DP6000 V2

Automatic Coating & Drying System

Coater Oven

Operation / Maintenance Trouble Shooting

Program HMI DP6000_ATS2_Ethernet_WIP_02-09-12

Dc1/sales/sales tools/manuals/DP6000/DP6000v2_OM_80328_AT&S

CIRCUIT AUTOMATION 5292 System Dr. U.S. Patent 5,265,531 Huntington Beach, CA 92649 USA U.S. Patent 4,957,044 Phone 1.714.763.4180 FAX 1.714.763.4181 Price $250.00 www.circuitautomation.com 2012 V2 CAI R17

- I -

EC Declaration of Conformity

In accordance with EN ISO 7050-1:2004

We Circuit Automation, Inc. Of 5292 System Drive, Huntington Beach, CA 92649 USA In accordance with the following Directive(s): 92/36/EEC The Low Voltage Directive EN 1050:1996 Safety of Machinery 98/37/EC The Machinery Directive 89/336/EEC Electromagnetic Compatibility Hereby declare that: Equipment Vertical Screen printer Model Number DP6000-v4.5 Serial Number 80324 Is in conformity with the applicable requirements of the following documents Ref No. Title Edition/date BSS EN 1050 Safety of machinery- Principles for risk assessment 1996 EN 60204-1 Safety of machinery. Electrical equipment of machines. 2006 General requirements. I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications. The unit complies with all applicable Essential Requirement of the Directives. Signed Name: Thomas Meeker Position: President Location Huntington Beach, CA On October 26, 2012 Document ref. No,

12

- II -

TABLE OF CONTENTS

EC DECLARATION OF CONFORMITY ................................... I 

INTRODUCTION ....................................................................... 3 

WARRANTY.............................................................................. 4 

CONVENTIONS ......................................................................... 4 

SUPPORT EQUIPMENT .............................................................. 5 

Ink Pumps .............................................................................................. 5 

INSTALLATION ........................................................................ 6 

WORK AREA ............................................................................ 6 

FLOOR PLAN ............................................................................ 6 

UNLOADING AND UNPACKING .................................................... 7 

INSTALLATION ........................................................................ 10 

AN OVERVIEW OF THE DP6000 V2 ..................................... 16 

CONTROLS ............................................................................ 18 

On/Off .................................................................................................. 18 Emergency Stop ................................................................................. 19 Reset ................................................................................................... 19 Touch screen ...................................................................................... 19 Pneumatic Controls ............................................................................ 21 

Regulator Calibration .............................................................................. 22 Other Controls .................................................................................... 23 

Board review .......................................................................................... 24 Foot Switches .......................................................................................... 24 

TOUCHSCREEN MMI ............................................................ 25 

Main Screen ....................................................................................... 26 Main Coater Screen ........................................................................... 27 System Status Menu .......................................................................... 27 

AUTOLOADER ....................................................................... 29 

Auto Loader Servo Main Set Up Screen ........................................... 30 Centering Servo # 3 .............................................................................. 30 Centering Servo # 3 .............................................................................. 32 

- III -

Autoloader Roller Setup ..................................................................... 35 Autoloader Outputs ............................................................................ 36 Autoloader Input Screens .................................................................. 37 

Second Pinch Roller Peel Off ................................................................. 38 Servo # 4 Vacuum Box Set up .......................................................... 40 

Mechanical Grip ............................................................................................... 42 Servo #4 Vacuum Box Rotate ........................................................... 47 

CONTROL PANEL ................................................................... 49 

ELECTRICAL CABINET ............................................................ 50 

PNEUMATIC CABINET ............................................................. 50 

CONTROLS AND ADJUSTMENTS ....................................... 51 

LOAD/UNLOAD STATION ........................................................ 51 

Traveling Frame Panel Transport...................................................... 51 

COATING CHAMBER ............................................................... 52 

QC Swing Arm .................................................................................... 52 Ink Reservoir ....................................................................................... 53 Chase Lock Clips ............................................................................... 54 Chase Lock Cylinders ........................................................................ 54 Chase Alignment Knob ...................................................................... 55 Print Head ........................................................................................... 56 

Squeegees .............................................................................................. 57 MAIN COATER CONTROLS ............................................................ 58 UPS ..................................................................................................... 59 Emergency Stop ................................................................................. 59 Touch screen ...................................................................................... 60 

PNEUMATIC CABINET ............................................................. 61 

Regulator Calibration ......................................................................... 62 ITV Functions ........................................................................................ 63 

Internal Pneumatic Regulators .......................................................... 63 Tilt LEFT SV # 2 ..................................................................................... 63 Tilt RIGHT SV # 3 ................................................................................... 64 Ink RES SV # 8 ....................................................................................... 64 Top HOLDER SV # 10 ........................................................................... 64 Bottom HOLDER SV # 11 ..................................................................... 64 Top CLAMP SV # 12 ............................................................................. 64 Bottom Clamp SV # 13 ......................................................................... 65 Chase Lock SV #4 ................................................................................. 65 

TOUCH SCREEN HMI ............................................................ 66 

color coded operational scheme ........................................................ 66 Start / Stop ............................................................................................. 68 

Reset ................................................................................................... 69 Mode ................................................................................................... 69 

Flood/Print (FP) ....................................................................................... 69 Flood/Print/Print (FPP) ............................................................................ 69 

- IV -

Double Print (FPFP) ................................................................................ 70 Triple Print (FPFPP) ................................................................................ 70 

Display Information ............................................................................. 71 READY ............................................................................................... 71 Running ............................................................................................... 71 Resetting ............................................................................................. 71 Manual ................................................................................................ 71 Errors and Alarms. ............................................................................. 72 

Flood ........................................................................................................ 72 Flood Only .............................................................................................. 73 

Options ................................................................................................ 73 Floods ..................................................................................................... 73 ISOprint .................................................................................................. 74 Skew CCW and Skew CS ..................................................................... 74 Skew CW and Straight ......................................................................... 74 Ink Pump ................................................................................................ 74 Jog .......................................................................................................... 75 PEEL OFF ............................................................................................... 75 Shuffle ..................................................................................................... 75 

Status .................................................................................................. 75 Counter Reset .................................................................................... 75 Miscellaneous ..................................................................................... 76 Ink Fill .................................................................................................. 76 Passwords .......................................................................................... 76 

SETUP AND RECIPE ............................................................... 76 

SQUEEGEE POSITIONS ........................................................... 80 

Squeegee Position Screen Defined .................................................. 81 Machine Mechanical Functions: ........................................................ 81 Chase Open/Close ............................................................................. 81 Chase Lock/Unlock ............................................................................ 81 Ink Tray Lock/Unlock ......................................................................... 81 Print Retract/Extend ........................................................................... 82 ISOPrint Retract/Extend ..................................................................... 82 Flood Extend/Retract ......................................................................... 83 Panel Tension On/Off ........................................................................ 83 Squeegee, Flood, Printing Positions: ................................................ 84 Squeegee JOG Shuttle JOG: ............................................................ 84 Timers ................................................................................................. 84 Edit ...................................................................................................... 84 Positions and Timers .......................................................................... 85 Traveling Frame ................................................................................. 85 

Panel Height ............................................................................................ 85 Flood Speed ............................................................................................ 86 Print Speed .............................................................................................. 86 Traveling Frame Speed .......................................................................... 86 

Service Motors .................................................................................... 87 Squeegee Servo 5 ................................................................................. 89 Shuttle Servo 6 X -Axis .......................................................................... 91 Panel Height Servo 7 .............................................................................. 93 

Door Interlock ..................................................................................... 95 Light Curtain ....................................................................................... 95 Emergency Stop ................................................................................. 96 Servo Error Code ............................................................................... 96 Servo Alarm ........................................................................................ 96 

- V -

ALARMS DISPLAY .................................................................. 96 

Alarm History ........................................................................................... 98 

COATER SET-UP ................................................................... 98 

QUICK START ........................................................................ 99 

ADJUSTING PANEL HEIGHT .................................................. 101 

SCREEN FRAMES ................................................................ 101 

Installation of Screen Frames .......................................................... 101 Registration of Print Window ........................................................... 102 Stretching Screen Frames ............................................................... 102 

Screen Mesh Selection ......................................................................... 102 Screen Frame Types ............................................................................ 103 Screen Tension ..................................................................................... 104 Stretching Screens ................................................................................ 105 

Defining the Print Window ............................................................... 107 Blockout Material ................................................................................... 110 

Direct Emulsion .............................................................................................. 110 Blockout .......................................................................................................... 110 Direct/Indirect Emulsion ................................................................................. 110 Physical Barrier .............................................................................................. 110 

The Print Window .................................................................................. 111 

PRINT HEAD SET-UP............................................................ 111 

Theory of Operation ......................................................................... 111 Squeegee Angle and Pressure ............................................................ 111 Squeegee pressure and length vs. ink-deposit thickness ................... 112 

Quick set-up ...................................................................................... 112 Initial set-up ....................................................................................... 113 

Floating Squeegee Set-Up ................................................................... 114 Flood Bar Retract Limit ......................................................................... 115 Flood Bar Lower Limit ........................................................................... 115 

Printing in Automatic Modes ............................................................ 116 Aligning Squeegee Head - New style Swing Arm .......................... 116 

SERVICE MOTORS .............................................................. 120 

Inputs ................................................................................................ 120 Outputs ............................................................................................. 122 

Timing Belt Maintenance and Replacement ........................................ 123 Lead Screw Lubrication ........................................................................ 125 Vertical Linear Bearing Rod Lubrication ............................................... 125 Squeegee Head Lubrication ................................................................. 125 Shuttle timing Belt ................................................................................. 126 Squeegee Head .................................................................................... 126 

VERTICAL TRANSPORT SCREEN (ROBOT) .................... 128 

Robot Towers ................................................................................... 130 

HC-340 HANGING OVEN ..................................................... 134 

- VI -

UNLOADER .......................................................................... 138 

MAINTENANCE CHECKLIST .............................................. 149 

SERVICE SCREENS .............................................................. 157 

Coater Servo Submenus ................................................................. 157 Frame motor .......................................................................................... 157 Upper rail motor ..................................................................................... 157 Squeegee motor ................................................................................... 157 Motor troubleshooting: .......................................................................... 157 Interlocks and E-stops........................................................................... 157 

Coater Inputs/Outputs ...................................................................... 157 Chase .................................................................................................... 157 Front/Rear squeegee arm .................................................................... 158 Clamps .................................................................................................. 158 

Loader Inputs/Outputs ..................................................................... 158 Loader Servo Submenu ................................................................... 159 

Centering arm ........................................................................................ 159 Robot Input/Output ........................................................................... 159 

8 (In/out) motor. ..................................................................................... 159 Robot Servos .................................................................................... 159 

APPENDIX B – ALARMS & ERROR CODES ..................... 160 

FATAL ALARMS .................................................................... 160 

ERROR CODES .................................................................... 161 

SERVO AMPLIFIER ERRORS ................................................. 161 

SPARE PARTS ..................................................................... 162 

- VII -

TABLE OF FIGURES

  Figure 1 DP6000 V2 Automation Printing Machine .......................................................................... 3   Figure 2 DP6000 V2 Layout Drawing ............................................................................................... 7   Figure 3 Adjust feet to same length before installing them ................................................................ 8   Figure 4 Oven Leveling feet ............................................................................................................... 9   Figure 5 Oven and Unloader leveling feet ......................................................................................... 9   Figure 6: Level machine Y direction ............................................................................................... 10   Figure 7 Level Machine in X direction ............................................................................................. 11   Figure 8 Connect the robot frame to the Coater .............................................................................. 12   Figure 9 Robot to Coater Attachment Points .................................................................................. 12   Figure 10 Top View VTS connection to Oven .................................................................................. 13   Figure 11 Inside View Robot to Oven ............................................................................................. 13   Figure 12 Unloader connection to Oven Frame .............................................................................. 14   Figure 13 Oven frame to unloader frame connection points (2 places) ........................................... 14   Figure 13 Infeed Loader Section ...................................................................................................... 17   Figure 15 Movable pendant controller HMI touch screen ............................................................... 18   Figure 16 Master Reset on MMI ...................................................................................................... 19   Figure 17 Oven Reset on cabinet ..................................................................................................... 19   Figure 18 Coater Pneumatics ........................................................................................................... 21   Figure 19 Ink Pump connection and Coater Pneumatic Regulator .................................................. 21   Figure 20 ITV Regulator .................................................................................................................. 22   Figure 21 ITV Input Screens ............................................................................................................ 23   Figure 22 VTS Panel release Switch ................................................................................................ 24   Figure 24 foot switch ........................................................................................................................ 25   Figure 25 Main Screen ..................................................................................................................... 26   Figure 26 DP6000 subsystems in standby mode ............................................................................. 26   Figure 27 DP6000 subsystems in "operate" mode ........................................................................... 26   Figure 28 Main Coater Screen ......................................................................................................... 27   Figure 29 Safety System in Run Mode .............................................................................................. 27   Figure 30 Safety System Screen ........................................................................................................ 28   Figure 31 Resets Doors and E Stops ................................................................................................ 29   Figure 32 Loader Servos #3, #4 and #5 ........................................................................................... 30   Figure 33 Servo # 3 Centering ......................................................................................................... 31   Figure 34 Autoloader set points and offsets ..................................................................................... 32   Figure 35 Board clear Sensor .......................................................................................................... 33   Figure 36 Panel Guard .................................................................................................................... 33   Figure 37 Roller Assembly Front View ........................................................................................... 34   Figure 38 Dual Sensors on each arm ............................................................................................... 34   Figure 39 Chain tensioner ................................................................................................................ 34   Figure 40 Servo 2 Roller Setup ........................................................................................................ 35   Figure 41 Output Screen ................................................................................................................ 36   Figure 42 Output 2 ........................................................................................................................... 37   Figure 43 Loader Input Screen ....................................................................................................... 37   Figure 44 Loader Input 2 ................................................................................................................. 38   Figure 44 Second Pinch Roller Assembly ........................................................................................ 39   Figure 45 Vacuum Box 2nd Pinch .................................................................................................... 39   Figure 46 Vacuum Box Servo #4 Setup ............................................................................................ 40 

- VIII -

  Figure 47 Edge Sensor and pinch roller assemblies ........................................................................ 41   Figure 48 Mechanical Gripper ......................................................................................................... 42   Figure 49 Loader Electrical Pneumatic Cabinet ............................................................................ 43   Figure 50 Vacuum box home position .............................................................................................. 44   Figure 51 Panel properly held in vacuum box system ...................................................................... 44   Figure 52 Vacuum box system at load position ................................................................................ 45   Figure 53 Load cylinder for vacuum box assembly .......................................................................... 45   Figure 54 Home Sensors .................................................................................................................. 46   Figure 55 Servo # 4 Rotate Vacuum Box .......................................................................................... 47   Figure 55 Vacuum Box loading into clamps .................................................................................... 48   Figure 56 Coating Chamber............................................................................................................. 49   Figure 26: HMI ................................................................................................................................ 50   Figure 57: Electrical Cabinet ........................................................................................................... 50   Figure 58 Pneumatic Cabinet .......................................................................................................... 50   Figure 59: Footswitch ...................................................................................................................... 51   Figure 60: Footswitch attachment point ......................................................................................... 51   Figure 61: QC Lever, handle and swing arm .................................................................................. 52   Figure 62: Swing Arm Print Assembly ............................................................................................ 52   Figure 64 Ink trough attachment point on Drip tray ........................................................................ 53   Figure 63: Drip Tray, Ink Trough .................................................................................................... 53   Figure 65: Ink trough attachment studs / 5/16 -18 special nuts ...................................................... 53   Figure 66: Attached to drip tray ...................................................................................................... 53   Figure 67: Chase lock clip .............................................................................................................. 54   Figure 68: Chase Lock Cylinders .................................................................................................... 54   Figure 69: Chase Alignment Knob ................................................................................................... 55   Figure 70: Chase height knob ......................................................................................................... 55   Figure 71: Print Head ..................................................................................................................... 56   Figure 72: Pneumatic docking station ............................................................................................ 56   Figure 73: Squeegee Assembly ........................................................................................................ 57   Figure 74: 635mm and 660 mm squeegees ..................................................................................... 57   Figure 74 Main Coater Screen Run Mode ....................................................................................... 58   Figure 75: UPS unit ........................................................................................................................ 59   Figure 76 Master Reset .................................................................................................................... 59   Figure 77: Main Screen HMI ........................................................................................................... 60   Figure 78 DP2500 V4.5 Pneumatic System ..................................................................................... 61   Figure 79: ITV Electro Mechanical Regulators .............................................................................. 62   Figure 80: Internal Regulators ......................................................................................................... 63   Figure 81 Skew Cylinders Front View............................................................................................. 64   Figure 82: Ink Reservoir Holders .................................................................................................... 64   Figure 83 Bottom Clamp .................................................................................................................. 64   Figure 84 Top Clamp ....................................................................................................................... 65   Figure 85: Chase Lock Cylinder ..................................................................................................... 65   Figure 85 Machine in Reset Condition ............................................................................................. 66   Figure 96 Main Screen in Operation / Run condition ...................................................................... 67   Figure 86 Machine Modes ............................................................................................................... 71   Figure 87: Flood Choices Main Screen .......................................................................................... 72   Figure 88 Options ............................................................................................................................ 73   Figure 89 Recipe Setup .................................................................................................................... 77   Figure 90: Recipe ............................................................................................................................ 78   Figure 91: Are You Sure? ................................................................................................................. 78   Figure 92: Complete Recipe Screen ................................................................................................. 79   Figure 93: Squeegee Positions ......................................................................................................... 80 

