Công nghệ SMT máy DEK mô đun dual lane module

DUAL LANE MODULE OVERVIEW CHAPTER 21 DUAL LANE MODULE OVERVIEW Figure 21 1 Front Print Machine Item Description Item Description 1 Rear Pass Through Rail (rail 4) 4 Front Print Rail (rail 1)..............

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CHAPTER 21 DUAL LANE MODULE

OVERVIEW

Figure 21-1 Front Print Machine

1 Rear Pass Through Rail (rail 4) 4 Front Print Rail (rail 1)

2 Front Pass Through Rail (rail 3) 5 Rear Print Rail (rail 2)

1

2

3 4

5

6

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Figure 21-2 Rear Print Machine

1 Rear Print Rail (rail 4) 4 Front Pass Through Rail (rail 1)

2 Front Print Rail (rail 3) 5 Rear Pass Through Rail (rail 2)

1

2

3 4

5

6

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Transport Rails

Figure 21-3 Board Sensors and Motors

Rear Pass Through Rail

Rear Pass Through Rail Belt Motor

Rear Print Rail Belt Motor

Front Print Rail Belt Motor

Front Pass Through Rail Belt Motor

Rear Print Rail Front Pass Through Rail

Front Print Rail

Board Present Sensor

Board at Right Sensor Board at Left Sensor

NOTE

The pass through and print rails would

be reversed on a rear print machine. Plan View

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Figure 21-4 Rail Sensors

The dual lane module consists of two sets of transport rails, one being a print lane and the other being a pass through lane There are two dedicated machine variants:

• Front print machine

• Rear print machineThe front print machine prints the product on the front rails (rails 1 and 2) Rails

3 and 4 (rear) are the pass through rails designed to act as a conveyor passing the product through the machine to the next stage

On the rear print machine, rails 1 and 2 (front) are the pass through rails and rails 3 and 4 (rear) are the print rails

The machines have a rail clash sensor and vane fitted to rails 2 and 3 which prevents rail 2 being driven into rail 3

The machines may be installed in the following configurations:

4 Rail Clash Vane

7

6

1 2

3

4 5

View on Left Hand Side

NOTE The pass through and print rails would

be reversed on a rear print machine.

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Figure 21-5 In-Line Install Plan View on Machines

DEK Rear Print Machine

Print Lane

Pass Through Lane

Lane 1

DEK Front Print Machine

Dual Lane Placement Machine

Board

Loader

Board

Loader

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Figure 21-6 Staggered Install

Print Lane The print rails are a programmable width conveyor system, set by the board

product file, which transports the board using belts from the upline machine, into this machine, where the board is positioned, clamped and printed After printing the board is transferred using the same belts to the downline machine

The front print rail is the fixed rail, rail 1 on the front print machine and rail 3 on the rear print machine The rear print rail homes to the fixed rail

The print rails can be fitted with one of the following board clamping ments:

arrange-• 250mm or 500mm Board Clamps

• 250mm or 500mm Foil-less Clamps

• Board Snugger Assembly

• Over the Top Snugger (see Transport Rail Chapter for details)Foil-less clamps are utilized for thin pliable boards where there is a requirement

to print close to the board edge The foil-less clamps are assisted with the use

of a vacuum box beneath the product board

Board snuggers are an alternative to the standard board clamps and are utilized when there is a requirement to print close to the board edge

Board

Loader

Board Loader

Conveyor

Lane 2 Lane 1

Dual Lane Placement Machine

Plan View on Machines

DEK Standard Machine

Print Lane DEK Front Print Machine

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1 The dual lane machines use narrow board clamps allowing rail 2 and 3 to abut each other Standard DEK board clamps must not be fitted to a dual lane machine.

2 With board snuggers fitted, the rail clash sensor becomes inactive Care must be taken to avoid a collision between rails 2 and 3 when setting the board width in the product file and when driving the rails in diagnostics.

3 For tooling details see the tooling chapter.

4 For over the top snugger details see the transport rails chapter.

Pass Through Lane The pass through rails are a programmable width conveyor system, set by the

M40 Dual Lane Controller, which transports the board unhindered through the machine

NOTE The pass through rails are designed to continue running with the front printhead cover in the open position and to stop when the E-Stop is pressed.

