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Accuflex™ Reference Guide Part No. 1010280-01/A April 2003
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Page 1: Accuflex Reference Guide

Accuflex™Reference Guide

Part No. 1010280-01/AApril 2003

Page 2: Accuflex Reference Guide

©2003 Speedline Technologies, Inc.16 Forge Park

Franklin, Massachusetts U.S.A. 02038(508) 520-6999

All rights reservedPrinted in U.S.A.

24-hour Toll-free Technical Support Hotline

(800) 737-8110

Proprietary InformationInformation and descriptions contained herein are the property of Speedline Technologies, Inc. Such descriptions and information may not be copied or reproduced (duplicated) by any means (in any form), or disseminated or distributed without the express prior written permission (consent) of Speedline Technologies, Inc.

The information in this document is subject to change without notice and should not be construed as a commitment by Speedline Technologies, Inc. Speedline Technologies, Inc. assumes no responsibility for any errors that may appear in this document. The software described in this document is furnished under a license and may be used (not copied) only in accordance with the terms of such license. Unlawful tampering with any portion of the software or hardware contained in the Speedline Technologies, Inc. equipment automatically voids the expressed and/or implied warranty and will be construed as a copyright infringement.

No responsibility is assumed for the use or reliability of hardware or software on equipment that is not supplied by Speedline Technologies, Inc.

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Table of Contents

Proprietary Information . . . . . . . . . . . . . . . . . . . . . 2General Description . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . 8Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . 8Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Classification of Hazards. . . . . . . . . . . . . . . . . . . . . . . 9Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9International Symbols . . . . . . . . . . . . . . . . . . . . . . 9

Listing of Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Printer Component Movement . . . . . . . . . . . . . . . 11

Listing of Hazards (Continued). . . . . . . . . . . . . . . . . . 11Solder Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Solvent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Lockout/Tagout Recommendations. . . . . . . . . . . . . . 14Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Emergency Stop System . . . . . . . . . . . . . . . . . . . . 16

Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 16Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dimensions and Floor Space Requirements. . . . . . . 17Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Machine Dimensions - Front View . . . . . . . . . . . . 17Machine Dimensions - Side and Top Views. . . . . 18

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(continued)

Power, Utility and Environmental Requirements . . . 19Power Requirements . . . . . . . . . . . . . . . . . . . . . . . 19Utility and Environmental Requirements . . . . . . . 19

Unpacking and Installation. . . . . . . . . . . . . . . . . . . . . 20Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Unpack the Printer . . . . . . . . . . . . . . . . . . . . . . . . . 20Power Up and Test . . . . . . . . . . . . . . . . . . . . . . . . . 23

Controls, Indicators and Alarms . . . . . . . . . . . . . . . . 24Beacon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Permission Levels. . . . . . . . . . . . . . . . . . . . . . . . . . 24Creating a New User Account . . . . . . . . . . . . . . . . 25Using the Trackball Controller. . . . . . . . . . . . . . . . 26Clicking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Double-Clicking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Dragging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Resizing Windows . . . . . . . . . . . . . . . . . . . . . . . . . 27Closing Windows . . . . . . . . . . . . . . . . . . . . . . . . . . 27Scrolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Selecting Menu Options (Menu Bar) . . . . . . . . . . 28Using the Keyboard . . . . . . . . . . . . . . . . . . . . . . . . 28Entering Data in Dialogs . . . . . . . . . . . . . . . . . . . . 28

Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29If the User Logon Dialog Does Not Appear . . . . . 29

Shutting Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Opening an Existing Product File. . . . . . . . . . . . . . . . 31Placing Paste and Printing . . . . . . . . . . . . . . . . . . . . . 31

Placing Paste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Production Status Dialog. . . . . . . . . . . . . . . . . . . . 32Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Kneading the Paste. . . . . . . . . . . . . . . . . . . . . . . . . 33

Adjusting Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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(continued)

Initialize Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Tooling Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Manual and Automatic Board Posts . . . . . . . . . . . . . 35Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Placing Board Posts . . . . . . . . . . . . . . . . . . . . . . . . . . 36Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Using the Grid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Auto Tooling Placement . . . . . . . . . . . . . . . . . . . . 36Manual Tooling Placement . . . . . . . . . . . . . . . . . . 37Placing Individual Posts . . . . . . . . . . . . . . . . . . . . . 37Vacuum Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Moving Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Deleting Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Checking Post Positions. . . . . . . . . . . . . . . . . . . . . 38

Rail Width Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 38Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Automatic Rail Width Adjustment . . . . . . . . . . . . 39Manual Rail Width Adjustment . . . . . . . . . . . . . . . 39

Creating a File (New Board) . . . . . . . . . . . . . . . . . . . . 40Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Enter PCB Information . . . . . . . . . . . . . . . . . . . . . . 40

Product Information - PCB Tab . . . . . . . . . . . . . . . . . 41Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Product Information - Stencil Tab . . . . . . . . . . . . . . . 42Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42To Set up the Stencil Position . . . . . . . . . . . . . . . . 43To Position the Correct Image in the

Printing Position. . . . . . . . . . . . . . . . . . . . . . . . . . 43Product Information - Stencil Position Tab. . . . . . . . 43

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Setting Print Parameters. . . . . . . . . . . . . . . . . . . . . . . 45Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Print Parameters - Standard Tab . . . . . . . . . . . . . . . . 46

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(continued)

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Independent Settings. . . . . . . . . . . . . . . . . . . . . . . 47Set Stroke Parameters . . . . . . . . . . . . . . . . . . . . . . 47Set Squeegee Forward Offset . . . . . . . . . . . . . . . . 48Set Snap-Off Speed . . . . . . . . . . . . . . . . . . . . . . . . 48Set Snap-Off Distance . . . . . . . . . . . . . . . . . . . . . . 48

Print Parameters - Advanced Tab . . . . . . . . . . . . . . . 48Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Stencil Y and Board Stop Offsets. . . . . . . . . . . . . . . . 51Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51To Enter a Stencil Y Offset. . . . . . . . . . . . . . . . . . . 51To Adjust the Board Stop Offsets . . . . . . . . . . . . . 51

Set Up the Vision System. . . . . . . . . . . . . . . . . . . . . . 52Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Methods for Locating Fiducials . . . . . . . . . . . . . . . 52Accessing the Vision System . . . . . . . . . . . . . . . . 53Learning Fiducials . . . . . . . . . . . . . . . . . . . . . . . . . 53

Optimizing the Vision System . . . . . . . . . . . . . . . . . . 54Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Calibrating the Table. . . . . . . . . . . . . . . . . . . . . . . . . . 55Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55To Calibrate the Table . . . . . . . . . . . . . . . . . . . . . . 55To Perform a Test Align. . . . . . . . . . . . . . . . . . . . . 55

Setting Print Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . 56Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56To Set the Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 56To Set an Offset Value . . . . . . . . . . . . . . . . . . . . . . 57

How to Improve the Fiducial Learn Results . . . . . . . 58Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58To Change the Correlation Box. . . . . . . . . . . . . . . 60Setting the Fiducial Location Options. . . . . . . . . . 60

Squeegee Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 61

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(continued)

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Squeegee Calibration Tabs . . . . . . . . . . . . . . . . . . 62

Squeegee Calibration - Standard Tab . . . . . . . . . . . . 62Calibrate Squeegee Zero Pressure . . . . . . . . . . . . 63Calibrating the Standard Open-Loop

Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . 63Calibrating the Optional Closed-Loop

Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . 64Squeegee Calibration - Advanced Tab . . . . . . . . . . . 64

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Closed Loop Squeegee Control. . . . . . . . . . . . . . . 65

Frequently Performed Functions . . . . . . . . . . . . . . . . 66Removing/Installing Blades . . . . . . . . . . . . . . . . . . . . 67

Removing Blades . . . . . . . . . . . . . . . . . . . . . . . . . . 67Installing Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Adding Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Changing Wiper Paper . . . . . . . . . . . . . . . . . . . . . . . . 69Print Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 71

Irregular Print Thickness . . . . . . . . . . . . . . . . . . . . 71Thin Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Poor Edge Definition . . . . . . . . . . . . . . . . . . . . . . . 72Incomplete Print . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Print Peaking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Smearing - Bridging. . . . . . . . . . . . . . . . . . . . . . . . 73

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . 74Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Daily Preventive Maintenance. . . . . . . . . . . . . . . . 74Weekly Preventive Maintenance. . . . . . . . . . . . . . 75Monthly Preventive Maintenance . . . . . . . . . . . . . 75Semi-Annual Preventive Maintenance . . . . . . . . . 75Annual Preventive Maintenance . . . . . . . . . . . . . . 76Preventive Maintenance - Every Three Years . . . 76

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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General Description

IntroductionThe AccuFlex printer is a fully automatic screen/stencil printer that deposits print medium on circuit boards to enable application of surface mount components.