- IX -

  Figure 94: Print Squeegees Extended ............................................................................................. 82   Figure 95 Flood Assy ....................................................................................................................... 83   Figure 96: Panel Tensioner Right .................................................................................................... 83   Figure 97: Panel Tensioner Left ...................................................................................................... 83   Figure 98 Position and timers ......................................................................................................... 85   Figure 99: Main Coater Menu ....................................................................................................... 87   Figure 100 Coater Servos ................................................................................................................ 88   Figure 99 Resets Main Menu............................................................................................................ 88   Figure 3 Resets Main Menu.............................................................................................................. 89   Figure 56: Service Coater Motor screen servo screen .................................................................... 89   Figure 101 Servo #5 Squeegee Drive ............................................................................................... 90   Figure 102 Servo #5 ......................................................................................................................... 91   Figure 103 Shuttle over travel .......................................................................................................... 91   Figure 104 Shuttle Servo #6 ............................................................................................................. 92   Figure 106 Servo # 6 Set up ............................................................................................................. 92   Figure 107 Servo #6 Advance .......................................................................................................... 93   Figure 108 Servo #7 Panel Height ................................................................................................... 93   Figure 109: Servo 7 Panel Height Motor and Gear ........................................................................ 94   Figure 110 Servo #7 Panel Height ................................................................................................... 95   Figure: 111: Alarm Display ............................................................................................................. 97   Figure 113: Stretch mesh at 22.5° ................................................................................................. 104   Figure 114 Tension measurement points ....................................................................................... 105   Figure 115: Tension is lower in the corners ................................................................................. 106   Figure 116: Install screen to mark print window .......................................................................... 108   Figure 117: Window in Screen Mesh ............................................................................................ 108   Figure 118: Blockout screen ......................................................................................................... 109   Figure 119 Coated panel showing clear border area ................................................... 109   Figure 120 Dynamic squeegee pressure ........................................................................................ 111   Figure 121: Flood bar retract limit ............................................................................................... 115   Figure 122: New Swing Arm ......................................................................................................... 116   Figure 123: Adjustable Print Platen ............................................................................................. 117   Figure 124 Aligning Ring .............................................................................................................. 117   Figure 125 Level Blocks ................................................................................................................ 118   Figure 125 Belt Tension Release .................................................................................................... 118   Figure 127 Squeegee Head Level ................................................................................................... 118   Figure 128 Squeegee Head Level ................................................................................................... 119   Figure 129 Head to Head Level ..................................................................................................... 119   Figure 130 Servo Screens .............................................................................................................. 120   Figure 131: Inputs .......................................................................................................................... 121   Figure 132 Output .......................................................................................................................... 122   Figure 133 Output 2 ...................................................................................................................... 123   Figure 134 Timing Belt Drive System ............................................................................................ 124   Figure 135 Bearing Block .............................................................................................................. 125   Figure 136 Shuttle Belt tension ..................................................................................................... 126   Figure 137: Squeegee Alignment ................................................................................................... 127   Figure 139 Main Screen ................................................................................................................. 128   Figure 140 Robot Main Set up screen ............................................................................................ 129   Figure 141 Servo 8 Set up Screen .................................................................................................. 130   Figure 141 robot Towers ................................................................................................................ 131   Figure 142 Finger Gripper Assy with sensors .............................................................................. 131   Figure 143 Panel in Robot system ................................................................................................. 132  ............................................................................................................................................................. 132 

- X -

  Figure 144 Robot unloading a Panel ............................................................................................. 132   Figure 145 Servo 10 and 11 Set up screen ..................................................................................... 133   Figure 146 Panel Buffer Station Assy ............................................................................................ 133   Figure 147 Panel at exit ................................................................................................................ 134   Figure 148 Oven Control Sub Panel .............................................................................................. 135   Figure 147 Panel Clip Opener ....................................................................................................... 135   Figure 165 Clip Opener ................................................................................................................. 136   Figure 148 Oven Drive Motor ........................................................................................................ 137   Figure 149 Unloader Cooling ........................................................................................................ 137   Figure 150 Oven exhaust ................................................................................................................ 138   Figure 152 Servo 12 Unloader Set up screen ................................................................................. 139   Figure 153 Servo #12 Advanced Set up .......................................................................................... 140   Figure 154 Servo #12 Unload arm lifter ........................................................................................ 141   Figure 155 Panel approaching Unload arms ................................................................................. 142   Figure 156 Unload sensors and hooks ........................................................................................... 143   Figure 157 Seven Belt Unload Conveyor ....................................................................................... 143   Figure 158 Board Clear Sensors .................................................................................................... 144   Figure 159 Belt Tensioner .............................................................................................................. 145   Figure 160 Unloader Motor and Speed Control ............................................................................ 145   Figure 161 Center Belt tensioner .................................................................................................. 146   Figure 162 AC Unloader Motor Speed control and belt tension .................................................... 146   Figure 163 Redesigned Unloader arm .......................................................................................... 147   Figure 164 Connection box for Unloader ...................................................................................... 147   Figure 165 Redesigned exit end for the unloader. .......................................................................... 148 

- - 1

TABLE OF LAYOUT DRAWINGS DRAWING NUMBER DESCRIPTION

451-004 Autoloader

11-6376 Assembly, Second Pinch Roller, Autoloader 11-8588 Assembly, Board Grip, Autoloader 11-8633 Assembly, Pinch Roller, Autoloader 11-8750 Assembly, Pendant Arm Mount MMI Autoloader 11-8792 Assembly, Infeed Roller, Autoloader 11-9121 Assembly, Doors and Covers 11-9282 Assembly, Centering Device, Autoloader 11-9583 Assembly, Pump, Filter and Gate Valves 11-9631 Assembly, Rotate, Autoloader 11-9633 Assembly, Large Vacuum Box, East, Autoloader 11-9640 Assembly, Vacuum Box Sub Assy (sub of 11-9644) 11-9644 Assembly, Small Vacuum Box, West, Autoloader 11-9645 Assembly, Drive Vacuum Box

DPS-2500-V4.4 DP-6000 Coater 11-6114 Assembly, Squeegee Head, ISO print, Coater 11-7123 Assembly, Quick Release Flood Mount (sub of 11-7501) 11-7129 Assembly, Block, Squeegee Drive, NE, Coater 11-7130 Assembly, Block, Squeegee Drive, NW, Coater 11-7131 Assembly, Block, Squeegee Drive, SE, Coater 11-7132 Assembly, Block, Squeegee Drive, SW, Coater 11-7178 Assembly, Ink Reservoir Arm, W, Coater 11-7179 Assembly, Ink Reservoir Arm, E, Coater 11-7180 Assembly, Bottom Plate, Coater 11-7501 Assembly, Squeegee Tube ISO West, Coater 11-8630 Assembly, Drive Traveling Frame, Coater 11-8631 ` Assembly, Motor, Squeegee Drive, Coater 11-8774 Assembly, Traveling Frame, Coater 11-9173 Assembly, Belt Tensioner 11-9305 Assembly, Doors and Covers, Coater 11-9308 Assembly, Frame Components 11-9396 Assembly, Squeegee Drive, ISO Print 11-9563 Assembly, Clamp, Upper, Coater 11-9564 Assembly, Clamp, Lower, Coater 11-9572 Assembly, Flood Bar Control, metric (sub of 7501) 11-9709 Assembly, Top Plate, Coater

- - 2

470-004 Transport System VTS 11-6490 Assembly, Cable Carriers, Horizontal Drive, VTS 11-8922 Assembly, Doors and Covers, VTS Transport System 11-8994 Assembly, Screw Drive Width Adjust VTS 11-9025 Assembly, Horizontal Drive, Slide Back Transport System VTS 11-9065 Assembly, Left Arm Vertical Drive, VTS 11-9066 Assembly, Right Arm Vertical Drive, VTS 11-9070 Assembly, Lower Right Finder, VTS 11-9071 Assembly, Lower Left Finger, VTS 11-9072 Assembly, Upper Right Finger VTS 11-9073 Assembly, Upper Left Finger VTS 11-9085 Assembly, Cable Carrier, Vertical, VTS 11-9189 Assembly, Limit Switch Width Adjust 11-9643 Assembly, Horizontal Drive, Transport System VTS

HCS-340-V4.50 System Oven 11-5470 Assembly, Heater wiring 11-7091 Assembly, Chain with Clips, Oven 11-8536 Assembly, Covers, Upper Hood, Unloader Side 11-8563 Assembly, Alignment, Clip Holder, Oven 11-8585 Assembly, Elevator, Oven 11-9205 Assembly, Access Door (sub of 11-9317) 11-9297 Assembly, Heater 11-9317 Assembly, Chassis, Doors and Cover, Oven 11-9318 Assembly, Chain Drive, Upper Infeed, Oven 11-9319 Assembly, Chain Drive, Upper Outfeed, Oven 11-9320 Assembly, Conveyor 38mm centers 11-9594 Assembly, Clip Opener, Oven 11-9607 Assembly, Fan Housing (sub of 11-9317)

HC-340-UNL-V4.3 Unloader Oven 11-9286 Assembly, Motor Drive, Unloader (sub of 11-9446) 11-9419 Assembly, Frame, Covers, Unloader 11-9446 Assembly, Belt Drive Conveyor, Unloader 11-9449 Assembly, Main Drive, Flat Belt Conveyor (sub of 11-9446) 11-9450 Assembly, Main Drive, Center Belt (sub of 11-9446) 11-9486 Assembly, Arm Rotate, Unloader 11-9501 Assembly, Grabber, Unloader, Oven (sub of 11-9486) 11-9627 Assembly, Screw Drive Arm Rotate, Unloader 11-9628 Assembly, Screw Drive Limit Switch, Unloader (sub of 11-9627)

- - 3

INTRODUCTION The DP6000 V2 coating and drying system is the ideal choice for automated coating and drying of liquid photoimageable soldermask. The DP6000 family is specifically designed for thin printed circuit boards. DP6000s may be used to apply all types of liquid photoimageable inks including soldermask, primary image, dielectric, and legend as well as laser ablated dielectrics. These versatile machines are used all over the world in a variety of applications. The guidelines presented in this manual come from years of experience in coating panels. This manual is intended as a training and reference source for anyone who operates and/or maintains the Circuit Automation DP6000 V2 Automatic coating and drying systems. It gives the correct procedures for the installation, start-up, operation, and shutdown of the DP6000 V2. Also included are pictures, diagrams, and reference information to assist operators and maintenance personnel in completing their work safely and efficiently. Keep it on hand and use it for reference whenever you are working with the DP6000 V2.

Figure 1 DP6000 V2 Automation Printing Machine

- - 4

WARRANTY Circuit Automation warrants that all products sold shall be free from defects in workmanship and material when used within the service and scope for which they were designed. Such warranty shall apply for a period of two years after shipment of the product. If, at any time within this period it is determined that the product was defective at time of shipment, Circuit Automation, at its option, shall furnish replacements or repair the product. It is understood that the liability of Circuit Automation shall be limited to such repair or replacement and that Circuit Automation shall not be liable for any direct or consequential damages arising out of any defects or from any cause whatsoever. This warranty does not cover deterioration from normal wear and tear.

Neither the DP6000 V2 nor any part thereof should be returned to Circuit Automation without written authorization from Circuit Automation.

This warranty is effective only under the condition that the DP6000 V2 system is installed in accordance with Circuit Automation specifications.

Additionally the warranty is null and void if the coater is abused or operated contrary to the instructions, or if alterations or major repairs are made by other than authorized Circuit Automation representatives or by written permission from Circuit Automation.

Notwithstanding the above and regardless of the circumstance Circuit Automation’s total liability for all claims, losses, or damages arising out of any cause whatsoever shall not exceed the purchase price of the equipment. In no event shall Circuit Automation be liable for any incidental or consequential damages, whether arising from contract, negligence, strict liability, or warranty.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTY OF MERCHANTABLITY OR FITNESS FOR A PARTICULAR PURPOSE.

CONVENTIONS In this manual, left and right always refer to orientations facing the machine. The “front” of the DP6000 V2 is the side one faces when loading panels into the in feed conveyor. The other side is the “back”. When a specific switch or control is referred to, it will appear in emphasis font, e.g., MODE. The specific position of a switch will be italicized, e.g., Flood Only.

- - 5

SUPPORT EQUIPMENT

The productivity of the DP6000 V2 system can be enhanced by utilizing automated loading and unloading equipment. Your Circuit Automation representative can make recommendations as to the type of ancillary equipment best suited for a particular application.

Ink Pumps

The automatic ink pump will pump directly from one, five or 25 kg containers and replenish the coater’s ink reservoirs. The IP-08 model features two pumps. One pump fills front ink trough, while the second pump fills the rear ink trough. (See the ink pump manual for specific operational details.

- - 6

INSTALLATION

Planning before you receive your system will allow you to set up the machine and have it operating in the shortest possible time.

WORK AREA The work area should be equipped with yellow safe lights to meet photoimageable ink specifications. Dust air conditioning and humidity control measures will reduce coating defects from contamination and enhance the results obtained from the coating process.

Although the DP6000 V2 is equipped with levelers, the work area should be as level as possible. Surfaces that are not level may result in future difficulties.

Certain minimal clearance must be maintained for safe operation and service of the coater. This includes adequate walk-around space and room for the electrical, air pressure, and ventilation lines to be installed.

FLOOR PLAN Layouts are included in the Drawings section of this manual. Please refer to these drawings when planning the installation of the DP6000 V2.

The plan view shows the footprint of the DP6000 V2. Locate the DP6000 V2 so that there is at least four feet (1.2 meters) of clear area around all sides, and so that there are no obstructions to walking completely around the machine. Note the swing radii of the doors and the QC arms of the coating heads. Enough room needs to be included to allow these to be fully opened without interference.

Note the height of oven and check that adequate clearance exists between the ceiling and the top of the oven to permit access to exhaust duct points of connection and the installation of control dampers. A minimum of two feet (610mm) is recommended.

Refer to the utility layout in the Drawings section. The DP6000 V2 requires three-phase power and has 2 electrical points of connection, 230V and 380-400-480V. Multiple points of connection for the oven exhaust and coater ventilation can be attached to a single manifold with control dampers installed on each drop to modulate and balance airflow. A suggested duct plan is shown in the drawings section. There is one point of connection for compressed air supply, which must be clean, dry, and oil-free.

- - 7

Figure 2 DP6000 V2 Layout Drawing

UNLOADING AND UNPACKING The DP6000 V2 system modules are shipped bolted to wood pallets, wrapped in bubble pack and stretch wrap. Accessories and small parts are wrapped separately and packed inside the modules in cardboard boxes or wrapped and banded on separate pallets. Machines shipped via ocean freight will be containerized and vacuum packed. Machines shipped via airfreight will be crated. Care should be taken using knives or similar tools when removing packaging so as not to damage the finish of the equipment.

A forklift capable of lifting 10000 lbs. (4545 kg) and having forks spaced at least 72” apart (1.8m) will be needed to move and set the equipment. Fork extensions at least 60” (1.5m) are helpful to lift and position the modules.

To remove the modules from the skids, open the lower access doors or remove the side panels as required to reach the shipping bolts. Remove the nuts securing the module to the studs at each corner of the skid.

Once the studs are removed, one may lift the module from its skid. Each module has a rigid steel frame that allows it to be moved with a forklift. Position the blades of the forklift as far apart as practical. The individual modules do not necessarily have symmetrical weight distribution. A broad base ensures the lifting and moving of the equipment is done safely.

- - 8

After lifting a module from the wooden skid, install the adjustable leveling feet. The machine may now be moved into the installation location.

CAUTION: MODULES HAVE HIGH CENTERS OF GRAVITY AND MAY HAVE ASYMMETRICAL

WEIGHT DISTRIBUTION. USE CARE WHEN REMOVING A MODULE FROM THE SKID AND MOVING

IT INTO POSITION.

NOTE: Before installing the leveling feet adjust the bottom nuts so that all feet are the same length.

Figure 3 Adjust feet to same length before installing them

This system utilizes several different leveling feet on each of the various subsystems.

- - 9

Figure 4 Oven Leveling feet

Figure 5 Oven and Unloader leveling feet

- - 10

INSTALLATION Examine each module carefully for damage and remove all other securing and packing materials. It is suggested that the installation plan be laid out on the floor using tape or chalk lines to assist in accurate placement.

If possible, the oven should be set first and smaller modules moved to match its position. Adjust the feet of the oven so that the distance from the bottom of the pad to the top of the nut is 4.0” (100mm) above the floor. If the oven is too high, one may not be able to match it up with other modules. Check that the oven is level and adjust feet as required.

Figure 6: Level machine Y direction

Level Y direction

- - 11

Figure 7 Level Machine in X direction

This system is a modular system but for wiring convenience and installation ease, many parts are pre-assembled at the factory. The machine is pre-assembled into five main components. The Coating Section and the Autoloader Section are shipped as one unit. The Robot is separate. The HC Series Oven is shipped as a unit. The HCS-Unloader is detachable from the end of the oven. Ink Pumps are packaged as standalone units.

The Autoloader and Coater module need to be attached to the Robot and Oven Module. This is accomplished by firstly assembling all the leveling feet on the machines with the recommend 4” (100mm) spacing from the bottom of the pad to the top of the height nut. The Robot unit is pushed into the load end of the oven should be pushed together and bolted together. Level the coater. Confirm that the coater is level by placing a machinist's level at the center of the ground steel plate that forms the base of the coating section. Bolt the coater to the robot frame. Attach the pneumatic supply line and electrical interconnects between the coater, Robot, and oven. Remove split collars from the Thompson shafts of the coater.

Level in X direction on main base plate.

- - 12

Figure 8 Connect the robot frame to the Coater

Bolt the bottom section together in two places as shown in the above picture.

To bolt the top section together, utilize two M10 bolts to firmly attach the top of the VTS unit to the Coater frame.

Figure 9 Robot to Coater Attachment Points

Connect the unloader to the back of the oven. The unloader frame has tabs that attach to the oven frame in the same manner as the robot, however, it is necessary to have the feet adjusted to as short a position as possible in order to allow the unloader to be low enough to fit under the oven hood. Once located under the hood raise the unloader to match the hood height, move the unloader over so that the tabs are over the oven frame

M10 bolts Two Places

- - 13

and adjust the feet accordingly. Check level and attach the unloader frame to the oven. Attach the alarm beacon to the top of the oven control panel.

Figure 10 Top View VTS connection to Oven

Figure 11 Inside View Robot to Oven

- - 14

Figure 12 Unloader connection to Oven Frame

The Top of the Unloader frame is then bolted to the Unload section of the HC-340 Oven frame. Securely bolt both sides as shown below.

Figure 13 Oven frame to unloader frame connection points (2 places)

This system utilizes a central power drop to the center electrical panel attached to the oven. The oven module is wired for 380-400V, 3, 150A, 50Hz

CAUTION: A SURGE SUPPRESSOR AND UPS SYSTEM IS SUPPLIED TO PROTECT THE PLC

FROM POWER SURGES AND ELECTRICAL SPIKES.

M8 1.20 bolts – 2 places

M8 125 bolts two places

- - 15

Before connecting power to the DP6000 V2, ensure that ON/OFF switches (located on the control panels) are Off and that the CIRCUIT BREAKERS (located on the electrical cabinets) are Off (turn fully counterclockwise).

There are two Pneumatic points of connection. The first is on the right hand side of the coater module. The DP6000 V2 requires 10 cfm @ 100 psi (12 m³/hr @ 7 bar) compressed air. The compressed air connection is required. The second pneumatic connection is at side of the oven electrical panel. The Oven connection requires 20 cfm @ 100psi (24 m 3/hr @ 7bar).

CAUTION: INCOMING AIR SHOULD BE CLEAN AND DRY. UNDER NO CIRCUMSTANCES SHOULD

AN OILER BE INSTALLED IN THE INCOMING LINE.

DP6000 V2 must be vented for operator safety and comfort. Two eight inch (203mm) round outlets and three six inch (152mm) round outlets and one 5 inch (127mm) are provided. Connect to building exhaust with galvanized ducting. A minimum of 250 cfm (425 m3/hr) per drop for a total of 1250 cfm (2125 m3/hr) is recommended. It is the exhaust from the vacuum blower on the panel loader should be vented as well. .

NOTE: The coater exhaust is normally drawn only through the vent above the load/unload station. When a coating chamber door is opened, a pneumatic cylinder opens a slide gate damper to direct exhaust flow to the coating chamber.

CAUTION: KEEP EXHAUST DUCT CONNECTED AT ALL TIMES TO THE EXHAUST FAN. CONTINUOUS INHALATION OF SOLVENT FUMES MAY BE HARMFUL. VENT TO BUILDING

EXHAUST SYSTEM OR DIRECTLY OUTDOORS. DO NOT VENT WHERE FUMES MAY BE PICKED UP

BY BUILDING HVAC SYSTEM.