Rear Board Clamp

Board Clamps

Rear Foil-less Clamp

Foil-less Clamps

Rear Snugger Plate

Counterweight Block

Board Snuggers

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The front pass through rail is the fixed rail, rail 3 on the front print and rail 1 on the rear print machine The rear pass through rail homes to the fixed rail.

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Rising Table

Manual Tooling Plate Splash Guard

Manual Tooling Plate Frame 3mm Allen Key

Rising Table Motor

Rising Table Home Sensor and Vane

Manual Tooling Plate

Manual Tooling Plate Frame

Splash Guard 3mm Allen Key

Rising Table Motor Rising Table Home Sensor and Vane

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The rising table on the dual lane machine is identical to the rising table on the standard DEK machine with the exception of the manual tooling plate and the home vane.

The manual tooling plate is raised by 37mm to prevent the splash guard lifting the pass through lane when the rising table moves to print height To compen-sate for the extra height, the rising table home vane allows the table to home 37mm lower than a standard machine

As no tooling is required for the pass through lane, the manual tooling plate extends below the print rails only A splash guard replaces the manual tooling plate below the pass through rails to prevent print material falling on to the rising table motor assembly

NOTE Objects must not be placed on the splash guard as damage may occur to the pass through rails as the rising table moves to print height.

MMI The MMI beacon on the Dual Lane machine incorporates a blue light at the top

of the beacon This indicates that a board has failed to reach the board present sensor on the end of the pass through rails within 10 seconds of leaving the upline machine

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C Chase

Figure 21-9 Dual Lane C Chase (Manual Screen Load)

Figure 21-10 Dual Lane C Chase (Auto Screen Load)

The dual lane C chase is unique to the dual lane machine, allowing the screen

to locate further back in the machine This is a requirement so that a front justified screen image can be aligned to the board on a rear print machine

NOTE The front print machine may be fitted with an Adjustable Screen Mount (ASM) For further information on the ASM, refer to the Adjustable Screen Mount (ASM) chapter.

Manual Screen

Load The manual screen load C chase is fitted with a screen present sensor which informs the software that a screen is in the chase

On a front print machine, the screen depth adjuster extension is not fitted to the

Screen Support Plates

View on Left Hand Side of Dual Lane C Chase

Counter Roller Plate

(in 4 positions)

Screen Location Sensor (Rx)

Screen Location Sensor (Tx)

Screen Location Sensors (Tx)

Screen Location Sensors (Rx)

Pneumatic Screen Clamp (in 6 positions)

Screen Support Plates

View on Left Hand Side of Dual Lane C Chase

Counter Roller Plate (in 4 positions)

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Auto Screen Load The auto screen load C chase is fitted with two screen location sensors When

an auto screen load sequence is initiated, the software uses the screen location sensors to ascertain whether the screen is located at the front or rear of the C chase This is essential as the software cannot differentiate between the front and rear frames of the screen

Board Specifications

Maximum

Dimensions The minimum board width for the print lane and the pass through lane is 40.5mm.

The maximum board width is determined by the following:

• Position of rail 3

• Whether the machine is front print or rear print

• Size of the manual tooling plate

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Figure 21-12 Pass Through Lane

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Foreign Machine Interface (FMI) Connections

The dual lane machine requires separate FMI communications for the print lane and the pass through lane

For the print lane, the normal DEK FMI rules apply If the DEK machine is connected to upline and downline machines/conveyors that use SMEMA, Fuji

or Panasonic communications protocol, an FMI pod is used If either of the communication protocols is not SMEMA, Fuji or Panasonic, a Multi-Interface Unit (MIU) must be used

For the pass through lane, if the DEK machine is connected to upline and downline machines/conveyors that use SMEMA, Fuji or Panasonic communi-cations protocol, connection is made to the M40 Dual Lane enclosure If either

of the communications protocol is not SMEMA, Fuji or Panasonic, an MIU must

be used

Figure 21-13 FMI Location

Print Lane MIU FMI Pod

M40 Dual Lane Controller Pass Through Lane MIU

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There are many configurations depending on the rules mentioned previously Below is an example on how to connect two side-by-side printers to an upline and a downline machine/conveyor using MIU’s:

NOTE

1 The pass through lane MIU would not be required if the connecting upline and downline machines use SMEMA, Fuji or Panasonic communications protocol Connection would be made to the M40 Dual Lane enclosure

2 The print lane MIU would be replaced with an FMI pod (located at the rear

of the machine) if the connecting upline and downline machines use SMEMA, Fuji or Panasonic communications protocol.