Operator InterfaceA trackball controller and monitor provide the operator interface to the AccuFlex system software, allowing computerized motion control and easy access to all of the following system functions:

• File creation through various user-friendly dialogs and displays.

• Unlimited file storage. You can save new files and delete existing files as required.

• Automatic and manual printing

Standard FeaturesStandard features of the AccuFlex printer include:

• Easy access to components for quick maintenance and troubleshooting

• Fully configurable permission levels to prevent unauthorized file access and access to selected printer functions

• Safety interlocks to prevent personal injury

OptionsOptional features of the AccuFlex printer include:

• Fully programmable squeegee head (closed loop)• Automatic stencil cleaner• Automatic paste dispensing system• Automatic support post placement

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Safety Information

IntroductionAlthough Cookson Electronics Equipment does its best to design and build safe machines, some safety issues must be observed when operating this equipment. These issues are classified throughout the manuals as Cautions, Warnings, and Dangers.

Classification of Hazards

IntroductionSEMI S13-0298 classifies hazards as cautions, warnings, and dangers.

CautionsA caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Caution may also be used to identify unsafe practices.

WarningsA warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

DangersA danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Danger is limited to the most extreme situations.

International SymbolsEach caution, warning, and danger listed within this documentation is accompanied by the international symbol which best represents the hazard. Leading text will indicate whether the hazard is a caution, warning, or danger. For example, the following symbol and leading text would be used to identify a chemical hazard which may result in minor or moderate injury:

Chemical Hazard

CAUTION. Text describing the chemical hazard.

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Listing of Hazards

IntroductionThis section lists, by category, the hazards which may be encountered when operating the AccuFlex™ printer.

Compressed Air

Air Pressure

CAUTION. Compressed air can cause dirt/debris to dislodge under pressure. Airborne particles and solvents may be hazardous to your health. Do not use compressed air to clean or to dry printer components. Failure to comply may result in personal injury.

Air Pressure

CAUTION. The impact of pressurized air can injure skin and eyes. Be sure to remove air pressure to the printer before servicing air pressure components. Failure to comply may result in personal injury.

Electrical

Electrical Hazard

WARNING. High voltage is present on the line (supply) side of the printer main disconnect switch when the switch is in the OFF position. Turn OFF the main disconnect switch, lock-out and tag-out the main disconnect switch and remove the power cable from its power source before servicing. Failure to comply could result in serious injury or death.

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Printer Component Movement

Hand Crush Hazard

WARNING. Before performing maintenance procedures, you may need to reposition printer components to gain better access. Stay clear as components move. Failure to comply may result in personal injury.

Listing of Hazards (Continued)

Hand Crush Hazard

CAUTION. Remove power from the printer before you perform maintenance on internally mounted components. Moveable axes are present that move quickly with force. Serious injury can occur.

Hand Crush Hazard

WARNING. Moving parts, capable of causing injury, are accessible through the printer input/output conveyor track openings. Keep hands clear of input/output conveyor track openings. Failure to comply could result in serious injury.

Hand Crush Hazard

WARNING. Moving Input/Output conveyor rails can cause injury. Conveyor rails can move during reset, jog, process changeover, or teaching operations. Keep hands clear of conveyor rails under these circumstances. Failure to comply could result in serious injury.

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Hand Crush Hazard

WARNING. Moving parts can cause injury. Certain types of motion can be commanded with the printer interlocked hood in the open position for the purposes of setup and troubleshooting. Keep hands clear of moving parts when setting up or troubleshooting the printer with the hood opened. Failure to comply could result in serious injury.

Hand Cut Hazard

CAUTION. Edges of the board clamping foils are sharp. Keep hands clear. Apply foil safety covers before manually adjusting the rails, setting up, cleaning, or servicing the printer. Exercise caution when cleaning foils and rails.

Solder Paste

Poison

WARNING. Solder paste and other printing medium contain lead and are hazardous to your health and the environment. Review the material safety data sheet before use. Always wear protective gloves and safety goggles when handling printing medium and make sure you properly dispose of all waste material according to manufacturer’s instructions. Failure to comply could result in personal injury and/or damage to the environment.

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Solvent

Poison

CAUTION. Solvent may cause skin irritation or eye injury. Always wear protective gloves and safety glasses when handling solvent, and be careful not to spill the solvent when filling the solvent tank. Review solvent’s Material Safety Data Sheet before use. Failure to comply may result in personal injury and/or damage to the environment.

Chemical Hazard

WARNING. Isopropyl alcohol is extremely flammable and must not be used in your solvent system. Use ONLY approved solvents. Failure to comply could result in personal injury, fire, or other equipment damage.

Chemical Hazard

CAUTON. Remove power from the printer before you use an approved solvent to clean the printer’s components. Be careful when you use solvents, they are combustible. Use personal protective equipment when cleaning with solvents to prevent personal injury. Review solvent’s Material Safety Data Sheet before use.

Safety Glasses

CAUTION. Wear protective safety glasses when handling solvent or printing media. These chemicals can cause eye injury. Review material safety data sheet before use.

Safety Glasses

CAUTION. Wear protective gloves when handling solvent or printing media. Solvent can cause skin irritation. Review material safety data sheet before use.

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Lockout/Tagout Recommendations

IntroductionIn order to ensure complete safety when maintaining and/or repairing your AccuFlex printer, Cookson Electronics Equipment strongly recommends that you adhere to standard shop lockout/ tagout practices. In addition to your own procedures, Cookson Electronics Equipment recommends the following.

ProcedureLockout your printer as follows:

Step Action

1 Set the Main Disconnect switch to O (off).

2 Secure the switch in the Off position using an approved lock.

3

Electrical Hazard

WARNING. Main Disconnect terminals are live. Cookson Electronics Equipment recommends that you unplug the machine power cord from its power source for added safety.

Unplug the power cord from its power source.

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Interlock System

IntroductionThe AccuFlex hood interlock system limits access to moving parts capable of causing serious injury when the printer hood is open.

Hand Crush Hazard

WARNING. Limited motor-driven and pneumatically-driven motion, for the purposes of process set-up and machine troubleshooting, is available with the interlocked cover open. Keep hands clear of moving parts when commanding motion with the interlocked cover in the open position.

ATTENTION

WARNING. Do not attempt to defeat the interlock through the use of spare interlock actuators or any other means.

4 Apply tags.

ATTENTION

The AccuFlex printer is designed to effectively dissipate stored energy when power is removed. Once power is removed and the system is efficiently locked and tagged, there is no danger of electrical shock due to stored energy.

Step Action

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Emergency Stop SystemThe AccuFlex printer features two emergency stop push button actuators on the face of the printer. The actuators are identified by large red push buttons with yellow backgrounds.

Pushing either of the emergency stop push button actuators immediately halts all machine motion by removing power from all motors and motor drives (including the solvent pump) and venting air pressure from the machine pneumatic system. The actuator is reset by twisting it counter-clockwise.

ATTENTION

WARNING. Do not use the emergency stop system as a substitute for safe machine operating practices.

Printer Specifications

IntroductionThis section describes physical requirements, utility/environmental requirements, and audible noise levels.

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Dimensions and Floor Space Requirements

EnvironmentInstall the AccuFlex in a clean, dust-free environment. There should be 2 feet (60.96cm) of clearance around the machine to provide adequate space for service.

Machine Dimensions - Front ViewThe following figure details machine dimensions as viewed from the front:

UP54936.0" Maximum

(152mm)

31.75"(807mm)

51"(1295mm)

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Machine Dimensions - Side and Top ViewsThe following figure details machine dimensions as viewed from the side and top:

UP5494

Right Side View

76.25"(1937mm)

56.0"(1420mm)

6.0" Max.(152mm)

54.5"(1384mm)

(Install either side)

Top View

26.75"(679mm)

Triple Tracks52"(1321mm) 1500OPT-8060"(1524mm) 1500OPT-8168"(1727mm) 1500OPT-82

Single Track45.5"(1156mm)

47.25"(1200mm)

ComputerAccess Door

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Power, Utility and Environmental

Requirements

Power RequirementsThe printer is factory configured to one of the voltages shown below. The voltage for the machine is displayed on the rear panel label.

