of the axis controller NOTE With this zero adjustment a reference run should not be carried out for the axes The machine must have been switched on at least 20 minutes before the adjustment work begins NOTE This zero adjustment is required for both axes and is carried out in the same manner for both axes Zero adju stment must be carried out before all other adjustment work on the axes e Connect the axis tester to the interface front panel of the axis board e Connect a digital multimeter to the sockets for the nominal value at the back of the axis tester e Switch the ax
20. 2 is added to the machine data Connect the axis testing box Set the axis selector switch to axis 0 Connect track signals A and B on the axis testing box to the oscilloscope PLEASE NOTE The preset guideline value of 1200 ms corresponds to a period of 95 2us Setting the P gain on the servo Set the P gain so that no overshooting or humming occurs at the axis 23 WPC 80F Type 3 Service Manual 6 Fault Description a n Edition 09 97 6 Fault Description The first stage in fault correction is to refer to the fault descriptions and possible causes listed below The possible reasons are issued in an order which corresponds to the best order to attack the problem on the basis of the amount of work involved and the likelihood of the fault For more detailed information on fault locating and correction please refer to the corresponding section of the service manual DANGER A A A You should comply with all safety instructions in the user s manual while carrying out fault correction work 6 1 Errors with Error Messages These errors are displayed on the SIPLACE 80F station and are split into General errors Feed axis errors and Lifting axis errors 6 1 1 General Errors Error 162 WPC must be moved from the refill position WPC is in the refill position Finish refill position in the window wafflepack changer Error 475 Communication with WPC faulty Error already occurred during reference run check plug connect
21. 36 WPC Axis error of feed or lifting axis NOTE Load WPC test program Check axis errors Using the Feed axis function gt check Status whether Position outside travel range applies The MA data of the wafflepack changer are not correct gt Correct on the basis of the current printout or determine data with the WPC test program following fault correction work e Transfer position e Maximum and minimum travel range Axis error with the feed axis during reference point run Tray in the transfer position bero is defective Other errors gt Notify Siemens SMD Service department 6 1 3 Lifting Axis Errors Error 539 WPC Fault in lifting axis servo or axis board See Error 534 The axis board or servo of the lifting axis is defective Replace the axis board or servo board Error 540 WPC Lifting axis at limit switch top or bottom Possible causes Situation t The limit switch is not being operated mechanically the signal remains 0 actuated The limit switch is defective or there is an electrical interruption gt If necessary replace the limit switch Intermittent electrical contact in the signal line of the limit switch gt If necessary notify the SMD Service department Situation 2 The limit switch is not being operated mechanically the signal 1 not actuated NOTE The following causes may be present if during operation the signal state of the bero or of the limit switch was bri
22. Control unit start up e Power supply unit k Machine start up f Display Tab 6 1 33 WPC 80F Type 3 Service Manual 6 Fault Description a li Edition 09 97 a Axis board The wafflepack changer will only function with axis EPROMs from version 3 4 onwards with sine mode Settings of the axis numbers Feed axis the top axis controller axis number 0 Lifting axis the middle axis controller axis number 1 The bottom axis controller is not used but the axis number must be set Axis number 2 Coding of the switches Axis number Switch 0 1 2 3 0 off off off off 1 on off off off 2 off on off off The axis board can therefore only be addressed by the machine controller if the wrap connections at the SMP bus are correct Each axis has its own interrupt line a wrap wire on the SMP bus b Machine controller The program of the machine controller is held in the EPROM You can check the EPROM version in the menu item Version The machine data and the set up are held in RAM memory If the machine is switched off the data are saved by means of a back up battery The battery is located behind the front panel The machine controller contains a gold capacitor 33 mF which can hold the machine data even in the absence of an external back up battery in other words even when the board has been removed The battery can retain the data for a period of between several hours to several days c Se
