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Watkiss DigiVAC - User Manual

Watkiss DigiVAC
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Watkiss DigiVAC Service Manual - Issue 2 - 29/11/04
Watkiss DigiVAC
Service Manual
Issue Date: 29 November 2004
Issue Number: 2
Part Number: 969-251
Watkiss Automation Ltd
1 Blaydon Road
Middlefield Industrial Estate
Sandy, Bedfordshire
SG19 1RZ U.K.
Tel: +44 (0)1767 682177
Fax: +44 (0)1767 691769
Email: info@watkiss.com

Table of Contents

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Summary

Chapter 1 Overview

1.1 Introduction

General introduction to the DigiVAC collating system and its capabilities.

1.1.1 Safety

Important safety precautions to observe when handling the machine.

1.1.2 Operation

Refers to operating instructions in the relevant operating manual.

1.1.3 Orientation

Defines the viewing perspective for R/H and L/H sides of the machine.

1.1.6 Moving the DigiVAC

Instructions on how to safely move the DigiVAC unit.

1.2 Modules & Configuration

Details the modular system and configuration options for DigiVAC.

1.2.1 DigiVAC Standard

Description of the DigiVAC Standard version and its features.

1.2.2 DigiVAC+

Description of the DigiVAC+ version with GUI and multi-tower capabilities.

1.2.3 Modules

Lists and illustrates the various modules that make up the DigiVAC system.

1.3 System Overview

Provides a high-level overview of the DigiVAC system architecture and components.

1.4 Fuses

Details the location, function, and rating of fuses used in the DigiVAC system.

Chapter 2 Tools & Materials

2.1 Recommended Tools

Lists the essential tools recommended for Watkiss engineers to service the DigiVAC.

2.2 Consumables

Lists consumable items required for maintenance and repair of the DigiVAC.

2.3 Service Aids

Lists special service aids and diagnostic equipment for the DigiVAC.

Chapter 3 Service Procedures

3.1 General Service Procedures

Covers common service procedures applicable to the DigiVAC system.

3.1.1 Bin Test Mode

Procedure for entering Bin Test Mode for diagnostics and testing.

3.1.2 Removing the Rear Conveyor Assembly

Step-by-step instructions for removing the rear conveyor assembly.

3.1.4 Removing L;H Side Plates

Instructions for removing the left-hand side plates for access.

3.1.5 Bin Addressing

Procedure for addressing bins after installation or PCB replacement.

3.2 Top Module

Procedures related to the Top Module of the DigiVAC.

3.2.1 Replacing the Top Drum & Conveyor Belts

Instructions for replacing worn or damaged top drum and conveyor belts.

3.3 Control Panel (DigiVAC Standard)

Procedures for servicing the control panel of the DigiVAC Standard.

3.3.1 Removing the Control Panel (DigiVAC Standard)

Step-by-step guide for removing the standard control panel assembly.

3.3.2 Engineering Mode

Instructions for accessing and using the Engineering Mode on the standard control panel.

3.4 GUI Control Panel (DigiVAC+)

Procedures for servicing the Graphical User Interface (GUI) control panel.

3.4.5 Cleaning the GUI Screen

Guidelines for cleaning the GUI touch-screen to ensure proper operation.

3.4.7 Calibrating the GUI Screen Display

Procedure for calibrating the GUI touch-screen for accurate input response.

3.5 Feeder Modules

Procedures for servicing the various feeder modules.

3.5.1 Removing the Feeder Assembly

Instructions for removing the feeder head assembly.

3.5.3 Replacing a Feeder Clutch

Procedure for replacing a faulty feeder clutch assembly.

3.5.5 Replacing Bin Emitter;Sensor

Instructions for replacing a faulty bin emitter or sensor.

3.5.11 Replacing Bin Feeder Drive Belts

Procedure for replacing damaged or broken bin feeder drive belts.

3.5.12 Setting Bin Feeder Drive Belt Tension

Guidelines for correctly tensioning bin feeder drive belts for optimal performance.

3.6 Base Module

Procedures related to the Base Module of the DigiVAC.

3.6.1 Replacing Drive Motor

Step-by-step guide for replacing the main drive motor and gearbox.

3.6.3 Replacing the Vacuum Pump Motor

Instructions for replacing the vacuum pump motor.