After completing the utilities hook-up, turn power on to the DP6000 V2 by turning the CIRCUIT BREAKERS On. The PLC and servo amplifier LED indicators will illuminate to indicate power to the machine.

- - 16

AN OVERVIEW OF THE DP6000 V2 The DP6000 V2 is a fully automatic double-sided coating and drying machine. The DP6000 V2 version of the DP6000 system adds an additional feature to the field proven DP6000 Systems.

This coater may be used with many screen printable inks. The DP6000 V2 is very easy to use, featuring the ISOprint System for cleaning the screens, QC (Quick Change) Technology for rapid changeover of ink and screens, and a touch-screen MMI (man-machine interface). The in-feed conveyor has a centering device that automatically detects the width of the panels being loaded. An automatic ink pumping system feeds ink as it is consumed into the coating chamber.

At the start of a coating, cycle a panel is placed on the in-feed conveyor. The panel is transported inwards and the conveyor stops when the panel is detected in the middle of the centering device. The centering fences move the panel to the center of the conveyor and square it with respect to the direction of transport. The panel moves forward between two pinch rollers, stops and finds the front edge of the panel. The panel is then moved forward. A second Tensioning Pinch Roller creates backpressure to control the rate of infeed over the vacuum boxes. The front vacuum box grips the panel and pulls it forward. The rear vacuum box grips the trailing end of the panel and the two boxes move in tandem, tensioning the panel between them to the load position.

The loader pivots 90 degrees and places the panel in the tensioning transport. The tensioning transport’s top and bottom clamps grip the panel and apply tension. The loader releases the panel, withdraws and returns to the horizontal position. The tensioning transport runs into the coating chamber. The coating routine is executed and the tensioning transport runs back to the load/unload “home” position. The VTS (Vertical Transfer Unit) Robo transfer unit grips the edges of the panel, applies tension, and the tensioning transport clamps release the panel. The VTS removes the panel from the traveling Frame, and inserts the panel in the oven elevator buffer. When the SupraConveyor clamps are in position, pneumatic driven wedges open the clamps and the elevator places the panel in the clamps. The robot fingers allow the clamps to close and grip the panel and the panel is transported through the oven.

The DP6000 V2 has many modules: the auto load in-feed conveyor, centering device, loader, the coating chamber, the VTS panel transfer module, one panel buffer, the SupraConveyor tack-dry oven, and the oven unloader. In addition, the IP08 ink pump is controlled by the DP6000 V2 to deliver ink to the coating chamber automatically.

- - 17

Figure 13 Infeed Loader Section

- - 18

CONTROLS Controls include:

An ON/OFF switch, located on the control panel suspended from a pendant.

Five EMERGENCY STOP pushbuttons

A TOUCH SCREEN MMI also located in the control panel.

Pneumatic controls

There are other controls, described below, that are not used in the routine operation of the machine.

Figure 15 Movable pendant controller HMI touch screen

On/Off

ON/OFF controls the electrical power to the touch screen. In the Off position, the screen will not illuminate; however, the HMI is wired directly to the CIRCUIT BREAKER in the electrical cabinet and is powered as long as CIRCUIT BREAKER is On. In the On position, the electrical and pneumatic functions operate. Select On or Off by

Emergency Stop

Touchscreen HMI

System Reset Push Button

System ON/OFF

- - 19

rotating the ON/OFF switch. If the electrical and pneumatic systems do not function with ON/OFF On, check that an EMERGENCY STOP has not been activated and that the CIRCUIT BREAKER is On.

Emergency Stop

EMERGENCY STOP interrupts the electrical and pneumatic systems. To operate, depress the pushbutton. To restart after EMERGENCY STOP has been pressed, rotate the pushbutton clockwise until it releases. There are eight EMERGENCY STOPS: one on the control panel, two next to the robot section doors, two on the electrical panel on the coater, one on the Oven Control panel and two on either side of the in-feed conveyor. If EMERGENCY STOP has been activated while the machine is in an automatic MODE, the machine must be reset to return to an operational condition.

There are two zones for the resets. The coater zone is reset by the Master reset button located on the MMI. The 9 oven and unloader E stops can be reset by the Oven Reset located on the Oven Electrical cabinet

The reset sequence, from the coater display, is: RESET. Then choose a MODE

Reset

RESET allows the machine to continue after a Safety Interlock has been broken. To operate, depress the pushbutton. This unit has three Master Resets. On the HMI, one on the Oven Electrical box and one on the Coater Electrical Cabinet.

Touch screen

Figure 16 Master Reset on MMI Figure 17 Oven Reset on cabinet

- - 20

The touch screen MMI controls the entire system

These displays can be selected and viewed by pressing the corresponding button at the bottom of the screen. In addition, there is a logo start-up screen. The logo screen appears when the DP6000 V2 is first powered up. When touched the logo screen disappears and the Menu display appears.

CAUTON: DO NOT USE BENZENE, PAINT THINNER, OTHER VOLATILE SOLVENTS, OR

CHEMICALLY TREATED CLOTHS TO CLEAN THE TOUCHSCREEN.

Each display has various submenus. MAIN MENU is the display used to select printing modes, set up the coating parameters, and operates the DP6000 V2 routinely. COATER is the screen displayed during normal operations. LOADER and ROBO are used to monitor and troubleshoot these modules. Submenus permit manual control. OVEN is used to monitor oven status and to interrupt panel loading to permit inspection of coated product.

A detailed overview of the displays and their use is presented in the next section, Touch screen MMI.

- - 21

Pneumatic Controls

Figure 18 Coater Pneumatics

A pneumatic cabinet contains the air pressure regulators and the solenoid valves that modulate and control air flow to the air cylinders of the machine. There are two types of regulators in the pneumatic cabinet: the ITVs; which can be addressed and adjusted via the touch screen controls, and conventional regulators; which must be set manually. The conventional regulators have LCD displays and the ITVs have red LED displays. The conventional regulators are set at the factory to the proper air pressure. These

settings do not normally require adjustment.

Figure 19 Ink Pump connection and Coater Pneumatic Regulator

- - 22

In addition to the regulators in the pneumatic cabinet, an additional regulator is located beneath the electrical panel. This regulator modulates the air supply to the IP08 automatic ink pump. This regulator is factory set and does not require adjustment. The ink pump is equipped with its own regulator. To adjust air pressure to the IP08, use the ink pump regulator.

CAUTION: DO NOT ADJUST THE INK PUMP AIR SUPPLY REGULATOR. HIGH AIR PRESSURE

TO THE INK PUMP CAN RESULT IN HIGH PRESSURE INK SUPPLY AND RUPTURE INK TUBING.

REGULATOR CALIBRATION

The ITVs and digital regulators are solid state devices and do not normally require calibration. Their accuracy may be checked with a mechanical gauge if desired. Each ITV has a gauge port that is plugged by a hex key screw. Remove the plug to measure regulated pressure. The digital regulators are mounted on a hinged panel. Remove the two hex key cap screws at the top corners of the panel and open the panel downwards. The pneumatic tubing can then be removed from the outlet of the regulator and a pressure gauge attached. If a regulator or ITV proves to be inaccurate, contact the factory for instructions.

Figure 20 ITV Regulator

- - 23

Figure 21 ITV Input Screens

Other Controls

The DP6000 V2 has several other control devices that are not used in routine machine operations. These devices are the disconnect switch, the foot switches, and the PANEL button.

- - 24

BOARD REVIEW

Figure 22 VTS Panel release Switch

The Panel Release switch is located on the Robot housing. It releases a panel from the grip of the Robot system. This switch is found near the Coater on the side of the Robot. When the switch is lighted, (after pressing the switch) by depressing the foot switch, the panel will release from the Oven Buffer station. When the light is lit, the buffer station will not load the panel into the oven. When the review is finished, push the bottom and load the panel back into the buffer for baking.

FOOT SWITCHES

There are two-foot switches. One is located on the right-hand side of the coater and one on the left side of the Loader.

Panel Release

CAUTION: Manually removing a panel from an automatic system can create pinch point safety hazards. This system is to be utilized with great care by qualified, thoroughly trained personnel.

- - 25

Figure 24 foot switch

In the event that a cycle is interrupted, one may have to remove panels from the machine manually. To remove a panel first the SCREEN SET UP mode. When the panel is in the coating chamber, open the Front Swing Arm, the one can then grasp the panel being held by the robot or the coater, and depress the appropriate foot switch to release the panel into ones’ hand.

TOUCHSCREEN MMI A touch screen MMI (man-machine interface) located on a pendant is used to control the loading, coating, and transfer modules, drying and unloading, or the entire system. The IP08 ink pump also has separate On/Off controls that allow its operation when not slaved to the DP6000 V2.

The DP6000 V2 MMI has seven primary screens and a number of submenus that can be accessed from the main screens. The primary screens correspond to the major machine modules:

Main Screen Main Coater Menu Recipe Set up Squeegee Positions Resets Service Alarms System Status

- - 26

Main Screen

Figure 25 Main Screen

The DP6000 V2 HMI control panel features a new all-encompassing screen indicating the general condition of the machine and its status and availability. This status screen gives a visual indication of the interlocks, and critical functions of the various subsections of the unit.

Each sub unit: Autoloader, Coater, Robot, Oven and Unloader have separate switches to enable each device. The oven has three separate controls for each of the subsystem in the oven.

Figure 26 DP6000 subsystems in standby mode

Subsystems in Standby or OFF position

Figure 27 DP6000 subsystems in "operate" mode

E Stops and Light curtain status stop/go

- - 27

Each of the sub unit: Autoloader, Coater, Robot, Oven, and Unloader have set up screens and troubleshooting screens attached to them. By pressing on the touch screen on the device that you need to access, the sub screens will appear.

Main Coater Screen

Figure 28 Main Coater Screen

System Status Menu

Figure 29 Safety System in Run Mode

The DP6000 has two modes. A RUN MODE SAFE which is a Safe Condition where the machine will Operate and a Safety Mode where one of the predescribe conditions prevent safe operation. Items like doors opened breaking the interlocks

- - 28

or E-Stops pushed will put the machine into a Safe Mode. By Pressing the System Status screen you will bring up the Safety Sub Menu. This screen shows the status of the monitored functions.

Figure 30 Safety System Screen

All Green lights indicate safe and ready condition. A red light indicates a device that needs attention. Pressing the Master Reset on the MMI is used to reset these devices.

The Door E-Stops screens give a visual indication of the door system and E-stops.

This screen is broken into the various components on the system: Loader, Coater, Robo, Unloader which contains Servo Driven Motors and is controlled Mecatrol links and device net communications. Each Servo is listed by number (referenced in the electrical prints) and gives a status:

SVON Servo ON/OFF to the unit

STATUS Code various codes for different conditions.

Device Net Nodes controlling functions

Critical Position of certain cylinders and switches

- - 29

Figure 31 Resets Doors and E Stops

All Green lights indicate safe conditions for operation, while Red lights indicate a condition that needs attention. From the RESETS screen touching the device in question will bring up the SUB MENUS for each device.

AUTOLOADER The Automatic loader incorporated into the machine serves many functions and consists of different parts:

1. Centering Device Servo #3

2. Roller Assembly Servo #2

3. Vacuum box Assy Servo #4

4. Vacuum Box Rotate Servo #1

5. Mechanical Grippers

6. Panel Loader

- - 30

Auto Loader Servo Main Set Up Screen

Figure 32 Loader Servos #3, #4 and #5

This screen is the detailed set up for the three adjustable settings for the Autoloader mechanism. This allows for adjustment for the Centering Device, Vacuum loader and Lift mechanism. Each of these servos also have a corresponding detailed screen that covers additional parameters such as accel or decell settings, Speed rates, etc.

CENTERING SERVO # 3

The Centering device is designed to Center the panels that are being fed into the system. The DP6000 panel throughput is based on the panels entering the unit centered. Because the machine can accept a variety of widths and thickness panels considerable flexibility needed to be designed into this unit. DP6000s require that you tell the machine what the width of the panels will be. It is critically important that the panels be square and consistent with their dimensions. The machine will not reliability load without the panels ± .5mm of the specified dimension.

- - 31

Figure 33 Servo # 3 Centering

- - 32

CENTERING SERVO # 3

Figure 34 Autoloader set points and offsets

The DP6000 offers unprecedented access to adjustment and offsets to allow the machine to do a wide variety of panel sizes and types. Touching the desired setting will allow a different number to be entered.

- - 33

The centering device set up screen allows for critical parameters to be set. The Dithering distance is the distance where the centering arms will start to “jog” and release a panel. This motion of pressure and relaxation has proven an effective way to center very thin panels, and slick S polished surfaces. The Offset value is the value that the device will release the panel to allow it to be transferred by the rollers into the next station.

When a Mode is selected and the Start Cycle switch is selected, the rollers on the machine will rotate and will allow a panel to be loaded.

After a panel activates the panel sensor, the guard rises up to prevent additional panels from entering the loader until the panel has been successfully loaded into the traveling frame on the coater.

The Centering device gently centers each panel. Each side of the centering device has two sensors, one for course adjustment, the second for fine. The device will “dither” the sheet to nudge it into a centerline position

for machine loading.

The Stainless Steel rollers are tensioned by a Nylatron bushing that is spring loaded to add tension to the chain drive. The Chain is #35 roller chain.

After centering, the panel is then released to travel into the vacuum loading section of the machine. The panel then enters a series of pinch and tension rollers. These drive the panel onto the vacuum section and pretension.

Figure 35 Board clear Sensor

Figure 36 Panel Guard

- - 34

Figure 37 Roller Assembly Front View

Roller assembly is driven by a motor and gear.

Large Vacuum box

Figure 38 Dual Sensors on each arm

Figure 39 Chain tensioner

- - 35

Autoloader Roller Setup

Figure 40 Servo 2 Roller Setup

The Roller motor utilizes a 200 Watt servo motor with a gear box. This controller allows for a motor release and a jog switch to allow for forward or reverse movement. There is no “home” position or reset position for this device.

- - 36

Autoloader Outputs

The PLC Outputs detailed on two screens along with their addresses and visual indicators as to their current status.

Figure 41 Output Screen

- - 37

Figure 42 Output 2

Autoloader Input Screens

The inputs to the PLC are listed on these two screens. A green light on the far right indicates that the input is made.

Indicates active input

Figure 43 Loader Input Screen

- - 38

SECOND PINCH ROLLER PEEL OFF

A SECOND PINCH ROLLER ALLOWS the machine to back pressure thin panels to insure that they load properly into the vacuum box assembly. The back pressure amount is controlled in the Recipe Function.

Figure 44 Loader Input 2

- - 39

Figure 44 Second Pinch Roller Assembly

Figure 45 Vacuum Box 2nd Pinch

- - 40

The Pinch rollers drive the sheet. Several important functions happen at this point:

1) The tri-angulations sensors find the edge of the sheet.

2) The pinch rollers propel the sheet onto the vacuum platen

3) The 2nd pinch roller system adds backpressure to keep the sheet loading uniform.

Servo # 4 Vacuum Box Set up

Figure 46 Vacuum Box Servo #4 Setup

- - 41

Figure 47 Edge Sensor and pinch roller assemblies

The vacuum box loading system is designed to expand to the size of the sheet being loaded into the printer. Upon initial set up of the machine the panel, height is loaded into the machine. The panel height adjustment adjusts the size of the panel clamps also the distance that the panel will travel onto the vacuum boxes.

The pinch rollers drive the edge of the panel into the edge sensors. The servo then backs the panel up until the panel breaks the beam. This aligns the edge of the panel and allows the machine to precisely load the panel. The panel then proceeds forward unto the home position of the two vacuum boxes. When the panel arrives at the proper position on the second vacuum box, the vacuum engages. In addition, on the second vacuum box the secondary vacuum engages along with the 2nd pinch roller. The secondary vacuum and the 2nd pinch roller are designed to add tension to the panels. The lead screw on first vacuum box expands to the predetermined distance pulling the panel along with it. When the panel arrives at the final destination, then the primary vacuum engages on the second vacuum box. In addition, the servo adds some slight tension to the panel to keep it from drooping.

The overhang distance on both the leading edge and trailing edge of the panel is critical for some applications. These distances are adjustable via the MMI on the Advanced Set up Screen.

Tri-angulations Sheet Edge sensor

Pinch Drive Roller

2nd Pinch roller Assy

Vacuum box loading assembly

- - 42

Mechanical Grip

MECHANICAL GRIP ACTIVATES the function during loading a clamp attaches to the panel to assist the vacuum to hold the panel in place. The grips need to be manually adjusted to the panel width before activation.

Figure 48 Mechanical Gripper

- - 43

Figure 49 Loader Electrical Pneumatic Cabinet

Secondary Vacuum System

Pressure adjustment for 2nd vacuum

- - 44

Figure 50 Vacuum box home position

Figure 51 Panel properly held in vacuum box system

The system then rotates up and places the panel into the clamps on the traveling frame. There are a series of flow control, pressure regulators, springs and shock absorbers to adjust and modify the load position into the clamps.

- - 45

Figure 52 Vacuum box system at load position

The entire load mechanism is actuated by a pneumatic cylinder that transports the Vacuum load system into the clamps of the coating machine.

Figure 53 Load cylinder for vacuum box assembly

Adjustable position Control

- - 46

The product is then placed into the clamps on the Traveling frame. The clamps hold and tension the product. The traveling frame is the transport device that moves the product into and out of the coating chamber.

The clamps in the traveling frame are positioned via a servo motor control from the set up screen on the MMI. The dimension of the panel is typed into the PLC. The program in the PLC automatically offsets the set point for the distance to be gripped by the clamps. The amount of gripping can be adjusted via an advanced set up screen on the coater.

The tension that the machine uses to dewarp each panel is also adjustable at the machine level.

Figure 54 Home Sensors

Small vacuum box Home sensor switch

Small vacuum box Decel Sensor

Large Vacuum box Home Sensor

i h

- - 47

Servo #4 Vacuum Box Rotate

Figure 55 Servo # 4 Rotate Vacuum Box

- - 48

Figure 55 Vacuum Box loading into clamps

Traveling frame

Upper panel clamp

Lower panel clamp

- - 49

COATER MAIN MENU The coating chamber consists of front and back print heads, the drive and support system for the print heads, and the screens. When the operator loads a board and a cycle is started, the circuit board moves to the center of the coating section. In the flood/print mode, the screens close and the print heads flood the screens on the upward stroke. The print heads stop, reverse direction, and print the circuit board on the downward stroke. (In the No Flood Mode, the flood bar will carry the ink to the top of the screen where the ink is deposited for the squeegee to push down on the squeegee stroke.) The board returns to the load station. Other print modes may be selected to print twice, with or without a second flooding of the screen.

Figure 56 Coating Chamber

CONTROL PANEL The control panel features a touch screen HMI that allows selection and control of all manual and automatic operations of the DP6000. Additional controls on the control panel are an EMERGENCY STOP, a LIGHT SWITCH and an ON/OFF switch.

- - 50

ELECTRICAL CABINET The electrical Cabinet locates the three servo motor controls; the PLC’s and the various connectors required to power and control the machine. The cabinet is wired to be compliant with applicable CE directives.

PNEUMATIC CABINET

The pneumatic cabinet houses the solenoid valves that activate the pneumatic actuators. It also houses controls and regulators that do not usually require adjustment.

