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SIPLACE F

Preventive Maintenance

03/2003 US Edition
(The reproduction, transmission or use of this document or its con- (We have checked the contents of the printed documentation to en-
tents is not permitted without written authority. sure that it is in agreement with the hardware and software described
Offenders will be liable for damages. All rights, including rights creat- therein. However, since discrepancies cannot be ruled out, we cannot
ed by patent grant or registration of a utility model or design, are re- assume responsibility for complete agreement. The information given
served.) in this printed documentation is however regularly reviewed and nec-
essary corrections included in subsequent editions.
We would appreciate any suggestions for improvements.)

SIEMENS DEMATIC AG 2003 All rights reserved Subject to change without prior notice

Item no. 00192156-04 Siemens Aktiengesellschaft

To be ordered from:
SIEMENS DEMATIC AG,
SD EA 1
Rupert-Mayer-Strasse 44
D-81359 Muenchen

Printed in the Federal Republic of Germany


Maintenance Instructions F
03/2003 US Edition

Table of contents 0

Page

1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Explanation of the symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Everything you will need for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8


2.1 Tools and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Important points to note when carrying out maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Daily maintenance jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6 Maintenance work every week. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7 Monthly maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8 2-monthly maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

9 4-monthly maintenance jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58


9.1 Fitted placement heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

10 Annual maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

11 Maintain the sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

12 Maintain the valve plungers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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Maintenance Instructions F
03/2003 US Edition

4
Maintenance Instructions F Maintenance
03/2003 US Edition 1 Safety instructions

1 Safety instructions

Fig. 1 - 1 Safety devices

1
1. Protective cover on input conveyor 2. Safety window, right
3. Protective hood 4. Protective cover on output conveyor
5. Protective hood 6. Safety window, left

5
Maintenance Maintenance Instructions F
1 Safety instructions 03/2003 US Edition

: Always follow the safety and accident prevention regulations applicable in your country when
carrying out any maintenance work.

: Follow the safety instructions in the corresponding user manual.

: Pay particular attention to the special safety instructions in this chapter.

RISK OF COMBUSTION 1

: Never use alcohol for cleaning purposes when working in the vicinity of a naked flame
or fire.

: Never spray lubricants or cleaning agents from aerosol cans in the vicinity of a naked
flame or fire.

: Do NOT smoke.

WARNING 1

: Always wear safety goggles and gloves when using concentrated ethyl alcohol to
clean modules.

: If ethyl alcohol is accidentally sprayed in the eyes, immediately flush the eyes with
plenty of water.

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Maintenance Instructions F Maintenance
03/2003 US Edition 1 Safety instructions

WARNING 1

SIPLACE cleaning tissue 1


: Harmful: May cause lung damage if swal-
lowed.

: Do not inhale vapor / aerosol. Avoid contact


with the skin. If swallowed, do not induce
vomiting. See medical attention immediately
and show the packaging or label.

: Wear gloves while using the cleaning tissue.

1.1 Explanation of the symbols


1
1

Tools and consumables required 1

1
1

Note 1

1
1

Tip 1

1
1

Caution 1

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Maintenance Maintenance Instructions F
2 Everything you will need for maintenance 03/2003 US Edition

2 Everything you will need for maintenance

The following lists of materials contain all the tools, equipment and consumables that you will
need to maintain the placement machine. 2

Always use ethyl alcohol for cleaning – do not use solvents. 2

Apply all lubricants sparingly and exactly where they are needed. 2

2.1 Tools and equipment

Have the following tools and equipment to hand before you start the maintenance:

Tools and equipment Article number

Waste bin

Vacuum cleaner

Drip tray

Brush

Short-bristled brush

Pliers (in the service box) 00346929-01

Scissors

Set of hexagon socket spanners

Set of slotted-head screwdrivers

Laboratory gloves

Metal drill bit, 1.1 mm diameter 00092020-01

Metal drill bit, 1.4 mm diameter 00092026-01

Whetstone / oilstone

Pallet jack

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Maintenance Instructions F Maintenance
03/2003 US Edition 2 Everything you will need for maintenance

2.2 Consumables

Have the following consumables to hand before you start the maintenance:

Consumables Article number

Protective latex gloves 00372972-01

Soft, lint-free cloths

Lint-free cottonwool buds 00352931-02

SIPLACE cleaning cloth 00315253-02

Lens cleaning tissue (e.g. Kodak)

Ethyl alcohol

ISOFLEX TOPAS, NCA 52 00328369-01 1 kg can,


00330850-01 50g tube

WD40, 400 ml 00325833-01

UNISILKON L250L 00310259-01

Z axis oil dispenser with Structovis GHD 00367071-01

Grease cartridge with Urethyn E/M2 02101696-01

2.3 Spare parts

Have the following spare parts to hand before you start the maintenance:

Spare parts Article number

Pneumatic maintenance unit


F4 / F5 / F5HM 00357795-01
F3 / F4 Old 00315948-02

Filter G1/2 Modulair, 112 5µ


F4 / F5 / F5HM 00343010-01
F3 / F4 Old 00316488-01

Filter insert, 5 microm. for series 112


F4 / F5 / F5HM 00355386-01
F3 / F4 Old 00330406-01

Silencer for Collect & Place head 00320964-01

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Maintenance Maintenance Instructions F
2 Everything you will need for maintenance 03/2003 US Edition

Spare parts Article number

Vacuum generator for Pick&Place head 00305378-01

O-ring 6x1 00323535-02

O-ring for valve plunger 00345127-01

Viledon filter mat, 225 x 362 00304048-01

Set of cleaned ceramic nozzles or new nozzles

Set of clean sleeves

Set of clean valve plungers

Valve plunger 00330711-02 (12 x)

Z axis toothed belt 00334936-01

Distributor 00319827-02

O-ring, turning station 00320043-01

Toothed belt, turning station 00320041-01

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Maintenance Instructions F Maintenance
03/2003 US Edition 3 Important points to note when carrying out maintenance work