Below is an example on how to connect two printers separated by a conveyor,

to an upline and a downline machine/conveyor using MIU’s:

NOTE The conveyor separating the printers must be considered as the downline machine to the rear print machine and the upline machine to the front print machine.

Print Lane

Pass Through Lane

M1SK1 DOWNLINE M1SK2

M1PL3 DEK M/C M1SK4

DEK USB

+12V +24V SW SEND UPLINE SEND DOWNLINE CONTROL IN UPLINE READY DOWNLINE READY CONTROL OUT POWER

I/P'S

O/P'S PROTOCOL SELECTION UP LINE DOWN LINE

MIU 191114

M1PL3 DEK M/C M1SK4

DEK USB

I/P'S

O/P'S PROTOCOL SELECTION UPLINE DOWN LINE

MIU 191114

M1PL3 DEK M/C M1SK4

DEK USB

I/P'S

MIU 191114

M1PL3 DEK M/C M1SK4

DEK USB

I/P'S

Conveyor

Pass Through Print Pass Through Print

Print Lane

Pass Through Lane

M1PL3 DEK M/C M1SK4

DEK USB

I/P'S

MIU 191114

M1PL3 DEK M/C M1SK4

DEK USB

I/P'S

MIU 191114

M1PL3 DEK M/C M1SK4

DEK USB

I/P'S

MIU 191114

M1PL3 DEK M/C M1SK4

DEK USB

I/P'S

Pass Through Print Pass Through Print

Conveyor Lane 1

Lane 2

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ADJUSTMENTS AND SETTINGS

Rail Lifted Sensors

1 Select Maintenance.

2 Select Diagnostics.

3 Use Next or Previous to highlight Rising Table.

4 Select Select Module.

5 Ensure that Home Rising Table is highlighted.

6 Select Run Diagnost.

7 Select Exit.

8 Use Next or Previous to highlight Rail System.

10 Ensure that Home Rail Width is highlighted.

12 Remove the left and right hand safety covers to gain access to the rear rail

13 Place a 0.5mm feeler gauge between the rail shock absorber on the rear

right rail transport leg and the rail stop bar (clatter bar)

Right Transport Leg

Rear Rail

Front View of Rail System

Left Transport Leg

Linear Bearing

Feeler Gauge

Rail Stop Bar

Opto Vane Opto

Shock Absorber

Sensor LED

Enlarged View of Right Rail Opto

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14 Adjust the vane bracket using a 2.5mm Allen key, so that the sensor LED is

Off with a 0.5mm feeler gauge fitted and On with a 0.7mm feeler gauge

fitted

15 Repeat Steps 13 and 14 for left hand end of the rear rail

16 Use Next or Previous to highlight Drive Rail To Max Board Width.

18 Repeat Steps 13 to 15 for setting the vane at this position

19 Use Next or Previous to highlight Home Rail Width.

21 Repeat Steps 13 to 15 at the home position

22 Use Next or Previous to highlight Cycle Rails.

24 Ensure the left and right sensor LED’s remain Off over the full travel of the

There are two different types of sensors available:

• Ultrasonic - For use with product boards that have large holes or cut-outs

• Background Suppressed Opto - Standard

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Ultrasonic The ultrasonic sensor switching threshold can be set by utilising the sensor’s

teach facility To achieve an optimum setting carry out the following procedure:

1 Ensure that there is no board on the rails near the sensor

2 Press and hold the yellow SET button on the sensor until the status LED

flashes green (approximately 2 seconds)

NOTE Ensure that use of the Set button is not approached from above the sensor

to avoid the sensor detecting hand movement.