23. ED on the servo board will be on When the tacho circuit is closed the green LED will be on The tacho circuit can be closed with a dummy plug k Machine start up The SIPLACE wafflepack changer cannot be operated as an independent machine It only operates in con junction with a SIPLACE 80F The settings machine data are held in the RAM memory of the machine controller If the machine data are changed you should make a new print out 36 Switch off the miniature circuit breakers Test the incoming voltage 3 x 380 V Test the power supply 220 V to the control unit Check the voltages at the transformer Test the servo voltage 90 100 V at plug X7 at the control unit Test the emergency stop circuit and the guard Check to see whether the power supply to the servo and brake is being switched out Test the inputs Test the check back signal of the emergency stop button light on the start up control cabinet Con nect the feed axis X3 and X6 Check to see whether the scale is counting correctly from 0 to 35000 in the Status menu with updating The axis must be initialized first Reference point run with control switched off Perform a reference run with the control switched on For the first run an identification module should be used with adjustable current at the servo the current should be set low Continuous operation of about 30 minutes and adjustment of the tacho Set the offset at the servo and the ampli
24. SIEMENS SIPLACE WPC 80F type 3 Service Manual 09 1997 Edition The reproduction transmission or use of this document or its We have checked the contents of the printed document to ensure that contents is not permitted without written authority itis in agreement with the hardware and software described therein Offenders will be liable for damages All rights including rights However since discrepancies cannot be ruled out we cannot assume created by patent grant or registration of a utility model or design responsibility for complete agreement are reserved The information given in this printed document is however regularly reviewed and necessary corrections included in subsequent editions We would appreciate any suggestions for improvements SIEMENS AG 1997 All rights reserved Subject to change without prior notice Order No XXXXXXXX XX Siemens Aktiengesellschaft To be ordered from SIEMENS L amp A Electronic Assembly Systems Rupert Mayer Strasse 44 D 81359 Muenchen Printed in the Federal Republic of Germany Service Manual SIPLACE 80S 20 F4 Edition 03 97 Content Page Antrod ucHon 5 3 em 1 1 1 General Comments oces aa nise nereste eee hh 1 1 2 Safety Instructions 0 0 0 0 a eae ehh 1 2 Integration into the SIPLACE Placement Machine eeeeeee BIB 2 2 1 Interfaces with the SIPLACE 80F 2 tee eae 2 2 1 1 RS 232 V24 Interface cc 6 eee niet eme bee dde RR Ree x 2
25. SS OHSS Fig 3 2 Overall view of the Type 3 WPC 80F Key 1 Front view 2 Viewed from above 3 Viewed from the back voltages from the power supply unit can be measured WPC 80F Type 3 Service Manual 3 Design and Method of Operation a ali Edition 09 97 3 3 Control Unit Y1 The following modules are accommodated in the control unit Machine controller with RS232 interface Axis controller for lifting axis and feed axis 5V 15 V 24 V power supply Lifting axis brake controller on the axis rear panel Lifting axis ballast circuit Servo boards for feed and lifting axes Reactance coils for the motor feed lines L1 L2 L3 L4 3 3 1 Machine Controller Duties Communication with the SIPLACE 80F station computer Data exchange with the axis controller Memory storage for machine data RAM with back up battery Inputs for sensors The program for the machine controller is held in EPROM You can check the EPROM version under the menu item Version The machine data and the set up are held in RAM memory If the machine is switched off the data are saved by means of a back up battery The battery is located behind the front panel The machine controller contains a gold capacitor 83 mF which can hold the machine data even in the absence of an external back up battery in other words even when the board has been disconnected The battery can retain the data for a period
26. anger is defective gt Instal a new board ATTENTION Set the addresses correctly first see the wafflepack changer service manual Error 538 WPC Error in jaws position NOTE When the storage unit is moving the position of the jaws is checked Load the WPC test program gt Check inputs e The reference point bero or the bero cable is defective If necessary replace the bero and adjust the sen sing distance e Input at the controller wafflepack changer control unit is defective Measure the voltage to check the input If necessary replace controller A18 The reference point bero of the feed axis is not set correctly WPC test program Menu item Feed axis reference bero gt Check the switching position adjust if necessary 28 WPC 80F Type 3 Service Manual Edition 09 97 a ai 6 Fault Description The zero point correction is incorrect record with WPC test program Counting error of the feed axis WPC test program gt Check feed axis tracks gt Counting errors will be displayed If necessary check the tracks using the oscilloscope track missing A and B pulse edges offset e Constant counting error The drive unit incremental encoder of the feed axis is defective The axis controller board in the wafflepack changer is defective Insert a new board to test ATTENTION Set the addresses correctly first e Sporadic counting error Check the screening of the motor cable track signals Error 5
