Công nghệ SMT máy DEK bảo dưỡng phòng ngừa preventive maintenance MACHINE INFORMATION INTRODUCTION DEK PART NUMBERS CLEANING AND LUBRICATION SUMMARY OF THE PROGRAMME DAILY MAINTENANCE DESCRIPTION OF THE MONTHLY MAINTENANCE SCHEDULE MONTHLY MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS
PREVENTIVE MAINTENANCE MACHINE INFORMATION CHAPTER 37 PREVENTIVE MAINTENANCE MACHINE INFORMATION The maintenance engineer should complete the following information boxes as a permanent record of the machine details Machine Serial Number Line Number Customer Engineer Chapter Issue Jul 10 Technical Reference Manual 37.1 PREVENTIVE MAINTENANCE MACHINE INFORMATION 37.2 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE INTRODUCTION INTRODUCTION Philosophy Recommended Preventive Maintenance (PM) is to be performed daily and monthly as defined in the programme If any items or parts are found to be defective, please contact your local DEK agent The PM must be adhered to in the order that it has been presented The plan follows the same procedures employed in the DEK Equipment Utilization Programme (EUP), information has been reproduced here as a guide for customers who wish to develop a comparable programme that conforms to the DEK standard For more information on how to obtain the DEK EUP please contact your local DEK agent for details The Preventive Maintenance Schedule Each process of the service programme is only described in enough detail to act as guidance to those DEK authorized personnel using it The daily schedule can be performed by a suitably trained operator, the tasks should take approximately 15 minutes The monthly schedule consists of two modules each taking approximately hours to complete These modules are to be carried out by DEK authorized personnel who have successfully completed the DEK Maintenance Course Information in this chapter can be photocopied or if accessed via the Internet, downloaded for printing The pages which are reproduced can be stored away as the PM record of the machines’ service history Material Safety Data Sheets Material Safety Data Sheets (MSDS) listing the health and safety aspects applicable to consumables such as cleaning materials, oils and greases are available on request from the purchase source If difficulty is experienced in obtaining any MSDS, assistance is available from DEK Contact your local DEK agent Disposal of Waste Materials All waste materials including fluids and contaminated materials must be disposed of in accordance with national, federal or local legislation Warranty Compliance with the preventive maintenance procedures described in this chapter is an essential element of the machine warranty policy as defined in the ‘DEK Standard Warranty Statement’ Chapter Issue Jul 10 Technical Reference Manual 37.3 PREVENTIVE MAINTENANCE DEK PART NUMBERS DEK PART NUMBERS Cleansing and Lubrication Description DEK Part Number IPA Impregnated Wipes 115806 IPA Impregnated Swabs 115846 THK AFB Grease 141146 Aeroshell Grease 115290 Light Grease 120011 Light Oil 120008 Lubrication Chart Module Description DEK Part Number (Lubricant) Camera X and Y Linear Bearing Guide Rails 141146 Omni Track Bearings 120011 Paste Dispenser Linear Bearing Guide Rail 141146 Print Carriage Linear Bearing Guide Rails 141146 ProFlow Linear Bearing Guide Rails 141146 Rail System Linear Bearing Guide Rails 141146 Rising Table Ballscrew 141146 Screen Actuator Bearings 120011 Screen Actuator Striker Plates 120011 Squeegee Spindle Shafts 141146 Squeegee Leadscrews and Supernuts 115290 Transport Rail Ballscrews 141146 Vacuum Filters Description 37.4 DEK Part Number VF35i Carbon Filter 173357 VF35i Standard Pre-Filter 173358 VF35i HEPA Pre-Filter (cleanroom use) 173359 VF35i Filter Kit (1 X 173357 and X 173358) 173373 VF35i Filter Kit (1 X 173357 and X 173359) 173374 VF25 Carbon Filter 163552 VF25 Standard Pre-Filter 163551 VF25 Filter Kit (1 X 163552 and X 163551) 173102 VF10 HDPE Foam Filter (pack of 3) 187871 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING AND LUBRICATION CLEANING AND LUBRICATION MANDATORY TOXIC CHEMICALS MAY BE PRESENT SAFETY GLOVES MUST BE WORN MANDATORY TOXIC CHEMICALS MAY BE PRESENT EYE PROTECTION MUST BE WORN Linear Bearings and Guide Rails All linear bearing blocks, fitted to the machine, are greased for life and require no greasing although a grease nipple may be fitted The linear bearing guide rails require no maintenance unless they become contaminated In the event of contamination, carry out the following procedure: Clean the linear bearing guide rail using a plastic spatula Remove any build up of grease around the linear bearing block Apply a very thin coating