Figure 26: HMI

Figure 57: Electrical Cabinet

Figure 58 Pneumatic Cabinet

- - 51

CONTROLS AND ADJUSTMENTS LOAD/UNLOAD STATION

Traveling Frame Panel Transport

The Traveling Frame Panel Transport system carries panels in and out of the coating chamber. Panels are held at the top and bottom by clamps. The panel clamps are opened and closed by using the FOOTSWITCH. The FOOTSWITCH is plugged into the side of the machine. Yellow illuminated CLAMP SELECTOR pushbuttons select and indicate which clamp is controlled by the FOOTSWITCH.

NOTE: In rigid panel mode both clamps are opened and closed simultaneously by the FOOTSWITCH.

Figure 59: Footswitch

Foot Switch ATTACHMENT point

Figure 60: Footswitch attachment point

- - 52

COATING CHAMBER QC Swing Arm

The print head QC (Quick Change) swing arm is held in place by the QC Lever. Lift the lever to allow the print head arm to pivot outwards. This allows access to the print head and removal of the screen chases.

The QC (Quick Change) swing arm supports the flood bar and print head. The flood bar mounts on a rail and held in place by tightening two large knurled knobs. The flood bar is slotted and slides into place. The print head is supported by the print head mounting platen. The air cylinders below the platen are used to tilt it when the SKEW function is activated.

Figure 61: QC Lever, handle and swing arm

Figure 62: Swing Arm Print Assembly

- - 53

Ink Reservoir

The ink reservoir and drip pan are mounted on a separate swing arm below the print head QC swing arm. This swing arm is held in place with the reservoir lock cylinder. The ink reservoir is held on the swing arm by two M8 serrated flange hex nuts. The swing arm is slotted to permit the studs on the underside of the reservoir to slide on without removing the flange nuts. Ink troughs come either with or without welded on tubes depending on whether they are used with or without the automatic IP-08 Ink Pump. When using the ink pump route plastic tubing through the guide clip provided.

The Ink trough attaches to the drip tray trough the keyed assembly. A 13mm wrench is required to

tighten the two M8 nut. Care in assembly is required to position the feed tube for the IP-08 Ink Pump to the outside.

Figure 64 Ink trough attachment point on Drip tray

Figure 63: Drip Tray, Ink Trough

Figure 65: Ink trough attachment studs / 5/16 -18 special nuts

Figure 66: Attached to drip tray

- - 54

Chase Lock Clips

The screens are held in place at the top by the chase lock clips located on the CHASE OPEN/CLOSE cylinders. These clips are designed to be swiveled out of the way to remove the chase. The clips are also reversible to accommodate frames of differing thickness. By reversing the clip, one can use either stretch-and-glue or self-tensioning style screen chases.

Figure 67: Chase lock clip

Chase Lock Cylinders

The chase lock cylinders hold the chase in position during operation.

Figure 68: Chase Lock Cylinders

- - 55

Chase Alignment Knob

Figure 69: Chase Alignment Knob

The chase alignment knob allows the chase to be offset to the right or left. It is used to assist in lateral alignment of the print window of the screen with the panel to be coated. Each machine has an adjustment for each side of the screen frame.

Chase Height Knobs

Figure 70: Chase height knob

The chase height knobs elevate or lower either corner of the chase. In this way one can raise, lower, or rotate the screen print window to accurately align with the panel to be coated. The Chase Height will allow independent movement of 10mm on all four corners of each screen frame.

- - 56

Print Head

The print heads are secured to platens by two spring-loaded bolts topped by knurled knobs. The bolts and two pins on the inside of the platen locate the print heads accurately. To remove the print head, turn the machine main ON/OFF to Off. Unscrew the compressed air manifold locking knobs, and pull the connector from the head. A blind flange with locking knobs is provided for storage of the dismounted manifold. Loosen the print head by unscrewing the two large knurled knobs on the top of the print head. Slide the print head back, and then lift it up and out to remove it. Reverse the procedure to replace the print head, taking care to slide the print head onto the locating pins before tightening the knurled knobs. Seat the air connection firmly and secure the air connector knobs.

Figure 71: Print Head

Figure 72: Pneumatic docking station

- - 57

SQUEEGEES

The print and ISOprint squeegees are each secured to the print head with three M6 nuts. . To install the squeegee, place squeegee on the studs extending from the Print Head and secure with hex nuts using a 10mm box-end wrench. The print squeegee with the square edge is mounted on the lower bar. 50mm X 10mm at 70-75 durometer is standard. The ISOprint squeegee is a special beveled edge rubber of 70 durometer and is mounted on the upper bar. Squeegee angle may be adjusted by loosening the M6 bolts on the squeegee bar clamps.

The squeegee rubber is clamped between the two halves of the squeegee assembly. To replace the squeegee rubber, loosen the bolts that hold the two halves of the squeegee blade holder together. Remove the rubber. Insert new rubber and seat it carefully in the squeegee blade holder. Tighten the bolts.

Figure 73: Squeegee Assembly

Figure 74: 635mm and 660 mm squeegees

- - 58

MAIN COATER CONTROLS

Figure 74 Main Coater Screen Run Mode

Exterior Controls include:

The main ON/OFF switch, located on the control panel controls HMI screen.

A TOUCH SCREEN HMI also located in the control panel.

A FOOTSWITCH functions as a clamp open/close switch.

Seven EMERGENCY STOP pushbuttons. On the Control Panel, on the electrical panel front and rear, on the oven, near the unloader

A CIRCUIT DISCONNECT on the electrical cabinet.

Power On/Off. Master Reset.

- - 59

UPS

The PLC is wired directly to the UPS uninterrupted power supply and CIRCUIT

DISCONNECT on the electrical cabinet and is powered as long as CIRCUIT DISCONNECT is On. Since, by specification, the PLC is wired to a UPS system supplying PLC even shutting off the power to the machine will not inhibit the PLC from operation. To

reboot the PLC requires shutting off the UPS to the PLC pushing the OFF button on the unit from the UPS. The UPS unit is located under the load section of the machine. In the On position, the electrical and pneumatic functions operate. Select On or Off by rotating the ON/OFF switch. If the electrical and pneumatic systems do not function with ON/OFF On, check that an EMERGENCY STOP has not been activated and that the CIRCUIT DISCONNECT is On. MASTER RESET is used to clear a safety related fault. Hold the button to clear the fault and reactivate the machine.

Emergency Stop

EMERGENCY STOP turns off the electrical power to the servo motor and pneumatic systems. To operate, depress the pushbutton. To restart after EMERGENCY STOP has been pressed, rotate the pushbutton clockwise until it releases. There are three

Figure 75: UPS unit

Figure 76 Master Reset

- - 60

EMERGENCY STOPS: one on the control panel and two next to the coating section doors located on the electrical cabinet of the DP6000. If EMERGENCY STOP has been activated while the machine is in an automatic MODE, the machine must be reset via the MASTER RESET to return to an operational condition. If the LIGHT CURTAIN stops the machine, the machine must be MASTER RESET TO return to an operational condition. If one of the five doors is opened, the Master Reset must be pushed. If the Main On/OFF switch is turned to the OFF Position, or the Main Disconnect is turned to OFF then the Master Reset needs to be active. The reset sequence is: hold the MASTER RESET BUTTON UNTIL THE MACHINE CLEARS.

Touch screen

The touch screen has many screens to enable the machine to operate and be serviced properly.

Figure 77: Main Screen HMI

These displays can be selected and viewed by pressing the corresponding button at the bottom of the screen. In addition, there is a logo start-up screen. The logo screen appears when the DP6000 is first powered up. When touched the logo screen disappears and the Menu display appears.

- - 61

NOTE: An after-image will remain if the same patterns are displayed continuously for extended periods of time (e. g., 24 hours). A screen saver will blank the screen after approximately two hours of inactivity. Touching the screen will restore the display.

CAUTON: DO NOT USE BENZENE, PAINT THINNER, OTHER VOLATILE SOLVENTS, OR

CHEMICALLY TREATED CLOTHS TO CLEAN THE TOUCHSCREEN.

MENU is the display used to select various printing modes and is the screen displayed during normal operations. RECIPE is used to view, select, and create pre-programmed coating routines. SETUP is used when configuring the machine for a new job. SERVO STATUS, SERVICE, and ALARMS are used for machine maintenance and servicing.

A detailed overview of the displays and their use is presented in the next section.

PNEUMATIC CABINET The pneumatic cabinet contains the electro pneumatic digital regulators and the solenoid valves that control the air cylinders of the machine. Two types of

Figure 78 DP2500 V4.5 Pneumatic System

- - 62

regulators are housed within the cabinet. The ITVs, which are digital proportional controllers, can be addressed and adjusted via the touch screen controls. The electro pneumatic regulators must be set and adjusted manually. The electro pneumatic regulators are set at the factory and do not normally require adjustment.

Regulator Calibration

The ITVs and digital regulators are solid state devices and do not normally require calibration. Their accuracy may be checked with a mechanical gauge if desired.

Figure 79: ITV Electro Mechanical Regulators

Each ITV has a gauge port, which is plugged by a hex key screw. Remove the plug to measure regulated pressure. The digital regulators are mounted on a hinged panel. Remove the two hex key cap screws at the top corners of the panel and open the panel downwards. The pneumatic tubing can then be removed from the outlet of the regulator and a pressure gauge attached. If a regulator or ITV proves to be inaccurate, contact the factory for instructions.

- - 63

ITV FUNCTIONS

ITV 1 Flood Controls the pressure for the Extend Pressure to the Flood Cylinders and SV (Solenoid Valve) #1

ITV 2 ISO Print Controls the pressure for the Retract Pressure to the ISO Cylinders both front and rear and SV (Solenoid Valve) #6

ITV 3 Front Print Controls the pressure for the Retract Pressure to the Front Print Cylinder and SV (Solenoid Valve) # 5

ITV 4 Rear Print Controls the pressure from the Retract Pressure to the Rear Print Cylinders and SV (Solenoid Valve) #5

ITV 5 Chase Open Controls the Extend Pressure and opening pressure to the Chase Open Cylinders and SV (Solenoid Valve) #9

ITV 6 Panel Tension Controls the pressure for the Extend stroke pressure Cylinders and SV (Solenoid Valve) # 14.

Internal Pneumatic Regulators

TILT LEFT SV # 2 Cylinder on the Swing Arm used to Skew or Tilt the Squeegee Head.

Figure 80: Internal Regulators

- - 64

TILT RIGHT SV # 3 Cylinder on the Swing Arm used to inhibit movement of Skew or Tilt the Squeegee Head. Also engages to hold the Squeegee Head Level.

Figure 81 Skew Cylinders Front View

INK RES SV # 8 Cylinders on the base plate utilized to hold the Ink Reservoir in place.

Figure 82: Ink Reservoir Holders

TOP HOLDER SV # 10 cylinder on the Top Clamp located on the traveling frame utilized to close the clamp on the panel.

BOTTOM HOLDER SV # 11 cylinder on the Bottom Clamp located on the traveling frame utilized to close the clamp on the panel.

TOP CLAMP SV # 12 cylinders on the Top Clamp located on the Traveling Fame/Shuttle utilized to lock the panel in place.

SV 2SV 3

SV 8

Figure 83 Bottom Clamp

Front View

Shown with cover removed

- - 65

BOTTOM CLAMP SV # 13 cylinder on the Bottom Clamp located on the Traveling Frame/Shuttle utilized to lock the panel in place.

CHASE LOCK SV #4

These cylinders hold the screen chase in place yet have enough give for the screen frames to open and close in order for the traveling frame to move into and out of the coating chamber. Recommended maximum pressure is 4 bar (60 psi).

SV 12

SV 10

Figure 85: Chase Lock Cylinder

Figure 84 Top Clamp

Chase lock cylinder

- - 66

Touch screen HMI

The touch screen HMI, has many screen displays used in the control, setup, and troubleshooting of the DP2500. There is also a startup display, a screen saver (blank

Menu Display screen) and displays for advanced setup and control applications.

Figure 85 Machine in Reset Condition

COLOR CODED OPERATIONAL SCHEME

Incorporated into the HMI Touch screen is a series of Color Codes to indicate the machine Status. We have adopted three colors to help the operator know the status of the machine they are:

YELLOW RESET CONDITION

GREEN OPERATIONAL / RUN CONDITION

BLUE MANUAL MODE.

Reset Condition Indicator

- - 67

Figure 96 Main Screen in Operation / Run condition

GREEN OPERATIONAL / RUN CONDITION

Machine is ready operational. In this example the FPP (Flood Print Print) program has been selected along with various print and function options.

. BLUE MANUAL MODE.

The machine is set to Manual Mode which allows the Machine Mechanical Functions to Operate on the SETUP SCREEN. See Set up for more details on their

Machine in Operational /Run Condition

- - 68

START / STOP

NOTE: START will not operate if a MODE is not enabled.

Stop: Pressing ► will halt the machine. Pressing ║ will allow the machine to continue as before. If the interlocks have been broken

after Stop has been pressed, then a MASTER RESET must be cleared first, then START can be pressed to reactive the machine and continue to run.

Machine in Manual Mode

- - 69

Reset

RESET returns the machine to a ready position after automatic operation of the DP6000 has been interrupted by activation of EMERGENCY STOP, STOP, door interlock or the Light Curtain. First the MASTER RESET ON THE CONTROL PANEL

MUST CLEAR THE MACHINE. When RESET is an orange light blinking it must be pressed. The print heads will return to the bottom or home position with squeegees and flood bars retracted. The traveling frame will move to the board load/unload area. PROPER SEQUENCE: MASTER

RESET, RESET MODE

Mode

Any of four automatic printing modes may be selected. When the START button is pushed, a circuit board is moved into the coating chamber and the screen flooded. The flood bar retracts and the squeegee is positioned to begin a print stroke. The DP6000 floods with the print head moving from the bottom position upward and prints on the downward stroke. (In the No Flood Mode or Flood Down Mode the ink bar will carry the ink to the top of the screen. There the ink is deposited and pushed down the screen by the downward squeegee print stroke.

Action then is governed by which mode has been selected:

FLOOD/PRINT (FP)

The squeegee extends, prints on the down stroke, and retracts. The circuit board is unloaded.

FLOOD/PRINT/PRINT (FPP)

The squeegee extends, prints on the down stroke, retracts, returns to the upper position without a second flood cycle, prints a second time, and retracts. The circuit board is unloaded.

- - 70

DOUBLE PRINT (FPFP)

The squeegee extends, prints on the down stroke, and retracts. The flood bar extends, floods the screen on an upward stroke, retracts, and the squeegee positions for printing. The squeegee extends, prints a second time, and retracts. The circuit board is unloaded.

Select a mode by depressing the button corresponding to the desired mode. When selected, the button will change from light blue to green. Selection of the proper print mode depends on the ink used, the circuit geometry and height, the screen mesh, and the result desired.

TRIPLE PRINT (FPFPP)

The squeegee extends, prints on the down stroke, and retracts. The flood bar extends, floods the screen on an upward stroke, retracts, and the squeegee positions for printing. The squeegee extends, prints a second time, and retracts. The print head returns to the upper position, prints a third time without flooding, and retracts. The circuit board is unloaded.

- - 71

Display Information

Figure 86 Machine Modes

READY

The Ready screen indicates that all conditions in the machine are OK and the machine is waiting for a command.

Running

The Running screen gives a written description of that machine is in operation and performing tasks.

Resetting

The Resetting screen indicates that the machine is in the process of resetting devices and systems to their home positions.

Manual

The Manual screen indicates that the machine is in a setup position where it responds to specific commands.

Machine MODES READY

RUNNING RESETTING

MANUAL

- - 72

Errors and Alarms.

The Error screen gives a written description of the machine faults in operation highlighting the function that is happening and suggest solutions for the errors.

Figure 87: Flood Choices Main Screen

FLOOD

Flooding is the action of applying soldermask ink to a screen mesh. This machine has three different settings for flooding the screen. The normal, default flooding sequence is to flood the machine on the Flood Up stroke from the squeegee mechanism. The machine will also carry ink to the top of the panel and Flood Down. The Flood Down method of ink application has been effective in reducing the amount of ink that is pushed into holes on the panels. Flood Down also slightly reduces the amount of ink that will cover the surface of the traces compared to

Three Flood Choices

Flood Only

Status Action

Alarms and Errors

- - 73

the default Flood Up method. The third method of Flooding is called No Flood. No Flood will scoop ink from the ink trough and carry the ink to the flood stop position then deposit all the ink on the top of the screen prior to the squeegees engaging.

When START is pressed and Flood Mode (Normal) or Flood Up is enabled the flood bar extends and the print head moves to the upper position, flooding the screen. The flood bar retracts and the print head returns to the lower position. The traveling frame functions are not enabled when in Flood mode. To continue printing after the Flood cycle has been completed select another automatic mode, load a board into the machine and press START / Reset to begin coating.

Flood Pressure must be set via the ITV pressure regulator found on the Setup mode or in the Recipe modes.

FLOOD ONLY

Flood Only mode is the standard flood mode uses the flood bar to pick up the ink at the ink trough and spread the ink upward, flooding the screen. The head then reverses direction and returns to the Home or Flood Start Position.

This mode is effective for wetting the screen prior to breaks or lags in production. Many soldermask inks tend to dry out and keeping the screen wetted has proven to be an effective way to reduce screen sticking on subsequent work.

Options

Any of nine options may be enabled to improve coating quality or machine operation. The BLUE screen (switches) indicates the OFF position while the GREEN SCREEN (switches) indicates the ON choice of options enabled will depend upon the coating being applied and the panel being coated.

FLOODS

Flood choices were discussed earlier.

NOTE: Flood only always utilizes a Flood UP mode and ignores any Flood setting for standard printing routines

Figure 88 Options

- - 74

ISOPRINT

ISOprint is a dual squeegee stroke cycle to remove the ink that remains on the back of the screen, for example, over holes or slots. ISOprinting forces the residual ink back to the front side of the screen, where it is combined into the next flood stroke.

This system utilizes a second set of squeegee blades to redistribute the ink on the proper side of the screen for printing. The two squeegees press the screens together and wipe the screens without a panel in between them to wipe the ink back to the front side of the screen. The system can be easily engaged or disengaged depending on the types of panels being produced or the soldermask characteristics. ISOprint is enabled when the ISOPRINT switch is green.

The recommended angle for the ISOprint squeegee is 37.5. We recommend that 70 durometer squeegees with "V" bevels be used.

SKEW CCW AND SKEW CS

SKEW CCW and SKEW CW enable the squeegee to tilt or skew to the printing direction, and in which direction. When disabled, the squeegees will be perpendicular to the print direction. With Skew CCW enabled squeegees will tilt counter clockwise on the first print stroke and then tilt clock wise on the remaining stroke if there is a second print stroke.

In general, coverage on high traces is improved if one of these options is enabled. In Flood/Print/Print (FPP) or Double Print (FPFPP), the initial direction is usually irrelevant, but if only one print stroke is used, then there may be a preference for skew CW or skew CCW due to the geometry of the circuits.

SKEW CW AND STRAIGHT

SKEW CW and STRAIGHT enable the squeegee to tilt or skew to the printing direction, and in which direction. When disabled, the squeegees will be perpendicular to the print direction. With Skew CW enabled squeegees will tilt clockwise on the first print stroke and then hold the print head perpendicular on the remaining stroke if there is a second print stroke.