27. ary check the tracks using the oscilloscope track missing A and B pulse edges offset e Constant counting error The drive unit incremental encoder of the feed axis is defective The axis controller board in the wafflepack changer control unit is defective To test insert a new board gt ATTENTION Set the addresses correctly on the board first e Sporadic counting error Check the screening of the motor cable track signals No counting error but the zero point of the axis has shifted e The pitch of the belt has been jumped Check the tension of the toothed belt e Feed axis of incremental encoder is defective toothed wheel is loose If necessary replace the drive unit and carry out electrical adjustment of the axis NOTE The corresponding zero point correction will have to be reset after replacement of the motor drive unit or too thed belt The machine data of the feed axis are incorrect The zero point correction is not correct Record with WPC test program The front limit switch transfer end is not set correctly WPC test program gt Limit switch The electrical adjustment of the axis is incorrect or the servo board is defective Other electrical causes gt Notify Siemens SMD Service department Error 537 WPC Feed axis servo released The axis has been isolated at the axis controller board in the wafflepack changer gt Switch the axis on The axis controller board in the wafflepack ch
28. ce run with the lifting axis To allow you to move the lifting axis away from the lower limit switch the lifting axis limit switch loop can be bridged by pressing the button Lifting axis limit switch 5 1 3 Electrical Adjustment Tools and auxiliary materials Multimeter Oscilloscope Size 0 screwdriver SIPLACE axis tester WPC 80F test program 22 WPC 80F Type 3 Service Manual Edition 09 97 ia a 5 Lifting Axis Electrical adjustments to the axis board and servo are carried out analogously to those for the x axis of the SIPLACE 80F The current is fixed cannot be changed the current monitor checks the correct P gain 1 mm travel corresponds to 520 increments Adjustment values Adjustment parameters Setting values m s fixed 7A Belt tension 260 10 Hz Speed track signals period 95 us 2 us Positioning time 0 200000 digits V 10 approx 1200 ms guideline value Tab 5 1 Adjustment work Zero adjustment of the axis controller do this only when you change the board Servo amplifier offset do this only when you change the servo board Tachometer adjustment Controller optimization via P gain Zero adjustment of the axis controller See feed axis zero adjustment Adjusting the speed at the servo Adjust the speed with the help of the oscilloscope under the menu item Set tachometer in a way that the period amounts 95 us 2 us if a speed of v
29. controller Type 3 WPC 80F Machine Data The items which may have to be changed during adjustment work are shown against a gray background Feed axis Lifting axis Axis number 0 1 Zero point correction 3558 Maximum position 239523 Minimum position 778 Speed correction 10 Force correction 99 Type of force 0 Reference point speed 6 Minimum speed 3 Minimum section acceleration Rounding constant Rounding path 1 Rounding path 2 Rounding constant 1 Rounding constant 2 Speed factor Reference point run Starting speed Maximum deviation P factor factor Mode 1 Mode 2 Mode 3 Positioning force Standstill time Reduced force Tab 2 1 WPC 80F Type 3 Service Manual 3 Design and Method of Operation Edition 09 97 Positions of the feed axis Transfer position 38639 position 52 Transfer position gap 130 Tab 2 2 Positions of lifting axis Refill position 3000 conveyor area 250 Conveyor position 238680 Tab 2 3 These machine data can be modified with the aid of version V100 06 or later of the WPCTEST testing program item number 00710199 06 These are the parameters Zero point correction for the lifting axis Zero point correction of the feed axis Minimum and maximum position of the lifting axis Min
30. djust the sensing distance e Input at the controller wafflepack changer control unit is defective gt Measure the voltage to check the input If necessary replace controller A18 Error 550 WPC Take over position already occupied Load WPC test program gt Check inputs e The bero Tray furnished is defective signal remains 1 If necessary replace the bero and adjust the sensing distance e Input at the controller wafflepack changer control unit is defective gt Measure the voltage to check the input If necessary replace controller A18 Error 551 WPC Tray in incorrect position or protection not closed correctly Load WPC test program Check inputs e The bero Anti rotation lock has not been set correctly e The bero or bero cable is defective If necessary replace the bero and adjust the sensing distance e Input at the controller wafflepack changer control unit is defective gt Measure the voltage to check the input If necessary replace controller A18 Error 552 WPC The feed axis has touched protection If the guard was opened during changing Close the guard If the guard was not opened during changing The tray has been removed from the furnishing position and then replaced incorrectly Or Load WPC test program gt Check inputs 32 WPC 80F Type 3 Service Manual Edition 09 97 ia a fifi 6 Fault Description e The bero Anti rotation lock has not been set correctly e The bero or bero cable is