3 Place a board across the top of the rails (not on the belts) as shown in the graphic below:

4 Press the SET button on the sensor The status LED remains on for

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Ultrasonic Sensor

Resetting The sensor is equipped with an anti-tamper protection feature which locks the teach facility Use the following procedure to reset the sensor:

1 Disconnect the electrical connection to the sensor

2 After 5 seconds, reconnect the sensor

3 Press and hold the yellow SET button on the sensor until the status LED

flashes rapidly (approximately 10 seconds)

4 The sensor is reset

5 Re-teach the sensor as detailed in the previous section

Background

Suppressed Opto The background suppressed opto switching threshold can be adjusted by means of a sensitivity control To achieve an optimum setting carry out the

following procedure:

1 Place a board on the rails covering the sensor

2 Turn the sensitivity control fully anti-clockwise, ensure that the amber LED

is extinguished

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3 Re-adjust the sensitivity control clockwise until the amber LED illuminates.

NOTE

If the amber LED is flashing, this indicates a week signal Re-adjust the sensitivity control.

4 Remove the board from the rails and confirm the amber LED extinguishes

5 Turn the board 90° and position back onto the rail system, (so that the board lies on top of the rail system as shown in the figure below)

6 Confirm that the amber LED is extinguished If the amber LED illuminates, turn the sensitivity control anti-clockwise until the amber LED extinguishes

7 Remove the board

8 Position the board back on the rail system, as in Step 1, and confirm that the amber LED illuminates

9 Remove the board from the rails and confirm that the amber LED guishes

extin-10 This completes the adjustment If the board has holes or cut-outs, continue with this procedure

11 Slide the board backward and forward across the sensor ensuring that the LED is only triggered by the leading and trailing edges of the board

12 If the LED flickers when encountering holes or cut-outs, turn the sensitivity control clockwise a further quarter turn

13 Repeat Steps 11 and 12 until the correct setting is achieved

14 Remove the board from the rails and confirm that the amber LED guishes

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extin-Rail Parallelism

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.

Front Print Rail 1 Select Open Cover Commands.

2 Select Carriage To Rear.

3 Select Unload Screen.

4 Open the front printhead cover

5 Remove the screen from the machine

6 Close the front printhead cover

7 Press the System button.

8 Select Back.

15 Select Exit.

16 Use Next or Previous to highlight Rising Table.

18 Use Next or Previous to highlight Raise Table to Vision Height.

20 Select Exit.

22 Select Select Module The board clamps are released.

24 Remove any tooling from the manual tooling plate

25 Remove the board clamp from the front transport rail, Board Clamp Replacement - Replacement Procedures section of this chapter refers

26 There are two versions of the rail setting jig (DEK Part No 191156) and they are labelled:

• Standard Rails (round belts)

• Heavy Board Rails (flat belts)

27 Confirm which type of rails are fitted to the machine and select the ate rail setting jig

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appropri-28 Place the jig on the manual tooling plate ensuring that the location pins on the underside of the jig abut the front face of the manual tooling plate Check

there is no gap using a 0.05mm feeler gauge.

29 Secure the jig to the front rail using the two jig to rail thumbscrews

Rail Setting Jig

Jig to Table Thumbscrews

Jig to Rail Thumbscrew Jig to Rail Thumbscrew

View on Rear of Transport Rails

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30 Secure the jig to the rising table using the two jig to table thumbscrews

31 Check that the location pins are up against the front edge of the manual

tooling plate using a 0.05mm feeler gauge, as in Step 28.

32 Using feeler gauges check that the gap between both alignment pads and

the belt support plate of the front rail is 0.25mm ±0.05mm.

33 If adjustment is not necessary continue with Step 46

Jig to Table Thumbscrews

Jig to Rail Thumbscrew Jig to Rail Thumbscrew

View on Rear of Transport Rails

Feeler Gauge Alignment

Pad

Belt Support Plate

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34 Using a 3mm Allen key, slacken the four securing bolts attaching the right

hand transport leg to the carriage nut

35 Repeat Step 34 on the left hand transport leg

36 Using a 4mm Allen key, through the access holes in the board edge guide,

slacken the four rail securing bolts (two each side)

37 Loosen the two jig to rail thumbscrews on the rail setting jig

38 Adjust the front rail position to achieve the settings in Step 32

39 Tighten the two jig to rail thumbscrews on the rail setting jig

Rail Setting Jig

Securing Bolts Securing Bolts

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40 Recheck the parallelism as detailed in Step 32.