In general, coverage on high traces is improved if one of these options is enabled. In Flood/Print/Print (FPP) or Double Print (FPFPP), the initial direction is usually irrelevant, but if only one print stroke is used, then there may be a preference for skew CW or skew CCW due to the geometry of the circuits.

INK PUMP

INK PUMP Activates the ink pump to fill the ink troughs. Pumping routines may be selected for each recipe.

- - 75

JOG

JOG activates the jogging function during automatic operation enabled. The BLUE screen (switch) indicates the OFF position while the GREEN SCREEN (switch) indicates the ON position. The Jog function moves the panel the preselected

distance between successive panels when coating a series of panels without and E-Stop. E-stop will reset the sequence. The jog setting is predetermined in mm with a range of 0-12mm. If the function is deselected then the panel is placed in the same position in the coating chamber on each panel.

PEEL OFF

PEEL OFF allows the screen chases to open during a print stroke. The Peel Off function helps the screens to snap off cleanly from the panel when printing. It is useful when printing very thin panels or to compensate for less than optimal conditions such as warped boards, loose screens, or sticky inks. If Peel Off is disabled the screen chases will not open until the automatic coating routine has been completed.

THE PEEL OFF pressure is set via the touch screen utilizing the ITV 4.

SHUFFLE

SHUFFLE activates the shuffle function during automatic operation enabled. The Shuffle function moves the panel the preselected distance between successive print strokes on an individual panel. The distance is set in 1mm increments.

Status

A small icon below the legend Status indicates if an alarm condition exists by blinking red. A steady green color indicates the ready state. The icon must be steady green in order to operate the coater.

Counter Reset

Pressing and holding the TODAY total button resets the daily run counter on the display

Indicator of Jog set distance. Adjustment is made in Setup or Recipe Menu

Indicator of SHUFFLE set distance. Adjustment is made in Setup or Recipe

- - 76

Miscellaneous

In addition to the daily counter there is the total counter, which displays the total number of cycles and position indication of jog, frame travel, and panel height (top rail) adjustments.

Ink Fill

Pressing the INK FILL button sends the squeegee arm assembly up to the 500mm point without engaging the flooding or ISO print or printing functions. This allows an operator to add additional ink to the ink troughs or adjust the screen frames. Release of the screen frames or adjustment of the heights is accomplished through the MANUAL Mode on the screen.

Passwords

This program is PASSWORD protected on several different levels utilizing several passwords. The machine is shipped with the passwords installed. A Certified Circuit Automation Installation representative will share the appropriate passwords with the designated Representative of the customer. Changing password is possible and the customer will be trained for the procedure.

SETUP AND RECIPE The setup screen is used when configuring the machine to process a particular job. It enables all machine parameters to be configured. Allows an operator to check the set up parameters prior to machine operation. This screen allows the Setup menu to be saved as a Recipe.

Total panels Panels today

Average Cycle time

Critical Present values (PV)

Ink Fill

- - 77

This screen shows the current setup on the left side of the screen along with 10

Recipes listed on the right side of the screen. Each recipe list two features of that particular recipe. For example, Recipe #1 is a FPP (Flood/Print/Print) routine set for panels that are 310mm high. By touching any of the recipes, then the particular recipe will illuminate in more detail.

Figure 89 Recipe Setup

Main Menu Screen Displays the Current Recipe Recipe #10

- - 78

Figure 90: Recipe

To Change the Recipe name or title by touching the number to edit and bring up the Keyboard. Type in the desired new name or number. Press Enter. The machine will ask you if you are sure? At this point you can either accept or reject.

There is also an UNDO button that allows you to cancel the entire edit.

Figure 91: Are You Sure?

- - 79

Figure 92: Complete Recipe Screen

Touching any parameter will allow the operator to set each position. Several switches, like Panel Height and Shuttle indicate both a Set Value (SV) and a Present Value (PV) to help with orientation and set up. There are buttons to allow one to SAVE TO RECIPIE or TRANSFER TO SETUP OR UNDO. With the model DP6000 V4.5 all the machine variable functions are now able to be saved into a Recipe.

- - 80

SQUEEGEE POSITIONS The machine has many offsets to allow for different set ups, operations and conditions. It is possible to adjust speeds, settings and conditions from the touch screen. The Squeegee Positions screen allows the operator to monitor and adjust the machine controls. It has two different methods for adjustment. One can TEACH the machine. I.e. this means to manually position the machine to the desired location and the press TEACH for 2 seconds. This will change the set position. Or one can enter the number directly into the screen.

Squeegee Flood Printing Positions

Mechanical Machine Functions

Timer Readout

Servo Movement

Figure 93: Squeegee Positions

- - 81

Squeegee Position Screen Defined

Machine Mechanical Functions are mechanisms within the DP2500 that activate the specific features depicted in the adjacent picture.

Machine Mechanical Functions:

The default position is for each of these machine functions are to be in the GREEN condition. The GREEN condition is the default condition for automatic operation of the machine. The RED condition is an adjustment setting or cleaning position. The machine functions for each of these seven conditions are defined earlier in this manual.

Chase Open/Close

In any automatic mode the CHASE OPEN/CLOSE air cylinders (located at the top of the chases) operate automatically. During the Flood/Print functions, the cylinders will be in the Closed position, except when Peel Off is selected during board transport into or out of the coating area, the cylinders will be in the Open position. You can open or close these cylinders with this button.

Chase Lock/Unlock

The screen chases are held in place at the bottom by four pneumatic cylinders. CHASE LOCK controls these cylinders. In the Unlock position, the cylinders are retracted and the chase can be inserted or removed. In the Lock position, the cylinders extend to lock the chase in place.

NOTE: The CHASE LOCK also enables or disables the compressed air supply to the CHASE

OPEN/CLOSE air cylinders. Without the CHASE LOCK in the Lock position, the CHASE

OPEN/CLOSE function will have no compressed air and the cylinders (located at the top of the chases) will allow the chases to float. Therefore, you can easily pull or push the cylinder open when changing screen chases.

Ink Tray Lock/Unlock

INK TRAY activates the clamping device that locks the ink reservoir trough against the screen chase. The ink reservoir needs to be Locked for the machine to operate. While in the Unlocked position the soldermask holding troughs may be filled, serviced or removed.

- - 82

Print Retract/Extend

PRINT Extend/Retract is used to extend or retract the printing squeegees. It may be used to position the squeegees to print in manual operation. Extend puts the squeegees in contact with the screen.

Figure 94: Print Squeegees Extended

CAUTION: ALWAYS POSITION THE SQUEEGEE IN THE RETRACT POSITION WHEN NOT IN

USE WHEN IN MANUAL MODE.

ISOPrint Retract/Extend

ISOPRINT Extend/Retract is used to extend or retract the ISOprint squeegees. It may be used to position the squeegees to print in manual operation. Extend puts the squeegees in contact with the screen.

- - 83

CAUTION: ALWAYS POSITION THE ISO SQUEEGEE IN THE RETRACT POSITION WHEN NOT

IN USE WHEN IN MANUAL MODE.

Flood Extend/Retract

Flood Extend / Retract activates the Flood Bar to Extend or Retract. The Flood bar applies the soldermask ink to the screen frame. The Flood mechanism has a hard stop and also a series of flow controls used to smooth out the application of the ink and also to reduce leakage of the ink after application.

Panel Tension On/Off

PANEL TENSION ON / OFF ACTIVATES the two panel tensioning cylinders to TENSION OR DETENSION The panel while it is in the traveling frame. The Panel Tension pressure is controlled by ITV controls and is measured in bar. An increase in bar will tighten the panel more. CAUTION: The DP2500 is designed to handle and print a

wide variety of panel sizes, thickness and constructions. The entire pressure range of this mechanism is not suited for all panel types and configurations. Care must be taken as to not exceed the maximum tension required that any given panel design. Over tension can result in damage to the substrates while under tension can lead to printing and processing problems.

Figure 96: Panel Tensioner Right Figure 97: Panel Tensioner Left

Figure 95 Flood Assy

- - 84

Squeegee, Flood, Printing Positions:

These positions are required for the DP6000 to coat panels utilizing all the printing functions. The Default Position has been defined in the software and in most cases is relative to the Panel Height setting for the machine. The User Offset is a defined movement from the Default Position that a user may adjust the machine position. The Offsets allow the machine to compensate for various options and settings that a customer may have that would affect the printing functions on the machine. For example the machine allows for a changeable squeegee angle on the printing head. This could require an adjustment to adapt the machine to different squeegee angle which in effect is a different starting and stopping position.

The GO function has the squeegee arm travel to the defined position.

The TEACH function allows one to JOG the servo to the proper position then have the machine “remember” the position.

Squeegee JOG Shuttle JOG:

These JOG allow one to move the position of the Squeegee or the Shuttle to various positions for either testing parameters or in order to teach the machine.

Timers

These Timers allow one to delay certain movements of the machine or of pneumatic components. The Timer screen may be accessed by holding down the DEFAULT POSITION accessing the password log in and correctly entering the password.

Edit

The PUSHING the desired data brings up the popup keypad to enable one to change parameters. ENTER loads the new parameters. (X) will CLOSE AND will hide the popup keypad.

- - 85

Positions and Timers

The machine has many offsets and timers. This screen allows the user to control all aspects of the machine operation. Password assigned at installation of machine.

Traveling Frame

To simplify set up the frame can be moved in and out of the coating chamber from the setup display. FRAME ALLOWS THE OPERATOR TO ENTER A FRAME DISTANCE

VALUE AND THEN CHECKS to see if the panel is properly centered in the coating chamber. By moving the frame into and back out of the chamber by using the IN and OUT buttons a value can be reached through trial and error.

PANEL HEIGHT

Measure the panel height and input the value in millimeters. Border width need not be subtracted from the height as this is automatically compensated for.

NNOOTTEE:: TTHHIISS IISS AA PPAASSSSWWOORRDD PPRROOTTEECCTTEEDD SSCCRREEEENN.. NNEEEEDD PPAASSSSWWOORRDD FFOORR AACCCCEESSSS.. OONNLLYY FFOORR QQUUAALLIIFFIIEEDD TTEECCHHNNIICCIIAANNSS..

Figure 98 Position and timers

- - 86

FLOOD SPEED

FLOOD SPEED between 15 and 30 cm/sec is recommended.

PRINT SPEED

PRINT SPEED 10 and 30 cm/sec is recommended for Speed 1 and Speed 2. The type of ink being printed and the geometry of the panel determine the print speed required for optimal results. Speed 2 controls the print speed on the second print stroke when in FPP or FPFPP mode.

Note: In general faster print speeds deposit more ink. Slower print speeds yield thinner deposits.

TRAVELING FRAME SPEED

Frame Speed controls the speed of the Traveling Frame into and out of the coating chamber.

- - 87

Figure 99: Main Coater Menu

Service Motors

Maintenance and service may be performed via the SERVICE MOTORS screen. By pressing Resets the following screen.

Press Resets for Servo Motor S i

- - 88

Figure 99 Resets Main Menu

Path to Servo Motor Setup and Reset

Figure 100 Coater Servos

- - 89

Figure 3 Resets Main Menu

Figure 56: Service Coater Motor screen servo screen

The Service Motors screen allows for Servo motor set up and service. Each separate servo has a Jog screen and also a set up blue button. The Set up Blue button is password protected.

SQUEEGEE SERVO 5

This Screen controls the 1500 watt servo motor located under the main plate. This motor is coupled with an angled gear box that drives the squeegee arm assemblies up and down.

- - 90

Figure 101 Servo #5 Squeegee Drive

- - 91

Figure 102 Servo #5

SHUTTLE SERVO 6 X -AXIS

This Screen controls the panel transport shuttle that drives the traveling frame into and out of the coating chamber. The Shuttle couples a 25: 1 gear box with a 400 watt servo motor.

1500 W Servo Motor with right angle gear.

Figure 103 Shuttle over travel

- - 92

Figure 104 Shuttle Servo #6

Figure 106 Servo # 6 Set up

- - 93

Figure 107 Servo #6 Advance

PANEL HEIGHT SERVO 7

This Screen controls the panel size adjusting mechanism and is attached to the traveling frame. This system allows the DP6000 to transport panels as small as 12” (305mm) up to 30” (762mm) tall panels. By selecting a panel height, in millimeters, the machine automatically moves the panel clamps to the correct position.

Figure 108 Servo #7 Panel Height

- - 94

Figure 109: Servo 7 Panel Height Motor and Gear

The Panel Height Motor incorporates two over travel limit switches to prevent the servo from over traveling in event of a memory loss. These limit switches are also used to home the Servo after the motor or cable are disconnected. The DP6000 machine utilizes absolute encoder on the servo motors to have absolute control of the position of the device.

Bottom over travel switch

Top over travel switch

- - 95

Figure 110 Servo #7 Panel Height

Door Interlock

If one of the seven door interlocks is broken the legend Door Interlock will appear. To clear this alarm shut all doors and Master Reset the machine. Door Interlocks cuts power to all motors. Will trigger alarm message on screen.

Light Curtain

If the light curtain is broken during operation, the machine will stop. Remove the obstruction from the path of the light curtain and Master Reset the machine to clear this alarm. Will trigger alarm message on screen.

- - 96

Emergency Stop

When one of the three emergency stop switches is depressed, the legend Emergency Stop will appear. Emergency Stop cuts power to Shuttle, Squeegee and upper rail motors and all other major components. Rotate the latched pushbutton clockwise to release it. Master Reset the machine to clear the alarm and resume operation.

Servo Error Code

This is a password protected screen designed to add additional error messages into the HMI touch screen.

Servo Alarm

In the event of servo over travel, a failsafe limit switch will be tripped and the servo will shut down and alarm. It will trigger alarm message on screen.

To reset the servo:

1. Select the Service by touching its icon on the screen.

2. Press the Release button to override the failsafe limit switch.

3. MOMENTARILY press the jog button to move the servo off the switch. Be sure to move the servo in the appropriate direction. Once off the limit switch reset the machine

ALARMS DISPLAY The alarms display shows what is causing the alarm indication by the icon on the menu screen.

- - 97

Figure: 111: Alarm Display

The alarm conditions can be read from the display and appropriate action taken. A history screen shows what alarms have occurred in the past so that recurring alarms can be addressed by appropriate maintenance and training.

STATUS Indicates what the machine is currently doing.

Alarm Indicates the error or Alarm at the current state.

Action Items Indicates what the recommended action to repair the machine.

Servo Alarms Indicates a servo problem. See Appendix D for code details.

Alarm or error

Recommend Action

Current status or action of unit

- - 98

Figure 112: Alarm History

ALARM HISTORY

This screen lists by recent occurrence the Alarms that have been registered to the machine. The DP2500 stores the most recent history for 100 Alarms.

COATER SET-UP To set-up the DP6000 coater, one needs to adjust the Panel Height, the Print Heads, and install screens that have been blocked out with the exact size print window, choose appropriate squeegees and flood bars and choose the proper recipe.

Review the panel to be processed for manufacturability. The panels may be coated in either of two panel orientations (Portrait or Landscape). There are several important considerations when choosing the panel orientations for coating:

Landscape orientation is faster allowing for more panels coated per hour.

Border area on the panel. Generally, the machine coats more reliably with the largest border area located at the top and bottom of the panel. This minimizes interference from the board guides.

Active Alarm listed in Yellow and RED Squares.

Alarm History with Blue Squares.

- - 99

Portrait orientation locates the panel more ideally in the screen frame making coating easier and causing less squeegee wear.

Additional types of boards to be coated. The machine will be more productive to minimizing the amount of changes necessary to shift from part number to part number.

NOTE: During set-up the machine should be on and the MODE switch set to Manual unless otherwise noted.

NOTE: Before setting the machine up to print panels many operators mask off the machine exterior and line the drip pans and base plate to facilitate clean up.

QUICK START 1. Install the screen frames with the properly defined print windows.

2. Be sure to install the frames against the aligning screws

3. Turn machine On. Touch anywhere on the touch screen to go to the MAIN MENU.

4. Make sure that all doors and closed.

5. E-Stops are not engaged

6. ON/OFF is in the ON position

7. Press MASTER RESET: Reset Note:

8. GO TO SETUP / PROCESS PARAMETER SCREEN

9. SELECT THICK/ THIN MODE.

10. FILL IN ALL DESIRED PARAMETERS.

11. LOAD SEQUENCE Thin Panel

A. Inset board and align with the top clamp.

B. Press foot switch and remove hands to clear light curtain.

C. ALIGN BOARD WITH TOP CLAMP AND PRESS FOOT SWITCH TO CLOSE TOP CLAMP.

D. Remove hands to clear light curtain.

- - 100

12. LOAD SEQUENCE Thick Panel

A. Insert panel on load assist and press panel against top clamp

B. Press foot switch to soft lock the clamp.

C. remove hands to clear light curtain to lock top clamp

D. Remove hands to clear light curtain Load assist will retract and bottom latch will lock.

13. Check pneumatic gauges and confirm that pressures are at desired settings.

14. Set up parameters and print and flood speeds.

15. Set switch positions to enable desired optional actions (e.g. ISOprint, Thin Panel, and Shuffle).

16. Program shuttle control for desired jog and speed.

17. START THE Machine if machine is ready.

18. TO SET UP SCREEN FRAMES. JOG THE SHUTTLE INTO THE COATING CHAMBER.

19. With the panel in the coating chamber, examine very closely the panel in the window on both sides. Push the screen against the panel to check registration of print window.

20. Adjust frame position as necessary to register print window with panel.

21. RESET Machine.

22. Run INK FILL TO, raise the print head to the filling setting

23. Fill the ink troughs 75% full with ink.

24. Set feed rate on ink pump.

25. Turn ink pump to Auto

26. RESET Machine

27. Set MODE to Flood Only and press START

28. Check to see that screens have been properly flooded.

29. Turn machine to desired automatic run mode. Flood/Print/Print for example.

30. Press START and begin coating panels.

- - 101

31. Note: STOP THEN RESET clears errors most problems. If not, turn the machine off (at the disconnect) and start from the beginning.

32. Check the ALARM screen for possible errors in trouble shooting this equipment.

33. Error Codes are Detailed in Appendix D.

ADJUSTING PANEL HEIGHT 1. Set the desired panel height, PANEL HEIGHT INCLUDES a five mm border

on the top and bottom. Press Stop and Reset. Height will move.

2. Open the panel clamp by depressing the Footswitch.

3. LOAD THE PANEL.

SCREEN FRAMES Installation of Screen Frames

NOTE: Instructions on making up screens and defining the print window appear below under Preparation of Screens

1. Turn off the machine using the ON/OFF switch. This turns off the air supply to the air cylinders, which lock the screen frames and reservoirs.

2. Open the coating chamber doors. Lift the QC swing arm-locking lever and pull the print head out of the way.

3. Pull the reservoir arm outwards out of the way.

4. Lift the overhead sheet metal panel upwards

5. Place the bottom edge of the screen chase into the bottom chase locks. Install the screen side first, with the frame portion outwards.

6. Swivel the top clamp bar out of the way and push the top of the chase into the top clamp assembly. Swivel the clamp bar back into position to hold the screen frame in place.