31. e 3 WPC 80F in the SIPLACE 80F is determined with the vision system during the reference point run The fiducial is located on the right hand pusher of the feed axis 2 1 Interfaces with the SIPLACE 80F 2 1 1 RS 232 V24 Interface All commands from the SIPLACE line computer are output via this interface Example reference point run and set up data input 2 1 2 380 V Power Supply The Type 3 WPC 80F is supplied with 380 V via cable YAW1 from the SIPLACE 80F 2 1 3 EMERGENCY STOP Interface The Type 3 WPC 80F is also integrated into the emergency stop circuit of the SIPLACE 80F A check back signal is returned from this emergency stop circuit in the form of an alternating voltage of 24 V which switches on the control unit in the Type 3 WPC 80F The contactors switch off the servo voltage 90 100 V In addition the power supply to the brake is switched off after a brief delay The break contact of the emergency stop button is integrated into the safety circuitry of the SIPLACE 80F it is hard wired to an input If the EMERGENCY STOP loop in a machine is interrupted by the EMERGENCY STOP button the control System for the entire station will drop out If the guard is opened only the control voltage of the Type 3 WPC 80F will switch out WPC 80F Type 3 Service Manual Edition 09 97 2 2 Machine Data 2 Integration into the SIPLACE Placement Machine The machine data are kept in a RAM facility with back up battery in the machine
32. e ee OS gt B S wm E T E O o o x x o x 4 EL 55 93 98 TESS ui Poot m lt 22 E O O O9 E E 0 DAAAH 0 ES CCOUCPPP s c Bl d te A A B i E F F 1 U e o z a Plx oje joie ESEJE ESEJE JEJEJEJEJEJE a N FERSRERSRSRERSRERSRERENE z bal basi bal Cad Cad Lad Cad Cad Cad Pal bal ba x Oo x o x t j m k d IM AV ZEM VA n o ala el he 5 oje TD M va LEM VA zz v o o gt u k xx eue 9M vA ZZ W s Ero 15 r5 olo 4 Z Zen gt gt pz SEM SSZA 5 o STS xx o gg i o PM VA c v M SSZA alm c E 5 x EEM SSZA NO S i is EE EI SM vA M A8 g o 5 x sl 2 g x x x E E gt gt m a a 5 ZX So IX 5 8 E 8 5 0 0st 8 E as 2 eX 88 W gt Fig 3 4 Overall circuit diagram Overall circuit diagram With some machines the lifting axis motor was connected directly to the control servo unit With this type of machines you must also fit cable Y255 which is also supplied when you replace the motor of the lifting axis Plug X8 plugs directly into the motor 11 WPC 80F Type 3 Service Manual 3 Design and Method of Operation Edition 09 97
33. efly 0 actuated and the machine then is once again 1 not actuated normal state 29 WPC 80F Type 3 Service Manual 6 Fault Description a n Edition 09 97 The corresponding axis controller board in the wafflepack changer is defective gt Insert a new board to test ATTENTION Set the addresses correctly first Intermittent electrical contact in connection with the limit switch gt Notify the service engineer of Siemens SMD Service department The axis overshoots The electrical adjustment of the axis on the servo amplifier board is incorrect Situation 3 The lifting axis is at the limit switch top or bottom signal 0 actuated Move the lifting axis away from the limit switch top or bottom Call the WPC test program Press the Release limit switch in the control unit and keep it pressed drown Select Make reference run with wafflepack changer in the WPC test program DANGER AAAS To move away from the limit switch you can also use the Release brake button An increased risk of accident is to be encountered here You must NOT bridge or tamper with the circuit breaker All wafflepack trays must be removed Close the guard of the wafflepack changer ATTENTION The lifting axis will drop If the fault reoccurs the causes listed below may be responsible for this The lifting axis contacts the top position limit switch during its reference run in addition check the refe rence point bero of
34. f the incremental encoder appears repeatedly in the travel range of the axis For this reason the reference switch is approached first during the reference point run after which the first zero pulse of the incre mental encoder is sought Reference point run with reference point switch Transfer position The transfer position is the position of the feed axis of the wafflepack tray when it has been brought up to the SIPLACE 80F The transfer position is held in the machine data in the WPC 80F A bero is fitted for the purpose of monitoring the wafflepack tray in the transfer position In the transfer position the wafflepack tray must press lightly against the spring plate stops You can reduce the acceleration of the feed axis by pressing the slow key This is necessary to prevent small components in the wafflepack tray from slipping When the wafflepack tray moves back to the storage unit the feed axis first positions itself at 52 digits and then at 0 digits This ensures that when the lifting axis moves the pushers of the feed axis will be located pre cisely in the center of the groove in the wafflepack tray 4 1 Adjusting and Testing CAUTION ZA Do not carry out adjustment work with the wafflepack tray in the storage unit NOTE You will need the WPC 80F test program for adjustment of the machine item no 00710199 06 as well as the corresponding user s manual item no 00190799 01 4 1 1 Zero Point Correction The re
