Công nghệ SMT máy DEK bảo dưỡng phòng ngừa preventive maintenance

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

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37.1


PREVENTIVE MAINTENANCE
MACHINE INFORMATION

37.2

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Chapter Issue 4 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 2
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’.

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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 5 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 1 X 173358)

173373

VF35i Filter Kit (1 X 173357 and 1 X 173359)

173374

VF25 Carbon Filter

163552

VF25 Standard Pre-Filter

163551

VF25 Filter Kit (1 X 163552 and 1 X 163551)

173102

VF10 HDPE Foam Filter (pack of 3)

187871

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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:
1. Clean the linear bearing guide rail using a plastic spatula.
2. Remove any build up of grease around the linear bearing block.
3. Apply a very thin coating of THK AFB grease (DEK part No 141146) along
the whole length of the guide rail using a cloth.
4. Ensure that the three exposed faces are greased to prevent surface rust.
5. 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

3 (2 Y and 1 X)

5

Paste Dispenser

1

1

Print Carriage

2

3

ProFlow

2

2

Rising Table

2

4

Transport Rails

6

6

Underscreen Cleaner

Uses the 2 Camera Y Rails

2

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:
1. Clean the ballscrew using a plastic spatula.
2. Remove any build up of grease around the ballscrew bearing block.
3. Apply a very thin coating of THK AFB grease (DEK part No 141146) along
the whole length of the ballscrew using a cloth.
4. Using the cloth, remove any surplus grease near the ballscrew bearing
blocks.

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PREVENTIVE MAINTENANCE
SUMMARY OF THE PROGRAMME

SUMMARY OF THE PROGRAMME
The PM Plan
Daily Schedule

Approximately 15 Minutes

Monthly Schedule

Approximately 4 Hours

SPC Alignment Check
(where available)

Monthly Hardware Check

Machine Cycle Count
Software Check
Monthly Maintenance Check
2 Hours

2 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 2 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.

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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
1

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.
2

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.
3

4

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PREVENTIVE MAINTENANCE
DAILY MAINTENANCE
No

Task

Tools

Completed

Reference Figure

5

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)

6

Camera:

a. Up and down camera lens
b. Board at stop opto
Remove any debris and clean.

Spatula,
IPA Impregnated
Wipes

Board Opto Locations

7

Underscreen Cleaner:
a. Linear Bearings
b. Magnet Assemblies
Remove any debris and clean.

Spatula,
IPA Impregnated
Wipes

Underscreen Cleaner

8

Vortex Plus Underscreen Cleaner (only):
Spatula,
Remove any debris and clean the filter housing. IPA Impregnated
Wipes

Vortex Plus Underscreen
Cleaner

9

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.

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PREVENTIVE MAINTENANCE
DAILY MAINTENANCE
Summary/Remarks

Signed:
Chapter Issue 4 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 1

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 2

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
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PREVENTIVE MAINTENANCE
DESCRIPTION OF THE MONTHLY MAINTENANCE SCHEDULE

•
Accuracy Check

Visit

Pre X

Adjustable Screen Mount (ASM)

For an accuracy check, except where stated otherwise, thirty test cycle measurements are set (preceded by ten cycles unmeasured to allow the machine to
settle). Pre and Post print measurements are taken to record the accuracy of
the alignment in CPK values and the front and rear squeegee pressures
displayed in bar units.
Pre Y

Pre Theta

Post X

Post Y

Post Theta

Front Sqy

Rear Sqy

1st

2.00

1.63

1.97

1.84

1.40

1.60

5.15

4.86

2nd

1.89

1.63

1.84

1.80

1.40

1.60

5.00

4.86

3rd

1.86

2.00

1.98

1.48

1.48

1.70

4.98

4.86

4th

100 Cycles
1.84

100 Cycles
1.94

100 Cycles
1.76

100 Cycles
1.63

100 Cycles
1.46

100 Cycles
1.56

100 Cycles
4.50

100 Cycles
4.80

5th
6th
7th
8th
9th
10th
11th
12th

SPC Results

Where the QC Calc for Windows program is installed and customers have

employed the DEK Equipment Utilization Programme, SPC data capture can
graphically show critical alignment and squeegee pressure accuracy. The
graphs in their visual form are often useful in determining the optimum maintenance plan.
NOTE
DEK Equipment Utilization Programme is available from DEK Customer Support Group.
Customers may opt to use the collected data in their own management system,
DEK cannot provide support for any programme other than DEK EUP.