3 Important points to note when carrying out main-


tenance work

The maintenance intervals given for inspecting and replacing the filter elements are only valid for
the specified compressed air quality (compressed air specification). If other qualities are used,
the maintenance intervals should be shortened accordingly. 3

CAUTION
NEVER use compressed air to clean inside the placement machine’s modules. 3

Enter the completed maintenance work in the maintenance schedule. We recommend that you
carry out the tasks in the order given in the maintenance schedule. 3

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Maintenance Maintenance Instructions F
4 Maintenance schedule 03/2003 US Edition

4 Maintenance schedule

Interval Location Equipment / spare parts Done


(date)

Day Empty reject bin, vacuum around machine Collecting container,


vacuum cleaner

Vacuum the nozzle changer Vacuum cleaner

Vacuum the feeders Vacuum cleaner

Empty reject bins Waste bin

Week Vacuum the PCB conveyor / sonar sensor Vacuum cleaner

Clean the X/Y scales Lint-free cloths, ethyl


alcohol

Change the nozzle changer magazines Set of cleaned ceramic


nozzles or new nozzles

Empty the component drawer of the 2x8 mm Collecting container


conveyor and the flap of the 3x8 mm conveyor
(if present)

Vacuum filter mats for control / servo unit, control unit Pliers, vacuum cleaner and
for PCB conveyor new filter mat, if necessary

Vacuum the WPC filter mats Vacuum cleaner

Month Replace the sleeves and valve plungers Laboratory gloves,


cottonwool buds, ethyl
alcohol, lens cloth, set of
cleaned sleeves, set of
cleaned and very lightly
greased valve plungers

Clean and preserve the linear guides for the X and Y SIPLACE cleaning cloth,
axes lint-free cloths

Clean the IC camera Phillips screwdriver,


lens cleaning cloth

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Maintenance Instructions F Maintenance
03/2003 US Edition 4 Maintenance schedule

Interval Location Equipment / spare parts Done


(date)

Month Clean the FC camera Phillips screwdriver,


lens cleaning cloth

Clean the coplanarity module Lens cleaning cloth

Clean the guides for the protective hoods Ethyl alcohol, brush,
ISOFLEX TOPAS NCA 52

80 F4 Pallet jack, set of hexagon


Maintain the electric used tape cutter socket spanners, SIPLACE
cleaning cloth, lint-free
cloths, WD40

2 months Inspect or replace the filter cartridge Drip tray, Phillips


screwdriver, new filter
cartridge, if necessary

Inspect or replace the silencer for the Collect & Place New silencer, if necessary
head

Check the silencer for the Pick&Place head/replace If necessary, new vacuum
the vacuum generator for the Pick&Place head generator for the
Pick&Place head

Clean and grease the toothed belts for the X, Y and Z Short-bristled brush,
axes ISOFLEX TOPAS NCA52

Maintain the component feeder table Vacuum cleaner,


whetstone, scissors,
lint-free cloths, WD40

Clean the nozzle changer for the Pick & Place head Nozzle removal tool,
vacuum cleaner

Check the nozzles on the Pick & Place head / Nozzle removal tool
replace the diaphragms

Preserve the feed axis linear guide SIPLACE cleaning cloth

4 months Z axis:

Remove dirt from the toothed belt Brush

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Maintenance Maintenance Instructions F
4 Maintenance schedule 03/2003 US Edition

Interval Location Equipment / spare parts Done


(date)

4 months Clean the rollers, toothed wheels and toothed belt Ethyl alcohol, lint-free cloth

Check toothed belt for wear

Grease the toothed belt ISOFLEX TOPAS, NCA 52

Check the Z axis guide

Check the jaws for damage

Oil the miniature roller table Oil dispenser with


Structovis GHD

Distributor plate:

Blow air through the distributor plate Compressed air

Clean the distributor plate Ethyl alcohol, lint-free cloth

Apply film of grease to distributor plate Unisilkon L250L

Star:

Wipe the star Lint-free cloth

Apply film of grease to running surface of the star ISOFLEX TOPAS, NCA 52
brake

Segments:

Clean the segments Ethyl alcohol, cottonwool


buds

Remove dirt from around the segments Ethyl alcohol, cottonwool


buds

Valve channels:

Clean the valve channels and their environment Ethyl alcohol, cottonwool
buds

Distributor:

Clean and grease the O-rings Unisilkon L250L

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Maintenance Instructions F Maintenance
03/2003 US Edition 4 Maintenance schedule

Interval Location Equipment / spare parts Done


(date)

4 months Check the distributor for damage

Wipe the distributor Ethyl alcohol, lint-free cloth

Blow air through the distributor Compressed air

Check that the ball catches run easily

Star brake:

Check the star brake for damage and to ensure it is


working correctly

Wipe the star brake / remove grease Lint-free cloth

Fill the holes with grease ISOFLEX TOPAS, NCA 52

Apply film of grease to surface of the star brake ISOFLEX TOPAS, NCA 52

Distributor seat:

Clean the distributor seat Ethyl alcohol, lint-free cloth

Valve adjustment drives:

Wipe the valve adjustment drives Lint-free cloth

Clean plate and gap Lint-free cloth

Clean ball bearing Lint-free cloth

Check that ball bearing is working correctly

Remove visible dirt

Turning station:

Wipe the black O-ring Ethyl alcohol, lint-free cloth

Check the O-ring for damage

Check the toothed belt for damage

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Maintenance Maintenance Instructions F
4 Maintenance schedule 03/2003 US Edition

Interval Location Equipment / spare parts Done


(date)

4 months Vacuum generator:

Clean the Venturi nozzles Ethyl alcohol, lint-free cloth

Blow air through Venturi nozzles Compressed air

Grease the O-rings Unisilkon L250L

Clean and blow air through the vacuum generator Ethyl alcohol, cottonwool
block buds

Silencer:

