Công nghệ SMT máy DEK bảo dưỡng phòng ngừa preventive maintenance

Công nghệ SMT máy DEK bảo dưỡng phòng ngừa preventive maintenance MACHINE INFORMATION INTRODUCTION DEK PART NUMBERS CLEANING AND LUBRICATION SUMMARY OF THE PROGRAMME DAILY MAINTENANCE DESCRIPTION OF THE MONTHLY MAINTENANCE SCHEDULE MONTHLY MAINTENANCE CLEANING, LUBRICATION AND MAINTENANCE DIAGRAMS

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

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 tion 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.

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 dis- posed 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’

DEK PART NUMBERS

Cleansing and

Lubrication

Lubrication Chart

Vacuum Filters

VF35i Filter Kit (1 X 173357 and 1 X 173358) 173373VF35i Filter Kit (1 X 173357 and 1 X 173359) 173374

VF25 Filter Kit (1 X 163552 and 1 X 163551) 173102

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:

Rising Table and

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.

Location Linear Bearing Guide Rails Linear Bearing Blocks

SUMMARY OF THE PROGRAMME

The PM Plan

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.

Approximately 4 Hours

SPC Alignment Check(where available)

2 Hours

Software CheckMonthly Maintenance Check

Machine Cycle Count

2 HoursMonthly Hardware CheckMonthly Schedule

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

1 Inspect the following linear bearings for

Refer to Cleaning and Lubrication - Linear

Bear-ings and Guide Rails, earlier in the chapter.

Spatula, THK AFB Grease Camera SystemPaste Dispenser

Print CarriageProFlow MechanismRising TableRail System

2 Inspect the following ballscrews for

contamina-tion:

a Rising Table

b Transport Rails

NOTE

Refer to Cleaning and Lubrication - Rising Table

and Transport Rail Ballscrews, earlier in the

chapter.

Spatula, THK AFB Grease Rising TableRail System

3 Paste Dispenser:

Remove any debris and clean the drip tray Spatula,IPA Impregnated

Wipes

Paste Dispenser

4 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 Any items heavily contaminated requiring thorough cleaning must be re-lubri- cated in accordance with the appropriate monthly maintenance task.

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

Underscreen Cleaner

8 Vortex Plus Underscreen Cleaner (only):

Remove any debris and clean the filter housing Spatula,IPA Impregnated

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

c Splash guard (Dual Lane only)

Remove any debris and clean

Spatula,IPA Impregnated Wipes

Rising TableRail SystemDual Lane

Machine Covers

Signed: Date:

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 ware is checked to give a snapshot of the machine condition, performance

hard-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 nance tasks which are performed every month.

mainte-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 In this module, over the course of a year, the following assemblies are checked.

• ProFlow (if fitted)

• Temperature Control Module (TCM)

• Adjustable Screen Mount (ASM)

Accuracy Check For an accuracy check, except where stated otherwise, thirty test cycle

meas-urements 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.

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 mainte- nance plan.

NOTE DEK Equipment Utilization Programme is available from DEK Customer Sup- port 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 dis-

played in a text editor and specific data can be examined eg, events between

dates or a specific word or phrase.

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.

NOTE The following pages can be used as a template to create a preventive mainte- nance schedule They can be photocopied and stored as a permanent record

of maintenance tasks performed.

readings.dek event.dat

27/04/2000 14:00:02 40022 Valid Dongle Detected

27/04/2000 14:00:22 41570 Rail Lifted Error 27/04/2000 14:00:14 48273 System Initialised

27/04/2000 14:00:14 48273 System Initialised

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

27/04/2000 14:00:30 50001 Machine Recovery Started 27/04/2000 14:00:14 56183 System Power On

27/04/2000 14:00:14 56183 System Power On 27/04/2000 14:00:28 41212 Product Data Changed 27/04/2000 14:00:16 325876 PCIB Ready

Error

Re lace p Go To Error

y

Summary/Remarks

Signed: Date:

Count Record the machine cycle count for each visit.

-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.

