untitled PROACTIV™ OVERVIEW CHAPTER 10 PROACTIV™ OVERVIEW Introduction ProActiv™ is an active squeegee module The ProActiv mount assembly, which is similar to the standard squeegee mount and shares co.
PROACTIV™ OVERVIEW CHAPTER 10 PROACTIV™ OVERVIEW Introduction ProActiv™ is an active squeegee module The ProActiv mount assembly, which is similar to the standard squeegee mount and shares common functionality and construction, houses the active squeegees The difference is apparent when using ProActiv during a print stroke, the squeegee blade is activated, this provides additional forces in the print direction; it modifies the rheology of the solder paste increasing its fluidity Figure 10-1 ProActiv Mechanism Number Elements Chapter Issue Nov 11 Description ProActiv Mount Assembly Electrical Connector Bracket Active Squeegees The ProActiv module consists of: • A squeegee mechanism • Electronic control modules and associated wiring looms • A pair of active squeegees (sizes available: 170/200/250/300mm with or without a pair of paste deflectors) 10.1 PROACTIV™ OVERVIEW Squeegee Mechanism The squeegee mechanism houses a pair of motors, which lift and lower the squeegees Driving the squeegee down, onto the stencil, creates the print pressure needed to force the paste through the stencil apertures The mechanism has an electrical bracket that houses the electrical connectors, switches and indicators, which are used to supply power and signals to the active squeegees Active Squeegees The front and rear squeegees have active elements, which provide the motive forces that are used to ‘work’ the paste NOTE Only use the original matched ProActiv squeegee pair, as supplied with the printer or as part of a machine upgrade Optimum performance may not be achieved if an alternative ProActiv squeegee pair is used Contact DEK customer support for assistance Handling active squeegees Do not mishandle or drop active squeegees This may cause damage to the active elements Always stow away securely Active Power and Signal Cable Squeegee Blade Fixing Screws (in 14 positions) Squeegee Blade Mounting Bar Figure 10-2 Rear View of an Active Squeegee Assembly The squeegee blades are mounted, as shown above, and secured to the mechanism by the mounting bar Squeegee Blades Squeegee blades are available in sizes: 170,200,250 and 300mm blade widths and two blade depths, either or 15mm These measurements refer to the portion of the blade that is used to work the paste, as shown below The part number and width are engraved on each blade or 15 mm Options Blade Width Mount the blades in the active squeegee assemblies with the part number and 10.2 Chapter Issue Nov 11 PROACTIV™ OVERVIEW size facing the front Paste Deflectors Paste deflectors are available to deflect paste back to the centre of the blade and prevent the formation of tramlines The deflectors are available for 170,200,250 and 300mm sized squeegee blades and are secured to either end of the squeegee 170mm 250mm 200mm 300mm Paste Deflector Securing Screws Paste Deflector Chapter Issue Nov 11 10.3 PROACTIV™ ELECTRICAL SCHEMATIC ELECTRICAL SCHEMATIC M37 Power Supply Enclosure M37SK20 Drive Board 9SK74 Front ProActiv Squeegee N18SK14 N18PL13 9SK75 Rear ProActiv Squeegee JP1 Front ProActiv Sensor Rear ProActiv Sensor ProActiv Enable SW ProActiv Enable Indicator Blue 50 Node Board JP1 N18PL04 N18PL05 M37SK10 9SK68 N18PL01 N18PL08 10.4 ProActiv Status Indicator Green Chapter Issue Nov 11 PROACTIV™ ELECTRICAL SCHEMATIC Electronics On the left hand side of the machine, behind the print carriage bearing support, the drive board, and the node board, are mounted on a DIN rail Power to the boards is derived from the M37 power enclosure Drive Board Node Board Active squeegee drive signals are generated on the drive board The node board is used for routing signals from the driver to the switches and sensors Chapter Issue Nov 11 10.5 PROACTIV™ ELECTRICAL SCHEMATIC Drive Board The drive board and the node board are located together, behind the print carriage bearing support, on the left-hand-side of the printer The drive board generates the signals required to drive the active elements of the squeegees Drive Board Node Board N18SK01 N18PL13 JP1 N18PL05 N18PL04 N18PL14 