Siplace S-27 HM

Service Manual
R

10/2005 US Issue
UNIX is a trade mark of AT&T
X-Windows is a trade mark
LINUX is a trade mark
Microsoft and MS-DOS are registered trade marks of Microsoft Corporation
Microsoft Windows is a registered trade mark of Microsoft Corporation

(The reproduction, transmission or use of this document or its (We have checked the contents of the printed documentation to
contents is not permitted without written authority. ensure that it is in agreement with the hardware and software
Offenders will be liable for damages. All rights, including rights described therein. However, since discrepancies cannot be ruled out,
created by patent grant or registration of a utility model or design, we cannot assume responsibility for complete agreement.
are reserved.) The information given in this printed documentation is however
regularly reviewed and necessary corrections included in
subsequent editions.
We would appreciate any suggestions for improvements.)

Siemens AG 2005 All rights reserved Subject to change without prior notice

Order No.: 00193 530-02 Siemens AG

To be ordered from:
Siemens AG, Automation and Drives
Electronics Assembly Systems
Rupert-Mayer-Strasse 44
D-81359 Muenchen
Service Manual S-27 HM
10/2005 US Issue

Contents 0

Page

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1.1 How to get information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1.2 SIPLACE on the World Wide Web (WWW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2 Important notes on the user manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.2.1 Qualification and training of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.2 User classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.3 Danger notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.4 Liability of the manufacturer/supplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.5 Revision index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Operational safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1.1 Conventions for the use of hazard symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.2 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.3 Use as prescribed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.4 Failure to use as prescribed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.5 Important notes on operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.6 Safety instructions for laser units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.7 Important notes on environmentally-friendly disposal of materials and components 17

2.2 Warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.2.1 Warning labels W201, W203, W204, and W206 on the machine . . . . . . . . . . . . . . . 18
2.2.2 Warning label W205 on the tape cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.3 Warning label W207 on the servo unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.4 Warning label W110 on the EMERGENCY-STOP buttons . . . . . . . . . . . . . . . . . . . . 24
2.2.5 Warning label "laser class 2" on the PCB conveyor . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2.3 Laser classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.3.1 Laser class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.2 Laser class 1M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.3 Laser class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.4 Safety instructions for docking and undocking the component trolley . . . . . . . . . . . . 28
2.3.5 Safety instructions for lowering the component table bed . . . . . . . . . . . . . . . . . . . . . 29
2.3.6 Safety instructions for changing the table height of component trolleys . . . . . . . . . . 29
2.3.7 Safety instructions for the changeable component feeder table . . . . . . . . . . . . . . . . 30
2.3.8 Safety instructions for opening the protective covers . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.9 Securing the placement machine to prevent it slipping . . . . . . . . . . . . . . . . . . . . . . . 34
2.3.10 Safety instructions for processing capacitors based on powdered metal . . . . . . . . 35
2.3.11 Safety instructions for docking and undocking the matrix tray changer. . . . . . . . . . 36

2.4 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.4.1 Protective covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.2 Guard on the input/output belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.3 EMERGENCY STOP mushroom-head push buttons, protective cover switches ... . 41
2.4.4 Safety circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4.5 Guard on the component table locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.5 Residual voltages and discharge times in the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.5.1 Operating voltages, residual voltages and discharge times after pressing
the emergency stop mushroom-head push-button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.5.2 Residual voltages and discharge times after switching off at the main switch . . . . . 48

2.6 Disabling the compressed air supply and discharging the pressure . . . . . . . . . . . . . . . . . . . . . 49

2.7 Energy state of the machine after switching off at the main switch . . . . . . . . . . . . . . . . . . . . . . 50
2.7.1 Placement system switched off at the main power switch, but still connected . . . . . 51
2.7.2 Placement system switched off at the main power switch and disconnected . . . . . . 51
2.7.3 Compressed air conditions in the machine after switching off at the
main power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.8 Lock out and tag out procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.8.1 Purpose and scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.8.2 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.8.3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.8.4 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.8.5 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.8.6 Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.9 Emissions and ergonomics of the touchscreen monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.9.1 X-ray radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.9.2 Ergonomics and electromagnetic emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.10 ESD guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.10.1 What does ESD mean? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.10.2 Important measures to protect against static charging . . . . . . . . . . . . . . . . . . . . . . 56
2.10.3 Handling ESD modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.10.4 Measurements and modifications to ESD modules . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.10.5 Dispatching ESD modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.1 Position of the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.2 Power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3.2.1 Standard version used to SN 259 (00336812-04) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2.2 Standard version used from SN 260 (00375503-01). . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2.3 Japanese version (00356395-04 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2.4 Description of the power supply functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.2.5 Supply voltages - standard version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.2.6 Supply voltages - Japanese version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.2.7 Measuring voltages on the power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.2.8 Measuring voltages at rectifiers V1 to V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.3 Measuring power supply voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.4 Servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.5 Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.6 Terminal panels - voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

3.7 Terminal panel - input/output distribution unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4 Gantries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

4.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

4.2 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.3 Points to do before starting servicing work... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.4 Replacing the X-axis scale (00329316-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.4.1 Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.4.2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.4.3 Removing the X-axis scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.4.4 Installing the X-axis scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.4.5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.5 Replacing the X-axis tensioning key (00200468-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4.5.1 Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.5.2 Removing the tensioning key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.5.3 Installing the tensioning key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.5.4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

4.6 Replacing the deflection unit (00330938-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.6.1 Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.6.2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.6.3 Removing the deflection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.6.4 Installing the deflection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.6.5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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4.7 Replacing the X-axis toothed belt (00334180-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.7.1 Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.7.2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.7.3 Removing the X-axis toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.7.4 Installing the X-axis toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.7.5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.8 Replacing the X-axis motor unit (00334153-04). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

4.8.1 Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.8.2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.8.3 Removing the X-axis motor unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.8.4 Installing the X-axis motor unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.8.5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

4.9 Replacing the Y-axis motor unit (00334154-04). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4.9.1 Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.9.2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.9.3 Removing the Y-axis motor unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.9.4 Installing the Y-axis motor unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.9.5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

5 Pneumatic Cutter and Empty-Tape Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.1 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5.3 Tools, Expendable Materials, Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5.4 Overview of Mechanical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

5.5 Diagrams of Pneumatic System and Functional Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

5.6 Changing of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

5.6.1 Exchanging the Pneumatic Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.6.2 Replacing the articulated joint on the short-stroke cylinder (00348579-02). . . . . . . 130
5.6.3 Exchanging the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.6.4 Exchanging the Solenoid Valve on Left or Right (and/or Cable) . . . . . . . . . . . . . . . 137
5.6.5 Exchanging the Inductive Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.6.6 Exchanging the Empty-Tape Duct Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.6.7 Exchanging Baffles and / or Reject Box (Profile). . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.6.8 Final Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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6 Modular PCB conveyor system (used to SN 381) . . . . . . . . . . . . . . . . . . . . . . . 147

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

6.2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

6.3 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

6.4 Tools, testing aids, documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

6.5 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6.6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

6.6.1 Single conveyor system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.6.2 Dual conveyor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

6.7 Replacing the complete drive unit (00359284-02). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

6.7.1 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.7.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.7.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

6.8 Exchanging the DC geared motor of the relevant PCB conveyor drive (003009269-01). . . . . 157
6.8.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.8.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

6.9 Replacing the toothed belt of the relevant PCB conveyor drive (00355553-01) . . . . . . . . . . . 160
6.9.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
6.9.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

6.10 Replacing the conveyor toothed belt (00364847-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

6.10.1 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.10.2 Replacing the conveyor toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.10.3 Adjusting the tension of the conveyor toothed belt . . . . . . . . . . . . . . . . . . . . . . . . 167

6.11 Lifting table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

6.11.1 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6.11.2 Replacing the lifting table (00358653-04)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6.11.3 Replacing and adjusting the silencer (00358684-05) . . . . . . . . . . . . . . . . . . . . . . 173
6.11.4 Replacing the solenoid valve (00358663-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6.11.5 Replacing the fork light barrier (00363079-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.11.6 Replacing the PCB clamping device sensor BB1/BB2 (00368272-01) . . . . . . . . . 179
6.11.7 Replacing the complete lifting table cylinder (00358703-01). . . . . . . . . . . . . . . . . 181

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 Service Manual S-27 HM
10/2005 US Issue

6.12 Setting the fixed conveyor side (single and dual conveyor) . . . . . . . . . . . . . . . . . . . . . . . . . . 186

6.13 Width adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

6.13.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.13.2 Replacing the stepping motor of the width adjustment system (00367174-02) . . . 192
6.13.3 Replacing a toothed belt for the drive of the width adjustment system
(00356841-01) 194
6.13.4 Replacing the limit switches for the end position of the width adjustment system
(00365108-02) 197
6.13.5 Adjustment unit for the width adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . 200

6.14 Light barriers and stopper for scanning the PCB positions along the transport routes . . . 206
6.14.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.14.2 Replacing the light barriers for transmitter and receiver modules
(from 00370063-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.14.3 Replacing the laser light barriers for stopper positions (00364782-01) . . . . . . . . . 212
6.14.4 Setting the light barriers in the placement area . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

6.15 Checks to be performed after mechanical work on the conveyor system . . . . . . . . . . . . . . . 217

6.16 Overview of the electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

6.16.1 Conversion board of the conveyor side (00359424-01). . . . . . . . . . . . . . . . . . . . . 218
6.16.2 Conversion board of the conveyor system (00359425-01) . . . . . . . . . . . . . . . . . . 219
6.16.3 Transport control TSP 301 for HS-60 (00370397-01) . . . . . . . . . . . . . . . . . . . . . . 220
6.16.4 Transport control TSP 201 for S-27 HM (00358068-01) . . . . . . . . . . . . . . . . . . . . 222
6.16.5 Conversion board of the lifting table (00362766-01) . . . . . . . . . . . . . . . . . . . . . . . 223

6.17 Block diagrams for modular transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

6.18 Final steps and functions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

6
Service Manual S-27 HM
10/2005 US Issue

7 Modular PCB Conveyor System (used from SN 382) . . . . . . . . . . . . . . . . . . . . 237

7.1 Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

7.2 Service Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

7.2.1 Replacing the Complete Drive Unit [00359284-xx] . . . . . . . . . . . . . . . . . . . . . . . . . 238
7.2.2 Replacing the DC Geared Motor [03009269-xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
7.2.3 Replacing the Toothed Belt of the Drive Unit [00355553-xx]. . . . . . . . . . . . . . . . . . 242
7.2.4 Replacing the Conveyor Toothed Belt [00359917-xx] . . . . . . . . . . . . . . . . . . . . . . . 245
7.2.5 Replacing the Lifting Table Unit [00358653-xx]. . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
7.2.6 Replacing the Lifting Table Stabilizer [00358684-05] . . . . . . . . . . . . . . . . . . . . . . . 252
7.2.7 Replacing the Lifting Table Solenoid Valve [00358663-xx] . . . . . . . . . . . . . . . . . . . 253
7.2.8 Replacing the Lifting Table Fork Light Barrier [00363079-xx] . . . . . . . . . . . . . . . . . 255
7.2.9 Replacing the Complete Lifting Table Cylinder [00358703-xx] . . . . . . . . . . . . . . . . 256
7.2.10 Replacing the Stepping Motor of the Width Adjustment System [00367174-xx] . . 258
7.2.11 Replacing the Limit Switch for the End Position Width Adjustment System
[00365108-xx] 260
7.2.12 Replacing the Solenoid Valve for the Adjustment Unit [00369014-xx] . . . . . . . . . 262
7.2.13 Replacing the Cylinder Switch for the Adjustment Unit [00369016-xx] . . . . . . . . . 263
7.2.14 Replacing the Proximity Switch for the Adjustment System [00363268-xx] . . . . . 264
7.2.15 Replacing the Light Barriers for Transmitter and Receiver Modules [00370063-xx] 266
7.2.16 Replacing the Laser Light Barriers for Stopper Positions [00370385-xx] . . . . . . . 269
7.2.17 Overview of the Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

8 Collect+Place Head DLM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

8.1 Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

8.1.1 Back Part, Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.1.2 Star, Fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
8.1.3 Front Part, Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
8.1.4 Subdistributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.1.5 Component Camera 24 x 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.1.6 Overview of Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

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 Service Manual S-27 HM
10/2005 US Issue

8.2 Service Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

8.2.1 Replacing the Collect+Place Head 6/12 [00367281-xx] . . . . . . . . . . . . . . . . . . . . . 279
8.2.2 Replacing the Front Part of the Collect+Place Head [00367769-xx] . . . . . . . . . . . . 281
8.2.3 Replacing the Component Camera [00336791-xx] . . . . . . . . . . . . . . . . . . . . . . . . . 283
8.2.4 Replacing the Subdistributor [00330648-xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
8.2.5 Replacing the Turning Station [00341780-xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
8.2.6 Replacing the Valve Positioning Drive for the Placement Circuit [00368075-xx]. . . 286
8.2.7 Replacing the Valve Positioning Drive for the Reject Circuit [00349432-xx] . . . . . . 288
8.2.8 Replacing Light Barrier "Z-axis Up" [00347297-xx] . . . . . . . . . . . . . . . . . . . . . . . . . 290
8.2.9 Replacing the Z-axis Drive [00341011-xx]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.2.10 Replacing the Toothed Belt of the Z-axis [00334936-xx]. . . . . . . . . . . . . . . . . . . . 292
8.2.11 Replacing the Forced Air Unit [00367793-xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.2.12 Replacing the Silencer [03003134-xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.2.13 Replacing the Star [00341181-xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.2.14 Replacing the Star Drive [00368077-xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
8.2.15 Replacing the RSF Digital Rotary Encoder [00335990-xx] . . . . . . . . . . . . . . . . . . 300
8.2.16 Replacing the "Z-axis Down" Sensor [00321524-xx] . . . . . . . . . . . . . . . . . . . . . . . 302
8.2.17 Replacing the Complete Z-axis [03001959-xx] . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
8.2.18 Replacing the Control Board for the Nozzle Changer 6/12 [00317353-xx] . . . . . . 306

9 Movable Component Changeover Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

9.1 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

9.2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

9.3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

9.4 Overview of Mechanical Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

9.5 Resolving Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

9.5.1 Preparatory Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
9.5.2 Exchanging the Bellows Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
9.5.3 Exchanging Fixed Castor(s) and/or Guide Castor(s). . . . . . . . . . . . . . . . . . . . . . . . 316
9.5.4 Exchanging the Communications Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
9.5.5 Exchanging the Bowden Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
9.5.6 Final Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

8
Service Manual S-27 HM 1 Introduction
10/2005 US Issue 1.1 General

1 Introduction

1.1 General

1.1.1 How to get information

If you have any further questions concerning this manual or if you would like additional information
on a particular topic, please get in touch with your local SIEMENS dealer or contact us directly at1

Siemens AG, Automation and Drives

Electronics Assembly Systems
Rupert-Mayer-Str. 44
D-81359 Munich, GERMANY 1

1.1.2 SIPLACE on the World Wide Web (WWW)

We also have our own site on the Internet. Why not log onto our SIPLACE home page at
http://www.siplace.com. 1

All the menus and other information are available in two languages:You can choose between the
German and English versions. 1

The various headings contain information on 1

– our products

– services

– contacts, etc.

Registered customers can also access the SIPLACE User Group. There you can call up special
information on our placement machines, such as 1

– technical documentation

– technical information

– spare parts lists, etc.

Registering for access to the User Group is sheer child’s play: 1

Æ Click on the ‘Register now’ button

Æ Complete the registration form and just send it off.
You will then quickly receive access authorization with USER ID and a password. 1

9
1 Introduction Service Manual S-27 HM
1.2 Important notes on the user manual 10/2005 US Issue

1.2 Important notes on the user manual

1.2.1 Qualification and training of personnel

Personnel used for service must hold the relevant qualifications for the job. The user must keep
tight control over their responsibilities, assignment and supervision. Any employee who does not
have the relevant training must be trained and given appropriate instruction. If necessary the user
of the machine can have training provided by the manufacturer/supplier. 1

In addition, the user must ensure that the employees have fully understood the contents of the
service manual. 1

1.2.2 User classification

The operating software is structured so that certain functions or menus can only by used or called
by appropriately trained personnel. There are three different classes of user: 1

– operator,

– line engineer and

– service engineer.

Access to each class may be password-protected. 1

Operators 1
The operator class consists of any person who has been trained in operation of the machine.
These people are authorized to use any functions associated with operating the machine and may
call up any menus needed to use the machine. 1

Line engineers 1
Line engineers have undergone special training and are authorized to carry out line engineer ac-
tivities, such as creating set-up configurations, determining vision parameters, etc. 1

Service engineers 1
This class is intended for engineers from SIEMENS AG. They are trained to carry out servicing
work and to upgrade and retrofit the placement system. 1

10
Service Manual S-27 HM 1 Introduction
10/2005 US Issue 1.3 Danger notes

1.3 Danger notes

WARNING 1

– A thorough knowledge of the relevant part of this Service Manual is required before carrying
out any work on the machine.

– All work must be carried out by appropriately trained and qualified personnel.

– All warning, caution and danger notes MUST be observed.

– In addition, read through chapter 2 of the user manual carefully.

1.4 Liability of the manufacturer/supplier

We draw your attention to the fact that this service manual only contains descriptive and explan-
atory material and does not include any contractual conditions or undertakings. All obligations of
Siemens AG proceed from the conclusion of the contract concerned, under which you have the
machine described herein. This applies in particular to all statements regarding performance or
service life and the agreed liability for faults or defects. The provisions of the contract regarding
the liability for faults or defect are neither extended nor restricted by any statements in this service
manual. 1

1.5 Revision index

Manual Issue

First Version Service Manual S-23 HM 09/1999

Revision to Service ManualS-27 HM 03/2003

Revision to Service ManualS-27 HM 10/2005

1

11
1 Introduction Service Manual S-27 HM
1.5 Revision index 10/2005 US Issue

12
Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.1 Safety instructions

2 Operational safety

2.1 Safety instructions

2.1.1 Conventions for the use of hazard symbols

This Manual contains notes that must be observed to guarantee your personal safety and to avoid
damage to equipment. These notes are highlighted by warning triangles and are indicated as fol-
lows according to the level of risk:

DANGER or DANGER

as used in this Manual means that death, severe injury or considerable damage to equipment will
occur if the danger instructions are not followed.

WARNING or

as used in this Manual means that death, severe injury or considerable damage to equipment may
occur if the warning instructions are not followed.

CAUTION or

as used in this Manual means that slight injury or damage to equipment may occur if the caution
instructions are not followed.

NOTE

as used in this Manual provides information on the product or indicates a part of the Manual that
requires particular attention.

2.1.2 Qualified personnel

Qualified or adequately trained personnel means that these people are familiar with the setting up,
operation and maintenance of automatic placement systems and add-on devices and are suitably
qualified, e.g.

– have been trained, instructed or authorized to switch on and off, isolate, earth and identify elec-
trical circuits and system components in accordance with normal safety standards.

– have been trained or instructed in the upkeep and use of appropriate safety equipment in ac-
cordance with normal safety standards.

– have received first aid training.

13
2 Operational safety Service Manual S-27 HM
2.1 Safety instructions 10/2005 US Issue

2.1.3 Use as prescribed

The product must only be used for its intended purposes as described in the catalogues and tech-
nical descriptions, namely the placement of SMD components, and only with the third-party equip-
ment and components recommended or permitted by Siemens AG. Use for a different or extended
purpose is not prescribed.

If the product is not used as prescribed, SIEMENS AG accepts no liability for any damage that
may occur and does not guarantee that the components will work properly and without problems.

Use as prescribed also includes compliance with all the instructions in the user manual.

For the product to operate correctly and reliably, it must have been transported, stored, erected
and assembled correctly and must be operated and maintained with care.

2.1.4 Failure to use as prescribed

Failure to use the product as prescribed can result in both danger to life and limb and material
damage. For this reason any use that is not prescribed is not allowed. If the product is not used
as prescribed, SIEMENS AG accepts no liability for any damage that may occur and does not
guarantee that the components will work properly and without problems.

Examples of failure to use the product as prescribed:

– Placement of components that do not meet the permitted specification

– The use of component feeders that have not been approved

– The use of unauthorized accessories and additional modules

2.1.5 Important notes on operational safety

The following points MUST be observed in order to maintain operational safety:

2.1.5.1 General

Æ The operational safety of SMD automatic placement systems can be guaranteed only if the
system is used as prescribed and in accordance with the instructions in the User/Service Man-
uals.
Æ Always follow any safety regulations specific to your country.
Æ Make sure that the warning labels are always clearly identifiable and always easily readable.
Æ Replace any damaged warning or notice labels. Replace any labels that are missing.
Æ The machine key for releasing the covers on the machine must be kept in a safe place where
it is only accessible to qualified personnel.

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.1 Safety instructions

NOTE
The machine owner, and only the machine owner, is responsible for the safekeeping of the
machine key and for ensuring that it is handed over to authorized persons. 2

Æ If it is necessary to work on the machine and you do not have adequately trained personnel
within your operation, always call in a SIEMENS AG service technician. SIEMENS AG will not
accept liability for any damage or consequential damage that is the result of incorrect work.
Æ If particularly hazardous situations are identified while the machine is in use, the machine
owner must immediately notify the manufacturer in writing so that appropriate action can be
taken to reduce the potential danger.

WARNING
In spite of all the safety precautions taken by the manufacturer, failure to use the system as pre-
scribed can result in severe physical injury (e.g. from the moving gantry or lifting table) and/or con-
siderable damage to equipment. For the machine to be safe, it must be used correctly by qualified
personnel and all warnings must be observed. Some work on the machine (e.g. setting up) re-
quires training that goes beyond the scope of this Manual. 2

2.1.5.2 Safety of operators and other persons

Æ Machine operators must only carry out work for which they have been adequately trained and
with which they are totally familiar.
Æ NEVER open one of the protective covers if you are not totally familiar with the use and func-
tioning of the machine! Do not open the protective covers during operation unless you are told
to do so in this Manual or in the station software dialog.
Æ Only trained and qualified personnel may set the key switch to setup mode ("I").
During operation, do not set the key switch to the "I" position (setup mode) unless prompted to
do so in this manual or by the station software. 2

Æ NEVER place your head or arms in the gantry and lifting table traveling range while the station
is switched on!
Æ For your own safety, wear work clothes that conform to the guidelines of the professional as-
sociation, i.e. no wide sleeves etc.
Æ Reduce the risks by not wearing scarves, chains or ties at your work post.
Æ People with long hair must wear a protective head covering.

15
2 Operational safety Service Manual S-27 HM
2.1 Safety instructions 10/2005 US Issue

WARNING 2
The system is electrically driven. When electrical devices are in use, certain parts carry dangerous
voltage levels.

Æ Switch off at the main switch and disconnect the placement system from the power supply be-
fore carrying out any work on live components.
Æ Lock the systems as described in Section 2.8, page 52.
There is a risk of death, severe injury and/or considerable damage to equipment if these instruc-
tions are not followed.

2.1.5.3 Safety of plant and equipment

Æ Never make changes, however minor, unless you are totally aware of the effect they will have
on the overall functioning of the system.
Æ The stations must always be set up, retooled and maintained by appropriately trained person-
nel.
Æ Only use SIEMENS AG original spare parts and authorized accessories. The use of other
parts will affect safety and will invalidate the liability for any consequential damage.
Æ Do not make modifications to the safety equipment. In particular, NEVER bypass circuit-break-
ers or remove safety devices.

2.1.6 Safety instructions for laser units

Permission to operate components that are classified as lasers is withdrawn if

– mechanical damage to the unit is observed, or

– any work is done on the mechanical or electrical parts of the unit.

Even damaged or missing screw locking paint on laser components (e.g. cover plates, fas-
teners, adjusting potentiometer) counts as work.

– Only SIEMENS AG service engineers, or the machine owner's service engineers who have
been trained by SIEMENS AG are allowed to replace laser components.

– Repairs to laser units are carried out at the SIEMENS AG factory exclusively.

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.1 Safety instructions

2.1.7 Important notes on environmentally-friendly disposal of materials and com-

ponents

SIPLACE systems are manufactured using only materials and parts that can be easily separated
and disposed of in an environmentally-friendly way. Hazardous materials are not necessary for
the installation, dismantling or operation of the system.

NOTE 2

The owner of the system has sole responsibility for the proper environmentally-friendly disposal
of machines, working materials, consumables and wear parts.

Æ Please observe your national statutory provisions for waste disposal and environmental pro-
tection.

17
2 Operational safety Service Manual S-27 HM
2.2 Warning labels 10/2005 US Issue

2.2 Warning labels

2.2.1 Warning labels W201, W203, W204, and W206 on the machine

The warning labels are made from soft PVC film, and are abrasion-proof, light-fast and resistant
to water and weathering.

Their design meets the requirements of ISO 3864-2 and ANSI Z535.4.

Fig. 2.2 - 1 Warning labels on the machine - part 1

WARNING 2

– Do not use abrasive cleaners or solvents for cleaning warning labels.

– Replace any damaged or illegible warning or notice labels.

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.2 Warning labels

Fig. 2.2 - 2 Warning labels on the machine - part 2

Fig. 2.2 - 3 Warning labels on the machine - part 3

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2 Operational safety Service Manual S-27 HM
2.2 Warning labels 10/2005 US Issue

2.2.1.1 Warning label W201

2

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

SAFE OPERATION OF THE MACHINE

Safe operation of the machine depends abso-

lutely on the operator being familiar with the user
manual and safety instructions and putting them
into effect.
Pos. W201 in Fig. 2.2 - 1, item no. 03009338-01

2.2.1.2 Warning label W203

2

2
2
2

DANGER OF CRUSHING!

Reaching in here can lead to injuries to the

arms and hands.

Do not reach into the machine while it is run-

ning
Pos. W203 in Fig. 2.2 - 1, item no. 03009342-01

2.2.1.3 Warning label W204

2

2
2
2

DANGER OF CRUSHING!

Reaching in here can lead to injuries to the

arms and hands.

Do not reach into the machine while it is run-

ning
Pos. W204 in Fig. 2.2 - 1, item no. 03009343-01

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.2 Warning labels

2.2.1.4 Warning label W206

2

DANGEROUS VOLTAGES!

The labeled parts are still live when the main power switch is off.
Disconnect the machine from the mains before servicing it.

NAFTA region: RISK OF ELECTRIC SHOCK OR BURN!

Pos. W206 in Fig. 2.2 - 1, item no. 03009345-01

2.2.2 Warning label W205 on the tape cutter

2
2
2
2
2
2
2
2

RISK OF CUTTING!

Danger of cutting is present even when the ma-

chine is switched off

Pos. W205 in Fig. 2.2 - 1, item no. 03009343-01

2

Fig. 2.2 - 4 Warning label W205 on the top of the tape cutter

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2 Operational safety Service Manual S-27 HM
2.2 Warning labels 10/2005 US Issue

WARNING 2
If you wish to do work on the tape cutter, you must disconnect the machine from the mains sup-
ply and the compressed air supply.
Wait until the operating pressure has dropped to 0 MPa.

2.2.2.1 Warning label W205 on the used tape channel and on the waste tape chute
2

Fig. 2.2 - 5 Warning label W205 on the used tape channel and waste tape chute

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.2 Warning labels

2.2.3 Warning label W207 on the servo unit

2
2

MAIN POWER VOLTAGE!

Switch off the main power switch and wait 30 seconds until the
capacitors have discharged.

NAFTA region: RISK OF ELECTRIC SHOCK OR BURN!

Pos. W207, item no. 03009346-01

2

Fig. 2.2 - 6 Warning label W207 on the servo unit Macrolon panel

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2 Operational safety Service Manual S-27 HM
2.2 Warning labels 10/2005 US Issue

2.2.4 Warning label W110 on the EMERGENCY-STOP buttons

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

For Australia, Canada, Mexico and USA, warn-

ing label W110 is affixed to the mounting kit in-
stead of the yellow ring on the EMERGENCY-
STOP buttons.

Warning label W110, item no. 03009349-01

2

Fig. 2.2 - 7 Warning label W110 on the EMERGENCY-STOP buttons

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.2 Warning labels

2.2.5 Warning label "laser class 2" on the PCB conveyor

LASER RADIATION!

Do not look into beam

Laser class 2

Warning label "Laser class 2" on the PCB conveyor, item no. 03009347-01
2

Fig. 2.2 - 8 Warning label "Laser class 2" on the PCB conveyor

25
2 Operational safety Service Manual S-27 HM
2.3 Laser classification 10/2005 US Issue

2.3 Laser classification

2.3.1 Laser class 1

2.3.1.1 Classification of the whole machine

2

All installed camera systems and the whole machine when ready
for operation are assigned to laser class 1.

The laser classes are determined according to DIN EN 60825-1.

PLEASE NOTE: 2
Modules in laser classes 1 and 1M are not identified.

2.3.1.2 Classification of the camera systems

2

The following camera systems are assigned to laser class 1:

– PCB multicolor camera

2.3.2 Laser class 1M

Do not look directly at this with optical instruments!

2

The following camera systems are assigned to laser class 1M:

– 24 x 24 component camera on the 12-segment Collect&Place head

– 39 x 39 component camera on the 6-segment Collect&Place head

– 16 x 16 DCA camera on the 6-segment or 12-segment Collect&Place head

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.3 Laser classification

2.3.3 Laser class 2

The following modules are assigned to laser class 2:

– Laser light barrier, placement area 1 in the PCB conveyor

– Laser light barrier, placement area 2 in the PCB conveyor

– PCB barcode scanner

2

Laser radiation

Do not look into beam!

27
2 Operational safety Service Manual S-27 HM
2.3 Laser classification 10/2005 US Issue

2.3.4 Safety instructions for docking and undocking the component trolley

WARNING 2
Æ Never reach into the gaps between the component trolley and the placement system frame
while the machine is running (item 1).
Æ Always check that the component trolley is docked on the placement system before connect-
ing or disconnecting the power cable for the component trolley at the socket on the placement
system (item 2).
Æ NEVER connect the connecting cable for the component trolley to the socket on the placement
system and then operate the component trolley outside the machine via the compressed air
control unit (item 3).

Fig. 2.3 - 1 Safety instructions on the component trolley

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Service Manual S-27 HM 2 Operational safety
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2.3.5 Safety instructions for lowering the component table bed

WARNING DANGER OF CRUSHING 2

When lowering the component trolley tray, never reach into the gap between the feeders and the
used tape channel. 2

2.3.6 Safety instructions for changing the table height of component trolleys

WARNING DANGER OF CRUSHING 2

The component trolley must only be converted to modify the default height by trained service per-
sonnel.
Act with considerable care during the conversion process since the system contains large weights
or compression springs (potential energy). 2

Converting the component trolley to suit a different line height

Æ Use the placement system’s pneumatic controller to raise the table bed. Then insert a 120mm
spacer block between the table bed and crossbeam, and lower the bed onto the block.
Æ Dismantle the internal paneling.
Æ Swivel the handle down. The latching disk swivels down as well.
Æ Set the screw to the desired dimension and lock in place with the locknut.

PLEASE NOTE:
If you cannot loosen the adjusting screw far enough, the crossbeam must be raised. 2
Æ Fix the lifting device to the crossbeam.
Æ Carefully open the crossbeam clamp.
Æ Raise the crossbeam until the end of the tube projects approx. 1mm out of the clamp.
Æ Tighten the crossbeam clamp.
Æ Then turn the adjusting screw to the desired dimension and lock in place with the locknut.

Æ Swivel the component trolley handle up.The latching disk will also swivel up.

29
2 Operational safety Service Manual S-27 HM
2.3 Laser classification 10/2005 US Issue

PLEASE NOTE: If you cannot swivel the latching disk up to its end position, the crossbeam
must be raised. 2
Æ Fix the lifting device to the crossbeam.
Æ Carefully open the crossbeam clamp.
Æ Raise the crossbeam until the end of the tube projects approx. 1mm out of the clamp.
Æ Tighten the crossbeam clamp.
Æ Then turn the adjusting screw to the desired dimension and lock in place with the locknut.

Æ Then carefully open the crossbeam clamp.

Æ Lower the crossbeam until the adjusting screw comes into contact with the latching disk.
Æ Tighten the crossbeam clamp.
Æ Then check the distance between the crossbeam and floor.
Æ Refit the internal paneling.
Æ Raise the table bed and remove the spacer block.

2.3.7 Safety instructions for the changeable component feeder table

If you use a changeable component feeder table rather than a component trolley, then follow
these safety instructions to prevent injury or damage to machines.

WARNING 2
If you have installed a changeable component feeder table, do not forget to secure it with the two
M10 hexagon socket-head bolts (see items 1 and 2 in fig. 2.3 - 2). If you do not do this, the com-
ponent feeder table could tip over and the placement head could collide with the feeder as it ap-
proaches the feeder area. 2

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.3 Laser classification

Fig. 2.3 - 2 Securing the changeable component feeder table

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2 Operational safety Service Manual S-27 HM
2.3 Laser classification 10/2005 US Issue

2.3.8 Safety instructions for opening the protective covers

To prevent any risk of injury when the protective covers on automatic placement machines are
opened, the owner must instruct his operators to use the protective covers exactly as specified in
the following description.

RISK OF TRAPPING FINGERS IF THE PROTECTIVE

COVERS ARE OPENED OR CLOSED INCORRECTLY
When you open the protective covers, if you place one hand in one of the
recessed grips (1) and place the other hand on the protective cover in order to
guide it (item (5) in 2.3 - 3), you risk trapping your fingers in the narrow gap (4) between the mon-
itor traverse (3) and the protective cover (2). 2

Fig. 2.3 - 3 Protective covers on the SIPLACE automatic placement machine

(1) Recessed grips for opening and closing the protective covers
(2) Protective cover
(3) Monitor traverse

32
Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.3 Laser classification

2
2

(4) Narrow gap (between 4 and 10 mm) between

the monitor traverse and protective cover
2
2
2

(5) Do NOT place your hand on this surface!

Every protective cover on the automatic placement machine has two recessed grips (1).

PLEASE NOTE
To open or close the protective covers, hold the recessed grips with both hands (see point (1) in
Fig. 2.3 - 4). This “two-handed operation” will prevent any risk of injuring your hands.
You will also avoid tilting the protective covers during opening or closing, which would place an
excessive load on the guides. 2

Fig. 2.3 - 4 Two-handed operation

(1) Two-handed operation

33
2 Operational safety Service Manual S-27 HM
2.3 Laser classification 10/2005 US Issue

2.3.9 Securing the placement machine to prevent it slipping

In areas with an earthquake risk, it is essential to secure the placement machine to prevent it
slipping.

Two holes for M8 bolts are provided in the machine feet for this purpose.

Æ Use the bolts to fix the placement machine to the floor as shown in the diagram below.

Fig. 2.3 - 5 Securing the placement machine to prevent it slipping

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Service Manual S-27 HM 2 Operational safety
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2.3.10 Safety instructions for processing capacitors based on powdered metal

There is a risk associated with processing capacitors based on powdered metal (e.g. tantalum).
The risk is that

– an exothermic reaction, i.e. a sudden buildup of heat, may occur, if these components are dam-
aged. If the ambient conditions are unfavorable, and depending on the capacitance, this
buildup of heat can cause damage.

– This effect can occur when these components are cut.

Please contact your suppliers to clarify whether the components that you handle are affected.

In extremely rare cases, this risk can occur in the tape cutter of SIPLACE machines, with the
remote possibility of causing a smoldering fire in the waste tape.

The ambient conditions are unfavorable if:

(1) The components remain on the tape while the set tape cycle is checked (since the operator
can cycle the feeder onward without removing components during this check).
(2) The components remain on the tape, e.g. due to a tear in the cover foil.
(3) The components remain on the tape, and the components or tape do not conform to the
specification, thus increasing the pickup error rate.
Please follow the instructions given below to minimize the risk when placing capacitors based on
powdered metal.

(1) If the component tape is cycled onward manually, the operator must remove any components
remaining in the tape pocket.
(2) If the cover foil tears, the operator must remove any components remaining on the tape.
(3) The waste tape container must be emptied regularly (recommended interval: every hour).
2

The feeders are labeled as shown

below:
WARNING 2

To avoid the risk, it is essential to use only feeders that have Approved for
been approved for placing such components, namely: capacitors based on
metal-powder

for model C/D item no.: 00141118-01 Freigegeben für

Kondensatoren auf
for model E item no.: 00141117-01 2 Metallpulver-Basis

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2 Operational safety Service Manual S-27 HM
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2.3.11 Safety instructions for docking and undocking the matrix tray changer

Fig. 2.3 - 6 Safety instructions for coupling and uncoupling the matrix tray changer

(1) Gap when the matrix tray changer is coupled

(2) Matrix tray changer control cable
(3) Control cable for component feeder table
(4) Power supply connection

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Service Manual S-27 HM 2 Operational safety
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WARNING 2
Æ NEVER place your hand in the gaps between the matrix tray changer and machine frame (item
1) while the machine is running.
Æ Always couple the matrix tray changer to the machine before connecting or disconnecting the
matrix tray changer control cable at the machine socket (item 2).
Æ Always couple the matrix tray changer to the machine before connecting or disconnecting the
control cable for the matrix tray changer’s integral component feeder table at the machine
socket (item 3).
Æ Always couple the matrix tray changer to the machine before connecting or disconnecting the
power cable from the external power supply (item 4).
Æ NEVER operate the matrix tray changer if it is not coupled to the machine.

37
2 Operational safety Service Manual S-27 HM
2.4 Safety equipment 10/2005 US Issue

2.4 Safety equipment

2.4.1 Protective covers

Fig. 2.4 - 1 Safety equipment in the placement machine

(1) Cover and guard on the input belt

(2) Safety panels, right-hand side
(3) Protective cover
(4) Cover and guard on the output conveyor
(5) Protective cover
(6) Safety panels, left-hand side

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Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.4 Safety equipment

2.4.1.1 General

The gantry positioning range is covered by two protective covers. If you want to open the protec-
tive covers, first press the Stop button (item 1 in Fig. 2.4 - 2) or the emergency stop mushroom-
head push-button (item 2 in Fig. 2.4 - 2). The power to the gantry axes will be switched off and
the gantries will stop immediately.

If you open one of the protective covers or a guard on the incoming or outgoing conveyor, the
power to the gantry axes will be switched off. They will stop immediately.

If the key switch is closed (position I), you can continue to pace the star at reduced speed while
the protective covers are open.

Placement will stop if you press the emergency stop button. You can then either cancel or con-
tinue placement of the PCB. The protective covers at the sides can be opened in order to refill
with components when the machine has stopped.

WARNING
The protective covers must only be opened, with the key switch closed (position I), by appropri-
ately qualified and trained personnel. 2

Fig. 2.4 - 2 Stop and EMERGENCY-STOP mushroom-head push buttons

(1) Stop button

(2) EMERGENCY-STOP mushroom-head push-button

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2 Operational safety Service Manual S-27 HM
2.4 Safety equipment 10/2005 US Issue

2.4.2 Guard on the input/output belt

WARNING
The guard must always be set to the height of the PCB to be processed. Ensure that the gap be-
tween the guard and the safety bar is as small as possible. 2

Guards are fitted on the input and output belts of the PCB conveyor.

The height of the guard must be set using the slots so that the processed PCB can travel
through.

Fig. 2.4 - 3 Guard on the placement machine

(1) Safety bar (fixed)

(2) Guard (adjustable)
(3) Slots for adjusting the height
(4) Cover

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Service Manual S-27 HM 2 Operational safety
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2.4.3 EMERGENCY STOP mushroom-head push buttons, protective cover

switches ...

Fig. 2.4 - 4 Location of the buttons and protective contactor combinations K1, K2

(1) Stop button

(2) Start button
(3) EMERGENCY-STOP mushroom-head push-button
(4) EMERGENCY-STOP mushroom-head push-button
(5) Start button
(6) Stop button
(7) Component counter
(8) Key switch open: position 0 for normal mode
Key switch closed: position I for service purposes
(9) Protective cover switch (output conveyor, 00303617-xx)
(10) Protective cover switch (right, 00321417-xx)
(11) Protective cover switch (input conveyor, 00303614-xx)

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2 Operational safety Service Manual S-27 HM
2.4 Safety equipment 10/2005 US Issue

(12) Protective cover switch (left, 00321416-xx)

(13) Main power switch
(14) Protective contactor combination K1
(15) Protective contactor combination K2
(16) Compressed air unit

2.4.3.1 Description of the functions

EMERGENCY-STOP mushroom-head push-button

When the emergency stop mushroom-head push-button is pressed (item 3 or item 4. in Fig. 2.4
- 4), the motor voltage to the gantry axes is switched off. The gantry axes are no longer powered,
and thus are not dangerous.

PLEASE NOTE
Placement is interrupted and can then either be continued or canceled once the system is working
correctly again. 2

Protective cover switch

If one of the protective covers is opened (see item 9, 10, 11 or 12 in Fig. 2.4 - 4), the gantry axes
will stop immediately. They are no longer powered, and thus are not dangerous.

Key-operated switch:
If the key switch (item 8 in Fig. 2.4 - 4) is closed (position I), the star can still be paced at low
speed while the protective covers are open. The gantry axes are no longer powered, and thus
are not dangerous.

