MPM Calibration Crash Course

COOKSON ELECTRONICS EQUIPMENT
MPM | AP Series Printers

Calibrations Course

ii
© 2002, 2003 Cookson Electronics Equipment
580-A Tollgate Road
Elgin, Illinois 60123
(800) 737-8110
www.cooksonelectronics.com
All Rights Reserved
Printed in U.S.A.
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Information and descriptions contained herein are the property of Cookson Electronics. Such
descriptions and information may not be copied or reproduced (duplicated) by any means (in
any form), or disseminated or distributed without the express prior written permission
(consent) of Cookson Electronics Equipment.
The information in this document is subject to change without notice and should not be
construed as a commitment by Cookson Electronics Equipment. Cookson Electronics
Equipment assumes no responsibility for any errors that may appear in this document
Equipment.
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Cookson Electronics Equipment
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Contents
MPM | AP Series Printers Calibrations Course .......................................................... vii
Student Skills Performance Check List ....................................................................... ix
Tab 1. Factory User Levels

Accessing the Factory User Modes (DOS) ................................................................ 1-3
Accessing the Factory User Modes (NT) ................................................................... 1-5
Tab 2. Operations
Re-timing the AP Vision Gantry................................................................................. 2-3
Tab 3. Advanced Operations

Backup System ............................................................................................................3-3
Restore System............................................................................................................3-3
Tab 4. General Calibrations

5410 Step Driver Adjustment Procedure................................................................... 4-3
Tactile Sensor Height Calibration .............................................................................. 4-7
Tab 5. Motion System

Calibration Chart ......................................................................................................... 5-3
Motion Axis Calibrations Jig & Tool List ................................................................... 5-4
Motion Calibration Notes ........................................................................................... 5-5
X Axis Calibration ....................................................................................................... 5-7
Track Width Calibration ............................................................................................ 5-13
Theta Axis Calibration ............................................................................................... 5-17
Y Axis Calibration ...................................................................................................... 5-23
Z Axis Calibration ..................................................................................................... 5-29
Vision Y Axis Calibration ........................................................................................... 5-33
Vision X Axis Calibration........................................................................................... 5-37
Squeegee Stroke Calibration .................................................................................... 5-39
Squeegee Height Calibration ................................................................................... 5-43
Camera to Track Calibration .................................................................................... 5-47
Tactile Calibration..................................................................................................... 5-49
Motion Calibration Checkout ................................................................................... 5-51
v
Boardstop Sensor Calibration .................................................................................. 5-53
Camera Park Position Adjustment and Calibration................................................. 5-55
Stencil Wiper Calibration ......................................................................................... 5-63
Winder Setup and Calibration ................................................................................. 5-69
Paste Dispenser Calibration ..................................................................................... 5-73
Snugger Height Calibration ...................................................................................... 5-75
Tab 6. Vision System

Calibration Chart ........................................................................................................ 6-3
Vision Calibrations Jig & Tool List ............................................................................. 6-4
Vision System Calibration Checkout ......................................................................... 6-5
Vision System Calibration Procedure ........................................................................6-9
3D Post Print Verification, Laser Setup and Calibration ......................................... 6-21
Using the Diagnostic Test........................................................................................6-29
Tab 7. ProHead System

Calibration Chart ........................................................................................................ 7-3
ProAir ProHead Calibration Jig & Tool List ............................................................... 7-4
ProHead Lift Cylinder System Test ............................................................................ 7-5
ProHead Squeegee System Test For ProAir Style MPM Printers ............................. 7-7
ProAir ProHead System Calibration Procedure ........................................................ 7-9
Crush Bearing Adjustment ...................................................................................... 7-19
Swing Arm Bar Leveling Procedure ..........................................................................7-21
Checking Level of the Mount Bar ............................................................................ 7-25
Refurbishing the Programmable Squeegee Head .................................................. 7-27
Flip Levers Adjustment ............................................................................................ 7-32
Squeegee Flip Cylinders Adjustment ....................................................................... 7-33
Setting the Attack Angle (45 degrees) ...................................................................... 7-35
Pneutronics Programmable Squeegee Calibration Procedure ................................7-37
Addendum A: Programmable Squeegee Control Engineering Drawing .............. 7-45
Appendix
List of critical machine backup files ..................................................................... TAB-8
Newer Style Vision Probe Calibration .................................................................. TAB-8
AP -20/24 Vision Calibration ................................................................................ TAB-8
AP -20/24 Laser Calibration ................................................................................. TAB-8
vi
MPM | AP SERIES PRINTERS CALIBRATIONS C OURSE
ALIBRATIONS
This course is designed for maintenance personnel who are responsible for calibrating of the MPM AP Series
Printers. The course offers valuable ‘hands on’ practice of each calibration as the participants are required
to perform each procedure to receive a certificate of completion.
Objectives: Given an AP Series MPM Printer, Documentation, Boards, Stencil, Instructor

Demonstration and any additional items, the student will be able to:
Enable factory user levels

Calibrate the base motion axis’
Calibrate the boardstop sensor
Calibrate the optional Y-snugger system *
Calibrate the vision system
Calibrate the optional 3D Verification system *
Calibrate the printhead control system
Calibrate the optional wiper system *
Calibrate the optional dispenser system *
Perform automated diagnostic tests
Perform a System Backup
Calibrate a 5410 Stepper Driver *
Calibrate a worknest mounted tactile sensor *
The student will perform these functions to MPM standards.