35. fective board 1710460 Y0212 gt This can only be corrected by the service engineer or Siemens SMD Service department Error 535 WPC Feed axis at limit switch If the feed axis is at the limit switch Open the guard again slide the axis away from the limit switch and reset the fault If the feed axis is not at the limit switch Possible causes Situation 1 Reference point run The feed axis travels to the limit switch operator side The machine data of the feed axis are incorrect The zero point correction is incorrect Record with WPC test program The limit switch rear is not set correctly WPC test program Limit switch WPC test program Check inputs 27 WPC 80F Type 3 Service Manual 6 Fault Description a ili Edition 09 97 e The reference point bero has not been adjusted correctly can be activated WPC test program gt Menu item Feed axis reference bero gt Set switching position e The reference point bero or the bero cable is defective If necessary replace the bero and adjust The axis board is defective Replace the board ATTENTION Set the addresses correctly first The electrical adjustment of the axis is incorrect or the servo board is defective Situation 2 During operation sequence The front or rear limit switch is mechanically operated Counting error in the feed axis WPC test program Check feed axis tracks gt Counting error is dis played gt If necess
36. ference point is determined with the aid of zero point correction At the reference point the pusher will be located precisely in the center of the groove of the wafflepack tray in the storage unit Only in this position is the lifting axis permitted to move WPC 80F Type 3 Service Manual Edition 09 97 a n 4 Feed Axis WARNING A A The lifting axis must be located on a track position in order to be able to record the feed axis zero point correc tion Setting the zero offset Reference the feed axis with the magazine plate inserted Disable the axis Manually move the axis with the magazine plate until it is 0 2 mm away from the front vertical guide rails Move the pusher into the middle of the recess in the magazine plate Accept the zero offset value CAUTION A An incorrectly set reference point may result in a crash with the magazine carriers in the store Once you have modified the zero offset you must also make the following changes 1 Check the reference BERO The reference BERO must be active in the reference point When moving back the reference point BERO must not switch until the vertical axis can move with the frame 2 Correct the transfer position position of the frame supplied 3 Check the rear limit switch maximum travel 4 Check the front limit switch minimum travel Check the maximum and minimum travel The minimum travel must be at least 52 digits The response of the reference p
37. fier Start up the lifting axis analogously to the feed axis X4 and X8 The lifting axis scale covers 0 200000 digits Set the zero point correction for the lifting axis Check the position of the reference bero adjust the limit switches Move the lifting axis with a 50 kg load Check servo on off at the lifting axis The lifting axis must not drop upon being switched off or jolt WPC 80F Type 3 Service Manual Edition 09 97 a li 6 Fault Description upon being switched on Set the zero point correction of the feed axis Adjust the reference bero and the limit switches Determine the transfer position of the feed axis Test the tacho sensor the tacho monitoring unit must respond if the motor plug has been pulled out Make a reference point run with both axes Approach the fill position insert tray change tray move out Continuous operation with 28 trays 37 WPC 80F Type 3 Service Manual 6 Fault Description Edition 09 97 38 SIEMENS AG 1997 All rights reserved Order no XXXXXXXX XX To be ordered from SIEMENS L8A Electronic Assembly Systems Rupert Mayer Strasse 44 D 81359 Muenchen Printed in the Federal Republic of Germany Subject to change without prior notice Siemens Aktiengesellschaft
38. gh height to 15 mm If a tray is raised by the IC head the light barrier will respond when the tray is brought in and the feed axis will be stop ped WPC 80F Type 3 Service Manual 5 Lifting Axis a ali Edition 09 97 5 Lifting Axis Schmersal S2 Feed axis n j FE BY S1 AY BS L State W a Lift axis bot pos BY B Guide rail O d BY B2 CL ev RS Buffer Belt drive Fig 5 1 Lifting axis side view The drive unit of the lifting axis consists of a direct current servo system with step down spindle drive The storage unit runs on two prism guides When the wafflepack tray is moved into or out of the storage unit the lifting axis is lowered by 0 4 mm and then raised again to make movement in either direction easier The lifting axis is equipped with a brake which is mounted on the motor shaft The brake is activated when the machine is switched off or the axis is isolated DANGER AAA Before you do any work on the lifting axis motor for example to change the belt or the motor you must first move the lifting axis down to its lower position as otherwise the brake will have no effect and the lifting axis will drop immediately