N18PL08 Figure 10-3 Electronic Control Boards Located on the Printer L.H.S Power comes from the M37 power supply enclosure, via plug N18SK01, supplies the following voltages: 42V, +24V SW, +24V US and +12V Drive signals activate a squeegee via N18PL14 This cable divides to provide independent drive signals to the front and rear squeegees Node Board The node board routes signals from the drive board, or the sensors and switches, as follows: Signals routed from the drive board to the node board across JP1: • Enable and status indicators Feedback signals from the node board to the drive board across JP1: 10.6 • The system is ready to activate the squeegees (enable switch) • A squeegee has moved from dwell to contact height or vice-versa (front and rear proximity sensors) Chapter Issue Nov 11 PROACTIV™ MECHANICAL DETAIL MECHANICAL DETAIL Front and Rear Proximity Sensors Locking Thumbscrews Cable (shown as a stub for clarity) Keyway Slot Active Elements Squeegee Blade Figure 10-4 Front Active Squeegee The active squeegees are fitted to the squeegee mechanism using the top mounted locking thumbscrews To prevent the squeegees from being fitted to the wrong holder each squeegee is constructed with a keyway and a pair of locking thumbscrews The thumbscrews on the rear squeegee have their holecentres further apart than the hole-centres on the front squeegee The keyway aligns with the dowel pins on the squeegee holder The integrated cables, shown as a stub in the figure above, connect each squeegee to the drive board via connectors on the mount assembly bracket (9SK74/75) The cables carry power and signals to drive the active elements in each squeegee The cables are loomed through the drag chain back to the drive board to plug (N18PL14) Proximity switches located above each squeegee are used to sense when the squeegee moves from dwell height to contact height This movement causes proximity switches to trigger, if ProActiv is on, the active drive to the squeegee blades turns ON The active squeegee remains on until it is: turned off by the operator, or the machine is powered down, or emergency stopped, or the squeegee returns to either the dwell position or the home position Chapter Issue Nov 11 10.7 PROACTIV™ ADJUSTMENTS AND SETTINGS ADJUSTMENTS AND SETTINGS This section details the adjustments and settings required to set up the active squeegee mechanism Proximity Switch Setting Power up and initialise the printer With the printer in the ready page; select Maintenance Select Machine Setup Select Options Select Pressure Hardware; and select Fitted Navigate back to the Ready page Select Open Cover Commands Select Carriage To Front Open the front printhead cover 10 Remove the active squeegees NOTE Handling active squeegees Do not mishandle or drop active squeegees This may cause damage to the active elements Always stow away securely Squeegee Pressure Calibration A force meter calibration jig and a squeegee pressure plate are required to perform the squeegee pressure calibration NOTE The front squeegee mount (foot) has two mounting locations, the inner locations are for ProActiv, and the outer locations are for mounting the 10.8 Chapter Issue Nov 11 PROACTIV™ ADJUSTMENTS AND SETTINGS squeegee test jig Mount Locations for the Front ProActiv Squeegee Assembly Mount Locations for Pressure Test Jig or Standard Squeegee Mount Locations for the Rear ProActiv Squeegee Assembly Mount Locations for Standard Squeegee Foot Assemblies (showing the two squeegee mount locations) Chapter Issue Nov 11 10.9 PROACTIV™ ADJUSTMENTS AND SETTINGS NOTE Ensure that the rising table print reference height is set correctly before commencing, (the calibration relies upon accurate positioning of the table to make a reference) WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP Select Open Cover Commands Select Carriage To Rear Select Unload Screen Open the front printhead cover Remove the screen from the machine Remove the tooling from the tooling plate Close the front printhead cover Press the System button Select Back 10 Select Maintenance 11 Select Calibrations 12 Select Pressure 13 Select Calibrat Readings The rails are checked for the presence of a board, the print carriage moves to the calibration