* Denotes an optional topic.
Prerequisites: 30 days operational experience with the equipment ; Have attended an AP

Troubleshooting & Maintenance Course
Length: 3 Days Start: Monday 9 am End: Wednesday 5 pm
The course may end earlier, depending upon the specific machines and options of the participant
group. Please do NOT make flight arrangements earlier than 7:30 p.m. on Wednesday
All courses are structured according to PBET standards. The PBET standards, developed by the Technician Training Council and
sponsored by SEMATECH and SEMI/SEMITECH include six concepts that are integrated into every course:
· Derive performance objectives from analysis
· Establish course content from performance objectives
· Identify prerequisite skills
· Maximize hands-on practice
· Develop skill tests to measure competency
· Repeat practice and skill tests until mastery of each objective is achieved
vii
viii
MPM | AP SERIES PRINTERS
CALIBRATIONS COURSE
STUDENT SKILLS PERFORMANCE CHECK LIST

N AME:___________________________ C OMPANY:____________________________
The following skills are required to be demonstrated, as a condition of PBET (Performance Based Equipment
Training), for a certificate of completion:
SKILL Student Initials Instructor Initials

1-1 Enable factory user levels
2-1 Re-time the vision gantry
3-1 Perform a System Backup
4-1 Calibrate a pre-HiE 5410 stepper driver *
4-2 Calibrate a worknest mounted tactile assembly *
5-1 Calibrate all standard motion axis’
5-2 Calibrate the camera mounted boardstop sensor
5-3 Calibrate the optional Y-Snugger System *
5-4 Calibrate the optional Camera Park Sensor*
5-5 Calibrate the optional wiper system *
5-6 Calibrate the optional dispenser system *
6-1 Perform vision calibration
6-2 Calibrate the optional 3D verification system *
6-3 Perform automated diagnostic test
7-1 Perform basic Prohead setup
7-2 Calibrate the Pneutronics style control system *
7-3 Calibrate the ProAir style control system *
All skills must be accomplished before a certificate of completion can be issued. If some skills were not accomplished
within the course of instruction, arrangements can be made for additional instruction at a later time.
Student Signature Instructor Signature
ix
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Local Info
16
Randall Rd.
ALGONQUIN
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62
59
31 Alg
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68
WEST EAST .
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DUNDEE DUNDEE Dund
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10 11 68
72 8 12 13
9 M ain St.
7
6
14 72
17
31 Higgins
Rd.
3 25
90
1 2
4
90
5
Golf Rd.
58
Kimball
59
Highlan
d
Chicago
20 15 ELGIN
Lake St.
31
20
Randall Rd.
Lake
25 18 St .
59
Cookson Electronics Equipment xi

Local Info
xii Cookson Electronics Equipment

Local Info
1 - Cookson Electronics
- Baymont Inn
2 -Crowne Plaza by Holiday Inn

Crowne
- Bennigan’s at the Crowne Plaza

Crowne
3 - Courtyard by Marriott
-Towne Place Suites by Marriott

Towne
- Alexander’s Restaurant
4 - Super 8 Motel
- Baymont Inn
-Cracker Barrel
Cracker
5 - Best Western
Western
6 - La Zaza Cucina Restaurant
- Cooper’s Charhouse
7 - McDonald’s
8 -Walgreens Drugstore
Walgreens
9 - Chilli’s Restaurant
- Best Buy
10
10 - Red Lobster
Lobster,,
- Olive Garden
-Wendy’s
Wendy’s
-Taco Bell
Taco
- Rosati’s Pizza
-Famous Dave’s Bar-B-Que

Famous
- TGI Friday’s
Friday’s
11 - China Buffet
- Circuit City
Cookson Electronics Equipment xiii

Local Info
12 - Emmett’s Micro Brewery & Restaurant
13 - El Faro Mexican Restaurant

Faro
14 -Walmart
Walmart
-Wendy’s
Wendy’s
15 - Prairie Rock Micro Brewery & Restaurant
- Grand Victoria Riverboat C asino

Casino
16 - Port Edward’s Seafood Restaurant
17 - Country Inn & Suites
18 -C adillac Ranch (music, dancing)

Cadillac
xiv Cookson Electronics Equipment

Factory User Levels
Tab 1. Factory User Levels

Factory
Calibrations C ourse Objectives
Course
Enable the factory user levels
MPM Series Printers