41 Tighten the bolts slackened in Steps 34 to 36

42 Recheck the parallelism as detailed in Step 32

43 When the adjustment is complete, remove the board edge guides from each end of the rail

44 Remove each bolt disturbed (one at a time), apply a suitable locking compound and fully tighten

45 Refit the board edge guide to each end of the rail

46 Remove the rail setting jig from the rising table

47 Fit the board clamp to the front rail

48 Close the front printhead cover

49 Press the System button.

50 Select Exit.

51 Select Exit.

52 Select Back.

Rear Print Rail NOTE

Ensure Front Print Rail parallelism has been carried out prior to commencing this procedure It is recommended this procedure is carried out by two persons.

1 Select Shut Down.

2 Select Continue.

3 Switch the mains isolator to OFF.

4 Remove the left and right machine side panels

5 Using a pair of rail parallelism H jigs (DEK Pt No 158109) fit the jigs to the front transport rail left and right leg linear guides Ensure the linear guides fit snugly in the jig slots

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6 Move the rear transport rail forwards, towards the front rail, until the rear leg linear guides fit into the slots of the H jigs.

7 If both sets of linear guides fit snugly in the slots of the jigs, the rear transport rail is parallel to the front rail, go to Step 15

8 Remove the H jigs and, carry out the Front Rail Parallelism check as detailed earlier in this chapter

9 Refit the H jigs

10 If both sets of linear guides fit snugly in the slots of the jigs, the rear transport rail is parallel to the front rail, go to Step 15

Linear Guide Rails

Rear Right Transport Rail Leg

H Jig

View on Front Right Hand Side

Front Right Transport Rail Leg

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11 Loosen the four bolts securing the rear right hand side rail leg to the bearing block.

12 Repeat Step 11 on the left hand side

13 Reposition the rear rail until the linear guides fit snugly in the jig slots

14 Tighten the eight securing bolts loosened in Steps 11 and 12

15 Remove the H jigs

16 Refit the machine panels removed in Step 4

Front Pass Through

Rail The front pass through rail is paralleled to the front print rail using a pair of rail setting jigs The pass through reference rail position must be known so that the

correct rail setting jig can be used To obtain the pass through reference rail position, use the procedure below and refer to the table below to obtain the part number for the correct jig

NOTE Ensure the Front Print Rail parallelism has been carried out prior to commencing this procedure.

1 If the Pass Through Reference Rail Position is known go to Step 23

View on Right Hand Side of Transport Rails

Pass Through Reference Rail Position Rail Setting Jigs

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2 To obtain the Pass Through Reference Rail Position on a front print machine, go to Step 4.

3 To obtain the Pass Through Reference Rail Position on a rear print machine,

16 Select Set Rail Offset.

27 Place one of the rail setting jigs on the far left hand side of the rails as shown

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in the graphic below.

NOTE Ensure that the rail setting jig sits on top of the transport belts on the front print and the front pass through rails.

28 Secure the setting jig to rail 1 using the rail locking thumbscrew

29 Repeat Steps 27 and 28 on the far right hand side of the rails with the second rail setting jig

Front Print Machine

Rear Print Machine

Rail Locking Thumbscrew Rail Setting Jig

Front Print Rail (rail 1)

Front Print Rail (rail 3)

Front Pass Through Rail (rail 1)

Front Pass Through Rail (rail 3)

Transport Belt

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30 Ensure that there is a gap between the rail setting jig and the board guide

using a 0.2mm feeler as a Go gauge and a 0.3mm feeler as a No Go gauge,

at both ends of the rail

31 If adjustment is not required, go to Step 37

32 Using a 4mm Allen key, loosen the rail stop securing screws on the left and

right hand sides

33 Using a 3mm Allen key, loosen the front pass through rail securing block

securing screws on the left and right hand sides

NOTE Both securing screws must be loosened to prevent any bending of the rail.

34 Move the front pass through rail to achieve the setting in Step 30

35 Tighten the front pass through rail securing block securing screws on the left and right hand sides Recheck the setting

36 Move the rail stops up against the front pass through rail securing blocks and lock in position by tightening the securing screws

37 Remove the rail setting jigs from the rails

38 Refit the left and right safety covers

Front Pass Through Rail Securing Block

Front Pass Through Rail Support

Securing Screws Rail Stop

View on Right Hand Side

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Rear Pass Through

Rail NOTE Ensure the Front Pass Through Rail parallelism has been carried out prior to

commencing this procedure.