3.6.5 Replacing or Cleaning the Main Air Filter

Procedure for checking, cleaning, or replacing the main air filter.

3.6.8 Replacing the SMD 8200 Inverter

Instructions for replacing the SMD 8200 Inverter unit.

3.9 X-Jogger

Procedures for servicing and maintaining the X-Jogger module.

3.9.2 X-Jogger Sidelay;Endlay Screw Adjustment;Cleaning

Guide for adjusting and cleaning X-Jogger sidelay and endlay screws.

3.9.3 X-Jogger Control PCB;Fuse Replacement

Instructions for replacing the X-Jogger control PCB or fuse.

3.9.5 X-Jogger Power Adjustment

Procedure for adjusting the jogging power of the X-Jogger.

Chapter 4 Electronics & Software

4.1 Connection Diagrams

Provides wiring and connection diagrams for the DigiVAC system.

4.1.1 DigiVAC Block Diagram

Illustrates the overall block diagram of the DigiVAC system.

4.1.3 DigiVAC High Voltage Connections (S;Nos. up to DIG;0000149) (sheet 1 of 2)

High voltage wiring connections for early serial numbers (sheet 1).

4.1.7 DigiVAC Standard Low Voltage Connections (S;Nos. up to DIG;0000149)

Low voltage wiring connections for Standard models (early serial numbers).

4.2 PCBs

Details of the various Printed Circuit Boards (PCBs) used in the DigiVAC.

4.2.2 900-104 e X-Jogger Control PCB

Information on the X-Jogger Control PCB.

4.2.6 900-176 h DigiVAC Base PCB

Details of the DigiVAC Base PCB, a key component for system operation.

4.3 SMD 8200 Inverter

Information on the SMD 8200 Inverter, used in later Base Modules.

4.4 Software - GUI Control Panel

Information on the GUI software, installation, and updates.

4.4.1 Installing New Software

Overview of methods for installing new software revisions.

4.4.1.3 Updating Software Via a Memory Card

Procedure for updating software using an SFM Memory Card.

4.4.1.4 Updating Software Via an RS232 Connection

Method for updating software via a serial RS232 connection.

4.4.1.5 Updating Software Via a Network Connection

Method for updating software using a network Ethernet connection.

4.4.3 Installing Software Via an RS232 Connection

Detailed procedure for installing software using RS232.

4.4.4 Installing Software Via an Ethernet Connection

Detailed procedure for installing software via Ethernet.

4.4.4.5 Networking DigiVACs

Instructions on setting up network connections between DigiVAC units.

4.4.9 Error Bleeps

Explanation of error codes indicated by audible bleeps.

Chapter 5 Machine Inspections

5.1 DigiVAC - After-Build Inspection

Checklist for inspecting the DigiVAC after it has been built or reconfigured.

5.2 DigiVAC - Pre-Delivery Inspection

Checklist for inspecting the DigiVAC before it is shipped to the customer.

Chapter 6 Routine Maintenance

6.1 DigiVAC Routine Maintenance Schedule

A schedule outlining routine maintenance tasks for the DigiVAC.

Chapter 7 Installation

7.1 Prior to Installation

Checks and considerations before installing the DigiVAC.

7.2 Unpacking and Installing a DigiVAC

Procedure for safely unpacking and physically installing the DigiVAC.

7.3 Upgrade an 8 DigiVAC to a 12 DigiVAC

Instructions for upgrading an 8-bin DigiVAC system to a 12-bin configuration.

7.4 Upgrade a DigiVAC Standard to a DigiVAC+

Procedure for upgrading a DigiVAC Standard to a DigiVAC+ with GUI.

7.6 Installing a Second Tower

Instructions for installing a second tower to create a multi-tower system.

Chapter 8 Trouble Shooting

8.1 Trouble Shooting Chart

A chart listing common faults and their probable causes and solutions.

8.2 Fuse Failure

Information on identifying and resolving faults related to fuse failures.

Chapter 9 Appendix

9.1 Specifications

Technical specifications for the DigiVAC system.

Watkiss DigiVAC Specifications

General IconGeneral
BrandWatkiss
ModelDigiVAC
CategoryIndustrial Equipment
LanguageEnglish