39. imum and maximum position of the feed axis Transfer position of the feed axis The remaining machine data are protected by password since they contain parameters which have been defi ned by SIEMENS 3 Design and Method of Operation When installed in the SIPLACE machine the wafflepack changer also referred to as the WPC 80F expands the component supplying capacity of an individual SIPLACE machine by 28 wafflepack trays Due to its special design the changeover times for the individual wafflepacks wafflepack trays are very short In practice changeover times of less than 3 sec are possible A fast slow switch can be used to reduce the acceleration on the horizontal axis when especially light or sensitive components are to be handled WPC 80F Type 3 Service Manual Edition 09 97 a al 3 Design and Method of Operation Power supply 5V 15V 15V 24V RS 232 SIPLACE gt gt Machine controller A18 80F SMP bus EMERGENCY STOP Axis board 3 circuit SIPLACE 80F 8 YYY Y EMERGENCY Sensors STOP interface Feed axis Lifting axis Fig 3 1 Function groups of the WPC 80F or F3 control system The set up for the Type 3 WPC 80F is also included in the line computer software of a SIPLACE line The hardware of the machine itself consists of a tray storage unit with a capacity of 28 channels Depending on the si
40. ions Error during placement run The interface cable 1710 470 D0515 W1 in SIPLACE 1710 460 YO242 W3 in the WPC is not connected properly or the cable or plug is defective gt Make sure the plug is connected properly gt Check cable for con tinuity for plug assignments see circuit diagrams folder replace cable if necessary The power supply cable is not connected correctly the cable or plug is defective check the voltages in the wafflepack changer 3 x 380 V or 3 x 220 V in the case of the US version The communication module in the SIPLACE 80F4 control unit gt The plug is not properly plugged in or the module is defective The WPC A18 machine controller is defective replace the module The power supply unit in the wafflepack changer control unit is defective gt Check the voltages in the con trol unit 5 V 15 V 15 V Other electrical fault the wafflepack changer control unit is defective bus board or wiring gt Notify Siemens SMD Service department 24 WPC 80F Type 3 Service Manual Edition 09 97 RE a fifi 6 Fault Description Error 522 Syntax error in command to WPC Error already occurred during reference run interface cable mixed up or restart run Error during placement run Cable break in the wafflepack changer interface cable gt Check the cable for continuity and replace if neces sary for plug assignments see the circuit diagrams folder Check the EPROM version of
41. is selector switch to the axis which is to be tested e Set the setpoint potentiometer on the front of the axis board to 0 volts e Set the power potentiometer on the front of the axis board to 0 volts Adjusting the offset at the servo e Allow the machine to warm up at least 20 minutes after switching on before making any adjustments e Set KI in the machine data to 0 and the position deviation to 100 before adjusting the offset of both axes You will need to enter your password e After positioning to a specific position see Table 4 1 adjust the offset at standstill to setpoint position 1 digit NOTE If the axes are modified carry out a reference point run Adjusting the speed at the servo With the help of the oscilloscope under the menu item Set tachometer adjust the speed in a way that when a speed of V 2 is added to the machine data the period amounts to 100 us 2 us Connect the axis testing box Set the axis selector switch to axis 0 Connect track signals A and B on the axis testing box to the oscilloscope PLEASE NOTE The preset guideline value of 1150 ms corresponds to a period of 100 2us Setting the P gain on the servo Set the P gain so that no overshooting or humming occurs at the axis 18 WPC 80F Type 3 Service Manual Edition 09 97 RE a 4 Feed Axis 4 1 4 Setting the crash light barrier There is a crash light barrier in the middle of the feed axis Set the pass throu
42. larly those concerning VDE 0113 gt gt Star ting screen no 4 Poor connection between the servo amplifier board and the motor The drive motor is defective Check the LED on the servo amplifier board If the red LED is on fault axis is switched off Overvoltage servo is defective the tacho line is interrupted motor short circuit to ground The drive unit or servo board is defective Replace the drive unit or servo board and carry out electrical adjustment of the axis The axis controller board in the wafflepack changer has not been inserted properly insert it firmly The axis controller board in the wafflepack changer is defective Insert a new board to test gt ATTENTION Set the addresses correctly first The power supply to the drive unit has been interrupted Check the servo voltage 90 V to 100 V at plug X7 at the control unit The servo board is defective gt Replace the board and carry out adjustment of the axis DANGER AAA With the following work serious physical injury may be encountered You must NOT bridge the circuit breaker All wafflepack trays must have been removed Close the guard of the wafflepack changer Only with Error 539 The brake will not release NOTE You can check the functioning of the brake by pressing the Release brake button in the wafflepack changer control unit If the brake is defective there is an electrical interruption cable plug or the controller is de