NOTE: The top clamp bar is reversible to accommodate the different widths of stretch and glue and self-tensioning screen frames.

7. Close the swing arms and doors and turn the machine back on.

- - 102

Registration of Print Window

Sometimes the print window on the screen does not exactly register with the area on the panel to be coated. When this happens one must adjust the screen or the panel location. This may be done as follows.

1. Load a panel by placing a panel on the traveling frame and depressing PANEL Load

2. Press the CHASE switch to Unlock

3. Press the RESERVOIR switch to Unlock

4. The screen may be moved laterally by turning the CHASE ALIGNMENT

KNOB. The screen may be raised or lowered by turning the CHASE

HEIGHT KNOBS together. The screen may be rotated, or rolled, by raising one corner and lowering the other by turning the CHASE HEIGHT KNOBS in opposite directions.

5. Once adjustment is complete, close the doors, lock the chase and reservoir and unload the panel.

NOTE: If the screen cannot be moved laterally one can move the panel by adjusting the STOP 1 position via the Shuttle control. Use care when making such an adjustment as moving the panel from the center of the print head vertical axis can result in a substandard coating.

NOTE: When loading a panel manually it will be justified to the load/unload side of the coating chamber (the right on a right-handed machine). With the Jog and/or Shuffle feature enabled then, the panel will be further into the coating chamber when automatically offset. (To the left on a right-handed machine). When adjusting the print window keep in mind if these functions will be used and factor in the Jog/Shuttle offsets into the window distance calculations.

Stretching Screen Frames

SCREEN MESH SELECTION

Polyester Monofilament, medium thread (T), Plain weave (PW)

60 inches (152 cm) wide bolt of fabric

- - 103

Large open area between threads

Make sure that both screen frames are using the same mesh at the same tension.

General mesh recommendations and results:

74 (29) mesh covers 5-8 mil high traces with 0 .5 -0 .8 mil coverage

86 (34) mesh covers 3-5 mil high traces with 0.4 -0.8 mil coverage

92 (38) mesh covers 2-4 mil high traces with 0.5 -0.8 mil coverage

110 (43) mesh covers 2-4 mil high traces with 0.3 -0.5 mil coverage

NOTE: Coverage and performance of this equipment is directly related to the characteristics of the inks used. Different types and brands of soldermask produce different results.

SCREEN FRAME TYPES

There are two types of frames available for mounting the mesh. The "static" or passive "stretch and glue" frames and the self-tensioning (active) frames.

The passive frames require that the mesh be pre-stretched on a stretch device. The frame is then positioned on the mesh and glued in place. The "stretch and glue" type frames have significant advantages over other screen frame types. The mesh can be held in the tensioning device in a straight form and tensioned to the proper tension very accurately. Before the frame is glued to the mesh, the frame can be easily aligned to the proper 22.5° angle. Once glued into place the mesh cannot move. The disadvantage of "stretch and glue" is that the stretching device is quite large taking up floor space. In addition, glue must be found that is compatible with the soldermask and with the cleaning chemicals. Finally, it is not possible to retension the screens after they have been made up.

The self-stretching frames are quite popular in the U.S. The biggest advantage is to allow one to retension of the fabric to keep it at a constant level of tension. It is possible at any time, and in a few seconds to retension.

- - 104

Figure 113: Stretch mesh at 22.5°

The disadvantages of these types of frames are that they are much heavier than glue type frames. It is difficult to stretch the mesh in them at a perfect 22.5° angle at the same tension across the frame. In addition, these frames tend to bow under higher tensions.

SCREEN TENSION

The importance of fabric stretching cannot be over emphasized. The screen is the carrier palate in the screen-printing process. It is also probably the most ignored part of the total screen process.

To be conscious of the state of the tensioning the mesh requires that we first understand how to measure it. Mesh tension is measured in N/cm (Newton/centimeter). This tension measurement is determined with an apparatus called a “tensiometer".

At the level of the fabric as a whole, the threads/inch will change due to tension. For example: 110 thread/inch becomes 103 thread/inch at 15 N/cm and 97 thread/inch at least 25 N/cm. "Length of time" is a factor that all tensioning examples made in this area clearly demonstrate a phenomenon related to the cold flow characteristics of polyester. Screens will lose between 15% and 20% of their initial tension value within 48 hours. This means that a fabric tensioned at 20 N/cm will decrease to 16 N/cm. The act of printing applies forces to the stretched fabric to which it is not accustomed. These forces are necessary to pass the ink through the mesh overcoming the internal cohesion of the ink's molecules between themselves and capillary action, which causes adhesion of the ink to the threads.

- - 105

The rubbing of the squeegee and the successive "traction and retraction" causes and additional loss of 3-5 N/cm in tension of the screen mesh. This action occurs during the first 500 prints of a new fabric. With a fabric of the "stretch and glue" type, this loss is permanent and cannot be recovered. With the self-tensioning frames, one can retension the fabric after this “break in” period.

STRETCHING SCREENS

The tensioning operation must be done in four steps for "stretch and glue" and in five steps for self-tensioning. The fifth tension consists of returning to the optimum initial tension after the first printing cycle.

The fabric must be positioned on the stretching machine or the self-stretching frame at 22.5° on a bias.

Measure tension in the warp and weft directions at five points (see figure 62). The measure of tension in the center of the screen is considered the reference value for the global tension. To avoid the risk of fabric failure, mostly at the corners of the self-tensioning frames, it is necessary to lower the tension here by 5-6 N/cm under the tension level of reference (Fig 63).

Figure 114 Tension measurement points

- - 106

Figure 115: Tension is lower in the corners

First Tension 110 = 16 N/cm

Relax the fabric for 45 minutes

Residual tension = 12 N/cm

Second tension = 22 N/cm

Relax the fabric for 45 minutes

Residual tension = 12 N/cm

Third Tension = 28N/cm

Relax the fabric for one night

Residual tension = 21 N/cm

Fourth Tension = 30N/cm

After the fourth tension allow one-hour relaxation and glue the screen if it is of the "stretch and glue" type. A self-stretching frame will also have to remain in stabilization for at least on hour. After stenciling or blocking out the residual tension will be 30N/cm.

- - 107

Defining the Print Window

Circuit Automation LPI coating equipment involves the use of the flood screening technique. Flood screen is the process by completely coating a screen with soldermask then applying it evenly to the substrate. The print window needs to be defined for two reasons. First, by not covering the entire panel with soldermask a significant amount of ink can be saved. For example, a .5"(12.5mm) border on an 18" x 24" (457 x 610mm) panel represents a 9% savings in ink. Secondly, Circuit Automation equipment transports panels by their top and bottom borders. A well-defined print window reduces cleanup time and mishandling problems due to ink fouling.

Dot patterns or pad masters are not required to protect the holes from plugging with ink using dual sided coaters. Briefly, to define a print window one will go through the following steps:

Install screen frames in the Coater

Adjust screw stops to midpoint and register screen frame to screw stops.

Lock Chase (Frame)

Close Chase (Frame)

Load the panel into the coating chamber.

Note: In high production operations, where it is not possible to shut production down, a jig is fabricated which holds the screen frame and the panel in the same relationship as they are in the machine. This permits screens to be prepared off-line.

Mark the screen mesh for blocking out the screen window.

Note: The machine Jogs subsequent panels, sufficient allowance in the picture window must be left to allow for this movement. With a Manual Loaded board the machine will right justify the panel in the frame. (Fig. 10).

Unlock Chase (Frame)

Open Chase (Frame)

Remove the screen frame to prepare print window.

A more detailed procedure follows.

- - 108

Figure 116: Install screen to mark print window

Install screen chase in coating area to be marked for screen window. Check front to rear screen chase alignment before marking screen window.

Confirm that screen mesh is stretched at a 22.5° angle.

Set Chase height adjustment to approximately the center of adjustment range. This will allow chase adjustment to align top and bottom borders of the screen window to panel.

Figure 117: Window in Screen Mesh

In Manual Mode Load a representative panel into the coating area. Adjust panel stop position to center panel in screen chase. Make reference marks to define screen window approximately 0.5 inch (12 mm) inside upper and lower sheet

- - 109

metal guides and at lateral edges of panel. This will define the screen window to be smaller than the panel to be coated.

Figure 118: Blockout screen

Remove screen chase to define print window. After blockout has dried, install front and rear chase. Check front to rear screen window alignment and adjust as necessary. Load panel into coating area and check screen window alignment to panel. The front and rear screen chase may be aligned independently to match screen window to the panel image area.

Figure 119 Coated panel showing clear border area

Figure 45 indicates a panel coated with soldermask. The panel borders are clear of soldermask. With a properly defined screen window, coated panels should always have a clear border as indicated.

- - 110

BLOCKOUT MATERIAL

Varieties of materials are use to blockout the screen and form the print window. The difference between the materials and methods used is primarily how long they last.

Direct Emulsion

Direct emulsions are the most commonly used. They are inexpensive and water-soluble which permits easy removal. Direct emulsions cover and encapsulate the mesh from both sides so they offer durability. Ulano Screen Filler #60 and Blockout #10 and Superblox are examples of direct emulsions.

Blockout

On a clean and degreased screen, define the area that will transfer ink to the panel. Cover that area with masking tape. Use excess emulsion such as Blockout #10 and place on the masking tape. Using a spreading tool to apply an even coating over the rest of the screen. Remove the tape and place in front of a fan to dry the blockout. When dry we have found that a support piece of tape placed on the inside of the screen mesh inhibits soldermask from leaking past the defined area. Drying frames in an oven causes the tension to change due to an elongation of the mesh.

Direct/Indirect Emulsion

Direct/indirect emulsion should be considered as a process. It combines a long shelf life film with an emulsion, called a transfer emulsion. The process is quite simple. The screen mesh is laid on the unsensitized film and the sensitized transfer emulsion is squeegee through the mesh. The transfer emulsion sensitizes the film, it bonds the film to the mesh and the result is a stencil with the durability of direct emulsions but also photo definable.

Physical Barrier

Tape is quite often used to define the print window for printing. Mylar tapes and plating tapes have proven to be easy to apply at the coater and substantial enough to last for many prints. Care should be taken to find a tape that is compatible with the solvent system used in the soldermask. In addition, the adhesive used must be compatible to be clean up when changing print windows. Generally, we have found that thin tapes work superior. They define the print window yet they do not adversely affect the tension of the screen

Many customers use a combination of physical barrier and direct emulsion to define the print window for screening.

Note: A layer of tape is required on in inside of both screens at the bottom of the print window. This layer inhibits leakage of soldermask below the bottom edge.

- - 111

THE PRINT WINDOW

The print-through window for the DP6000's screens may be made with block-out; permanent or temporary stencil material, tape, or a combination. The dimensions and location of the window must allow for at least one-half inch of uncoated area on the top and bottom of the panel

PRINT HEAD SET-UP Theory of Operation

Unique to Circuit Automation coaters is the way the squeegees attack the screen mesh and subsequently the panel. We utilize the Trailing edge first method of applying the squeegee to the panel. Traditional flatbed screen printer and both competitive double-sided screen printers utilize the Leading edge method of printing. The Trailing edge method is also known as the Push stroke or as the Surf stroke. The Leading edge method is also known as the Pull stroke.

The difference in the method of application is the single biggest reason why Circuit Automation Products can coat high traces fill areas between close traces and coat consistently even across the panel.

SQUEEGEE ANGLE AND PRESSURE

Pressure on the squeegee vs. dynamic squeegee pressure

Although CAI coaters have three separate squeegee-functions adjustment (angle, speed and pressure) each on affects the action of the other two. The net result of adjusting one or more of these variables determines the ultimate or dynamic printing pressure on the substrate. This pressure is not the same as the pressure adjustment on the squeegee (see following figure).

Figure 120 Dynamic squeegee pressure

For example, if the dynamic squeegee pressure on the panel is 1 lb. /in at 35° squeegee angle, the pressure on the squeegee may be 60 psi at a squeegee

- - 112

speed of 3 in/sec (ips). The same dynamic pressure could also be achieved at 27.5º angle 100 psi at 5 in/sec. All other things being equal, if the dynamic squeegee pressure is the same in two different setups, the soldermask deposit will be also the same.

Unfortunately, while the effects of dynamic pressure of the squeegee is known, setting the dynamic pressure is done by trial and error. It is possible to get the same dynamic pressure by adjusting the three squeegee functions.

SQUEEGEE PRESSURE AND LENGTH VS. INK-DEPOSIT THICKNESS

Research indicates that squeegee length affects the ink-deposit variations that normally a function of squeegee-pressure variations. Sizing the squeegee for the panel helps reduce variations. The same squeegee pressure setting utilizing different squeegee lengths will produce different ink-deposits.

Quick set-up

Choose and install the appropriate squeegee/flood bar/ink trough for the size panel(s) to be coated, 20" (508mm) or 26"(660mm).

Note: Squeegees and flood bars are supplied in sets. Two standard sizes are shipped with the machine. 26" (660mm) for panels up to 24" (610mm) wide and 20" (508mm) for panels up to 18" (457mm) wide. Choose the flood bar to match the squeegee selected. Custom size squeegees and flood bars are available for specialized work.

Following are example steps for Squeegee setup:

Set the squeegee angle at 27.5° - 37.5°

Set the squeegee speed to 6 in/sec (ips) (15.2 cm/sec)

Start with 4.5 bar (60 psi) front and rear

Increase squeegee pressure until there is no thick areas on the edges of the panel.

Increase print speed until moiré pattern disappears.

Decrease print speed if micro bubbles appear along the traces.

Decrease squeegee angle if excesses ink is in the holes.

Increase squeegee angle if skips develop.

- - 113

Initial set-up

The heart of all Circuit Automation equipment is the squeegee heads. These devices hold the squeegee assemblies and flood bars. Proper alignment and adjustment of the heads is critical to produce consistent, repeatable and acceptable panels at the desired coverage of soldermask.

The basic principle behind our coaters is:

Panels are held vertical

The screen mesh and chase are equidistant from the vertical panel

Both squeegee heads are at the exact same position on opposite sides of the panels

The squeegee angle of attack is the same for both squeegees

The squeegees exert the same dynamic pressure on both sides of the panels.

The flood bars exert the same force to evenly flood the screen mesh.

The DP6000 is designed to operate on a range of panel thicknesses and panel sizes. The maximum panel thickness ranges from a minimum of 0.010" (0.25mm) to a maximum of 0.400" (10mm). The tension on the screen mesh is changeable depending on prints and the squeegee rubber wear.

The DP6000 self-adjusting squeegee heads automatically adjust to variations in panel thickness, mesh tension, squeegee rubber wear, air pressure changes, different print speeds, and other variables.

We have defined the self-adjusting feature as FLOATING / FLOATING POSITION.

This operational position allows the front and rear squeegees to both self-center at less than the maximum travel position. This head position is RECOMMENDED under most situations. This position makes the air pressure to the individual squeegee critical.

One advantage of this position is that the heads are self-adjusting; generally, squeegee head adjustments are not necessary for varying panel thickness. To use this setting critical care must be given to screen make up and screen tension.

- - 114

FLOATING SQUEEGEE SET-UP

When utilizing a "Floating /Floating" squeegee set-up the floating squeegees set the reference to keep a panel centered between the front and rear screen chase. The above picture depicts squeegees extended against a panel, as they should be during a print stroke.

The compressed air set point at the squeegee air gauge should be nominally 60 psi. It is extremely important that the squeegee pressure is set to achieve even pressure at the front and rear squeegee head.

Note: Verify front and rear screens for proper tension. Screen tension will have a direct impact on floating squeegee stroke pressure setting to achieve equal dynamic printing pressure.

Adjustments should not be necessary at the squeegees to compensate for panel sticking to either the front or rear screen after the floating squeegees have been set up properly. The floating squeegees should be set with sufficient clearance at squeegee drive bar slot, Item B and D, to automatically compensate for minor adjustments to the air pressure settings.

The Flood Bar stroke length is factory set and should not require adjustment. It is, however, a good practice to verify that the stroke length is correct. During the flood stroke, clearance must be maintained between the flood drive bar and bottom of the guide slot at Item B. This ensures the tip of the Flood Bar is always in firm contact with the screen mesh.

- - 115

Note: Prior to making any adjustments to flood bar stroke length, check the flood bar air pressure set point. Pressure should be 20 psi to 30 psi 2 -4 bar.

FLOOD BAR RETRACT LIMIT

Figure 121: Flood bar retract limit

The Flood Bar retract limit is factory set and should not require adjustment. As part of the Flood Bar stroke length check, it is important to verify that the Flood Bar is retracting back far enough that ink will be scooped into the Flood Bar when it extends forward. As indicated in Fig. 68 at Item A, the Flood Bar is positioned with space to move forward and scoop ink into the Flood Bar prior to starting the flood stroke.

FLOOD BAR LOWER LIMIT

The Flood Bar Lower Limit is set by adjusting limit Flood Start (home) position. This limit switch should be adjusted to set the Flood Bar lower limit in the Ink Reservoir. For machines equipped with screen chase height adjusters, set the chase height prior to adjusting. Clearance of 2mm must be maintained between the Flood Bar and bottom of Ink Reservoir to allow the Flood Bar to stroke forward and scoop ink.

- - 116

Printing in Automatic Modes

The normal way to print with the DP6000 is to utilize an automatic print mode. Before printing, make certain that the instructions for squeegee setup, and board guide and shuttle alignment have been followed. Install the screens and fill the ink troughs to about 15mm from the top.

Select an automatic mode from the touch screen choices (flood/print/print, etc.) and choose between one of the three Flooding Modes; Flood Down, the No Flood Mode or the Flood Up Mode. Begin an automatic print cycle by placing a board in the load station and pressing START.

After the instructions above for adjusting the squeegees and flood bars have been followed, any further adjustments should only be made by adjusting the pressure settings of printing or flooding.

Aligning Squeegee Head - New style Swing Arm

Swing Arm has greatly improved coating thickness control on the machines and allowed for fine micro-adjustment of the squeegee heads.

Figure 122: New Swing Arm

Adjustability and strength were the hallmarks behind this major improvement on the machine. A key feature of this system is the new “screw Adjusters”. These devices are round in design as compared to the old style square nut holders.

- - 117

Figure 123: Adjustable Print Platen

Aligning the heads is critical to the machine. The Leveling device allows to micro adjust each individual head.

Figure 124 Aligning Ring

- - 118

On an initial startup with the timing belt removed, the following procedure should be followed. Loosen the four bolts holding the Aligning Ring in place (Fig 72).

Set the four bearing blocks on the Leveling blocks as in Fig 73.

Install the belt, and then activate the belt tensioner from the Service position to the Operate position.

Figure 125 Belt Tension Release

After the belt is in tension tighten the bolts on the bearing blocks. Do not over tighten the bolts. Excess torque on the bolts can cause the MH195 (Red Nut) to bind the lead screw. After the 16 bolts are tight, run the squeegee head up approximately 6” (152cm). Then Check the level between the heads. (Fig 75).

Leveling Block in Proper position

Figure 125 Level Blocks

Figure 127 Squeegee Head Level

- - 119

Figure 128 Squeegee Head Level

Figure 129 Head to Head Level

- - 120

Service Motors

Pressing the Service Motor button brings up the Service Menu for the Servo Motors. This screen allows movement. From this screen several screen can be accessed to aid in trouble shooting the machine and functions.