Factory User Levels
MPM Series Printers

Factory User Levels
Accessing the Factory User Modes (DOS)

Factory
This procedure directs the user to enter the machine level software (DOS) and alter the
machine configuration settings. It is recommended that before attempting this procedure,
that the user execute the “Backup System” command under the File pulldown menu, which
will create a duplicate copy of the machine configuration and calibration files on the first
backup disk.
Tools required
· Keyboard
Procedure
1. Plug the keyboard into the computer at the rear of the machine.
2. Power on the machine and allow the machine to boot.
3. Press the ESC key on the keyboard to exit the machine menu system. The machine should
display “C:\AP>”
4. From the keyboard type the following: optedt and press the enter key.
5. From the trackball enter the Calibrate level password to access the machine configuration
settings editor.
6. Move the cursor arrow to the NEXT button on the bottom of the screen and press the
trackball SELECT button to advance the display, page by page, until the field “KEYLOCK” is
displayed.
Note: Pressing the trackball EXIT button will abandon all changes and exit the editor.
7. Align the trackball cursor to the SET button to left of the field “KEYLOCK” and press the
trackball SELECT button to alter as follows:
Standard -> Normal user list (Operator, Supervisor and Maintenance)
Extended -> Allows access to two more user levels (Calibrate and Test)
Note: Pressing the trackball EXIT button at this time will abandon the change.
Move the trackball cursor to the desired setting circle and press the SELECT trackball
button.
8.) Align the trackball cursor to the SAVE button on the bottom of the display and press the
SELECT trackball button to save the configuration change.
Note: Pressing the trackball EXIT button at this time will abandon all changes and exit the
editor.
MPM Series Printers 1-3

Factory User Levels
9. The machine should display “C:\AP>” .

10. From the keyboard type UP2000 and press the enter key to restart the machine menu
system software.
Note: For machines below version 5 software, it will be necessary to cycle the power off
and on again to restart the machine menu software.
11. At the main menu display, roll the trackball over the MAINTENANCE pulldown and to roll
the trackball down to USER MODE.
12. SELECT the Calibrate or Test user level and enter the password qmpm
qmpm.
13. Remove the keyboard from the rear of the machine.
1-4 MPM Series Printers

Factory User Levels
Accessing the Factory User Modes (NT)

Factory
This procedure directs the user to alter the machine configuration settings. It is
recommended that before attempting this procedure, that the user execute the “Backup
System” command under the File pulldown menu, which will create a duplicate copy of the
machine configuration and calibration files on the first backup disk.
• During troubleshooting and calibration of the machine, you will be requested to go to the
factory user levels of access. They are:
– Calibrate
– Test
Enabling/Disabling this Feature

Feature
The factory user levels feature can be enabled or disabled by using the following steps:
• Shutdown the APNT software by selecting the close (X) button at the top right corner of
the window.
• On the WindowsNT desktop, double-click the OptionEditor icon
• The Option Editor is Password Protected, using the keyboard enter the password ‘qmpm’
in lower case letters and the select the OK button.
• The first Option page appears with the first parameter being ‘MACHINE TYPE’.
• Advance thru the pages of parameters to the parameter called ‘Keylock’
– To advance, select the right arrow button
– To retreat, select the left arrow button

Factory User Levels
• Select the SET button next to the parameter and change it’s setting as follows:
– Standard: Operator, Supervisor and Maintenance users only
– Extended: Calibrate and Test user levels added
• After making the change:

– Select OK to keep the new setting
– Select CANCEL to abandon the change
• If you are done making changes, to leave the Option Editor, select either the SAVE or EXIT
button on the bottom of the screen:
– Select the SAVE button and then EXIT button to leave the option editor.
– If you select the EXIT button after any un-saved changes, you will be asked whether or
not you would like to save the changes.
• Select Yes to save and exit the editor.
• Select No to exit without saving
• Double-click the MPM icon on the desktop to restart the machine application.

Factory User Levels
The C alibrate and T

Calibrate est User Menus
Test
• Never enter these menus unless you are qualified!
– The software routines in these levels have most of the software safeties removed, and
if used improperly, could cause harm to the user and the machine!

Factory User Levels
- Training Solutions -
Training

Operations
Tab 2. Operations
Course
Navigate the operation screens and user levels
Change and restore machine default passwords
Retime the machine vision Gantry
MPM Series Printers

Operations
Training
MPM Series Printers

Operations
Re-timing the AP Vision Gantry

• Use this procedure to manually re-time (or “reset”) the vision assembly forcers. Re-timing
the Y-axis gantry is necessary if any of the following problems occur:
– “Camera Not Parked” error message occurs
– “Stencil Model Not Found” or “Board Model Not Found” error messages occur
– “Hardware Limit” warnings for the Vision System or the Stencil Wiper occur
– The vision system “freezes” or “skews” during travel because of:
• incorrect air pressure settings
• contaminants on the vision gantry
• kinked or damaged airlines
Procedure
• Select Input/Output Test from the Maintenance pulldown Menu.