Check the date and time settings

Check the software loaded and options

Check the software version is the latest issue

Check for initialisation errors

Check for screen position errors (31210, 31211, 31212)

Check for camera errors (31207, 31208)

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)

Monthly Hardware Check

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

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

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

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

M36 Control 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: Date:

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.

Check the date and time settings

Check the software loaded and options

Check the software version is the latest issue

Check for initialisation errors

Check for screen position errors (31210, 31211, 31212)

Check for camera errors (31207, 31208)

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)

Monthly Hardware Check

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

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

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

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: Date:

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.

Check the date and time settings

Check the software loaded and options

Check the software version is the latest issue

Check for initialisation errors

Check for screen position errors (31210, 31211, 31212)

Check for camera errors (31207, 31208)

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)

Monthly Hardware Check

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

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

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

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

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

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: Date:

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

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

Software

Monthly Maintenance

Check the date and time settings

Check the software loaded and options

Check the software version is the latest issue

Check for initialisation errors

Check for screen position errors (31210, 31211, 31212)

Check for camera errors (31207, 31208)

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)

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

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

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

Summary/Remarks

Signed: Date:

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.

Check the date and time settings

Check the software loaded and options

Check the software version is the latest issue

Check for initialisation errors

Check for screen position errors (31210, 31211, 31212)

Check for camera errors (31207, 31208)

Monthly Maintenance

Monthly Hardware Check

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)

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

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

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

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

Inspect the condition of the rising table drive belt

Check for correct operation of the table brake

Cycle the table, ensure smooth running, no looms fouled

Check the critical home setting

Check the vision height of the table

Check the print height of the table

Cycle the carriage, ensure smooth operation

Check the carriage up and down sensors operate correctly

Check the vanes do not foul the sensors

Check the linear bearing guides for contamination

Check the paste dispense movement on the linear bearing

Check the critical home dimension

Inspect wiring/connections and pneumatics

Clean the attachment spindles, apply a wipe of light oil

Check the pressure mechanism operates smoothly

Check the pressure mechanisms secure when raised

Check the pneumatics and connectors are secure

Check the operation and setting of the paste low sensor

Signed: Date:

Month June 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.

Check the date and time settings

Check the software loaded and options

Check the software version is the latest issue

Check for initialisation errors

Check for screen position errors (31210, 31211, 31212)

Check for camera errors (31207, 31208)

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)

Clean the evaporator and condenser fans

Monthly Hardware Check

Clean the evaporator and condenser coils

Clean the evaporator and condenser filters

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

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

Inspect the wiring and connections

Inspect the three striker plates, clean and apply a wipe of light grease

Check the actuator fixed ball at the end of the actuator shaft is clean

Check all actuators home correctly

If pre purchased, replace the paper, HEPA and carbon filters

DC Power Supplies Tick

Check the DC voltage levels are within tolerance as detailed in the DEK Power Monitor program

Ensure machine is level and all feet exert pressure on the floor

Signed: Date:

Month July 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.

Check the date and time settings

Check the software loaded and options

Check the software version is the latest issue

Check for initialisation errors

Check for screen position errors (31210, 31211, 31212)

Check for camera errors (31207, 31208)

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)

Monthly Hardware Check

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

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

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

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

Screen Change Tick

Remove and clean the auto drip tray

Fully extend the auto drip tray telescopic plungers and clean

Clean the screen stop actuator arm lever

Clean the screen at stop sensor

Refit the auto drip tray and check operation of the screen change mechanism

Inspect the condition of wiring/pneumatic connections

Check operation of the chase clamps

Clean and lubricate with light oil, the omni track bearings and the underside of the track plates

Clean the left and right screen at centre optos

Clean the stencil guide strips of debris/paste

Check operation of the ASM

Check ASM flap clamp cord tension (Cord stretch may cause it to wrap around the pulley shaft.)

Summary/Remarks

Signed: Date:

Month August 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.

Check the date and time settings

Check the software loaded and options

Check the software version is the latest issue

Check for initialisation errors

Check for screen position errors (31210, 31211, 31212)

Check for camera errors (31207, 31208)

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)

Monthly Hardware Check

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

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

Inspect the camera for signs of damage

Check 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

Check the full movement of axes of travel, no fouling of looms

Check the vanes do not foul the sensors