Examining the
Collected Data

In addition to examining the SPC data which is displayed graphically in the QC
Calc for Windows program, engineers can extract information about machine
performance from other sources.
The data collected on the machine is stored in ‘event.dat’ and ‘readings.dek’
files, accessible in the following locations, E:\config\readings.dek for SPC
data and E:\config\event.dat for error occurrences. Information can be displayed in a text editor and specific data can be examined eg, events between

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PREVENTIVE MAINTENANCE
DESCRIPTION OF THE MONTHLY MAINTENANCE SCHEDULE

dates or a specific word or phrase.
27/04/2000

27/04/2000
27/04/2000
27/04/2000
27/04/2000
27/04/2000
27/04/2000
27/04/2000
27/04/2000
27/04/2000
27/04/2000
27/04/2000

14:00:02
14:00:14
14:00:14
14:00:16
14:00:22
14:00:30
14:00:28
14:00:02
14:00:02
14:00:14
14:00:14
14:00:16

40022
56183
48273
325876
41570

50001
41212
3867
40022
56183
48273
325876

Valid Dongle Detected
System Power On
System Initialised
PCIB Readyy
Rail Lifted Error
Machine Recovery Started
Product Data Changed
Power Up
Valid Dongle Detected
System Power On
System Initialised
PCIB Ready

Find and Replace

Find

Replace Go To

Find what:

Error

Options: Search Down

Find Next
Cancel
More

event.dat
DATA X reverse [mm]
,0,0000.0,0000.0,0.414,-0.02234
DATA Y reverse [mm]
,0,0000.0,0000.0,0.521,-0.07776
DATA T reverse [mm]
,1,0000.0,0000.0,2.414,-0.05568
CONFIG CamAx2
CONFIG FACTORAL TTHJXCK

readings.dek
Each occurrence of an error for example, can be examined to see if the rate at
which it has occurred has increased (is it a random occurrence or an increasing
trend?).
Authorization

At the end of each monthly task a Summary/Remarks form is provided to allow
the engineer to make comments or express observations. He must sign off and
date the form so that there is a record that the schedule has been completed.
Summary/Remarks

Signed:

Date:

NOTE
The following pages can be used as a template to create a preventive maintenance schedule. They can be photocopied and stored as a permanent record
of maintenance tasks performed.
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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

MONTHLY MAINTENANCE
Each month the following tables are filled in prior to carrying out any equipment
checks. Run ten cycles prior to making the thirty test measurements.
SPC Alignment
Check
Visit

Follow details in the Accuracy Check section previously described in this
chapter. Record details for each visit.

Pre X

Pre Y

Pre Theta

Post X

Post Y

Post Theta

Front Sqy

Rear Sqy

100 Cycles

100 Cycles

100 Cycles

100 Cycles

100 Cycles

100 Cycles

100 Cycles

100 Cycles

1
2
3

4
5
6
7
8
9
10
11
12

Machine Cycle
Count

Record the machine cycle count for each visit.
Visit

Insert the Cycle Count

No. of cycles between visits

1

Chapter Issue 4 Jul 10

2

-

3

-

4

-

5

-

6

-

7

-

8

-

9

-

10

-

11

-

12

-

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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Month January Maintenance Procedure
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.
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.
MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. SAFETY GLOVES MUST BE WORN.

MANDATORY

TOXIC CHEMICALS MAY BE PRESENT. EYE PROTECTION MUST BE WORN.

SPC Alignment
Check and Machine
Cycle Count

Fill out details: SPC Alignment Check and Machine Cycle Count at the start of
this section.