• Select the red output “Stepper Power” to disable power to the stepper motors.
– You will have to acknowledge a Z brake alarm!
MPM Excel Series Printers 2-3

Operations
• Raise the hood and open the front doors.

• Grasp the left and right sides of the X-axis gantry with both hands, and gently pull the
assembly forward until it touches the two hard stops.
• Exit the Output Test screen, and select Reset from the Maintenance menu to return the
gantry to it’s park position.
2-4 MPM Excel Series Printers

Operations
Lab
• Retime the Vision Gantry

Operations
Training

Advanced Operations
Tab 3. Advanced Operations

Course
Perform file management functions
Review machine configuration settings
Enable factory user levels
Change the MPM Software Language
Use message log to review machine history file
MPM Series Printers

Advanced Operations
Training
MPM Series Printers

Advanced Operations
Backup System
• This is actually the most critical function on the machine. Backup System copies setup
files from the hard drive to a user-defined location or path (the default path is set to Drive
A: 3.5 inch 1.44MB floppy disk).
– Use the options editor function to modify the backup path.
– Backup System also copies all system and calibrate information and stores it for recall
in case of hard disk failure.
– System backup is printer specific and cannot be interchanged with other printers.
– When saving to a floppy, some system files may be too large to store on a single disk.
The system will prompt you to install additional disks as required for file storage
completion.
– Only one backup is allowed per disk set.
• Backup System can be found under the File pulldown menu of the Supervisor and
Maintenance user levels.
Maintenance Level
Supervisor Level
Restore System
• Restore System copies setup files from a user-defined location or path to the hard disk.
Calibration Files (Disk1)

Configuration Files (Disk1)
All Board Files (Disk1++)
Restore System
Backup System

Advanced Operations
Training

Pre-HiE
Tab 4. General C alibrations

Calibrations
Calibrations Course Objectives
Course
Calibrate a Pre-HiE 5410 Stepper Driver *
Calibrate a worknest mounted Tactile Sensor Assembly *
MPM Series Printers

Pre-HiE
Training
MPM Series Printers

Pre-HiE
5410 Step Driver Adjustment Procedure

The standard AP-series configuration utilizes both the Sigma 5410-002 (P878) and Sigma
3060MC (P879) drivers for step motor drive power. The AP20, AP24X, and AP-25 utilize
the 5410 exclusively, while the AP-36 uses the 3060MC for Z-tower motion. This document
provides the proper settings and current adjustment technique for each driver type.
There are two versions of the 5410 driver. Original versions carried a 4 pole dip switch (SW1)
and two on-board jumpers. The present version utilizes a 6 pole dip switch that replaces the
jumpers.
SW1
R43 R42
Tools required:
• DC Ammeter (capable of reading 10A DC minimum)

• Clip Test Lead for ammeter
• 9/64” hex wrench
• Trimpot adjuster
• Small flat-blade screwdrivers
• Needle Nose Pliers

Pre-HiE
Procedure:
Follow this procedure to set current on the 5410 driver. A motor must be connected to the
driver during the calibration.
Caution: Never connect or disconnect step driver wires with power applied.
1. Disable power to the machine.

2. Use a 9/64” hex wrench to remove the two screws that mount the driver to the drawer.
Place the screws aside for reassembly.
3. Write down the existing dip switch (or jumper) settings for later reference.
4. Set the all six dip switches to the On position.
5. Remove the Phase A wire (the black wire) from J1-1
J1-1.
6. Install a DC (Direct Current) ammeter in series with the Phase A wire and J1-1 terminal.
7. Enable machine power (it is not necessary to perform a reset).
8. Set the motor Phase A current using potentiometer R43 (located on the step driver) for
the appropriate axis current level, as provided in Table 1.
Axis Output Current Exceptions

X 3 ADC
Y 3 ADC
Z 5 ADC (AP36 set at 7.5ADC)
Theta 3 ADC
Squeegee Stroke 5 ADC
Transport 5 ADC
Track Width 3 ADC
Vision X 4 ADC
Vision Y Right 4 ADC
Vision Y Left 4 ADC
Wiper 3 ADC
Squeegee Downstop 3 ADC
Dispenser 3 ADC
Table 1: Driver output current settings
Driver Current Requirements
The current requirements for different axes vary: Table 1 provides the proper current
settings. The 3060MC drivers are factory adjusted for 7.5A DC and should not be re-
adjusted. The 5410 drivers are factory shipped at 5A DC unless appropriately marked
otherwise. Refer to the Engineering Drawings section of your AP Maintenance Manual for
complete information.