ATTENTION

Do not connect to source of supply with over-current protection greater than 20 amperes.

Utility and Environmental RequirementsBelow are the utility and environmental requirements necessary to safely operate the AccuFlex printer. The weight of the printer is also shown

Configuration Current Load

(Amperes)

110-115 V Power 5

220-230 V Power 3

220-230 V Power (with vacuum stencil wiper)

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Utility Requirements

Pneumatic 1 CFM at 90 PSI/620 kpa(24 liters/minute)

25 CFM required for optional vacuum system

Pneumatic Interface Bulkhead fitting accepts a 1/2 inch (12mm) O.D. nylon tube

Temperature 50 TO 95˚F (10 to 35ºC)

Weight 1650 pounds (950 kg)

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Unpacking and Installation

IntroductionThis section describes the steps to unpack and install the AccuFlex printer.

Unpack the Printer

CAUTION

The AccuFlex is heavy. Do not attempt to lift it or move it by hand. You should lift and carry it to its operating position using a carefully positioned forklift truck. Always lift from the rear of the printer.

1. Inspect/open the shipping crate:

• Check for signs of damage to the shipping crate.• Remove the crate lid and sides.• If the printer is vacuum sealed, open the moisture

protection bag and peel it down to expose the printer. Take care when using a knife not to damage the printer body.

• Remove the foam pads from the base of the shipping crate.

2. Install the printer feet:

• Using a forklift, pick-up the printer from the rear and remove the foam pads from the legs.

• Install the feet in the positions vacated by the studs.• Move the machine to its operating location.• Adjust the feet until the machine is at the correct

operating height.• Adjust the feet until the table is level to within 0.002"

(0.05mm) over 12" (300mm) in all directions.3. Install the beacon:

• Unpack the beacon, and pass its lead through the hole at the rear right side of the printer hood.

• Connect to the fitting under the hood. Screw the beacon into position.

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4. Install the monitor support arm and monitor:

• Assemble the monitor support arm and table.• Secure the bracket to the front side of the printer. The

bracket will be on the left or the right side of the machine depending on the configuration.

• Unpack the monitor and place on the support table.• Pass the signal and main wires through the bracket

hole and connect to the corresponding cables inside the printer cabinet. Secure the monitor to the table using the clamps provided.

• Secure the monitor cables to the support arm using the cable clips on the rear of the arm.

5. Install the trackball:

• Pass the trackball lead through the support arm bracket and connect to the socket mounted on the internal framework of the printer.

• Secure the trackball cable to the monitor table so that it can be used comfortably and not touch the floor if accidentally dropped.

6. Remove the top rear cover using a phillips screwdriver. Remove the ground wire connectors on the cover.

7. Remove the lower rear cover using a 5mm hex wrench.

8. Retain brackets for future use.

9. The print carriage is secured by a small bracket on the rear left hand end of the print carriage casting (viewed from the rear of the printer). Remove this bracket.

10. Remove the table transit bracket using a 4mm hex wrench.

11. Lift the transport tracks and remove the four support pads.

12. The camera is secured by a screw and sleeve to the right hand main casting. Remove both the screw and the sleeve.

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ATTENTION

Bumping or jarring the vision probe may cause misalignment, requiring re-calibration of the assembly.

13. Cut the tie wraps and remove the bubble-wrap from the vision gantry.

14. Remove the clamping foil covers:

• Remove the ty-wraps.

ATTENTION

The foil clamps are sharp and may cause cut injury. Do not touch the foil clamps.

• Remove the covers and retain for future use.15. The stencil cleaner carriage is secured to the right hand

main casting by a screw and sleeve. Remove both the screw and the sleeve and set aside for future use.

16. Cut the tie-wrap securing the dispenser carriage to the dispenser drive belt.

17. Replace the upper and lower rear panels. Remember to replace the earth ground wire connectors when replacing this panel.

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Power Up and Test1. Ensure that:

• The mains isolator on the front of the printer is OFF.• No stencil is installed.• No squeegees are installed.• The print carriage, table and squeegee mechanisms

are free to move.2. Close the hood.

3. Connect the air supply to the printer.

4. Connect main electricity to the printer.

ATTENTION

Before power-up, verify that the supply power matches the machine’s voltage configuration.

5. Turn the electricity mains isolator switch ON. The printer will boot-up and display the User log on dialog.

6. Use the system Log-on name and Password to log onto the system. Contact your printer supplier if you need the system name/password.

7. Initialize all printer mechanisms.

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Controls, Indicators and Alarms

BeaconThe beacon is a three or four tiered indicator that displays operational status:

• Green lamp indicates normal/safe operation.• Red lamp indicates an abnormal or unsafe condition.• Blue (or white) lamp is for other states (intervention

required).

Permission LevelsA fully privileged user account is provided with each new machine. It allows you to setup the machine, and create other user accounts with varying permission levels.

Each user is assigned a permission level from 1 to 10. In addition, each user may have varying permission levels for each menu. The user must have a permission level equal to or greater than that of the menu to access the contents of that menu.

For example, if the Production menu is set to 1, the File menu to 3 and the Configuration to 5, a user with a permission level of 4 will be able to access the contents of Production and File menus, but not the Configuration menu.

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Creating a New User AccountTo create a new account:

ATTENTION

If you find that some menu options are dimmed, you cannot use them, because your user account does not allow for this level of access.

Step Action

1 Select Users from the Configure menu to view the Users dialog.

2 Click Next user, or Previous user to view the details of existing user accounts. You may delete a user from this list by clicking the Delete user button.

3 Click New user to clear the user name and password fields.

4 Enter first and last names and a password. Retype the password for confirmation. If the passwords do not match, you will be prompted to retype them.

5 In addition to the user name and password, a default log on name, such as ADMIN, appears with a preset permission level.

6 To change the user’s permission level:Select a level from 1 (lowest) to 10 by using the scroll bar to the right of the permission level field.

7 Click Close to exit the dialog.

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Using the Trackball ControllerUse the trackball to move the pointer around the screen to the desired field or function.

Use the left button to select all menu items, buttons, and check boxes.

ClickingClicking tells the AccuFlex that you have selected a choice or an action.

To click, position the pointer on the object and press the left button on the trackball. The object will change state.

Clicking a selected object a second time reverses the state.

ATTENTION

Command buttons, lists, check boxes and option buttons are collectively known as ‘controls’.

When you click in a data field, the pointer will change to a vertical bar (cursor). This is the editing cursor, and when it’s visible you can type into the field.

Double-Clicking

UP5450

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A quick way of selecting an object and an action.

ATTENTION

If you leave too long an interval between clicks, the AccuFlex treats them as two separate clicks.

Dragging To drag (move) an object to a new location on screen:

1. Position the cursor on the object, press and hold the left button on the trackball.

2. Move the trackball to reposition the object on the screen.

3. Release the left button.

Resizing Windows1. Position the cursor at the lower right hand corner of the

window; press and hold the left button on the trackball.

2. Drag the corner in or out to resize the window.

3. Release the left button.

Closing Windows To close a window, click the close (X) box on the right of the group of boxes at the top right-hand corner of the window.

Scrolling Scroll bars have a scroll arrow at either end, and a scroll box inside the body of the bar.

Move through the list one item at a time by clicking the scroll arrows, or several items at a time by clicking next to the scroll box. You can also ‘slide’ up and down the list by dragging the scroll box.

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Selecting Menu Options (Menu Bar)1. Position the cursor on the item and click the left button

on the trackball.

2. Click the option in the drop-down menu. This may take you to a dialog box, or cause more menu options to appear. Click on an option in the new menu in the same way.

ATTENTION

Additional menu options may appear. If you see another menu, click selections as described above.

Using the Keyboard The keyboard slides out of the front of the machine. To release the keyboard, push it into the machine a little, and release.

Use the keyboard for typing and editing words and numbers.

Entering Data in Dialogs 1. Click in the field with the left trackball button.