Software
Software Check

Record

Tick

Check the date and time settings.
Check the software loaded and options.
Check the software version is the latest issue.

View Event Log

Tick

Check for initialisation errors.
Check for screen position errors (31210, 31211, 31212).
Check for camera errors (31207, 31208).

Monthly Maintenance
Environmental Control Module (if fitted)

Tick

Inspect the air filters clean/replace (as detailed in the equipment manual).
Check for leakage in the system.
Check the system holds the temperature (as described in the equipment manual).

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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE
Under Screen Cleaner (USC) (if fitted)

Tick

Check that the paper feed mechanism operates correctly (Blue/Cyclone only).
Check the oscillation motor moves the cleaner mechanism back and forth (Vortex/Cyclone only).
Check the condition of the squeegee blades (Blue only). Squeegee blades must be replaced every 6 months.
Check that the cleaner mechanism raises and lowers smoothly.
Check the screen cleaner height.
Check that the solvent dispenses and it is at a suitable pressure.
Check that solvent dispenses evenly across the paper or cassette.
Check the condition of all hoses and connections.
Check the correct operation of the vacuum filtration unit.
Perform a USC cycle and confirm correct operation.

Pump USC Solvent for 10 seconds to keep the spray bar clear of paste.

General Maintenance

Tick

Check the condition of the board clamps.
Cycle the board clamps ensure that clamping and release is smooth.
Cycle the Test 265test 1 board on the transport rails ensure smooth operation.
Clean the table top of paste and debris, apply a wipe of light oil.
Clean the transport rails of paste and debris.
Inspect tooling pins/assemblies/modules for wear.
Inspect the air filters and clean/recommend replacement.

Monthly Hardware Check
Machine Safety

Tick

Check operation of the cover interlock.
Check operation of the Emergency Stop button.
Examine the condition of the mains input lead.
Check all earth leads and bonding points are connected.
Toggle all beacon lights.

Pneumatics

Tick

Check air pressure switch is set to 3 bar.

Check the air inlet regulator is set to 4.5 bar.
Check pipes for air leaks.
Check and empty the air line water trap.
Check and empty the air line water trap on the Grid-Lok Control Unit.

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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

M36 Control Enclosure

Tick

M37 Power Supply Enclosure

Tick

PC Enclosure

Tick

Inspect wiring and connections.
Ensure cards are seated properly.
Clean area around air inlets.

Inspect wiring and connections.
Clean area around air inlet.

Remove debris from enclosure.
Clean area around air inlets.

Summary/Remarks

Signed:
37.16

Date:
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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Month February Maintenance Procedure
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.
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.
MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. SAFETY GLOVES MUST BE WORN.

MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. EYE PROTECTION MUST BE WORN.

SPC Alignment
Check and Machine
Cycle Count

Fill out details: SPC Alignment Check and Machine Cycle Count at the start of
this section.

Software
Software Check

Record

Tick

Check the date and time settings.
Check the software loaded and options.
Check the software version is the latest issue.

View Event Log

Tick

Check for initialisation errors.

Check for screen position errors (31210, 31211, 31212).
Check for camera errors (31207, 31208).

Monthly Maintenance
Environmental Control Module (if fitted)

Tick

Inspect the air filters clean/replace (as detailed in the equipment manual).
Check for leakage in the system.
Check the system holds the temperature (as described in the equipment manual).

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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Under Screen Cleaner (USC) (if fitted)

Tick

Check that the paper feed mechanism operates correctly (Blue/Cyclone only).
Check the oscillation motor moves the cleaner mechanism back and forth (Vortex/Cyclone only).
Check the condition of the squeegee blades (Blue only). Squeegee blades must be replaced every 6 months.
Check that the cleaner mechanism raises and lowers smoothly.

Check the screen cleaner height.
Check that the solvent dispenses and it is at a suitable pressure.
Check that solvent dispenses evenly across the paper or cassette.
Check the condition of all hoses and connections.
Check the correct operation of the vacuum filtration unit.
Perform a USC cycle and confirm correct operation.
Pump USC Solvent for 10 seconds to keep the spray bar clear of paste.