PLEASE NOTE
The key switch remains open for normal mode, i.e. in the 0 position. 2

WARNING
The protective covers must only be opened, with the key switch closed (position I), by appropri-
ately qualified and trained personnel. 2

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2.4.3.2 Status messages and the action required

The following displays may appear in placement mode. If they appear, carry out the action spec-
ified in the third column.
2

Status Display on screen Action required

EMERGENCY STOP Emergency stop pressed ... Release the pressed EMERGENCY-
mushroom-head push- Machine stopped. Release but- STOP mushroom-head push-button
button pressed ton (item 3 or 4 in Fig. 2.4 - 4)

Press start button Press the white start button (item 2 or 5

in Fig. 2.4 - 4)

Protective cover open Close the cover Close the protective cover (item 9, 10,
11 or 12 in Fig. 2.4 - 4)

Press start button Press the white start button (item 2 or 5

in Fig. 2.4 - 4)

Tab. 2.4 - 1 Screen display when the emergency stop mushroom-head push-button is pressed or the protective cover
is open

2.4.4 Safety circuits

The SIPLACE automatic placement system has two separate safety circuits which are monitored
by protective contactor combinations K1 and K2. Both protective contactor combinations are
incorporated into the power supply (see items 14 and 15 in Fig. 2.4 - 4).

WARNING
Automatic placement systems from the SIPLACE family are powered with 3 x 400 VAC (3 x 208
VAC for the U.S.A. version) ± 5 %, 50/60 Hz main power voltage.This means that some parts of
the system carry potentially lethal voltages - even when switched off at the main power
switch.Death, serious injury or considerable damage may result if these automatic placement sys-
tems are handled incorrectly.Always follow the applicable accident prevention and DIN regulations
(particularly EN 60204, part 1) and the applicable regulations in your own country.The guard over
the power supply must ONLY be opened by appropriately qualified and trained personnel. 2

Protective contactor combinations K1 and K2 monitor the following circuits:

K1:EMERGENCY-STOP circuit, safety circuits for the component trolleys or waffle-pack changer,
protective cover switches and the enable software signal K2:EMERGENCY-STOP circuit, K1 pro-
tective contactor combination, software enable signal and key switch

43
2 Operational safety Service Manual S-27 HM
2.4 Safety equipment 10/2005 US Issue

K1 or K2 is triggered if any of these functions fail. The mains voltage to the heavy current trans-
former that supplies the gantry axis motors will be interrupted. The voltage to the star-type motor
for the Collect&Place head is reduced from 70 V to 10V. The DP and DR axes of the placement
heads continue to be supplied with 30V. The next diagram illustrates the various statuses of K1
and K2 and their effects on the axes and the PCB conveyor components.

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Service Manual S-27 HM 2 Operational safety
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Start button pressed

Compressed air
No
min. 0.51 MPa
(5.1 bar)?

Yes

Emerg. stop
mushroom-head push-but- Yes
ton pressed?

No

Component table safety Yes

circuit interrupted?

No

No Yes
Protective cover open ?

Yes Key switch No

closed (position I)?

Active Active Active

K1 *) yes K1 *) no K1 *) no
K2 *) yes K2 *) yes K2 *) no
Voltage Voltage Voltage
Y-axis 155 V Y-axis 0V Y-axis 0V
X-axis 155 V X-axis 0V X-axis 0V
Star axis 70 V Star axis 10 V Star axis 10 V
DP-axis 30 V DP-axis 30 V DP-axis 30 V
Z-axis 30 V Z-axis 30 V Z-axis 30 V
Active Active Active
PCB conveyor yes PCB conveyor yes PCB conveyor no
Lifting table yes Lifting table no Lifting table no
PCB clamping device yes PCB clamping device no PCB clamping device no
Width adjustment yes Width adjustment yes Width adjustment no
Laser light barrier yes Laser light barrier no Laser light barrier no
Used tape cutter yes Used tape cutter no Used tape cutter no

*)K1, K2 protective contactor combination

Fig. 2.4 - 5 Safety circuits

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2 Operational safety Service Manual S-27 HM
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2.4.5 Guard on the component table locations

WARNING
All locations must be equipped with feeders in order to guarantee operational reliability.If there are
not enough feeders available, a guard ("dummy feeder") must be fitted in place of the feeder.The
following variants can be used:
Item no.00116820-01SIPLACE guard for 1 location
Item no.00116821-01SIPLACE guard for 6-10 locations
Item no.00116822-01SIPLACE guard for 11-20 locations 2

Fig. 2.4 - 6 Guard

(1) Guard for 1 location

(2) Guard for 6 to 10 locations
(3) Guard for 11 to 20 locations

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Service Manual S-27 HM 2 Operational safety
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2.5 Residual voltages and discharge times in the

machine

When the emergency stop mushroom-head push-button is pressed or the placement system is
switched off, the electrolytic capacitors quickly discharge to safe residual voltage levels via
switched resistors on the discharge board (00308443-xx).
The voltages can be tapped off at test sockets 001 - 009 on the voltmeter unit in the servo unit.

WARNING 2
Automatic placement systems from the SIPLACE family are powered with 3 x 400 VAC (3 x 208
VAC for the U.S.A. version) ± 5 %, 50/60 Hz main power voltage.This means that some parts of
the system carry potentially lethal voltages - even when switched off at the main power
switch.Death, serious injury or considerable damage may result if these automatic placement sys-
tems are handled incorrectly.Always follow the applicable accident prevention and DIN regulations
(particularly EN 60204, part 1).The guard over the servo unit must ONLY be opened by appropri-
ately qualified and trained personnel. 2

Servo
unit

*1'

unswitched switched

9'& 9'& 9'& 9'& 9'& 9'&

9'&

9'& 9'&9'&

Fig. 2.5 - 1 Test sockets on the voltmeter unit in the servo unit

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2 Operational safety Service Manual S-27 HM
2.5 Residual voltages and discharge times in the machine 10/2005 US Issue

2.5.1 Operating voltages, residual voltages and discharge times after pressing
the emergency stop mushroom-head push-button
2

Test socket 00X Residual Discharge times of

Voltage in normal
measured at 007 voltage after electrolytic
mode
(GND) EMERG. STOP capacitors at 12 VDC

001 70 VDC 10 VDC < 2 sec

002 30 VDC 30 VDC –
003 30 VDC < 12 VDC < 2 sec
004 24 VDC 24 VDC –
005 12 VDC 12 VDC –
006 5 VDC 5 VDC –
008 70 VDC 10 VDC < 2 sec
009 155 VDC 10 VDC < 1 sec
Tab. 2.5 - 1 Operating voltages, residual voltages and discharge times after pressing the emergency-stop
mushroom-head push-button

2.5.2 Residual voltages and discharge times after switching off at the main switch
2

Test socket 00X Residual voltage when Discharge times of electrol.

measured at 007 (GND) main power switch is off capacitors at 12 VDC

001 < 12 VDC < 2 sec

002 < 12 VDC < 2 sec
003 < 12 VDC < 2 sec
004 0 VDC –
005 0 VDC –
006 0 VDC –
008 < 12 VDC < 2 sec
009 < 12 VDC < 1 sec
Tab. 2.5 - 2 Residual voltages and discharge times after switching off at the main switch

CAUTION To avoid losing data, evaluate the following criteria before switching off your
automatic placement system (apart from in emergencies):
– Has the placement system finished transmitting machine, setup and panel data?
– Has the placement system finished processing the PCB?
– Has the placement system completed the run-up phase?
– Has the Windows NT operating system been shut down correctly? 2

48
Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.6 Disabling the compressed air supply and discharging the pressure

2.6 Disabling the compressed air supply and discharg-

ing the pressure
The compressed air working pressure is set to 0.51 MPa (5.1 bar). It may fluctuate between 0.5
MPa (5.0 bar) and 0.53 MPa (5.3 bar). The position of the compressed air unit is indicated by
item 5 in Fig. 2.6 - 1. The compressed air supply to the machine can be interrupted using the
shutoff valve (item 1 in Fig. 2.6 - 1).

– You must remove the cover plate to use the shutoff valve.

– Turn the lever on the shutoff valve (item 1 in Fig. 2.6 - 1) from the vertical to the horizontal po-
sition.

– Watch the working pressure gauge (item 2 in Fig. 2.6 - 1) and the pressure gauge for the com-
pressed air supply to the stopper (item 4 in Fig. 2.6 - 1). When the automatic placement system
is switched on, the pressure discharges to 0 MPa (0 bar) within 1 minute.

Fig. 2.6 - 1 Compressed air unit on the automatic placement system

(1) Shutoff valve lever in the CLOSED position

(2) Working pressure gauge
(3) Solenoid valve for venting the tape cutter during an EMERGENCY STOP
(4) Pressure gauge for the PCB stopper working pressure
(5) Compressed air supply, gantry 2
(6) Compressed air supply, gantry 1
(7) Position of the compressed air unit

WARNING Never disconnect compressed air lines while they are pressurized. 2

49
2 Operational safety Service Manual S-27 HM
2.7 Energy state of the machine after switching off at the main switch 10/2005 US Issue

2.7 Energy state of the machine after switching off at

the main switch

WARNING 2
Automatic placement systems from the SIPLACE family are powered with 3 x 400 V or 3 x
208 VAC (U.S.A. version) ± 5 %, 50/60 Hz mains voltage. This means that parts of the system
carry potentially fatal voltages - even when switched off at the main switch.Death, serious injury
or considerable damage may result if these automatic placement systems are handled incor-
rectly.Always follow the applicable accident prevention and DIN regulations (particularly
EN 60204, part 1).The guards over the control and servo units must ONLY be opened by appro-
priately qualified and trained personnel. 2

)DLO *1'
9
9
9
9 *1'
9
9

unswitched switched
9'& 9'& 9'& 9'& 9'& 9'&
9'&

9'& 9'&9'&

Fig. 2.7 - 1 Position of the control unit, servo unit, main switch, service socket and compr. air unit
in the placement system

(1) Main power switch Q1 (2) Compressed air unit

(3) Service socket (4) Servo unit
(5) Control unit (6) Power supply in the control unit
(7) Measuring unit, servo unit

50
Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.7 Energy state of the machine after switching off at the main switch

2.7.1 Placement system switched off at the main power switch, but still connected

The following table specifies the voltages of assemblies when the automatic placement system is
switched off at the main switch, but still connected to the mains supply.

Assembly Voltage

Main power filter Z1 3 x 400 VAC (3 x 208

Terminals L1, L2, L3 VAC)

Service socket
230 VAC(115 VAC)

Main power switch Q1

Terminals 1, 3, 5 3 x 400 VAC (3 x 208
Terminals 2, 4, 6 VAC)
0 VAC

Servo unit (item 7 in Fig. 2.7 - 1)

Test socket 001 < 12 VDC
Test socket 002 < 12 VDC
Test socket 003 < 12 VDC
Test socket 004 0 VDC
Test socket 005 0 VDC
Test socket 006 0 VDC
Test socket 008 < 12 VDC
Test socket 009 < 12 VDC
GND 007

Control unit (item 6 in Fig. 2.7 - 1)

Test socket 5V 0 VDC
Test socket + 12 V 0 VDC
Test socket – 12 V 0 VDC
Test socket + 15 V 0 VDC
Test socket – 15 V 0 VDC
Test socket + 24 V 0 VDC
GND

Tab. 2.7 - 1 Voltages of assemblies when the automatic placement system is switched off at the main switch,
but still connected to the main power

2.7.2 Placement system switched off at the main power switch and disconnected
The automatic placement system is unpowered, apart from slight residual voltages in the servo
unit.

51
2 Operational safety Service Manual S-27 HM
2.8 Lock out and tag out procedure 10/2005 US Issue

2.7.3 Compressed air conditions in the machine after switching off at the
main power switch
When the system is switched off at the main power switch (item 1 in Fig. 2.7 - 1) or if the power
supply fails, the electrically-controlled main valve Y1 of the compressed air unit closes (Fig. 2.6 -
1, page 49 ). The pressure will drop to 0 MPa (0 bar) within 5 seconds.

2.8 Lock out and tag out procedure

2.8.1 Purpose and scope

Before performing any maintenance work or service work, a procedure of locking and tagging
must be followed. The procedure, when followed correctly eliminates the possibility of an
employee being injured.

NOTE:
These procedures represent the minimum lock/tag out requirements for maintenance and servic-
ing work. Any additional safeguards needed to complete work safely can be specified by facilities
supervision, the safety officer, the safety committee and the health department. 2

2.8.2 Description

Whenever it becomes necessary to isolate, control and release energy, the following procedure
is to be followed

1. Notify affected employees.

2. Shut down the equipment. Carry out all normal stopping procedures, such as

– depressing the stop button

– shutting down the station computer or

– switching off the placement system at the main switch and

– opening of toggle switches.

3. Isolate the equipment from all its energy sources such as

– compressed air supply and

– power supply.

4. Lock out the equipment.

– Apply the lock and the lockout whenever possible.

52
Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.8 Lock out and tag out procedure

– Alternative:Tagging out
If a machine can be locked out, it must be. However, there are situations where energy iso-
lating devices cannot accommodate locks. In these cases, the energy isolating devices
must be tagged to warn employees that the machine is de-energized for servicing. The tag
must be securely fastened, it must be placed in a position visible to all and it may only be
removed by the person who attached it.

5. Relieve stored energy Stored energy in the compressed air supply or electrical energy in elec-
trolytic capacitors must be released by appropriate means.

– After switching off the placement machine wait until the voltages and the compressed air
have discharged to be able work without any risk (see sections 2.5 and 2.6).

6. Verify the lock out.

– Testing the lock out can be done simply by pressing the start button.

7. The following steps must be taken to restore the machine to operation.

8. Check the area. Authorized employees should remove all of their tools and reinstall all guards.

9. Notify all affected employees. Before removing even one lock or tag, inform all workers in the
area that the machine is going to be restarted.

10. Remove locks/tags Each authorized employee must remove his or her own lock. Each autho-
rized employee will have his or her own lock.

11. Turn the machine on. Authorized workers should observe the equipment in operation to
insure repairs were done correctly.

2.8.3 Testing

The maintenance or electrical person may test the circuits by energizing the circuit for a short
period of time without voiding the lock out procedure provided. This may be done only when no
other work is being performed by any other person on the equipment being tested.

It is extremely important that all remote start switches be tagged with the “Do Not Operate” tag to
prevent inadvertent operation of the equipment during these periods.

2.8.4 Responsibilities

1. It shall be the responsibility of the maintenance and electrical personnel to make sure this pro-
cedure is adhered to.

2. It shall be the responsibility of the maintenance and electrical personnel’s immediate supervi-
sor to instruct his personnel on this procedure.

3. It shall be the responsibility of the Safety Officer with assistance from the Safety Committee,

53
2 Operational safety Service Manual S-27 HM
2.8 Lock out and tag out procedure 10/2005 US Issue

Health Service Department, and the various managers and Vice-presidents to administer the
Lock Out / Tag Out Procedure.

2.8.5 Training

1. Employee training The safety regulations require training for every individual, of course every
employee is not exposed to the same degree of danger or is involved with LO/TO as others
are. So extensive training is not necessary for everyone.

2. To determine how much training to provide for each worker, the employees are divided into
three groups. Each group has its own level of training.

3. Authorized employees
These workers actually install the locks and tags and do the maintenance or service work. So
they must know the most about controlled energy. First, they must be able to recognize all
energy sources and measure the amount of energy. Authorized employees must look for
energy sources out of the realm of the obvious. These energy sources include electrical,
mechanical, hydraulic, pneumatic, chemical, thermal and gravitational. Once these workers
can recognize all energy sources they must be taught how to isolate, control, and release the
energy without any risk.

4. Affected employees These are workers who operate the machinery or equipment that may be
de-energized. Other employees who may be affected include those who work in an area that
contain equipment that may be locked/tagged out. These employees have to be instructed
about the nature of the energy control program. They must know why lock/tag out is impor-
tant, what tags and locks look like and why they must not remove tags or locks.

5. All others As the name implies, any employee who is not affected or authorized fits into this
category. There employees include office personal, engineers, managers, and upper man-
agement. Although they do not have a direct relationship to the machinery being locked or
tagged, they have to receive some training.

6. To evaluate the lock/tag out procedure, the safety department will conduct periodic inspec-
tions. As part of the inspection the safety department will document that all facets of the pro-
cedure are followed. The safety department will follow up with formal classroom review or
retraining of the LO/TO procedure.

2.8.6 Review

This procedure will be reviewed and amended as required but in no case less frequently than
once a year.

54
Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.9 Emissions and ergonomics of the touchscreen monitor

2.9 Emissions and ergonomics of the touchscreen monitor

2.9.1 X-ray radiation

The X-ray radiation generated in the monitor is adequately shielded by the intrinsically safe cath-
ode-ray tube. The local emissions are less than 1 S/h (micro-Sievert per hour). The accelerating
voltage is limited by the device to a maximum of 26 kV.

The monitor conforms to the German Directive for protection against harmful X-ray radiation. The
X-ray emissions from the monitor conformed to the DHHS Rules 21 CFR, subsection J on the
date of manufacture and to the FCC Rules, part 15.

2.9.2 Ergonomics and electromagnetic emissions

The monitor fulfills the conditions for ergonomics (to ISO 9241-3) and safety (to EN 60950).

The low-frequency electromagnetic emissions fall below the MPR II guidelines issued by the
Swedish Radiation Institute in Stockholm.

55
2 Operational safety Service Manual S-27 HM
2.10 ESD guidelines 10/2005 US Issue

2.10 ESD guidelines

2.10.1 What does ESD mean?

Almost all of the modules in use today are equipped with highly integrated MOS blocks and com-
ponents. The manufacturing techniques used mean that these electronic components are
extremely sensitive to overvoltage and thus to electrostatic discharge.

The abbreviation for such modules is 'ESD' (Electrostatic Sensitive Device). ’ESD’ is used inter-
nationally.

The following symbol on cabinet rating plates, racks or packaging indicates that components
which are sensitive to electrostatic discharge have been used and thus that the modules con-
cerned are also touch-sensitive.

ESDs can be destroyed by voltages and power levels that are far below the
level that can be perceived by humans. Such voltages occur if a person
touches a component or module without earthing themselves. Components
that are exposed to such overvoltages do not generally appear to be defective
immediately - incorrect behavior starts after the component or module has
been in operation for some time.

2.10.2 Important measures to protect against static charging

– Most plastics can easily become charged and must therefore be kept away from at-risk com-
ponents.

– Always ensure that people, the workplace and packaging are safely earthed when handling
electrostatic sensitive components.

2.10.3 Handling ESD modules

Do not touch electronic modules unless it is absolutely essential to do so in order to carry out
other work. If it is necessary, make sure that you do not touch the pins or printed conductors
when you pick up flat modules.

Do not touch components unless

– you are constantly earthed by an ESD wrist strap or

– you are wearing ESD shoes or ESD shoe earthing strips on an ESD floor.

Always discharge yourself before you touch an electronic module. To do this, simply touch a con-
ductive and earthed object immediately before you touch the module (such as unpainted parts of
a switch cabinet, a water pipe, etc.).

56
Service Manual S-27 HM 2 Operational safety
10/2005 US Issue 2.10 ESD guidelines

Do not allow modules with chargeable and highly insulating materials to touch one another, e.g.
plastic films, insulating table surfaces or items of clothing made from synthetic fibers.

Always place the modules on a conductive surface (table with an ESD coating, conductive ESD
foam, ESD bag or container).

Do not bring modules near visual display units, monitors or televisions. Keep them at least 10 cm
away from the screen.

2.10.4 Measurements and modifications to ESD modules

Do not take measurements on such modules unless

– the measuring device is earthed (e.g. via PE conductors) or

– you discharge the measuring head just before taking measurements with a potential-free mea-
suring device (e.g. by touching an unpainted metal part of the controller casing).

Æ Always use an earthed soldering iron if you carry out any soldering work.

2.10.5 Dispatching ESD modules

Always store modules and components in conductive packaging (e.g. metallized plastic bags or
metal sleeves) and dispatch them in conductive packaging.

If the packaging is not conductive, place the modules in a conductive envelope before packag-
ing. (Use ESD bags, domestic aluminum foil or paper, for example. NEVER use plastic bags or
film).

If the module has integral batteries, ensure that the conductive packaging does not touch or
short-circuit the battery terminals and, if necessary, first cover the terminals with insulating tape
or material.

57
2 Operational safety Service Manual S-27 HM
2.10 ESD guidelines 10/2005 US Issue

58
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.1 Position of the modules

3 Power Supply

3.1 Position of the modules

The diagram below shows the position of the modules that generate or distribute the power
needed to operate the placement system:

Fig. 3.1 - 1 Position of the power supply modules

Key

(1) Power supply unit (4) Servo unit

(2) Terminal panels - voltages (5) Terminal panel - input/output distribution

unit

(3) Control unit

59
3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

3.2 Power supply unit

3.2.1 Standard version used to SN 259 (00336812-04)

The power supply unit is located under a fixed cover (see Fig. 3.1 - 1).

Fig. 3.2 - 2 Standard power supply unit - side view

Key

(1) Front view

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Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

Table of parts - side view

Pos. Specification Item No.

A1 Inrush current limiter board
00342988-01
V1 Rectifier 40A/800V
00323854-01
V2, V3 Rectifier 4.5A/800V
00323853-01
V4,V5 Compact rectifier 200V
00321450-01
T1 Transformer (single-phase) 4AM52
00329498-01
T2 Transformer (three phase a.c.)
00336811-01
F5.1 Fine-wire fuse 10A
00317195-01
F5.2 Fine-wire fuse 10A
00317195-01
F6.1 Fine-wire fuse 10A
00317195-01
F6.2 Fine-wire fuse 10A
00317195-01
F8.1 Fine-wire fuse 10A
00317195-01
F9.1 Fine-wire fuse 10A
00317195-01

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3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

Fig. 3.2 - 3 Standard power supply unit - side view from the back

Key

(1) Side view

Parts - side view from the back

Pos. Designation Item No.

K4 Contactor
00343013-01

62
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

Fig. 3.2 - 4 Standard power supply unit - front view

63
3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

Parts overview- front view

Pos. Designation Item No.

Q1 Main switch
00368782-01
F1 Miniature circuit-breaker 3 x 16A - AC
00307159-01
F3, F9 Miniature circuit-breaker 1 x 10A - AC
00307163-01
F4 Miniature circuit-breaker 1 x 20A - DC
00305019-01
F4.1 Miniature circuit-breaker 2 x 25A - DC
00372794-01
F5, F6, F8 Miniature circuit-breaker 1 x 6A - AC
00362661-01
F7, F10, F11 Miniature circuit-breaker 1 x 6A - DC
00302818-01
K1 Combined protective device 3TK28050AC2
00321067-01
K2 Combined protective device 3TK28040AC2
00320030-01

64
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

Fig. 3.2 - 5 Standard power supply unit - cables

Pos. Designation Item No.

1 Main power cable: main power filter - main switch
00356539-xx
2 Main power supply cable - terminal panel
00357898-01
3 Power supply grounding cable - terminal panel
00324358-02
4 Power supply cable - terminal panel
00321113-02
5 Power supply cable - terminal panel
00356733-01

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3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

3.2.2 Standard version used from SN 260 (00375503-01)

The power supply unit is located under a fixed cover (see Abb. 3.2 - 6).

X201 V3
A1
-

V2

1
PE

T1 8

10

11

12

13

14

15

T2

Abb. 3.2 - 6 Standard power supply unit - side view

Key

(1) Front view

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Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

Table of parts - side view

Pos. Specification Item No.

A1 Inrush current limiter board
00342988-01
V1 Rectifier 40A/800V
00323854-01
V2, V3 Rectifier 4.5A/800V
00323853-01
V5 Compact rectifier 200V
00321450-01
T1 Transformer (single-phase) 4AM52
00372773-01
T2 Transformer (three phase a.c.)
00362672-01
F5.1 Fine-wire fuse T 20A
00375476-01
F5.2 Fine-wire fuse T 20A
00375476-01
F6.1 Fine-wire fuse T 20A
00375476-01
F6.2 Fine-wire fuse T 20A
00375476-01
F9.1 Fine-wire fuse T 20A
00375476-01

67
3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

Abb. 3.2 - 7 Standard power supply unit - side view from the back

Key

(1) Side view

Parts - side view from the back

Pos. Designation Item No.

K4 Contactor
00343013-01

68
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

Q1
1 3 5

N N PE PE PE PE

2 4 6

2 4 6 2 2 2

F1 F3 F4 F4.1 F5

0 0 0 0 0 0 0 0

16A 10A 20A 25A 6A

1 3 5 1 1 1

2 2 2 2 2

F6 F7 F9 F10 F11

0 0 0 0 0
K3

6A 6A 10A 6A 6A

1 1 1 1 1

L1 X1 X3 X5 13 23 33 43 53 65

Netz
Powe r
K1
Ka na l 1
Channel 1

K2
Ka na l 2
Channel 2

L2 X2 X4 X6 14 24 34 44 54 66

Abb. 3.2 - 8 Standard power supply unit - front view

69
3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

Parts overview- front view

Pos. Designation Item No.

Q1 Main switch
00368782-01
F1 Miniature circuit-breaker 3 x 16A - AC
00307159-01
F3 Miniature circuit-breaker 1 x 10A - AC
00627163-01
F4 Miniature circuit-breaker 1 x 20A - ACDC
00625019-01
F4.1 Miniature circuit-breaker 2 x 25A - D- AC
00375475-01
F5, F6 Miniature circuit-breaker 1 x 6A - ACDC
00362661-01
F7, F10, F11 Miniature circuit-breaker 1 x 6A - DC
00622818-01
F9 Miniature circuit-breaker 1 x 10 A - ACDC
00624324-01
K1 Combined protective device 3TK28050AC2
00321067-01
K2 Contactor 3RT10
00375508-01
K3 Contactor 3TH2
00625027-01

70
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

Abb. 3.2 - 9 Standard power supply unit - cables

Pos. Designation Item No.

1 Main power cable: main power filter - main switch
00356539-xx
2 Main power supply cable - terminal panel
00357898-01
3 Power supply grounding cable - terminal panel
00324358-02
4 Power supply cable - terminal panel
00321113-02
5 Power supply cable - terminal panel
00356733-01

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3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

3.2.3 Japanese version (00356395-04 )

The power supply unit is located under a fixed cover (see Fig. 3.1 - 1).

Fig. 3.2 - 10 Power supply unit - side view

Key
(1) Front view

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Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

Parts overview - side view

Pos. Designation Item No.

K4, K5 Contactor
00343013-01
A1, A2 Inrush current limiter board
00342988-01
V1 Rectifier 40A/800V
00323854-01
V2 to V5 Rectifier 4.5A/800V
00323853-01
T1 control-unit transformer
00369306-01
T2 Three-phase transformer
00362672-01

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3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

2 2 2 4
1 3 5

6A N
6A 6A

F7 F10 F11
N
S1
2 4 6
1 1 1 3

2 4 6 2 4 6 2 4 6

16 A 16 A 10 A

F1 F2 F3
1 3 5 1 3 5 1 3 5

2 2 2 2 2 2 4 2 4

20 A 6A 6A 6A 10 A 6A 6A

F4 F5 F6 F8 F9 F12 F13
1 1 1 1 1 1 3 1 3

L1 X1 X3 X 5 1 3 23 33 4 3 5 3 65 L1 X1 X3 X 5 1 3 23 33 4 3 5 7 65

K2
Netz
Power K1 Ein
On
Kanal 1
Channel 1

Frei
Kanal 2
Ready
Channel 2

L2 X2 X4 X 6 1 4 24 34 4 4 5 4 66 L2 X2 X4 X 6 1 4 24 34 4 4 5 8 66

K3 PE PE PE PE M M

X200

Fig. 3.2 - 11 Power supply unit - Front view

74
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

Parts overview - front view

Pos. Designation Item No.

Q1 Main switch
00362461-01
F1, F2 Miniature circuit-breaker 3 x 16A - AC
00307159-01
F3 Miniature circuit-breaker 3 x 10A - AC
00356397-01
F4 Miniature circuit-breaker 1 x 20A - DC
00305019-01
F5, F6, F8 Miniature circuit-breaker 1 x 6A - DC
00362661-01
F9 Miniature circuit-breaker 1 x 10A - DC
00304324-01
F7, F10 Miniature circuit-breaker 1 x 6A - AC
00348597-01
F11, F12, F13 Miniature circuit-breaker 2 x 6A - AC
00316397-01
K1 Combined protective device 3TK28050AC2
00321067-01
K2 Combined protective device 3TK28040AC2
00320030-01
K3 Contactor 30V DC
00305027-01

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3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

Fig. 3.2 - 12 Power supply unit - cables

Pos. Designation Item No.

1 Main power cable: power supply filter - main switch
00356539-01
2 Main power supply cable - terminal panel
00356540-01
3 Power supply grounding cable - terminal panel
00324358-02
(earthing wire
00359822-01
4 Power supply cable - terminal panel
00321113-02
5 Power supply cable - terminal panel
00356733-01

76
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

3.2.4 Description of the power supply functions

The placement system cannot be in placement mode until all the supply voltages have been en-
abled by the protective circuit. The following conditions must also be fulfilled:

– All four component change-over tables must be docked.

– All covers must be closed.

– Both emergency stop push-buttons must be released.

– All component flaps over the component tables must be closed.

– The software enable signal must have been sent.

3.2.5 Supply voltages - standard version

The power supply unit provides the following supply voltages:

– 150 VDC for the link circuits for the servo amplifier of the x and y axes

– 70/100 VDC for the lifting table/star

– 24 V DC for the tape cutter

– 30/34 VDC for the dp/z-axes and the width adjustment system

– 10 VDC for the star (slow-mode)

3.2.6 Supply voltages - Japanese version

The power supply unit provides the following supply voltages:

– 150 VDC for the link circuits for the servo amplifier of the x and y axes

– 70/100 VDC for the lifting table/star

– 24 V DC for the tape cutter

– 30/34 VDC for the dp/z-axes and the width adjustment system

– 12 VDC for the star

– 150VAD for the power supply unit power pack

– 230 VAD for the station computer and component tables

– 400 VDC for the WPC and component tables

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3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

3.2.7 Measuring voltages on the power supply unit

3.2.7.1 Safety instructions

DANGER The placement system is supplied with 3 x 400 V~ (or

3 x 204 V~ / 3 x 230 V~ / 3 x 380 V~ / 3 x 415 V~) ± 5 %, 50/60 Hz mains voltage. 3

– Consequently, parts of the system carry potentially lethal voltages, even when switched off at
the main switch.

– Incorrect handling of the placement system can therefore result in death or severe injury or
considerable damage to equipment.

– Measurements and repairs must always be carried out by appropriately qualified personnel.

– Always follow the safety instructions in chapter 2 of this manual.

– Always follow the applicable accident prevention and VDE regulations (particularly DIN EN 60
204, part 1) or the regulations specific to your country.

– Before starting any repairs, switch off at the main switch and disconnect the placement system
from the mains power supply.

– Secure the system to prevent it being switched on again. If these instructions are not followed,
it is possible to touch live parts, which could result in death or severe injury.

3.2.7.2 Tools and equipment required

– Digital voltmeter, class 1,5

Measuring ranges
AC voltage 750 V

Alternating current 40 A

DC voltage 300 V

Direct current 30 A

Resistance 200 Ohm - 20 MOhm

– Test cable with test probes or terminals

– S-27 HM detailed circuit diagrams, article number 00193426-02

– DIN 911 Allen key, size 6

– 3 mm key, double-bit, DIN 43668-J33, article number 00304191-01

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Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.2 Power supply unit

3.2.7.3 Preparing the power supply unit for measurement

The power supply unit and main switch are located in the machine frame (see Fig. 3.1 - 1). In front
of the unit there is a cover, fixed with a screw.

The unit is fixed to the machine frame with an M8 hexagon socket-head screw.

To measure the power supply, proceed as follows:

Æ Switch the placement system off at the main switch.

Æ Loosen the M8 lock screw on the underside.
Æ Pull the unit out as far as the stop.

WARNUNG Make sure that the main power cable and supply lines do not be-
come caught up in the placement system, otherwise the insulation will be damaged. 3

Æ Switch the placement system on at the main switch and start it up.

3.2.7.4 Measuring voltages on the front panel of the power supply unit

NOTE: The placement system must be started in order to take these measurements. This means
that the protective covers and component flaps must be closed and the component tables docked.
The emergency stop button must be released and the START button pressed. If this is not the
case, the operating voltages will not be switched through to the servo amplifiers, lifting tables etc..

The inputs to the modules all have odd numbers and the outputs have even numbers.

In the case of fuses (F1 etc.), the input is always on the underside of the module, whereas with
contactors (K1 etc.), it is always at the top.

NOTE
After triggering the miniature circuit-breakers F5, F6, F8 or F9 (see ) always check the fine-wire
fuses (see Fig. 3.2 - 2) F5.1, F5.2 or F6.1, F6.2 or F8.1 or F9.1.

79
3 Power Supply Service Manual S-27 HM
3.2 Power supply unit 10/2005 US Issue

3.2.8 Measuring voltages at rectifiers V1 to V5

To take measurements on rectifiers V1 and V5, you must first remove the perspex safety panel.

DANGER RISK OF DEATH BY ELECTRIC SHOCK 3

Æ Switch the placement system off at the main switch.

Æ Disconnect the placement system from the power supply.
Æ Wait approximately 1 minute until the residual voltages have dropped to a safe level (electro-
lytic capacitor C1).
Æ Loosen the two M5 fillister head screws on rectifiers V1 and V5.
Æ Remove the perspex safety panel.
Æ Switch the placement system on and start it up.
Æ Measure the voltages.
3

NOTE: The placement system must have started, otherwise there will be no AC voltage
(3 x 140 V~) at rectifier V1. V1 uses the 3 x 140 V~ to generate the 200 V- supply voltage for the
servo amplifiers of the gantry axes and 100 V- for the servo amplifiers of the star axes. These
100 V- and 4 V- supplies are fed to the AC voltage inputs of rectifier V2. Rectifier V2 serves to
"OR" the 4 V- and 100 V-supplies. If the placement system has not started, only 4 V- will be
present at the positive pole of rectifier V2.

NOTE: Remember to replace the perspex safety panel over rectifiers V1 and V5 once the mea-
surements have been completed.

80
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.3 Measuring power supply voltages

DANGER RISK OF DEATH BY ELECTRIC SHOCK 3

Æ Switch the placement system off at the main switch.

Æ Disconnect the placement system from the power supply.
Æ Wait approximately 1 minute until the residual voltages have dropped to a safe level (electro-
lytic capacitor C1).
Æ Attach the perspex safety panel and fix in place with the M5 fillister head screws.

CAUTION
Do not overtighten the fillister head screws otherwise the perspex panel might break. 3

3.3 Measuring power supply voltages

Please see below for power supply circuit diagrams. For detailed and comprehensive circuit dia-
grams please refer to the current versions of the SIPLACE S-27 HM detailed circuit diagrams.

NOTE
Observe the different versions of the power supply.

81
82
1 2 3 4 5 6 7 8

Q1 F1 16 A
Main power switch
1 L1 T1 1 2 bk (1) bk (1)

2 L2 T2 3 4 bn (2) bn (2)
00356539-xx
3 L3 T3 5 6 wh (3) wh (3)
A A
To main power filter N bl (6) bl (6) 00357898-xx
N´
3 Power Supply

4 N N rd (5)
To terminal panel
gegn X200:N gy (4)
AWG14 bk
13 23 33 gnye
00342917-xx(W3) X200:PE
Route the N conductor via the
A1 Inrush current limiter
main power switch. (IT net)
bk F11 F3
e.g. France / Italy / USA AWG16 2 1
11 1 K1
56R 25R 12 2
6A 1 10A 2

00341193-xx
13 3

25R 56R
B 14 14 24 34
B
Grundgestell Stromversorgung Frontabdeckung 21 4
Erdungsbolzen 1 2 3 4 5 6 6
22 5
56R 25R
3.3 Measuring power supply voltages

23 6

-5%
0
+5%
K4 1 3 5

120
150
230
25R 56R 24
Warning! Power supply!
T1
31 7 2 4 6
If the machine is operated with 208/120V (USA), 56R 25R 32 8 6x =130

28
24
10
0
10
24
28

make sure to: 33 9

25R 56R

Proprietary date, company confidential. All rights reservd.

Confie a titre de secret d´entreprise. Tous droits reserves.
Comunicado como segredo empresarial. Reservados todos os direilos.
Confiado como secrete industrial. Nos reservamos todos los derechos.
1.) connect the inrush current limiter A1 in parallel. 34 12 14 15
13 7 8 9 10 11
(i.e. disconnect wire 3 from 13 and connect it to 14,

(1)
(2)

(3)
disconnect wire 2 from 12 and connect it to 13.

(1)
(2)
For the other phases, apply this system as
C appropriate. ) C
Wiring instructions ! 1 1

PE

1U1
1U3
1V1
1V3
1W1
1W3
1N
F9.1
F8.1
10AT
10AT

2.) Reconnect transformer T1 infeed from 230 to 120V Make sure that the leads to the inrush 400 204 400 204 400 204 0 AWG16 sw
2 2
transformer T2 infeed (1), (2), (3) from 400 current limiter A1 are long enough and
to 208. run them in a way that they can easily be
reconnected.
T2
Warning! Machine type! F10 1

V4 + - V5 + -
6x =130
When operating the machine with a modular 6A 2
105 105 105 68 48 68 48 68 48 42 42 42 0
conveyor system (S27 HM) make sure to:
F8 F9

1
2
- reconnect the conductors (1) and (2) at 1 1

2U1
2V1
2W1
3U1
3U3
3V1
3V3
3W1
3W3
4N

4U1
4V1
4W1
Not-Aus int. 24VAC.
D transformer T1 in the following way: D
zTo sheet 2
To sheet 2 K2:A2

(4)
(5)
(6)
1 3 6A 2 10A 2
wire (1) from terminal 7 to terminal 13 F4.1
wire (2) from terminal 11 to terminal 12 1 1 1 1

F5.1
F5.2
F6.1
F6.2
2 4 AWG14

10AT
10AT
10AT
10AT
This ensures, that a voltage (6L+) of 25A 2 2 2 2

34VDC is available at F9. AWG12 bk A1(+)

bk AWG14

- reconnect the conductors (4), (5), and (6) at K4

A2(-)
transformer T2 in the following way: V1 + - V2 + - V3 + -

AWG14 23 13
wire (4) from terminal 3U3 to terminal 3U1 AWG12 bk

wire (5) from terminal 3V3 to terminal 3V1

wire (6) from terminal 3W3 to terminal 3W1 F4 F5 F6 F7
1 1 1 1

10qmm
E E
This ensures the a voltage (2L+) of
100VDC is available at F5. 20A 2 6A 2 6A 2 6A 2
K2 K2
24 14

bk 0,75qmm
X200:PE

A note regarding fine-wire fuses ! Emerg.-stop, ext. 24VAC.

To sheet 2

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pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins
besondere für den Fall der Patenterteilung oder GM-Eintragung
Please note !

1 1L+ (bk)
2 1L+ (bk)
11 1L+ (bk)
4 1L+ (bk)
3 2L+ (bk)
5 3L+ (bk)
6
4L+ (bk)
7
5L+ (bk)
8
2L- (bk)
9
6L+ (bk)
10
7L+ (bk)
yegn

Always check the fine-wire fuses F5.1, F5.2

1L- 00324358-xx
or F6.1, F6.2 or F8.1 or F9.1, when any of the
The wiring in this circuit diagram
150VDC 70/100VDC 24VDC 10VDC 10VDC GND 30/34VDC 30/34VDC
automatic circuit breakers F5, F6, F8 or F9 corresponds to the state of delivery Link circuit Lifting table/star Tape cutter spare Star, slow motion dp/Z axes Width adjustment
00356733-xx
has tripped. of the power supply unit.

GND
To terminal panel
F F
4. Function status 20.09.2002 Tuth Date 05.11.2002
SD EA1 SIEMENS DEMATIC SMD- Placement System
3. Product status 05.11.2002 Tuth Author Tuth
1. Document status 20.09.2002 Tuth Checked
SD EA1 R&D Sheet 1
Power supply circuit diagram 00336812-040301LD3 2 Sh.
Status Modified Date Name Standard Orig. Repl. f. Repl. by
1 2 3 4 5 6 7 8
10/2005 US Issue
Service Manual S-27 HM

3
83
F
E
C
B

D
A

Weitergabe sowie Vervielfältigung dieser Unterlage,Ver- Proprietary date, company confidential. All rights reservd.
wertung und Mitteilung ihres Inhalts nicht gestattet, soweit Confie a titre de secret d´entreprise. Tous droits reserves.
1.
3.
4.

nicht ausdrücklich zugestanden. Zuwiderhandlungen ver- Comunicado como segredo empresarial. Reservados todos os direilos.
Status

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
1

1
Modified
Product status
Function status

Document status
GND

Date
To sheet 1
To sheet 1

To sheet 1

20.09.2002
05.11.2002
20.09.2002
F7:2 24V AC

F10:2 24V AC

Tuth
Tuth
Tuth

Name

To external emerg.-stop circuit gr

AWG 16bk
AWG 16bk
2

2
Date

24V AC wh
Author
Checked
Standard

24V AC bn
Tuth
K1

To On button gn
05.11.2002

From emerg.-stop circuit bl

13

14

Orig.
K3

24V DC wh/gn
3

3 From emerg.-stop circuit bk

SD EA1

Repl. f.
To keyswitch vi
To signaling circuit, control On bn/gn
From On button ye
4

4
Repl. by
21

22
K3

Software Enable gy/bn

SD EA1 R&D
00321113-xx
A2(-)

SIEMENS DEMATIC
A1(+)

Software Enable pk/br

5

5
From signaling circuit, software Enable wh/gy

SMD- Placement System

Power supply circuit diagram

6

6
43

44

MP1
K2
K3
To On button gy/pk

M
From On button rd/bl
Sheet 1 7/E

Sheet 1 7/E
50VDC Enable rd
+24V DC wh/ye
7

7
bk 0.75
Signaling circuit, input ye/bn
50VDC Enable pk

00336812-040301LD3
Temperature monitoring T1 and T2 wh/pk

2
14

15
8

8
T1

T2
Temperature switch

Sheet
2
2
Sh.
F
E
C
B

D
A
3
3.3 Measuring power supply voltages 10/2005 US Issue
3 Power Supply Service Manual S-27 HM
84
1 2 3 4 5 6 7 8

Q1
11
Warning!
1 L1 T1 1 2
2 L2 T2 3 4 12
00356539-xx
3 Power Supply

13
If the machine is operated with 208/120V (USA)
3 L3 T3 5 6
A or 200/115V (Japan) make sure to:
N N´ 14 A
4 N N AWG14 bk
F1 16 A 1.) connect the inrush current limiters A1 and A2
gegn in parallel.
(i.e. disconnect wire 3 from 13 and connect it to 14,
F2 1 3 5 disconnect wire 2 vom 12 and connect it to 13. For the
X200:PE X200:PE bk other phases, apply this system as appropriate .)
1 AWG16
11
16A 2 4 6 12 2 2.) disconnect the infeed (*) for transformers T1 and T2
Power supply base 56R 25R
Ground bolt 13 3 from the 400V terminal and connect it to the 204 V
13 23 33 terminal.