2. Drag to select any existing text you wish to replace.

3. Type the data, words or numbers.

ATTENTION

If entering numeric data, you can use the on-screen numeric keypad. Simply double-click in the field to display the numeric keypad and click on the numeric keypad to enter digits.

4. Use the Backspace or Delete button to correct mistakes.

5. Click in the next box or click OK if you’ve finished with the dialog.

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Power Up

ProcedureTo turn on and log on to the printer:

1. Turn on the rotary isolator switch (front of the printer).

2. Turn the computer monitor on (if not already on). The AccuFlex displays the Windows Log On screen. Press OK. No password is necessary.

3. If the printer is connected to a network, enter your password and press OK. The User log on dialog appears.

4. Enter your name and password. The password will appear as asterisks. Check Remember log on name, and click OK. The next time you log on, you will enter only your password.

5. A message appears telling you to be sure the EMERGENCY STOP buttons are released and to press the SYSTEM POWER button.

6. Press the SYSTEM POWER button. It will illuminate. Click OK.

7. The AccuFlex initializes and the AccuFlex main window appears.

ATTENTION

System power to the moving parts is controlled by software and hardware interlocks, and is off at this point.

If the User Logon Dialog Does Not AppearCheck the following:

• Mains supply properly connected?• Computer turned on with its own switch?• Monitor turned on with its own switch?• Monitor brightness and contrast controls set correctly?

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Shutting Down

ProcedureTo log off and turn off the printer:

1. Select File > Exit. If you have made changes since you last saved, you will be asked if you want to save them first. If an operation is in progress, you will be asked if you want to abort it and close down, or ignore the Exit command and continue.

2. Click the Windows Start menu. Select Shut Down...

3. Select Shut down the computer.

4. Click Yes. Wait for the message saying it is safe to turn the computer off.

ATTENTION

Always shut down the AccuFlex computer by using the Start menu, Shut Down command.

5. Turn the rotary isolator switch to OFF.

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Opening an Existing Product File

1. Click or select Open from the File menu. The

Open dialog displays.

2. Click the file you want from the list of files.

3. Click Open.

4. If a file is already loaded, you will be asked if you wish to save it. Choose Yes or No. The new file name appears on the title bar.

Placing Paste and Printing

Placing Paste

Poison

WARNING. Solder paste contains lead. Refer to Solder Paste and Solvent in the Safety section (at the front of this manual) before continuing with this procedure.

1. Apply solder paste to the stencil by clicking or

by selecting Utilities > Dispense paste.

ATTENTION

If your printer is not equipped with the automatic paste dispenser option, lift the front cover and put a fillet of solder paste on the front of the stencil just in front of the nearest apertures.

2. Enter Production mode by clicking or by selecting Production > Run.... The Production Status dialog appears on the screen.

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Production Status DialogThis dialog consists of seven individual tabs:

• Use Progress to view progress of printing job.• Use Setup to view current print profile data.• Use Options to set up batch and operator intervention

intervals in addition to other controls to enable inspection and paste kneading.

• Use Counters to monitor or setup the various interval counters in the system.

• Use Notes to read or enter product or system notes.• Use Utilities to operate the paste dispenser and the

stencil cleaner.• Use Vision to monitor the camera field of view.

This dialog can only be closed when printing has stopped.

Printing1. Click the Start button. The Production status dialog

displays. Printing will continue automatically until operator attention is required.

2. If hand-feeding, instructions will appear on the screen.

3. If you have selected Show alignment, the screen will show the alignment correction. The alignment correction is always displayed in this box. The software switches to this tab so that the video window becomes visible.

4. To stop printing, click the Stop button, or click Cancel on the hand-feeding instruction dialog.

ATTENTION

The dialog can only be closed when printing has stopped.

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Kneading the PasteThe printer automatically starts a kneading cycle if you request a print after the medium has been idle for longer than the knead counter allows.

1. When the Knead Cycle dialog displays, click Yes to accept or No to reject.

2. To stop printing, click Stop.

3. If you are hand-feeding boards, you can also stop printing by canceling the request for a board to be supplied.

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Adjusting Tooling

IntroductionTooling comprises the physical positions of the board support posts, the moving rail and the board stop.

Initialize Tooling

Click , or choose Setup > Tooling.

Tooling TabsSupport - Use to position support posts automatically, or to record post positions which you position manually.

Rails - Use to position the conveyor rail at the correct width.

Offsets - Use to move the board stop or stencil position.

ATTENTION

Click on the tab you require to bring it to the top.

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Manual and Automatic Board Posts

IntroductionThere are some differences between the way that you place board posts and operate the dialog when you have the auto-tooling option and when you have the manual tooling option. The following section describes both.

ATTENTION

The autotooling carousel holds up to 48 board posts in its carousel.

Hand Crush Hazard

DO NOT ATTEMPT TO OVERRIDE the safety interlock system which prevents you placing your hand near the table, the board support posts, or the carousel during operation of the auto tooling system. The camera carriage, which is used to position the board support posts, moves very fast and could cause injury.

ATTENTION

You can use many standard posts and 4 vacuum posts with this option.

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Placing Board Posts

IntroductionPosition posts individually or by using the grid function.

Using the GridThe grid allows you to define a regular rectangular grid of posts within the area of the board. You define the number of posts you want in each direction and the printer determines where to place them. You can then add or delete posts, or move any post to a new position.

ATTENTION

The AccuFlex will not permit you to place any post too near an obstruction such as a conveyor rail or another post, or too near the auto-tooling access holes or board stop position.

1. Click or select Setup>tooling.

2. Click the Support tab.

3. Within the grid area, set the number of posts for the X direction (X scroll control in the Grid area of the dialog).

4. Set the number of posts for the Y direction (Y scroll control in the Grid area of the dialog).

5. Click Create.

Auto Tooling Placement

1. Click or select Setup>tooling.

2. Click the Support tab.

3. Click Position in the Autotooling area of the dialog. Support posts are automatically placed.

4. Click Stop to halt post placement.

5. Click Store to replace posts in the carousel.

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Manual Tooling Placement

1. Click or select Setup>tooling.

2. Click the Support tab.

3. Click on the representation of the post in the PCB diagram. The X and Y coordinates of the post will appear in the Post position area of the dialog.

4. Position a standard tooling post in the location specified.

5. If using a vacuum post, delete the standard post (see below) and replace it with a vacuum post (see below).

6. Repeat for each post in the grid.

Placing Individual Posts 1. Click on where you want to place the post. See also

Vacuum Posts (below) if using manual tooling.

ATTENTION

To reposition posts using coordinates, see Moving Posts (below).

2. When the layout is complete, position the actual posts on the table as described in Using the Grid.

Vacuum Posts

ATTENTION

If using the manual tooling system with the venturi vacuum support kit, you can position up to four vacuum posts in place of standard posts.

To specify a vacuum post, click the Vacuum post control (instead of the Standard post control), and proceed as normal.

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Moving Posts1. Click on the representation of the post you want to

move. The X and Y coordinates of the post will appear in the Post position area of the dialog.

2. Move the post position by:

• Dragging the post to its new location.• Over-typing the X and Y coordinates in the X and Y

post position boxes.3. If you have autotooling and there are support posts on

the table, a message will display instructing you to store them.

• Click OK.• Click Store to replace all the posts in the carousel. You

can now proceed with repositioning the posts.

Deleting Posts1. Click on the post you want to delete.

2. Click Delete.

3. To delete all the posts, click on Delete All.

4. If you have autotooling and there are posts on the table, you will be asked to store them.

• Click OK.• Click Store to replace all the posts in the carousel. You

can now proceed with deleting the posts.

Checking Post Positions1. Click PCB in to load a board.

2. Click Table up to bring the table to tooling height.

3. Click Board Stop to toggle the board stop up and down.

Rail Width Adjustment

IntroductionDepending upon the specification of your printer, either the front or rear rail is fixed. The other rail moves under manual control or automatic control (optional) to accommodate the width of your board. You can adjust the

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width of the conveyor rails using this tab or you can adjust the rails manually.

ATTENTION

The printer will set the default width of the rails to be 0.5mm wider than the board width that you set in the PCB information dialog.

Automatic Rail Width AdjustmentTo change the width of the conveyor:

1. Click in the Rail width box and type the required width of the conveyor rails. Alternatively, click on the arrow controls to increase or decrease the width in 0.5mm steps.