of THK AFB grease (DEK part No 141146) along the whole length of the guide rail using a cloth Ensure that the three exposed faces are greased to prevent surface rust Remove any surplus grease using the cloth ensuring that there is no build up of grease near the linear bearing block For locations of linear bearings, refer to the table below: Location Rising Table and Transport Rail Ballscrews Linear Bearing Guide Rails Linear Bearing Blocks Camera (2 Y and X) Paste Dispenser 1 Print Carriage ProFlow 2 Rising Table Transport Rails 6 Underscreen Cleaner Uses the Camera Y Rails The rising table and transport rail ballscrew bearing blocks are greased for life and require no greasing The rising table and transport rail ballscrews require no maintenance unless they become contaminated In the event of contamination, carry out the following procedure: Clean the ballscrew using a plastic spatula Remove any build up of grease around the ballscrew bearing block Apply a very thin coating of THK AFB grease (DEK part No 141146) along the whole length of the ballscrew using a cloth Using the cloth, remove any surplus grease near the ballscrew bearing blocks Chapter Issue Jul 10 Technical Reference Manual 37.5 PREVENTIVE MAINTENANCE SUMMARY OF THE PROGRAMME SUMMARY OF THE PROGRAMME The PM Plan Daily Schedule Approximately 15 Minutes Monthly Schedule Approximately Hours SPC Alignment Check (where available) Monthly Hardware Check Machine Cycle Count Software Check Monthly Maintenance Check Hours Hours Daily This maintenance schedule is a recommended programme which should be carried out on a daily basis Tasks are generally limited to surface cleaning and minor inspections and should take no more than fifteen minutes to complete Monthly This maintenance schedule is a recommended programme which should be carried out on a month by month basis It comprises two modules that are designed to take approximately hours each to complete In the first module, SPC Alignment, Machine Cycle Count, Software Checks and a standard Monthly Maintenance Check make up the elements NOTE SPC Alignment is included in the QC Calc Software package which is an optional measurement tool The second element comprises the Monthly Hardware Check, each month one or more hardware modules are scheduled for maintenance Over a twelve month period all machine modules are checked and serviced at least once Each monthly schedule, January through to December is the same no matter where the machine resides DEK service engineers already have maintenance history on which modules have been serviced and those that are in need of service If an error occurs the precise service history is known and this could prove useful in tracking a fault condition 37.6 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE DAILY MAINTENANCE DAILY MAINTENANCE WARNING HARMFUL SUBSTANCES CLEANING WIPES AND CLEANING SOLUTIONS MAY CONTAIN SUBSTANCES HAZARDOUS TO HEALTH OBSERVE ALL MANUFACTURERS’ HEALTH AND SAFETY GUIDELINES ALWAYS WEAR APPROVED PROTECTIVE CLOTHING WHEN CLEANING THE MACHINE 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 MANDATORY TOXIC CHEMICALS MAY BE PRESENT SAFETY GLOVES MUST BE WORN MANDATORY TOXIC CHEMICALS MAY BE PRESENT EYE PROTECTION MUST BE WORN Preparation The machine must be isolated from electrical power and air pressure Remove the stencil if fitted General No Task Tools Inspect the following linear bearings for contam- Spatula, THK AFB Grease ination: a Camera Carriage b Paste Dispenser c Print Carriage d ProFlow e Rising Table f Transport Rails Completed Reference Figure Camera System Paste Dispenser Print Carriage ProFlow Mechanism Rising Table Rail System NOTE Refer to Cleaning and Lubrication - Linear Bearings and Guide Rails, earlier in the chapter Inspect the following ballscrews for contamination: a Rising Table b Transport Rails Spatula, THK AFB Grease Rising Table Rail System Paste Dispenser: Remove any debris and clean the drip tray Spatula, IPA Impregnated Wipes Paste Dispenser Screen Change Mechanism: a Auto Drip Tray b Auto Drip Tray Actuator Pistons Remove any debris and clean Spatula, IPA Impregnated Wipes Screen Change Mechanism NOTE Refer to Cleaning and Lubrication - Rising Table and Transport Rail Ballscrews, earlier in the chapter Chapter Issue Jul 10 Technical Reference Manual 37.7 PREVENTIVE MAINTENANCE DAILY MAINTENANCE No Task Tools Completed Reference Figure Adjustable Screen Mount (ASM): a ASM Assembly b Pulley Assemblies c Stencil Guide Strips Remove any debris and clean Spatula, IPA Impregnated Wipes Adjustable Screen Mount (ASM) Camera: a Up and down camera lens b Board at stop opto Remove any debris and clean Spatula, IPA