43. machine You should take the following steps in order to keep damage resulting from wiring faults to the minimum Remove all boards Check the 220 V connection at the power supply unit Check the 5 V voltage at the distributor A8 Load the 5 V voltage with 2 A with a resistance of approximately 2 5 ohms and a rating of 10 W Measure the voltages 5 V 15 V 15 V distributor A8 and 24 V plug X9 Measure the voltages 5 V 15 V 15 V at the SMP bus 35 WPC 80F Type 3 Service Manual 6 Fault Description a n Edition 09 97 Plug in the machine controller and remove the 2 A load on the 5 V Test the machine controller with the aid of the test program menu Version You will need a connec ting cable between the serial port of the PC and the machine controller Initialize the machine data in the machine controller Test the back up battery 2 3 days after copying in the machine data initialization you will need to check whether the machine data are still present Set the axis board axis number Insert and then test the axis board using the test program menu item Axis status Set the offset for the speed and power of the two axes Test the 15 V 15 V power supply to the servo boards Test the voltage of the servo boards and of the ballast circuit This voltage is fed in from outside plug X7 and is 90 100 V Test the tacho connection in the control unit When the tacho circuit is open the red L
44. oint BERO and the limit switch can be set by moving the actuator on the magazine carriage ATTENTION The value of the minimum travel must be a negative value Once you have set the zero offset the value may be positive in which case an Error in the feed axis message will appear Hint Enter a negative value of 100 digits in the machine data and then continue 4 1 2 Adjusting the Beros and Limit Switches Adjusting the feed axis reference point bero Ay B1 In the Feed axis column select the menu item Adjust reference point bero and with the aid of the test pro gram adjust the actuating element of the reference point bero If the operating position is too small 0 5 digits it is possible that the reference bero will not be actuated when the lifting axis moves The lifting axis will be halted and error message 538 output WPC 80F Type 3 Service Manual 4 Feed Axis ia a Edition 09 97 538 Fault in the position of the jaws pusher If the operating position of the reference bero is too large gt 20 digits a crash could occur during the reference run The bero should operate within the 10 15 digits range Recording the transfer position Setting on the WPC 80F with 2 pushers Select the Transfer position option from the Feed axis column Approach the transfer position with a maga zine plate The plate should press lightly against both stop springs The program will automatically record the value
45. rection in the Lifting axis column Now press F4 to go to Inch lifting axis Inch the lifting axis until the guide rails of the feed axis and the footprint area of the first storage unit po sition are parallel Use a straight edge to check this Now quit Inch lifting axis and press F3 to accept this value If the zero point correction value is greater than 4000 it can only be added manually to the machine data After that make a reference run 5 1 2 Adjusting the Beros and Limit Switches Adjusting the reference point bero Select the menu item Set reference point in the Lifting axis column and use the program to adjust the refe rence point BY B1 This adjustment is needed to prevent the zero pulse of the incremental encoder from coinciding with the swit ching point of the bero this can lead to different reference points Adjusting the lifting axis limit switches BY S2 and BY S1 Select the menu item Limit switch X in the Lifting axis column and use the program to adjust the limit switch in question NOTE If the error message Limit switch loop open is displayed the limit switch is responding too early in other words the limit switch projects into the travel range of the axis in question In the case of the error message Axis on the buffer the limit switch is responding too late in other words the limit switch is located too far outside the travel range of the axis in question Now make a referen