00359822-xx
25R 56R
A1 Inrush current limiter
bk 14 K5 1 3 5
AWG16
11 1
B 4 B
3.3 Measuring power supply voltages

K1 Front cover 21
12 2
56R 25R 5
2 4 6
56R 25R 22
13 3
23 6
25R 56R
14 25R 56R
14 24 34
24
AWG14 bk
21 4
31 7
22 5
56R 25R 8
56R 25R 32
23 6
33 9
K4 1 3 5
25R 56R

Proprietary date, company confidential. All rights reservd.

Confie a titre de secret d´entreprise. Tous droits reserves.
Comunicado como segredo empresarial. Reservados todos os direilos.
Confiado como secrete industrial. Nos reservamos todos los derechos.
24 25R 56R
34
2 4 6
31 7

C 32 8 A2
56R 25R C
33 9
Inrush current limiter

25R 56R

(1)
(2)
(3)

(1)
(2)
(3)
34

1U1
1U3
1U4
1U5
1U6
1V1
1V3
1V4
1V4
1V5
1W1
1W3
1W4
1W5
1W6
1N

1U1
1U3
1V1
1V3
1W1
1W3
1N
400 204 400 204 400 204 0

X200:PE
400 230 204 150 400 230 204 400 230 204 150 0

X200:PE
Wiring note !
F11 1 3 F12 1 3 F13 1 3 F3 1 3 5
Make sure that the leads to the inrush T2
current limiters A1 and A2 are long enough T1
and run them in a way that they can easily be 6A 2 4 6A 2 4 6A 2 4 10A 2 4 6
reconnected.

6x =130 3x =130
D D
105 105 105 68 48 68 48 68 48 42 42 42 0 0 48 42 15 48 42 15 48 42 15
Warning!
10
1
2
3
4
5
6
7
8
9
14
13
12
11

2N

4N
1
2
yegn

1
2

2U1
2U3
2U4
2V1
2V3
2V4
2W1
2W3
2W4

2U3

2U1
2V1
2W1
3U1
3U3
3V1
3V3
3W1
3W3
4U1
4V1
4W1
To sheet 2 K2:A2

(4)
(5)
(6)
AWG14
X200:PE

When operating the machine with a modular Power supply Station Component WPC Component

(4)
(5)
(6)

bk for control unit. computer tables tables

PCB conveyor: AWG14 AWG16 bk
- reconnect the conductors (4), (5), and (6) A1(+) A1(+) (800VA) (500VA) (500VA) (1200VA) WPC
of transformer T1 in the following way:
K4 K5
V1 + - V2 + - V3 + - A2(-) A2(-) V4 + - V5 + -
wire (4) from terminal 2U3 to terminal 2U1

bk
AWG14
wire (5) from terminal 2V3 to terminal 2V1
wire (6) from terminal 2W3 to terminal 2W1 AWG12 23 13

bk
bk
bk
This ensures, that a voltage (6L+) of F4 1 F5 1 F6 1 F7 1 F10 1 F9 1 F8 1

10mm²
34VDC is available at F9.
E E
-reconnect the conductors (4), (5), and (6) 20A 2 6A 2 6A 2 6A 2 6A 2 10A 2 6A 2
for transformer T2 in the following way:
Internal emerg.-stop 24VAC.
To sheet 2
Wire (4) from terminal 3U3 to terminal 3U1 K2 K2
24 14
X200:PE

bk 0.75mm² External emerg.-stop 24VAC.

wire (5) from terminal 3V3 to terminal 3V1 To sheet 2
wire (6) from terminal 3W3 to terminal 3W1

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wertung und Mitteilung ihres Inhalts nicht gestattet, soweit
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pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins
besondere für den Fall der Patenterteilung oder GM-Eintragung
1 1L+ (bk)
2 1L+ (bk)
11 1L+ (bk)
4 1L+ (bk)
3 2L+ (bk)
5 3L+ (bk)
8
2L- (bk)
9
6L+ (bk)
7
5L+ (bk)
6
4L+ (bk)
10
7L+ (bk)
yegn

This ensures the a voltage (2L+) of

1L- 00324358-xx
150VDC 70/100VDC 24VDC 00356733-xx GND 30/34VDC 12VDC 12VDC 30/34VDC
00356540-xx

100VDC is available at F5. Link voltage Lifting table/Star Tape cutter dp/Z-axes Star, slow motion Spare Width adjustment

GND
zum Klemmenfeld To terminal panel
F F
4. Function status 26.06.2001 Tuth Date 26.06.2001
Product status Author PLEA1 E SIEMENS DEMATIC Siplace S27 HM SMD Placement System
2. 21.08.2001 Tuth Tuth
Document status Check.
SD EA 1 R&D Power supply circuit diagram Sheet 1
1. 08.02.2001 Tuth
Option for Japan 00356395-040201LD3 2 Sh.
Status Modified Date Name Standard Orig. Repl.f. Repl. by
1 2 3 4 5 6 7 8
10/2005 US Issue
Service Manual S-27 HM

3
85
F
E
C
B

D
A

Weitergabe sowie Vervielfältigung dieser Unterlage,Ver- Proprietary date, company confidential. All rights reservd.
wertung und Mitteilung ihres Inhalts nicht gestattet, soweit Confie a titre de secret d´entreprise. Tous droits reserves.
1.
2.
4.

nicht ausdrücklich zugestanden. Zuwiderhandlungen ver- Comunicado como segredo empresarial. Reservados todos os direilos.
Status

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
1

1
Modified
Product status
Function status

Document status
GND

Date
To sheet 1
To sheet 1

To sheet 1

08.02.2001
21.08.2001
26.06.2001
F7:2 24V AC

F10:2 24V AC

Tuth
Tuth
Tuth

Name

To external emerg.-stop circuit gy

AWG 16bk
AWG 16bk
2

2
Date

24V AC wh
Check.
Author

Standard
A1

A2

24V AC br
Tuth
X1

X2
K1

To On button gn
3TK2805

26.06.2001
X3

X4

From emerg.-stop circuit bl

13

14

X5

X6

Orig.
K3

24V DC wh/gn
3

3 From emerg.-stop circuit bk

13 23 33 43 53

14 24 34 44 54

PLEA1 E
65

66

Repl.f.
To keyswitch vi
To signaling circuit, Control On br/gn
button
Start Ein
FromTaste
vom ye
4

4
Repl. by
21

22
K3

SD EA 1 R&D
Software release gy/br
00321113-xx
A2(-)

SIEMENS DEMATIC
A1(+)

Software release pk/br

5

5
To signaling circuit, software release wh/gy

Option for Japan

Power supply circuit diagram
A2

Siplace S27 HM SMD Placement System

6

6
43

44

X2

MP1
K2
K3

3TK2804
To Start button gy/pk

M
From Start button rd/bl

A1 X1 X2 X3 X4 X5 X6
Sheet 1 7/E

Sheet 1 7/E
50VDC release rd

13 23 33 43

14 24 34 44
+24V DC wh/ye

58
57
7

7
65

66
bk 0.75
Input signaling circuit ye/br
50VDC release pk

00356395-040201LD3
T1 and T2 temperature monitoring wh/pk

1
1

2
2
8

8
T1

T2
Temperature switch

Sheet

2
2
Sh.
F
E
C
B

D
A
3
3.3 Measuring power supply voltages 10/2005 US Issue
3 Power Supply Service Manual S-27 HM
3 Power Supply Service Manual S-27 HM
3.4 Servo unit 10/2005 US Issue

3.4 Servo unit

Fig. 3.4 - 13 Servo unit - voltage measuring unit and power pack

Key
(1) Power pack (3) Servo unit - top part

(2) Voltage measuring unit

The test sockets are shown in the block diagram "S-27 HM servo unit, front view, 00334810-
XXXXXXTD3, page 1" of the detailed circuit diagrams.

The supply voltages for the servo unit’s electronic circuits are generated from the supply inte-
grated in the servo unit and can be tapped at the measuring points of the power supply unit (see
S-27 HM servo unit, front view, 00334810-XXXXXXTD3, page 2 of the detailed circuit diagrams).

86
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.5 Control unit

3.5 Control unit

Fig. 3.5 - 14 Power pack in control unit

Key
(1) Power pack

When the main switch is switched on, the power pack in the control unit is supplied with 150 V AC
by the power supply unit. The following voltages are then generated in the control unit

+ 5 V- to supply the digital electronic circuits 3

± 12 V- to supply the digital electronic circuits 3

± 15 V- to supply the analogue electronic circuits 3

+ 24 V- to supply the control circuits, relays etc. 3

The connection details are shown in the block diagram "S-27 HM control unit, front view,
00334808-XXXXXXTD3" of the detailed circuit diagrams.

87
3 Power Supply Service Manual S-27 HM
3.6 Terminal panels - voltages 10/2005 US Issue

3.6 Terminal panels - voltages

The connection details are shown in the block diagram "S-27 HM control unit, front view,
00334808-XXXXXXTD3" of the detailed circuit diagrams.

Fig. 3.6 - 15 Terminal panels - voltages

Key
(1) Rectifier board 60 V (3) Discharge board

(2) Rectifier board 30 V

88
Service Manual S-27 HM 3 Power Supply
10/2005 US Issue 3.7 Terminal panel - input/output distribution unit

3.7 Terminal panel - input/output distribution unit

The connection details are shown in the block diagram "S-27 HM control unit, front view,
00334808-XXXXXXTD3" of the detailed circuit diagrams.

Fig. 3.7 - 16 Terminal panel - input/output distribution unit

Key

(1) CAN input/output module (3) Relay connector 24 V DC

(2) Terminal adapter for SLIO module (4) Transportation control

89
3 Power Supply Service Manual S-27 HM
3.7 Terminal panel - input/output distribution unit 10/2005 US Issue

90
Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.1 Functions

4 Gantries

4.1 Functions

The placement system is equipped with two gantries. These enable the two
collect&place heads to be positioned in the x and y directions with great accuracy and indepen-
dently of one another. Precise mechanical movement of the axes is produced by axis recirculating
ball screw units. 4

High-precision positioning systems determine the positions of the x and y axes. To do this, the
graduations on metal scales are optoelectronically scanned and the track signals sent to the axis
control in the control unit. 4

A toothed belt is used to convert the rotary movement of the turning motors for the X- and Y-axes
directly into a translatory movement of the placement head in the x and y direction. 4

91
4 Gantries Service Manual S-27 HM
4.2 Parts overview 10/2005 US Issue

4.2 Parts overview

Fig. 4.2 - 1 Gantries on the placement system

Key

(1) Gantry 1 (2) Gantry 2

92
Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.2 Parts overview

Fig. 4.2 - 2 Structure of the gantry - components on the X-axis

Key

(1) Motor X-axis (2) Toothed belt X-axis

(3) Deflection pulley - complete (4) X-axis scale

(5) Tensioning key for the X-axis (6) Reference proximity switch strip

(7) Head mount (8) X-axis end position proximity switch

(9) Digital scanning head, X-axis 4

93
4 Gantries Service Manual S-27 HM
4.2 Parts overview 10/2005 US Issue

Fig. 4.2 - 3 Structure of the gantries - components of the Y-axis

Key

(1) Friction block, Y-axis (2) Attenuation, Y-axis

(3) Guide slide, Y-axis (4) Tensioning key, Y-axis

(5) Synchronizing disk for the Y-axis (6) Conversion board for the main axis

(7) Gantry for the distributor head board 4

94
Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.2 Parts overview

Fig. 4.2 - 4 Structure of the gantry - components of the Y-axis

Key

(1) Y-axis scale (2) Y-axis motor

(3) Y-axis toothed belt (4) Y-axis belt guide

95
4 Gantries Service Manual S-27 HM
4.3 Points to do before starting servicing work... 10/2005 US Issue

4.3 Points to do before starting servicing work...

Æ End all placement operations on the placement system.

Æ Switch the placement system off at the main switch.
Æ Wait until the operating system has shut down and the UPS has switched off.
Æ Disconnect the placement system from the power supply.
Æ Disconnect the placement system from the compressed air supply.
Æ Switch off the motor contactor in the power supply unit and secure the operating lever with a
padlock.
4

Fig. 4.3 - 1 Locking the motor contactor

(1) Turn the operating lever (1) counter-clockwise.

(2) Use the screwdriver to push the locking lug (2) out of the operating lever (1).
(3) Secure the operating lever with a padlock (3).

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.3 Points to do before starting servicing work...

– The Tag Out alternative

If a machine can be locked, it must be. However, there are situations where energy isolating
devices can not accommodate locks. In these cases, the energy isolating devices must be
tagged to warn employees that the machine is de-energized for servicing. The tag must be
securely fastened, it must be placed in a position visible to all and it may only be removed
by the person who attached it. 4

WARNING
To avoid damaging the collect&place head, ALWAYS observe the following points when moving
the gantry: 4

– NEVER move the gantry by pushing with your hands against the collect&place head.

– NEVER push the gantry while the Z-axis is lowered.

– Take hold of the cast iron part of the X-axis - ideally near the X-axis toothed belt deflection
pulley - and then move the gantry.

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4 Gantries Service Manual S-27 HM
4.4 Replacing the X-axis scale (00329316-01) 10/2005 US Issue

4.4 Replacing the X-axis scale (00329316-01)

4.4.1 Tools and Equipment

– Set of DIN 911 Allen keys
– Spacer gauge 0.4 mm, plastic
– SITEST program

4.4.2 Parts
X-axis scale, item number 00301086-01 4

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.4 Replacing the X-axis scale (00329316-01)

4.4.3 Removing the X-axis scale

4

Fig. 4.4 - 1 Replacing the X-axis scale

Key

(1) X-axis motor (2) X-axis toothed belt

(3) Fastening screws for the X-axis (4) X-axis scale

scale

(5) Locating pins (6) Reference proximity switch strip

(7) Deflection pulley 4

Æ Switch the placement system off and secure it to prevent it being switched on again, as de-
scribed in Section 4.3, page 96 onwards.
Æ Loosen the two M3x8 hexagon socket-head screws to remove the reference proximity switch
strip (6) for the X-axis.

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4 Gantries Service Manual S-27 HM
4.4 Replacing the X-axis scale (00329316-01) 10/2005 US Issue

Æ Move the head mount across as far as the deflection pulley (7) in order to prevent any damage
to the proximity switches.
Æ Loosen the 11 screws fastening the X-axis scale (3).
Æ Lift the scale (4) out of the locating pins (5) and remove it.

4.4.4 Installing the X-axis scale

Æ Carefully insert the scale onto the locating pins.

CAUTION 4
Do not touch the incremental tracks with bare fingers. 4

Æ Loosely tighten the 11 M2.5x5 hexagon socket-head screws with washers.

Æ Tighten the M2.5x5 hexagon socket-head screws.
Æ Use the spacer gauge to set the 0.4mm gap between the reference proximity switch strip and
the scale.
Æ Use the two M3x8 hexagon socket-head screws to fix the X-axis reference proximity switch
strip.

4.4.5 Settings

Æ Use the SITEST program to set the collect&place head and calibrate the gantry axes.

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.5 Replacing the X-axis tensioning key (00200468-02)

4.5 Replacing the X-axis tensioning key (00200468-02)

4.5.1 Tools and Equipment

– Set of DIN 911 Allen keys

– TSM belt tension measuring device, item number 00326015-01

– "Measuring belt tensions" operating instructions

4.5.2 Removing the tensioning key

Æ Switch the placement system off and secure it to prevent it being switched on again, as de-
scribed in Section 4.3, page 96 onwards.
Æ Remove the placement head from the head mount (1). See also Chapter 7.5 in this Service
Manual. You can now access the tensioning keys.
Æ To slacken the toothed belt
– Undo the fastening screws (3) on the tensioning key (2)

– And turn the tensioning key to loosen the toothed belt

Æ Lift the tensioning key off the synchronizing disk (4).

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4 Gantries Service Manual S-27 HM
4.5 Replacing the X-axis tensioning key (00200468-02) 10/2005 US Issue

Fig. 4.5 - 1 Replacing the X-axis tensioning key

Key

(1) Head mount (2) Tensioning key

(3) Fastening screw (4) Synchronizing disk

4 4

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.5 Replacing the X-axis tensioning key (00200468-02)

4.5.3 Installing the tensioning key

Æ Place the tensioning key on the synchronizing disk.

Æ Turn the synchronizing disk slightly until the fastening screw can be screwed in.
Æ Tension the toothed belt by turning the tensioning key clockwise and tightening the fastening
screw.

4.5.4 Settings

Æ Push the head mount towards the X-axis motor, as far as the stop on the elastomeric spring.
Æ Set the belt tension. Please refer to the label on the machine for details of the settings.

CAUTION 4
Do not overstretch the toothed belt when adjusting the belt tension. 4

Æ Install the placement head. See also Chapter 7.5 of this Service Manual and perform the nec-
essary settings.
4

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4 Gantries Service Manual S-27 HM
4.6 Replacing the deflection unit (00330938-02) 10/2005 US Issue

4.6 Replacing the deflection unit (00330938-02)

4.6.1 Tools and Equipment

– Set of DIN 911 Allen keys

– TSM belt tension measuring device, item number 00326015-01

– "Measuring belt tensions" operating instructions

– Drift punch

4.6.2 Parts

Deflection unit X, item number 00330938-02 4

4.6.3 Removing the deflection unit

Æ Switch the placement system off and secure it to prevent it being switched on again, as de-
scribed in Section 4.3, page 96 onwards.
Æ Remove the placement head from the head mount. See also Chapter 7.5 in this Service Man-
ual. You can now access the tensioning keys.
Æ To slacken the toothed belt
– Undo the fastening screws on the tensioning key,

– And turn the tensioning key to loosen the toothed belt.

(See also Fig. 4.5 - 1).

Æ Remove the tensioning key from the synchronizing disk. Pull the toothed belt out through the
opening in the tension jack.
Æ Weave the toothed belt out of the deflection unit.
Æ Use the drift punch to carefully knock the axis (3) out of the clamping fixture (6) and remove
the deflection unit.

NOTE
Make sure you do not lose the two disks (7). You will need these again during installation. 4

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.6 Replacing the deflection unit (00330938-02)

Fig. 4.6 - 1 Replacing the deflection unit

Key

(1) Nut incl. locknut (2) Thrust washer

(3) Axis (4) Deflection pulley

(5) Toothed belt (6) Clamping fixture

(7) Disks 4

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4 Gantries Service Manual S-27 HM
4.6 Replacing the deflection unit (00330938-02) 10/2005 US Issue

4.6.4 Installing the deflection unit

Æ Insert the new deflection pulley with the two disks into the clamping fixture and carefully knock
the axis into the guidance.
Æ Place the toothed belt around the synchronizing disk of the deflection unit.
Æ Feed the toothed belt into the opening in the tension jack so that it runs approximately 270°
around the long synchronizing disk.
Æ Place the tensioning key on the synchronizing disk (item 4 in Fig. 4.5 - 1).
Æ Turn the synchronizing disk slightly until the fastening screw can be screwed in.
Æ Pre-tension the toothed belt by turning the tensioning key clockwise and tightening the fasten-
ing screw.

NOTE:
Position the deflection unit (item 1 in Fig. 4.6 - 2) so that the axis (2) is in the center of the slot.
This leaves enough room to later tension or relieve the tension on the toothed belt, without remov-
ing the placement head. 4

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.6 Replacing the deflection unit (00330938-02)

Fig. 4.6 - 2 Position of the deflection unit

Key

(1) Deflection unit (2) Axis in the center of the slot

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4 Gantries Service Manual S-27 HM
4.6 Replacing the deflection unit (00330938-02) 10/2005 US Issue

4.6.5 Settings

Æ Push the head mount towards the X-axis motor, as far as the stop on the elastomeric spring.
Æ Set the belt tension. Please refer to the label on the machine for details of the settings.

CAUTION 4
Do not overstretch the toothed belt when adjusting the belt tension. 4

Æ Fasten the nut on the thrust washer with the locknut.

Æ Install the placement head. See also Chapter 7.5 in this Service Manual and perform the nec-
essary settings.

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.7 Replacing the X-axis toothed belt (00334180-02)

4.7 Replacing the X-axis toothed belt (00334180-02)

4.7.1 Tools and Equipment

– Set of DIN 911 Allen keys

– TSM belt tension measuring device, item number 00326015-01

– "Measuring belt tensions" operating instructions

4.7.2 Parts

Toothed belt, Synchroflex 50 ATS5-1205 E9-11, item number 00334180-02 4

4.7.3 Removing the X-axis toothed belt

Æ Switch the placement system off and secure it to prevent it being switched on again, as de-
scribed in Section 4.3, page 96 onwards.
Æ Remove the placement head from the head mount. See also Chapter 7.5 in this Service Man-
ual. You can now access the tensioning keys.
Æ To slacken the toothed belt
– Undo the fastening screws of both tensioning keys,

– And turn the tensioning key to loosen the toothed belt.

(See also Fig. 4.5 - 1).

Æ Remove the tensioning key (1) from the synchronizing disk (2). Pull the toothed belt (3) out
through the opening in the two tension jacks.
Æ Weave the toothed belt out of the deflection unit.
Æ Remove the toothed belt from the synchronizing disk of the X-axis motor unit.

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4 Gantries Service Manual S-27 HM
4.7 Replacing the X-axis toothed belt (00334180-02) 10/2005 US Issue

Fig. 4.7 - 1 Removing the X-toothed belt

Key

(1) Tensioning key (2) Synchronizing disk

(3) Toothed belt 4

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.7 Replacing the X-axis toothed belt (00334180-02)

4.7.4 Installing the X-axis toothed belt

Æ Place the toothed belt around the synchronizing disk of the deflection unit.
Æ Feed the toothed belt into the deflection unit.
Æ Feed the two ends of the toothed belt into the openings in the tension jack so that the belt runs
approximately 270° around the long synchronizing disk.
Æ Fit the two tensioning keys.

NOTE:
Position the deflection unit (item 1 in Fig. 4.6 - 2) so that the axis (2) is in the center of the slot.
This leaves enough room to later tension or relieve the tension on the toothed belt, without remov-
ing the placement head. 4

4.7.5 Settings

Æ Push the head mount towards the X-axis motor, as far as the stop on the elastomeric spring.
Æ Set the belt tension. Please refer to the label on the machine for details of the settings.

CAUTION 4
Do not overstretch the toothed belt when adjusting the belt tension. 4

Æ Install the placement head. See also Chapter 7.5 in this Service Manual and perform the nec-
essary settings.

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4 Gantries Service Manual S-27 HM
4.8 Replacing the X-axis motor unit (00334153-04) 10/2005 US Issue

4.8 Replacing the X-axis motor unit (00334153-04)

4.8.1 Tools and Equipment

– Set of DIN 911 Allen keys

– Cable ties

– TSM belt tension measuring device, item number 00326015-01

– "Measuring belt tensions" operating instructions

4.8.2 Parts

X-axis motor unit, item number 00334153-04 4

4.8.3 Removing the X-axis motor unit

Æ Switch the placement system off and secure it to prevent it being switched on again, as de-
scribed in Section 4.3, page 96 onwards.
Æ Cut the cable ties holding the X-axis motor cable.
Æ Remove the cable clamp of the flat ribbon cable.
Æ Unplug all the X-axis motor plugs from the X/Y distributor.
Æ Remove the board holder for the X/Y distributor.
Æ Remove the cable holder for the trailing cable.
Æ To slacken the toothed belt, undo the nut incl. locknut on the clamping fixture (see Fig. 4.6 - 1).
Æ Remove the four fastening screws and pull out the X-axis motor unit.

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.8 Replacing the X-axis motor unit (00334153-04)

Fig. 4.8 - 1 Replacing the X-axis motor unit

(1) Fastening screws for X-axis motor unit (2) Pulling out the motor unit

4 4

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4 Gantries Service Manual S-27 HM
4.8 Replacing the X-axis motor unit (00334153-04) 10/2005 US Issue

4.8.4 Installing the X-axis motor unit

Æ Carefully insert the X-axis motor unit as far as the stop, making sure that the toothed belt is
run around the synchronizing disk and not damaged.
Æ Fasten the X-axis motor unit with the 4 screws.
Æ Fit the cable holder for the trailing cable.
Æ Fit the board holder.
Æ Plug all the X-axis motor plugs into the socket on the X/Y distributor.
Æ Use the cable clamp to fix the flat ribbon cable.
Æ Use cable ties to fix all cables.

CAUTION 4
Make sure that the cables are firmly seated. Otherwise, the high acceleration forces could
cause the cable to slip out of position and shear through. 4

Æ Use the clamping device to pre-tension the X-axis toothed belt.

Æ Reconnect the fan motor.

4.8.5 Settings
Æ Push the head mount towards the X-axis motor, as far as the stop on the elastomeric spring.
Æ Set the belt tension. Please refer to the label on the machine for details of the settings.

CAUTION
Do not overstretch the toothed belt when adjusting the belt tension. 4

Æ Fasten the clamping device in place with the locknut (see Fig. 4.6 - 1).

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.9 Replacing the Y-axis motor unit (00334154-04)

4.9 Replacing the Y-axis motor unit (00334154-04)

4.9.1 Tools and Equipment

– Set of DIN 911 Allen keys

– Cable ties

– TSM belt tension measuring device, item number 00326015-01

– "Measuring belt tensions " operating instructions“

– SITEST program

– Spirit level

4.9.2 Parts

Y-axis motor unit, item number 00334154-04 4

4.9.3 Removing the Y-axis motor unit

Æ Switch the placement system off and secure it to prevent it being switched on again, as de-
scribed in Section 4.3, page 96 onwards.
Æ Remove the cover plate (1) on the machine base.
Æ Dismantle the nozzle changer and its complete bracket (2).
Æ Dismantle the cutter and the empty-table duct plus bracket, as described in Chapter 5 of this
Service Manual.
Æ Undo and remove the two screws for the component table guidance (4).
Æ Undo and remove the fastening screws (fixed with loctite) for the component table base plate
(5).

– You can now access the Y-axis motor.

Æ Relieve the tension of the toothed belt with the aid of the Y-axis tensioning keys.
Æ Unplug the connection plug on the servo unit.
Æ Undo and remove the two fastening screws on the Y-axis motor.
4

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4 Gantries Service Manual S-27 HM
4.9 Replacing the Y-axis motor unit (00334154-04) 10/2005 US Issue

Fig. 4.9 - 1 Replacing the Y-axis motor unit

Key

(1) Cover plate (2) Bracket for nozzle changer

(3) Cutter (4) Component table guidance

(5) Component table base plate (6) Y-axis motor

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Service Manual S-27 HM 4 Gantries
10/2005 US Issue 4.9 Replacing the Y-axis motor unit (00334154-04)

4.9.4 Installing the Y-axis motor unit

Æ Carefully insert the Y-axis motor unit. Make sure that the toothed belt is run around the syn-
chronizing disk and is not damaged.
Æ Fix the Y-axis motor unit with the fastening screws.
Æ Reconnect the electrical cables between the Y-axis motor unit and the servo unit.
Æ Use the Y-axis tensioning keys to pre-tension the toothed belt.
Æ Install the component table base plate, secure the fastening screws with loctite and assemble
the component table guidance.
Æ Secure the screws of the component table base plate with loctite.
Æ Install the cutter and the empty-table duct plus bracket, as described in Chapter 5 of this Ser-
vice Manual.
Please observe all safety instructions during this procedure.
Æ Install the nozzle changer. Adjust the position of the mount with a spirit level.
Æ Install the cover plate

4.9.5 Settings

Æ Set the belt tension. Please refer to the label on the machine for details of the settings.

CAUTION
Do not overstretch the toothed belt when adjusting the belt tension. 4

Æ Measure the nozzle changer with the SITEST test program.

NOTE
THe position of the nozzle changer must be aligned with the aid of a spirit level. 4

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4 Gantries Service Manual S-27 HM
4.9 Replacing the Y-axis motor unit (00334154-04) 10/2005 US Issue

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Service Manual S-27 HM 5 Pneumatic Cutter and Empty-Tape Duct
10/2005 US Issue 5.1 Safety Instructions

5 Pneumatic Cutter and Empty-Tape

Duct

5.1 Safety Instructions

DANGER

The chapters "Operational Safety" in User Manual SIPLACE S-27 HM and in this Service Manual
take precedence.

The machine SIPLACE S-27 HM is powered by

219/380 V +/- 5% or
230/400 V +/- 5% or
239/415 V +/- 5% or
117/204 V +/- 5% or
133/230 V +/- 5%,
50/ 60 Hz line voltage
Portions of the system therefore conduct dangerous electricity. Inside the machine frame this is
true even while the master switch is turned off.

The machine has to be switched OFF and disconnected from the mains before you perform any
work in the area of the cutter.
In addition, the compressed air supply must be turned off at the main valve of the compressed air
unit in the machine frame and the compressed air lines must be bled by actuating the needle valve
on the compressed air unit.

Always secure the machine against unauthorized reactivation, as described in the User Manual,
chapter "Lock-Out and Tag-Out Procedure ...". 5

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5 Pneumatic Cutter and Empty-Tape Duct Service Manual S-27 HM
5.2 Parts 10/2005 US Issue

5.2 Parts

All spare parts are listed in the S-27 HM spare parts catalogue, with their article numbers and di-
agrams. 5

NOTE:
These instructions are only valid for the version 04 pneumatic cutter and the associated version
03 empty-tape duct.
One of the new features of cutter version 04 is a tape deflector which is installed over the movable
blade (see Fig. 5.4.2 -> 6). 5

5.3 Tools, Expendable Materials, Documentation

– Thick protective gloves

– Set of socket wrenches, cross-slotted screwdriver size 4,

– Open-end wrench, width across flats 10; slotted screwdriver size 1

– Torque wrench, Diagonal cutter, Sliding caliper

– Feeler gauge 0.05mm; 1.0mm; 1.5mm, 2.0mm; 2.50mm

– Straight-edge (for check of tape deflector)

– Mounting plate, Item no.: 00312731-01

– 2 large parallel clamps (or mounting plate, see above)

– Flat, sturdy work bench to fasten the removed cutter (or mounting plate, see above)

– Loctite no. 234, Item no.: 00334892-01

– Molykote paste, Item no. 02100335-01, 250 g, (preferred) or

ISOFLEX TOPAS NCA 52, Item. no. 00330850-01, tube 50 g

– Water-insoluble, fine-tip marker and a dry and clean cloth

– Current edition of SIPLACE S-27 HM spare parts catalogue and SIPLACE S-27 HM detailed
circuit diagrams

– SITEST program and current SITEST operating manual

– Current edition of „S-27 HM Adjustment Instructions“ documentation

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Service Manual S-27 HM 5 Pneumatic Cutter and Empty-Tape Duct
10/2005 US Issue 5.4 Overview of Mechanical Layout

5.4 Overview of Mechanical Layout

Fig. 5.4.1 Overview of Pneumatic Cutter Version 04 and Empty-Tape Duct Version 03

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5 Pneumatic Cutter and Empty-Tape Duct Service Manual S-27 HM
5.4 Overview of Mechanical Layout 10/2005 US Issue

Key to Fig. 5.4.1:

1. Pneumatic cutter S-27 HM

2. Retaining bracket for cutter, left

3. Retaining bracket for cutter, right

4. Fastening of the cutter,

2 socket hex head cap screws M6 x 25 each on left and right *)
Re-install any disks or plates that were previously removed.

5. Mounting surface for cutter on the machine frame

6. Empty-tape duct assembly

7. Side panel (left) of the empty-tape duct

8. Side panel (right) of the empty-tape duct

9. Fastening of "empty-tape duct assembly":

2 socket hex head cap screws M 4 x 16 each on left and right

10. Mounting surface for the "empty-tape duct assembly" on the machine frame

11. Baffle, inside

12. Baffle, outside

13. Reject box for nozzles

14. Reject box (profile)

15. Stop buffer assembly on left- and right-hand side of the machine frame,
Fastening: 2 socket hex head cap screws M8 each on left and right

*) Loosen these screws only when removing/installing the cutter (see Section 5.6.1.1).

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Service Manual S-27 HM 5 Pneumatic Cutter and Empty-Tape Duct
10/2005 US Issue 5.4 Overview of Mechanical Layout

Fig. 5.4.2 Overview: Removing and Installing the Cover Plate and the Tape Deflector

CAUTION
Tighten the screws to the correct torque -> see Table, Fig. 5.4.2. 5

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5 Pneumatic Cutter and Empty-Tape Duct Service Manual S-27 HM
5.4 Overview of Mechanical Layout 10/2005 US Issue

Key to Fig. 5.4.2:

1. Cover plate

2. Cover plate holder, left

3. Cover plate holder, right

4. Screws to fasten the cover plate holder:

2 hexagon socket head screws M4 x 8 DIN 84 or 2 countersunk screws R M4 x 6 DIN 965 each

5. Screws to fasten the cover plate (incl. tape deflector) -> do not loosen!

6. Tape deflector (with moveable blade underneath)

7. Tape deflector holder, left

8. Tape deflector holder, right

9. Screws to fasten the tape deflector holders: 2 socket hex head cap screws M4 x 35 each on
the left and right

10. Screws to fasten the tape deflector: 1 countersunk screw each -> do not loosen!

11. Holddowns (at left and right) with spacers inserted underneath them

12. Deflector plate

13. Screws to fasten the deflector plate: 4 socket hex head cap screws M4 x 8

14. Screws to fasten the cutter on the machine frame

4 socket hex head cap screws M 6 x 25 *)

15. Any disks or plates installed underneath

16. Stationary blade

17. Rubber-metal vibration damper

18. Any disks and spring washers installed underneath

*) Loosen these screws only when removing/installing the cutter (see Section 5.6.1). 5

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Service Manual S-27 HM 5 Pneumatic Cutter and Empty-Tape Duct
10/2005 US Issue 5.5 Diagrams of Pneumatic System and Functional Sequence

5.5 Diagrams of Pneumatic System and Functional

Sequence

Fig. 5.5.1 Diagram of Pneumatic System: Cutter per Conveyor Side

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5 Pneumatic Cutter and Empty-Tape Duct Service Manual S-27 HM
5.6 Changing of parts 10/2005 US Issue

5.6 Changing of parts

DANGER
Strictly adhere to the instructions in the DANGER text in Section 5.1! 5

WARNING
Wear appropriate thick protective gloves whenever working near the blades / the tape deflector.

High risk of injury exists from stationary blade and movable blade and the tape deflector of the
cutter, even when the machine has been turned off.

Never reach into the pneumatic cutter from below or into the empty-tape duct from above, not
even to resolve a problem (e.g., when tape is jammed). 5

5.6.1 Exchanging the Pneumatic Cutter

WARNING
Wear appropriate thick protective gloves.
When removing the cutter, hold it only on the left and right, on the outside.

Never support the cutter on your body, e.g., on your knees or thighs.
Do not place your feet under the cutter.
You could injury yourself severely or at least damage your clothing.

Make certain that no one can injury themselves on the cutter after it has been dismantled. 5

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Service Manual S-27 HM 5 Pneumatic Cutter and Empty-Tape Duct
10/2005 US Issue 5.6 Changing of parts

5.6.1.1 Removing the Cutter

Æ Turn the machine and then the compressed air ON.

Æ Disconnect the movable component changeover table from the machine and move it out of the
machine.
Æ Turn the machine OFF, disconnect the machine from the mains and turn off the flow of com-
pressed air at the compressed air unit. Actuate the needle valve on the compressed air unit to
bleed the compressed air lines (see DANGER text in Section 5.1).
Æ Loosen the screws fastening the nozzle changer, lift it up somewhat and hold it in this position.
Æ Unplug the electrical cable and the pneumatic hose of the nozzle changer.
Æ Carefully put the nozzle changer down.
Æ Loosen the screws fastening the empty-tape duct assembly (see Fig. 5.4.1) and lift the duct
out of the machine.

WARNING
There is always a risk of injuring yourself with the cutting edge of the blades.
For this reason, the deflector plate, the cover and the protective sheet (see Fig. 5.4.2) must be left
mounted in place. 5

Æ Take the cover off the cable pit (see Fig. 5.6.7 -> 5).
Æ Loosen the cutter’s compressed air connection (Y-socket union: see Fig. 5.6.3 -> 9) in the ca-
ble pit (see Fig. 5.6.7 -> 5).
Æ Remove the cover from the control board (see Fig. 5.6.5 -> 14).
Æ Unplug the plug-and-socket connection of the power supply and the drive on the control board
(see Fig. 5.6.5 -> 11, 10).
Æ Carefully undo the corresponding cable tie (left or right) on the outside of the control board box
(see Fig. 5.6.5 -> 15).
-> Do not damage the cables in this process.
Æ Place the cover back on the control board and on the cable pit.
Æ Remove the tape chute (it is only hooked in).
This makes the cutter easier to access for removal.

WARNING
The area under the cutter must be clear (e.g., do not place your feet under it either). 5

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5 Pneumatic Cutter and Empty-Tape Duct Service Manual S-27 HM
5.6 Changing of parts 10/2005 US Issue

Æ Undo the fasteners for the stop buffer assembly on left- and right-hand side of the machine
frame (two M8 socket hex head cap screws on each side, see Fig. 5.4.1 -> 15) under the
surface supporting for the component table.
Æ Loosen the screws fastening the cutter to the machine frame (2 screws, M6, on the left and
right retaining bracket, see Fig. 5.4.1 -> 2, 3 and 4):

– In exceptional cases, disks or plates may have been installed between the contact surface
of the cutter on the machine frame and the cutter itself.
-> Save these disks / plates and re-install them later.

Æ Securely hold the cutter tight at both ends.

Æ Pull the cutter out away from the contact surfaces (on the machine frame) towards the outside
of the machine (towards your body).
Æ Set the cutter down such that it does not pose a risk of injury to uninvolved personnel either.
Put it in its own crate / container immediately.

5.6.1.2 Installing the Cutter

Æ Make certain that the following warning signs are on the cover plate over the movable blade.
If not, install them (Item No.: see Section 5.2):

– Adhesive Label with text " Disconnect machine from mains voltage and....",

– Adhesive Label: Triangle warning symbol "Hand injury".

CAUTION
Tighten the screws to the correct torque -> see Table, Fig. 5.4.2. 5

Æ If there were disks or plates inserted between the contact surface of the cutter on the machine
frame and the cutter itself, re-install them now.
-> The cutter must be shimmed to the same height at all contact points however.
Æ In the reverse order to disassembly, place the new pneumatic cutter (Item no.: see Section 5.2)
on the contact surfaces of the machine frame and push it in to the threading position.
Æ To avoid dropping the cutter, insert all four M6 screws into the holes now:
Æ Pull the cutter as far as possible away from the PCB conveyor for the time being.
Æ Snug up the screws somewhat for the time being.
Æ Remove the cover from the control board of the new cutter.
Æ Make the plug-and-socket connections for the power supply and drive on the control board (al-
location: see Fig. 5.6.5 -> 11, 10).

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Æ Use a cable tie to fasten the cables running to the cable pit to the fixing pedestal on the control
board box (see Fig. 5.6.5 -> 15).
The strain on the cables / plug-and-socket connections must be relieved (see Fig. 5.6.7 -> 8).
Æ Remove the cover from the cable pit and make the compressed air connection to the machine
at the Y-plug-in coupling (see Fig. 5.6.3 -> 9).
Æ Place the cover back on the control board and the cable pit.
Æ Install the empty-tape duct assembly and check the entire length of the gap between the lead-
ing edge of the tape deflector and the "empty-tape baffle, inside", as described in Section 5.6.6.
Æ If necessary, slide the cutter in the slots parallel to the direction of the PCB conveyor until you
reach the TARGET distance 1.0 to 1.5 mm (see Fig. 5.4.2 -> Detail).
Æ In this position tighten all 4 screws crosswise.
-> Tighten the screws to the correct torque -> see Table, Fig. 5.4.2.
Æ Perform the appropriate “Final Steps” (see Section 5.6.8).

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5.6.2 Replacing the articulated joint on the short-stroke cylinder (00348579-02)

WARNING
Wear thick protective gloves.
You might cut yourself on the blades and the tape deflector.
Never reach into the pneumatic cutter from below or into the empty-tape duct from above. 5

Fig. 5.6.1 Replacing the articulated joint on the short-stroke cylinder

Key to Fig. 5.6.1

(1) Deflector plate (4) Articulated joint

(2) Cover (5) Screws to fasten short-stroke cylinder

(3) Screws to fasten the moveable blade 5

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Æ Remove the cutter from the machine, as described in Section 5.6.1.