General Maintenance

Tick

Check the condition of the board clamps.
Cycle the board clamps ensure that clamping and release is smooth.
Cycle the Test 265test 1 board on the transport rails ensure smooth operation.
Clean the table top of paste and debris, apply a wipe of light oil.
Clean the transport rails of paste and debris.
Inspect tooling pins/assemblies/modules for wear.
Inspect the air filters and clean/recommend replacement.

Monthly Hardware Check
Camera System

Tick

Check the full movement of axes travel, no fouling of looms.
Check the vanes do not foul the sensors.
Inspect camera for signs of damage.
Check the camera at the reference position.
Check the camera to screen focus.

Check the camera carriage drag chain for droop.
Check the X and Y belts for tension and wear.
Inspect the camera optics windows (board/screen) clean as necessary.
Check the board stop operates correctly.
Check the camera X critical home position.
Check the camera Y critical home position.

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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Squeegee Mechanism

Tick

Check housing is free from debris.
Inspect wiring and connections.
Check the correct seating of the load cell.
Lubricate the spindle shafts (in 2 positions).
With the squeegees in the down position, wipe the leadscrews and supernuts with an IPA wipe and re-grease.
Check the condition and tension of the drive belts.
Check the squeegees home correctly.
Cycle the squeegees over their entire movement.
Perform a calibration of the squeegee reference height.

Summary/Remarks

Signed:
Chapter Issue 4 Jul 10

Date:
Technical Reference Manual

37.19


PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Month March Maintenance Procedure
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.
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.
MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. SAFETY GLOVES MUST BE WORN.

MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. EYE PROTECTION MUST BE WORN.

SPC Alignment
Check and Machine
Cycle Count

Fill out details: SPC Alignment Check and Machine Cycle Count at the start of
this section.

Software
Software Check

Record

Tick

Check the date and time settings.
Check the software loaded and options.
Check the software version is the latest issue.

View Event Log

Tick

Check for initialisation errors.
Check for screen position errors (31210, 31211, 31212).
Check for camera errors (31207, 31208).

Monthly Maintenance
Environmental Control Module (if fitted)

Tick

Inspect the air filters clean/replace (as detailed in the equipment manual).
Check for leakage in the system.
Check the system holds the temperature (as described in the equipment manual).

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MONTHLY MAINTENANCE

Under Screen Cleaner (USC) (if fitted)

Tick

Check that the paper feed mechanism operates correctly (Blue/Cyclone only).
Check the oscillation motor moves the cleaner mechanism back and forth (Vortex/Cyclone only).
Check the condition of the squeegee blades (Blue only). Squeegee blades must be replaced every 6 months.
Check that the cleaner mechanism raises and lowers smoothly.
Check the screen cleaner height.
Check that the solvent dispenses and it is at a suitable pressure.
Check that solvent dispenses evenly across the paper or cassette.
Check the condition of all hoses and connections.
Check the correct operation of the vacuum filtration unit.
Perform a USC cycle and confirm correct operation.

Pump USC Solvent for 10 seconds to keep the spray bar clear of paste.

General Maintenance

Tick

Check the condition of the board clamps.
Cycle the board clamps ensure that clamping and release is smooth.
Cycle the Test 265test 1 board on the transport rails ensure smooth operation.
Clean the table top of paste and debris, apply a wipe of light oil.
Clean the transport rails of paste and debris.
Inspect tooling pins/assemblies/modules for wear.
Inspect the air filters and clean/recommend replacement.

Monthly Hardware Check
Machine Safety

Tick

Check operation of the cover interlock.
Check operation of the Emergency Stop button.
Examine the condition of the mains input lead.
Check all earth leads and bonding points are connected.
Toggle all beacon lights.

Pneumatics

Tick

Check air pressure switch is set to 3 bar.

Check the air inlet regulator is set to 4.5 bar.
Check pipes for air leaks.
Check and empty the air line water trap.
Check and empty the air line water trap on the Grid-Lok Control Unit.