Pre-HiE
9. Press the OFF button on the front control panel to power down the machine. Failure to
remove power from the machine will result in damage to the step motors and drivers.
10. Remove the ammeter from the circuit.
11. Reconnect the Phase A wire to J1-1. Ensure that the wire is connected properly.
12. Remove the Phase B wire (the red wire) from J1-3J1-3.
13. Install the DC ammeter in series with the Phase B wire and J1-3 terminal.
14. Enable machine power (it is not necessary to perform a reset).
15. Set the motor Phase B current using potentiometer R42 (located on the step driver).
Adjust for the appropriate axis current level as provided in Table 1.
16. Disable power to the machine.
17. Remove the ammeter from the circuit.
18. Reconnect the Phase B wire to J1-3. Ensure that the wire is connected properly.
19. Reset all dip switches (or jumpers) to the original settings (step 3, Table 2).
20. Mount the driver back in the drawer using the original mounting hardware.
21. Enable power to the machine.
AXIS STEP VOLT AMPS SWITCH 1

AC 1 2 3 4 5 6
X 1/5 40 3 O N N N O N
Y 1/5 40 3 O N N N O N
THETA 1/5 40 3 O N N N O N
Z 1/5 70 5 O N N N O N
SQUEEGEE STROKE 1/5 70 5 O N N N O O
BOARD TRANSPORT 1/5 40 5 O N N N O O
TRACK WIDTH 1/5 40 3 O N N N O O
VISION X 1/5 60 4 O N N N O N SPECIAL E-PROMS
VISION Y LEFT 1/5 60 4 O N N N O N SPECIAL E-PROMS
VISION Y RIGHT 1/5 60 4 O N N N O N SPECIAL E-PROMS
WIPER 1/5 40 3 O N N N O O
DOWN STOP 1/5 40 3 O N N N O O
PASTE DISPENSE 1/125 40 3 N N O N O O
N = ON O = OFF
Table 2: Switch settings
Micro-Step Output Mode:
Positions 1 through 3 of the dip switch allow setting of the micro-step output mode. The
standard setting for most AP-series axes is 1/5 step, or:
• SW1-1 = Off
• SW1-2 = On
• SW1-3 = On

Pre-HiE
Note: Th
The standard setting for the AP-series Paste Dispenser driver is 1/125 step, or:
• SW1-1 = On
• SW1-2 = On
• SW1-3 = Off
Micro-Step Current Boost:
Position 4 allows the micro-step current boost to be enabled or disabled. The standard
configuration is for boost enabled, or:
• SW1-4 = On
Stability control
Stability control is accessed via an on-board jumper on early versions and should be set to
In to enable the control. On recent versions the control is accessed via SW1-5 which
should be set to Off to enable stability control.
• SW1-5 = Off
Idle Current Reduction
Idle current reduction is accessed via an on-board jumper on early versions and should be
set according to the table below. Recent versions use SW1-6 to set the current reduction
feature; Table 3 provides the proper switch or jumper settings depending upon which axis
the driver will be used for.
Note: AP36 only: The 3060MC driver has a 4 pole dip switch and on-board jumpers; set
this driver exactly like the original version model 5410.
Axis SW 1-6 Jumper Reduction

X On Out Disabled
Y On Out Disabled
Z On Out Disabled
Theta On Out Disabled
Squeegee Stroke Off In Enabled
Transport Off In Enabled
Track Width Off In Enabled
Vision X On Out Disabled
Vision Y Right On Out Disabled
Vision Y Left On Out Disabled
Wiper Off In Enabled
Squeegee Downstop On Out Disabled
Dispenser Off In Enabled
Table 3: Driver current reduction settings

Pre-HiE
Tactile Sensor Height Calibration

Calibration
How to determine when calibration is needed
The Tactile Sensor assembly allows the printer to automatically determine the height that the
Z-tower must move to elevate the substrate for printing. The printer is able to repeatedly
perform this function provided two conditions are met:
• the correct board thickness is entered on Setup Menu 1

• the Tactile Sensor is calibrated within factory specification
Calibration test for the Tactile Sensor

Tactile
1. Load a board profile.

2. Enter “0” into the Snapoff field in Setup menu 1.
3. Enter “yes” for Vacuum in the Board Parameters box.
4. Use the “Set Stencil Height” utility (from the Utilities pulldown menu).
5. Use the Load Board utility (from the Utilities pulldown menu) to load a board to stencil
height.
6. Visually inspect the distance between the upper surface of the substrate and the lower
surface of the stencil. Calibration is needed if a gap between the board and stencil exists,
or the board is pressed too tightly into the stencil.
Materials needed for calibration:
• a Height Gauge, capable of accurately measuring from 0 to 7 inches

• an Ohmmeter (or use the Input Test screen from the Main Menu’s Maintenance pulldown
menu)
• Gauge Blocks, or a similar reference equaling 6.5 inches thread sealer
• a clear area of the AP printer workholder (as depicted in Figure 1.)
Procedure
1. Enable power to the machine and perform a reset.