Æ Remove the deflector plate from the cutter.
Æ Loosen the screws holding the moveable blade.
Æ Loosen the compressed air connections on the short-stroke cylinder (see Fig. 5.6.2.
5

Fig. 5.6.2 Compressed air connections

Æ Using a fine-tip, water-insoluble marker, accurately mark the specified position of the proximity
switch on the short-stroke cylinder.
Æ In addition, mark the allocation of the proximity switches to the short-stroke cylinder (position
front/back).
Æ Loosen the screws fastening the two inductive proximity switches to the short-stroke cylinder
(1 screw each: see Fig. 5.6.3 -> 4, 5).
Æ Loosen the screws fastening the short-stroke cylinder (2 screws: see Fig. 5.6.3 -> 5) and re-
move the cylinder, incl. the articulated joint screwed into it.
Æ Dismantle articulated joint from the cylinder by turning the open-end wrench (width across flats
10) on the surface indicated in Fig. 5.6.4 -> 3).

NOTE:
The threaded pin is secured with Loctite no. 243, so it takes somewhat more strength to loosen it.5

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Fig. 5.6.3 Removing and Installing the Short-Stroke Cylinder

Key:

1. Short-stroke cylinders 1 and 2

2. Screws fastening the short-stroke cylinders: 2 socket hex head cap screws each, M5 x 65

3. Screws fastening the articulated joint (see also Fig. 5.6.4)

4. Proximity switch (for position cylinder moved in). Fastener: 1 cross-slotted screw

5. Proximity switch (for position cylinder moved out). Fastener: 1 cross-slotted screw

6. One-way restrictor (for running cylinder out)

7. One-way restrictor (for running cylinder in)

8. Allocation of the compressed air connections, air hoses

9. Y-socket union (in the cable pit)

10. Multiple-Y-distributor on the safety valve (5 bar from compressed air unit)

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5.6.2.1 Installing the articulated joint and short-stroke cylinder

WARNING
You might cut yourself on the blades and the tape deflector. 5

Fig. 5.6.4 Removing Articulated Joint, Installing It on New Master Cylinder and Bonding It in Place

Key to Fig. 5.6.4 (right):

1. Short-stroke cylinder (1 or 2)

2. Articulated joint (complete)

3. Wrench surface for disassembling the articulated joint

4. Secure articulated joint thread with Loctite no. 243

5. Open-end wrench surface of articulated joint

6. Slide surface of the movable blade

7. Screw fastening the articulated joint to the movable blade:

one M4 x 24 DIN 912 socket hex head cap screw each, strength 12.9, secured with Loctite no.
243

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8. Movable blade with slot to prevent the articulated joint from turning if the articulated joint is
damaged, use a (complete) new one (Item no.: see Section 5.2) or clean the residues of Loctite
from the thread of the existing articulated joint pin.

CAUTION
Tighten the screws to the correct torque -> see Table, Fig. 5.4.2. 5

Æ Apply a small amount of Loctite no. 243 (Item no.: see Section 5.3) to the thread.
Æ Take note of the following WARNING. If the enamel on the one-way restrictor is damaged use
a new "short-stroke cylinder".

DANGER
One-way restrictors are not to be set on the machine. This is only permitted at the factory.
For this reason the replacement short-stroke cylinder must always be installed, together with the
new, already adjusted restrictors attached to it. 5

Æ Screw the articulated joint into the short-stroke cylinder.

Æ Turn the articulated joint into the mounting position (see Fig. 5.6.4, diagram on the left).
Once the cylinder is installed, the slot in the moveable blade prevents the articulated joint from
turning.
Æ Copy the exact mounting position of the proximity switch to the short-stroke cylinder (feeler
gauge, fine-tip marker).
Æ Install the prepared cylinder - complete with one-way restrictors - on the cutter, in the correct
rotational position for the articulated joint.
Æ Fasten the cylinder in this position with the 2 screws M5x65 (Fig. 5.6.3 -> 2) provided.
Æ Install the proximity switch (article no. see Section 5.2) precisely in the position you marked on
the short-stroke cylinder with the permanent marker (see Fig. 5.6.3 -> 4, 5).
Æ Connect the compressed air hoses to the one-way restrictor on the cylinder, in the correct al-
location (see markings). For allocation details please refer to Fig. 5.4.2 -> 6, 7, 8.
Æ Perform the following steps as described in Section 5.6.2.1:
Æ Fasten the moveable blade to the articulated joint.
Æ Re-install the empty-tape duct on the machine frame (2 screws each on LH and RH, see Fig.
5.4.1 -> 6, 9).
Æ Check the gap between the leading edge of the tape deflector and the "empty-tape baffle, in-
side", as described in Section 5.6.6.
Æ Check the switching points of the proximity switches, as described in Section 5.6.5.

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NOTE:
If the tapes are not cut correctly even though the switching points are set properly and the short-
stroke cylinder has been exchanged, complete with the one-way restrictor, the cause of the prob-
lem may be:
incorrect compressed air level/ leaking compressed air connection or Y-socket union, blade in
poor condition, faulty solenoid valve or a break in the drive circuit of the solenoid valve. 5

Æ Perform the appropriate "Final Steps" (see Section 5.6.8).

5.6.3 Exchanging the Control Unit

Fig. 5.6.5 Exchanging the Control Unit, Allocation of the Plug-and-Socket Connections

Key:

1. Drive of solenoid valve for cylinder 2 (left)

2. Drive of solenoid valve for cylinder 1 (right)

3. to the proximity switch on cylinder 2, FRONT

4. to the proximity switch on cylinder 1, FRONT

5. to the proximity switch on cylinder 2, BACK

6. to the proximity switch on cylinder 1, BACK

7. Cutter power supply (only busy on S-23 and F5)

8. Drive of cutter (only busy on S-23 and F5)

9. Service plug (to be used exclusively by Siemens)

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10. CAN bus

11. Power supply

12. Spring-mounted elements to disconnect the control board box

13. Support bar

14. Cover

15. Fixing pedestal adhesive type (LH and RH) with cable tie
Relieve tensile stress on cable/plug-and-socket connections.

16.Coding plug

WARNING
You might cut yourself on the blades and the tape deflector.
Never reach into the pneumatic cutter from below or into the empty-tape duct from above. 5

The cutter remains installed in the machine. 5

Æ Turn the machine and then the compressed air ON.

Æ Disconnect the movable component changeover table from the machine and move it out of the
machine.
Æ Turn the machine OFF.
Æ Remove the cover from the control board.
Æ Carefully undo the cable ties (left and right) on the outside of the control board box (see
Fig. 5.6.7 -> 10).
-> Do not damage the cables in this process.
Æ Mark the allocation of all plug-and-socket connectors and disconnect all plug-and-socket con-
nections on the control unit (see Fig. 5.6.5).
Æ Disconnect the control unit (box) from the support bar by pushing both of the spring-mounted
elements away from the ba.
Æ Install the new control unit (Item no.: see Section 5.2), correctly rotated and positioned, on the
bar and engage the unit.
Æ Mount an adhesive fixing pedestal for cable ties on the outside LH and RH side of the control
board box (see Fig. 5.6.6 for location).

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Fig. 5.6.6 Control Unit

Æ Restore all plug-and-socket connections in the correct allocation (see Fig. 5.6.5).
Æ Use a cable tie to fasten the cables running to the LH and RH side of the cable pit to the fixing
pedestal (on control board box). The strain on the cables/plug-and-socket connections must
be relieved (see Fig. 5.6.7 -> 8).
Æ Place the cover back on the control board.
Æ Perform the appropriate “Final Steps” (see Section 5.6.8).

5.6.4 Exchanging the Solenoid Valve on Left or Right (and/or Cable)

WARNING
You might cut yourself on the blades and the tape deflector.
Never reach into the pneumatic cutter from below or into the empty-tape duct from above. 5

The cutter remains installed in the machine. 5

Æ Turn the machine and then the compressed air ON.

Æ Disconnect the movable component changeover table from the machine and move it out of the
machine.
Æ Turn the machine OFF, disconnect the machine from the mains and turn off the flow of com-
pressed air at the compressed air. Actuate the needle valve on the compressed air unit to bleed
the compressed air lines (see DANGER text in Section 5.1).

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Key to Fig. 5.6.7 (right):

1. Solenoid valve for cylinder 1, incl. mounting strap

2. Solenoid valve for cylinder 2, incl. mounting strap

3. to the plug-and-socket connection of the appropriate solenoid valve

4. Screws for fastening the solenoid valve: 2 socket hex head cap screws each, M3 x 6

5. Cover of the cable pit

6. Compressed air hoses for cylinder 1

7. Compressed air hoses for cylinder 2

8. No strain on cable/plug-and-socket connections

9. Cover

10. Fixing pedestal, adhesive type, with cable tie (LH and RH)

11. Plug-and-socket connection on the solenoid valve

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Fig. 5.6.7 Exchanging the Solenoid Valve

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If the cable of the solenoid valve is faulty:

Æ Carefully undo the corresponding cable tie (left or right) on the outside of the control board
box (see Fig. 5.6.7 -> 10).
-> Do not damage the cables in this process.

Æ Remove the cover from the control board (see Fig. 5.6.7 -> 9).
Æ Unplug the plug-and-socket connection of the cable "Control board for tape cutter - valve"
of the appropriate solenoid valve on the control board (see Fig. 5.6.5 -> 1, 2).

Æ Loosen the plug-and-socket connection of the cable "Control board for tape cutter - valve"
of the appropriate solenoid valve (see Fig. 5.6.5).

Æ Take the cover off the cable pit (see Fig. 5.6.7 -> 5).
Æ Remove the cable and run the new cable "Control board for tape cutter - valve" (Item no.:
see Section 5.2). Push the excess lengths of cable into the cable pit.

Æ Make the plug-and-socket connection on the board (see Fig. 5.6.5) and on the solenoid
valve with correct allocation (see Fig. 5.6.7).

Æ Place the cover back on the control board (see Fig. 5.6.7 -> 9).
Æ Install the cover on the cable pit (see Fig. 5.6.7 -> 5).
Æ Use a cable tie to fasten the cables running to LH and/or RH side of the cable pit to the
fixing pedestal (on control board box).
The strain on the cable / plug-and-socket connections must be relieved (see Fig. 5.6.7 -> 8).

Æ Perform the appropriate “Final Steps” (see Section 5.6.8).

If the solenoid valve is faulty:

Æ Undo the 2 compressed air connections on the one-way restrictors at the faulty solenoid
valve (see Fig. 5.6.7 -> 1, 2, 6).

Æ Unplug the plug-and-socket connection of the cable "Control board tape cutter - valve"
on the faulty solenoid valve (see Fig. 5.6.7 -> 11).

Æ Undo the screws fastening the faulty solenoid valve (2 M3 screws: see Fig. 5.6.7 -> 4) and
remove the solenoid valve.

Æ Mount the new solenoid valve (Item no.: see Section 5.2) in the correct position, as shown
in Fig. 5.6.7. Make the plug-and-socket connection at the solenoid valve:
-> Tighten the screws to the correct torque -> see Table, Fig. 5.4.2.
-> The strain on the cable must be relieved (see Fig. 5.6.7 -> 8).

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Æ Mount the short-stroke cylinder compressed air connections to the one-way restrictors on
the solenoid valve with the correct allocation (see Fig. 5.6.3 -> 6, 7, 8).

Æ Perform the appropriate “Final Steps” (see Section 5.6.8).

5.6.5 Exchanging the Inductive Proximity Switch

5.6.5.1 Removing the Proximity Switch

The cutter remains installed in the machine.

Æ Turn the machine and then the compressed air ON.
Æ Disconnect the movable component changeover table from the machine and move it out of the
machine.
Æ Turn the machine OFF, disconnect the machine from the mains and turn off the flow of com-
pressed air at the compressed air. Actuate the needle valve on the compressed air unit to bleed
the compressed air lines (see DANGER text in Section 5.1).
Æ Remove the cover from the control board (see Fig. 5.6.5 -> 14).
Æ Carefully undo the corresponding cable tie (left or right) on the outside of the control board box
(see Fig. 5.6.5 -> 10).
-> Do not damage the cables in the process.
Æ Using a fine-tip permanent marker, precisely mark on the short-stroke cylinder the specified
position of the proximity switch that is to be exchanged.
Æ Disengage the plug-and-socket connection of the faulty proximity switch on the control board
(allocation: see Fig. 5.6.5).
If you loosen more than one of the plug-and-socket connection simultaneously, mark the allo-
cation.
Æ Take the cover off the cable pit (see Fig. 5.6.7 -> 5).
Æ Undo the screw fastening the proximity switch to the short-stroke cylinder (1 screw: see pic-
ture) and remove the proximity switch including the cable.

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5.6.5.2 Installing the Proximity Switch

Æ Install the new proximity switch (Item no.: see Section 5.2) precisely in the position you marked
on the short-stroke cylinder with the permanent marker.
-> Tighten the screws to the correct torque -> see Table, Fig. 5.4.2.
Æ Lay the cable in the cable pit and make the plug-and-socket connection to the proximity switch
on the control board with correct allocation to the proximity switch left/right and front/back (see
Fig. 5.6.5) -> Push the excess lengths of cable into the cable pit.
Æ Use a cable tie to fasten the cables running to the cable pit to the fixing pedestal on the control
board box (see Fig. 5.6.7 -> 10).
The strain on the cables / plug-and-socket connections must be relieved (see Fig. 5.6.7 -> 8).
Æ Place the cover back on the control board (see Fig. 5.6.7 -> 9).
Æ Install the cover on the cable pit (see Fig. 5.6.7 -> 5).
Æ Perform the "Final Steps" including the substep "Load the SITEST program and initiate the cut-
ting strokes" (see Section 5.6.8).

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5.6.6 Exchanging the Empty-Tape Duct Assembly

WARNING
You might cut yourself on the blades and the tape deflector.
Never reach into the pneumatic cutter from below or into the empty-tape duct from above. 5

Æ Turn the machine and then the flow of compressed air ON.
Æ Disconnect the movable component changeover table from the machine and move it out of the
machine.
Æ Turn the machine OFF, disconnect the machine from the mains and turn off the flow of com-
pressed air at the compressed air. Actuate the needle valve on the compressed air unit to bleed
the compressed air lines (see DANGER text in Section 5.1).
Æ Loosen the screws fastening the nozzle changer, lift it up somewhat and hold it in this position.
Æ Unplug the electrical cable and the pneumatic hose of the nozzle changer.
Æ Carefully put the nozzle changer down.
Æ Loosen the screws fastening the empty-tape duct assembly (see Fig. 5.4.1 -> 11, 9) and lift the
duct out of the machine.
Æ If you only want to exchange the faulty baffle inside/outside and/or the reject box, proceed as
indicated in Section 5.6.7.
Æ Screw the "empty-tape duct assembly" (Item no.: see Section 5.2) on the machine base (2
screws each on left and right, M4 x 16).
-> Tighten the screws to the correct torque -> see Table in Fig. 5.4.2.

WARNING
The following check can only be conducted from the bottom of the cutter after it has been installed
in the machine. Wear thick protective gloves; there is a risk of injury from the blades and the edge
of the tape deflector. 5

NOTE:
For the adjustments it is the best, if a second person is available 5

Æ With the feeler gauge, check:

The distance between the empty-tape baffle and the leading edge of the tape deflector must
again be within the TARGET distance 1.0 to 1.5 mm over the entire length (see Fig. 5.4.2 ->
Detail).

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If the gap is not OK.

Æ Loosen the screws holding the empty-tape duct once again and correct the position of the
duct in the holes.

Æ If this is not enough, you may assume that the cutter was already not in the optimal position
before the empty-tape duct was exchanged:
In this case, correct the position of the cutter in the slots of the retaining brackets in the man-
ner described for the installation of the cutter in Section 5.6.1.2.

5.6.7 Exchanging Baffles and / or Reject Box (Profile)

The "empty-tape duct assembly" has already been removed, as described in Section 5.6.6.
Æ Undo the self-tapping M4 screws fastening the baffle or reject box that you want to dismantle
(see detail in Fig. 5.4.2, 13 to 18).
Æ Insert the new baffle inside/outside and /or the new reject box (Item no.: see Section 5.2) and
fasten it with the self-tapping screws (see Fig. 5.4.2 -> 13 to 18).
Æ Install the empty-tape duct assembly and check the gap between the leading edge of the tape
deflector and the “empty-tape baffle, inside", as described in Section 5.6.6.
Æ Perform the appropriate “Final Steps” (see Section 5.6.8).

5.6.8 Final Steps

CAUTION
Tighten the screws to the correct torque -> see Table, Fig. 5.4.2. 5

Æ Make certain that each of the cables running out of the left and right of the control board box
is again fastened to the fixing pedestal with cable tie.
The strain on the cables / plug-and-socket connections must be relieved (Fig. 5.6.7 -> 8).
Æ Check the gap between the leading edge of the tape deflector and the "empty-tape baffle, in-
side", as described in Section 5.6.6.
Æ Where applicable, mount the tape chute into the machine.
Æ From below mount the stop buffer assembly on the machine frame (two M8 socket hex head
cap screws on left and right).
Æ If the nozzle changer is removed, stop the nozzle changer over the installation position and
and make the electrical and pneumatic connections.
Æ Mount the nozzle changer.
Æ Turn the compressed air back on at the main switch on the compressed air unit.

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Æ Move the changeover table back into the machine and connect it.

DANGER

It is a basic rule that the SITEST program is only to be started by personnel who have been trained
in its use at Siemens AG and are therefore authorized to start it.

When the SITEST program is used, additional, higher risk of an accident exists aside from the
generally higher danger posed by the blades of the cutter.

The cutter and the empty-tape duct have to be completely assembled at all times.

The component changeover table must be moved into the machine and connected correctly.

Never move your hand near the cutter, neither from below nor from above (via the empty-tape
duct), not even to resolve a problem.

When the SITEST program is running, you must always make certain that there is no 2nd person
at the machine, i.e., that no 2nd person can trigger the cutting process or is within the operating
area of the cutter.
Secure the area of the cutters appropriately to keep away other personnel.

The key switch remains locked (= normal mode = position "0").

One-way restrictors are not to be set on the machine. This is only permitted at the factory. 5

Æ Load the SITEST program and actuate the cutting strokes (see Operating Manual "SITEST
Program").
Æ If the nozzle changer was removed:
Use SITEST program to calculate the position of the nozzle changer.
Æ Exit the SITEST program.
Æ Perform a visual check to make certain that all empty-tape ends are correctly guided down-
ward in the empty-tape duct.
Æ Start the placement sequence.
5

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6 Modular PCB conveyor system (used

to SN 381)

NOTE
Before dismantling motors, light barriers etc. make sure that the problem is not due to poor con-
nections. For connection details please see Section 6.16 and Section 6.17.

6.1 Introduction

The modular PCB conveyor system is used for both the HS-60 and S-27 HM. This service manual
applies to both machine types. The differences between the two machines are mentioned in the
relevant sections of this manual.

CAUTION
This service manual contains item numbers for the individual spare parts applicable to both the
HS-60 and the S-27 HM. These are for general reference only. When identifying and ordering
spare parts, you should always use the current version of the spare parts catalog for the machine
concerned.

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6.2 Safety instructions

DANGER
For all procedures, please observe the safety instructions described in Chapter 2.

CAUTION
Customers must not undo any screws secured with loctite.

DANGER

The machines in the SIPLACE family operate on 3 x 400 V +/- 10%, 50/60 Hz mains voltage.
Consequently, portions of the system carry dangerous high voltage. Inside the machine base this
is true even when the main switch is switched off.
For all work in the vicinity of the PCB conveyor, the machine must be turned off and discon-
nected from the mains. In addition, the compressed air inlet on the main valve of the com-
pressed air unit in the machine base must be turned off and air must be bled from the
compressed air lines by actuating the needle valve. Make sure you have properly secured the ma-
chine so that it can not be restarted by unauthorized personnel!
During assembly and disassembly of PCB conveyor components and the lifting table, there is a
greater danger of injury through pinching, crushing or cutting off a body member, even when the
machine is turned off!
During assembly and disassembly of conveyor components there is also a risk of unhealthy pos-
ture due to the physical positioning and the weight of these components.
Two people must be available for some of these jobs.
Always wear strong protective gloves when removing or installing the PCB conveyor!
When a dual conveyor is involved, there is a risk of having a body member pinched or crushed
between the fixed side of conveyor 1 and the movable side of conveyor 2 when the conveyors are
traveling at maximum width.
If the pneumatic cutter is removed to improve accessibility, you must also comply with the safety
instructions in the chapter „Cutter, pneumatic....“ in the service manual.
There is additional, higher risk of accident when working with the SITEST program.
As a basic rule, the SITEST program may only be started by personnel who have been trained
in its use at Siemens AG and are therefore authorized to do so!

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The cutter must always be completely installed for work with the SITEST program and the com-
ponent changeover table must be moved in and correctly connected.
Only authorized personnel are to have access to the key for the key-operated switch. As a final
step, this switch must always be locked (= normal operation) and the key must be locked away.

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6.3 Parts

For spare part item numbers and diagrams please refer to the S-27 HM spare parts catalog.

6.4 Tools, testing aids, documentation

– 1 set of Allen wrenches

– Slotted and cross-slotted screwdriver, size 1

– Small rubber mallet

– 1 diagonal-nosed wire cutters, small

– Cable ties

– Set of open-end wrenches, width across flats 5.5 and 8

– 1 digital voltmeter (class 1.5)

– Shim to adjust the guide rails.

– Caliper gauge and feeler gauge, 0.2 mm

– Various gauge blocks

– Current spare parts catalog for SIPLACE S-27 HM and folder of circuit diagrams for SIPLACE
S-27 HM

– SITEST program including current operating instructions for SITEST program

– Current documentation „Adjusting instructions for S-27 HM“

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6.5 Function

6.5.1 General

The standard machine is equipped as a single PCB conveyor. A dual PCB conveyor system is
optionally available. Depending on individual requirements, either the left or right conveyor side
can be selected as the fixed conveyor side.

During placement, the PCB is clamped in place from underneath.The gap between the upper side
of the PCB and the placement head is not dependent on the thickness of the PCB and therefore
remains constant. This has the following benefits:

– The placement rate no longer depends on the thickness of the PCB.

– The recognition of PCB fiducials is optimized.

The constant distance between the PCB upper edge and the PCB camera means that the PCB
camera is always focussed clearly on the PCB surface. The PCB fiducial are always optimally
displayed on the CCD chip of the PCB camera.

PCB conveyor systems are configured within the machine so that, with the 12-segment col-
lect&place head, placement can be performed on components to a maximum height of 6 mm and,
with the 6-segment collect&place head (S-27 HM), on components to a max. of 8.5 mm.

The transport height can be set to allow the machines to be integrated into lines with 830, 900,
930 or 950 mm transport height. Communication between the PCB conveyors of the individual
machines is possible via either a SIEMENS or SMEMA interface.

PCB transport is monitored and controlled by light barriers, consisting of both a transmitter and
receiver module:

– Once a PCB reaches the placement area, it is recognized by a light barrier and the speed of
the conveyor belt is reduced.

– Approximately 100 ms later, the front edge of the slowly progressing PCB is detected by a laser
beam and the PCB is stopped and clamped in placed from underneath.

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6.6 Overview

6.6.1 Single conveyor system

The HS-60 single conveyor system consists of an input conveyor, two placement areas, the inter-
mediate conveyor and the output conveyor. The S-27 HM has only one placement area. In this
case, the single conveyor system consists of input conveyor, placement area and output con-
veyor. Each conveyor system has automatic width adjustment and a lifting table for clamping the
PCB in place.

Fig. 6.6.1 Overview - modular conveyor system (single conveyor)

Key

(1) Input conveyor (6) Lifting table placement area 1

(2) Placement area 1 (7) Width adjustment drive unit

(3) Intermediate conveyor (8) Lifting table placement area 2

(4) Placement area 2 (9) Width adjustment for adjustment units 1

and 2

(5) Output conveyor (10) Direction of transport

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6.6.2 Dual conveyor system

The dual conveyor system has two conveyor tracks. In the standard model, the fixed conveyor
side is on the right side of each track.
As in the case of the single conveyor system, the dual conveyor system consists of an input con-
veyor, two placement areas (HS-60 only), the intermediate conveyor (HS-60 only) and the output
conveyor. The dual conveyor system has automatic width adjustment and a lifting table to clamp
the PCB in place. See also Fig. 6.6.1)

Fig. 6.6.2 Overview - modular conveyor system (dual conveyor)

Key

(1) Conveyor track 1 (3) Direction of transport

(2) Conveyor track 2

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6.7 Replacing the complete drive unit (00359284-02)

Fig. 6.7.3 Replacing the complete drive unit (00359284-02)

Key

(1) Cable connections (4) Clamping ring

(2) Heat-shrinkable sleeves (5) Conveyor toothed belt

(3) Fastening screws (6) Motor mount

DANGER
Please observe the safety instructions in Chapter 2.

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CAUTION
The toothed belts must not be stretched or kinked!

6.7.1 Parts

– 00359284-02 drive unit

6.7.2 Removal

The DC geared motors, including the motor mounts of all 5 conveyor areas, are of like construc-
tion. Please bear in mind the following differences during assembly and disassembly.

– The motor mount in installed at an angle (tilted), according to the requirements of the installa-
tion site.

– Depending upon the installation position, the motor mount will either be fixed with a clamping
ring or a circlip.

Conduct the procedures for replacement as described below:

Æ For disassembly at PCB conveyor 2 (dual conveyor):

Move conveyor 1 only far enough apart, that the outside of the fixed conveyor assembly of
conveyor 2 and the screws fastening the motor are still accessible.
Æ For disassembly at the single conveyor or conveyor 1 of the dual conveyor:
Move the conveyor to maximum width.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Mark the polarity of the cable connections (+ / -) - important for the direction of rotation!
Æ Disconnect the cable shoes from the motor terminals.
Æ The heat-shrinkable sleeves which hold the connecting cable in place must be stripped off the
circumference of the DC geared motor.
Æ Remove the clamping ring (or circlip).
Æ Remove the 3 screws holding the motor mount in place.
Æ Carefully dismantle the motor mount and gently weave out the conveyor toothed belt.

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NOTE:
The way in which the conveyor toothed belt is run around the belt guide depends upon the trans-
port area concerned. Please observe this belt guidance during assembly.

NOTE:
If you have discovered a break in the motor cable during a continuity check, the motor cable must
be woven out as far as the conversion board of the conveyor side (see circuit diagrams of the
same name) and unplugged at the corresponding point. This may be somewhat complicated de-
pending on the routing of cables inside the machine base.
You may wish to contact Siemens AG SMD Service regarding this work.

6.7.3 Installation

Æ Install the new drive unit in the reverse order.

Æ Please check: the entire width of the conveyor toothed belt must engage at all synchronizing
disks and be run around the belt guide.
Æ Where applicable, install the guide rails on the conveyor component. Do not tighten this com-
pletely as it still needs to be adjusted.
Æ If guide rails have been loosened or remounted, you will need to readjust the alignment of
the guide rails (see Section 6.15).
Æ Perform the „Final steps including function check“ (see Section 6.18).

NOTE:
After the new drive unit has been installed, you must make certain that the direction of rotation and
the conveyor speed (motor voltage) are correct.
After reconnecting the geared motor, you will only need to check the direction of rotation.

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6.8 Exchanging the DC geared motor of the relevant

PCB conveyor drive (003009269-01)

Fig. 6.8.4 Exchanging the DC geared motor of the relevant PCB conveyor drive

Key

(1) DC geared motor (3) Synchronizing disk (conveyor toothed

belt)

(2) Fastening screws (4) Synchronizing disk (toothed belt for PCB
conveyor drive)

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DANGER
Please observe the safety instructions in Chapter 2.

CAUTION
The toothed belts must not be stretched or kinked!

6.8.1 Removal

The DC geared motors, including the motor mounts of all 5 conveyor areas, are of like construc-
tion. Please bear in mind the following differences during assembly and disassembly.

– The motor mount in installed at an angle (tilted), according to the requirements of the installa-
tion site.

– Depending upon the installation position, the motor mount will either be fixed with a clamping
ring or a circlip.

Conduct the procedures for replacement of all DC geared motors as described below:

Æ Remove the complete drive unit, as described in Section 6.7.

Æ Working from the fixed exterior side of the conveyor, undo the screws fastening the DC geared
motor (4 hexagonal socket-head screws, see Fig. 6.8.4).
Æ Tilt the DC geared motor with its synchronized disk a little, so that the small toothed belt of the
drive comes free of the synchronizing disk and then pull the motor out.
Please note:

– The toothed belt on the motor pinion must not be stretched or kinked during this pro-
cess.

– The synchronizing disk on the motor shaft must be moved out in such a manner that is does
not get caught in the toothed belt.

NOTE:
If you have discovered a break in the motor cable during to a continuity check, the motor cable
must be woven out as far as the conversion board of the conveyor side (see circuit diagrams
of the same name) and unplugged at the corresponding point. This may be somewhat compli-
cated depending on the routing of cables inside the machine base.You may wish to contact Sie-
mens AG SMD Service regarding this work.

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6.8.2 Installation

CAUTION
The toothed belt must not be stretched or kinked!

Æ Install the new DC geared motor in the reverse order

The entire width of the toothed belt must engage at the top and bottom synchronizing disk.
Æ Fix the DC geared motor with the 4 M3 hexagonal socket-head screws (see Fig. 6.8.4).
Æ Install the complete motor unit as described in Section 6.7.3.
Æ Perform the „Final steps including function check“ (see Section 6.18).

NOTE:
After the new drive unit has been installed, you must make certain that the direction of rotation and
the conveyor speed (motor voltage) are correct.
After reconnecting the geared motor, you will only need to check the direction of rotation.

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6.9 Replacing the toothed belt of the relevant PCB conveyor drive (00355553-01) 10/2005 US Issue

6.9 Replacing the toothed belt of the relevant PCB con-

veyor drive (00355553-01)

Fig. 6.9.5 Replacing the toothed belt of the relevant PCB conveyor drive

Key

(1) DC geared motor (4) Toothed belt

(2) Circlip (5) Synchronizing disk

(3) 4 x fastening screws

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DANGER
Please observe the safety instructions in Chapter 2.

CAUTION
The toothed belt must not be stretched or kinked!

6.9.1 Removal

The DC geared motors, including the motor mounts of all 5 conveyor areas, are of like construc-
tion. Please bear in mind the following differences during assembly and disassembly.

– The motor mount in installed at an angle (tilted), according to the requirements of the installa-
tion site.

– Depending upon the installation position, the motor mount will either be fixed with a clamping
ring or a circlip.

Conduct the procedures for replacement of all toothed belts as described below:

Æ Remove the complete drive unit, as described in Section 6.7

Æ Working from the fixed exterior side of the conveyor, undo the screws fastening the DC geared
motor
(4 hexagonal socket-head screws, see Fig. 6.8.4).
Æ Tilt the DC geared motor with its synchronized disk a little, so that the small toothed belt of the
drive comes free of the synchronizing disk and then pull the motor out.
Please note:

– The toothed belt on the motor pinion must not be stretched or kinked.

– The synchronizing disk on the motor shaft must be moved out in such a manner that is does
not get caught in the toothed belt.

Æ Remove the circlip and shim, see Fig. 6.9.5.

Æ Use a small rubber mallet to carefully knock the synchronizing disk out of the motor mount.
Æ Remove the toothed belt from the mount.

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6.9.2 Installation

CAUTION
The new toothed belt must not be stretched or kinked! during the following procedure.

Æ Insert the new toothed belt into the motor mount and place the belt around the synchronizing
disk of the geared motor.
Æ Place the toothed belt around the synchronizing disk of the conveyor toothed belt and insert
the synchronizing disk in its mount.
Æ Use a rubber mallet to carefully knock the synchronizing disk into position.
Æ Loosely fasten the DC geared motor with the 4 M3 hexagonal socket-head screws The entire
width of the toothed belt must engage at the top and bottom synchronizing disk.
Æ Install the complete motor unit as described in Section 6.7.3.
Æ Perform the „Final steps including function check“ (see Section 6.18).

NOTE:
After the new drive unit has been installed, you must make certain that the direction of rotation and
the conveyor speed (motor voltage) are correct.
After reconnecting the geared motor, you will only need to check the direction of rotation.

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6.10 Replacing the conveyor toothed belt (00364847-01)

DANGER
Please observe the safety instructions in Chapter 2.

NOTE
The following diagrams apply for the standard conveyor system (fixed side - right). The mount is
installed on one side of the conveyor, while the DC geared motor is mounted on the other side.

6.10.1 Parts

– 00356851-01 Synchroflex toothed belt for input-, output- or intermediate conveyor

– 00356850-01 Synchroflex toothed belt for placement area 1 + 2

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Fig. 6.10.6 Overview of conveyor toothed belt (example with mounting))

Key

(1) Input conveyor (4) Placement area 2 (HS-60 only)

(2) Placement area 1 (5) Output conveyor

(3) Intermediate conveyor (HS-60 only)

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6.10.2 Replacing the conveyor toothed belt

Fig. 6.10.7 Replacing the conveyor tooted belt (example with mounting)

Key

(1) Motor mount (3) Deflection pulley with slot (not visible)

(2) Clamping ring or circlip (4) Conveyor toothed belt

6.10.2.1 Removal

The way in which the conveyor toothed belt is run around the deflection pulley depends upon the
transport area concerned. Please observe this belt guidance during assembly and disassembly.
Please also observe the following differences during assembly and disassembly work.

– The drive unit is installed at an angle (tilted), according to the requirements of the installation
site.

– Depending upon the installation position, the drive unit will either be fixed with a clamping ring
or a circlip.

– The mount is installed on one side of the conveyor, while the DC geared motor is mounted on
the other side.

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6.10 Replacing the conveyor toothed belt (00364847-01) 10/2005 US Issue

Conduct the procedures for replacement as described below:

Æ Move the PCB conveyor to the position which gives you best access to the conveyor belt.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ If the drive unit is installed, remove it as described in Section 6.7.
Æ If the mount is installed, remove the clamping ring or circlip on the mount and the 3 screws
fastening the mount in place (see Fig. 6.10.7).
Æ Loosen the deflection pulley with the slot and relieve the tension on the belt.
Æ Carefully extract the mount or the drive unit, while also gently weaving out the conveyor
toothed belt.

6.10.2.2 Installation

CAUTION
The new toothed belt must not be stretched or kinked!

Æ Feed the new toothed belt into the drive unit and weave around the deflection pulleys.
Æ Insert the drive unit with the conveyor toothed belt and fasten the mount or the drive unit.
Please refer to Section 6.7.3 for installation instructions for the drive unit.
Æ Adjust the belt tension as described in Section 6.10.3.

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6.10.3 Adjusting the tension of the conveyor toothed belt

Fig. 6.10.8 Example for adjusting belt tension

Key

(1) Deflection pulley with slot (2) Measuring point of belt tension measuring
device (Strand center)

Æ The deflection pulleys, around which the conveyor toothed belt is run at approximately 180°,
are fastened at a slot. The tension of the conveyor toothed belt can be adjusted at this slot.
Æ Position the measuring point of the belt tension device at the strand center (i.e. the longest dis-
tance between the two deflection pulleys) of the conveyor toothed belt.
Æ Set the tension of the conveyor toothed belt according to the following values.

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6.10.3.1 Belt tension HS 60 for conveyor track 1 (single and dual conveyor)

– Input conveyor: 170 Hz +/- 17 Hz

– Placement area 1: 70 Hz +/- 7 Hz

– Intermediate conveyor: 147 Hz +/- 15 Hz

– Placement area 2: 70 Hz +/- 7 Hz

– Output conveyor: 170 Hz +/- 17 Hz

6.10.3.2 Belt tension HS 60 for conveyor track 2 (dual conveyor)

– Input conveyor: 170 Hz +/- 17 Hz

– Placement area 1: 70 Hz +/- 7 Hz

– Intermediate conveyor:118 Hz +/- 12 Hz

– Placement area 2: 70 Hz +/- 7 Hz

– Output conveyor: 170 Hz +/- 17 Hz

6.10.3.3 Belt tension S 27 HM (single and dual conveyor)

Fixed conveyor side (DC motors)

– Input conveyor: 110 Hz +/- 5 Hz

– Placement area: 100 Hz +/- 5 Hz

– Output conveyor: 100 Hz +/- 5 Hz

6.10.3.4 Belt tension S 27 HM (single and dual conveyor)

Movable conveyor side

– Input conveyor: 95 Hz +/- 5 Hz

– Placement area: 110 Hz +/- 5 Hz

– Output conveyor: 150 Hz +/- 5 Hz

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6.11 Lifting table

DANGER
Please observe the safety instructions in Chapter 2.

6.11.1 Function

Depending on the model (single or dual conveyor), each placement area has one or two indepen-
dently functioning lifting tables in use. The lifting table is driven indirectly via a pneumatic cylinder,
with magnetic valve control. Different PCB thicknesses are automatically compensated. Move-
ment along the Z-axis is measured at four points on the lifting table plate. A position measuring
system determines the lifting path. The top position of the lifting table is recognized by the position
measuring system and a Piezo force transducer (see also Section 6.11.6). The bottom position of
the lifting table is identified by the position measuring system and the end position proximity switch
on the pneumatic cylinder.

NOTE:
The standard space under the PCB is 40 mm. The previously used PCB supports are no longer
suitable.

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6.11.2 Replacing the lifting table (00358653-04))

DANGER
Please observe the safety instructions in Chapter 2.

Fig. 6.11.9 Replacing the lifting table

Key

(1) Lifting table plate (4) Connection cable for lifting table unit

(2) Fastening screws for the lifting table unit (5) Pneumatic connections

(3) Lifting table unit

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6.11.2.1 Parts

– 00358653-04 Lifting table unit for single conveyors

– 00358654-04 Lifting table unit for dual conveyors

6.11.2.2 Removal

Æ For single conveyor systems, move the PCB conveyor to its maximum position, giving you the
best access to the lifting table unit.

NOTE:
For dual conveyor systems, you will need to move the conveyor track 1 to the minimum position
and then move the fixed side of the conveyor track 2 mechanically.

Æ Move the Y-gantries into the area outside the PCB conveyor.

Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.

Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ For dual conveyor systems, you will need to mechanically release and then move the fixed
side of conveyor track 2, to enable you to lift the lifting table out of the machine.
Æ To do this, undo the screw fastening the brake in place (see Section 6.12). Slightly loosen (do
not unscrew fully) the grub screw in the fastening screw.
Æ Remove the fastening screw. Take care not to lose the spring inside.
Æ Move the side of the conveyor on the fixed side so that you can lift the lifting table out of the
machine.
Æ Undo the screws fastening the lifting table plate and remove the lifting table from the lifting ta-
ble unit.
Æ Undo the 6 screws fastening the lifting table unit.
Æ Remove the cover of the conveyor conversion board and unplug the lifting table connection
cable.
Æ Remove the pneumatic connection from the vacuum valve.
Æ Carefully lift the lifting table out of the locating pins.

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6.11.2.3 Installation

Æ Lift the lifting table into the machine and insert it onto the locating pins.
Æ Insert the fastening screws.
Æ Plug in the electrical and pneumatic cables.
Æ Carefully place the lifting table plate onto the lifting table unit and tighten the fastening screws
diagonally so that the lifting table is not tilted.
Æ Check the speed of the lifting table and the PCB clamping function. Adjust where necessary.
See also Section 6.11.7.2)

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6.11.3 Replacing and adjusting the silencer (00358684-05)

The silencer moves the lifting table gently upwards. It prevents the PCBs being clamped in with
too much impact.

Fig. 6.11.10 Replacing and adjusting the silencer

Key

(1) Actuator (3) Fastening screws

(2) Locknut (4) Handle

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6.11.3.1 Removal

Æ Move the PCB conveyor to the position which allows you best access to the lifting table unit.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Undo the screws fastening the lifting table plate and remove the lifting table plate from the lift-
ing table unit.See also Fig. 6.11.9
Æ Undo the two screws fastening the silencer.
Æ Undo the locknut. Take the silencer by its handle and twist it out of the mounting block.

6.11.3.2 Installation and adjustment

Æ Insert and twist the new silencer into the mounting block until the slide just touches the actu-
ator, so that the lifting table can be gently moved upwards.
Æ Secure this position with the locknut.
Æ Install the lifting table.
Æ Check whether the silencer has been fixed onto the mounting block with the locknut and that
the silencer slide has a gap of approx. 0.1 - 0.2 mm to the actuator (untriggered mode). In this
basic position, the lifting table should move gently upwards and activate the clamping sensor
in the conveyor side.
Æ If this is not the case, loosen the locknut and turn the silencer approx. one rotation into the
mounting block.
Æ Start the SITEST program and move the lifting table upwards.
Æ The lifting table must move gently upwards and activate the clamping sensor.
You should not hear the PCB clamping device loudly locking into place and no clamping device
errors messages should be issued.
Æ Check the speed of the lifting table and correct where necessary (see also Section 6.11.7.2).

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6.11.4 Replacing the solenoid valve (00358663-02)

Fig. 6.11.11 Replacing the 5/3 solenoid valve

Key

(1) Solenoid valve with 2 fastening screws (3) Pneumatic connections

(2) Connection plug

Æ Move the PCB conveyor to the position which gives you the best access to the lifting table unit.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.