2. Press Apply or Default (to return to the original setting).

Manual Rail Width Adjustment

Hand Cut Hazard

To avoid cut injury from the board foil clamps, be sure to install the board foil clamp safety covers before handling the foils.

1. Install the board foil clamp safety covers.

2. Release both rail clamps.

3. Grasp the rail and position it at the approximate board width.

4. Place a board on each end of the rails, slide the boards along the rails, and adjust the rail width so that the boards are secure and not binding (.020 - inch overplay).

5. Tighten both rail clamps by moving them to the locked position.

6. Remove the board foil clamp safety covers.

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Creating a File (New Board)

IntroductionIn summary, this process involves:

• Starting a new product file• Entering information about the PCB• Selecting Print Parameters (pressure, stroke length,

etc.)• Adjusting tooling• Setting up the vision system• Setting stencil cleaning parameters• Changing the stencil• Aligning the stencil and the board• Saving the file

Enter PCB Information

To enter PCB information, click or select Setup

>Product information. Three tabs are available:

• Use the PCB tab to enter the board description and dimensions, and also the coordinates of the board fiducials.

• Use the Stencil tab to enter information about the position of the board image on the stencil.

• Use the Stencil Position tab to position the stencil manually.

ATTENTION

If the desired dialog is not currently on top, simply click on the tab you require.

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Product Information - PCB Tab

IntroductionUse the PCB tab to set the following:

• Product Description - Click in the Description box and type a short description.

• Product Dimensions - Enter the board dimensions as accurately as possible:

– Use X to calculate the position of the board stop, so that the board is positioned centrally in the X direction to the stencil.

– Use Y to position the conveyor system. By default the rails are positioned 0.5mm (.195 in) wider than the pro-grammed board width. It is possible to change this value in the Tooling dialog (Rails tab).

– Use Z to calculate the printing position of the table when it is raised to printing height.

• Fiducial Locations - You can enter the coordinates of up to ten fiducials or you can click in the box to place the fiducials directly. The coordinates of the board fiducials are entered on this dialog. These are measured from the corner of the PCB.

ATTENTION

Make sure that you enter the coordinates of each of the fiducials that you are interested in (a minimum of two).

To delete a fiducial (i.e. set its status to “not set”), set both its X and Y coordinates to zero.

• Adjust Rail - Available when manual rails is enabled. When you click on this button, the system prompts the user to adjust the rails manually.

Hand Cut Hazard

CAUTION. To avoid cut injury from the board foil clamps, be sure to install the board foil clamp safety covers before handling the foils.

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Product Information - Stencil Tab

IntroductionPermits you to alter the position of the board image on the stencil and to position the stencil in the correct position for printing.

If your board sizes permit, you may have two or more board images on one stencil. You can then use this dialog to mark the coordinates of each board image and position the stencil with the correct image over your board.

ATTENTION

The Load, Unload, and Position buttons do not appear on the Stencil tab screen if the stencil auto load feature is not installed.

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To Set up the Stencil Position1. Set the Number of images using the scroll control.

2. If you have set just one image click Front, Center or Rear to indicate where on the stencil the image is placed.

3. Click Create.

4. Click on the desired board image. The current coordinates of that image appear.

5. Click in the coordinate boxes if necessary and overtype with the actual values.

6. Press Enter on the keyboard.

7. To load/unload the stencil, click on Load or Unload as appropriate.

To Position the Correct Image in the Printing Position1. Click on the board image position you want to use.

2. Click Position. The stencil will move backwards or forwards to position the correct image over the printing area.

3. To exit the dialog, click OK.

ATTENTION

If manual rails are enabled and the Y dimension changed, the system prompts you to adjust the rails when the tabs are clicked.

Product Information - Stencil Position Tab

IntroductionUsed to position the stencil manually.

Procedure1. Select the Position button. A prompt instructs you to

place the stencil at a specific mark on the y axis.

2. Click OK. Another prompt instructs you to place a board on the track.

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3. Click OK. The PCB loads and the camera moves to Fiducial 1.

4. Move Fiducial 1 on the PCB to the center of the live video display using the arrows.

ATTENTION

To the left of the arrows, a window with a scroll bar allows you to adjust the amount of movement each click of an arrow produces.

5. Select Stencil View and move to the same fiducial using the arrows. We are concerned with the image in the Y direction (top to bottom in the window). When both the Stencil and PCB views show the fiducial centered in the Y direction, press OK.

6. Select Stencil View before manually moving the stencil to position the fiducial in the center of the screen.

ATTENTION

Select Stencil View before manually moving the stencil to position the fiducial in the center of the screen. When Stencil View is selected, the up and down camera move arrows are not available.

7. Select Board View before moving the camera to Fiducial 1.

8. Select the Position button to position the camera over Fiducial 1. Fiducials must be entered in the PCB information tab first.

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Setting Print Parameters

Introduction

To open the Print parameters dialog, Click or choose

Setup > Print profile. Two tabs are available:

• Use the Standard tab to set the print speed and pressure, the print stroke limits, snap-off speed and distance.

• Use the Advanced tab to enter print mode, the paste kneading parameters, vacuum control, prints per cycle (deposits), alignment options, and print gap.

ATTENTION

If the desired dialog is not currently on top, simply click on the tab you require.

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Print Parameters - Standard Tab

IntroductionThe standard tab consists of seven fields:

Field Function

Print Speed Determines how quickly the squeegee moves across the stencil. Click in the Speed box and type the print speed. Alternatively set the required value with the corresponding scroll control.

Print Pressure The pressure applied to the squeegees during the printing stroke. Too little causes smearing on the stencil and poor deposition. Too much can cause “scooping”–loss of paste from larger areas–especially with a polyurethane squeegee. Click in the Pressure box and type the pressure required. Alternatively set the required value with the corresponding scroll control.

Stroke Start The distance from the fixed rail to the position of the squeegee where the stroke begins or ends. Alternatively set the required value with the corresponding scroll control.

Stroke Distance

The distance that the squeegee travels when printing a board. Alternatively set the required value with the corresponding scroll control.

Squeegee Forward Offset

The distance that the start of the squeegee travel will be offset from the zero position. The purpose of this setting is to overcome excessively wide glue lines on stencils. Alternatively set the required value with the corresponding scroll control.

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Independent SettingsTo set the print speed and pressure profiles independently for each direction of print, or automatically set them to be the same:

1. Check the Independent profiles box.

2. Select Forward or Backward as appropriate when setting the Print speed or Print pressure.

ATTENTION

To keep the forward and reverse profiles the same, clear the Independent profiles box.

ATTENTION

The squeegee zero pressure must be calibrated before printing.

Set Stroke ParametersYou need to set the limits to which the front and rear squeegees travel during printing, usually a minimum of 6mm beyond the furthest aperture on the stencil. The distances are set in terms of a stroke length and start position. Set the following:

1. Click in the Stroke start box and type the required value, or use the scroll box to change the display.

2. Click in the Distance box and type the required value, or use the scroll box to change the display.

Snap Off Speed

The speed at which the table moves down for the first few millimeters of travel, separating the board and stencil after printing. A slower speed helps the paste to come out of stencil apertures on small areas.

Snap Off Distance

The distance over which the snap-off speed applies.

Field Function

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Set Squeegee Forward Offset1. Click in the Squeegee forward offset entry box.

2. Type the required value, or use the scroll box to change the display.

Set Snap-Off SpeedClick in the Speed box and type the required value, or use the scroll box to change the display.

ATTENTION

An excessive gap and/or an excessively slow snap-off speed will increase cycle time.

Set Snap-Off DistanceClick in the Distance box and type the required value, or use the scroll box to change the display.

Print Parameters - Advanced Tab

IntroductionSet values based on the following:

Field Function

Print Mode Three modes are available:• Print Print • Print Flood • Flood Print

To set the Print Mode, click the button alongside your choice.

Deposits Defines how many print strokes constitute one print cycle. Select 1 or 2 deposits as required

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Print Gap The gap between the stencil and the board during the print stroke. Normally left at the default value of zero (on-contact). To set the print gap:Click in the Print Gap entry box and type the required value, or use the scroll box to change the display.