position, the rear rail moves to home position, the table homes and the board clamps are closed 14 The machine cover is unlocked and the message ‘Fit the pressure calibration rig.’ is displayed with the following window: CALIBRATION DATA Gain Factor 1.02 15 Open the front printhead cover 16 Ensure that the calibration jig is secured to the mounting plate as shown in 10.10 Chapter Issue Nov 11 PROACTIV™ ADJUSTMENTS AND SETTINGS the following graphic: S Mounting Plate A Mounting Holes A S Calibration Jig 17 Fit the calibration jig to the front squeegee position using the outer mounting Chapter Issue Nov 11 10.11 PROACTIV™ ADJUSTMENTS AND SETTINGS holes on the front foot assembly 00.00 Squeegee Pressure Plate MAX Zero RESET UNITS TXD O OFF I ON Portable Force Gauge (Calibration Jig) Locating Dowel (in positions) View on Front of Rising Table and Squeegee Mechanism 18 Fit the squeegee pressure plate to the rising table ensuring that the locating dowels insert into the holes of the rising table NOTE During the squeegee pressure calibration the dwell height of the rear squeegee is 15mm regardless of the set up value This height is set during calibration only 19 Switch the force meter ON and check the reading is 0kg, (ensure the force meter is not in contact with the squeegee pressure plate) 20 Select Continue 21 The front squeegee mechanism steps down until a change in pressure is detected and continues stepping down until the pressure value stored on the machine is reached If the calibration jig displays 10kg, go to Step 25 22 Select Jog Rig 23 Use the left and right jog buttons to move the front squeegee mechanism up or down until the calibration jig displays 10kg NOTE Achieving exactly 10kg may not be possible as some calibration jigs display down to three decimal places 24 Select Set Calib 25 Select Exit 26 The front squeegee mechanism moves to the home position The message ‘Confirm that the pressure calibration jig has been removed.’ is dis10.12 Chapter Issue Nov 11 PROACTIV™ ADJUSTMENTS AND SETTINGS played 27 Remove the calibration jig and the squeegee pressure plate from the machine On completion select Yes, the table resets, the print carriage moves to home position, board clamps open and the rear rail moves to the board width setting Chapter Issue Nov 11 10.13 PROACTIV™ ADJUSTMENTS AND SETTINGS Active Squeegee Reference Height This procedure sets the squeegee reference height to establish the correct print pressure If a Ptest.dat file is not required, go to Step Select Maintenance Select Test Cycles Select Data Logging On Select Back Select Back Select Setup Product Select Squeegees Select Unload Screen 10 Open the front printhead cover 11 Remove the screen from the machine 12 Close the front printhead cover 13 Press the System button 14 Select Calibrate Heights 15 The message ‘Ensure that the correct squeegees are fitted!’ is displayed 16 Select Restore Defaults 17 Fit the active squeegees to the front and rear squeegee mounts NOTE Handling active squeegees Do not mishandle or drop active squeegees This may cause damage to the active elements Always stow away securely 18 Select Continue 19 Select Continue 20 The following machine sequence is carried out: a The presence of a board, on the rails, is checked b The rising table drives to print height c The board clamps are closed d The print carriage drives the front squeegee over the front rail e The rear squeegee moves to dwell height f The stepper motor drives the front squeegee down until it contacts the board clamp g The front squeegee continues to drive down until a 2kg pressure difference is detected; the motor pauses 10.14 Chapter Issue Nov 11 PROACTIV™ ADJUSTMENTS AND SETTINGS h The system records the pressure and the number of steps (that the motor took to get to this position) i The stepper motor drives down another 15 steps; this is recorded with the pressure detected This is repeated a further 18 times to achieve 20 results 21 The rear squeegee is calibrated in a similar manner 22 The message ‘Calibrate Squeegee heights complete’ is displayed 23 Select Back 24 Select Back 25 Select Maintenance 26 Select Test Cycles 27 Select Data Logging Off 28 Select Back 29 Select Back Chapter Issue Nov 11 10.15 PROACTIV™ ADJUSTMENTS AND SETTINGS Ptest.dat File The file displays 20 front squeegee readings followed by 20 rear squeegee readings, showing the relationship between steps, displacement and pressure applied From the readings taken, the front and rear pressure factors and squeegee reference heights are calculated At the end of the file, five readings of flood pressure and reference height readings are displayed (these are also listed in the Config.txt file) The Ptest.dat file is located on the hard drive of the machine PC To view the file carry out the following procedure: From the Windows start menu, select Programs Select Accessories Select Windows Explorer Under My Computer, locate and open the E:\Log\Ptest.dat file The figure below gives a representation of the Ptest.dat file Front Squeegee (kg) (steps) 13.778456 4039.000000 4054.000000 NOTE Text shown in italics is not displayed in the Ptest.dat file 14.236444 4069.000000 14.724963 4084.000000 15.121886 4099.000000 15.579873 4114.000000 16.007328 4129.000000 16.465315 4144.000000 16.892770 4159.000000 17.350757 4174.000000 17.839277 4189.000000 18.266732 4204.000000 18.694187 4219.000000 19.213239 4234.000000 19.640694 4249.000000 20.129213 4264.000000 20.587201 4279.000000 21.045188 4294.000000 21.472643 4309.000000 21.930630 4324.000000 22.388617 Rear Squeegee (steps) 4016.000000 (kg) 13.564729 4031.000000 13.992184 4046.000000 14.480703 4061.000000 14.908158 4076.000000 15.396678 4091.000000 15.885198 4106.000000 16.343185 4121.000000 17.801172 4136.000000 17.289692 4151.000000 17.747680 4166.000000 18.266732 4181.000000 18.724719 4196.000000 19.182706 4211.000000 19.640694 4226.000000 20.068149 4241.000000 20.587201 4256.000000 21.045188 4271.000000 21.503175 4286.000000 21.961163 4301.000000 (Fwd Press Flood) 33.1004 10.16 22.480215 (Rear Press Flood) (Flood Ref Height) 31.9668 3951.6971 (Front Ref Height) 3947.7037 (Rear Ref Height) 3935.1178 Chapter Issue Nov 11 PROACTIV™ ADJUSTMENTS AND SETTINGS Setting the Proximity Switches Ensure that squeegee pressure and squeegee reference height calibrations have been completed before proceeding Select Setup Product, Squeegees Ensure that Dwell Height is set to the default value of 30 Select Maintenance Select Diagnostics Select the Squeegee Module from the list Drive the front squeegee to Dwell Height Select Drive Front Squeegee Using Jog Buttons Drive the squeegee down by approximately 2mm Use a flat bladed trimmer to adjust the front squeegee proximity sensor until the sensor light is OFF 10 Drive the squeegee back to Dwell Height; ensure the light is ON 11 Repeat step 6; ensure the light is OFF 12 Repeat steps through for the rear squeegee Chapter Issue Nov 11 10.17 PROACTIV™ REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES Fitment NOTE The ProActiv option cannot be used if a Paste Drip Tray is fitted to the printer Remove the paste drip tray before fitting the active squeegee module to the printer Do not attempt to fit a paste drip tray to a printer, which has a ProActiv module fitted WARNING! Squeegee Drip tray MUST be removed when using ProActiv Squeegees Only use Drip tray with Standard Squeegees ATTENTION! Le plateau sous racles DOIT ętre retiré quand les racles ProActiv sont utilisées Le plateau sous racles ne peut ętre utilisé qu'avec des racles standard WARNUNG! Das Abtropfblech der Rakel MUSS entfernt Werden, falls die ProActiv Rakel verwendetwerden Das Abtropfblech darf nur mit Standard Rakel verwendet werden Figure 10-5 The Warning Label as Fitted to the Active Squeegee Set 10.18 Chapter Issue Nov 11 PROACTIV™ REPLACEMENT PROCEDURES This procedure details the fitment of the ProActiv unit to the printer From the Ready page select Open Cover Commands Select Move Carriage to Front Navigate back to the Ready page Select Shut Down Select Confirm Turn the mains isolator to the OFF position Open the printer front cover Remove the stencil Remove any applicator modules fitted to the printhead mechanism; refer to the relevant chapter of this manual or the module’s stand alone manual NOTE The ProActiv option cannot be used if a Paste Drip Tray is fitted to the printer Remove the paste drip tray before fitting ProActiv active squeegee module to the printer Do not attempt to