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Æ Undo the screws fastening the lifting table plate and remove the lifting table plate from the lift-
ing table unit.See also Fig. 6.11.9
Æ Switch off the compressed air supply and release the air at the filter of the pneumatic unit.
Æ Undo the screws fastening the connection plug and unplug.
Æ Remove the pneumatic connections.
Æ Install the new solenoid valve and reconnect the electrical and pneumatic systems.
Æ Check the speed of the lifting table and correct where necessary (see also Section 6.11.7.2).

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6.11.5 Replacing the fork light barrier (00363079-01)

Fig. 6.11.12 Replacing the fork light barrier

Key

(1) Connection cable for the conversion board (3) Conversion board of the lifting table (under
of the lifting table the
cover)

(2) 2 x fork light barrier (position measuring

system tracks A + B)

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6.11.5.1 Parts

– 00363079-01 light barrier for track A - dual conveyor

– 00363080-01 light barrier for track B - dual conveyor

– 00363111-01 light barrier for track A - single conveyor

– 00363113-01 light barrier for track B - single conveyor

6.11.5.2 Removal

Æ Move the PCB conveyor to the position which gives you the best access to the lifting table unit.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Undo the screws fastening the lifting table plate and remove the lifting table plate from the lift-
ing table unit.See also Fig. 6.11.9
Æ Undo the two screws fastening the fork light barrier.
Æ Remove the cover from the conversion board of the lifting table.
Æ Unplug the conversion board of the lifting table.
Æ Install the new fork light barrier and reconnect the system to the electrical supply.

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6.11.6 Replacing the PCB clamping device sensor BB1/BB2 (00368272-01)

6.11.6.1 Function

The sensor indicates that the lifting table has activated the PCB clamping device.

The PCB is raised for placement and pressed against the PCB hold-down device (guide rail at the
side). As the lifting table moves upwards, the supporting plates on the sides raise the PCB with
the complete conveyor drive and clamp it in place. This enables the placement level to remain
constant, irrespective of the PCB thickness i.e. the placement height of the PCB remains un-
changed.

PCBs up to a length of 460 mm are clamped down in the relevant processing areas. No clamping
takes place in the input and output conveyors. PCBs with lengths between 460 mm and 510 mm
lie on the conveyor belt and are only supported in the placement area by the lifting table.

Fig. 6.11.13 Replacing the PCB clamping device sensor BB1/BB2

Key

(1) Cover with two fastening screws (behind (3) Grub screw
the sensor)

(2) Clamping actuator 1 (4) Clamping actuator 2

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6.11.6.2 Parts

– 00368272-01 PCB clamping device sensor BB1

– 00368273-01 PCB clamping device sensor BB2

6.11.6.3 Removal and installation

Æ Move the PCB conveyor to the position which gives you the best access to the sensor.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Undo the two screws fastening the cover and remove the sensor.
Æ Weave out the connection cable and unplug it at the relevant conversion board for the con-
veyor side. (See also Fig. 6.16.33).
Æ Place the new sensor in the area provided and replace the cover.
Æ Reconnect the electrical supply.
Æ Adjust the clamping device sensor (see also Section 6.11.6.4).

6.11.6.4 Adjusting the clamping device sensor

The clamping actuators (see Fig. 6.11.13) are arranged set so that clamping actuator 1 activates
the clamping device sensor first.

Æ To adjust the clamping device sensor, first loosen the grub screw. Then position the grub screw
so that it just touches the contact.
Æ When slight pressure is applied to the grub screw with the thumb, the input clamping sensor
should react. (SITEST -> I/O menu 3 conveyor 1 or I/O menu 4 conveyor 2, in each case on
the left under Reserve).

CAUTION
If the grub screw is over-tightened, the clamping device sensor could be destroyed.

Please check:
To rule out any unevenness on the lifting table, the clamping device sensor is checked for func-
tionality with and without the PCB and along the entire transport path. The clamping device sensor
settings are checked in continuous lifting table operation. If the clamping device sensor does not
react to the moving lifting table, an error message will be issued.

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6.11.7 Replacing the complete lifting table cylinder (00358703-01)

WARNING
Before performing adjustment work press the emergency STOP to ensure that the lifting table has
been secured against movement.

Fig. 6.11.14 Replacing the complete lifting table cylinder

Key

(1) End position proximity switch (3) Piston rod with locknut

(2) Lifting table cylinder

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6.11.7.1 Removal/installation

Æ Move the PCB conveyor to the position which gives you the best access to the lifting table
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Switch off the compressed air supply.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Undo the screws fastening the lifting table plate and remove the lifting table plate from the lift-
ing table unit.See also Fig. 6.11.9
Æ Undo the fastening screws for the solenoid valve (see also Fig. 6.11.11) and remove it from the
lifting table cylinder.
Æ Loosen the grub screw at the end position proximity switch and push the end position proximity
switch out of the lifting table cylinder guide rail.
Æ Loosen the locknut on the piston rod and twist the piston rod out until it releases itself from the
actuator.
Æ Undo and remove the two screws fastening the lifting table cylinder.
Æ Insert and fasten the new lifting table cylinder and install the piston rod.
Æ Move the lifting table by hand to its end position.
Æ Switch the machine on.
Æ Push the end position proximity switch into the guide rail until the LED lights up.
Æ Fix this position with the grub screw.
Æ Install the solenoid valve and the lifting table plate.
Æ Check the speed of the lifting table and correct where necessary (see also Section 6.11.7.2).

6.11.7.2 Adjusting the speed of the lifting table (service personnel only)

NOTE
The lifting table must be installed on the lifting table unit!

Æ Connect the service notebook to the conveyor control via the serial port.
Æ Open Start => Programs => Accessories and select the function Hyperterminal.
Æ Create a new connection.
Æ Select COM 1 => OK
Æ Select 57600 Bits/second => OK
Æ Select protocol => No => OK

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Æ A hyperterminal window will open => Press the Enter key =>and the main conveyor menu will
appear.

Fig. 6.11.15 Main menu "Test software conveyor"

Æ Select => 3 "Einstellen Meldungen" from the menu.

Æ Select "Standard Einstellungen" => Exit the menu with " 0 = Ende ".
Æ Select => 5 "Einzelkomponenten" from the menu.
Æ Select => 2 "Hubtisch" from the menu.
Æ Select => " a ", Auswahl Hubtisch (BB1,BB2 track 1 or track 2) from the menu.
Æ Press " Strg+E " to issue TSP reports.
Æ Select 2 or 3 from the menu, to move the lifting table upwards or downwards.

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Fig. 6.11.16 Issuing times for the lifting table

Æ Adjust the valves on the lifting table cylinder to give the following values:
– Lifting table upwards: 500ms +/- 20ms

– Lifting table downwards: 480ms +/- 20ms

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Transport direction

Pneumatic valve

Lifting table cylinder

Piston rod

Valve setting Valve setting

Time chracteristic for lifting table Time chracteristic for lifting table
below above

Abb. 6.11 - 17 Adjustment valves on the lifting table cylinder

– Rotating adjustment valve to the left: increases the lifting table travel time

– Rotating adjustment valve to the right: reduces the lifting table travel time

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6.12 Setting the fixed conveyor side (single and dual

conveyor)

NOTE
After undoing the conveyor side fixtures you MUST check the settings for the fixed conveyor side.
If these values are not correctly set for single or dual conveyers, this could cause the placement
nest to shift out of position. This could again lead to errors in the fiducial recognition.

Fig. 6.12.18 Moving fixed conveyor side for conveyor track 2 (in example of S-27 HM)

Key

(1) Fixed side - conveyor track 1 (4) Fastening screw

(2) Fixed side - conveyor track 2 (5) Moving the fixed side - conveyor track 2

(3) Side flange with grub screw (6) Direction of travel

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NOTE:
It is not normally necessary to adjust the fixed conveyor side. An exception to this rule is when
service work requires prior movement of the fixed conveyor side.

Procedure:
Æ Undo the fastening screw(1) (s. Fig. 6.12.19) on the side flange.
– The fastening screw also has a (1) hexagon socket-head grub screw, which you will need
to loosen slightly - do not unscrew it fully!

6
2

1
Fig. 6.12.19 Modular transport details

Æ Remove the fastening screw (1). Make sure you do not lose the spring inside.
Æ Push the fixed transport side as far as to the stop ring (2) (s. Fig. 6.12.19).
Æ Check the measurements in line with Fig. 6.12.20.
Æ Insert the spring and tighten the screw fastening the brake.
Æ First fasten one side flange with the fastening screw and check the measurements on both
sides. Both conveyor sides must run parallel to one another
Æ Fasten the second side flange with the fastening screw and check the measurements again.
Æ Test run the PCB conveyor to a distance of 216 mm and move the test PCB
(item no. 00359535-01) in the PCB conveyor. The PCB must be moved through the entire PCB
conveyor system.

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Single conveyor Dual conveyor

Conveyor side walls Conveyor side walls

track 2 track 1
movable stationary movable stationary
station.

Direction of PCB transport

251.7 mm

Shaft
Shaft

Shaft Shaft
support support

34.5mm 30.5mm

Screw to loosen the Screw to loosen the

stationary wall stationary wall

Fig. 6.12.20 Setting the "fixed conveyor side" HS-60, S-27 HM

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6.13 Width adjustment

DANGER
Please observe the safety instructions in Chapter 2.

6.13.1 Function

The width adjustment system is motor-driven with program control. For dual conveyor systems,
differing widths can be set for the two conveyor tracks. The width adjustment uses a stepping mo-
tor, meaning that the PCB width can be set independently of other machine components (e.g. the
Y-gantry).

The conveyor width set is fixed to a steel strip, with the help of a clamping device.

The PCB width is adjusted via two adjustment units (pneumatic cylinders), installed under the in-
put or output conveyor.

– The stepping motor moves the two adjustment units synchronously through the use of ball
screws and a toothed belt.

– To adjust the PCB width, the two adjustment units are positioned under the conveyor side con-
cerned. The exact position is determined with the help of an end position proximity switch on
the relevant adjustment unit.

– The pneumatically operated fixing pins mechanically connect the conveyor side with the ad-
justment unit. The conveyor side is unclamped (on the steel strip).

– After the new PCB width has been set, the conveyor side is reclamped and the adjustment unit
fixing pins are disconnected.

For dual conveyor systems, the widths of the transport paths are set one after the other (only one
drive unit for both conveyor tracks). Maximum and minimum PCB widths are monitored by the end
position switch. If the two conveyor sides of any one conveyor track are not parallel to one another,
this will be automatically corrected during width adjustment. The two adjustment units are then
moved under the conveyor side concerned. The adjustment unit first reaching its position under
the conveyor side fixes this. Travel continues until the second adjustment unit has also reached
its position and fixed the conveyor side.

The conveyor track has now been corrected and the two conveyor sides should be parallel. If nec-
essary, the correct PCB width can now be set.

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Fig. 6.13.21 Overview of width adjustment (example shows the HS-60)

Key

(1) Adjustment unit (4) Toothed belt for the width adjustment drive

(2) Synchronizing disk with spindle (5) Direction of travel

(3) Width adjustment stepping motor (6) Bearing flange

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Fig. 6.13.22 Overview of width adjustment on the S-27 HM

Key

(1) Adjustment unit (4) Toothed belt for the width adjustment drive

(2) Synchronizing disk with spindle (5) Direction of travel

(3) Width adjustment stepping motor

CAUTION
The bearing flange for the HS-60 (see Fig. 6.13.21) and S-27 HM MUST NOT be loosened or ad-
justed. This would prevent the PCB conveyor from functioning and it would need to be completely
replaced.

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6.13.2 Replacing the stepping motor of the width adjustment system (00367174-02)

DANGER
Please observe the safety instructions in Chapter 2.

Fig. 6.13.23 Replacing the stepping motor of the width adjustment system

Key

(1) Loosening the eccentric axle on the deflec- (3) Screws fastening the stepping motor
tion pulley

(2) Locknut on the eccentric axle

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6.13.2.1 Removal/installation

CAUTION
During the following removal and installation of the motor, the toothed belt for the width adjustment
drive must not be stretched or kinked!

Æ Move the PCB conveyor to the position which allows you best access to the stepping motor of
the width adjustment system.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Undo the screws fastening the lifting table plate and remove the lifting table plate from the lift-
ing table unit. See also Fig. 6.11.9.
Æ Loosen the eccentric axle on the deflection pulley and relieve the tension on the drive belt.
Æ Remove the 4 fastening screws and then lift out the stepping motor.
Æ Unplug the connection cable in the cable duct.
Æ Install the new stepping motor and reconnect the system to the electricity supply.
Æ Tension the drive belt as described in Section 6.13.3.

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6.13.3 Replacing a toothed belt for the drive of the width adjustment system
(00356841-01)

Fig. 6.13.24 Replacing a toothed belt for the drive of the width adjustment system

Key

(1) Fastening screw on spindle block (4) Spindle

(2) Spindle block with synchronizing disk (5) Adjustment unit

(3) Stepping motor on flange (6) Measuring point of belt tension measuring
device (Strand center)

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6.13.3.1 Removal/installation

Æ Move the PCB conveyor to the position which allows you best access to the width adjustment
system.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Undo the screws fastening the lifting table plate and remove the lifting table plate from the lift-
ing table unit. See also Fig. 6.11.9
Æ Loosen the eccentric axle of the deflection pulley and relieve the tension on the toothed belt
of the width adjustment system drive (see also Fig. 6.13.25).

Fig. 6.13.25 Loosening the eccentric axle on the deflection pulley

Æ Undo the two fastening screws on the stepping motor flange and weave the toothed belt out
of the drive.
Æ Undo the fastening screws on the spindle block of the input or output conveyor and lift the spin-
dle block out of the locating pins. You can now remove the toothed belt from the synchronizing
disk.
Æ Undo the second spindle block and remove the toothed belt.

CAUTION
The new toothed belt must not be stretched or kinked!

Æ Place the new toothed belt on the two synchronizing disks for the spindle block and run over
the deflection pulley into the drive unit.

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Æ Set the parallelism of the adjustment unit to the fixed side.

Æ Manually turn the spindle and place any gauge block between the adjustment unit and the
conveyor side.

Æ Turn the spindle until both adjustment units reach this limit.
Æ Check the distance on both sides with this gauge block.
Æ Tension the toothed belt (see also Fig. 6.13.24) on the eccentric axle until it engages fully with
the teeth of the synchronizing disk.
Please check: The entire width of the toothed belt must be engaged on the synchronizing disk
and must also run along the entire length of the deflection pulley.

6.13.3.2 Setting the tension of the toothed belt for the width adjustment system drive

Æ Position the measuring point of the belt tension measuring device at the strand center (i.e. the
longest distance between two synchronizing disks) of the toothed belt (see also Fig. 6.13.24).
Æ Set the belt tension according to the following values.
– Width adjustment: 24 Hz (+/- 2 Hz)

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6.13.4 Replacing the limit switches for the end position of the width adjustment sys-
tem (00365108-02)

DANGER
Please observe the safety instructions in Chapter 2.

Limit switch in the input conveyor:

In the vicinity of the input conveyor, there are 4 limit switches under the conveyor sides. The limit
switch is designed to prevent the conveyor sides hitting one another or the conveyor base.

Limit switch in the output conveyor:

In the vicinity of the output conveyors, there are 2 limit switches for the adjustment unit. They serve
to secure the transport area and to initialize the adjustment unit during width adjustment.

6.13.4.1 Parts

– 00365002-03 Limit switch on the mounting tray

– 00365108-02 Limit switch for width adjustment 1

– 00365109-02 Limit switch for width adjustment 2

– 00362345-01 Limit switch for width adjustment - on the conveyor side

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Fig. 6.13.26 Replacing the limit switch for the width adjustment system (example shows HS-60)

Key

(1) Limit switch on the mounting tray (3) Limit switch for width adjustment 1

(2) Limit switch for width adjustment 1 or 2 for (4) Limit switch for width adjustment 2
dual conveyors

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6.13.4.2 Removal/installation

NOTE:
The limit switches are pre-assembled and include cables.
However, if the limit switch itself is faulty, the wiring can also be unsoldered/soldered right at the
switch in question.

Æ Unsolder the connection wires on the faulty limit switch (see also Section 6.16 and Section
6.17).
Æ Undo and remove the two screws on the faulty limit switch.

NOTE:
If you have discovered a break in the limit switch cable during a continuity check, the cable must
be woven out as far as the conversion board of the mounting tray (see circuit diagrams of the
same name) and unplugged at the corresponding point. (see also Section 6.16 and Section 6.17).

This may be somewhat complicated depending on the routing of cables inside the machine base.

You may wish to contact Siemens AG SMD Service regarding this work.

Æ Install the new limit switch and re-solder the connection wires with the correct allocation.

6.13.4.3 Checking the position of the limit switch

Æ Check the minimum and maximum width for the relevant machine type and the parallelism of
the conveyor sides.

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6.13.5 Adjustment unit for the width adjustment system

The position of the adjustment unit in the width adjustment system is shown in Fig. 6.13.21

Fig. 6.13.27 Overview of the adjustment unit for the width adjustment system

Key

(1) Short-stroke cylinder (3) Proximity switch

(2) Solenoid valve (4) Proximity switch for the adjustment unit

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6.13.5.1 Replacing the valve of the adjustment unit (00363779-01)

Parts
– 00363779-02 Adjustment unit valve 1

– 00363780-02 Adjustment unit valve 2

Æ Move the PCB conveyor to the position which allows you best access to the adjustment unit.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Switch off the compressed air supply.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Undo and remove the screw fastening the connection plug (see also Fig. 6.13.27).
Æ Disconnect from the pneumatic system.
Æ Undo the two fastening screws and remove the valve from the short-stroke cylinder.

NOTE:
If you have discovered a break in the connection cable during a continuity check, the cable must
be woven out as far as the conversion board of the mounting tray (see circuit diagrams of the
same name) and unplugged at the corresponding point. (see also Section 6.16 and Section 6.17).
This may be somewhat complicated depending on the routing of cables inside the machine base.
You may wish to contact Siemens AG SMD Service regarding this work.

Æ Install the new valve and reconnect to the electrical and pneumatic systems.

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6.13.5.2 Replacing the proximity switch for width adjustment systems 1+2 (00363777-01)

The proximity switch on the adjustment unit cylinder should operate when the adjustment unit pin
is pushed out by the pneumatic cylinder and therefore connected to the conveyor side. This signal
enables the motor of the width adjustment system.

Parts
– 00363777-01 Proximity switch for width adjustment system 1

– 00363778-01 Proximity switch for width adjustment system 2

Æ Move the PCB conveyor to the position which allows you best access to the adjustment unit.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Switch off the compressed air supply.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Loosen the grub screw on the proximity switch (see also Fig. 6.13.27) and move the proximity
switch out of the lifting table guide rail.
Æ Extract the connection cable as far as the conversion board of the mounting tray.
Æ Run the connection cable for the new proximity switch.
Æ Insert the new proximity switch into the guide rail.
Æ Switch the machine on.

NOTE
The width adjustment system proximity switch is set adjusted in engaged mode.

Æ Move the width adjustment system until the proximity switch switches - LED (H36/H37) lights
up.
Engage the cylinder - i.e. the cylinders are moved to the upper limit by the controls.
Æ Set the proximity switch so that the LED lights up when it is in engaged mode.
Æ Fix the position of the proximity switch with the grub screw.

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6.13.5.3 Replacing the proximity switch for adjustment units 1+2 (00363775-01)

The proximity switch serves as a signal for controlling the pneumatic valve of the adjustment unit.
Once the switching point has been reached, the conveyor side is connected via the short-stroke
cylinder.

Parts
– 00363775-01 Proximity switch adjustment unit 1

– 00363776-01 Proximity switch adjustment unit 2

Æ Move the PCB conveyor to the position which allows you best access to the adjustment unit.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Switch off the compressed air supply.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Loosen the grub screw on the clamping device (see also Fig. 6.13.27) and extract the connec-
tion cable as afar as the conversion board of the mounting tray.
Æ Insert the new proximity switch and reconnect to the electricity supply.
Æ Fix the proximity switch with the grub screw. The proximity switch must be level with the ad-
justment unit housing.
Æ The switching point is set at the actuator on the conveyor side.
Move the adjustment unit to under the conveyor side (see also Fig. 6.13.28).
Æ Place a gauge block of 2/10mm on the adjustment unit, press the actuator onto the gauge
block and tighten the screw.

NOTE
This setting must be performed at all conveyor sides.

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6.13.5.4 Replacing the actuator for the width adjustment system (00355533-02)

Fig. 6.13.28 Replacing the actuator for the width adjustment system

Key

(1) Actuator (3) Adjustment unit

(2) Fastening screw for actuator (4) Proximity switch for adjustment unit

Æ Move the PCB conveyor to the position which allows you best access to the adjustment unit.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Switch off the compressed air supply.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.

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Æ Undo and remove the screw fastening the actuator. (see also Fig. 6.13.28).
Æ Install the new actuator and screw in loosely.
Æ The switching point is set at the actuator on the conveyor side.
Move the adjustment unit to under the conveyor side.
Æ Place a gauge block of 2/10mm on the adjustment unit, press the actuator onto the gauge
block and tighten the screw.

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6.14 Light barriers and stopper for scanning the PCB

positions along the transport routes

6.14.1 Function

The positions of the PCBs are scanned with the help of light barriers (transmitter and receiver
modules). The light barriers are installed above the conveyor belt and feel along the length of the
conveyor belt.

The light barrier signal stops the PCBs on the input conveyor, intermediate conveyor (HS-60 only)
and output conveyors. The light barrier in the placement area can be moved 50 mm against the
direction of transport to guarantee secure positioning of the PCB.

In the placement area the light barrier triggers the braking procedure via a DC motor. The soft-
ware regulates a constant time interval for the slow travel towards the laser light barrier.

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6.14.2 Replacing the light barriers for transmitter and receiver modules
(from 00370063-01)

Fig. 6.14.29 Light barriers for transmitter and receiver modules (example shows S-27 HM)

Key

(1) Transmitter on input conveyor (4) Receiver on placement area

(2) Receiver on input conveyor (5) Transmitter on output conveyor

(3) Transmitter on placement area (6) Receiver on output conveyor

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6.14.2.1 Parts

NOTE
Please note the different item numbers for the individual light barriers. These are for the different
lengths of the connection cable.
Please refer to the relevant spare parts catalogue for the different S-27 HM item numbers.

– 00370063-01 Light barrier transmitter input conveyor

– 00370064-01 Light barrier transmitter placement area1

– 00370065-01 Light barrier transmitter intermediate conveyor (HS-60 only)

– 00370066-01 Light barrier transmitter placement area 2 (HS-60 only)

– 00370067-01 Light barrier transmitter output conveyor

– 00370068-01 Light barrier receiver input conveyor

– 00370069-01 Light barrier receiver placement area1

– 00370070-01 Light barrier receiver intermediate conveyor (HS-60 only)

– 00370071-01 Light barrier receiver placement area 2 (HS-60 only)

– 00370072-01 Light barrier receiver output conveyor

6.14.2.2 Important instructions for replacing the light barrier

– The transmitter is installed on the fixed side of standard conveyor models, while the receiver
is on the moveable side.

– Check whether it would be helpful to feed in the new cable with the aid of the old one, as least
in some areas.

– The connection plug is equipped with contacts, which are pressed onto the wires. You may find
it helpful to remove the contacts from the connection plug, in order to run the cable better
through openings.

– For replacement purposes, the connection cable must be woven out as far as the relevant con-
version board of the conveyor side. This may be somewhat complicated depending on the rout-
ing of cables inside the machine base.
Either contact Siemens AG SMD Service regarding this work or proceed as follows:

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6.14.2.3 Exchanging the transmitter or receiver for placement area 1 + 2

General/function
– Switch on the laser light barrier

– The travel profile to brake the PCB starts

The light barrier in the placement area can be moved within a range of 50 mm. it is not necessary
to move the light barrier in order to reduce the speed of the PCB, so that it stops securely at the
laser light barrier.In its standard form, the light barrier is installed in the direction of conveyor input,
giving the maximum distance between the light barrier and laser. The software automatically
learns the slow travel of the PCB of approx.100 ms up to the laser light barrier. Once the travel
profile for braking the PCB has begun, the PCB will be reliably stopped at the laser light barrier
after a maximum of 100 ms.

Receiver
Æ Undo the screw fastening the light barrier.
Æ Pull the side cover plate out of its guidance.
Æ Undo and remove the 7 fastening screws from the guide rail.
Æ Carefully remove the plate beneath and weave out the connection cable as far as the relevant
conversion board of the conveyor side.
Æ Unplug the conversion board of the conveyor side.
Æ Rerun the connection cable accordingly and reconnect the conversion board of the conveyor
side to the electricity supply.
Æ Fix the new light barrier in the original position.
Æ Insert the cover plate and install the guide rail.
While doing this, press the PCB take-up upwards and tighten the 7 fastening screws.

Transmitter
Æ Undo the 2 screws on the guide rail. You can now access the light barrier.
Æ Undo and remove the two screws fastening the light barrier.
Æ Weave out the connection cable as far as the relevant conversion board of the conveyor side.
Æ Unplug the conversion board of the conveyor side.
Æ Rerun the connection cable accordingly and reconnect the conversion board of the conveyor
side to the electricity supply.
Æ Fix the new light barrier in the original position and install the guide rail.

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6.14.2.4 Changing the receiver for the input or output conveyor

Transmitter

NOTE
The transmitter on the input and output conveyors is freely accessible. The bracket must be loos-
ened and the screws fastening the light barrier removed.

Æ Loosen the bracket and remove the screws fastening the light barrier.
Æ Weave out the connection cable as far as the relevant conversion board of the conveyor side.
Æ Unplug the conversion board of the conveyor side.
Æ Rerun the connection cable accordingly and reconnect the conversion board of the conveyor
side to the electricity supply.
Æ Fix the new light barrier in the original position.

Receiver
Æ Remove the screws fastening the light barrier.
Æ Undo and remove the 6 screws fastening the guide rail.
Æ Check whether it is possible to weave out the connection cable with its plug.

NOTE
Otherwise check whether you can run the cable through the opening by removing the contacts in
the connection plug.

Æ Relieve the tension on the conveyor belt, if necessary and remove the deflection pulley at the
opening, so that the cable can be woven out
Æ Weave out the connection cable as far as the relevant conversion board of the conveyor side.
Æ Unplug the conversion board of the conveyor side.
Æ Rerun the connection cable accordingly and reconnect the conversion board of the conveyor
side to the electricity supply.
Æ Fix the new light barrier in the original position.
Æ Install the deflection pulley and conveyor toothed belt. Tension the belt (see also Section
6.10.3).

210
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
10/2005 US Issue 6.14 Light barriers and stopper for scanning the PCB positions along the transport routes

6.14.2.5 Removing and installing the light barrier for the intermediate conveyor

Receiver
Æ Undo the screw fastening the light barrier.
Æ Pull the side cover plate out of its guidance.
Æ Undo and remove the 7 fastening screws from the guide rail
Æ Carefully remove the plate beneath and weave out the connection cable as far as the relevant
conversion board of the conveyor side.
Æ Unplug the conversion board of the conveyor side.
Æ Rerun the connection cable accordingly and reconnect the conversion board of the conveyor
side to the electricity supply.
Æ Fix the new light barrier in the original position.
Æ Insert the cover plate and install the guide rail.While doing this, press the PCB take-up up-
wards and tighten the 7 fastening screws.

Transmitter

NOTE
The transmitter on the input and output conveyors is freely accessible. The bracket must be loos-
ened and the screws fastening the light barrier removed.

Æ Loosen the bracket and remove the screws fastening the light barrier.
Æ Weave out the connection cable as far as the relevant conversion board of the conveyor side.
Æ Unplug the conversion board of the conveyor side.
Æ Rerun the connection cable accordingly and reconnect the conversion board of the conveyor
side to the electricity supply.
Æ Fix the new light barrier in the original position.

211
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6.14 Light barriers and stopper for scanning the PCB positions along the transport routes 10/2005 US Issue

6.14.3 Replacing the laser light barriers for stopper positions (00364782-01)

6.14.3.1 Functions

The PCB is stopped in the placement area with the aid of a laser light barrier. As soon as the light
barrier detects the front edge of an approaching PCB, the PCB is stopped. This method avoids
the impact previously caused when the PCB reached the stopper.

The position accuracy of the stopped PCB is +/-0,5 mm.

The S-27 HM is designed for the placement of longer PCBs but it does not have 2 stopping posi-
tions as in the case of HS-60. The situation is therefore different in the S-27 HM, as the machine
gantry has a larger travel range and can reach any position on the PCB. The PCB does not need
to be moved to the second stopping position in order to perform placement work on the rear area
of the PCB.

DANGER
The laser light barrier emits class 2 laser beams. These do not require any additional safety mea-
sures!
However, DO NOT expose your eyes to the laser beam!

Since laser beam deviation is at its greatest during maximum conveyor width, we recommend a
comparison at maximum conveyor width.

NOTE
After setting the laser light barrier you must check or re-teach the laser light barrier!

212
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
10/2005 US Issue 6.14 Light barriers and stopper for scanning the PCB positions along the transport routes

Fig. 6.14.30 Laser light barrier for stopper positions

Key

(1) Transmitter module (amplifier) with 2 (2) Transmitter module (round laser diode)
screws with 3 screws

6.14.3.2 Parts

– 00364782-01 Laser light barrier for transmitter module BB1

– 00364782-01 Laser light barrier for transmitter module BB2

213
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6.14 Light barriers and stopper for scanning the PCB positions along the transport routes 10/2005 US Issue

6.14.3.3 Removal/installation

NOTE
Since laser beam deviation is at its greatest during maximum conveyor width, we recommend a
comparison at maximum conveyor width.For laser diode settings, use the input/output function of
the SITEST program to activate the laser diode.

Æ Move the PCB conveyor to the position which allows you best access to the laser light barrier.
Æ Move the Y-gantries into the area outside the PCB conveyor.
Æ Turn the machine off at the main switch and disconnect the machine from the mains voltage.
Æ Make sure the machine has been properly secured to prevent it being switched on again dur-
ing servicing.
Æ Undo the 2 fastening screws on the large transmitter module and the 3 fastening screws on
the small transmitter module.
Æ Weave out the connection cable as far as the relevant conversion board of the conveyor side.
Æ Unplug the conversion board of the conveyor side.
Æ Rerun the connection cable accordingly and reconnect the conversion board of the conveyor
side to the electricity supply.
Æ Fix the new light barrier in the original position.
Æ Switch the machine on.

6.14.3.4 Setting and checking the laser light barrier for the stopper positions

Æ Set the maximum conveyor width.

Æ Activate the relevant laser diode via the SITEST input/output function.
Æ Check the path of the laser beam. To do this, you might want to make the laser beam visible
with the help of a piece of white paper or a light-colored PCB (see Fig. 6.14.31).
Æ Use the three adjustment screws to set the laser beam to the middle of the receiver.
Æ Check the placement nest and re-teach it, if necessary.

NOTE:
When you move the paper, the beam should follow the edge of the PCB as accurately as possible.
Any deviation to the left or right should be kept to a minimum.

214
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
10/2005 US Issue 6.14 Light barriers and stopper for scanning the PCB positions along the transport routes

Fig. 6.14.31 Setting the laser beam

6.14.4 Setting the light barriers in the placement area

Function:
– Switch on the laser light barrier

– Start the PCB braking procedure, see Fig. 6.14.32.

The light barrier in the placement area can be moved within a range of 50 mm. This function was
designed for PCBs with recesses on the side, to ensure that they are stopped by the laser light
barrier. In its standard version, the light barrier is installed in the direction of conveyor input, giving
the greatest distance between the light barrier and laser. The software automatically sets the slow
travel of the PCB so that it takes approx.
100 ms until it reaches the laser light barrier.

215
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6.14 Light barriers and stopper for scanning the PCB positions along the transport routes 10/2005 US Issue

1st board
Travel profile
braking process
Start End
Speed (v)

150 ms

Time (t)
Light barrier Laser

Input belt Placement area

Direction of PCB transport

Travel profile
braking process
2nd board
Start End
Speed (v)

< 100 ms

Time (t)
Light barrier Laser

Input belt Placement area

Fig. 6.14.32 Diagrams v(t), PCB braking procedure

The travel profile to brake the PCB (see Fig. 6.14.32) is initiated at the correct moment to ensure
that the PCB is stopped at the laser light barrier after a maximum of 100ms. The automatic learn-
ing process at the beginning of the travel profile ensures that the stopper position is reached in a
constant time, irrespective of the PCB weight. The transport time remains constant.

216
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
10/2005 US Issue 6.15 Checks to be performed after mechanical work on the conveyor system

6.15 Checks to be performed after mechanical work on

the conveyor system

DANGER
Please observe the safety instructions in Chapter 2.

Æ Check the distance between the top edge of the conveyor belt and the top of the guide rail.
This measurement should be 6 mm.
Æ Check the distance between the top edge of the conveyor belt and the top of the guide rail at
the clamping sensor.
This measurement should be 5.8 mm.
Æ Check the distance between the actuator clamping device (lifting table) and the top edge of
the belt.
This measurement should be 94.2 mm for the HS-60.
This measurement should be 74.2 mm for the S-27 HM.
Æ Check the distance between the actuator clamping device (lifting table) and the top edge of
the belt at the clamping sensor.
This measurement should be 94.4 mm for the HS-60.
This measurement should be 74.2 mm for the S-27 HM

TIP
Move one PCB into the placement area and clamp the PCB in place. Now measure the distance
between the top edge of the lifting table (rubber stop) and the bottom edge of the PCB. This height
should be exactly 94 mm for the HS-60 and 74 mm for the S-27 HM.

NOTE
The actuator under the clamping sensor must be mounted 0.2 - 0.3 mm lower to guarantee reliable
actuation of the clamping sensor.

Æ Push one PCB manually through the entire PCB conveyor system and make sure that it
moves easily through the entire system.
Place a PCB in the previous station at the input point and transport it with the relevant functions
through all 5 transport areas - all the way to the next PCB or to the output point.

217
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6.16 Overview of the electrical components 10/2005 US Issue

6.16 Overview of the electrical components

6.16.1 Conversion board of the conveyor side (00359424-01)

Fig. 6.16.33 Conversion board of the conveyor side (00359424-01)

218
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
10/2005 US Issue 6.16 Overview of the electrical components

6.16.2 Conversion board of the conveyor system (00359425-01)

Fig. 6.16.34 Conversion board of the conveyor system (00359425-01)

219
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6.16 Overview of the electrical components 10/2005 US Issue

6.16.3 Transport control TSP 301 for HS-60 (00370397-01)

Fig. 6.16.35 Transport control TSP 301 (00370397-01)

220
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
10/2005 US Issue 6.16 Overview of the electrical components

6.16.3.1 Extension card TSP 301E for dual conveyors (00370398-01)

Fig. 6.16.36 Extension card TSP 301E for dual conveyors (00370398-01)

221
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6.16 Overview of the electrical components 10/2005 US Issue

6.16.4 Transport control TSP 201 for S-27 HM (00358068-01)

Fig. 6.16.37 Transport control TSP 201 (00358068-01)

222
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
10/2005 US Issue 6.16 Overview of the electrical components

6.16.5 Conversion board of the lifting table (00362766-01)

Fig. 6.16.38 Conversion board of the lifting table (00362766-01)

223
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6.17 Block diagrams for modular transport 10/2005 US Issue

6.17 Block diagrams for modular transport

Please refer to this summary of the block diagrams when disconnecting/connecting the electrical
connections and plugs for the limit switch, laser light barriers etc.) and for the motors.

CAUTION
This service manual contains block diagrams for the HS-60 which may also appear useful for gen-
eral reference about the S-27 HM. The detailed and compete circuit diagrams can be found in the
folder of circuit diagrams for the relevant machine.

224
 Sensors/actors Sensors/actors Sensors/actors f. lifting table Sensors/actors f. lifting table
on side panel A on side panel B Placement sector 1 Placement sector 2
10/2005 US Issue

X1kv X15kv X1kw X15kw X1lv X5lv X1lw X5lw

X1kv X15kv X1kw X15kw X5lw
Service Manual S-27 HM

X1lv X5lv X1lw

Conversion board, side panel A Conversion board, side panel B Conv. board, lifting table Conv. board, lifting table
(kv) 00359424-xx (kw) 00359424-xx Placement sector 1 Placement sector 2
(lv) 00362766-xx (lw) 00362766-xx
X16kv X16kw X6lv X6lw
X16kv X16kw X6lv X6lw

00363667-xx
00363668-xx
00363438-xx
00363439-xx
X54kt X55kt X1kt X2kt

Proprietary date, company confidential. All rights reservd.

Confie a titre de secret d´entreprise. Tous droits reserves.
Comunicado como segredo empresarial. Reservados todos os direilos.
Confiado como secrete industrial. Nos reservamos todos los derechos.
X54kt X55kt X1kt X2kt

Conversion board, assembly trough

(kt) 00359425-xx

X51kt X52kt X53kt X6kt X48kt

X51kt X52kt X53kt X6kt X48kt

Sensors / actors in assembly trough

Connection for options

00363419-xx
00363431-xx

00363420-xx
X11ao X12ao X13ao
X11ao X12ao X13ao

CAN bus

X22ao
X22ao
00355321-xx
X10ao

TSP-301 conveyor control

(ao) X21ao X21ap
00370397-xx 1 40V 40V
2 24V 24V
3
X21ao

4 GND GND

X1ao X2ao X23ao X24ao X25ao

00372807-xx

X79
RS-232
40V
24V
GND

Start signal
1
2
3
4

X79
Barcode reader

Upstream machine

Weitergabe sowie Vervielfältigung dieser Unterlage,Ver-

wertung und Mitteilung ihres Inhalts nicht gestattet, soweit
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pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins
besondere für den Fall der Patenterteilung oder GM-Eintragung
RS-232 Boot/Debug

Downstream machine
Machine interface From power supply
Track 1 (Siemens)

01 Function status 22.01.02 Raabe Date 22.01.02

02 Product status 24.06.02 Raabe Author Raabe SD EA1 R&D SIEMENSDEMATIC Wiring for PCB single conveyor Sheet
02 Document status 17.12.02 Raabe Checked 1
00119460-010202LD3 Sh.
State Modified Date Name Standard Orig. Created f. Created by 5

225
6.17 Block diagrams for modular transport
6 Modular PCB conveyor system (used to SN 381)
 226
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wertung und Mitteilung ihres Inhalts nicht gestattet, soweit Confie a titre de secret d´entreprise. Tous droits reserves.
nicht ausdrücklich zugestanden. Zuwiderhandlungen ver-
State

Comunicado como segredo empresarial. Reservados todos os direilos.

02
02
01

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

00363438-xx
Document status

Conversion board f. lifting table, placement sector 1

X1kt
X1kt
X6lv

00363439-xx
Conversion board f. lifting table, placement sector 2
Date
X2kt
X2kt
X6lw

17.12.02
24.06.02
22.01.02

00363667-xx
Conversion board, side panel A
X54kt
X54kt
X16kv

Name

00363668-xx
Raabe
Raabe
Raabe

Conversion board, side panel B

X55kt
X55kt
X16kw

Date
Author
Checked
Standard
X6kt

Raabe
22.01.02
X7kt

Orig.
X8kt
X9kt
X10kt
X11kt

SD EA1 R&D

Created f.
X12kt
X13kt

1 1
2 2
X14kt

X51kt

X11ao
X51kt

X11ao
(kt)

00363419-xx
34 34
X15kt

Created by
(ao)
1 1
X16kt

2 2
X52kt

X12ao
X52kt

X12ao

00363420-xx
50 50
X17kt

00359425-xx

SIEMENSDEMATIC
1 1
X18kt

TSP-301 conveyor control

00370397-xx
2 2
X53kt

X13ao

2 IN
X19kt

Conversion board, assembly trough

X53kt

X13ao
Limit switch, width adjustment on the right
00363431-xx 3 P24
X19kt

40 40
00365002-xx
X29kt
X30kt
X31kt
X32kt

Wiring for PCB single conveyor

X33kt
1 1
2 2
X40kt

Options for placement sector 1 Step motor, width adjustment

X49kt

X40kt
X49kt

X34kt
00365299-xx 00360901-xx
18 10
2 OUT
1

X41kt
2 6 GND Adjustment drive 1 , valve

X41kt
Options for placement sector 2 00363779-xx
2 IN

X35kt
X42kt
18 3 P24
Adjustment drive 1, cylinder switch

X42kt
6 GND
00363777-xx
2 IN
1

X43kt
3 P24
2 Adjustment drive 1, sensor for side panel

X43kt
6 GND
00363775-xx
Options f. placement sector 1 (spare) 2 IN

X36kt
X44kt
18 Width adjustment, limit switch f. spindle, on the right
3 P24

X44kt
00363269-xx
2 OUT
1

X45kt
2 6 GND Valve f. adjustment drive 2

X45kt
00363780-xx
Options f. placement sector 2 (spare) 2 IN

X37kt
X46kt

00119460-010202LD3
18 3 P24
Adjustment drive 2, cylinder switch
6 GND

X46kt
00363778-xx
2 IN

X47kt
3 P24
Adjustment drive 2, sensor f. side panel
6 GND

X47kt
00363776-xx
2 IN

X48kt
3 P24 Width adjustment, limit switch f. spindle, on the left

X48kt
00363293-xx

Sheet

5
2
Sh.
10/2005 US Issue 6.17 Block diagrams for modular transport
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
227
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wertung und Mitteilung ihres Inhalts nicht gestattet, soweit Confie a titre de secret d´entreprise. Tous droits reserves.
nicht ausdrücklich zugestanden. Zuwiderhandlungen ver-
State

Comunicado como segredo empresarial. Reservados todos os direilos.