Impregnated Wipes Board Opto Locations Underscreen Cleaner: a Linear Bearings b Magnet Assemblies Remove any debris and clean Spatula, IPA Impregnated Wipes Underscreen Cleaner Vortex Plus Underscreen Cleaner (only): Spatula, Remove any debris and clean the filter housing IPA Impregnated Wipes Vortex Plus Underscreen Cleaner Board Optos: Spatula, Clean the top of the board at left and board at IPA Impregnated right sensors Wipes Board Opto Locations 10 Tooling: Remove any debris and clean Spatula, IPA Impregnated Wipes Rising Table 11 Grid-Look Tooling Modules: Remove any debris and clean Spatula, IPA Impregnated Wipes Rising Table 12 Rising Table: a Manual tooling plate of the rising table b Clatter bars c Splash guard (Dual Lane only) Remove any debris and clean Spatula, IPA Impregnated Wipes Rising Table Rail System Dual Lane 13 Machine Covers: Remove any debris and clean Spatula, IPA Impregnated Wipes Machine Covers NOTE Use only soap and water on the machine viewing panels Estimated time required for daily tasks 15.0 mins NOTE Any items heavily contaminated requiring thorough cleaning must be re-lubricated in accordance with the appropriate monthly maintenance task 37.8 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE DAILY MAINTENANCE Summary/Remarks Signed: Chapter Issue Jul 10 Date: Technical Reference Manual 37.9 PREVENTIVE MAINTENANCE DESCRIPTION OF THE MONTHLY MAINTENANCE SCHEDULE DESCRIPTION OF THE MONTHLY MAINTENANCE SCHEDULE Introduction Two modules form the basis of the monthly schedule The process requires that each month a machine repeatability check is performed on Squeegee Pressure and the X, Y and Theta axes This is done using the Statistical Process Control (SPC) data collection program (where available) Module The first module comprises the following elements: • SPC Alignment Check - used to set a benchmark each month, the hardware is checked to give a snapshot of the machine condition, performance is monitored to predict failure before it has an affect on production • Machine Cycle Count - machine usage is logged in the table • A Software Check is carried out, if a newer version is available this may contain known defect fixes or equipment enhancements The service engineer can recommend an upgrade for the equipment in service In addition, the machine event log is checked to identify any re-occurring errors which if not inspected/diagnosed may lead to unplanned downtime • A standard Monthly Maintenance Check consists of a series of maintenance tasks which are performed every month Machine safety checks are carried out on a basis as laid down in the monthly schedule In addition, the engineer performs maintenance on set machine modules, checks software version and records the cycle count Module 37.10 In this module, over the course of a year, the following assemblies are checked • Printhead • All Electrical Enclosures • Camera System • Squeegee Mechanism • Rising Table • Paste Dispenser • ProFlow (if fitted) • Temperature Control Module (TCM) • Screen Alignment • DC Supplies • Vacuum Filtration Unit • Pneumatic System • Safety System • Rail System • Print Carriage • Machine Level • Screen Change Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS Auto Drip Tray Actuator Piston Screen Stop Actuator Arm Lever Screen at Stop Sensor Auto Drip Tray Figure 37-11 Screen Change Mechanism 37.60 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS View on Front of Print Carriage Drive Belts Leadscrew (rear squeegee leadscrew not shown) Supernut (rear squeegee supernut not shown) Spindle Shafts Grease Nipples Figure 37-12 Squeegee Mechanism Chapter Issue Jul 10 Technical Reference Manual 37.61 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS View on Front of Print Carriage Drive Belt Leadscrew Linear Bearing Guides Figure 37-13 ProFlow Mechanism 37.62 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS View on Left Side of Machine Vertical Linear Bearing Guide (in positions) Horizontal Linear Bearing Guide (in positions) Clatter Bar (in positions) Ballscrew (in positions) Plan View on Rail Drive System Figure 37-14 Rail System Chapter Issue Jul 10 Technical Reference Manual 37.63 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS Oscillation Motor Vacuum Pressure Switch Solvent Pump Lift Solenoid Drive Pulley Filter Housing Drive Belt Oscillator Assembly Vortex Plus - Mechanical Detail (covers removed) Figure 37-15 Vortex Plus Underscreen Cleaner 37.64 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS Camera Y Linear Bearing Guide Rail (in positions) USC Magnet (in positions) USC Linear Bearing Block (in positions) USC Home Sensor View from Left Side of Machine Figure 