Clean holes to the Venturi nozzles Ethyl alcohol, cottonwool


buds

Check for dirt

Check the plastic mount for breaks

Year Vacuum beneath the lifting table Vacuum cleaner

Clean and preserve the PCB conveyor SIPLACE cleaning cloth

Check the used tape cutter

Fill both grease nipples with grease Set of hexagon socket


spanners, grease gun,
Urethyn E/M2

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Maintenance Instructions F Maintenance
03/2003 US Edition 4 Maintenance schedule

Sleeves

Check the switching ring

Clean the longitudinal vacuum hole Metal drill bit, 1.4 mm

Clean the transverse vacuum hole Metal drill bit, 1.1 mm

Clean the suction plate Lint-free cloth

Clean the friction wheel Ethyl alcohol, lint-free cloth

Clean the incremental disk Ethyl alcohol, lint-free cloth

Clean the sleeve shaft Ethyl alcohol, lint-free cloth

Ball catch sleeves

Clean the circumference of the ball catch Ethyl alcohol, lint-free


cottonwool buds

Check the film

Clean the groove Ethyl alcohol, lint-free


cottonwool buds

Standard sleeves

Check the O-ring

Clean the snap-fit O-ring Lint-free cloth

Grease the snap-fit O-ring Unisilkon L250L

Valve plunger

Wipe the valve plunger with a dry cloth Lint-free cloth

Check the sealing lips, the spring O-ring and the


sleeve

Grease the valve plunger ISOFLEX TOPAS, NCA 52

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Maintenance Maintenance Instructions F
5 Daily maintenance jobs 03/2003 US Edition

5 Daily maintenance jobs

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Maintenance Instructions F Maintenance
03/2003 US Edition 5 Daily maintenance jobs

You will need a waste bin, a collecting container and a vacuum cleaner for the daily cleaning jobs.5

Carry out the cleaning work in the order shown in the diagram to keep periods of stoppage to a
minimum. 5

: Press the Stop button on the first station when the gantry is over the placement position.

This will stop it outside your working area. 5

: Open the protective hood.

Empty the reject bin 5

a Remove the reject bins for the Collect & Place and Pick & Place heads.

s Empty them into the collecting container.


5

We recommend that you empty the reject bin every day. In this way, you will be able to see whether
any components are being rejected frequently. Ascertain the cause of the fault using the track er-
ror menu or MaDaMaS (pick-up reliability). 5

d Vacuum all around the reject bin locations and then replace them in the machine.
5

Do not leave any loose components inside the placement machine since they could drop between
moving parts and cause malfunctions. 5

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Maintenance Maintenance Instructions F
5 Daily maintenance jobs 03/2003 US Edition

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Maintenance Instructions F Maintenance
03/2003 US Edition 5 Daily maintenance jobs

Vacuum the nozzle changer 5

Keep the vacuum cleaner at least 1 cm away from the nozzles so as not to damage them. 5
5

a Vacuum the nozzle changers of the Collect & Place and Pick & Place heads.
5

Do not leave any loose components around the nozzle changer since they could prevent nozzles
being picked up and set down correctly. 5

Vacuum the feeders 5

s Carefully clean around the nozzle changer and the feeder area with the vacuum cleaner. There
should be no loose components in the feeder area.
5

Keep at least 1 cm away from the feeder module to avoid damaging the component covers. 5

: Close the protective hood.

: Press the Start button.


5

Production can continue on the placement machine during the next steps. 5

Empty waste tape container 5

d Pull the waste tape container out of the component cart or from the locations on machines with
waffle-pack changer.

: Empty it into the waste bin.

f Vacuum all around the waste tape container location and then push it back into the component
cart.

: Repeat the "daily maintenance jobs" at every feeder area.

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Maintenance Maintenance Instructions F
6 Maintenance work every week 03/2003 US Edition

6 Maintenance work every week

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Maintenance Instructions F Maintenance
03/2003 US Edition 6 Maintenance work every week

You will need the following tools and consumables for the weekly maintenance. 6

– Vacuum cleaner
– Collecting container
– Brush
– Scissors
– Pliers
– Lint-free cloths
– Ethyl alcohol
– Set of cleaned ceramic nozzles or new nozzles
– If necessary, Viledon filter mat, 225 x 362 (from article no. 00304048-01).
6

There must be no PCBs in the placement machine during the following maintenance steps. 6

: Select “Block manually” (status closed) on the station computer and click on OK (for dual con-
veyor track 1 / track 2).

Wait until the last PCB has been produced and has left the placement machine.
The working area is now clear. 6

: Press the Stop button.

: Open the protective hood.

To move the gantry, take hold of the handle and push gently and carefully. 6

6
6
6

: Push the gantry over the component feeder table. This will stop it outside your working area.

Vacuum the PCB conveyor / sonar sensors 6

a Unscrew the barrel of the sonar sensor on the PCB stopper and remove any loose parts. Then
screw the barrel hand-tight back onto the sonar sensor.

s Use the vacuum cleaner to remove all loose components on and around the PCB conveyor.

Loose components on the PCB conveyor and in the barrel of the sonar sensor can cause malfunc-
tions. 6
6
6

6
6

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Maintenance Maintenance Instructions F
6 Maintenance work every week 03/2003 US Edition

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Maintenance Instructions F Maintenance
03/2003 US Edition 6 Maintenance work every week

Clean the X/Y scales 6

a Use a lint-free cloth dipped in ethyl alcohol to clean the incremental scales for the X and Y
axes.
6

Dirty scales can cause counting errors on the X and Y axes, and thus lead to incorrect or inaccu-
rate placing. 6
6

Change the nozzle changer magazines 6

: Use the "Single Functions" menu to return the nozzles of the Collect&Place head to the nozzle
changers.

s Remove the nozzle changer magazines and replace them with magazines with cleaned ce-
ramic nozzles or new nozzles.

: Use the Single Functions menu to pick up the nozzles of the Collect & Place head.

: Empty the nozzle reject bin.

: Repeat the job at the other location.