02
02
01

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

Document status

2 MOT+
X1

00362331-xx Belt motor, input belt

6 MOT-
X1kv

Cable: belt motor, input belt

Date

2 MOT+
17.12.02
24.06.02
22.01.02
X2

00362332-xx Belt motor, placement sector 1

6 MOT-
X2kv

Cable: belt motor, placement sector 1

2 MOT+
X3

00362334-xx Belt motor, intermediate belt

Name
Raabe
Raabe
Raabe

6 MOT-
X3kv

Cable: belt motor, intermediate motor

2 MOT+
X4

00362336-xx Belt motor, placement sector 2

6 MOT- Cable: belt motor, placement sector 2
X4kv

Date
Author

2 MOT+
Checked
Standard
X5

00362337-xx Belt motor, output belt

6 MOT- Cable: belt motor, output belt
X5kv

X6.1
X6

3 P24
Raabe

w2 w1 Light barrier, LPB detection, receiver

22.01.02
X6kv

6 GND Input belt 00371368-xx (00370068-xx)

2 IN
X7

3 P24 Light barrier, PCB detection, receiver

(kv)
X7kv

1 1 6 GND Placement sector 1 00370069-xx

Orig.

2 2 2 IN
X54kt
X16kv
X8

3 P24 Light barrier, PCB detection, receiver

X54kt
X16kv

Intermediate belt 00370070-xx

X8kv

6 GND
34 00363667-xx 34
2 IN
Flat ribbon cable, 34 wires
X9

3 P24 Light barrier, PCB detection, receiver

Placement sector 2 00370071-xx
X9kv

6 GND
00359424-xx

2 IN
X10.1
X10

3 P24 w2 w1 Light barrier, PCB detection, receiver

Output belt 00371369-xx (00370072-xx)
X10kv

6 GND
Conversion board, side panel A

2 IN
X11

3 P24
Laser, receiver f. placement sector 1

SD EA1 R&D
6 GND
X11kv

00363090-xx

Created f.
2 IN
X12

3 P24
Laser, receiver for placement sector 2
6 GND
X12kv

00363091-xx
2 IN
X13

3 P24
Limit switch f. width adjustment
X13kv

00362345-xx
X14kv

Created by
X15kv

(kt) 00359425-xx
2 MOT+
X1

SIEMENSDEMATIC
00362331-xx
6 MOT-
X1kw

Cable: belt motor, input belt

X2kw

Conversion board, assembly trough, track 1

X3kw
X4kw
Single conveyor, stationary conveyor side on the right

2 MOT+
X5

00362337-xx
X5kw 6 MOT- Cable: belt motor, output belt
3 P24 X6.1
X6

w2 w1 Light barrier f. PCB detection, transmitter

6 GND Input belt 00371366-xx (00370063-xx)

Wiring for PCB single conveyor

X6kw
3 P24 X7
w1 Light barrier f. PCB detection, transmitter 1
6 GND

(kw)
1 1 Placement sector 1 00370064-xx

X7kw
2 2

X55kt
X16kw
w2 Light barrier f. PCB detection, transmitter 2

X55kt
Placement sector 1 00370064-xx

X16kw
34 00363668-xx 34
3 P24
Flat ribbon cable, 34 wires Light barrier f. PCB detection, transmitter

X8
6 GND Intermediate conveyor 00370065-xx

X8kw
3 P24

X9
w1 Light barrier f. PCB detection (transmitter 1),

00359424-xx
6 GND Placement sector 2 00370066-xx

X9kw

Conversion board, side panel B

w2 Light barrier f. PCB detection (transmitter 2),
Placement sector 2 00370066-xx
2 IN
Piezo sensor f. PCB clamping

X10
3 P24
6 GND

X10kw
Placement sector 2 00368273-xx
2 IN
Piezo sensor f. PCB clamping

X11
3 P24
6 GND

X11kw
Placement sector 1 00368272-xx
3 P24 X12.1

X12
w2 w1 Light barrier f. PCB detection, transmitter
6 GND Output belt 00371367-xx (00370067-xx)

X12kw
2 IN

00119460-010202LD3
X13
Limit switch f. width adjustment
3 P24

X13kw
00362345-xx
2 OUT

X14
Laser, transmitter f. placement sector 1
6 GND

X14kw
00363092-xx
2 OUT

X15
Laser, transmitter f. placement sector 2
6 GND

X15kw
00363094-xx

Sheet

5
3
Sh.
6.17 Block diagrams for modular transport 10/2005 US Issue
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
 228
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wertung und Mitteilung ihres Inhalts nicht gestattet, soweit Confie a titre de secret d´entreprise. Tous droits reserves.
nicht ausdrücklich zugestanden. Zuwiderhandlungen ver-
State

Comunicado como segredo empresarial. Reservados todos os direilos.

02
02
01

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

Document status

2 MOT+
X1

00362331-xx
6 MOT-
X1kv

Cable: belt motor, input conveyor

Date
17.12.02
24.06.02
22.01.02
X2kv
X3kv

Name
Raabe
Raabe
Raabe
X4kv

Date

2 MOT+
X5

Author

00362337-xx
Checked
Standard

6 MOT- Cable: belt motor, output belt

X5kv

X6.1
X6

3 P24 w2 w1 Light barrier f. PCB detection (receiver),

Input belt 00371368-xx
X6kv

6 GND
Raabe
22.01.02

2 IN
X7

3 P24 Light barrier f. PCB detection (receiver) ,

(kv)
X7kv

1 1 6 GND Placement sector 1 00370069-xx

2 2 2 IN
Orig.
X54kt
X16kv

Light barrier f. PCB detection (receiver) ,

X8

3 P24
X54kt

Intermediate belt 00370070-xx

X16kv
X8kv

6 GND
34 00363667-xx 34
2 IN
Flat ribbon cable 34 wires
X9

3 P24 Light barrier f. PCB detection (receiver) ,

Placement sector 2 00370071-xx
X9kv

6 GND
00359424-xx

2 IN
X10.1
X10

3 P24 w2 w1 Light barrier f. PCB detection (receiver) ,

Output belt 00371369-xx
X10kv

6 GND
Conversion board, side panel A

2 IN
X11

3 P24
Laser, receiver, placement sector 1
6 GND
X11kv

00363090-xx
SD EA1 R&D
2 IN
Created f.
X12

3 P24
Lase, receiver, placement sector 2
6 GND
X12kv

00363091-xx
2 IN
X13

3 P24
Limit switch f. width adjustment
X13kv

00362345-xx
X14kv
X15kv

Created by
(kt) 00359425-xx
2 MOT+
X1

00362331-xx Belt motor, input belt

6 MOT- Cable: belt motor, input belt
X1kw

SIEMENSDEMATIC
2 MOT+
X2

00362332-xx Belt motor, placement sector 1

6 MOT- Cable: belt motor, placement sector 1

Conversion board, assembly trough 1

X2kw

2 MOT+
X3

00362334-xx
Single conveyor, stationary side on the left

Belt motor, intermediate belt

6 MOT- Cable: belt motor, intermediate belt
X3kw

2 MOT+
X4

00362336-xx Belt motor, placement sector 2

6 MOT- Cable: belt motor, placement sector 2
X4kw

2 MOT+
X5

00362337-xx Belt motor, output belt

6 MOT- Cable: belt motor, output belt
X5kw

3 P24 X6.1
X6

w2 w1 Light barrier f. PCB detection (transmitter),

6 GND Input belt 00371366-xx
X6kw

Wiring for PCB single conveyor

3 P24
X7

w1 Light barrier f. PCB detection (transmitter 1),

6 GND

(kw)
1 1 Placement sector 1 00370064-xx
X7kw
2 2

X55kt
X16kw
w2 Light barrier f. PCB detection (transmitter 2),

X55kt
Placement sector 1 00370064-xx

X16kw
34 00363668-xx 34
3 P24
Flat ribbon cable 34 wires Light barrier f. PCB detection (transmitter) ,
X8
6 GND Intermediate conveyor 00370065-xx

X8kw
3 P24

X9
w1 Light barrier f. PCB detection (transmitter 1),

00359424-xx
6 GND Placement sector 2 00370066-xx

X9kw

Conversion board, side panel B

w2 Light barrier f. PCB detection (transmitter 2),
Placement sector 2 00370066-xx
2 IN
Piezo sensor f. PCB clamping

X10
3 P24
6 GND

X10kw
Placement sector 2 00368273-xx
2 IN
Piezo sensor f. PCB clamping

X11
3 P24
6 GND Placement sector 1 00368272-xx

X11kw
X12kw
2 IN

X13
Limit switch f. width adjustment

00119460-010202LD3
3 P24

X13kw
00362345-xx
2 OUT

X14
Laser, transmitter f. placement sector 1
6 GND

X14kw
00363092-xx
2 OUT

X15
Laser, transmitter f. placement sector 2
6 GND

X15kw
00363094-xx

Sheet

5
4
Sh.
10/2005 US Issue 6.17 Block diagrams for modular transport
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
229
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wertung und Mitteilung ihres Inhalts nicht gestattet, soweit Confie a titre de secret d´entreprise. Tous droits reserves.
nicht ausdrücklich zugestanden. Zuwiderhandlungen ver-
State

Comunicado como segredo empresarial. Reservados todos os direilos.

02
02
01

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

Document status
Date
17.12.02
24.06.02
22.01.02

Name
Raabe
Raabe
Date Raabe
Author
Checked
Standard
Raabe
22.01.02

Orig.

2 IN
3 P24 00363111-xx
Incremental encoder, track A, lifting table
X1

6 GND Cable: incremental encoder, track A (long)

(upper fork light barrier)
2 IN
3 P24 00363113-xx
Incremental encoder, track B, lifting table
X2

6 GND Cable: incremental encoder, track B (long)

(lower fork light barrier)
1 1

SD EA1 R&D
2 2 2 IN
X1kt
X6lv

Created f.
3 P24 00363076-xx
Cylinder switch, lifting table
X6
X3

X1kt

6 GND Limit switch, lifting table

10
00363438-xx 10
2 OUT
00363078-xx
Lifting table, valve up (connector "14")
X4

00362766-xx (lv)

6 GND Cable: valve, lifting table up

Lifting table, placement sector 1

2 OUT
00363077-xx
Lifting table, valve down (connector "12")
X5

6 GND

(kt)
Cable: valve, lifting table down
Conversion board, lifting table (placement sector 1)

Created by
2 IN

00359425-xx
3 P24 00363111-xx
Incremental encoder, track A, lifting table
X1

6 GND Cable: incremental encoder, track A (long)

(upper fork light barrier)

SIEMENSDEMATIC
Conversion board, assembly trough
2 IN
3 P24 00363113-xx
Incremental encoder, track B, lifting table
X2

6 GND Cable: incremental encoder, track B (long)

(lower fork light barrier)
1 1
2 2 2 IN

X2kt
X6lw
3 P24 00363076-xx
Cylinder switch, lifting table

X6
X3

X2kt
6 GND Limit switch, lifting table
10 00363439-xx 10 00362766-xx
2 OUT
00363078-xx
X4

(lw)
6 GND Cable: valve, lifting table up Lifting table, valve up (connector "14")
2 OUT
Lifting table, placement sector 2

00363077-xx

X5
6 GND Lifting table, valve down (connector "12")
Cable: valve, lifting table down

Conversion board, lifting table (placement sector 2)

Wiring for PCB single conveyor

00119460-010202LD3
5 Sheet

5 Sh.
6.17 Block diagrams for modular transport 10/2005 US Issue
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
230
Sensors/actors Sensors/actors Sensors/actors f. lifting table Sensors/actors f. lifting table Sensors/actors Sensors/actors Sensors/actors f. lifting table Sensors/actors f. lifting table
on side panel A on side panel B Placement sector 1, track 1 Placement sector 2, track 1 on side panel C on side panel D Placement sector 1, track 2 Placement sector 2, track 2

X1kv X15kv X1kw X15kw X1lv X5lv X1lw X5lw X1ky X15ky X1kz X15kz X1ly X5ly X1lz X5lz
X1kv X15kv X1kw X15kw X1lv X5lv X1lw X5lw X1ky X15ky X1kz X15kz X1ly X5ly X1lz X5lz

Conversion board, side panel A Conv. board, lifting table Conv. board, lifting table Conversion board, side panel C Conversion board, side panel D Conv. board, lifting table
(kv) 00359424-xx (kw) 00359424-xx Placement sector 1, track 1 Placement sector 2, track 1 (ky) 00359424-xx (kz) 00359424-xx Placement sector 2, track 2
(lv) 00362766-xx (lw) 00362766-xx (ly) 00362766-xx (lz) 00362766-xx
X16kv X16kw X6lv X6lw X16ky X16kz X6ly X6lz
X16kv X16kw X6lv X6lw X16ky X16kz X6ly X6lz
6.17 Block diagrams for modular transport

00363441-xx

00363667-xx
00363668-xx
00363438-xx
00363439-xx
00363440-xx

00363670-xx

00363669-xx
6 Modular PCB conveyor system (used to SN 381)

X54kt X55kt X1kt X2kt X54ku X55ku X1ku X2ku

Proprietary date, company confidential. All rights reservd.

Confie a titre de secret d´entreprise. Tous droits reserves.
Comunicado como segredo empresarial. Reservados todos os direilos.
Confiado como secrete industrial. Nos reservamos todos los derechos.
X54kt X55kt X1kt X2kt X54ku X55ku X1ku X2ku

Conversion board, assembly trough (track 1) Conversion board, assembly trough (track 2)
(kt) 00359425-xx (ku) 00359425-xx

X51kt X52kt X53kt X6kt X48kt X51ku X52ku X53ku X6ku X48ku
X51kt X52kt X53kt X6kt X48kt X51kt X52kt X53kt X6kt X48kt

Sensors / actors in assembly trough Sensors / actors in assembly trough

Connector for options Connector f. options

00363419-xx
00363433-xx

00363431-xx

00363420-xx
00363432-xx
00363434-xx

X11ao X12ao X13ao X11ap X12ap X13ap

X11ao X12ao X13ao X11ap X12ap X13ap
1 X10ao X10ap 1
CAN bus 2 2
00364767-xx

X22ao
X22ao
00355321-xx
X10ap

X10ao
Conveyor control 64 64 Extension board f. conveyor control
TSP301 (00370397-xx) TSP301E (00370398-xx)
(ao) X21ao X21ap
1 40V 40V 1 (ap)
2 24V 24V 2
3 3

X21ao
X21ap

4 GND GND 4

X1ao X2ao X23ao X24ao X25ao X1ap X2ap

00372807-xx

X79

RS-232
40V
24V
GND

Start signal
1
2
3
4

X79

Upstream machine
Upstream machine

Weitergabe sowie Vervielfältigung dieser Unterlage,Ver-

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nicht ausdrücklich zugestanden. Zuwiderhandlungen ver-
pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins
besondere für den Fall der Patenterteilung oder GM-Eintragung
RS-232 Boot/Debug

Downstream machine
Downstream machine

Machine interface
Machine interface Barcode reader From power supply
(option) Track 2 (Siemens)
Track 1 (Siemens)

01 Function status 22.01.02 Raabe Date 22.01.02

02 Product status 17.06.02 Raabe Author Raabe SD EA1 R&D SIEMENSDEMATIC
02 Document status 17.12.02 Raabe Checked
Wiring for PCB dual conveyor Sheet 1
00119462-010202LD3 Sh.
Status Modified Date Name Standard Orig. Created for Created by 6
10/2005 US Issue
Service Manual S-27 HM
231
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wertung und Mitteilung ihres Inhalts nicht gestattet, soweit Confie a titre de secret d´entreprise. Tous droits reserves.
nicht ausdrücklich zugestanden. Zuwiderhandlungen ver- Comunicado como segredo empresarial. Reservados todos os direilos.
02
02
01

Status

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

00363438-xx
Document status

Conversion board, lifting table 1

X1kt
X1kt
X6lv

00363439-xx
Conversion board, lifting table 2
Date
X2kt
X2kt
X6lw

17.12.02
17.06.02
22.01.02

00363667-xx
Conversion board, side panel A
X54kt
X54kt
X16kv

Name

00363668-xx
Raabe
Raabe
Raabe

Conversion board, side panel B

X55kt
X55kt
X16kw

Date
Author
Checked
Standard
X6kt

Raabe
22.01.02
X7kt

Orig.
X8kt
X9kt
X10kt
X11kt

SD EA1 R&D

Created for
X12kt
X13kt

1 1
2 2
X14kt

X51kt

X11ao
X51kt

X11ao
(kt)

00363419-xx
34 34
X15kt

Created by
1 1
X16kt

2 2
X52kt

X12ao

(ao)
X52kt

X12ao
00363420-xx
50 50
X17kt

00359425-xx

Conveyor control

SIEMENSDEMATIC
1 1

TSP301 (00370397-xx)
X18kt

2 2
X53kt

X13ao
2 IN
X19kt

X53kt

X13ao
Limit switch, width adjustment, on the right
00363431-xx 3 P24
X19kt

40 40
00365002-xx
Conversion board, assembly trough (track 1)
X29kt
X30kt
X31kt

Wiring for PCB dual conveyor

X32kt
X33kt
1 1
2 2

X40kt
Options, placement sector 1 Step motor, width adjustment
X49kt

X40kt
X49kt

X34kt
00365299-xx 00360901-xx
18 10
2 OUT
1

X41kt
2 6 GND Adjustment drive 1, valve

X41kt
Options, placement sector 2 00363779-xx
2 IN

X35kt
X42kt
18 3 P24
Adjustment drive 1, cylinder switch

X42kt
6 GND
00363777-xx
2 IN
1

X43kt
3 P24
2 Adjustment drive 1, sensor f. side panel

X43kt
6 GND
00363775-xx
Options, placement sector 1 (spare) 2 IN

X36kt
X44kt
18 Width adjustment, limit switch, spindle, on the right
3 P24

X44kt
00365108-xx
2 OUT
1

X45kt
2 6 GND Adjustment drive 2

X45kt
00363780-xx
Options, placement sector 2 (spare) 2 IN

X37kt

00119462-010202LD3
X46kt
18 3 P24
Adjustment drive 2, cylinder switch
6 GND

X46kt
00363778-xx
2 IN

X47kt
3 P24
Adjustment drive 2, sensor f. side panel
6 GND

X47kt
00363776-xx
2 IN

X48kt
3 P24 Width adjustment, limit switch, spindle, on the left

X48kt
00365109-xx

Sheet

6
2
Sh.
6.17 Block diagrams for modular transport 10/2005 US Issue
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
 232
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nicht ausdrücklich zugestanden. Zuwiderhandlungen ver- Comunicado como segredo empresarial. Reservados todos os direilos.
02
02
01

Status

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

00363440-xx
Document status

Conversion board, lifting table, track 2, placement sector 1

X1ku
X1ku
X6ly

00363441-xx
Date

Conversion board, lifting table, track 2, placement sector 2

X6lz

X2ku
X2ku

17.12.02
17.06.02
22.01.02

00363669-xx
Conversion board, side panel C
X54ku
X54ku
X16ky

Name

00363670-xx
Raabe
Raabe
Raabe

Conversion board, side panel D

X16kz

X55ku
X55ku

Date
Author
Checked
Standard
Raabe
X6ku

22.01.02
X7ku

Orig.
X8ku
X9ku
X10ku
X11ku

SD EA1 R&D

Created for
X12ku
X13ku

1 1
2 2
X11ap
X51ku
X14ku

X11ap
X51ku

00363432-xx
34 34
(ku)
X15ku

Created by
1 1
2 2
X12ap
X16ku

X52ku

(ap)
X12ap
X52ku

00363433-xx
50 50
X17ku

00359425-xx

SIEMENSDEMATIC
1 1

TSP301E (00370398-xx)
2 2
X18ku

X13ap
X53ku

X13ap
X53ku

Extension board f. conveyor control

00363434-xx
40 40
X19ku

Conversion board, assembly trough (track 2)

X29ku
X30ku
X31ku

Wiring for PCB dual conveyor

X32ku
X33ku

1
2
Options, placement sector 1

X34ku
X40ku
18
1
2

X41ku
Options, placement sector 2

X35ku
18

X42ku
1
2

X43ku
Options, placement sector 1 (spare)

X36ku
18

X44ku
1
2

X45ku

00119462-010202LD3
Options, placement sector 2 (spare)

X37ku
18

X46ku
X47ku
X48ku

Sheet

6
3
Sh.
10/2005 US Issue 6.17 Block diagrams for modular transport
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
233
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nicht ausdrücklich zugestanden. Zuwiderhandlungen ver- Comunicado como segredo empresarial. Reservados todos os direilos.
02
02
01

Status

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

Document status

2 MOT+
X1

00362331-xx Belt motor, input belt

6 MOT-
X1kv

Date

Cable: belt motor, input belt

17.12.02
17.06.02
22.01.02

2 MOT+
X2

00362332-xx Belt motor, placement sector 1

6 MOT-
X2kv

Cable: belt motor, placement sector 1

2 MOT+
X3

00362334-xx
Name

Belt motor, intermediate belt

Raabe
Raabe
Raabe

6 MOT- Cable: belt motor, intermediate belt

X3kv

2 MOT+
X4

00362336-xx Belt motor, placement sector 2

6 MOT-
Date

Cable: belt motor, placement sector 2

X4kv

Author
Checked
Standard

2 MOT+
X5

00362337-xx Belt motor, output conveyor

6 MOT- Cable: belt motor, output belt
X5kv

X6.1
Raabe
X6

3 P24 w2 w1 Light barrier f. PCB detection, receiver

22.01.02

Input belt 00371368-xx (00370068-xx)

X6kv

6 GND
2 IN
X7

3 P24 Light barrier f. PCB detection, receiver

(kv)
X7kv

Placement sector 1 00370069-xx

Orig.

1 1 6 GND
2 2 2 IN
X54kt
X16kv

Light barrier f. PCB detection, receiver

X8

3 P24
X54kt

Intermediate belt 00370070-xx

X16kv
X8kv

6 GND
34 00363667-xx 34
2 IN
Flat ribbon cable, 34 wires
X9

3 P24 Light barrier f. PCB detection, receiver

Placement sector 2 00370071-xx
X9kv

6 GND
00359424-xx

2 IN
X10.1
X10

3 P24 w2 w1 Light barrier f. PCB detection, receiver

Output belt 00371369-xx (00370072-xx)
X10kv

6 GND
Conversion board, side panel A

2 IN
X11

3 P24

SD EA1 R&D
Laser, receiver f. placement sector 1
6 GND
X11kv

00363090-xx

Created for
2 IN
X12

3 P24
Laser, receiver f. placement sector 2
6 GND
X12kv

00363091-xx
2 IN
X13

3 P24
Limit switch f. width adjustment
X13kv

00362345-xx
X14kv

Created by
X15kv

(kt) 00359425-xx

SIEMENSDEMATIC
X1kw
X2kw

Conversion board, assembly trough, track 1

X3kw
X4kw
X5kw
3 P24 X6.1
X6

Wiring for PCB dual conveyor

w2 w1 Light barrier f. PCB detection, transmitter
6 GND Input belt 00371366-xx (00370063-xx)

X6kw
3 P24 X7
w1 Light barrier f. PCB detection, transmitter 1
6 GND Placement sector 1 00370064-xx

X7kw

(kw)
1 1
2 2

X55kt
X16kw
w2 Light barrier f. PCB detection, transmitter 2

X55kt
Placement sector 1 00370064-xx

X16kw
34 00363668-xx 34
3 P24
Flat ribbon cable, 34 wires Light barrier f. PCB detection, transmitter

X8
6 GND Intermediate belt 00370065-xx

X8kw
3 P24

X9
w1 Light barrier f. PCB detection, transmitter 1),

00359424-xx
6 GND Placement sector 2 00370066-xx

X9kw

Conversion board, side panel B

w2 Light barrier f. PCB detection, transmitter 2),
Placement sector 2 00370066-xx
2 IN
Piezo sensor f. PCB clamping

X10
3 P24
6 GND

X10kw
Placement sector 2 00368273-xx
2 IN
Piezo sensor f. PCB clamping

X11
3 P24
6 GND Placement sector 1 00368272-xx

X11kw
3 P24 X12.1

X12
w2 w1 Light barrier f. PCB detection, transmitter
6 GND Output belt 00371367-xx (00370067-xx)

X12kw

00119462-010202LD3
2 IN

X13
Limit switch f. width adjustment
3 P24

X13kw
00362345-xx
2 OUT

X14
Laser, transmitter f. placement sector 1
6 GND 00363092-xx

X14kw
2 OUT

X15
Laser, transmitter f. placement sector 2
6 GND 00363094-xx

X15kw

Sheet

6
4
Sh.
6.17 Block diagrams for modular transport 10/2005 US Issue
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
 234
Weitergabe sowie Vervielfältigung dieser Unterlage,Ver- Proprietary date, company confidential. All rights reservd.
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nicht ausdrücklich zugestanden. Zuwiderhandlungen ver- Comunicado como segredo empresarial. Reservados todos os direilos.
02
02
01

Status

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

Document status
X1ky

Date
17.12.02
17.06.02
22.01.02
X2ky

Name
Raabe
Raabe
Raabe
X3ky
X4ky

Date
Author
Checked
Standard
X5ky

X6.1
X6

3 P24
Raabe

w2 w1 Light barrier f. PCB detection, receiver

22.01.02
X6ky

6 GND Input belt 00371368-xx (00370068-xx)

2 IN
X7

3 P24 Light barrier f. PCB detection, receiver

(ky)
X7ky

6 GND Placement sector 1 00370069-xx

Orig.

1 1
2 IN
2 2
Light barrier f. PCB detection, receiver
X8

3 P24
X54ku
X16ky

Intermediate belt 00370070-xx

X8ky

6 GND
X54ku
X16ky

34 00363669-xx 34 2 IN
X9

Flat ribbon cable, 34 wires 3 P24 Light barrier f. PCB detection, receiver
X9ky

6 GND Placement sector 2 00370071-xx

2 IN
00359424-xx

X10.1
X10

3 P24 w2 w1 Light barrier f. PCB detection, receiver

Output belt 00371369-xx (00370072-xx)
X10ky

6 GND
Conversion board, side panel C

2 IN
X11

3 P24
Laser, receiver f. placement sector 1
SD EA1 R&D

6 GND
X11ky

Created for 00363090-xx

2 IN
X12

3 P24
Laser, receiver f. placement sector 2
6 GND
X12ky

00363091-xx
2 IN
X13

Limit switch f. width adjustment

3 P24
X13ky

00362345-xx
X14ky

Created by
(ku)
X15ky

2 MOT+

SIEMENSDEMATIC
00359425-xx
X1

00362331-xx
Belt motor, input belt
X1kz

6 MOT- Cable: belt motor, input belt

2 MOT+
X2

00362332-xx
6 MOT- Belt motor, placement sector 1
X2kz

Cable: belt motor, placement sector 1

2 MOT+

Conversion board, assembly trough, track 2

X3

00362334-xx
6 MOT- Belt motor, intermediate belt
X3kz

Cable: belt motor, intermediate belt

2 MOT+
X4

00362336-xx
6 MOT- Belt motor, placement sector 2
X4kz

Cable: belt motor, placement sector 2

2 MOT+
X5

00362337-xx
6 MOT-
Belt motor, output conveyor
Cable: belt motor, output belt
X5kz

3 P24 X6.1

Wiring for PCB dual conveyor

X6

w2 w1 Light barrier f. PCB detection, transmitter

6 GND
X6kz

Input belt 00371366-xx (00370063-xx)

3 P24
X7

w1 Light barrier f. PCB detection, transmitter 1

X7kz 6 GND Placement sector 1 00370064-xx

(kz)
1 1
2 2
w2 Light barrier f. PCB detection, transmitter 2

X55ku
X16kz
Placement sector 1 00370064-xx

X55ku
X16kz
34 00363670-xx 34 3 P24
X8 Light barrier f. PCB detection, transmitter
Flat ribbon cable, 34 wires
6 GND Intermediate belt 00370065-xx

X8kz

00359424-xx
3 P24

X9
w1 Light barrier f. PCB detection, transmitter 1),
6 GND Placement sector 2 00370066-xx

X9kz

Conversion board, side panel D

w2 Light barrier f. PCB detection, transmitter 2),
Placement sector 2 00370066-xx
2 IN
Piezo sensor f. PCB clamping

X10
3 P24

X10kz
6 GND Placement sector 2 00368273-xx
2 IN
Piezo sensor f. PCB clamping

X11
3 P24
6 GND

X11kz
Placement sector 1 00368272-xx
3 P24 X12.1

X12
w2 w1 Light barrier f. PCB detection, transmitter
6 GND Output belt 00371367-xx (00370067-xx)

X12kz

00119462-010202LD3
2 IN

X13
Limit switch f. width adjustment
3 P24

X13kz
00362345-xx
2 OUT

X14
Laser, transmitter f. placement sector 1
6 GND

X14kz
00363092-xx
2 OUT

X15
Laser, transmitter f. placement sector 2
6 GND

X15kz
00363094-xx

Sheet

6
5
Sh.
10/2005 US Issue 6.17 Block diagrams for modular transport
Service Manual S-27 HM 6 Modular PCB conveyor system (used to SN 381)
235
Weitergabe sowie Vervielfältigung dieser Unterlage,Ver- Proprietary date, company confidential. All rights reservd.
wertung und Mitteilung ihres Inhalts nicht gestattet, soweit Confie a titre de secret d´entreprise. Tous droits reserves.
nicht ausdrücklich zugestanden. Zuwiderhandlungen ver- Comunicado como segredo empresarial. Reservados todos os direilos.
02
02
01

Status

pflichten zu Schadenersatz. Alle Rechte vorbehalten, ins Confiado como secrete industrial. Nos reservamos todos los derechos.
besondere für den Fall der Patenterteilung oder GM-Eintragung
Modified
Product status
Function status

Document status

2 IN
3 P24 00363079-xx
Incremental encoder, track A, lifting table
X1

Date

6 GND Cable: incremental encoder, track A

(upper fork light barrier)
17.12.02
17.06.02
22.01.02

2 IN
3 P24 00363080-xx
Incremental encoder, track B, lifting table
X2

6 GND Cable: incremental encoder, track B

(lower fork light barrier)
Name

1 1
Raabe
Raabe
Raabe

2 2 2 IN
X1kt
X6lv

3 P24 00363076-xx
Cylinder switch
X6
X3

X1kt

6 GND Limit switch, lifting table

00363438-xx
10 10
Date
Author

2 OUT
Checked
Standard

00363078-xx
Lifting table, valve up ("14" connector)
X4

00362766-xx (lv)

6 GND Cable: valve f. lifting table up

2 OUT
Raabe

00363077-xx
22.01.02
(kt)
Conversion board, lifting table (track 1, PC1)

Lifting table, valve down ("12" connector)

X5

6 GND Cable: valve f. lifting table down

Lifting table, track 1, placement sector 1

Orig.
00359425-xx

2 IN
3 P24 00363079-xx
X1

6 GND Cable: incremental encoder, track A Incremental encoder, track A, lifting table
(upper fork light barrier)
2 IN
3 P24 00363080-xx
X2

6 GND Cable: incremental encoder, track B Incremental encoder, track B, lifting table
Conversion board, assembly trough (track 1)

(lower fork light barrier)

SD EA1 R&D
1 1
2 2 2 IN

Created for
X2kt
X6lw

3 P24 00363076-xx
X6
X3

Cylinder switch
X2kt

6 GND Limit switch, lifting table

00363439-xx
10 10
2 OUT
00363078-xx
X4

Lifting table, valve up ("14" connector)

00362766-xx (lw)

6 GND Cable: valve f. lifting table up

2 OUT
00363077-xx
X5

6 GND Lifting table, valve down ("12" connector)

Conversion board, lifting table, (track 1, PC2)

Cable: valve f. lifting table down

Lifting table, track 1, placement sector 2

Created by
SIEMENSDEMATIC
2 IN
3 P24 00363079-xx
Incremental encoder, track A, lifting table
X1

6 GND Cable: incremental encoder, track A

(upper fork light barrier)
2 IN
3 P24 00363080-xx
Incremental encoder, track B, lifting table
X2

6 GND Cable: incremental encoder, track B

(lower fork light barrier)
1 1
2 2 2 IN

X6ly

X1ku
3 P24 00363076-xx
Cylinder switch

X6
X3

X1ku
6 GND Limit switch, lifting table
10
00363440-xx 10
2 OUT
00363078-xx
Lifting table, valve up ("14" connector)

00362766-xx (ly)
X4
6 GND Cable: valve f. lifting table up

Wiring for PCB dual conveyor

2 OUT
00363077-xx

X5
6 GND Lifting table, valve down ("12" connector)

Conversion board, lifting table (track 2, PC2)

Cable: valve f. lifting table down

(ku)
Lifting table, track 2, placement sector 1

2 IN
00363079-xx

00359425-xx
3 P24
Incremental encoder, track A, lifting table

X1
6 GND Cable: incremental encoder, track A
(upper fork light barrier)
2 IN
3 P24 00363080-xx
Incremental encoder, track B, lifting table

X2
6 GND Cable: incremental encoder, track B
(lower fork light barrier)
1 1

Conversion board, assembly trough (track 2)

2 2 2 IN

X6lz

X2ku
3 P24 00363076-xx

X6
Cylinder switch

X3

X2ku
6 GND Limit switch, lifting table
10 00363441-xx 10

00362766-xx
2 OUT
00363078-xx

(lz)
Lifting table, valve up ("14" connector)

X4
6 GND Cable: valve f. lifting table up
2 OUT

00119462-010202LD3
00363077-xx

Conversion board, lifting table (track 2, PC2)

Lifting table, valve down ("12" connector)

X5
6 GND Cable: valve f. lifting table down
Lifting table, track 2, placement sector 2

Sheet

6
6
Sh.
6.17 Block diagrams for modular transport 10/2005 US Issue
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6 Modular PCB conveyor system (used to SN 381) Service Manual S-27 HM
6.18 Final steps and functions test 10/2005 US Issue

6.18 Final steps and functions test

DANGER
During the following functions test, adhere strictly to the safety instructions in Chapter 2.

Æ If the cutter has been removed, you will have to reinstall it, as described in the service man-
ual, Chapter „Cutter, pneumatic“ (see safety instructions in the above mentioned chapter).
Æ If the nozzle changer has been removed, you will have to recalculate the nozzle changer
positions after the changer has been reinstalled (SITEST program).
Æ Remove all tools etc. from the working area of the machine.
Æ Carry out all necessary adjustments and a functions test, depending on how the problems
were solved:

– with the station software, transport menu / width adjustment system,

– with the aid of the SITEST program and according to the „Setting Instructions for S-27 HM“.

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7 Modular PCB Conveyor System

(used from SN 382)
The service work for the modular conveyor system is described using the HS-60 as example. All graph-
ics and overviews show the HS-60. All service work applies for the S-27 HM as well. In the case that
there should be differences for the S-27 HM as, e. g., the belt tensions, this will be included additionally.

7.1 Module Overview

The modular conveyor system for the HS-60 consists of an input conveyor, two placement areas, the
intermediate conveyor and the output conveyor. The S-27 HM has one placement area only. So, the sin-
gle conveyor system for the S-27 HM consists of an input conveyor, a placement area and the output
conveyor. Each conveyor system has automatic width adjustment and a lifting table to clamp the PCB in
place. The standard machine is equipped as a single PCB conveyor. A dual PCB conveyor system is
optionally available. Depending on individual requirements, either the left or right conveyor side can be
selected as the fixed conveyor side.

Modular PCB Conveyor System HS-60

1. Input conveyor
2. Placement area 1
7 3. Intermediate conveyor
4. Placement area 2
5 5. Output conveyor
6 6. Lifting table - placement area 1
4
7. Lifting table - placement area 2

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LP-Transport modular S-27 HM

1. Input conveyor

3
2. Placement area
3. Output conveyor
4. Lifting table unit
2

7.2 Service Work

WARNING: Nonobservance of these safety instructions may cause

injury to personnel and damage to the machine!
The service work described in this manual may only be performed by specially
trained service technicians, with appropriate qualifications and expertise.

X Please observe the safety instructions in the Operating Manual for all ser-
vice work!

7.2.1 Replacing the Complete Drive Unit [00359284-xx]

Overview

1. Cable connections

5 2 2. Heat-shrinkable sleeve
6 3. Fastening screws
4. Conveyor toothed belt
4 5. Motor mount
6. Slot

The DC geared motors, including the motor

1
mounts of all 5 conveyor areas, are of like con-
struction. Please bear in mind the following differ-
ences during assembly and disassembly:
3 ƒ The motor mount is installed at an angle (tilt-
ed), according to the requirements of the in-
stallation site.

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Disassembly

X Move the side parts of the conveyor system

apart until the motor fixture screws (3) are ac-
5 2
cessible. This may differ, according to the con-
6
veyor type and area concerned.
X Move the Y-gantries into the area outside the
4 PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Mark the polarity (+ / -) of the cable connec-
tions (1) - important for the direction of rotation!
1
X Disconnect the cable shoes from the motor
terminals (1).
3
X Strip the heat-shrinkable sleeve, (2) used to
fasten the connection cable, from the circum-
ference of the DC geared motor.
Tip
If necessary, loosen the deflection pulley at the
slot (6). This will make it easier to unthread the mo-
tor mount.
See also „Adjusting the Tension of the Conveyor
Toothed Belt“.
X Remove the 3 screws (3) holding the motor
mount in place (5).
X Push the hexagonal shaft back and carefully
remove the motor mount (5). At the same time,
carefully unthread the conveyor toothed belt.
Attention: Do not damage the
toothed belt!
The toothed belts must not be
stretched or kinked!

NOTE:
The way in which the conveyor toothed belt is run around the belt guide depends upon the transport area
concerned. Please observe this belt guidance during assembly.
If you have discovered a break in the motor cable during a continuity check, the motor cable must be
unthreaded as far as the conversion board of the conveyor side (see circuit diagrams of the same name)
and unplugged at the corresponding point. This might be somewhat complicated depending on the rout-
ing of cables inside the machine base.
You may wish to contact Siemens AG SMD Service regarding this work.

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Installation

X Install the new drive unit in the reverse order.

X Please check:
1 ƒ The entire width of the conveyor toothed belt
(1) must engage at all toothed wheels (2) and
be run around the belt guide (3).
2
ƒ Perform the Final steps including function
test .
NOTE:
After the new drive unit has been installed, you
must make certain that the direction of rotation and
the conveyor speed (motor voltage) are correct.
After reconnecting the geared motor, you only
3
need to check the direction of rotation.

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7.2.2 Replacing the DC Geared Motor [03009269-xx]

Overview

1. DC geared motor
3 4
2. Fastening screws
2
3. toothed wheel (conveyor toothed belt)
4. Toothed disk (toothed belt for PCB conveyor
drive)
The DC geared motors, including the motor
mounts of all 5 conveyor areas, are of like con-
struction. Please bear in mind the following differ-
ences during assembly and disassembly:
ƒ The motor mount is installed at an angle (tilt-
ed), according to the requirements of the in-
1
stallation site.

Disassembly

X Move the PCB conveyor to a position in which

the fastening screws (2) are accessible.
2
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Mark the polarity (+ / -) of the cable connec-
4
tions (1) - important for the direction of rotation!
X Disconnect the cable shoes from the motor
3 1 terminals (1).
X Strip the heat-shrinkable sleeve, (4) used to
5 fasten the connection cable, from the circum-
ference of the DC geared motor.
X Working from the exterior side of the conveyor,
(2) undo the screws fastening the DC geared
motor (5).
X Tilt the DC geared motor (5) a little, so that the
small toothed belt (3) comes free of the
toothed wheel.
Attention: Do not damage the
toothed belt!
The toothed belts must not be
stretched or kinked!
X Pull the DC geared motor out.
X Please note:
ƒ The toothed wheel on the motor shaft must be
moved out in such a manner that it does not
get caught in the toothed belt.

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NOTE:
If you have discovered a break in the motor cable during a continuity check, the motor cable must be
unthreaded as far as the conversion board of the conveyor side (see circuit diagrams of the same name)
and unplugged at the corresponding point.
This might be somewhat complicated depending on the routing of cables inside the machine base.
You may wish to contact Siemens AG SMD Service regarding this work.

Installation

Attention: Do not damage the

toothed belt!
2 The toothed belts must not be
stretched or kinked!
X Install the new DC geared motor (5) in the re-
4
serve order.
3The entire width of the toothed belt must en-
gage at the top and bottom toothed wheels.
3 1
X Fix the DC geared motor (5) with the 4 M3 hex-
agonal socket-head screws (2).
5
X Tension the toothed belt (3) by moving the DC
geared motor in the fastening holes. The belt
tension must be between
10 and 15 N.
X Reconnect to the electrical system (1) and se-
cure the connection cable with a heat-shrink-
able hose (4).
NOTE
After the geared motor has been installed, you
must make certain that the direction of rotation and
the conveyor speed (motor voltage) are correct.

7.2.3 Replacing the Toothed Belt of the Drive Unit [00355553-xx]

Overview

1. DC geared motor
5 2. Circlip
3. 4 x fastening screws
4. Toothed belt
2 5. toothed wheel
4 The DC geared motors, including the motor
3 mounts of all 5 conveyor areas, are of like con-
struction. Please bear in mind the following differ-
ences during assembly and disassembly:
ƒ The motor mount is installed at an angle (tilt-
ed), according to the requirements of the in-
1 stallation site.