Figure 130 Servo Screens

Inputs

The DP6000 has inputs to the PLC. This screen lists the address of all inputs and also a green indicator will indicate any input that is high.

Access to Input and Output screen

- - 121

Figure 131: Inputs

Green indicator for active inputs

- - 122

Outputs

The DP2500 has two inputs screen to the PLC. These screens list the address of all outputs and also a green indicator will indicate any input that are high.

To move between Output Screen and Output Screen 2 press the MORE OUTPUT. Button located on the left hand side of the screen.

Figure 132 Output

- - 123

Figure 133 Output 2

TIMING BELT MAINTENANCE AND REPLACEMENT

Every week examine the belt for wear. Replace if worn, every 500,000 cycles, or two years, whichever comes first.

A servo motor drives the four lead screws via a double sided timing belt. A spring operated chain tensioner takes up slack. The quality and consistency of the DP6000's printing depends on the print heads being parallel and aligned to each other, and this alignment is maintained by proper installation and maintenance. The DP6000 uses its ground base plate as the reference for the print heads. Four leveling blocks for alignment are provided with the spare parts.

If binding or undue pressure is placed on any of the four lead screws then the belt will be thrown to prevent damage to the drive train. This will also happen if the print heads are driven into an obstruction. This prevents damage to the machine.

If the Belt is thrown or skips teeth on the pulleys, stop the machine by pushing EMERGENCY STOP. Turn ON/OFF Off.

- - 124

CAUTION: WHEN THE BELT IS THROWN, THE PRINT HEADS WILL USUALLY DESCEND UNDER

GRAVITY TO THE BOTTOM (HOME) POSITION. IF THE BELT HAS NOT BEEN THROWN

COMPLETELY, THE PRINT HEADS MAY REMAIN IN PLACE ABOVE THE HOME POSITION. IF THIS IS

THE CASE, THEN THE PRINT HEADS MUST BE SUPPORTED WHILE THE CHAIN IS REMOVED, AND

THEN THE PRINT HEADS LOWERED TO THE HOME POSITION. EXERCISE EXTREME CAUTION IN

PERFORMING THIS PROCEDURE. DO NOT REMOVE THE BELT WITHOUT SUPPORTING THE

PRINT HEADS.

Figure 134 Timing Belt Drive System

Remove the belt from all the pulleys and inspect for any binding or damage to the teeth, replace with a new belt if there is any damage.

With the belt removed and the print heads resting in the home position, pick up each end of the print head support bar and place a leveling block under the bar. This aligns the print head support bars parallel to each other and to the base plate.

Reduce the spring tension by switching the SERVICE/OPERATE RELEASE SWITCH to the SERVICE position. This switch is located on the rear of the electrical control panel and is accessed through the lower rear service door on the machine. Thread the BELT around the PULLEYS and over the Supports. Start at the motor and proceed to the two PULLEYS nearest the motor. Do not allow slack in the BELT between the motor and the pulleys. Then work towards the sprockets farthest from the motor, taking up slack between the pulleys, and making certain that the belt runs over the support riser blocks. Retension the system by turning the RELEASE SWITCH to the Operate position.

NOTE: The DP6000 has a safety interlock that prevents the machine from operating if the RELEASE SWITCH is in the Service position.

- - 125

Turn ON/OFF On and set MODE to Manual. Use JOG Up to move the print heads up a few inches. Remove the leveling blocks. Run the print heads up and down and check that the DP6000 is operating normally.

LEAD SCREW LUBRICATION

Every month, lubricate the lead screws with NSK Grease #2,

Ball Screw grease, available from Circuit Automation. Do not substitute any other lubricant. A tube of this grease is supplied with the standard parts kit.

VERTICAL LINEAR BEARING ROD LUBRICATION

On a weekly basis, inspect the vertical linear bearing rods (Thompson rods) and bearings with white lithium grease. If a rod does not have a very light coating of grease along its length, then lubricate via the Zurk fittings with the grease that was supplied with the machine.

Lubricate all the rods and bearings at least every month. There is a Zurk fitting located on each of the four bearing blocks. Two on the front and two (as pictured) on the rear.

Figure 135 Bearing Block

SQUEEGEE HEAD LUBRICATION

There are four linear bearings on each squeegee head; two for the squeegee and two for the flood bar. On a daily basis, inspect the linear bearings. If a rod does not have a very light coating of oil along its exposed length, then lubricate with 2

- - 126

drops of way lube or medium weight oil applied to the felt washers on the bearing blocks. To lubricate, stand the head on the squeegee end and apply the oil to the cavity under the outside adjusting nut or knob. Then turn the squeegee head so that the squeegee and flood bar are upright, and apply oil to the linear bearing.

SHUTTLE TIMING BELT

The Timing Belt for the Shuttle needs to be checked for wear and tension every month. This mechanism has two m8 lockdown hex head bolts along with an m8 socket head cap screw for tension adjustment. This mechanism must be tightened for the machine to maintain accuracy.

Figure 136 Shuttle Belt tension

SQUEEGEE HEAD

The edge on the squeegee is a very important factor with Circuit Automation equipment. Printing utilizing the Trailing Edge stroke makes edge management of the squeegee important. The sharpness of the edge or the roundness greatly affects the coating thickness and quality. If squeegees are sharpened, care should be exercised maintain the same height on the front and rear squeegee. A difference in height will cause the front and rear squeegee to contact a panel being coated at different heights. Most customers keep statistical controls of the panels per squeegee to be able to maintain good repeatability of the process.

Adjusting Screw and lock down bolts

- - 127

Figure 137: Squeegee Alignment

- - 128

Vertical transport Screen (ROBOT)

Figure 139 Main Screen

Robot

- - 129

Figure 140 Robot Main Set up screen

- - 130

Figure 141 Servo 8 Set up Screen

Panels are transferred from the tensioning transport of the coater to the tack-dry oven by a specially designed edge-handling robot. The robot reaches into the coater to grip the panel by the left and right edges, applies slight tension to the panel, and withdraws the panel from the coater. The robot then retracts and then it places the panel into the tack-dry oven elevator.

Robot Towers

Following coating, the panel is returned to the load/unload section of the coater to be removed by the Vertical Transport Device.

- - 131

Figure 141 robot Towers

After coating and transport to the Unload/Load station, the VTS moves into position to retrieve the panel. The Top and Bottom grippers are both top and bottom justified to the panel. The VTS moves into position and the Finger gripper engage by twisting and locking.

Figure 142 Finger Gripper Assy with sensors

After engagement of the finger grippers, the top and bottom clamps open. The Tension cylinders extend raising the top clamp. The product is then raised slightly in order to clear the bottom clamp and then it is extracted from the coater.

The U drive in the VTS system moves the product to the position where the ASA Sways can be attached. (ASA Anti swaying devices can be added to the bottom of the panel by a Menu selection).

Finger Gripper top

Finger Gripper Bottom

- - 132

Figure 143 Panel in Robot system

Figure 144 Robot unloading a Panel

- - 133

Figure 145 Servo 10 and 11 Set up screen

The Robo screen is reached by pressing the ROBO button while in the Service Menu. This screen enables one to initiate various programmed moves manually. To execute moves manually press the TRANSPORT button located in the System Control box. The button will change from green to red in color and the Off lamp will illuminate indicating that automatic mode is off and the robot is now in manual mode.

Figure 146 Panel Buffer Station Assy

HC oven spring clips

Insertion stop cylinders

One Panel Buffer Station

- - 134

Figure 147 Panel at exit

HC-340 Hanging Oven

Panels are dried for the prescribed time as set on the Oven MMI. The oven sub panel has three main features. It houses the MMI for the oven where time and cooling functions are chosen. The set point temperature is also selected via the Omron 5AN thermal controller. The Third main component is the chart recorder. The device records the temperature of the oven.

- - 135

Figure 148 Oven Control Sub Panel

The Buffer station loads the panel into the spring clips. When the oven conveyor has cycled to the correct position to align with the openers, the Top Chain align mechanism secures the conveyor chain. Then the wedges are driven into the spring clip assembly to open the spring clips. When the sensor senses that the clip is open and the Buffer has the panel in place, then the panel is lifted into the spring clip.

Figure 147 Panel Clip Opener

Wedge clip opener

Spring clips and bearing devices

Chart Recorder

Temperature Controller

Disconnect Reset

Emergency Stop

- - 136

The wedge clip opener has been redesigned into a 3rd generation product for a higher duty standard. The redesigned Assembly part number is 11-9594.

Figure 165 Clip Opener

Many innovations were incorporated into this 3rd generation design, including an upper travel limiting device, larger mounting brackets and hardware. Improved transition from the air cylinder to the wedge. Improved wedge material, and shock absorbing stops.

- - 137

The HC340 oven incorporates two exhaust ports to ventilate the oven body to insure that the air inside the oven has the capacity to properly dry the panels. Each oven vent should draw around 500 cfm of air.

Figure 148 Oven Drive Motor

Figure 149 Unloader Cooling

HC Exhaust Port,

- - 138

Figure 150 Oven exhaust

Unloader

The unloader section is designed to remove a panel from the cool down zone on the oven then place the panel on a horizontal unload conveyor for transport to a panel stacker or rack loader.

Figure 151 Unload end HC 340 oven

- - 139

Figure 152 Servo 12 Unloader Set up screen

The Unloader sub menu screen is reached by pressing the UNLOADER button while in the Service Menu. This screen enables one to initiate various programmed moves manually. It also allows one to change offset value for various predetermined moves.

- - 140

Figure 153 Servo #12 Advanced Set up

The Arm on the unloader is positioned at the raised position. When the ultrasonic sensors sense a sheet, the clamps close on the sheet. Then the wedge openers open the spring clips, and the retract mechanism removes the sheet from the clip area. After the sheet clears the top of the clip, the pneumatic cylinder retracts and moves the sheet from the vertical position to the horizontal.

The unload belt removes the sheet from the system for further processing.

- - 141

Figure 154 Servo #12 Unload arm lifter

All Servos (except Servo #2) have over travel limit switches to add additional safety to this system. These hard limit switches serve two functions:

1) Limit the mechanism within safe travel distances.

2) Provide a method to reset the system should position be lost.

Over travel limit switches

- - 142

Figure 155 Panel approaching Unload arms

The default position for the unloader arm is UP, with the panel clamping hooks open and the panel removing cylinder in the up position.

- - 143

Figure 156 Unload sensors and hooks

The Unloader utilizes two ultrasonic sensors to search for a panel. The sensors are configured in an either / or configuration. This configuration helps overcome issues with tooling holes usually found in top of panels. The sensors have a simple stroke adjustment for range. The ideal range is to sense the panels about 25 mm in front of meeting the unload arm.

Figure 157 Seven Belt Unload Conveyor

The unloader flat belt conveyor features flat belt conveyor along with an adjustable speed motor. Each belt has a tensioner.

Ultra Sonic panel sensors

- - 144

Figure 158 Board Clear Sensors

The panel has to clear the Board Clear Sensors before the arm will go to Up position. Should the panel fail to clear the system will send an alarm.

Board Clear Sensors

- - 145

Figure 159 Belt Tensioner

Figure 160 Unloader Motor and Speed Control

AC Motor

Motor Speed Control Adjustable

Individual belt tensioner

Screw adjuster 6mm set screw

Lock down hex head 12mm

- - 146

Figure 161 Center Belt tensioner

The center belt on the unloader has a tensioner to allow for the center belt to be adjusted. Loosening the underneath M8 bots, will allow the spring loaded part to be adjusted.

The spring loaded rear plate may be adjusted by loosening the two M8 bolts underneath the mechanism and sliding the block.

Figure 162 AC Unloader Motor Speed control and belt tension

Belt Tensioner M8 Adjustment blots

Unloader motor speed and accel and decell control

- - 147

The Unloader cabinet and arm has been redesigned to allow for smoother operation and also ease of maintenance. The arm has expanded wire ways and also more ergonomic connection points for the wires and pneumatic tubing.

Figure 164 Connection box for Unloader

Figure 163 Redesigned Unloader arm

- - 148

The unloader exit end has been redesigned to allow for seamless integration with additional equipment as loaders or unloaders

Figure 165 Redesigned exit end for the unloader.

- - 149

Maintenance Checklist

Examine timing belts for wear. Replace if necessary.

Examine belt on traveling frame for wear and tension.

Check and Lube Traveling Frame bearings.

Lubricate lead screws with No. 2 white lithium grease per instruction manual.

Lubricate bearing blocks with Lubriplate 1200-2 or equivalent grease per instruction manual.

Check alignment of the squeegee heads per instruction manual and realign if required.

Inspect for any worn or broken parts, repair or replace if necessary.

Check and adjust FLOOD BAR air pressure to be equal on both sides of the machine, set to 4 bar.

Check and tighten all electrical screw connections.

Check and tighten if necessary all set screws.

Check Thompson shafts for tightness, tighten if necessary.

Clean upper and lower board guides.

Check O-rings on air connectors, replace if worn.

Check air regulator and filter, drain water if necessary.

Sharpen squeegees at least every 1000 panels.

Check timing belt on PCB drive system, replace if necessary.

Oven Clip Openers require periodic maintenance. Several parts are considered wear items and must be changed yearly or every 750,000 cycles.

1. 11-9606 ,Plate, Slide, Clip Opener

2. 11-9599, Wedge

3. MH412, Step Stud M8 to M6

4. 11-9601. Weldment Spring Clip

List of Error Codes Appendix D

Indicator status Category Error name Error code

RUN ERC ERH ERM MLK

PCU set- Lit Flash- Not lit Not lit Lit Illegal operation Present Position 3030

tings and ing Unknown Error

opera-

Servo Unlock Error 3040

tions

Multistart Error 3050

- - 150

errors

PCU set- Lit Flash- Not lit Not lit Lit Illegal data Position Designation 3060

tings and ing Error

opera-

Speed Designation Error 3061

tions

Speed Control Speed 3062

errors

Designation Error

Torque Command Value 3063

Error

Option Command Value 3064

1 Error

Option Command Value 3065

2 Error

Override 3070

Initialization Axis Param- 3090

eter Check Error

Data Transfer Axis 3091

Parameter Check Error

Data Setting Error 3099

MECHA- Lit Flash- Not lit Flash- Lit External sensor input Forward Rotation Limit 3000

TROLINK ing ing Input

slave sta-

Reverse Rotation Limit 3001

tion

Input

device

Forward Software Limit 3002

errors

Reverse Software Limit 3003

Emergency Stop Signal 3004

Input

Origin search error No Origin Proximity or 3020

Origin Input Signal

Limit Input Already ON 3021

Limit Input Signal ON in 3022

Both Directions

Servo Drive error Drive Main Circuit OFF 3080

Error

MECHATROLINK device 4000 +

alarm Alarm code

for each

device

Alarm Displays for Servo Drives The following table lists the alarm displays for Servo Drives. When an alarm or warning occurs for one of the connected MECHATROLINK slave station devices, the PCU turns ON the Error Flag or Warning Flag and returns the following error code. G5-series Servo Drives/G-series Servo Drives Error code: 4@@@ hex The numbers in the boxes of the error codes displayed for alarms are given as decimal numbers for the Servo Drives and as hexadecimal numbers for the Position Control Units. The same numbers are given in the boxes of the error codes displayed for warnings for the Servo Drives and the Position Control Units.

- - 151

List of Error Codes Appendix D

Example: Position deviation overflow alarm (deviation counter overflow) Servo Drive alarm display: A.24 The PCU's error code in this example is 4018. Example: Battery warning Servo Drive warning display: A.92 The PCU's error code in this example is 4092. For details on alarm display and warning display numbers, and the difference between Servo Drives and Posi-tion Control Units, refer to the list in Appendix D List of Error Codes. W-series and SMARTSTEP Junior Servo Drives Error code: 40@@ hex The boxes (@@) indicate the alarm/warning display number for the Servo Drive. When using an R88D-WN@-ML2 W-series Servo Drive with built-in MECHATROLINK-II communications, how-ever, only the upper two digits of the display number's three digits will be displayed. The alarms that occur in the Servo Drive correspond to error codes that are detected by the PCU when a MECHATROLINK communications connection has been established, as shown in the following table. When using an R88D-WT@ Servo Drive, the two digits following “A.” in the Servo Drive’s display number in the table are displayed. When using an R88D-WN@-ML2 W-series Servo Drive, three digits are displayed (the value indicated by the display number box is used to further classify the alarm). For details on each alarm and countermeasures, refer to the operation manual for the Servo Drive being used.

List of G5-series Alarm Displays The Servo Drive has built-in protective functions. When a protective function is activated, the Servo Drive turns OFF the alarm output signal (ALM) and switches to the Servo OFF status. The alarm code will be displayed on the front panel. Alarm type Description

--- Protective function that allows the alarm to be reset, and leaves record in the alarm history. PR Protective function that does not allow the alarm to be reset, and requires the control power supply to be turned OFF and turned ON again after resolving the problem.

X Protective function that does not leave record in the alarm history.

Servo PCU Alarm Error detection function Detected error or cause of error Drive error type

display code

11 400B X Control power supply und- The DC voltage of the main circuit has dropped below the ervoltage specified value.

12 400C --- Overvoltage The DC voltage of the main circuit is abnormally high.

13 400D X Main power supply under- The DC voltage of the main circuit is low. voltage

14 400E PR Overcurrent Overcurrent flowed to the IGBT. Servomotor power line ground fault or short circuit.

15 400F PR Servo Drive overheat The temperature of the Servo Drive radiator exceeded the specified value.

16 4010 --- Overload Operation was performed with torque significantly exceeding the rating for several seconds to several tens of seconds. 18 4012 PR Regeneration overload The regenerative energy exceeded the processing capacity of the regeneration resistor.

21 4015 PR Encoder communications Communications between the encoder and the Servo Drive error failed for a specified number of times, thereby activating the error detection function. 23 4017 PR Encoder communications Communications error occurred for the data from the data error encoder.

- - 152

List of Error Codes Appendix D

Servo PCU Alarm Error detection function Detected error or cause of error

Drive error type

display code

24 4018 --- Error counter overflow The number of position deviation pulses exceeded the Error

Counter Overflow Level (Pn014).

25 4019 PR Excessive hybrid error The difference between the position of load from external

encode and the position of motor due to encoder was larger

than the number of pulses set by Internal/External Feedback

Pulse Error Counter Overflow Level (Pn328).

26 401A --- Overspeed The rotation speed of the Servomotor exceeded the setting

of the Overspeed Detection Level Setting at Emergency

Stop (Pn615) or Overspeed Detection Level Setting

(Pn513).

27 401B PR Command error The operation command resulted in an error.

29 401D --- Internal error counter over- The value of the internal deviation counter (internal control

flow unit) exceeded 227

(134217728).

30 401E PR Safety input error Safety input signal turned OFF.

33 4021 --- Interface duplicate alloca- A duplicate setting for the interface I/O signals was detected.

tion error

34 4022 --- Overrun limit error The Servomotor exceeded the allowable operating range set

in the Overrun Limit Setting (Pn514) with respect to the posi-

tion command input.

36 4024 PR Parameter error Data in the parameter save area was corrupted when the

X data was read from the EEPROM at power-ON.