Knead Paste Enables kneading of paste during production: Knead paste - enables the functionKnead paste Time delay - specifies the maximum time that paste on the stencil is allowed to stand idle before a knead paste cycle is triggered.Number of cycles - sets the number of knead paste printing cycles to perform when the Knead paste cycle is triggered.Number of boards - specifies the number of boards in each knead paste cycle. For example, when the knead timer expires, each board entering the printer during a production cycle will require the paste to be kneaded until the number of boards specified has passed.

Clean Stencil After Each Cycle

Cleans the stencil after every knead paste cycle.

Field Function

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Align Options

Align on every print - specifies alignment of board and stencil fiducials on every print.

Align on first print - specifies alignment of board and stencil fiducials on the first print only. Subsequent boards will be aligned to the position of the first board.

No alignment - Check when you do not want an alignment of board and stencil fiducials

Vacuum Control

If using vacuum board posts you can control whether the vacuum is automatically turned off as soon as the print stroke completes, or is switched off when the board has been lowered from the print position.Vacuum off after print - switches off vacuum immediately after the print cycle has completed.To switch off the vacuum after the board has been lowered from the print position, clear the Vacuum off after print box.

Field Function

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Stencil Y and Board Stop Offsets

IntroductionThe following offsets must be set for printing:

To Enter a Stencil Y Offset1. From the main screen, select Setup>Tooling>Offsets.

2. Click in the relevant box and type a new value. Alternatively, you can use the corresponding scroll controls to adjust the values.

3. Click Apply to move the stencil to the new position.

To Adjust the Board Stop Offsets1. From the main screen, select Setup>Tooling>Offsets.

Offset Description

Stencil Y Moves the stencil backwards or forwards relative to the board.

Board Stop Moves the board stop position left or right or for more specialized applications.

Adjusting the X offset will move the board stop position and thus effectively move the board left or right relative to the stencil.

X Move Defines the distance that the board overshoots the printing position when first loaded. The board is then brought back into the printing position under computer control.Normally only used in conjunction with product dedicated tooling.

Y Offset Defines the position of the board stop actuator across the width of the board.Useful if the normal position coincides with a routed hole or other feature on the board edge.

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2. Click in the relevant box and type the new required value, or use the corresponding scroll controls to adjust the values.

3. Click Apply.

Set Up the Vision System

IntroductionThe vision system needs to learn at least four fiducials, two on the stencil and two on the board in order to calibrate the vision system. You have already described the board and the positions of the fiducials in the PCB information dialog. This section describes how to calibrate the vision system.

Methods for Locating FiducialsThere are two basic methods that the vision system uses to locate fiducials:

Offset Mode Description

Boundary Tracking

Outlines the shape of a fiducial and stores the values for the area and perimeter of the fiducial and the height and width of a “bounding box” that surrounds the fiducial, touching it on four sides

Correlation Uses a statistical method of comparison (normalized correlation) to find a “model” of the fiducial image

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Accessing the Vision System

1. Click or select Setup > Vision.

2. Click Yes in response to the displayed message.

3. Place a board on the conveyor input side.

4. Click OK in response to the request to do so. A Vision

setup dialog displays.

ATTENTION

The Move: field in the lower right shows the rate of camera movement produced by each click of an arrow button. You can adjust this value by using the scroll bar to the right or typing directly into the field.

Learning Fiducials To learn the fiducials:

1. If not already there, access the vision system.

2. Select the Stencil button located under the Weight selector box.

3. Select a fiducial site in the Site selector box.

4. Double click on the fiducial.

ATTENTION

The camera will not detect a fiducial image if it or its surrounding area is very dark. If this is the case, click the Blue flood box to add blue coloring to the image, and then proceed. The default state is Blue flood ON.

5. Click on the fiducial image. In most cases, the vision system will learn the fiducial and respond with the following message: Fiducial learned, the fiducial is

unique.

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6. Click OK if the above mentioned dialog appears. You will return to the Vision system dialog, where the Not Learned symbol for the fiducial will have been replaced by an icon of the fiducial.

7. If the learn was unsuccessful you will need to click More>> and adjust parameters before re-learning the fiducial.

8. Select PCB from the option button under the Site selector box.

9. Learn the corresponding PCB fiducial in a similar manner to the stencil fiducial.

10. Repeat the above steps for each remaining pair of fiducials.

Optimizing the Vision System

IntroductionOptimizing the vision system brings the stencil and board fiducials as near as possible to the center of the camera field of view when the camera is at a fiducial site.

Procedure1. If not already there, access the vision system.

2. When the camera is at a fiducial site, both stencil fiducials and board fiducials must be as near the center of the field of view as possible.

3. It may be necessary to move the stencil forward or backward in the Y direction, or to move the board stop to achieve a movement in the X direction.

4. You can enter the X and Y offsets directly or, for automatic optimization, click Optimize.

5. The stencil and board will be moved under system control to their optimal positions and the board will eject and be repositioned.

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Calibrating the Table

IntroductionTable calibration is an automatic routine in which the system learns the relationship between the physical movement of the table and the movement of the board fiducials in the camera field of view.

To Calibrate the Table1. Click Calibrate. The sequence runs automatically.

2. Click OK to store the calibration settings.

To Perform a Test AlignClick Test Align. The board moves to its alignment position. Any errors encountered will be displayed on the monitor.

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Setting Print Offsets

IntroductionYou can compensate for any print registration inaccuracies by setting an offset for the print.

Procedure1. Click Print offsets. The Printing Offsets dialog displays.

2. Set independent offset values for forward and reverse printing:

• Check the Independent forward and reverse offsets box.

• Click the Forward or Reverse option button to set the offsets for the corresponding print direction.

ATTENTION

You can set the mode of entering offsets to be X, Y, and Ø, or X, Y1 and Y2. Three adjusters move the table, two in the ‘Y’ direction, Y1 and Y2, and one in the ‘X’ direction. The X,Y, Ø control calculates the required movement in each adjuster and moves them accordingly. The X, Y1 and Y2 control moves each adjuster individually. You can switch between the two modes without losing information.

To Set the ModeClick the X, Y, Theta or the X, Y1, Y2 option buttons as appropriate. A Printing Offsets dialog displays.

ATTENTION

If the Independent forward and reverse offsets box is not checked then there will be only one offsets setting panel, not two.

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To Set an Offset Value1. Click in the appropriate offset value box.

2. Type the required value directly into the box, or increase or decrease the existing values by clicking on the white arrow heads to the right of each.

ATTENTION

Alternatively, click on the blue directional arrows to change the values.The blue dot button in the center returns all values to zero.

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How to Improve the Fiducial Learn Results

Procedure

1. Select Vision from the Setup menu or Click . The

extended Vision setup window displays.

ATTENTION

You may be able to improve the location of the fiducials by editing the locate options. See Setting the Fiducial Location Options later in this section.

2. To adjust any of the controls in the Learn mode portion of the extended dialog, click Manual learn.

3. To obtain the best possible contrast between the fiducial and its surrounding area, adjust the scroll controls for Brightness and Contrast.

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ATTENTION

The image you see normally in the vision window is a gray-scale image. Internally, within the logic of the vision system, the system has a binary light threshold below which the image is considered to be dark, and above which it is considered to be light. You may find it helpful to check the Show threshold image box and adjust the threshold setting to achieve a better result.

ATTENTION

If the system can see more than one item in its field of view, it may not be able to distinguish between them when trying to locate a fiducial. You should try to make the fiducial unique within the field of view. If Correlation is used to locate a fiducial, you should consider the whole correlation box to be the effective fiducial and not an individual mark. You may therefore be able to make the fiducial unique by altering the size or position of the box within the camera field of view.

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To Change the Correlation Box1. Click Set Correlation box.

2. Click on a point in the camera field of view window where you want the first corner of your new correlation box to be.

3. Move the pointer to the opposite corner on the new correlation box.

4. Click OK.

ATTENTION

If Blue flood is not checked, do not attempt to define a new correlation box while the Show threshold image box is checked. This will turn part of the monitor screen dark and the mouse will not work in this area.

Setting the Fiducial Location OptionsWhen viewed by the vision system camera, each fiducial image will vary in some way from the stored information. A 100% match between the stored information and a fiducial in the camera field of view (during Locate) is unlikely. A level of acceptability must be established to Locate a matching fiducial. That level is determined in the Location

options dialog.