2. Raise the hood and open the front doors.
3. Remove all board supports and vacuum chambers from the worktable.
4. Select Jog-Z Axis from the Main Menu and move the worktable to a comfortable working
elevation.
5. Clean the worktable to completely remove any solder paste or other contaminants.
6. Inspect the upper surface of the worktable to locate any nicks or raised surfaces; mark
each location with a felt tip pen.

Pre-HiE
Remove raised surfaces as follows:

a.) Pour a small amount of alcohol over the nick.
b.) Lightly polish the surface using a flat fine-grit machinist stone with circular motions.
Apply enough alcohol to keep the stone wet
c.) Inspect the area with your fingertips to determine the need for further polishing.
Repeat steps a.) and b.) until the nick is leveled
d.) Clean the spot using lint-free cloths and alcohol. Wipe the spot with a dry cloth.
e.) Repeat for any other nicks found during inspection.
7. Set up the height gauge as shown in Figure 1. Set the Height Gauge to 6.5 inches using
gauge blocks (or a similar reference equaling 6.5 inches).
8. Use a 7/64” hex wrench to remove the four screws securing the tactile assembly side
cover. Place the cover aside for re-use.
9. Select Output Test from the Maintenance section of the Main Menu.
10. Select the Height_Sense_Up. The tactile sensing switch rises.
11. Connect an ohmmeter to the two tactile sensing switch contacts. Test the continuity of
the switch by depressing the switch actuator while watching for change on the ohmmeter.
Note: The continuity of the switch may also be tested using the Input Test screen from
the Main Menu’s Maintenance pull-down menu.
12. Apply a thread sealer (such as Locktite 222) to the height adjustment screw (shown in
Figure1).
13. Position the tactile sensing switch under the 6.5 inch reference set on the height gauge.
Pre-HiE
14. Position the height of the switch close to the 6.5 inch reference by turning the adjustment
screw. Raise the height of the switch until the ohmmeter indicates that the switch has
closed.
15. Slowly back the set-screw off until the switch opens.
16. Re-assemble and re-install the tactile sensor assembly.
17. Re-assemble and re-install the vacuum chucks.
18. Perform the “Set Stencil Height” and “Load Board to Stencil Height” utilities.
19. Visually inspect the distance between the upper surface of the substrate and the lower
surface of the stencil. Repeat steps 6-17 if a gap between the board and stencil exists, or
the board is pressed too tightly into the stencil.
20. Close the hood and front doors.

Pre-HiE
Training

Motion
Tab 5. Motion System

Course
Calibrate all standard motion axis’
Calibrate the camera mounted boardstop sensor
Calibrate the optional Y-Snugger System *
Calibrate the optional Camera Park Sensor*
Calibrate the optional wiper system *
Calibrate the optional dispenser system *
MPM Series Printers

Motion
Training
MPM Series Printers

Motion
Calibration Chart
Whenever you calibrate a motion axis, refer to the chart below for any followup
calibrations that need to be re-verified.
– Lettered calibrations are for optional equipment you may not have
– The only motion axis calibrations that make changes to the AP.CAL file are:
• Cam to Track
• Snugger Height
• Camera Park Position
– Remember to re-perform a Backup System if calibrations that make changes to the
AP.CAL file are performed.
User Menu
Procedure Affected Assemblies Maint Calibrate Test Pulldown
1X-Axis E 19 20 ï Calibrate
2Theta-Axis E 19 20 ï Calibrate
4Y-Axis E 14 19 20 ï Calibrate
5Z-Axis D 19 17 20 ï Calibrate
6Vision Y E 14 B 19 20 ï Calibrate
7Vision X E 19 20 ï Calibrate
8Squeegee Stroke ï Calibrate
Motion
9PSQUEEGEE (Squeegee Height) ï Calibrate

14Cam to Track ï Calibrate
15Tactile ï Calibrate
A Track Width E ï Calibrate
B Wiper ï Calibrate
C Paste Dispenser ï Calibrate
D Snugger Height (Y Snuggers) ï Calibrate
E Camera Park Position (rear track mounted) ï Test
16 Re-timing the Vision Gantry

17 2D Histogram ï Test
18 Vision Probe Alignment 19 20 G
Vision
19 Calibrate Vision 17 20 21 G ï Teach

20 Learn Offsets ï Teach
21 Calibrate Board Stop ï Teach
Utilities /
G 3D Laser Alignment ï Teach
ProHead
DAC Board Test ï Test

Motion
Motion Axis Calibrations Jig & T

Calibrations ool List
Tool
Jig/tool Part # OptionDescription

JIG0055 Theta calibration cube
JIG0057 X-Y Squeegee stroke calibration fixture
JIG0056 Autowidth Track width calibration plate
JIG0178 HiE Camera Mounted Sensor Board stop sensor calibration board
P4633 Flexible stainless steel ruler 24” long
Imperial ball end allen wrenches