fit a paste drip tray to a printer which has a ProActiv module fitted 10 Place a board over the rails at the tooling area; this is used to support the squeegee mechanism 11 Place the squeegee mechanism on the board 12 On the squeegee mechanism, connect the four spade connectors to the enable switch /indicator and the two spade connectors to the status indicator Chapter Issue Nov 11 10.19 PROACTIV™ REPLACEMENT PROCEDURES from N18PL08 (6) and N18PL05 (2) as follows: Enable Status Enable Status Status Status Enable Enable Enable Enable Enable switch/indicator • Grey lead to Pin • Violet lead to Pin • No connection Pin • No connection Pin • Red lead to Pin (marked +) • Black lead to Pin (marked -) Status indicator • Brown lead to Pin (Identified by the red dot on the indicator body.) • White lead to Pin 13 Carefully position the rear of the ProActiv squeegee mechanism (spring beam assembly) into the print carriage so that both printhead mechanism dowels locate into the print carriage locating holes Secure the unit to the 10.20 Chapter Issue Nov 11 PROACTIV™ REPLACEMENT PROCEDURES print carriage by means of the four captive screws, using a 4mm Allen key 4mm Captive Screws (4) Spring Beam Location Dowels (2) 14 Connect the following connectors to the print carriage, left-hand-side: Rear squeegee motor at 9SK17 Front squeegee motor at 9SK16 Home sensors at 9SK08 Squeegee pressure amplifier at N3SK16 15 Connect the proximity switch sensor connector 9PL68 to 9SK68 NOTE Handling active squeegees Do not mishandle or drop active squeegees This may cause damage to the active elements Always stow away securely 16 Fit the active squeegees to the squeegee mechanism 17 Connect the active front squeegee drive 9PL74 to 9SK74 18 Connect the active rear squeegee drive 9PL75 to 9SK75 19 Remove the board from the tooling area Chapter Issue Nov 11 10.21 PROACTIV™ REPLACEMENT PROCEDURES Removal This procedure details the removal of the ProActiv unit from the printer With the unit removed, the user can fit other compatible applicator modules to the printhead From the Ready page select Open Cover Commands Select Move Carriage to Front Navigate back to the Ready page Select Shut Down Select Confirm Turn the mains isolator to the OFF position Open the printer front cover Disconnect active front squeegee drive 9PL74 from 9SK74 Disconnect active rear squeegee drive 9PL75 from 9SK75 10 Detach both squeegees and stow away 11 Disconnect 9PL68 from 9SK68, and cable tie it away from the mount assembly 12 On the squeegee mechanism, disconnect the four spade connectors from the enable switch/indicator, and the two spade connectors from the status 10.22 Chapter Issue Nov 11 PROACTIV™ REPLACEMENT PROCEDURES indicator from N18PL08 (6) and N18PL05 (2) as follows: Enable Status Enable Status Status Status Enable Enable Enable Enable Enable switch/indicator • Grey lead to Pin • Violet lead to Pin • No connection Pin • No connection Pin • Red lead to Pin (marked +) • Black lead to Pin (marked -) Status indicator • Brown lead to Pin (Identified by the red dot on the indicator body.) • White lead to Pin 13 Cable tie the looms away from the mount assembly 14 Disconnect the following connectors from the print carriage, left-hand-side: Rear squeegee motor at 9SK17 Front squeegee motor at 9SK16 Home sensors at 9SK08 Squeegee pressure amplifier at N3SK16 15 Locate the four squeegee mount mounting screws; using a 4mm Allen key undo the screws to release the squeegee mechanism and lift it free Stow the unit away safely and securely Chapter Issue Nov 11 10.23 PROACTIV™ REPLACEMENT PROCEDURES 10.24 Chapter Issue Nov 11 ... Rear ProActiv Sensor ProActiv Enable SW ProActiv Enable Indicator Blue 50 Node Board JP1 N18PL04 N18PL05 M37SK10 9SK68 N18PL01 N18PL08 10.4 ProActiv Status Indicator Green Chapter Issue Nov 11 PROACTIV? ??... 10.3 PROACTIV? ?? ELECTRICAL SCHEMATIC ELECTRICAL SCHEMATIC M37 Power Supply Enclosure M37SK20 Drive Board 9SK74 Front ProActiv Squeegee N18SK14 N18PL13 9SK75 Rear ProActiv Squeegee JP1 Front ProActiv. .. matched ProActiv squeegee pair, as supplied with the printer or as part of a machine upgrade Optimum performance may not be achieved if an alternative ProActiv squeegee pair is used Contact DEK customer