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Maintenance Maintenance Instructions F
6 Maintenance work every week 03/2003 US Edition

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Maintenance Instructions F Maintenance
03/2003 US Edition 6 Maintenance work every week

Empty the component drawer or flap of the 8 mm S feeder 6

: Unplug the 8 mm S conveyor and lift it off the changeover table.

a Use a brush or the vacuum cleaner to remove loose components from the changeover table.

s Empty the component drawer of the 2x8 mm S conveyor (if present).

d Open the flap of the 3x8 mm S conveyor (if present) and remove the components.

f Wipe the base of the feeder to remove any dirt.

g Cut off the empty tape flush with the feeder.

: Return the feeders to their original (correct) locations.


6

Make sure that the feeder is placed firmly on the changeover table and is inserted in the correct
position. 6
6

: Repeat these tasks at both feeder areas.

: Close the protective hood.

: Select “Block manually” (status open) on the station computer and click on OK (for dual con-
veyor track 1 / track 2).

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6 Maintenance work every week 03/2003 US Edition

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Maintenance Instructions F Maintenance
03/2003 US Edition 6 Maintenance work every week

Vacuum the filter mats 6

a Remove the filter mats from the control and servo units using suitable pliers.

s Vacuum the filter mats. Replace them with new mats if they remain dark and discolored after
vacuuming. Then return the filter mat(s) to their correct positions.

The electronic modules will not be cooled adequately if the filter mats are dirty. 6
6
6

d Vacuum the filter mats for the control unit of the PCB conveyor.

: Repeat these tasks at every placement machine.

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Maintenance Maintenance Instructions F
6 Maintenance work every week 03/2003 US Edition

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Maintenance Instructions F Maintenance
03/2003 US Edition 6 Maintenance work every week

Vacuum the WPC filter mats (Waffle-pack changer) 6

a Clean the control unit filter mat of the WPC with a vacuum cleaner.
Replace them with new mats if they remain dark and discolored after vacuuming. Then return
the filter mat(s) to their correct positions.

The electronic modules will not be cooled adequately if the filter mats are dirty. 6
6
6

: Repeat these tasks at every WPC.

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7 Monthly maintenance work 03/2003 US Edition

7 Monthly maintenance work

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Maintenance Instructions F Maintenance
03/2003 US Edition 7 Monthly maintenance work

7
7

You will need the following tools, equipment and consumables for the monthly maintenance: 7

– Vacuum cleaner
– Brush
– Slotted-head screwdriver
– Set of hexagon socket spanners
– Pallet jack
– Laboratory gloves
– Ethyl alcohol
– SIPLACE cleaning tissue (article no. 00315253-02)
– SIPLACE cottonwool buds (article no. 00352931-02)
– Clean, lint-free cloths
– Lens cleaning cloth
– ISOFLEX TOPAS, NCA 52 (article no. 00328369-01)
– WD40
– Set of clean sleeves
– Set of cleaned and lightly greased valve plungers.
7

Remove component trolley 7

: Open the protective hoods and push the gantry over the PCB conveyor.
7

To move the gantry, take hold of the handle and push gently and carefully. 7

: Remove the reject bin from inside the machine and the waste bin from beneath the changeover
table.

Disconnect the changeover table from the power supply as follows: 7

a Remove the round mains plug

s When the yellow indicator lamp on the changeover table goes out, remove the square data
plug

d Detach the compressed air supply for the bulk case feeder

: Move the pallet jack beneath the changeover table and lift it until it just touches the changeover
table.

f Loosen the hexagon socket head screws.

g Release the clamps.

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Maintenance Instructions F Maintenance
03/2003 US Edition 7 Monthly maintenance work

a Raise the changeover table until it is flush with the top edge of the lateral anti-slip guard.

: Pull it out of the machine.

: Switch the placement system off at the main switch.

Replace the sleeves and valve plungers 7

The sleeves can be replaced at the same time as the clean ceramic nozzles. The procedure is as
follows: 7

s Use the Single Functions menu to return the nozzles of the Collect & Place head to the nozzle
changer.

: Open the protective hood.

Do not hold the sleeves or nozzles in your bare hands. Wear laboratory gloves when carrying out
any maintenance work on the sleeve.
7

In this way you will avoid dirtying the glass disk and friction wheel unnecessarily, which could
cause malfunctions (counting errors and overshoot). 7

d Remove the sleeves from the head.

Pull the sleeves out as shown in the diagram. 7


7

7
7

f Place them in the containers provided.


Use the “Single Functions” menu to step the star.

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Maintenance Maintenance Instructions F
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Maintenance Instructions F Maintenance
03/2003 US Edition 7 Monthly maintenance work

a Use a lens cleaning cloth to clean the glass disk of the turning station scanning unit.

s Remove the 12 valve plungers.

d Clean the valve casings using a cottonwool bud moistened with ethyl alcohol.

Never use pipe-cleaners or bottle brushes to clean the valve casing.


This could tear out the sleeve retaining springs or leave lint or hairs in the segment which, in turn,
could cause faults. 7
7

: Insert the cleaned and very lightly greased valve plungers into the valve casing.
See section ("Maintain the valve plungers").

: Move them backwards and forwards several times.

: If the valve plungers move very easily, replace them with new plungers.

If they do move very easily, they are not guaranteed to work correctly. 7
7

: Insert the cleaned sleeves into the segments.


See section ("Maintain the sleeves").

Use only gentle pressure to latch the sleeves into position so as not to damage the sleeve retain-
ing springs. 7
7

: Check that the sleeve can be moved easily in the segment.

If the sleeve does not move easily: 7

: Remove the sleeve once more.

f Clean the segment using a cottonwool bud moistened with ethyl alcohol.

Never use pipe-cleaners or bottle brushes to clean the segment.


This could tear out the sleeve retaining springs or leave lint or hairs in the segment which, in turn,
could cause faults. 7
7

: Use the "Single Functions" menu to pick up the nozzles of the Collect&Place head.

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Maintenance Instructions F Maintenance
03/2003 US Edition 7 Monthly maintenance work

Clean the linear guides for the X and Y axes 7

a Use the SIPLACE cleaning cloth to clean the linear guides for the X and Y axes thoroughly
along their entire length.

s Use a lint-free cloth to remove any remaining dirt from the linear guides.