Loctite 222 thread sealer

Motion
Motion Calibration Notes

Calibration
The following should be noted before attempting the required motion calibration:
– It is recommend to have the machine in English units (inches) for any calibration.
Scope
This document is intended for MPM Instructors, Service Reps, and Manufacturing
Assemblers, as well as certified maintenance personnel at customer sites.
Document Overview
Axis calibration must be performed whenever proximity switches are installed or replaced.
During the calibration process, minimum and maximum travel distances for each axis are
established, which ensures full and proper travel distances for the axis. Calibration is
performed by selecting calibrate under the user mode in the maintenance pulldown menu.
The password to activate the calibration screen is qmpm.
Note
The correct execution of the procedures outlined in this document are critical to the
operating performance of the stencil printer. This document is only presented to personnel
who have undergone a certificate training program given by MPM personnel. Performance of
these procedures by non-certified personnel (or without the usage of any specialized tooling
required) will result in immediate voiding of the printer’s warranty.
Accordingly, any MPM Service Representative sent to a customer site to correct damages
resulting from improper usage of the information contained in this document will submit
charges for the service per standard MPM service billing itemized list.
Safety
Before performing the procedures in this document, you should review the safety tips that
follow.
WARNING
Solvent may cause severe burns. Always wear protective gloves and safety glasses when
handling solvent, and be careful not to spill the solvent when filling the solvent tank. Failure
to comply may result in personal injury.

Motion
Training

Motion
X Axis Calibration
Calibration
Use the following procedure to calibrate the X axis. On-screen prompts guide you through
the procedure and the software automatically performs all machine motions needed to
calibrate the axis. When performing this procedure, make sure that the axis does not hit a
mechanical limit.
1. Power up the printer.

2. Select the user mode under the maintenance pull down menu and select ‘Calibrate’ in
the user mode selection box.
Note: If the Calibrate and Test user modes are not displayed, you will have to: Exit
the application, change the keylock parameter in the Option Editor to ‘Extended’
and restart the application.
3. Using the login keypad type in the password qmpm.

4. Under the calibrate pull down menu SELECT X Axis function.
5. Using the trackball cursor click on the power button (JOG) in the X Axis calibration
box. Jog the axis positive (right) as far as possible.
Note: The software will prompt to check the Z axis and verify it is in the home
location. If it is not, press the trackball exit button, select the Z Axis function under
the Calibrate pulldown and then use the JOG button to move the Z axis so the
worknest is below the track height.
Note: Also verify that the Theta and Y axis are close to their respective home
positions or a crash with the machine covers could occur.
6. Exit the jog function. Using the trackball cursor click on the Limit button (LIM) in the
X Axis calibration box and verify that the sensor input is active on the screen.
X-
X+
Note: The sensors can be access thru the rear cover, but removing the side panel
is preferred.

Motion
7. Locate the sensor and verify there is approximately 0.015~0.020” clearance between
the sensor and the flag block. Adjust if necessary, but ensure the LED is observable
when finished.
8. Exit the LIM function, click on the power button (PWR) in the X Axis calibration box to
remove stepper power to every motor.
9. By hand, push the axis to the right to ensure the electrical limit sensor did stop the
axis before reaching the mechanical stop.
10. Click on the PWR button in the X Axis calibration box to re-apply stepper power.
11. Using the trackball cursor click on the power button (JOG) in the X Axis calibration
box. Jog the axis negative (left) as far as possible. Exit the Jog function.
12. Using the trackball cursor click on the Limit button (LIM) in the X Axis calibration box
and verify that the sensor input is active on the screen.
when finished.
14. Click on the PWR button, push the axis to the left to ensure the electrical limit sensor
did stop the axis before reaching the mechanical stop.
15. Install and secure the X, Y, squeegee stroke fixture (Jig 0057/a) to the base frame using
the 2 captive screws which are part of the fixture (Figure 1). The jig is mounted
between the front of the worknest and the X, Y & Theta frames.
Note: Make sure that the spring loaded alignment pins are pulled out and locked in
the out position before installing fixture.
Motion
Jig Location (as viewed from the top)
Note: Some machines were shipped without the mounting holes for the jig. If this is
the case, look for timing marks on the front of the X frame and the base frame of the
machine. If they are not present, use a ruler and a pencil to scribe a center line on the
front of the base frame of the machine and the X frame. Use this as the zero reference
for this procedure.
16. Release the spring loaded pins by rotating the knurl knobs and manually push the X
axis (or turn the motor coupling) until the pins are fully seated into their
corresponding holes in the machine frame. Once the pins are seated this will establish
the zero reference (center) point for the X axis.
Note: If this machine does not have the mounting holes for the jig, align the timing
marks on the front of the X frame and the base frame of the machine. Use this as the
zero reference for this procedure.
Note: Make sure the Theta and Y axis frames are also centered.
17. Using the trackball cursor, click on the power button (PWR) in the X axis calibration
box. This will apply stepper power back to the drivers.
18. Remove the calibration fixture.
Motion
19. Using the trackball cursor click on the calibration button (CAL) in the calibration
control panel. The following messages and instructions will appear in the text box:
Z axis must be at home position.
Press SELECT to continue or EXIT to quit.
Note: If the machine has Y-snuggers, then both snuggers have to be down and the
‘Down’ sensors must be active (ON).
20. Press the trackball Select (left) button. The following messages and instructions will
appear in the text box:
Jog X axis to zero (mechanical) degrees.
Use fixture to set zero.
Press Exit when done jogging.
21. The X axis has already been set to zero position so do not jog the axis. Press the exit
key on the trackball to get out of the jog mode.
Disconnect both axis limit switches.
22. Disconnect both limit switches. Press Select to continue.