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Disassembly

X Switch off the machine and secure it to prevent

3 4 unauthorized reactivation.
2
X Remove the complete drive unit (5).
X Loosen the screws (2) holding the DC geared
motor (1).
X Tilt the DC geared motor (1) with its toothed
wheel (4) a little, so that the small toothed belt
comes free of the toothed wheel.
Attention: Do not damage the
toothed belt!
5
The toothed belts must not be
1 stretched or kinked!

X Pull the DC geared motor out.

X Please note:
ƒ The toothed wheel on the motor shaft must be
moved out in such a manner that it does not
get caught in the toothed belt.

X Remove the circlip (1) and the shims/washers

3 (2).
2 X Use a small rubber mallet to carefully knock
the toothed wheel (3) out of the motor mount
(5).
1
X Remove the toothed belt (4) from the mount.
4

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Attention: Do not damage the

4 toothed belt!
7
The toothed belts must not be
stretched or kinked!
X Insert the new toothed belt (1) into the motor
8 mount (2) and place the belt around the
1 toothed wheel (3) of the geared motor.
6
X Place the toothed belt around the toothed
wheel (4) of the drive shaft and insert the
2 toothed wheel in its mount.
X Use a rubber mallet to carefully knock the
3
toothed wheel into position.
5
X Install the shim/washer (7) and the circlip (8).
X Loosely fasten the DC geared motor (5) with
the 4 M3 hexagonal socket-head screws (6).
The entire width of the toothed belt must en-
gage at the top and bottom toothed wheels.
X Tension the toothed belt (1) by moving the DC
geared motor in the fastening holes. The belt
tension must be between
10 and 15 N.
X Install the complete motor unit.
NOTE
After the drive has been installed, you must make
certain that the direction of rotation and the con-
veyor speed (motor voltage) are correct.

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7.2.4 Replacing the Conveyor Toothed Belt [00359917-xx]

Parts for HS 60
ƒ [00359917-xx] Synchroflex toothed belt 1315 long for input- and output conveyor
ƒ [00364847-xx] Synchroflex toothed belt 1160 long for placement areas 1 + 2
ƒ [00356851-xx] Synchroflex toothed belt 990 long for intermediate conveyor

Parts for S27

ƒ [00364847-xx] Synchroflex toothed belt 1160 long for input conveyor
ƒ [00359917-01] Synchroflex toothed belt 1315 long for output conveyor and placement area

Overview

NOTE The following diagrams apply to the stan-

dard conveyor system (fixed side - right). Depend-
ing upon the installation procedure, the drive unit
will either be fixed with a clamping ring or a circlip.
1. Input conveyor
5 2. Placement area 1
3. Intermediate conveyor
4
4. Placement area 2
5. Output band
3

2
1

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Disassembly

1. Tape drive (mount)

2. Deflection pulley with slot
3
3. Conveyor toothed belt
The way in which the conveyor toothed belt is run
2 around the deflection pulley depends upon the
transport area concerned. Please observe this belt
guidance during assembly and disassembly.
Please also bear in mind the following differences
during assembly and disassembly:
ƒ The drive unit is installed at an angle (tilted),
according to the requirements of the installa-
1
tion site.
ƒ Respective to conveyor side, either the tape
drive (mount) or the drive unit with DC geared
motor is mounted.
X Move the PCB conveyor to the position which
gives you best access to the conveyor belt
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.

X Loosen the deflection pulley (2) with the slot

and relieve the tension on the conveyor
3
toothed belt (3).
Attention: The deflection pulleys
have been assembled with sliding
2 nuts.
The screw for the deflection pulley
should be loosened only! If the screw
is removed, the sliding nut will fall be-
hind the conveyor cheek side cover.
You then need to dismantle the cover
to retrieve the nut.
1 X If the drive unit is installed, remove it
X If the tape drive (mount) (1) is installed, re-
move the 3 fastening screws.
X Carefully pull off the tape drive (mount) (1) or
the drive unit, while also gently unthreading
the conveyor toothed belt (3).

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Installation

Attention: Do not damage the

3
toothed belt!
2
The toothed belts must not be
stretched or kinked!
X Feed the new conveyor toothed belt (2) into
3 the drive unit and weave it round the deflection
pulleys (3).
X Insert the tape drive (mount)(1) or drive unit
with the conveyor toothed belt (2) and fasten.
NOTE:
When replacing the belt on the passive side (tape
1 drive without drive unit), set the track width to 50
mm. The tape drive must be aligned towards the
3
active side, allowing smooth axial movement of
the hexagonal shafts.
X Tighten the fastening screws.
X Adjust the belt tension.

7.2.4.1 Adjusting the tension of the conveyor toothed belt

1. Deflection pulley with slot

2. Measuring point of the belt tension measuring
1 device (strand center)
X The deflection pulley, around which the con-
veyor toothed belt is run, is fastened at a slot.
The tension of the conveyor toothed belt can
be adjusted at this slot.
X Position the measuring point of the belt ten-
2
sion device at the strand center (i.e. the long-
est distance between the two deflection
pulleys) of the conveyor toothed belt.
X Set the tension of the drive toothed belt ac-
cording to the following values.
NOTE
The tension frequencies per area may vary ac-
cording to the different belt guides. The belt ten-
sion always remains the same.

Belt tension HS60 for track 1 (single and dual conveyor)

Input conveyor 90 Hz +/- 9 Hz
Placement area 1 72 Hz +/- 7 Hz
Intermediate conveyor 144 Hz +/- 14 Hz
Placement area 2 90 Hz +/- 97 Hz
Output conveyor 90 Hz +/- 9 Hz

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Belt tension HS60 for track 2 (dual conveyor)

Input conveyor 90 Hz +/- 9 Hz
Placement area 1 72 Hz +/- 7 Hz
Intermediate conveyor 115 Hz +/- 12 Hz
Placement area 2 90 Hz +/- 9 Hz
Output conveyor 90 Hz +/- 9 Hz

Belt tension S-27 HM (single and dual conveyor)

for track 1
Input conveyor 100 Hz +/- 10 Hz
Placement area 1 105 Hz +/- 10 Hz
Output conveyor 105 Hz +/- 10 Hz

Belt tension S-27 HM (dual conveyor)

track 2
Input conveyor 89 Hz +/- 9 Hz
Placement area 1 109 Hz +/- 11 Hz
Output conveyor 122 Hz +/- 12 Hz

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7.2.5 Replacing the Lifting Table Unit [00358653-xx]

Parts
ƒ (00358653-xx) Lifting table unit for single conveyors
ƒ (00358654-xx) Lifting table unit for dual conveyors

Disassembly

1. Fastening screws for the lifting table plate

1

2
2. 6 x fastening screws for the lifting table
(M8 x 100)
3. 2 x fastening screws for the lifting table
1 (M8 x 50)
3 2
X Move the PCB conveyor to a suitable position
from which you have best access to the lifting
table unit.
X Undo the screw fastening the lifting table plate
4 (1) and remove the lifting table plate from the
lifting table unit.
2
X Undo the screws (2) and (3) fastening the lift-
6 5 3
2 ing table unit.
X Remove the cover on the conveyor conversion
board and unplug the connection cable (4)
from the lifting table unit.
X Unplug the compressed air connection (5).
X Carefully lift the lifting table (6) off of the locat-
ing pins.
Attention: Heavy machine part!
When removing the lifting table, re-
member it is heavy (17.5 kg).

Installation

X Lift the lifting table unit (6) into the machine

1
and position it on the locating pins.
2
X Screw in the fastening screws (2) and (3).
X Reconnect to the electrical (4) and pneumatic
1 (5) systems.
3 2
X Check the lifting table speed and the function-
ality of the PCB clamping device, without the
lifting table plate.
X Set the values according to the following table.
4 X Carefully place the lifting table plate (1) onto
the lifting table unit and tighten the fastening
2
screws diagonally, so that the lifting table plate
6 5 3
2 does not stick.
X Check the lifting table speed once the lifting ta-
ble plate has been installed.

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7.2.5.1 Adjusting the speed of the lifting table

Parts
ƒ Transport software (item no. 00322132-xx)
ƒ Kvaser card

1. Kvaser card
2. Channel 1
3. Channel 2
X Use the Kvaser card (1) to connect the service
notebook via the CAN Bus interface to the con-
veyor control.
1
X Start the conveyor software
(LP_TSPMenu.exe).
X In the dialog box Einstellungen select the rele-
vant conveyor and machine type HS60 or S-27
2 3 HM aus.
X Confirm your choice with Übernehmen.
X Confirm the message Einstellung übernom-
men with OK.
X Click on the CAN-Karte button.
X Select the channel to be used with the Kvaser
card: channel 1 (2) or channel 2 (3).
X Confirm your setting with Übernehmen.

X Confirm the message Einstellung übernom-

men with OK.
X In the Komponenten menu, select the func-
tion Hubtisch. The Hubtisch dialog box will
open.

Precondition:
ƒ That the machine is switched on
ƒ That the safety covers are closed
ƒ That the control unit is switched on
X Select the lifting table you wish to check or ad-
just. Click on the Up and Down buttons.

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The time will be shown in front of the buttons.

ƒ The symbol shows the state "Lifting table down" (LED on the lifting table pneumatic cylinder).

ƒ The symbol shows the state "Lifting table up" (lifting table measuring system --> number of
counting pulses was counted correctly).

Issuing times for the lifting table

1. Direction of transport
2. Pneumatic valve
3. Lifting table cylinder
1 4. Piston rod
5. Adjustment valve – time characteristic for "lift-
3
ing table down"
2 6. Adjustment valve - time characteristic for "lift-
ing table up"
– Adjust the valves on the lifting table cylin-
der (5 / 6) so that the following values are
4 5 achieved.

Move upwards Move downwards Tolerance

Without lifting table 540 ms 540 ms +/- 20 ms
plate
With lifting table 500 ms 480 ms +/- 20 ms
plate

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7.2.6 Replacing the Lifting Table Stabilizer [00358684-05]

Overview
The stabilizer enables the lifting table to be moved gently upwards. It prevents the PCBs from being
clamped in with too much impact.

1. Actuator
1
3 2 2. Locknut
4 3. Fastening screws
4. Handle
X Move the PCB conveyor to the position which
allows you best access to the lifting table.
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Undo the screws fastening the lifting table
plate and remove the lifting table plate from the
lifting table unit.
X Undo the two screws (3) holding the stabilizer.
X Undo the locknut (2) and take the stabilizer by
its handle, (4) twisting it out of the mounting
block.

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Installation and adjustment

X Insert and twist the new stabilizer into the

1
3 2 mounting block until the slide just touches the
4
actuator (1), so that the lifting table can be
gently moved upwards.
X Secure this position with the locknut (2).
X Check whether the stabilizer has been fixed
onto the mounting block with the locknut and
that the stabilizer slide has a gap of approx.
0.1 mm to the actuator (gap in untriggered
mode). With this basic setting, the lifting table
should move gently upwards.
X If this is not the case, loosen the locknut and
turn the stabilizer approx. one rotation into the
mounting block.
X Install the lifting table plate.
X Start the SITEST program and move the lifting
table upwards.
X The lifting table should move gently upwards.
You should not hear the PCB clamping device
loudly locking into place and no clamping de-
vice error messages should be issued.
X Check the speed of the lifting table and correct
where necessary.

7.2.7 Replacing the Lifting Table Solenoid Valve [00358663-xx]

Removal/Installation

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1. Solenoid valve with 2 fastening screws

3
2. Connection plug
1
3. Compressed air connections
X Move the PCB conveyor to the position which
2
gives you best access to the lifting table.
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.
3
X Undo the screws fastening the lifting table
plate and remove the lifting table plate from the
2
lifting table unit.
NOTE
You may wish to completely dismantle the lifting
table, to give you better access to the solenoid
valves.
Attention: Heavy machine part!
When removing the lifting table, re-
member it is heavy (17.5 kg).
X Switch off the compressed air supply and re-
lease the air at the pneumatic unit filter.
X Undo the screws fastening the connection
plug and then unplug it.
X Remove the pneumatic connections.
X Install the new solenoid valve and reconnect
the electrical and pneumatic systems.
X Install the complete lifting table into the ma-
chine again.
X Check the speed of the lifting table and correct
where necessary.

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7.2.8 Replacing the Lifting Table Fork Light Barrier [00363079-xx]

Parts
ƒ Light barrier for track A – dual conveyor (00363079-xx)
ƒ Light barrier for track B – dual conveyor (00363080-xx)
ƒ Light barrier for track A – single conveyor (00363111-xx)
ƒ Light barrier for track B– single conveyor (00363113-xx)

Removal/Installation

1. Connection cable for the conversion board of

the lifting table
2. 2 x fork light barrier (position measuring sys-
tem, tracks A + B)
3. Conversion board of the lifting table (under the
cover)
X Move the PCB conveyor to the position which
gives you best access to the lifting table.
X Move the Y-gantries into the area outside the
2 1 PCB conveyor.
3
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Undo the screws fastening the lifting table
plate and remove the lifting table plate from the
lifting table unit.
X Undo the two screws (2) fastening the fork light
barrier.
X Remove the cover from the conversion board
of the lifting table (3).
X Unplug the lifting table conversion board.
X Install the new fork light barrier and reconnect
to the electrical system.

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7.2.9 Replacing the Complete Lifting Table Cylinder [00358703-xx]

Overview

DANGER OF CRUSHING: Press the

2 1
EMERGENCY STOP!
3 Before performing adjustment work
you must ensure that the lifting table
has been secured against movement.
1. End position proximity switch
2. Lifting table cylinder
3. Piston rod with locknut
4. Solenoid valve
4
X Move the PCB conveyor to the position which
gives you best access to the lifting table.
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Switch off the compressed air supply.

Disassembly

X Undo the screws fastening the lifting table

2 1
plate and remove the lifting table plate from the
3 lifting table unit.
X Undo the fastening screws for the solenoid
valve (4) and remove it from the lifting table
cylinder.
X Loosen the grub screw at the end position
proximity switch (1) and push the end position
proximity switch out of the lifting table cylinder
4 guide rail (2).
X Loosen the locknut on the piston rod (3) and
twist the piston rod out until it releases itself
from the actuator.
X Undo and remove the two screws fastening
the lifting table cylinder (2).

Installation

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X Insert and fasten the new lifting table cylinder

2 1
(2) and install the piston rod (3).
3
X Move the lifting table by hand to its end posi-
tion.
X Switch the machine on.
X Push the end position proximity switch (1) into
the guide rail until the LED lights up.
X Fix this position with the grub screw.

4 X Install the solenoid valve (4) and the lifting ta-

ble plate.
X Check the speed of the lifting table and correct
where necessary.

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7.2.10 Replacing the Stepping Motor of the Width Adjustment System [00367174-xx]
Overview

1. Width adjustment stepping motor

3 2. Toothed belt for the drive
3. Adjustment unit 1 and 2
2
1

1. Loosening the eccentric axle on the deflection

pulley
2. Locknut on the eccentric axle
3. Fastening screws for stepping motor
4. Stepping motor
4 1 2
Attention: Do not damage the
toothed belt!
3
During the following removal and in-
stallation of the motor, the toothed belt
for the width adjustment drive must
not be stretched or kinked!
X Move the PCB conveyor to the position which
gives you best access to the stepping motor of
the width adjustment system.
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.

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Removal/Installation

X Undo the screws fastening the lifting table

plate and remove the lifting table plate from the
lifting table unit.
X Loosen the eccentric axle (1) on the deflection
pulley and relieve the tension on the drive
4 1 2 toothed belt (5).
Attention: Toothed belt must not
come off!
3
When relaxing the toothed belt, make
sure the belt does not come off (skip)
the toothed wheels at the 2 adjust-
5 ment units. This would cause incor-
rect alignment of the adjustment units.
Secure these positions with a suitable
tool (screw clamp etc.)
X Remove the 4 fastening screws (3) and then
lift out the stepping motor (4).
X Unplug the connection cable in the cable duct.
X Install the new stepping motor and reconnect
the system to the electrical system.
X Tension the drive toothed belt.
Position the measuring point of the belt ten-
sion device at the strand center (i.e. the long-
est distance between two toothed wheels) of
the conveyor toothed belt.
X Set the tension of the drive toothed belt ac-
cording to the following values.

Belt tension- width adjustment system

Toothed belt for the drive 24 Hz +/- 2 Hz

Please also refer to ...

 Adjusting the tension of the conveyor toothed belt [-> 247]

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7.2.11 Replacing the Limit Switch for the End Position Width Adjustment System
[00365108-xx]
Parts
ƒ Limit switch on the mounting tray (00365002-xx)
ƒ Limit switch for width adjustment 1 (00365108-xx)
ƒ Limit switch for width adjustment 2 (00365109-xx)
ƒ Limit switch for width adjustment - on the conveyor side (00362345-xx)

Overview

1. Limit switch 1 for width adjustment system of

the adjustment unit
1 4
2. Limit switch for width adjustment system (for
side)
3. Limit switch for conversion board (for side)
4. Limit switch 2 for width adjustment system of
the adjustment unit
Limit switch on the input conveyor:
2
In the vicinity of the input conveyor there are 4 limit
2
3 switches under the conveyor sides. The limit
switch is designed to prevent the conveyor sides
hitting one another or the conveyor base.
Limit switch on the output conveyor:
In the vicinity of the output conveyors, there are 2
limit switches for the adjustment unit. They serve
to secure the transport area and to initialize the ad-
justment unit during width adjustment.

Removal/Installation

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NOTE
The limit switches are preassembled and include
1 2 cables.
However, if the limit switch itself is faulty, the wir-
ing can be unsoldered/soldered right at the switch
in question.
X Unsolder the connection wires on the faulty
limit switch (1).
X Undo and remove the two screws (2) fastening
the defect limit switch and remove the switch.
NOTE
If you have discovered a break in the limit switch
cable during a continuity check, the cable must be
unthreaded as far as the conversion board of the
mounting tray and unplugged at the corresponding
point.
This might be somewhat complicated depending
on the routing of cables inside the machine base.
You may wish to contact Siemens AG SMD Ser-
vice regarding this work.
Install the new limit switch and re-solder the con-
nection wires in the correct allocation.
Checking the position of the limit switch:
X Check the minimum and maximum width of
the relevant machine type and the parallelism
of the conveyor sides.

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7.2.12 Replacing the Solenoid Valve for the Adjustment Unit [00369014-xx]
Parts HS-60
ƒ Solenoid Valve for the Adjustment Unit 1 (00363779-xx)
ƒ Solenoid Valve for the Adjustment Unit 2 (00363780-xx)

Parts S-27 HM
ƒ Solenoid Valve for the Adjustment Unit 1 (00363266-xx)
ƒ Solenoid Valve for the Adjustment Unit 2 (00363270-xx)

Overview

1. Adjustment unit 1
2 2. Adjustment unit 2
3. Direction of transport
X Move the PCB conveyor to the position which
gives you best access to the adjustment sys-
tem.
1
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Switch off the compressed air supply.
3

Removal/Installation

X Remove the compressed air connections (2).

3 X Undo the two fastening screws and remove
the solenoid valve (3) from the short-stroke
cylinder.

2 X Unthread the connection cable (1) as far as the

relevant assembly tub conversion board and
unplug.
1 NOTE
This might be somewhat complicated depending
on the routing of cables inside the machine base.
You may wish to contact Siemens AG SMD Ser-
vice regarding this work.
X Install the new solenoid valve (3) and recon-
nect the system to the electrical (1) and pneu-
matic (2) supplies.

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7.2.13 Replacing the Cylinder Switch for the Adjustment Unit [00369016-xx]
Parts HS-60
Cylinder Switch for the width adjustment system 1 (00363267-xx)
Cylinder Switch for the width adjustment system 2 (00363291-xx)
Parts S-27 HM
Cylinder switch for adjustment unit 1 (00363267-xx)
Cylinder switch for adjustment unit 2 (00363291-xx)
Overview
The cylinder switch on the adjustment unit cylinder should operate when the adjustment unit pin is
pushed out by the pneumatic cylinder and therefore connected to the conveyor side. This signal enables
the motor of the width adjustment system.

1. Adjustment unit 1
2 2. Adjustment unit 2
3. Direction of transport
X Move the PCB conveyor to the position which
gives you best access to the adjustment sys-
tem.
1
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Switch off the compressed air supply.
3

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Removal/Installation

X Loosen the grub screw at the cylinder switch

(1) and push the cylinder switch out of the ad-
justment unit guide rail (2).
X Unthread the connection cable as far as the
conversion board of the mounting tray.
X Run the connection cable of the new cylinder
2
switch (2).
X Insert the new cylinder switch into the guide
rail.
X Switch the machine on.
NOTE
The width adjustment system cylinder switch is
1
set/adjusted in engaged mode.
X Move the width adjustment system until the
cylinder switch switches - LED (H36/H37)
lights up.
Engage the cylinder - i.e. the cylinders are
moved to the upper limit by the controls.
X Set the cylinder switch so that the LED lights
up when it is in engaged mode.
X Fix the position of the cylinder switch (2) with
the grub screw.

7.2.14 Replacing the Proximity Switch for the Adjustment System [00363268-xx]
Parts
ƒ Proximity switch for adjustment unit 1 (00363268-xx)
ƒ Proximity switch for adjustment unit 2 (00363292-xx)

Overview
The proximity switch serves as a signal for controlling the pneumatic valve of the adjustment unit. Once
the switching point has been reached, the conveyor side is connected via the short-stroke cylinder.

1. Adjustment unit 1
2 2. Adjustment unit 2
3. Direction of transport
X Move the PCB conveyor to the position which
gives you best access to the adjustment sys-
tem.
1
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Switch off the compressed air supply.
3

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Removal/Installation

X Loosen the grub screw on the clamping device

(1) and unthread the connection cable as far
as the conversion board of the mounting tray.
X Install the new proximity switch and reconnect
the system to the electrical system.
X Fix the proximity switch with the grub screw.

2 X The grub screw has to be tightened with a

tightening torque of 20 Ncm (+ 3Ncm). The
proximity switch has to lie flat with the housing
(2) for the adjustment unit.
The switching point is set at the actuator on the
1
conveyor side:
X Move the adjustment unit until it is under the
conveyor side.
X Place a 4/10mm gauge block on the adjust-
ment unit, press the actuator onto the gauge
block and tighten the screw.
NOTE
This setting must be performed at all conveyor
sides.
X Use the SITEST program to calibrate the con-
veyor sides.

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7.2.15 Replacing the Light Barriers for Transmitter and Receiver Modules [00370063-xx]
Parts
Please note the different item numbers for the individual light barriers - these are for the different lengths
of the connection cable.
Please refer to the Siplace HS-60 or S-27 HM spare parts cataogue for the different item numbers.

Overview

1. Transmitter at input conveyor

9 10
2. Receiver at input conveyor
8
7 3. Transmitter at placement area 1
4. Receiver at placement area 1
5. Transmitter at intermediate conveyor
6
5 6. Receiver at intermediate conveyor
7. Transmitter at placement area 2
8. Receiver at placement area 2
4
3 9. Transmitter at output conveyor
10. Receiver at output conveyor

1 2

Important instructions for replacing the light barrier

ƒ The transmitters are installed on the moveable side of conveyor models, while the receivers are on
the fixed side (applies to the standard conveyor system, fixed side - right).
ƒ Check whether it would be helpful to feed in the new cable with the aid of the old one, at least in some
areas.
ƒ The connection plug is equipped with contacts, which are pressed onto the wires. You may find it
helpful to remove the contacts from the connection plug, in order to run the cable better through
openings.
ƒ For replacement purposes, the connection cable must be unthreaded as far as the relevant conver-
sion board of the conveyor side. This might be somewhat complicated depending on the routing of
cables inside the machine base.
You may wish to contact Siemens AG SMD Service regarding this work or proceed as follows.

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7.2.15.1 Replacing the transmitter or receiver for placement areas 1 + 2

Receiver
X Remove the stop rail.
X Remove the short guide rail.
X Dismantle the holder and the receiver.
X Dismantle the receiver from the holder.
X Unthread the connection cable as far as the relevant conversion board of the conveyor side.
X Unplug the conversion board of the conveyor side.
X Rerun the connection cable accordingly and reconnect the conversion board of the conveyor side to
the electricity supply.
X Fix the receiver at the holder.
X Fix the holder together with the receiver at the base in such a way that the holder lies flat on the
base.
X Mount the short guide rail and align it.
X Mount the stop rail.

Transmitter
X Dismantle the holder and the receiver.
X Dismantle the receiver from the holder.
X Unthread the connection cable as far as the relevant conversion board of the conveyor side.
X Unplug the conversion board of the conveyor side.
X Rerun the connection cable accordingly and reconnect the conversion board of the conveyor side to
the electricity supply.
X Fix the new light barrier in the original position.

7.2.15.2 Replacing the transmitter or receiver for the input or output conveyor
Receiver
NOTE
The transmitters on the input and output conveyors are freely accessible. The bracket must be loosened
and the screws fastening the light barrier removed.
X Remove the stop rail.
X Remove the short guide rail.
X Dismantle the holder and the receiver.
X Dismantle the receiver from the holder.
X Unthread the connection cable as far as the relevant conversion board of the conveyor side.
X Unplug the conversion board of the conveyor side.
X Rerun the connection cable accordingly and reconnect the conversion board of the conveyor side to
the electricity supply.
X Fix the receiver at the holder.
X Fix the holder together with the receiver at the base in such a way that the holder lies flat on the
base.
X Mount the short guide rail and align it.
X Mount the stop rail.

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Transmitter
NOTE
Otherwise check whether you can run the cable through the opening by removing the contacts in the
connection plug.
X Dismantle the holder and the receiver.
X Dismantle the receiver from the holder.
X Unthread the connection cable as far as the relevant conversion board of the conveyor side.
X Unplug the conversion board of the conveyor side.
X Rerun the connection cable accordingly and reconnect the conversion board of the conveyor side to
the electricity supply.
X Fix the new light barrier in the original position.

7.2.15.3 Replacing the Light Barrier for the Intermediate Conveyor

Transmitter
X Dismantle the holder and the receiver.
X Dismantle the receiver from the holder.
X Unthread the connection cable as far as the relevant conversion board of the conveyor side.
X Unplug the conversion board of the conveyor side.
X Rerun the connection cable accordingly and reconnect the conversion board of the conveyor side to
the electricity supply.
X Fix the new light barrier in the original position.

Receiver
NOTE
The transmitter on the intermediate conveyor is freely accessible. The bracket must be loosened and the
screws fastening the light barrier removed.
X Remove the stop rail.
X Remove the short guide rail.
X Dismantle the holder and the receiver.
X Dismantle the receiver from the holder.
X Unthread the connection cable as far as the relevant conversion board of the conveyor side.
X Unplug the conversion board of the conveyor side.
X Rerun the connection cable accordingly and reconnect the conversion board of the conveyor side to
the electricity supply.
X Fix the receiver at the holder.
X Fix the holder together with the receiver at the base in such a way that the holder lies flat on the
base.
X Mount the short guide rail and align it.
X Mount the stop rail.

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7.2.16 Replacing the Laser Light Barriers for Stopper Positions [00370385-xx]
Parts
ƒ Laser light barrier transmitter module BB1 complete (00370385-xx)
ƒ Laser light barrier transmitter module BB2, complete (00370386-xx)
ƒ Laser light barrier receiver module BB1 (00365772-xx)
ƒ Laser light barrier receiver module PA2 (00365774-xx)

Overview

1. Transmitter module (amplifier) with 2 screws

2 2. Transmitter module (round laser diode) with 3

screws
LASER: The laser light barrier
emits class 2 laser beams (from its
1
transmitter).
You therefore do not require addition-
al protective measures!

X Keep your eyes away from the la-

ser beam!
NOTE
After setting the laser light barrier you must check
or re-teach the PCB reference corner!
X Move the PCB conveyor to the position which
gives you best access to the laser light barrier.
X Move the Y-gantries into the area outside the
PCB conveyor.
X Switch off the machine and secure it to prevent
unauthorized reactivation.

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Removal/installation of complete transmitter module

X Undo the 2 fastening screws on the large

transmitter module (1) and the 3 fastening
screws on the small transmitter module (2).
2
Make sure you do not lose the O-rings.
X Unthread the connection cable as far as the
relevant conversion board of the conveyor
side.
X Unplug the conversion board of the conveyor
side.
X Rerun the connection cable accordingly and
1
reconnect the conversion board on the con-
veyor side to the electrical system.
X Fix the new transmitter module in the original
position.
X Make sure that the 3 O-rings are placed on the
3 fastening screws.
X Switch the machine on.
X Move the side parts of the conveyor system
apart to maximum width.
X Turn the 3 fastening screws to align the trans-
mitter diode centrally to the receiver. The en-
tire height of the laser beam must hit the
receiver. Please also refer to the adjustment
instructions.

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Removal /installation of receiver module

X Undo the 2 screws fastening the receiver mod-

ule (1).
1 X Unthread the connection cable as far as the
relevant conversion board of the conveyor
side.
X Unplug the conversion board of the conveyor
side.
X Rerun the connection cable accordingly and
reconnect the conversion board of the convey-
or side to the electricity supply.
X Install the new receiver module in the original
position.
X Switch the machine on.
X Move the side parts of the conveyor system
apart to maximum width.
X Turn the 2 fastening screws to align the receiv-
er centrally to the transmitter diode. The entire
height of the transmitter diode laser beam
must hit the receiver. Please also refer to the
adjustment instructions.

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7.2.17 Overview of the Electrical Components

7.2.17.1 Conversion board of the Conveyor Side [00359424-xx]
Overview

1. Conversion board of the conveyor side

1 2. Cover
The conversion boards for the conveyor sides (1)
are situated on the respective conveyor sides, un-
2
der a cover (2).
For terminal assignment details, please refer to
the current version of the SIPLACE HS-60 respec-
tively S-27 HM detailed circuit diagrams.

7.2.17.2 Conveyor Conversion Board [00359425-xx]

Parts
ƒ HS-60 Conversion board (00359425-xx)
ƒ S-27 HM Conversion board (00359426-xx)

Overview

1. Conveyor conversion board

1 2. Cover
The conveyor conversion board (1) is situated in
the vicinity of the intermediate conveyor, under the
cover (2).
For terminal assignment details, please refer to
the current version of the SIPLACE HS-60 respec-
tively S-27 HM detailed circuit diagrams.

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7.2.17.3 Conversion board of the Lifting Table [00362766-xx]

Overview

1. Lifting table conversion board

1
2. Cover
The lifting table conversion board (1) is situated on
the lifting table unit, under the cover (2).
For terminal assignment details, please refer to
the current version of the SIPLACE HS-60 respec-
tively S-27 HM detailed circuit diagrams.

7.2.17.4 Conveyor Control TSP 301 [00370397-xx]

Parts
ƒ HS-60 conveyor control TSP 3201 (00370397-xx)
ƒ S-27 HM conveyor control TSP 201 (00360305-xx)
NOTE
For S-27 HM from SN 382 the clamping sensor n/a. The DIP switch 3 on the conveyor control system
must be set to OFF.

Overview

For terminal assignment details, please refer to

the current version of the SIPLACE HS-60 respec-
tively S-27 HM detailed circuit diagrams.

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7.2.17.5 Extension Controller Board TSP 301E for Dual Conveyors [00370398-xx]
Overview

For terminal assignment details, please refer to

the current version of the SIPLACE HS-60 respec-
tively S-27 HM detailed circuit diagrams.

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8 Collect+Place Head DLM2

8.1 Module Overview

Overall

ƒ Collect+Place Head DLM2/12 [00367770-xx]

ƒ Collect+Place Head DLM2/6 [00367020-xx]
NOTE
3 We have not included diagrams of both placement
head types. The structure, functionality and ser-
vice work described in this manual applies princi-
1
pally to the DLM2 C+P head with 6 and 12
segments.
5
1. Back Part, Complete
2. Star, fitted with 12 or 6 sleeves
3. Front part, complete
2
4
4. Subdistributor
5. Component camera

8.1.1 Back Part, Complete

Overview

The back part of the collect+place head is fixed

4
with four hexagon socket-head screws (A) to the
3 gantry head plate. Two parallel pins (B) are used
to center the front part of the collect+place head.

5 1. Back part /DLM2

2 2. Vacuum distributor

B A 3. Turning station
4. Vacuum generator/ DLM2
B
1
5. Vacuum measurement board SP6/12

7
6. Brake for star
9
6 7. Distributor piece
8
8. "Placement circuit" valve positioning drive
9. "Reject circuit" valve positioning drive

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8.1.2 Star, Fitted

Overview

The star is fixed to the drive shaft of the star motor

8
6 (B) with three M3x8 hexagon socket-head
7
5 screws (A).
1. Star
4
2. Distributor plate for distributing the vacuum
3 between the individual segments
3. 12 O-rings
4. 12 connecting hoses / DLM2
2
B 5. 12 valve plungers, complete, SP-12
9 6. 12 valves, SP-12
7. 12 forced air inlets
1 A
8. 12 sleeves
9. 12 segments

8.1.3 Front Part, Complete

Overview

The front part is centered by two holes (A), into

4 5
which the parallel pins of the back part engage.
3
The front is fixed to the back part with four M4x16
A hexagon socket-head screws.
1. Casing / DLM2
2. Forced air unit/ DLM2
3. RSF - digital rotary encoder/ DLM2 (beneath
the board with the safety cover)
6 4. Star drive, digital/ DLM2
5. Z-axis drive
2 6. Raceway for the 12 ball bearings on the seg-
A 7
1 ments
7. Snap jaws to raise or lower the sleeves

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8.1.4 Subdistributor
Overview

1. Subdistributor
5
2. Spacer bolt M3x10
3. Spacer bolt M3x7
4. Spacer bolt M3x9
1
5. Front part of the collect+place head

4
2

8.1.5 Component Camera 24 x 24

Overview

1. Component camera - Type 28

2. Fastening screws
3 3. Illumination control board

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8.1.6 Overview of Settings

Description Tools Values

Assembly of star on star Adjustment with power Check the magnetic neu-
motor shaft. pack and zero point gage tral position with SITEST.
for star. Maximum deviation: 95
digits.
Determine zero point cor- Zero point correction gage Enter result of zero point
rection factor of star. correction with SITEST at
„Positions“.
Star encoder resolution. None Switch set to 25
DP axis Incremental en- Test probes 1.4 mm – 1.6 Distance 1.5 mm.
coder setting - distance to mm
segment disk.
Valve positioning drive Feeler gage 0.2 mm 0.2 mm distance from
settings. (325445-xx) plunger to valve housing.
Light barrier Z-axis down. Test probe 1.0 mm Distance 1.0 mm.
Z-terminal block belt Tension jack must lie on
the belt teeth at the top
and bottom.
Z-axis belt tension. Belt tension measuring de- Belt tension
vice 270-290 Hz (+/- 5 Hz).
Z top stop Gage for Z end position Correct position for auto-
stop matic zero point identifica-
Star gage (03019865-xx) tion.
blast air tube on star. Sight check Check distance between
incremental encoder and
blast air tube.
Setting blast air supply. Feeler gage blast air tube must extend
approx. 0.7 mm above the
circular arc guide.
blast air - placement set- Compressed air measur- 150 mbar at an open 9x4
ting ing device nozzle.

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8.2 Service Work

WARNING: Nonobservance of these safety instructions may cause inju-

ry to personnel and damage to the machine!
The service work described in this manual may only be performed by specially
trained service technicians, with appropriate qualifications and expertise.

X Please observe the safety instructions in the Operating Manual for all ser-
vice work!

8.2.1 Replacing the Collect+Place Head 6/12 [00367281-xx]

Overview

1. Illumination controller
2
2. Pneumatic distributor
1
3. 4 x fastening screws

3
3

Disassembly

X Remove the compressed air hoses from the

2
pneumatic coupling of the pneumatic distribu-
tor (1).

4
X Undo the plug-and-socket connections to the
collect+place head board (2).

1 X Undo the 4 screws (3) fastening the col-

lect+place head.
X Carefully pull the collect+place head away
from the parallel pins (4) on the head mount (5)
3 and remove the collect+place head from the
placement system.
5

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Installation

X Carefully move the collect+place head to-

wards the head mount (3).
X Make sure that the parallel pins (2) on the
head mount slide into the holes in the back
2
part of the collect+place head.
X Carefully push the collect+place head towards
the head mount until it lies flat against it.
X Fix the collect+place head with the 4 screws
provided (1).

X Connect the compressed air hoses (1) to the

1 pneumatic coupling on the pneumatic distribu-
tor (2).
X Reconnect to the electricity system.
1
X Use the SITEST program to calibrate the col-
lect+place head.
2

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8.2.2 Replacing the Front Part of the Collect+Place Head [00367769-xx]

Disassembly

1. Front part
2. Back part
3. Intermediate distribution board (under the cov-
4 er)
4. 4 x fastening screws
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Remove the connecting cable plugs from the
2
sockets on the head interface.
X Remove the pneumatic hose.

3
1

X Undo the four fastening screws (3).

Attention: Hold on to the placement
head!
1 When you undo the last screw, hold
the collect+place head so that it does
not accidentally drop off the back part.
2
Attention: Make sure the star posi-
tion is correct!
When you remove the front part of the
collect+place head, make sure that
the star is pivoted roughly 15° away
from the vertical sleeve position. Oth-
erwise the valve plunger will remain
3
attached to the valve positioning
drive.
X Lift the front part of the collect+place head (1)
away from the parallel pins on the back part (2)
and place it on a soft, clean surface.

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Fitting the front part of the collect+place head

X Grease the O-rings with Unisilkon.

X Push the small O-ring onto the tube.
X Position the large O-ring onto the connecting
3 piece (4).
4 X Check that the O-rings are seated correctly.
1
X Insert the distributor block into the back part
(3).
X Place the front part (2) on the back part (3) so
that the parallel pins are aligned with the holes
in the front part.
X Carefully push the front part against the back
2
part until it lies flat against the back part.
X Tighten the four fastening screws.
X Reconnect to the electrical system.
Attention: Check how the cables
are run!
Make sure that the folded part of the
ribbon cable for the "Z-axis up" light
barrier is pushed back under the illu-
mination board.
X Use the SITEST program to calibrate the col-
lect+place head.

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8.2.3 Replacing the Component Camera [00336791-xx]

Removal/Installation
The component camera must be replaced as a complete unit. This consists of the lens system, camera,
amplifier, illumination planes and "illumination controller" board.

X Dismantle the front part of the collect+place

3 head (4).
2
X Remove the ribbon cable plug from the socket
on the "component illumination control" board
(2).
1
X Undo the four screws (3) holding the compo-
nent camera.
X Carefully detach the component camera (1).

X Make sure that all contact surfaces are clean.

3
X Place the holes in the camera on the parallel
2
pins (4).
X Carefully position the camera on the col-
1
lect+place head, until the camera plinth lies flat
on the contact surface of the front part of the
collect+place head.
X Fix the camera in place with the four screws
provided (3).
X Connect the ribbon cable to the socket on the
"component illumination board" (2).
4
X Install the front part of the collect+place head
(4).
X Start the placement system.
X Use the SITEST program to calibrate the com-
ponent camera.

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8.2.4 Replacing the Subdistributor [00330648-xx]

X Please observe the ESD regulations for the

following work and use an ESD ground strap.
X Loosen and remove the four fastening screws
and take off the cover (1).
2
X Undo the four spacer bolts (3) and tilt the inter-
1 mediate distribution board (2) slightly.

3
3

Disassembly

X Carefully remove the hose from the pressure

X3 X8
X1 sensor (U4).
X4
X9 X Remove the plugs from their sockets on the
X5 X2
X11 board. Refer to the respective detailed circuit
X6
X7 U4 X10 diagrams.
X12 X Remove the intermediate distribution board.

Installation

X Restore connections X1......X12.

X3 X1 X8
X Push the hose onto the pressure sensor
X4
X9 tube(U4).
X5 X2
X11
X6 X Fasten the intermediate distribution board.
X7 U4 X10
NOTE:
X12
No settings are required.

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8.2.5 Replacing the Turning Station [00341780-xx]

1. Turning station / DLM2

2. Fastening screw for turning station
NOTE:
1
The head does not need to be removed when dis-
mantling the turning station.
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Remove the motor cable and ribbon cable
from the slots on the head adapter.

Removal/Installation

X Move the collect+place head to a suitable po-

3 sition.
X Undo the screws fastening the turning station
1
(2).
X Carefully lever the turning station (1) off the lo-
cating pins and gently pull it (1) out.
X Make sure that the contact surfaces on the
turning station and back part (3) are clean.
X Insert the turning station holes (1) onto the par-
2 allel pins.
X Carefully push the turning station towards the
front part until it reaches the stop.
X Fasten the turning station with the screw pro-
vided (2).
X Plug the cable into the slots on the head adapt-
er. Make sure the cables are run correctly.
X Switch the placement system on and start it
up.
X Use the SITEST program to run a function test.

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8.2.6 Replacing the Valve Positioning Drive for the Placement Circuit [00368075-xx]
Disassembly

1. Valve positioning drive for the placement cir-

cuit [00368075-xx]
2. Valve positioning drive for the reject circuit
[00349432-xx]
X Remove the collect+place head from the head
plate.
X Undo the two M2x6 Phillips screws on the rib-
3 bon cable clamp(3) and (4).

4
1
2

1. Valve positioning drive for the placement cir-

cuit [00368075-xx]
2. Valve positioning drive for the reject circuit
[00349432-xx]
3
X Undo the fastening screw (4).
X Carefully remove the valve positioning drive
(1) or (2).
1

5
2
4

Installation

X Insert the valve positioning drive. Make sure

that it is seated correctly on the parallel
pins(5).
X Loosely tighten the hexagon socket-head
3
screw (4)
X Use the cable clamps to fix the ribbon cable in
position. Make sure that the ribbon cables are
not squashed.
1

5
2
4

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Attention: Check how the cables

are run!
Check that the ribbon cables are laid
correctly (1).