The amount of contrast and the reflectivity of the fiducial will determine the percent match value.

To set the locate options for each fiducial:

1. Select the fiducial using the Site selection box.

2. Click Options to display the Location options dialog.

3. Click the desired locate mode (Correlation with or

Tracking with).

4. Set the% match value on Correlation and/or Tracking to the required values.

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ATTENTION

Default values are excellent starting points. You might set a lower value if, for example, the paste deposits reflect light unevenly.

5. Test the ability of the vision system to locate a given fiducial by clicking Test Locate.

Squeegee Calibration

IntroductionThe AccuFlex uses one of two methods for applying squeegee pressure:

• Open Loop (Standard) where the system applies pressure calculated from stored system parameters.

• Closed Loop (Optional) where the pressure is constantly measured and may be adjusted during the print stroke.

This calibration applies to a particular pair of squeegees, and is stored in the board file. Provided you always use the same pair of squeegees with this board, you can remove and refit them without the need to re-calibrate.

CAUTION

Do not begin printing until this calibration has been carried out. Failure to comply can result in damage to the machine or stencil!

ATTENTION

You need to calibrate the zero pressure for both front and rear squeegees. Calibrating the squeegee zero pressure is not the same as setting squeegee printing pressures.

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Squeegee Calibration TabsThe Squeegee calibration menu is divided into two tabs:

• Standard which provides controls to set the squeegee zero pressure point.

• Advanced which provides general controls to:– Set the step values– Set the squeegee heights

Click on the tab you require to bring it to the top.

Squeegee Calibration - Standard Tab1. To access the Squeegee calibration dialog:

Click , or select Setup > Squeegees.

ATTENTION

Each squeegee has an independent current default position. These default positions are saved as machine parameters, not board file parameters, and you can change the default positions using this dialog.

2. To save the new positions of the squeegees as the new defaults, check the Store new values as default box. The new values will become effective when you click OK to leave the dialog.

3. To move a squeegee to the current default position:

• Select Front or Rear squeegee as required.• Click Move to front/rear squeegee default.

4. To reload the default position as the current calibrated position, click Use front/rear squeegee default.

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Calibrate Squeegee Zero PressureThe squeegees used for this procedure must be those used to print. A stencil must be fitted, but it can be any one. See Loading Stencils in Section H: Frequently Performed Functions. No board is required.

CAUTION

Forcing the squeegee down hard against the stencil could damage the stencil.

Calibrating the Standard Open-Loop Control System1. Fit the squeegees.

2. Click Rear to identify the squeegee being calibrated.

3. Click Initialize squeegees to begin calibration.

4. Click Coarse to select large incremental moves.

5. Click the Up and Down arrow buttons to move the selected squeegee down until it is near the stencil surface.

6. Click Fine to select small incremental moves.

7. Click the Down arrow button until the squeegee just contacts the stencil across its full length. Use the Up arrow to ease the squeegee up a little if necessary.

8. Click Calibrate to store the setting.

9. Click Front and repeat steps 4 to 8 to calibrate the front squeegee zero pressure.

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Calibrating the Optional Closed-Loop Control

System1. Fit the squeegees.

2. Click Rear to identify the squeegee being calibrated.

3. Click Find zero to automatically move the squeegee to the calibration point.

4. Click Calibrate to store the setting.

5. Click Front and repeat steps 3 and 4 to calibrate the front squeegee zero pressure.

ATTENTION

You may further fine tune the position of the squeegees using the arrow buttons before clicking Calibrate.

6. To view the readings taken during the last print cycle, select Utilities > Squeegee feedback chart.

Squeegee Calibration - Advanced Tab

IntroductionThis dialog allows you to control the coarse and fine incremental steps that the squeegee makes when you are calibrating the squeegee zero pressure.

You can also define:

• The height above the stencil of the non-printing squeegee.

• The height of the squeegees above the stencil after a print has occurred to allow paste to be released from the squeegee. The squeegee then returns to the non-printing height.

• The height above the stencil of the squeegees during a stencil inspection.

• How the pressure control is used in a printer fitted with the optional squeegee closed-loop control system.

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Closed Loop Squeegee ControlIf your printer has closed-loop squeegee control, the advanced tab displays an additional Feedback system dialog. Within this dialog:

1. Check Feedback enabled to allow feedback control.

2. Select whether you want continuous correction of squeegee pressure while printing.

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Frequently Performed Functions

ATTENTION

Adhere to the warnings printed in the front of this manual.

Loading Stencils

Poison

WARNING. Solder paste contains lead. Refer to Solder Paste and Solvent in the Safety section (at the front of this manual) before continuing with this procedure.

1. Click to access the Utilities dialog or select Utilities>Printer Utilities from the main screen.

2. Click the Stencil tab.

3. Click Load Stencil and follow system prompts.

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Removing/Installing Blades

Poison

WARNING. Solder paste contains lead. Refer to Solder Paste and Solvent in the Safety section (at the front of this manual) before continuing with this procedure.

Removing Blades1. Open the hood.

2. Loosen the squeegee blade thumb screws.

3. Remove the squeegee blade.

Installing Blades1. Open the hood.

2. Slide the rear blade into the holder with the blade angled away from you.

3. Tighten the thumb screws.

4. Slide the front blade into the holder with the blade angled toward you.

5. Tighten the thumb screws.

6. Close the cover.

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Adding Paste

Poison

WARNING. Solder paste contains lead. Refer to Solder Paste and Solvent in the Safety section (at the front of this manual) before continuing with this procedure.

ATTENTION

The paste dispenser uses 1 Kg Pyle-type solder paste cartridges.

To replace the paste cartridge:

1. Click to access the Utilities dialog or select

Utilities>Printer Utilities from the main screen.

2. Click the Paste tab.

3. Click Change cartridge.

4. Lift the front cover.

5. Unscrew the top of the cartridge cover and lift out the empty paste cartridge.

6. Take off the nozzle. It is advisable to clean the nozzle at this point.

7. Remove the caps from the new cartridge and attach the nozzle.

8. Put the new cartridge in the holder and screw the cover back on. The dispenser uses the common Pyle-type solder paste cartridge.

9. Click the close box to exit the dialog.

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Changing Wiper Paper

Poison

WARNING. Solder paste and solvent exposure potential. Refer to Solder Paste and Solvent in the Safety section (at the front of this manual) before continuing with this procedure

1. Select Utilities>Printer Utilities from the main screen.

2. Select the Stencil tab.

3. Click Change USC paper.

4. Determine whether or not you want to move the stencil and make the appropriate selection on screen.

5. Lift the front cover.

6. Remove the stencil.

ATTENTION

Reusing stencil cleaner paper on the opposite side is not advised.

7. Fold the end of the paper (into a point) to make it easier to feed into the mechanism:

8. Fasten the end of the paper to the take-up roll with a small piece of sticky tape.

9. Route the paper along the proper paper path:

UP5039

Fold

Fold

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10. When you have changed the paper, close the printhead.

11. Click Done.

Paper-Feed Roll

UP5038

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Print Troubleshooting

Irregular Print Thickness• Screen or stencil not parallel to PCB surface.• Squeegee pressure not even.• Squeegee not level.• Stencil aperture warped, dented, or bent.• Debris on bottom of stencil: Clean or scrape stencil.• Irregular solder mask.

Thin Print• Squeegee pressure too high (polyurethane blades).• Squeegee durometer too soft.• Stencil thickness incorrect or worn.

RG0021

RG0022

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Poor Edge Definition• Temperature/Humidity too high.• Worn or damaged stencil.• Snapoff too large.• Paste condition unacceptable (temperature/age).

Incomplete Print• Stencil clogged: Wipe and clean apertures.• Paste is low: Add paste.• Paste sticking to squeegee.• Paste not at working viscosity or not thawed

completely.• Stencil not wiped clean from squeegee.

RG0025

RG0020

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Print Peaking• Stencil snapoff too large.• Temperature/Humidity too high.• Excess solder paste clinging to bottom of stencil: Clean

stencil.• Slow snapoff speed too fast.

Smearing - Bridging• Excessive squeegee pressure or downstop.• Excess solder paste on bottom of stencil – Insufficient

wipe frequency.• Snapoff distance too large.• Poor gasketing of stencil to board.• Stencil aperture damaged.