: Preserve the linear guides using a new SIPLACE cleaning tissue.

: Switch the placement system off at the main switch.

Clean the IC camera 7

d Carefully pull the top part of the IC camera up and off.


This will enable you to remove loose components from the IC camera.

f Loosen and remove the two slotted screws from the mapping plate.

g Remove the glass disk.

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Maintenance Maintenance Instructions F
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Maintenance Instructions F Maintenance
03/2003 US Edition 7 Monthly maintenance work

a Clean the mirrored surfaces of the camera and the glass disk using a lens cleaning cloth.

: Insert the glass disk once more.

: Insert the top part of the IC camera.

When you insert the top part of the IC camera, make sure that it lies flat against the bottom part
and does not move.
7

Clean the FC camera


s Remove the top part of the FC camera in the same way.

d Clean the mirrored surfaces of the FC camera.

: Insert it again as described above.

Clean the coplanarity module 7

f Use lens cleaning paper to clean the lenses of the coplanarity module.

Clean the guides for the protective hoods 7

g Use a brush dipped in ethyl alcohol to clean the guides for the protective hoods.

: Grease the protective hood guides using a brush and ISOFLEX TOPAS NCA 52.

h Close and open the protective hoods to distribute the grease evenly.

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Maintenance Maintenance Instructions F
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Maintenance Instructions F Maintenance
03/2003 US Edition 7 Monthly maintenance work

SIPLACE 80 F4 7

Maintain the electric empty tape cutter 7

a The used tape cutter is free. Remove the cover.

s Vacuum the used tape cutter's linear guide.

d Clean the linear guides thoroughly over their entire length using the SIPLACE cleaning tissue.

f Use a lint-free cloth to remove any stubborn dirt from the linear guide.

: Oil and preserve the linear guides using a fresh SIPLACE cleaning cloth.

g Use WD 40 to preserve the cutting wheel.

Be careful not to cut yourself on the cutting wheel. It is extremely sharp. 7

7
7

: Replace the guard over the cutter.

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Maintenance Instructions F Maintenance
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a Oil and preserve the linear guides using a fresh SIPLACE cleaning cloth.

: Replace the guard over the cutter.

s Use a lint-free cloth dipped in ethyl alcohol to clean the contact surfaces, both inside the ma-
chine and on the changeover table.

: Preserve the contact surfaces using a lint-free cloth sprayed with WD40.

: Reverse the order described above to return the changeover table to the machine.

Make sure that the locating pins on the changeover table holders slide into their holes in the
changeover table.
7

: Fix the changeover table in position using the tensioners and socket-head cap screws, then
connect up the machine again in the following order:
1. Compressed air supply for the bulk case feeder
2. Rectangular data connector
3. Round main power plug.

: Close the protective hood.

: Repeat these tasks in all the feeder areas.

: Switch the placement machine on at the main switch.

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Maintenance Maintenance Instructions F
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8 2-monthly maintenance work

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Maintenance Instructions F Maintenance
03/2003 US Edition 8 2-monthly maintenance work

You will need the following tools, equipment and consumables for the 2-monthly maintenance. 8

– Vacuum cleaner

– Condensate drip tray

– Short-bristled brush

– Phillips screwdriver

– Set of hexagon socket spanners

– Nozzle removal tool (article no. 00311448-01)

– Whetstone / oilstone

– Scissors

– Lint-free cloths

– SIPLACE cleaning tissue (article no.: 00315253-02)

– ISOFLEX TOPAS NCA52 grease (article no. 00328369-01)

– WD40 (article no.00325833-01)

– If necessary, diaphragms for 418 (article no. 00307052-03)


and 419 nozzles (article no. 00310569-03)

– If necessary, filter insert, 5 microm. for series 112


F4 / F5 / F5HM (article no. 00355386-01)
F3 / F4 Old (article no. 00330406-01)

– New silencer for the Collect & Place head, if necessary (from article no. 00320964-01).

– If necessary, new vacuum generator for the Pick&Place head (article no. from 00305378-01).

Inspect or replace the filter cartridge 8

a Open the door to the compressed air supply.

s Place a drip tray beneath the compressed air maintenance unit.

: Close the main compressed air valve.

d Once both manometers read 0, switch the placement machine off at the main switch.

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Maintenance Instructions F Maintenance
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: Remove the black blanking cap by pressing down on the yellow cap release (at the back) and
turning the blanking cap counter-clockwise (bayonet fitting).

a Remove the condensate tank by pushing it up, turning it counter-clockwise and then pulling it
down (bayonet fitting).

s Unscrew the filter casing from the compressed air maintenance unit.

d Loosen the Phillips screw to remove the filter from the filter casing.

: Replace the filter if it is dirty.

: Reverse the order described above to fit the filter and filter casing.

: Then open the main compressed air valve again.

Inspect or replace the silencer on the Collect & Place head 8

f Check the silencer for the Collect & Place head for dirt.
If it is discolored, detach the retainer by turning it counter-clockwise.

g Replace the dirty silencer with a new one and reverse the order described above to fit.

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Maintenance Instructions F Maintenance
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Inspect or replace the silencer for the Pick & Place head 8

a Turn the silencer for the Pick & Place head counterclockwise to remove.

s Remove the filter from the casing and check for dirt.

: Replace the entire vacuum generator for the Pick&Place head, if the filter is dirty.

Make sure that the plastic thread of the silencer is straight. 8

Clean and grease the toothed belts for the X, Y and Z axes 8

: Clean the toothed belts for the X, Y and Z axes.

d Grease the toothed belt for the Y axis using a short-bristled brush dipped in ISOFLEX TOPAS
NCA 52.

f Grease the toothed belt for the X axis using a short-bristled brush dipped in ISOFLEX TOPAS
NCA 52.

g Grease the toothed belt for the Z axis using a short-bristled brush dipped in ISOFLEX TOPAS
NCA 52.

: Move the axes backward and forward to distribute the grease evenly over the toothed belts.

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Maintenance Instructions F Maintenance
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Maintain the component feeder table 8

a Clear the feeder area.