X The flat ribbon cable for the two

valve positioning units must be run
outside the holes (2). Otherwise, it
will be damaged when the col-
lect+place head is fitted onto the
1 head plate.

Mechanical adjustment

1. Stepping motor
3 4 A
5 2. Incremental plate

2 3. Deep-groove ball bearings

4. Valve plunger
5. Valve casing
1 6. M3x10 hexagon socket-head screw
7. Valve positioning drive (flange)
B
X Use the feeler gauge to set the distance be-
tween the valve plunger and valve casing to
7
0.2 mm (A).
6
X Turn the incremental plate (2) until the deep-
groove ball bearings (3) point towards the
valve casing.
X Move the valve positioning drive(7) so that the
deep-groove ball bearings(3) come into con-
tact with the valve plunger(4) at position(B).
X Use the hexagon socket-head screw to fix the
adjustment unit in this position(6).
X Attach the collect+place head to the head
plate.
X Use the SITEST program to test that the valve
positioning drive is functioning correctly.
X Use the SITEST program to calibrate the col-
lect+place head.

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8.2.7 Replacing the Valve Positioning Drive for the Reject Circuit [00349432-xx]
Disassembly

1. Valve positioning drive for the placement cir-

cuit [00368075-xx]
2. Valve positioning drive for the reject circuit
[00349432-xx]
X Remove the collect+place head from the head
plate.
X Undo the two M2x6 Phillips screws on the rib-
3 bon cable clamp (3) and (4).

4
1
2

1. Valve positioning drive for the placement cir-

cuit [00368075-xx]
2. Valve positioning drive for the reject circuit
[00349432-xx]
3
X Undo the fastening screw (4).
X Carefully remove the valve positioning drive(2)

4 2

Installation

X Insert the valve positioning drive. Make sure

that it is seated correctly on the parallel
pins(5).
X Loosely tighten the hexagon socket-head
3
screw (4)
X Use the cable clamps to fix the ribbon cable in
position. Make sure that the ribbon cables are
not squashed.
1

4 2

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Attention: Check how the cables

are run!
Check that the ribbon cables are laid
correctly (1).

X The flat ribbon cable for the two

valve positioning units must be run
outside the holes (2). Otherwise, it
will be damaged when the col-
lect+place head is fitted onto the
1 head plate.

Mechanical adjustment

1. Stepping motor
3 4 A
5 2. Incremental plate

2 3. Deep-groove ball bearings

4. Valve plunger
5. Valve casing
1 6. M3x10 hexagon socket-head screw
7. Valve positioning drive (flange)
B
X Use the feeler gauge to set the distance be-
tween the valve plunger and valve casing to
7
0.2 mm (A).
6
X Turn the incremental plate (2) until the deep-
groove ball bearings (3) point towards the
valve casing.
X Move the valve positioning drive(7) so that the
deep-groove ball bearings(3) come into con-
tact with the valve plunger(4) at position(B).
X Use the hexagon socket-head screw to fix the
adjustment unit in this position(6).
X Attach the collect+place head to the head
plate.
X Use the SITEST program to test that the valve
positioning drive is functioning correctly.
X Use the SITEST program to calibrate the col-
lect+place head.

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8.2.8 Replacing Light Barrier "Z-axis Up" [00347297-xx]

Disassembly

1. 2 x M2.0x4 hexagon socket-head screws

2. 2 Phillips screws (1.6x3)
3. Light barrier board "Z-axis up"
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Remove the plug from the socket on the inter-
mediate distribution board.
1 X Undo the two M2.0x4 hexagon socket-head
3 screws (1) and remove the ribbon cable
clamp.
X Loosen the two M1.6x3 Phillips screws (2).
X Remove the "Z-axis up" light barrier board (3)
2
together with its cable.

Installation

X Use the two M1.6x3 Phillips screws (2) to fix

the "Z-axis up" light barrier board (3).
X Connect the ribbon cable plug to the socket on
the intermediate distribution board.
X Use the ribbon cable clamp and the two hexa-
gon socket-head screws (1) to fix the ribbon
cables.
Attention: Check how the cables
1
are run!
3
Make sure that the ribbon cable is not
squashed in the guide channel.
Make sure that you push the folded
part of the flat ribbon cable for the "Z-
2 axis up" light barrier back under the il-
lumination board.

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8.2.9 Replacing the Z-axis Drive [00341011-xx]

Disassembly

1. 4 x M3x5 hexagon socket-head screws with

2 4
locking varnish
3
2. Z-axis drive
3. 2 x M2.5x12 hexagon socket-head screws
6 5 4. Motor clamp fitting 2 /DLM2
5. Motor clamp fitting /DLM2
6. 2 x M3x14 hexagon socket-head screws
1
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Remove the plug from the sockets on the inter-
mediate distribution board.
X Undo the four M3x5 hexagon socket-head
screws with locking varnish (1).
X First undo the upper M2.5x12 hexagon socket-
head screw (3) of the motor clamp fitting 2 (4),
then the lower one.
X Undo the two M3x14 hexagon socket-head
screws (6) on the motor clamp fitting (5).
X Carefully remove the Z-axis drive (2) together
with the cables.

Installation

X Insert the Z-axis drive (2).

X Make sure that the teeth of the toothed belts
engage in the teeth of the motor pinion (1)
X Use the four M3x5 hexagon socket-head
screws to fit the Z-axis drive.
X Tension the Z-axis toothed belt by pushing the
Z-axis drive unit upwards.
X Use the belt tension measuring device to
check the tension of the toothed belt (see set-
ting instructions).

1 2

Before continuous opera- After continuous operation

tion Frequency in Hz Frequency in Hz
Toothed belt T2 / DLM2 on 280 +/- 10 280 +/- 10
the Z-axis

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X Tighten the two M3x14 hexagon socket-head

2 4
screws (6) for fixing the motor clamp (5).
3
X Tighten the two M2.5x12 hexagon socket-
head screws (3) for fixing the motor clamp 2
(4).
6 5
X Now tighten the hexagon socket-head screws
on the Z-axis drive unit and the motor clamp.
1 X Check the Z-axis top stop with the adjustment
gage.

8.2.10 Replacing the Toothed Belt of the Z-axis [00334936-xx]

Disassembly

1. Z-axis drivestop
2. Z-axis toothed belt
3. 2 x deflection wheel / DLM2
4. Tension jack
X Switch off the machine and secure it to prevent
unauthorized reactivation.
X Loosen the two screws fastening the tension
jack (3).

3 2
1

X Undo the two M2.5x12 hexagon socket-head

2 4
screws (3) on the motor clamp fitting (4).
3
X Undo the two M3x14 hexagon socket-head
screws (6) on the motor clamp fitting (5).

6 5 X Loosen the four M3x5 hexagon socket-head

screws (1).
X Remove the toothed belt.
1

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Installation

X Place the new toothed belt over the pinion of

the Z-axis drive and the deflection wheels.
NOTE
Make sure that the teeth of the toothed belts en-
gage in the teeth of the pinion and deflection pul-
leys.
X Fit the tension jack (4) with the two fastening
screws, to the toothed belt.
NOTE
Make sure that both ends of the tension jack lie on
4
the teeth of the toothed belt.

3 2
1

X Loosely tighten the four M3x5 hexagon socket

2 4
head screws (1) on the Z-axis drive unit (2).
3
X Tension the Z-axis toothed belt by pushing the
Z-axis drive unit upwards.

6 5 X Use the belt tension measuring device to

check the tension of the toothed belt (see set-
ting instructions).
1 X Tighten the two M3x14 hexagon socket-head
screws (6) for fixing the motor clamp (5).
X Tighten the two M2.5x12 hexagon socket-
head screws (3) for fixing the motor clamp 2
(4).
X Now tighten the hexagon socket-head screws
on the Z-axis drive unit and the motor clamp.
X Check the Z-axis top stop with the adjustment
gage.

Before continuous opera- After continuous operation

tion Frequency in Hz Frequency in Hz
Toothed belt T2 / DLM2 on 280 +/- 10 280 +/- 10
the Z-axis

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8.2.11 Replacing the Forced Air Unit [00367793-xx]

Disassembly

1. Forced air unit / DLM2

2. To the "placement circuit" compressed air tube
and the compressed air sensor on the interme-
diate distribution board
3. To the "reject circuit" compressed air tube
4. M3x20 hexagon socket-head screw
5. SW8 union nut for the compressed air connec-
6 tion
6. "Forced air" micro-relay valve
5

1
X Remove the cable plug from the socket on the
3
4 2 intermediate distribution board.
X Detach the black compressed air hose from
the plug-in coupling on the vacuum distributor.
X Dismantle the intermediate distribution board.
X Detach the compressed air sensor.
X Detach the compressed air hose for the place-
ment position (2) from the "placement circuit"
compressed air tube.
X Detach the compressed air hose for the reject
position (3) from the "reject circuit" com-
pressed air tube.
X Undo the M3x20 hexagon socket-head screw.
X Remove the forced air unit (1).
X Loosen the union nut (5) and detach the com-
pressed air supply hose.

Installation

X Reconnect the hoses.

X Use the hexagon socket-head screw (1) to fas-
ten the forced air unit.
X Connect the plug to the socket on the interme-
diate distribution board.
Attention: Risk of injury!
Risk of injury from the compensating
6 tube when the hose is pushed onto
the measuring tube!
5 X Fit the intermediate distribution board.
1

3
4 2

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8.2.12 Replacing the Silencer [03003134-xx]

Removal/Installation

1. Fastening screw
2. Silencer
3
3. Pre-silencer
2 X Loosen and remove the fastening screw (1).
X Turn the silencer (2) counterclockwise to re-
move it.
X Remove the pre-silencer (3) from the silencer.
NOTE
1 Always wear gloves when handling new silencers.
X Insert the pre-silencer and the screw provided
and fasten the silencer.

8.2.13 Replacing the Star [00341181-xx]

Disassembly

1. Sleeve
2. Star, mounted/ DLM2
1 3. Star drive
4. Collect+Place Head - front part
7
5. 3 x M3x8 hexagon socket-head screws
6. Segment
2
7. Raceway
X Dismantle the front part of the collect+place
head.
X Place the front part of the collect+place head
4 3 6 on the tray.
5
NOTE
Wear laboratory gloves when you remove the
sleeves from the star.
X Remove all sleeves (1) and place them in a
sleeve box or on a clean, soft surface.
X Undo the three M3x8 hexagon socket-head
screws (5).
X Raise the star slightly.
X Use a rotary movement to lift the star up and
off.

Installation

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NOTE
Remove any remaining sleeves before fitting the
star.
1
Wear laboratory gloves when removing the
sleeves.
7
X Push all the segments (6) slightly outwards.
X Insert small Allen keys (e.g. size 2) into the
2
holes for the star fastening screws (5).
X Hold the star over the star drive shaft (3), so
that the Allen keys slide into the threaded
holes in the star drive.
4 3 6 X Insert the star.
5
NOTE
Make sure that the vacuum hoses of the seg-
ments are not squashed.
X Push all the segments inwards so that the seg-
ment ball bearings slide into the raceway (7).
X Check that the star is seated flat on the drive
shaft.
X Loosely tighten the three M3x8 hexagon sock-
et-head screws on the star so that the screws
can still move slightly in the fixing holes.

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8.2.13.1 Adjusting the star with respect to the star's magnetic neutral position
When adjusting the star, the aim is to make sure the vertically aligned segment axis of segment No. 1
corresponds with the magnetic rest position of the star stepping motor.
X To do this, insert the gauge pin into the gauge for the star and into the hole in segment no. 1, until it
reaches the stop.
X Pull the motor line plug of the star motor off the socket on the intermediate distribution board and
connect the motor line to the power supply.
X Connect the power supply unit to the mains power.
X Tighten the three M3x8 hexagon socket-head screws on the star and remove the gauge pin.
X To do this, re-insert the gauge pin into the star gauge and insert into the hole in the segment, until it
reaches the stop.
X Disconnect the power pack from the power source.
X Please check:
ƒ That the gauge pin can be inserted easily.
ƒ That the star does not rotate out of its current position as a result.
If both of these conditions are fulfilled, the star has been fitted correctly.
X Repeat the adjustment procedure if the gauge pin does not slide easily into the hole.

Attention: The power pack operating time is limited!

The maximum operating time of the power pack for the star motor is five min-
utes. Do NOT exceed this time If you have to disconnect the power pack from
the power source because it has been operating for five minutes, always insert
the gauge pin before switching the power pack back on again.

X If you still can not fit the star in the magnetic

neutral position of the star motor, follow the in-
structions below:
1. Star drive, digital/ DLM2
2. 4 x M5x16 hexagon socket-head screws
3. Collect+Place Head - front part
X Loosen the four M5x16 hexagon socket-head
3 1 screws (2) for fixing the star drive (1) and turn
the star drive in the direction that will allow the
star to be adjusted with respect to the magnet-
ic neutral position.
X Tighten the four hexagon socket-head screws.
2

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X Loosen the three M3x8 hexagon socket-head

screws (5) for fixing the star again and repeat
the adjustment procedure.
1
NOTE:
7 The star is fitted correctly if it no longer moves out
of position when the gauge pin is removed, after
the star drive has been disconnected from the
2
power supply.
X Remove the gauge for the star.
X Insert the power cable plug connector for the
star drive into the socket on the intermediate
4 6
distribution board. The plug connector is an
3
5 anti-rotation connector.
X Fit the front part of the collect+place head onto
the back part of the collect+place head.
X Check the magnetic neutral position.

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8.2.14 Replacing the Star Drive [00368077-xx]

Disassembly

1. Star drive, digital / DLM2

2. 4 x M5x16 hexagon socket-head screws
3. Front part of the collect+place head
(A) Connecting cable for the star drive on this side.
A
X Dismantle the intermediate distribution board.
X Dismantle the front part of the collect+place
head.
1
3 X Dismantle the star.
X Undo the four M5x16 hexagon socket-head
screws (2).
X Lift the star drive off the front part of the col-
2 lect+place head.

Installation

X Place the star motor onto the front part of the

collect+place head, so that the star drive con-
nection cable points to the position marked
(A).
X Fix the star drive in place with the four M5x16
A
hexagon socket-head screws (2).
X Fit and adjust the star.

1
X Fit the front part of the collect+place head.
3

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8.2.15 Replacing the RSF Digital Rotary Encoder [00335990-xx]

Disassembly

1. Front part of the collect+place head

6
3 2. RSF digital rotary encoder 12/DLM2
5
3. 2 x M2.5x8 hexagon socket-head screws 2 x
4. RSF board, type 950
5. 2 x M2.5x4 hexagon socket-head screws 2 x
4 6. Plug connector in the slot on the intermediate
distributor
X Dismantle the front part of the collect+place
head.
1 X Dismantle the star.
X Remove the black blanking cap over the RSF
2
board (4).
X Remove the plug connector (6) from the sock-
et on the intermediate distribution board.
X Undo the two M2.5x4 hexagon socket-head
screws (5) for fixing the RSF board.
X Undo the two M2.5x8 hexagon socket-head
screws (3) and remove the digital encoder.

Installation

X Insert the new rotary encoder and initially fix

6
loosely in place with the two M2.5x8 hexagon
3
5 socket-head screws (3).
X Insert the sleeve into the star and turn the star,
with the sleeve, until it reaches the rotary en-
coder.
4 X Fix the star in this position using the gauge for
the star.

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X Adjust the rotary encoder so that the distance

between the rotary encoder window and the
incremental disk on the sleeve is 1.5 mm.
Proceed as follows:
3
Attention: Sensitive component!
A
RISK OF BREAKING THE INCRE-
4 2 1
MENTAL DISK
X Carefully push the tapered end of the test
probe between the window of the incremental
encoder (1) and the incremental disk (2).
X Loosen the fixing screws for the incremental
encoder, if you can not push the test probe in
easily.
NOTE:
The test probe has a blunt and a tapered end. Only
push the tapered end of the test probe between
the incremental encoder and incremental disk of
the sleeve, to avoid scratching the disk and thus
causing counting errors.
X Carefully push the rotary encoder towards the
incremental disk and along the stop edge (A)
until the test probe lies flat against the incre-
mental disk (2) and the window of the rotary
encoder (1).

X Fix the rotary encoder in place using the two

M2.5x8 hexagon socket-head screws.
X Carefully pull the test probe out of the gap.
3 X Remove the gauge for the star.
A X Remove the sleeve from the star.
4 2 1 X Use the two M2.5x4 hexagon socket-head
screws (4) to fasten the RSF board (3).
X Connect the plug connector to the socket on
the intermediate distribution board.
X Place the black blanking cap over the RSF
board.
X Fit and adjust the star.
X Fit the front part of the collect+place head.
X Use the SITEST program to check that the ro-
tary encoder is working correctly.

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8.2.16 Replacing the "Z-axis Down" Sensor [00321524-xx]

Disassembly

1. "Z-axis down" sensor

2. Fixtures for sensor
3. Plug for intermediate distributor
X Dismantle the front part of the collect+place
head.
3 X Place the front part of the collect+place head
on the tray.
1 X Dismantle the star.

1 X Remove the plug from the socket on the inter-

mediate distribution board.
X Push the Z-axis down.
2 X Loosen the screws holding the sensor (2).
X Remove the cable clamps on the driver arm
and star motor.
X Carefully pull the sensor and cable out of the
front part of the collect+place head and re-
move the plug (3) from the socket on the inter-
mediate distribution board.

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Installation

X Thread the sensor cable from the Z-axis into

the front part of the collect+place head.
X Fix the sensor (1) in position with the screw
provided (2) and initially screw loosely into the
jaw of the Z-axis.
X Fix the cable into place with the cable clamps.
3
X Check how the cable is run inside the front part
of the collect+place head:
1
ƒ If the Z-axis has been pushed right out, the ca-
1 ble should lie loosely around the housing for
the star drive shaft. The cable must NOT be
pulled tight.
2 ƒ If the Z-axis is pushed right in, the cable should
run freely inside the front part of the col-
lect+place head, without touching the rotary
encoder for the DP axis.
Attention: Check how the cables
are run!
If the radius of the curvature is too
small, the Z-axis could jam or the light
barrier cable could break.
X Once the cable is run in line with the required
conditions, fix it in place with the angled clips.
X Connect the cable plug to the socket on the in-
termediate distribution board.

Adjusting the "Z-axis down" sensor

X Set the distance between the white sleeve ring and the light barrier to 0.95 -1.15 mm.
ƒ Use a test probe or drill (diameter 1.0 mm).
ƒ Check the distance with a test probe or drill (diameter 1.2 mm). – This drill should not fit!
X Fix the light barrier in place with the two screws provided.
X Fit and adjust the star.
X Fit the front part of the collect+place head.
X Use the SITEST program to check that the sensor is working correctly.

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8.2.17 Replacing the Complete Z-axis [03001959-xx]

NOTE
We recommend replacing the complete Z-axis DLM2 after approx. 100 million placements.

Diagram 1
X Dismantle the light barrier under the Z-axis by
loosening the two M1.6x3 DIN 84 screws.
Diagram 2
X Carefully pull the cable out of the cable duct
until it lies loosely.
Diagram 3
X Loosen the connection between the driver arm
and driver bracket by removing the two M2x14
DIN 912 screws.
Diagram 4
X Pull the driver arm, together with the centering
pin, out of the driver bracket and move the
driver arm into the stop position in the race-
way.
Diagram 5
Remove the three screws holding the Z-axis in
place (2x M3x14, 1x M3x4).

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Installation

Diagram 1
X Rotate the star into the position shown and
then pull the Z-axis out of the guide by holding
on to its assembly plate.
X Clean the contact surface with SIPLACE
cleaning tips and ethanol.
Diagram 2
X Push the new Z-axis guide into the groove pro-
vided.
X Press the reference edge (inner side) of the Z-
axis into the groove and fix the Z-axis with the
screws provided.
Diagram 3
X Use the feeler gauge to check the distance be-
tween the jaw and the groove of the raceway.
The permissible gap is between 0.2 and 0.3
mm.
Readjust the jaw if necessary.
X Reassemble the placement head as follows.
NOTE
The board must be fitted centered to the jaws.
Make sure that the board does not rub against the
frame (check with gauge if necessary).
Complete the following step at every second ser-
vice interval for the head:
Diagram 4
X Use the grease gun to apply a small amount of
oil [00367071-xx] to the hole provided.
Make sure that too much oil does not ooze out
of the hole.
NOTE Where dirt is not excessive, the oil can be
directly applied to the rail.

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8.2.18 Replacing the Control Board for the Nozzle Changer 6/12 [00317353-xx]
Overview

1. Nozzle changer 12 segments

2. Control board (installed on the underside)
NOTE:
The control board is also used for the 6-segment
nozzle changer.
X Remove the nozzle changer from the ma-
chine. The control board is situated on the un-
derside of the nozzle changer.
2

X Disconnect the control board (1) from the elec-

trical system.
X Undo the fastening screws and remove the
control board.
X Install the new control board and reconnect to
the electrical system.
1 X Install the nozzle changer in the machine.
X Measure the nozzle changer with SITEST.

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9 Movable Component Changeover

Table

9.1 Safety Instructions

DANGER

The chapters "Operational Safety" in User Manual SIPLACE S-27 HM and in this Service Manual
take precedence.
These SIPLACE machines are powered by 120V / 208V +/- 5% (US version) or 3 x 230V/400V
+/-5% 50/ 60 Hz line voltage.
Therefore portions of the system are carry dangerously high voltages! In specific modules inside
the machine base the voltage is present even when the main switch is turned off.

Handling the machines improperly or touching portions thereof which are conducting high voltage
may result in death or serious physical injury as well as extensive property damage.

Obey the applicable accident prevention regulations, DIN standards and special safety codes of
your country at all times. DIN EN 60204 must be adhered to during all work inside the machine
base.

The customer is prohibited from attempting to resolve any problems whatsoever with the power
supply unit (transformer), therefore:
Only the Siemens service engineer is permitted to exchange the cables "Power component table"
and "Transformer-Power supply" (see Fig. 9.5.3).
The Siemens service engineer is the only one permitted to adjust / change the voltage on the basis
of internal Siemens retrofitting instructions.

Furthermore, only the Siemens service engineer is permitted to adjust the height of the compo-
nent changeover table on the basis of internal Siemens retrofitting instructions.

While working with the SITEST program, comply with the instructions in the DANGER text in
Section 9.5.6 "Final Steps". 9

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DANGER: Disc of placement head CRASH

With all of the SIPLACE machines the Y- gantry must always be moved / pushed out of the area
of the component changeover table before changing tables.
This must be accomplished before actuating the compressed air switch in order to raise the table.
Otherwise there will be a risk that the placement head may crash!! 9

WARNING
Parts of your body may be pinched, crushed or severed by the component changeover table if:
- the height is incorrectly set (setting for SMEMA’s height only by Siemens service engineer:
see Siemens in-house "Retrofit Instructions"),
- a feeder module tips over or falls,
- the component changeover table which has been moved out of the machine tips over.

Aside from this, comply with the special safety instructions in the pertinent section below. 9

CAUTION
Improper actions while lowering or raising the handle of the component changeover table may
give rise to a risk of minor injury due to being pinched, etc., by the handle.
For this reason, always hold the handle with both hands. 9

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9.2 Parts

Quantity Designation Item No. Comments

- 1 Component changeover table 00116226-01

- 1 Bellows cylinder series 1916-09 00343720-01 Total of 2 units

- 1 Guide castor 00341942-01 Total of 2 units
- 1 Fixed castor 00341918-01 Total of 2 units
- 1 Communications unit 80,
incl. cable "Control signals, component
table SMD" without individual activation 00316265-04 Total of 1 units
- 1 Tape container knockout spindle 00343770-01 if needed
- 1 Bowden cable 00342324-02 Total of 2 units
- 1 Cable tie L x W = 140 x 3.6mm 00805141-01 Total of 5 units
- 1 Fixing pedestal, self-adherent 00805103-01 Total of 2 units

9.3 Tools

– Set of Allen wrenches

– Sliding caliper (for bowden cable)

– Diagonal cutter (for cable tie)

– 2 Open-end wrenches, width across flats 8 (for bowden cable)

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9.4 Overview of Mechanical Construction

Fig. 9.4.1 Overview: Layout and Exchangeable Parts of the Movable Changeover Table

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Key to Fig. 9.4.1:

1. Movable component changeover table S-27 HM (without feeders)

2. Feeder modules or dummy modules **)

3. Component table plate

4. Bellows cylinder for height adjustment *)

5. Communications unit 80, without individual activation *)

6. Power supply unit / transformer, component table

7. 2 Fixed castors *)

8. 2 Guide castors *)

9. Tape container

10. Bowden cable *)

11. Component table in "top" position" (= position to connect / disconnect)

12.Handle, can be bent after the activator tube has been pushed up.

13. Component table in "bottom" position (= position when connected)

14. Insertable tape reels: 7", 10", 15 ", 17", 19"

15. Knockout spindle for tape reels (if needed) *)

16. Cable duct

17. Compressed air connection of "component table air supply" to the pneumatic system of the
component table (operating pressure)

18. Compressed air connection of "component table air supply" (optional)

19. Cable "Power, component table" (not a spare part)

and cable "Control signals, component table SMD" (not a spare part)

20. Actuating lever for compressed air: Lifting / lowering the component table

*) Item No.: see Section 9.2

**) Option, Item No.: 00345462-01

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9.5 Resolving Problems

DANGER

Parts of your body may be pinched, crushed or severed by the component changeover table (see
Section 9.1).
No substantial lateral force is to be exerted on the component changeover table after it has been
disassembled (danger that it might tip over), therefore:
- Do not lean against it and do not brace any items against it.
- Place the component changeover table on a horizontal surface and secure it to prevent it from
starting to roll away all by itself.

Once the component changeover table has been moved out of the machine, NEVER connect the
plugs to the machine frame (= not use as intended = DANGER!).

Moving the component changeover table out of the machine leaves the cutter (etc.) accessible:
This increases the risk of injury on the cutter’s movable or stationary blades even while the ma-
chine is switched off.
NEVER reach into the cutter from below or into the empty-tape duct from above, not even to re-
solve a problem (e.g., jammed tape) involving the disassembly of the component changeover ta-
ble. 9

WARNING
It is a basic rule that the following sequence is to be adhered to when disconnecting and connect-
ing the plug-and-socket connections of the changeover table:
-> When unplugging the connectors:
Always pull out the round plug (power supply) first on the right-hand side of the component table
and only
afterwards the square plug (interface connector).
-> When plugging in the connector:
Proceed in the reverse order (plug in interface connector first, then the power supply connector).

If, by way of exception, the connectors have to be unplugged while the machine is ON, after you
unplug the power supply connector you must wait until the 30 V indicator goes out before unplug-
ging the interface connector. 9

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9.5.1 Preparatory Steps

Æ Turn the machine ON. The compressed air is attached.

Æ Cut the tapes between the front of the module and the empty-tape duct.
Æ Clock the tapes back.
Æ First, unplug the connector on the cable "Power, component table" and then unplug the con-
nector on the cable "Power, component table" on corresponding side of the machine frame.
Æ For the time being, the compressed air connection to the machine frame must be retained.
Æ Lift the component table (actuating lever on left side of table).
Æ Disconnect the compressed air connection on the corresponding side of the machine frame
(quick-release coupling).
Æ Move the component changeover table out of the machine, as described in the User Manual
(hold the handle with both hands!).
After disconnection the component changeover table is at the position "TOP".
Æ If a empty, movable component changeover table is available, first proceed as follows:
Æ Pull out the plug-and-socket connections of all of the feeder modules on the faulty compo-
nent changeover table.

Æ Place the feeder modules incl. the tape weel and Knockout spindles (see Fig. 9.4.1 -> 2,
14, 15) on new the component table in accordance with the specifications for set-up optimi-
zation, insert the tapes and check the allocation of component / track (component bar code
scanner).
If there is an external set-up location available, carry out the setting up and inspection there
(see also Section 9.5.6 "Final Steps").

Æ Connect the new component changeover table to the machine, as described in the User
Manual.

Æ Resolve the problems with the dismantled component changeover table as indicated in the
pertinent section below.

Æ If no other component changeover table is available,

continue as follows after resolving the problems as required:

– When exchanging the bellows cylinder:

Take the feeder modules from the changeover table and place them on a clean surface. In
this case, the tape reels can remain in the container.

– When exchanging the guide castors and fixed castors:

Same steps as above when exchanging the bellows cylinder.
In addition, remove all of the tape reels from the container and put them down in order.

– When exchanging the communications unit or the bowden cable:

The feeder modules do not have to be dismantled.

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9.5.2 Exchanging the Bellows Cylinder

DANGER

By way of exception, it may be unable to lift the component table automatically and therefore to
disconnect it - because the bellows cylinder is faulty. If this occurs, contact Siemens SMD Service
and discuss how to proceed, taking safety considerations into account.
The table is very heavy and the sticking component table may be released suddently while it is
beeing lifting manually, posing a high risk of injury by crushing. 9

WARNING
Parts of your body may be crushed, pinched or severed by the component changeover table!
The component table has to be in the top position (= position after disconnecting, Fig. 9.5.1) when
exchanging the bellows cylinder. The component table is securely held in the "top" position me-
chanically, regarding of the bellows cylinder. 9

The component changeover table is dismantled and prepared, as described in Section 9.5.1.

Æ Disconnect the pneumatic hose at the quick-release coupling of the faulty bellows cylinder
(see Fig. 9.5.1 -> 4, 6). The 2nd pneumatic hose (for 2.3 bar) is not connected.
Æ Undo the screws fastening the faulty bellows cylinder from the component top and bottom (to-
tal of 3 screws, see: Fig. 9.5.1 -> 2, 4, 5, size 6 Allen wrench). During this process, take the
washer enclosed (see -> 5).

Key to Fig. 9.5.1:

1. Component table in top position

2. Fasteners for bellows cylinder: 2 Socket hex head cap screws M 8 x 50

3. Component table plate

4. Bellows cylinders (2 units)

5. Bellow cylinder fasteners: 2 washers, 8.4 DIN 125-A, 2 Socket hex head cap screws M 8 x 16

6. Quick-release coupling, compressed air supply (operating pressure)

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Fig. 9.5.1 Exchanging the Bellows Cylinder(s)

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Æ Remove the bellows cylinder.

Æ Insert the new bellows cylinder (Item No.: see Section 9.2) and fasten the cylinder securely
from top and bottom (total 3 screws, see Fig. 9.5.1 -> 2, 5).
Æ Connect the pneumatic hose (for operating pressure) to the quick-release coupling of the bel-
lows cylinder and tighten the hex nut (see Fig. 9.5.1 -> 6).
Æ If you do not have to exchange any further parts, perform the appropriate "Final Steps" (see
Section 9.5.6).

9.5.3 Exchanging Fixed Castor(s) and/or Guide Castor(s)

The component changeover table is dismantled and prepared, as described in Section 9.5.1.

WARNING
The component changeover table has to be laid on its side to remove the fixed castor and/or guide
castor. Two people are required because the component changeover table is very heavy. 9

Æ Enlist the aid of a 2nd strong person and set the component changeover table on the side. (see
Fig. 9.5.2 -> 1).
Æ Undo the screws fastening the fixed castor and/or guide castor to be exchanged (size 6 Allen
wrench: see Fig. 9.5.2).
Æ Install the new guide castor(s) and/or the fixed castor(s) (Item No.: see Section 9.2) and refas-
tening each of them with 4 socket hex head cap screws.
Æ With the aid of a 2nd strong person set the component changeover table back up.
Secure the component changeover table to prevent it from starting to roll away all by itself.
Æ When you have no more parts that must be exchanged, perform the appropriate "Final Steps"
(see Section 9.5.6).

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Fig. 9.5.2 Exchanging Fixed Castor(s) or /and Guide Castor(s)

Key:

1. Lay the component table on the side (2nd person required) before removing the rollers.

2. Fixed castors (2 units)

3. 8 Socket hex head cap screws M8 x 16

4. Guide castor (2 units)

5. 8 Socket hex head cap screws M8 x 16

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9.5.4 Exchanging the Communications Unit

Fig. 9.5.3 Overview: Cable Guide at the Component Changeover Table

Key:

1. Communications unit

2. Power supply unit, transformer

3. Cable gland

4. Cable "Power, component table" (machine frame -> power supply unit)

5. Cable "Control signals, component table" (machine frame -> back of communications unit)

6. Cable "Transformer - power supply" (transformer -> back of the communications unit)

7. Cable tie with fixing pedestal, self-adherent (fastened with: 2 oval head cap screws M3 x 8)

8. Cable tie

9. Cable duct

10. 3 Cable tie in the cable duct

11. Cable tie with fixing pedestal, self-adherent

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Fig. 9.5.4 Exchanging: Communications Unit; View in Direction "Component Table Termination Panel"

Key:

1. Communications unit

2. Plug-and-socket connection of cable "Transformer - power supply"

3. Cable "Control signals, component table SMD" (spare communications unit incl. cable)

4. Cable duct

5. Retaining brackets for communications unit, on left and right

6. Fastening screws for the communications unit: 4 M4 x 10 socket hex head cap screws

NOTE:
The cable "Control signals, component table SMD" is only to exchange incl. the communications
unit. 9

Æ Perform the "Preparatory Steps" (see Section 9.5.1).

It is not necessary to dismantle the feeder modules.
Æ Remove the 3 cable ties in the cable duct and the cable tie of the fixing pedestal on the top of
the frame (see Fig. 9.5.3 -> 7, 10).

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Æ Unplug the connector of the cable "Transformer -> power supply" at the back of the communi-
cations unit (see Fig. 9.5.4 -> 2).

NOTE:
If necessary, enlist the aid of a 2nd person. 9

Æ Holding the communications unit, loosen its LH and RH fastening screws on the retaining
brackets under the table plate (2 screws: see Fig. 9.5.4 -> 5, 6).
Æ Remove the communications unit incl. the cable "Control signals, component table SMD".
Æ Place the new communications unit (Item No.: see Section 9.2) to the two retainig brackets and
tighten the screws to fasten it.
Æ Connect the cable "Transformer -> power supply" at the back of the communications unit
(seeFig. 9.5.4 -> 2).
Æ Run the cable "Control signals, component table SMD" in the cable duct and attach the 5 cable
ties (see Fig. 9.5.3 -> 7, 10, 11). Item No. of the cable tie: see Section 9.2.
->The strain on the plug-and-socket connections must be relieved.
Æ When you have no more parts that must be exchanged, perform the appropriate "Final Steps"
including using SITEST to check the table function (see Section 9.5.6).

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9.5.5 Exchanging the Bowden Cable

Fig. 9.5.5 Removing / Installing the Bowden Cable

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Key to Fig. 9.5.5:

1. Table in starting position "Top". Handle bent

2. Bowden cable, lower end in frame of the component changeover table

3. Retaining bracket, top and bottom

4. M6 hex nut to fasten the Bowden cable

5. M6 hex nut to adjust the Bowden cable

6. Teflon flange

7. End piece of Bowden cable (bottom)

8. Stop of activator tube left / right: one M4 socket hex head cap screw

9. Activator tube

10. Direction in which activator tube is moved

11. Bowden traction cable

12. Little plastic wheel to divert direction of Bowden traction cable

13. End piece of Bowden cable (top)

14. For the Bowden cable: Cutouts in the bottom part of the changeover table

15. Tape container

16. Screws to fasten internal cover: two M4 socket head hex cap screws

The component changeover table is dismantled and prepared, as described in Section 9.5.1.
After being disconnected the component table is already in the required position "Top".

Æ Use sliding calipers to ascertain the exact distance between the bottom hex nut on the retain-
ing bracket and the adjusting nut for the Bowden cable (see Fig. 9.5.5: Detail A -> 4, 5) and
record this dimension.

NOTE:
This distance/dimension must be restored after the new Bowden cable is installed. 9

Æ Simultaneously slide the actuator tube up to the stop on both sides and lower the handle (see
Fig. 9.5.5 -> 1, 9).
-> This relieves the tension on the Bowden cable.
Æ It may be necessary to move the tape container to gain access to the 2nd fastening screw for
the internal cover on the frame (see Fig. 9.5.5 -> 16):

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Æ To do so, loosen the screws fastening the tape container to the frame (4 round head screws
on the container base plate, size 6 Allen wrench),

Æ Move the tape container slightly (or lift out the container).
Æ Loosen the screws fastening the internal cover on the frame (two M4 socket hex head cap
screws: see Fig. 9.5.5 -> 16). Remove the internal cover.
Æ The next step is to relieve the tension on the bottom end piece of the Bowden cable (see Fig.
9.5.5, Detail A):
To do so, loosen the locknut (hex nut: see Fig. 9.5.5 -> 4; size 8 metric open-end wrench) on
the bottom retaining bracket.
Æ Loosen the screw on the bottom of the lowered handle (see Fig. 9.5.5,
Detail B -> 8). The activator tube will slide all the way to the end of the handle (-> 9, 10).
Æ Disengage the Bowden traction cable at the handle’s point of rotation by pulling the little plastic
wheel, including the cable, out toward the inside of the handle (see Fig. 9.5.5 -> 11, 12).
Æ Push the "Top" end piece (using a pin, for example) toward the inside of the handle and out of
the slot (see Fig. 9.5.5: Detail B -> 13).
Æ From below, thread the Bowden cable out of the cutouts in the frame of the changeover table
(see Fig. 9.5.5 -> 14).
Pull both ends of the Bowden cable down and out of the cutouts in the bottom part of the
changeover table.
Æ Install the new Bowden cable (Item No.: see Section 9.2) by executing the steps in reverse or-
der to disassembly:

Æ From below, thread the Bowden cable up into the cutouts in the bottom part of the
changeover table. Run the end with the pressure springs to the retaining brackets and the
other end up through the hole in the handle.

Æ Engage the Bowden cable on the 2 small retaining brackets down in the frame.
Æ To fasten the Bowden cable, tighten the hex nut under the bottom retaining bracket (see
Fig. 9.5.5: Detail A -> 4).

Æ For the time being, just hand-tighten the hex nut below the hex nut in the preceding step
(see Fig. 9.5.5: Detail A -> 5).

Æ Push the "Top" end piece into the slot in the lowered handle (see Fig. 9.5.5: Detail B -> 13).
Æ Lay the top end of the Bowden traction cable into the groove around the circumference of
the little plastic wheel and insert this wheel.

Æ Push the actuator tube back in the direction of the handle’s point of rotation and hold the
actuator tube in this position.

Æ From the bottom of the handle, screw the M4 socket head hex cap screw back in (see Fig.
9.5.5, Detail B -> 8).

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Æ The table is still in the "Top" position.

Swing up the handle (see Fig. 9.4.1 -> 12).
This places tension on the Bowden cable.

Æ The Bowden cable is then adjusted:

Æ Turn the bottom hex nut (see Fig. 9.5.5, Detail A -> 5) to adjust the Bowden cable until the
you have restored the exact distance measured between it and the hex nut above it prior to
disassembly.

Æ Fix the bottom hex nut in this position with a locknut.

Æ Mount the internal cover on the frame of the component changeover table (two M4 socket
head hex cap screws).
Æ If necessary, insert the tape container and screw it tight (4 round-head screws, size 6 Allen
wrench).
Æ When you have no more parts that must be exchanged, perform the appropriate "Final Steps"
(see, Section 9.5.6).

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9.5.6 Final Steps

Æ Check the contact surface for the feeder modules on the component table:
If necessary, clean the surface, as described in the User Manual in the chapter "Maintenance".
Æ Place the feeder modules incl. the tape reels on new the component changeover table in ac-
cordance with the specifications for set-up optimization.
If the "External set-up location" is available, perform there the set-up incl. inserting the tapes.
Æ Connect all feeder modules to the relevant jack of the communications unit (component table
termination panel).
Æ Turn the machine ON. The compressed air is attached. Move the changeover table back into
the machine and connect it, as described in the User Manual.

DANGER
The component changeover table which has been moved into the machine must always be com-
pletely equipped with feeder modules or dummy modules (see User Manual and Service Manual,
chapters "Operational Safety"). 9

Æ Make the plug-and-socket connection of the "Cable component table" at the machine frame.
Æ If this has not been done yet, insert the tapes now and check the allocation of feeder module
and component (component bar code scanner).
Æ Clock / transport the first component into the pick-up position. VISUALLY CHECK the front of
the module to see if all tapes move smoothly into the empty-tape duct.

DANGER

As a fundamental rule, the SITEST program is to be started only by personnel who have been
trained in its use by Siemens and are therefore authorized to do so.

The cutter must also be completely assembled for the work with the SITEST program.
The changeover table must be moved into the machine and correctly connected.

The component changeover table which has been moved into the machine must always be com-
pletely equipped with feeder modules or dummy modules (see User Manual and Service Manual,
chapters "Operational Safety").

The key switch remains locked (= normal mode = position "0").

9

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9 Movable Component Changeover Table Service Manual S-27 HM
9.5 Resolving Problems 10/2005 US Issue

Æ After exchanging the communications unit:

Note the DANGER text regarding the SITEST program.
Load the SITEST program and check the component table functions.
Æ Exit the SITEST program.
Æ Start the placement process.
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Siemens AG 2005 All rights reserved Subject to change without prior notice

Order No.: 00193 530-02 Siemens AG

To be ordered from:
Siemens AG, Automation and Drives
Electronics Assembly Systems
Rupert-Mayer-Strasse 44
D-81359 Muenchen

Printed in the Federal Republic of Germany