1 Select Shut Down.

2 Select Continue.

4 Using the drive belt, manually wind the rear pass through rail close to the front pass through rail

5 Slowly continue to wind the rail towards the front rail until contact is made

6 The first points to touch should be on the right hand side with a maximum of

0.2mm gap on the left hand side.

7 To adjust the parallelism, slacken the adjustable idler pulley

8 Jump the teeth (in the appropriate direction) of the moving rail drive pulley

9 Tension the belt with the adjustable idler pulley

10 Recheck the parallelism of the pass through rails

11 Repeat Steps 7 to 10 until parallelism is achieved

12 Using a suitable cable tie, engage a forcemeter with the adjustable idler pulley

13 Slacken the adjustable idler pulley and apply a horizontal force of 6kg.

14 Maintaining this force, tighten the adjustable idler pulley securing nut

15 Using a tension meter on the top of the drive belt (mid point between the

View on Rear of Rails and Rising Table Mechanism

Moving Rail (Pass-Through Lane)

Idler Pulley Drive Belt

Rail Drive Plate

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pulleys), check the tension is between 33Hz to 40Hz.

16 Adjust the drive belt tension as necessary to achieve the reading in Step 15

17 Power up and initialise the machine

18 During initialisation, the rails home and drive to the programmed board width This evens out the tension in the belt

19 Repeat Steps 15 and 16

Rail Clash Sensor

The rail clash sensor prevents rail 2 being driven into rail 3 during certain diagnostic functions where the software allows the rail width to exceed the maximum board width

NOTE Before making any adjustment to the rail clash sensor, it is essential to check that rail 3 is parallel to rail 1, Rail Parallelism section refers.

Use the following procedure to check and adjust the sensor:

9 Use Next or Previous to highlight Drive Rail Using Jog Buttons.

11 Press and hold the left hand jog button to drive rail 2 towards the rear of the machine Release the button immediately the rail clash warning is displayed

on the monitor

12 Remove the left and right hand side safety covers

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13 Using feeler gauges, measure the gap between rail 2 and rail 3 on the left hand side.

14 Repeat Step 13 on the right hand side of the rails

15 Ensure the measured gaps on both sides are the same, 2.5mm ±0.3mm.

16 If the measured gaps are the same and within the tolerance, go to Step 31

17 If the measured gaps are not the same, check the parallelism of rail 2 and

3, Rail Parallelism section refers

18 Continue with this procedure if both measured gaps are the same but not within the tolerance specified in Step 15

21 Loosen the two rail clash sensor bracket securing screws

22 Move the sensor towards the front of the machine to increase the gap or towards the rear of the machine to decrease the gap

View on Left Hand Side of Rail 2 and 3

Rail Clash Sensor Vane Rail Clash Sensor Bracket

Rail Clash Sensor Securing Screw

(in 2 positions)

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23 Tighten the two rail clash sensor bracket securing screws.

26 Use Next or Previous to highlight Drive Rail Using Jog Buttons.

28 Press and hold the left hand jog button to drive rail 2 towards the rear of the machine Release the button immediately the rail clash warning is displayed

on the monitor

29 Re-check the gap between rails 2 and 3 on the left and right hand sides

30 Repeat Steps 21 to 29 to achieve the measurement of 2.5mm ±0.3mm.

33 Refit the two safety covers

NOTE Board clamps are used in the following procedure, the procedure is identical for foil-less clamps and snuggers

1 Remove the belt guide from either side of the belt support plate on the rear rail

Belt Support Plate

Belt Guide

View on Rear Rail

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2 Using feeler gauges, check that the gap between the rear board clamp and

the belt support plate is 0.325mm ±0.025mm Ensure that the rear board

clamp is parallel to the belt support plate

3 If adjustment is necessary, go to Step 8 for 250mm board clamps and continue with Step 4 for 500mm board clamps

4 Remove the four board clamp securing screws and lift off the board clamp Retain the four screws

Cross Section of Rear Rail Assembly

View on Rear Board Clamp

Rear Board Clamp

Belt Support Plate

Rear Board Clamp

Moving Rail

500mm Board Clamp Mechanism

Board Clamp Securing Screws

Access Holes

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