: Remove any loose components from the component feeder table using the vacuum cleaner.

s Use a whetstone to remove any irregularities from the magnetic bar.

d Preserve the feeder area using a lint-free cloth sprayed with WD40.

f Vacuum up any loose components from the tape container and remove any unwanted stickers
and adhesive tape.

g Cut off the excess used tape flush with the feeder and empty the component drawer on 8 mm
S feeders.

: Return the feeders to the feeder area.

Make sure that each feeder is in the correct location and is connected correctly. 8

8
8

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Maintenance Instructions F Maintenance
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Clean the nozzle changer for the Pick & Place head 8

a Remove the nozzles for the Pick & Place head from the nozzle changer. Use the enclosed noz-
zle removal tool, if necessary.

s Vacuum up any loose components from the nozzle changer.

Check the nozzles on the Pick & Place head / replace the diaphragms 8

d Check the nozzles (418 and 419) for dirt and check the rubber diaphragms for damage.

f Replace any damaged diaphragms by pulling off the metal part.

: Return the nozzles to the nozzle changer in the correct order and positions.

: Repeat these tasks in all the feeder areas.

: Close the protective hood.

: Switch the placement machine on at the main switch.

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Maintenance Instructions F Maintenance
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Maintain the WPC 8

a Preserve the feed axis linear guide using a SIPLACE cleaning tissue.

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Maintenance Maintenance Instructions F
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9 4-monthly maintenance jobs

Structure of the 12-segment revolver head / DLM1 9

Fig. 9.0 - 1 Structure of the 12-segment revolver head / 12-segment revolver head DLM1

(1) Star with 12 sleeves (2) Motor, "Reject" valve adjustment drive

(3) Turning station (4) Component vision module

(5) Z axis drive (6) Star motor

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Maintenance Instructions F Maintenance
03/2003 US Edition 9 4-monthly maintenance jobs

You will need the following tools, equipment and consumables for the 4-monthly maintenance. 9

– Pliers in the service box (article no.: 00346929-01)


– Short-bristled brush
– Set of hexagon socket spanners
– Lint-free cottonwool buds (article no.: 00352931-02)
– Ethyl alcohol
– Lint-free cloths
– ISOFLEX TOPAS NCA52 grease (article no. 1 kg can, 00328369-01, 50g tube, 00330850-01)
– Unisilkon L250L (article no.: 00310259-01)
– Oil dispenser with Structovis GHD (article no.: 00367071-01)
– Set of clean sleeves
– Set of clean valve plungers
– New Z-toothed belt, if required (article no.: 00334936-01)
– New distributor, if required (article no.: 00319827-02)
– New O-ring for the turning station, if required (article no.: 00320043-01)
– New toothed belt for the turning station, if required (article no.: 00320041-01).
9

9.1 Fitted placement heads

Placement machines from the F family can have the following placement heads: 9

9
SIPLACE 8000 10000 DLM 1 IC CAN bus
F4 x (1x) x (1x)
F4-6 x (1x) x (1x)
F5 x (1x) x (1x)
F5 HM x x x (1x)

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Maintenance Instructions F Maintenance
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Dismantle front part of head 9

: Use the "Single Functions" menu to return the nozzles of every Collect&Place head to the noz-
zle changer.

: Switch the placement system off at the main switch.

Follow the correct shut-down routine. 9

9
9

Remember to follow the ESD regulations.

9
9

: Cover the feeder area to protect the feeder modules and front part of the head.

a Unplug the ribbon cables for the front part of head on the conversion board.

s Detach the compressed air hose.

To do this, use the pliers from the service box for the DLM 1 and DLM1-6 heads. 9

9
9

d Loosen the 3 (10.000er / 8000x head) or the 4 screws (DLM1 / DLM1-6) of the front part of
head (using a 3 mm Allen key) and remove it.

Hold the front part of head firmly as you remove the screws. 9

Look out for the white plastic distributor plate and the distributor. 9
9

Turn the star half a revolution to avoid damaging the valve plunger drive with the valve plunger.9

: Place the front part of the head on a soft ESD surface (with the valve plunger side underneath)
or place it on a suitable head stand.

: Remove the sleeves and place them in the containers provided.

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Maintenance Instructions F Maintenance
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Z axis (front part of head) 9

a Use a brush or cottonwool bud to move dirt from the Z axis toothed belt.

: Clean the rollers, toothed wheels and the toothed belt with a cottonwool bud or lint-free cloth
moistened with ethyl alcohol.

: Check the toothed belt for wear.


Replace the toothed belt if it shows signs of wear (see servicing instructions).

: Lightly grease the toothed belt with ISOFLEX TOPAS NCA 52 and remove any excess grease.

s Check that the Z axis guide runs easily and without play.

: Check the jaws for damage.

Contact your regional Service Center if defects are identified in the Z axis or jaws. 9

Oil the miniature roller table 9

: Move the Z axis into its bottom position.

: Wipe the needle of the oil dispenser.

Do not press any oil out of the oil dispenser. Just one visible drop would be too much oil. 9

9
9

d Simply place the needle against the grooves of the miniature roller table. When it makes con-
tact, sufficient oil will be transferred to the grooves (capillary effect).

: Move the Z axis up and down several times to distribute the film of oil.

Distributor plate 9

f Remove the distributor plate.

: Blow through with compressed air.

g Clean the sleeve shaft using a lint-free cloth moistened with ethyl alcohol.

: Grease the back very lightly with Unisilkon L250L to ensure it is sealed with respect to the star.
Remove any visible, excess grease.
9

There must be NO grease in the holes. 9

: Place the distributor plate on a clean surface.

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Maintenance Instructions F Maintenance
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Star 9

a Wipe the star including the distributor plate seat with a lint-free cloth.

: Apply a light film of ISOFLEX TOPAS NCA 52 grease to the running surface of the star brake.
Remove any visible excess grease.
9

Make sure that no dirt or grease gets into the vacuum channels. 9

Segments 9
9

When cleaning, be careful not to damage the sleeve retaining springs in the segments. 9

s Carefully clean the segments using a cottonwool bud moistened with ethyl alcohol.

d Remove any visible dirt around the segments.