46. rvo boards The servo boards model is TRS 120 10 Each axis has its own identification module In the identification module the current r m s current and peak current is defined by fixed resistors The offset tacho and amplification are set in the identification module The identification module also includes a solder bridge for setting with or without minimum time when switching back on the wafflepack changer will only function without this minimum time when switching back on The identification modules are preset to both motors The servo boards in the wafflepack changer are identical to those in the x axis of the SIPLACE 80S F G d Ballast circuit When the lifting axis is travelling downwards the motor functions as a generator especially when the storage unit is loaded It can actually generate an output of approximately 100 watts The consequence of this is that the voltage at the servo increases it is normally 90 100 V The job of the ballast circuit is to consume the energy thus created At around 140 V it switches ballast resistors into the power supply to the servo board When the ballast resistors have been switched in the LED in the 34 WPC 80F Type 3 Service Manual Edition 09 97 a ali 6 Fault Description ballast circuit comes on e Power supply unit The power supply unit supplies 5 V 15 V 15 V and 24 V For the power supply unit to function properly it needs a minimum load of 2 A on the 5 V voltage
47. the wafflepack changer machine controller must be later than 1 2 Other causes gt Notify Siemens SMD Service department Error 523 Command not executed WPC not referenced Power failure In the main view of the user interface select Conveyors gt WPC gt WPC reference run Error 525 WPC no tray available The tray has not reached the delivery position In the main view of the user interface select Conveyors gt WPC gt Furnish level The tray has reached the delivery position Fault location and correction will be carried out by the line engineer or the service engineer Possible causes Load the WPC test program and Check inputs The bero or bero cable is defective If necessary replace the bero and adjust the sensing distance Input on controller wafflepack changer control unit is defective gt Measure the voltage to check the input if necessary replace Controller A18 Error 526 WPC Sent set up contains errors If the fault cannot be corrected by switching the machine off and back on again notify Siemens SMD Service department Error 533 Data loss in WPC battery defective The back up battery in the wafflepack changer control unit is flat or defective gt Replace the battery The battery is located in the wafflepack changer control unit behind the front panel drawing 1710 460 Y0201 000 01 Z gt Load the WPC test program initialize the wafflepack changer and take over input manu ally the
48. tray in the correct position into the correct level of the storage unit You must make sure the occupancy of the wafflepack changer is as configured The cutout in the tray must be on the left The magazine of the tray must not be the wrong way round 180 positioning error as this will spoil the assignment of component and division which in turn can lead to pick up error 43 101during operation a division registered as full is in fact empty You can obtain information on the method used for counting the divisions of the magazine by clicking on the right arrow button on the symbols bar beneath this text Reset the error and continue with the sequence Error 548 WPC Returning tray level occupied Load WPC test program Check inputs e The bero Tray in the storage unit magazine or bero cable is defective If necessary replace the bero and adjust the sensing distance e Input at the controller wafflepack changer control unit is defective gt Measure the voltage to check the input If necessary replace controller A18 Error 549 WPC Tray has been taken out The magazine should contain the components specified in the set up It must not be the wrong way round 180 positioning error as this will result in components vision and pick up errors If the furnished tray has not been removed Load WPC test program gt Check inputs e The bero Tray furnished or the bero cable is defective e If necessary replace the bero and a
49. ze of the magazines the individual channels can be occupied mehrfach and with different compon ents Multiple assignment of the individual channels with varying components is possible The complete tray storage unit is moved vertically by a lifting axis in order to bring the magazine required up to the level of the feed axis The lifting axis drive unit consists of a direct current servo system and a step down ball screw drive The tray storage unit runs on prisms thus allowing precise mechanical positioning The servo motor is equip ped with a mechanical brake to prevent the lifting axis drifting out of position when the machine is switched off The brake is applied automatically when the servo motor is isolated or switched off The feed axis is used for moving horizontally the wafflepack tray in question The conveyor consists of a direct current servo system which uses a belt and a pusher to move the wafflepack tray into the SIPLACE 80F WPC 80F Type 3 Service Manual 3 Design and Method of Operation a ali Edition 09 97 3 1 Reference Point Run As with the SIPLACE machine the servo axes will have to carry out a reference point run when the Type 3 WPC 80F is switched on This run is coupled up with the SIPLACE 80F s reference point run and is performed simultaneously If the station computer is reset it will also be repeated The order in which the lifting and feed axes make their runs depends on the position of the feed axis If the feed axis
Download Pdf Manuals
Related Search