RG0024

RG0023

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Preventive Maintenance

IntroductionThis section lists the preventive maintenance schedules for maintaining the AccuFlex printer.

ATTENTION

Adhere to the warnings printed in the front of this manual.

Daily Preventive Maintenance Operator:

• Printer– Clean paste build-up– Check solvent supply– Clean top cover and monitor screen– Check wiper paper supply– Check wiper paper tension– Verify wiper plenum pressure. Adjust regulator

Technician:

• Stencil Cleaner– Replace cleaning paper (if required)– Add cleaning solvent (if required)– Add paste (if required)

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Weekly Preventive MaintenanceTechnician:

Perform daily maintenance

• Inspect:– Conveyor belts– Board foil clamps– Squeegee blades

• Clean:– Camera (top and bottom lenses)– Table top– Individual board posts– All electromechanical faces

Monthly Preventive MaintenanceTechnician:

• Perform weekly maintenance• Wipe the following:

– Print carriage bearings– Stencil cleaner/camera guide rails– Table rising rails– Front hood pneumatic struts

Semi-Annual Preventive MaintenanceTechnician:

• Perform monthly maintenance• Camera

– Re-grease the camera X ball screw• Stencil Cleaner

– Change the filter unit

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Annual Preventive MaintenanceTechnician:

• Perform monthly and semi-annual maintenance• Camera

– Re-grease the rack and pinion• Re-grease the following bearings:

– Printhead carriage– Stencil cleaner– Table rising rails– Camera carriage

• Check squeegee drive belts (condition and tightness)• Clean/grease rising table actuator shaft• Inspect conveyor belts• Inspect air lines to board stop and board foil clamps• Check downward motion of squeegees and carriers

Preventive Maintenance - Every Three YearsTechnician:

• Replace pneumatic hood struts

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Repair

IntroductionThis section describes the procedure for replacing failed components.

ATTENTION

Adhere to the warnings printed in the front of this manual when performing repair/replace procedures.

Procedure1. Power down the printer.

2. Replace failed component(s) using standard shop practices.

ATTENTION

Refer to the illustrated parts breakdowns in the AccuFlex™ Maintenance/Troubleshooting Guide for additional information as required.

3. Power up the printer and test the replaced component(s).

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Index

A

Adjust Rail button, 41Air, compressed

hazards of, 10removal of, 10use of, 10

Alcohol, isopropyluse of, 13

B

Beaconfunctional

description, 24Board clamping foils

hazards of, 12Board description and

dimensionsentering, 40

Board file creationsummary, 40

Board foil clampsweekly maintenance, 75

Board imagepositioning for

printing, 43Board image position

informationentering, 40

Board postsautomatic placement, 36checking position of, 38deleting, 38manual placement, 37moving, 38placing individual, 37specifiying vacuum, 37weekly maintenance, 75

Board posts, manual and automaticdescription of, 35

Board stop offsetadjusting, 51

Brackets (shipping)removal of, 21

C

Cameraannual maintenance, 76semi-annual

maintenance, 75weekly maintenance, 75

Camera carriageannual maintenance, 76

Camera field of viewmonitoring, 32

Camera movement rateadjusting, 53

Cautiondefinition of, 9

Closed loop control systemcalibrating, 64

Conveyor beltsweekly maintenance, 75

Conveyor track movementhazards of, 11

Conveyor track openingshazards of, 11

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Index

D

Dangerdefinition of, 9

Dataentering in dialogs, 28entering numeric, 28

Dialoglocation options, 60production status, 32squeegee calibration, 62

Dimensionsprinter, 17

E

Electrical hazards, 10Electromechanical faces

weekly maintenance, 75Emergency stop system

definition of, 16Energy

stored, 15Environmental requirements

printer, 17, 19

F

Featuresstandard, 8

Fiducial coordinatesentering in software, 41

Fiducial learn resultsimproving, 58

Fiducial location optionssetting, 60

Fiducialsdeleting, 41learning, 53making unique within

camera field of view, 59

methods for locating, 52Fiducials (board and stencil)

centering in camera field of view, 54

G

Gridusing to place board

posts, 36

H

Hazardsclassification of, 9listing of, 10

I

If 29Interlocks

defeating, 15

K

Keyboardreleasing, 28

L

Lockout/Tagout recommendations, 14

Logging off the printer, 30

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Index

M

Maintenanceannual, 76daily, 74monthly, 75semi-annual, 75three-year, 76weekly, 75

Menu optionsaccess to, 25

O

Offsetboard stop, 51Stencil Y, 51X move, 51Y, 51

Open loop control systemcalibrating, 63

Operating temperatureprinter, 19

Operation, printerwith open hoods, 12

Operational requirementspower, utility and

environmental, 19Operator interface, 8Operator intervention inter-

valssetting, 32

Optionslist of, 8

P

Paste disensercontrols, 32

Permission levelsdefinition of, 24

Pneumatic hood strutsmonthly

maintenance, 75replacement interval, 76

Pneumatic interfaceprinter, 19

Pneumatic requirmentsprinter, 19

Power requirementsprinter, 19

Power up procedure, 29Powering up the printer, 23Print carriage bearings

monthly maintenance, 75

Print cycle readingsviewing, 64

Print offsetsmodes for setting, 56setting, 56

Print parameteralign options, 50clean stencil after each

cycle, 49deposits, 48knead paste, 49print gap, 49print mode, 48vacuum control, 50

Print parametersprint pressure, 46print speed, 46snap off distance, 47snap off speed, 47squeegee forward

offset, 46stroke distance, 46stroke start, 46

Print parameters dialogopening, 45

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Index

Print pressuresetting for each direction of

print, 47Print profile data

viewing, 32Print speed

setting for each direction of print, 47

Print troubleshootingincomplete print, 72irregular print

thickness, 71poor edge definition, 72print peaking, 73smearing-bridging, 73thin print, 71

Printerdaily maintenance, 74lifting and moving, 20

Printer beaconinstallation of, 20

Printer component movementhazards of, 11

Printer coversremoval of, 21

Printer feetinstallation of, 20

Printer monitorinstallation of, 21

Printhead carriageannual maintenance, 76

Printingstarting, 32stopping, 32

Printing progressviewing, 32

Product descriptionentering in software, 41

Product dimensionsentering in software, 41

Product fileopening an existing, 31

R

Rail widthautomatic default

setting, 39Rail width adjustment

automatic 39manual, 39overview, 38

Railsfixed, 38

S

Set Correlation functionuse of, 60

Show threshold image boxuse of, 59

Shutting down the printer, 30

Snap-off distancesetting, 48

Snap-off speedsetting, 48

Solder pasteadding, 68kneading, 33placing, 31safe handling of, 12

Solventsafe handling of, 13use of in cleaning the

printer, 13Solvent hazards, 13Specifications

printer, 16

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Index

Squeegee bladesremoving and

installing, 67weekly maintenance, 75

Squeegee calibrationclosed loop system, 61open loop system, 61

Squeegee calibration tabadvanced, 64standard, 62

Squeegee control, closed loopdescription, 65

Squeegee default positions, 62

Squeegee forward offsetsetting, 48

Squeegee pressuremethods for applying, 61

Squeegee stroke parameterssetting, 47

Squeegee zero pressurecalibrating, 63

Stencilmanual positioning, 40

Stencil cleanerannual maintenance, 76controls, 32daily maintenance, 74monthly

maintenance, 75Stencil position

setting up, 43Stencil Y offset

entering, 51Stencils

loading, 66Stencl cleaner

semi-annual maintenance, 75

Symbolsinternational, 9

System, interlockdescription of, 15

T

Tableweekly maintenance, 75

Table calibration, 55Table rising rails

annual maintenance, 76monthly

maintenance, 75Tooling

adjusting, 34definition of, 34initializing, 34tabs, 34

Tooling carouselmaximum number of

board posts, 35Trackball

installation of, 21Trackball controller

use of, 26

U

User accountcreating a new, 25

User logon dialogdoes not appear, 29

Utility requirementsprinter, 19

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Index

V

Vacuum off after printdescription, 50

Vision systemaccessing, 53optimizing, 54setting up, 52

W

Warningdefinition of, 9

Weightprinter, 19

Windowsclosing, 27resizing, 27

Wiper paperchanging, 69

83