Valve channels 9

: Remove the 12 valve plungers.

f Clean the valve channels using a cottonwool bud moistened with ethyl alcohol.

: Then clean all around the valve channels.

Assembling the front part 9

: Insert cleaned or new sleeves into the segments.

: Insert cleaned or new valve plungers into the valve channels.

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Maintenance Instructions F Maintenance
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Distributor (back part of head) 9

a Carefully remove the distributor together with the two O-rings.

s Carefully remove the two O-rings.

: Clean them and grease them very sparingly with Unisilkon L250L.

: Check the distributor for damage.


Replace the distributor if it is damaged (see servicing instructions).

: Wipe the distributor using a lint-free cloth moistened with ethyl alcohol.

: Blow through with compressed air.

d Check that the ball catch moves easily.


Replace the entire distributor if it does not move easily.

f Place the clean distributor and the lightly greased O-rings on a clean surface.

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Star brake 9

: Check the star brake for damage and to ensure that it is working correctly.

a Wipe the star brake using a dry, lint-free cloth. Make sure that you remove all grease residues.

: Fill each of the three small holes in the star brake (see arrows) with ISOFLEX TOPAS NCA 52.

s Remove excess grease with a lint-free cloth.

: Apply a thin film of grease to the surface of the star brake.

Distributor seat 9

d Clean the distributor seat with a cottonwool bud moistened with ethyl alcohol.
9

Be careful not to push dirt into the vacuum openings with the cottonwool bud. 9

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Maintenance Instructions F Maintenance
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Valve adjustment drives 9

a Wipe the three valve adjustment drives using a dry, lint-free cloth.

: Clean the plate and the gap between the plate and the motor bracket.

s Clean the ball bearing with a dry lint-free cloth.

: Check that the ball bearing is working correctly.

: Remove any visible dirt.

Turning station 9

d Wipe the black O-ring of the turning station with a lint-free cloth moistened with ethyl alcohol.

: Check the O-ring for damage. Replace, if necessary.

: Check the toothed belt for damage, Replace, if necessary.

The turning station can be cleaned while still installed using a cottonwool bud moistened with ethyl
alcohol. 9

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Maintenance Instructions F Maintenance
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Assembly 9

: Insert the two O-rings into the back part of head.

: Carefully insert the distributor into its seat.


9

The small O-ring may be damaged if it is seated on the distributor. 9

a Insert the distributor plate into its seat.


9

Make sure that the distributor plate is seated correctly. The flat side must lie on the star. The side
with the step points towards the distributor. 9

: Fit the front part of head and screw it tight.

: Attach the ribbon cables to the appropriate connectors.

: Connect the compressed air hose.

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Maintenance Instructions F Maintenance
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Vacuum generator 9

a Detach the vacuum generator hoses.

To do this, use the pliers from the service box for the DLM 1 and DLM1-6 heads. 9

9
9

9
9

We recommend that you label or otherwise mark the compressed air hoses before you remove
them. 9

On the DLM1 heads, the hoses are already labeled and have a fixed assignment. 9

s Unscrew the block with the 2 Venturi nozzles using a 2.5 mm hexagon socket spanner.

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Maintenance Instructions F Maintenance
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: Carefully clean the Venturi nozzles using a lint-free cloth moistened with ethyl alcohol.

: Blow through the Venturi nozzles with compressed air.

: Lightly grease the O-rings of the vacuum generator with Unisilkon L250L.

: Clean the vacuum generator block with a cottonwool bud moistened with ethyl alcohol and
blow through with compressed air.

: Place the cleaned parts of the vacuum generator on a clean surface.

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Maintenance Instructions F Maintenance
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Silencer 9

: Turn the silencer counter-clockwise to remove.

a Clean the holes to the Venturi nozzles with a cottonwool bud moistened with ethyl alcohol.

: Check the silencer for dirt.


If there are any signs of discoloration, replace the silencer and reverse the sequence described
above to fit.
9

Don't forget the O-ring. 9

: Check the plastic silencer mount for breaks (10000x head).

Assemble the vacuum generator 9

: Assemble the block with the Venturi nozzles and carefully screw tight.

s Attach the compressed air hoses once more.

To do this, use the pliers from the service box for the DLM 1 and DLM1-6 heads. 9

Make sure that the connections are seated correctly. 9


9

The hoses must engage correctly in the couplings. 9


9

: Fit the head cover.

: Use the Single Functions" menu to pick up the nozzles once more.

Test placement 9

The distance between the component camera and the PCB camera can be changed by separating
the front and back parts of the head. 9

: Carry out a test placement run to test whether the placement accuracy is still guaranteed.

: If the placement accuracy is not guaranteed, remeasure the placement head.

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10

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Maintenance Instructions F Maintenance
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10

You will need the following tools, equipment and consumables for the annual maintenance. 10

– Vacuum cleaner

– Set of hexagon socket spanners

– SIPLACE cleaning tissue (article no. 00315253-02)

– Grease cartridge with Urethyn E/M2 (article no.: 02101696-01)

10

: Select “Block manually” (status closed) on the station computer and click on OK (for dual con-
veyor track 1 / track 2).
The placement machine will continue to produce until the last PCB is complete and has left the
PCB conveyor.

: Switch the placement system off at the main switch.

: Open the protective hood.

10

10

: Move the gantry over the feeders. This will stop it outside your working area.
10

To move the gantry, take hold of the handle and push gently and carefully. 10

10

10

Vacuum beneath the lifting table 10

: Lift the lifting table out of the placement machine.

: Carefully vacuum the area beneath the lifting table.

10

10

Clean and preserve the PCB conveyor 10

a Preserve the recirculating ball screw by running a SIPLACE cleaning tissue along the thread
of the screw.

s Preserve the sliding surfaces of the guide rails using a SIPLACE cleaning tissue.

d Preserve the hexagonal shafts using a SIPLACE cleaning tissue.

f Preserve the guide shafts of the PCB stopper using a SIPLACE cleaning tissue.