37-16 Underscreen Cleaner Chapter Issue Jul 10 Technical Reference Manual 37.65 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS VF35i Vacuum Filtration Unit To replace any of the filters in the Vacuum Filtration Unit, carry out the following: Ensure the machine is switched OFF Remove the machine front panel Remove the air duct from the carbon filter unit using a screwdriver or box spanner to release the securing clip Release the filter retaining clip to detach the filters from the base unit 37.66 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS The back of the carbon filter unit is secured beneath a filter securing bracket To remove the filter, lift the front and pull the filter out of the machine Turn the filter unit upside down To separate the pre-filter unit from the carbon filter unit, pull the pre-filter upwards using the pre-filter frame Chapter Issue Jul 10 Technical Reference Manual 37.67 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS Replace the carbon\pre-filter as required and refit the pre-filter into the carbon filter unit Refit the carbon filter unit to the vacuum filtration unit NOTE When refitting the carbon filter unit to the base unit, ensure that the rear of the carbon filter unit is located beneath the filter securing bracket 10 Secure the carbon filter unit using the filter retaining clip 11 Refit and secure the air duct to the carbon filter unit 12 Refit the panel removed in Step VF25 Vacuum Filtration Unit To replace any of the filters in the Vacuum Filtration Unit, carry out the following: Ensure the machine is switched OFF Remove the machine front panel 37.68 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS Disconnect the mains connector from the vacuum filtration unit Using an 8mm spanner, remove the two nuts on both earth bonding points and disconnect the earth wires Using a 4mm Allen key, remove the four securing screws, two on the left side and two on the right side of the vacuum filtration unit Slide the vacuum filtration unit part way out of the machine and undo the Chapter Issue Jul 10 Technical Reference Manual 37.69 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS vacuum tube securing clamp Pull off the vacuum tube from the base unit Carefully slide the vacuum filtration unit out of the machine ensuring that the cables not snag and place the unit on the floor Release the filter retaining clip to detach the carbon filter unit from the base unit 10 Remove the air duct from the carbon filter unit 11 Turn the carbon filter unit upside down 37.70 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS 12 To separate the pre-filter unit from the carbon filter unit, pull the pre-filter upwards using the pre-filter frame 13 Replace the carbon\pre-filter as required and refit the pre-filter into the carbon filter unit 14 Refit the air duct to the carbon filter unit 15 Refit the carbon filter unit to the vacuum filtration unit 16 Secure the carbon filter unit using the filter retaining clip 17 Slide the vacuum filtration unit back into the machine approximately halfway and refit the vacuum tube 18 Locate the vacuum filtration unit over its four securing holes and secure to the base of the machine using the four securing screws 19 Reconnect the two earth leads and the mains connector 20 Refit the panel removed in Step VF10 Vacuum Filtration Unit To replace the filter in the Vacuum Filtration Unit, carry out the following: Ensure the machine is switched OFF Remove the machine front panel Chapter Issue Jul 10 Technical Reference Manual 37.71 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS Unscrew the filter case from the vacuum filtration unit VF10 Vacuum Filtration Unit Machine Frame Vacuum Tooling (if fitted) Filter Case Replace the white HDPE foam filter and refit the filter case to the vacuum 37.72 Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS filtration unit Refit the panel removed in Step Chapter Issue Jul 10 Technical Reference Manual 37.73 PREVENTIVE MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS 37.74 Technical Reference Manual Chapter Issue Jul 10 ... 37.27 PREVENTIVE MAINTENANCE MONTHLY MAINTENANCE Summary/Remarks Signed: 37.28 Date: Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE MONTHLY MAINTENANCE Month June Maintenance. .. 37.31 PREVENTIVE MAINTENANCE MONTHLY MAINTENANCE Summary/Remarks Signed: 37.32 Date: Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE MONTHLY MAINTENANCE Month July Maintenance. .. 37.43 PREVENTIVE MAINTENANCE MONTHLY MAINTENANCE Summary/Remarks Signed: 37.44 Date: Technical Reference Manual Chapter Issue Jul 10 PREVENTIVE MAINTENANCE MONTHLY MAINTENANCE Month November Maintenance