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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Print Carriage

Tick

Inspect wiring for chaffing/drag chain for wear.
Check the vane does not foul the sensor.
Check the linear bearing guides for contamination.
Cycle the carriage ensuring smooth running.
Cycle the carriage, checking the belt tracking.
Check the critical home dimension.
Check the tension of the belt.

Rail System

Tick

Inspect wiring connections and pneumatic pipes.
Check the linear bearing guides for contamination.
Check the board clamp condition for damage.
Check the board clamp bearings operate smoothly.
Check the belts for wear, ensure no slippage.
Check the belt joint condition.
Check the condition of the rail lift pillars and anvils.
Check the condition of the rails for wear.
Cycle the rails ensuring smooth travel over entire travel.
Check the rails reach the minimum width setting.
Check the rail width setting, use setting plate 140403.
Check the belt tension is correct.
Check the rails for parallelism.
Check the rail to table height setting.

Summary/Remarks

Signed:
37.22

Date:
Technical Reference Manual

Chapter Issue 4 Jul 10


PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Month April Maintenance Procedure
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.
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.
MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. SAFETY GLOVES MUST BE WORN.

MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. EYE PROTECTION MUST BE WORN.

Full QC Calc
Fill out details: SPC Alignment Check and Machine Cycle Count at the start of
Performance Check this section. Perform 100 cycles.
Software
Software Check

Record

Tick

Check the date and time settings.
Check the software loaded and options.
Check the software version is the latest issue.

View Event Log

Tick

Check for initialisation errors.
Check for screen position errors (31210, 31211, 31212).
Check for camera errors (31207, 31208).

Monthly Maintenance
Environmental Control Module (if fitted)

Tick

Inspect the air filters clean/replace (as detailed in the equipment manual).
Check for leakage in the system.
Check the system holds the temperature (as described in the equipment manual).

Chapter Issue 4 Jul 10

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PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Under Screen Cleaner (USC) (if fitted)

Tick

Check that the paper feed mechanism operates correctly (Blue/Cyclone only).
Check the oscillation motor moves the cleaner mechanism back and forth (Vortex/Cyclone only).
Check the condition of the squeegee blades (Blue only). Squeegee blades must be replaced every 6 months.
Check that the cleaner mechanism raises and lowers smoothly.
Check the screen cleaner height.
Check that the solvent dispenses and it is at a suitable pressure.
Check that solvent dispenses evenly across the paper or cassette.
Check the condition of all hoses and connections.
Check the correct operation of the vacuum filtration unit.
Perform a USC cycle and confirm correct operation.
Pump USC Solvent for 10 seconds to keep the spray bar clear of paste.

General Maintenance

Tick

Check the condition of the board clamps.
Cycle the board clamps ensure that clamping and release is smooth.
Cycle the Test 265test 1 board on the transport rails ensure smooth operation.
Clean the table top of paste and debris, apply a wipe of light oil.
Clean the transport rails of paste and debris.
Inspect tooling pins/assemblies/modules for wear.
Inspect the air filters and clean/recommend replacement.

NOTE
Due to extended SPC checks (100 Cycles) the Monthly Hardware Check is not
included in Aprils’ schedule.
Summary/Remarks

Signed:
37.24

Date:
Technical Reference Manual

Chapter Issue 4 Jul 10


PREVENTIVE MAINTENANCE
MONTHLY MAINTENANCE

Month May Maintenance Procedure
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.
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.
MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. SAFETY GLOVES MUST BE WORN.

MANDATORY
TOXIC CHEMICALS MAY BE PRESENT. EYE PROTECTION MUST BE WORN.

SPC Alignment
Check and Machine

Cycle Count

Fill out details: SPC Alignment Check and Machine Cycle Count at the start of
this section.

Software
Software Check

Record

Tick

Check the date and time settings.
Check the software loaded and options.
Check the software version is the latest issue.

View Event Log

Tick

Check for initialisation errors.
Check for screen position errors (31210, 31211, 31212).
Check for camera errors (31207, 31208).

Chapter Issue 4 Jul 10

Technical Reference Manual

37.25