10

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Maintenance Instructions F Maintenance
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Check the used tape cutter 10

10

a Undo the 2 screws of the used tape channel.

s Take off the used tape channel.

: Check that the cutting blade is cutting correctly.


Turn the cutting blade if there are any irregularities on the cutting surfaces. A cutting blade
must be replaced if it has already been turned once.
Contact SIPLACE Service.

10

: Reverse the above sequence to fit the used tape channel.

10

: Select “Block manually” (status open) on the station computer and click on OK (for dual con-
veyor track 1 / track 2).

10

10

: Repeat these tasks at every placement machine on the line.

: Switch the placement system on again at the main switch.

: Repeat these tasks on both sides of the machines on the placement line.

10

10

10

10

10

10

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Maintain the WPC 10

10
10

Disconnect the WPC from the power supply as follows: 10

a Detach the round main power plug.

s Detach the rectangular data connector.

d Wind up the WPC.

f Loosen the 4 hexagon socket head screws for the left cover of the WPC and remove it.

10

g Fit the grease gun hose on the grease nipple of the ball screw.
Carefully press grease into the nipple until contaminated grease emerges from it.

: Remove excess grease with a lint-free cloth.

10

10

10

10

10

10

10

10

10

10

10

10

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Maintenance Instructions F Maintenance
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a Loosen the 2 screws on the cover plate over the conveyor area and remove the cover.

s Loosen the 4 screws on acrylic glass cover and remove the cover.

10

10

d Fill both grease nipples with grease from the grease gun.

10

10

: Reverse the above sequence to fit the WPC.

: Dock the WPC into the machine once more.

10

: Repeat these tasks at every WPC on the line.

10

: Close the protective covers for the placement machines.

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

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11 Maintain the sleeves

11

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Maintenance Instructions F Maintenance
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11

You will need the following tools and consumables for maintaining the sleeves. 11

– Laboratory gloves

– Metal drill bit, 1.1 mm

– Metal drill bit, 1.4 mm

– Lint-free cloths

– Lint-free cottonwool buds

– Ethyl alcohol

– Unisilkon L250L (article no.00310259-01)

– O-ring 6x1 Viton 60, if necessary (article no. 00323535-02).

11

11

Do not hold the sleeves or nozzles in your bare hands. Wear laboratory gloves when carrying out
any maintenance work on the sleeve.
11

Always return the sleeves to the containers provided. 11

11

a Check that the switching ring can be moved easily in the sleeve and springs back.
If it does not spring back, send the sleeve to Siemens Dematic for repair.

11

11

Remember to turn the drill bit as you push it into the vacuum holes, Otherwise you will push the
dirt further into the sleeve.
11

s Remove any dirt from the long vacuum hole by turning a 1.4 mm metal drill bit clockwise in the
hole.
Turning the bit will remove the dirt from the hole.

d Remove any dirt from the transverse vacuum hole by turning a 1.1 mm metal drill bit clockwise
in the hole.

11

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Maintenance Instructions F Maintenance
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a Clean the sleeve suction plate using a dry, lint-free cloth.

11

s Clean the friction wheel of the sleeve using a lint-free cloth moistened with ethyl alcohol.

11

d Clean the incremental disk using a lint-free cloth moistened with ethyl alcohol.

11

11

11

11

11

11

11

11

11

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Maintenance Instructions F Maintenance
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a Clean the sleeve shaft using a lint-free cloth moistened with ethyl alcohol.

11

Ball catch sleeves 11

s Clean the circumference of the ball catch with a lint-free cottonwool bud moistened with ethyl
alcohol.

11

d Check the inside film for damage.

11

f Clean the groove using a lint-free cottonwool bud moistened with ethyl alcohol.

11

11

11

11

11

11

11

11

11

11

11

11

11

11

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11

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Standard sleeves 11

a Check that the O-ring is lying closely against the sleeve. Replace the O-ring if it is too far away
or damaged.

11

s Clean the snap-fit O-ring with a lint-free cloth.

s Grease the O-ring by rubbing with Unisilkon L250L (ideally between your fingers). Then care-
fully pull the O-ring over the suction plate and into the groove.
Check that the O-ring is seated firmly in the groove.

Do not remove the O-ring in order to grease it, since this will stretch it and make it unusable. 11
11

11

11

11

11

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12 Maintain the valve plungers

12

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12

You will need to maintain the valve plungers: 12

– Valve plunger C&P 12 (6 in one package) (item no. 00351498-03)

– Valve plunger C&P 6 (6 in one package) (item no. 00351500-03)

– ISOFLEX TOPAS NCA52 (article no. 00328369-01, 00330850-01 tube 50g)

– Lint-free cloths.

12

a Wipe the valve plunger using a dry, lint-free cloth.

: Check the sealing lips, the spring O-ring and the sleeve for damage.
If they are damaged, replace the valve plunger.
A loose sleeve that is still intact may be refitted.

Distinguish between the dirty and the clean valve plungers by identifying the packings accordingly,
for example. 12
12

12
12

When inserting:
Test the valve plungers to ensure that they do not move too easily (too loose). 12
12

Replace any plungers that that are either too loose or too tight.
Move the valve plungers back and forward several times.
Make sure that the valve plungers are inserted as far as the stop. 12
12

During operation:
The "Segment leaking" error message generally indicates a valve plunger that is too loose. 12
12

12

s Grease the sealing lips extremely sparingly using a lint-free cloth dipped in ISOFLEX TOPAS
NCA 52 No grease residues must be seen.
12
12

The identified grooves must be left grease-free. 12

12

12
12

New valve plungers must also be greased before they are used for the first time.
12
12

12

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98
SIEMENS DEMATIC AG 2003 All rights reserved Subject to change without prior notice

Item no. 00192156-04 Siemens Aktiengesellschaft


To be ordered from:
SIEMENS DEMATIC AG,
SD EA 1
Rupert-Mayer-Strasse 44
D-81359 Muenchen

Printed in the Federal Republic of Germany

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