37 4025 PR Parameter destruction The EEPROM write verification data was corrupted when

X the data was read from the EEPROM at power-ON.

38 4026 X Drive prohibition input error Forward and Reverse Drive Prohibit Inputs (NOT and POT)

both became OPEN.

40 4028 PR Absolute encoder system The voltage supplied to the absolute encoder dropped below

down error the specified value.

41 4029 PR Absolute encoder counter The multi-turn counter of the absolute encoder exceeded

overflow error the specified value.

42 402A PR Absolute encoder over- The Servomotor rotation speed exceeded the specified

speed error value when power to the absolute encoder is supplied by the

battery only.

43 402B PR Encoder initialization error An encoder initialization error was detected.

44 402C PR Absolute encoder 1-rota- A one-turn counter error was detected.

tion counter error

45 402D PR Absolute encoder multi- A multi-turn counter error or phase-AB signal error was

rotation counter error detected.

47 402F --- Absolute encoder status The rotation of the absolute encoder is higher than the spec-

error ified value.

48 4030 PR Encoder phase Z error A phase-Z pulse was not detected regularly.

49 4031 PR Encoder CS signal error A logic error was detected in the CS signal.

50 4032 PR External encoder error An error was detected in external encoder connection or

communications data.

51 4033 PR External encoder status An external encoder error code was detected.

error

55 4037 PR External encoder connec- An error was detected in the external encoder phase A, B, or

tion error Z connection.

82 4052 PR Node address setting error The rotary switch for setting the node address of the Servo

Drive was set out of range.

83 4053 --- Communications error Data received during each MECHATROLINK-II communica-

tions cycle repeatedly failed, exceeding the number of times

set in the Communications Control (Pn800).

- - 153

List of Error Codes Appendix D

Servo PCU Alarm Error detection function Detected error or cause of error

Drive error type

display code

84 4054 --- Transmission cycle error While actuating MECHATROLINK-II communications, syn-

chronization frames (SYNC) were not received according to

the transmission cycle.

86 4056 --- Watchdog data error Synchronization data exchanged between the master and

slave nodes during each MECHATROLINK-II communica-

tions cycle resulted in an error.

87 4057 X Forced alarm input error The Forced alarm input signal was input.

90 405A --- Transmission cycle setting The transmission cycle setting error when the MECHA-

error TROLINK-II CONNECT command is received.

91 405B --- SYNC command error A SYNC-related command was issued while MECHA-

TROLINK-II was in asynchronous communications mode.

92 405C --- Encoder data restoration The initialization process of the internal position information

error was not performed properly.

93 405D PR Parameter setting error Parameter setting exceeded the allowable range.

95 405F PR Motor non-conformity The combination of the Servomotor and Servo Drive is not

X appropriate.

Others Others PR Other errors The control circuit malfunctioned due to excessive noise.

An error occurred within the Servo Drive due to the activa-

tion of its self-diagnosis function.

List of G-series Warning Displays

Priority Servo Drive PCU error Warning detection Warning details

display code function

94 4094 Data setting warn- • Command argument setting is out of the range.

ing • Parameter write failure.

• Command settings are wrong, and others.

95 4095 Command warning • Command output conditions are not satisfied.

• Received unsupported command.

• Subcommand output conditions are not satisfied.

96 4096 ML-II communica- One or more MECHATROLINK-II communications error

High tions warning occurred.

A.0 40A0 Overload warning 85% of the overload alarm trigger level has been exceeded.

A.1 40A1 Regeneration over- 85% of the regeneration overload alarm trigger level has

load warning been exceeded.

A.2 40A2 Battery warning Voltage of absolute encoder battery has dropped below

3.2 V.

A.3 40A3 Fan lock warning The internal cooling fan stop status continued for 1 second.

A.4 40A4 Encoder communi- An encoder communications error occurred for 3 consecu-

cations warning tive times.

A.5 40A5 Encoder overheat The encoder temperature exceeded 95C.

error

Low A.6 40A6 Vibration detection Vibrations were detected.

warning

A.7 40A7 Limit detection The limit of the capacitor or the fan fell below the specified

warning value.

A.8 40A8 External scale error The external scale detected a warning.

warning

A.9 40A9 External scale com- An external scale communications error occurred 3 consec-

munications warn- utive times.

ing

Note (1) All warnings are retained. After resolving the problem, clear the alarms and the warnings.

- - 154

List of Error Codes Appendix D

(2) When multiple warnings occur, the warning codes are displayed on the front panel in the order of

their priority (shown above). The value read from the network is set.

List of G-series Alarm Displays The Servo Drive has built-in protective functions. When a protective function is activated, the Servo Drive turns OFF the alarm output signal (ALM) and switches to the Servo OFF status. The alarm code will be displayed on the front panel. Alarm type Description

--- Protective function that allows the alarm to be reset, and leaves record in the alarm history.

PR Protective function that does not allow the alarm to be reset, and requires the control power supply

to be turned OFF and turned ON again after resolving the problem.

X Protective function that does not leave record in the alarm history.

Servo PCU Alarm Error detection function Detected error or cause of error

Drive error type

display code

A.11 400B X Control power supply und- The DC voltage of the main circuit has dropped below the

ervoltage specified value.

A.12 400C --- Overvoltage The DC voltage of the main circuit is abnormally high.

A.13 400D X Main power supply under- The DC voltage of the main circuit is low.

voltage

A.14 400E PR Overcurrent Overcurrent flowed to the IGBT. Servomotor power line

ground fault or short circuit.

A.15 400F PR Servo Drive overheat The temperature of the Servo Drive radiator exceeded the

specified value.

A.16 4010 --- Overload Operation was performed with torque significantly exceeding

the rating for several seconds to several tens of seconds.

A.18 4012 PR Regeneration overload The regenerative energy exceeded the processing capacity

of the regeneration resistor.

A.21 4015 PR Encoder communications Communications between the encoder and the Servo Drive

error failed for a specified number of times, thereby activating the

error detection function.

A.23 4017 PR Encoder communications Communications error occurred for the data from the

data error encoder.

A.24 4018 --- Deviation counter overflow The number of position deviation pulses exceeded the Devi-

ation Counter Overflow Level (Pn209).

A.26 401A --- Overspeed The rotation speed of the Servomotor exceeded the setting

of the Overspeed Detection Level Setting (Pn073).

A.27 401B PR Command error The operation command resulted in an error.

A.29 401D --- Internal deviation counter The value of the internal deviation counter (internal control

overflow 27

unit) exceeded 2 (134217728).

A.34 4022 --- Overrun limit error The Servomotor exceeded the allowable operating range set

in the Overrun Limit Setting (Pn026) with respect to the posi-

tion command input.

A.36 4024 PR Parameter error Data in the parameter save area was corrupted when the

X data was read from the EEPROM at power-ON.

A.37 4025 PR Parameter corruption The EEPROM write verification data was corrupted when

X the data was read from the EEPROM at power-ON.

A.38 4026 X Drive prohibit input error Forward and Reverse Drive Prohibit Inputs (NOT and POT)

both became OPEN.

A.40 4028 PR Absolute encoder system The voltage supplied to the absolute encoder dropped below

down error the specified value.

A.41 4029 PR Absolute encoder counter The multi-turn counter of the absolute encoder exceeded

overflow error the specified value.

List of Error Codes Appendix D

- - 155

Servo PCU Alarm Error detection function Detected error or cause of error

Drive error type

display code

A.42 402A PR Absolute encoder over- The Servomotor rotation speed exceeded the specified

speed error value when power to the absolute encoder is supplied by the

battery only.

A.44 402C PR Absolute encoder one-turn A one-turn counter error was detected.

counter error

A.45 402D PR Absolute encoder multi-turn A multi-turn counter error or phase-AB signal error was

counter error detected.

A.47 402F --- Absolute encoder status The rotation of the absolute encoder is higher than the spec-

error ified value.

A.48 4030 PR Encoder phase Z error A phase-Z pulse was not detected regularly.

A.49 4031 PR Encoder PS signal error A logic error was detected in the PS signal.

A.82 4052 PR Node address setting error The rotary switch for setting the node address of the Servo

Drive was set out of range.

A.83 4053 --- Communications error Data received during each MECHATROLINK-II communica-

tions cycle repeatedly failed, exceeding the number of times

set in the Communications Control (Pn005).

A.84 4054 --- Transmission cycle error While actuating MECHATROLINK-II communications, syn-

chronization frames (SYNC) were not received according to

the transmission cycle.

A.86 4056 --- Watchdog data error Synchronization data exchanged between the master and

slave nodes during each MECHATROLINK-II communica-

tions cycle resulted in an error.

A.87 4057 X Emergency stop input error The emergency stop input became OPEN.

A.90 405A --- Transmission cycle setting The transmission cycle setting error when the MECHA-

error TROLINK-II CONNECT command is received.

A.91 405B --- SYNC command error A SYNC-related command was issued while MECHA-

TROLINK-II was in asynchronous communications mode.

A.93 405D PR Parameter setting error Parameter setting exceeded the allowable range.

A.95 405F PR Servomotor non-conformity The combination of the Servomotor and Servo Drive is not

X

appropriate.

- - 156

Others Others PR Other errors The control circuit malfunctioned due to excessive noise.

An error occurred within the Servo Drive due to the activa-

tion of its self-diagnosis function.

List of G-series Warning Displays

Priority Servo Drive PCU error Warning detection Warning details

display code function

A.94 4094 Data setting warn- • Command argument setting is out of the range.

High

ing

• Parameter write failure.

• Command settings are wrong, and others.

A.95 4095 Command warning • Command output conditions are not satisfied.

• Received unsupported command.

• Subcommand output conditions are not satisfied.

A.96 4096 ML-II communica- One or more MECHATROLINK-II communications error

tions warning occurred.

A.90 4090 Overload warning 85% of the overload alarm trigger level has been exceeded.

A.91 4091 Regeneration over- 85% of the regeneration overload alarm trigger level has

load warning been exceeded.

A.92

4092 Battery warning Voltage of absolute encoder battery has dropped below

Low 3.2 V.

A.93 4093 Fan lock warning The built-in cooling fan stopped, or rotated abnormally.

Note (1) All warnings are retained. After resolving the problem, clear the alarms and the warnings.

- - 157

SERVICE SCREENS Coater Servo Submenus

FRAME MOTOR

(Motor that drives the frame in and out of the coating chamber)

Red flashing light =error

Green at home signal = Waiting at panel pick up position

UPPER RAIL MOTOR

(Drives the upper rail up and down according to panel height)

Red flashing light=error

This axis has no home signal

SQUEEGEE MOTOR

(Drives the squeegee heads up and down)

Red flashing light=error

Green at home signal=Waiting at position with flood bar in ink trough

MOTOR TROUBLESHOOTING:

If a red light is flashing on any motor servo am try the following:

-Look up error code on that particular servo motor screen. For example if the Frame motor has an error go to the coater main menu, select servo and select frame motor.

INTERLOCKS AND E-STOPS

Green lights should both be ON for operation.

Coater Inputs/Outputs

CHASE

Chase close cylinders Air valve that closes the chases. A green light would indicate the chases are closed. No light would indicate open and the chase open front and rear sensors should be on.

- - 158

FRONT/REAR SQUEEGEE ARM

These sensors indicate that the squeegee heads are in their proper position and latched.

CLAMPS

Top clamp open cylinder/ Bottom clamp open cylinder

Cylinder that opens the top/bottom clamp. When this output is ON the indicator for the top/bottom clamp open should be ON.

Note: All yellow descriptions indicate sensor inputs. All white descriptions indicate outputs (Relays or air cylinders)

Loader Inputs/Outputs

Vacuum box Vacuum box assembly. Pop back air cylinder that moves the whole vacuum assembly back. When this cylinder is ON, the “vac. box back” sensor should be ON.

Vac. rotate cyl Air cylinder that rotates the vacuum boxes up and down. When this cylinder is ON. The “vac. box rotate up cylinder should be ON.

Large vac. Valve Air valve that allows vacuum to flow through large vacuum box.

Small box lock Air cylinder that locks the small vacuum box at home position.

Small nut lock Air cylinder that allows the small vacuum box to travel with the large vacuum box.

Small vac. Valve Air valve that allows vacuum to flow through small vacuum box.

Pinch roll down Air cylinder that pulls the pinch rollers down on board.

Small vac. at home Sensor indicating when small vac. box is at home position.

Vac. Blower Power to vacuum blower motor.

Sensors at roller section PCB past pinch roll Triangulation sensor, senses board past pinch rolls, and detects leading edge of board.

PCB @ pinch Sensor in front of pinch roll

PCB @ middle Sensor in the middle of pinch rolls.

- - 159

Centering left Two sensors, one towards the middle and one of the outside. Used for picking up left edge of board.

Centering right Two sensors, same as above. Used for right edge.

Loader power Contactor that supplies all power to loader section.

Loader Servo Submenu

VACUUM BOX

(Drives the large and small vacuum boxes in and out)

If the vacuum box should become jammed, go to the vacuum box servo menu. Jog the vacuum box forward for a few inches then at the same time press the “small vac” button and the “forward” button. Jog for a few more inches to unlock the vacuum boxes. Press the “home” button. Once both boxes are home press the “home” button again. If errors keep accruing, cycle power, check homing sensors.

CENTERING ARM

(Drives the centering arms in and out) and Conveyor

These motors can be jogged in same fashion.

Robot Input/Output

Red flashing light = error

Green at Home signal = waiting to get panel out of coater for both finger motors and the

8 (IN/OUT) MOTOR.

Finger grip Air cylinders that grip the panel. Light ON indicates panel being gripped.

Robot lock in place cyl Air cylinder that locks the robot in place. When this is ON, the sensor “lock in place cyl. Up” should be OFF.

Robot rotate cylinder Air cylinder that rotates the robot to the unload position.” Robot at load position” sensor is on when robot is ready to pick up a panel and “robot rotate unload sensor is on when robot is unloading panel into oven.

Robot Servos

Follow steps in coater motor section.

11 (Left finger motor)

- - 160

10 (Right finger motor)

8 (In/out motor)

9 (Up/down motor)

APPENDIX B – ALARMS & ERROR CODES FATAL ALARMS

Alarm message Description Clearing Robot door interlock switch check doors

Doors to robot Close all doors

E-Stop hit check buttons Emergency stop button Check all E-stops Check wiring of E-stops

Robot left finger servo error Left finger motor error Check for error code on appropriate axis. 6100 or 6101 Press release prohibits then jogs in the free direction. 8000 Check for amplifier error. 6201 Check origin sensors Check wiring.

Robot right finger servo error Right finger motor error Same Robot extension arm servo error Robot extension arm motor error Same Robot vertical arm servo error Robot up/down motor error Same Centering motor general error Loader centering arm motor error Same Vacuum box motor general error Loader vacuum motor error Same Roller motor general error Loader conveyor motor error Same Frame motor general error Coater traveling frame motor

error Same

Upper rail motor error Upper rail on frame motor error Same Squeegee motor general error Squeegee motor error Same No controller link check comm. cable

Controller link network down Make sure oven is on Check 3 wire bus with schematic

Coater interlock check all doors Coater doors are open Close all doors to coater Check wiring

Coater E-stop Coater emergency stop Check all E-stops Check wiring

Oven no system power check E-stop

Oven E-Stop Check all oven E-stops Check wiring

Oven temperature alarm Oven temperature alarm Oven not at set point Make sure heaters are on

Oven phase fail Oven phase failure Set oven at lower set point and try running then gradually increase temperature.

Oven blower failure Blower motor failure Check contactor MCR2 in main oven electrical cabinet.

Oven heater off Oven heater not on Turn on heater from oven touch screen Coater swing out bar latch open (front or rear )

Latch on coater swing out arm is not latched

Close appropriate latch and continue.

Oven elevator sensor stuck. Clean sensor

One of the oven elevator arm sensors is stuck on.

Clean entire area including dowel pins in the elevator arm.

- - 161

Device Net error (DN---) Device net I/O Block error Cycle power Check wiring to appropriate block Check 24v power supply

Low PLC Bat (____) Battery in PLC is at 10 % Contact supplier

ERROR CODES - 40AO servo motor hot

- 0 no error

- 4000 stopped

SERVO AMPLIFIER ERRORS

Alarm message Description Clearing A10 Under Voltage Power failed or power failed

instantaneously. Cycle power Check power supply amplifier

A20 (A series) Encoder Error A16 (J series)

Problem with encoder Encoder disconnected Check / Replace encoder cable Cycle power

A50,51,52 Large move error Overload error Turn amplifier off Check axis for free rotation. Make sure axis moves freely without drag or binding.

- - 162

SPARE PARTS Quantity Units Part No. Description

4 Each 11-1460 Gripper, RH, HOR 7" Robot DP6000 V2

4 Each 11-1460 Gripper, LH, HOR 7" Robot DP6000 V2

1 Each AC9003 Cylinder, NCDJ2D16-250-H7AILS

1 Each AC9904 Sensor, Cyl Reed Sw, D-F9NVL

1 Each AV50 Valve, Solenoid, Air Pilot

1 Each AV79 Valve, Solenoid, 24VDC

1 Each AV96 Valve, Gate, SY%120-5LOZ--N9T

5 Each EC156 Fuse, 2A, Ceramic, Slo-Blo

5 Each EC3401 Fuse, 10A, Ceramic, Slo-Blo

3 Each EC3574 Relay, Low Consumption, 2N.O, 24V

2 Each EC3575 Relay, Low Consumption, 4N.O.

2 Each EC3639 Fuse, 10A, IEC, ATOR-10

5 Each EC64 Fuse, 1A, Ceramic

5 Each EC75 Fuse, 1.25A, Fast Blo

1 Each ES184 Sensor, Proximity, E2E-X1R5E1-N

1 Each ES185 Switch, Safety-Door, D4DS-3AFS

1 Each ES186 Switch, Safety, Key, D4DS-K3

1 Each ES32 Switch, Proximity, E2E-X5E1N

1 Each ES90 Fiber Optic, E32-TC200

1 Each ES9912 Switch, On/Off, 2-Position

1 Each ES9918 E-Stop, Push lock Turn Reset

1 Each ES9921 Switch, Limit, D4D-3172N

1 Each ES9923 Switch, Limit, D4C-1602

2 Each ES9927 Sensor, Slide Home Position, BES-517-399-NO-L-3

2 Each ES9928 Sensor, Slide Home Position, BES-517-352-NO-L-3

1 Each ES9940 Fiber, Cable, Grip, PDIS46UM12

1 Each ES9954 Sensor, E3C-S30T

1 Each MB12 Nut, Super, AFS21

1 Each MB19 Grease, Ball Screw, NSK-No.2

12.4 Feet MC02 Chain, 3/8", #35, Riveted

3 Each MC04 Link, Master, #35

16 Each MH18 O-Ring, Small, 008

16 Each MH53 O-Ring, Large, 011

2 Each MM01 Magnet, Retain, 02-10-101-10

2 Each MM02 Magnet, Retaining

2 Each MM03 Magnet, Latching

1 Each MP0196 Belt, Drive, Polyurethane

1 Each MP0212 Belt, Screw Dr, 6R25M64090

1 Each MP0256 Belt, Time, A6R25M059090

1 Each MP0257 Belt, Time, (HDT 5mm), A6R25M064150

3 Each MS04 Spring, E1000-105-5000M