X axis will now move to its positive
limit. MAKE SURE IT IS FREE TO MOVE!
23. Ensure the jig and any tools are removed from the working areas of the machine.
Press Select to continue and the X axis moves to the desired flag location.
Connect the positive limit switch.
24. Connect the sensor and press Select.

Position the positive limit switch just
off its flag. Press select the view LEDs.
25. Press Select to activate the LIM function.

X limits are being monitored.
Press EXIT when done.
26. Confirm that the sensor is just off by bending the sensor bracket slightly. Adjust the
sensor location if necessary. Press Exit when finished.
X axis will now move to its negative

Motion
27. Press Select to continue and the X axis moves to the desired flag location.
Connect the negative limit switch.

Position the negative limit switch just

X limits are being monitored.
X axis limit to limit distance will
now be measured.
31. Press Select to start the LTL measurement test.

Auto calibration in progress...
Measuring the limit to limit distance…
X axis is now calibrated.

Press EXIT to leave.
32. When the test is complete, the number in the ‘Measured’ box is the distance between
the 2 switches and should be between the numbers listed under the range field. (The
measured range should be between 1.18 -1.30").
33. If measured value is out of range, repeat the entire procedure.
34. Press the Exit trackball button to leave the calibration box.
35. Refer to the C alibration chart for any follow-up calibrations.
Calibration
36. Monitor each production program and use the Stencil Adjust function if required.

Motion
Training

Motion
Track Width C alibration

Calibration
Use the following procedure to calibrate the track width. On-screen prompts guide you
through the procedure and the software automatically performs all machine motions needed
to calibrate the axis. When performing this procedure, make sure the worknest is clear for a
minimum rail width of 10 inches.


4. Under the calibrate pull down menu Select the track width.
5. Using the trackball cursor click on the calibration button (CAL) in the calibration box.
The following messages and instructions will appear in the text box.
Y axis must be at home position!
Note: If the Y axis is not close to the home position, the moveable rail could be
damaged. To leave the calibration, press the Exit button.
6. Please the Select button to continue and the following prompt is displayed:
Disconnect the track width home sensor
sensor..
Track Width Home Sensor

Note: Early machines had this sensor located just behind the worknest. Newer
machines have the sensor mounted underneath the vision platen.
Motion
7. Disconnect the sensor and press Select to continue.

Jog the track width to 10.5 inches
8. Jog the axis to 10.5 inches and install the track width calibration plate (Jig 0056/a)
onto the tracks. Slowly jog the track width until the calibration plate fits snugly
between the rails. The plate should slide freely, but exhibit no forward to backward
play.
Calibration Plate
9. Remove the plate and press Exit to continue.

The track width will now move to its home
position.
10. Press Select to home the axis.

Reconnect the track width home sensor
sensor..
11. Reconnect the sensor and press Select to continue.

Position the track width flag so that it is just off its flag.
Press SELECT to view LEDs.
12. Press Select to activate the LIM monitor function.

The track width limits are being monitored...

Motion
13. Manually move the rail slightly front to back to test the position of the sensor flag. If
the sensor is not in the correct position, adjust the flag accordingly. Press Exit when
finished.
The track width will now home.

Insert Jig #0056A on conveyor tracks at
the 16 inch width to verify setting.
15. Install the track width calibration plate (Jig 0056/a) onto the tracks and press Select...
Check to ensure the tracks are parallel
to one another
another..
Press SELECT to continue or EXIT to Quit.
16. Test and then press Select...

Check to ensure the jig does not bind.
at any point.
17. Test and then press Select...

Check to ensure the jig exhibits no play
at any point.
18. Test and then REMOVE THE JIG! Press Select to continue.
The track width will now move to 10.5
inches.
19. Please Select to change the track width to 10.5 inches.

Slide the Jig along the C
Conveyor
onveyor T racks
Tracks
to the full travel from one end to another
another..
Press SELECT to Continue or EXIT to Quit.
20. Install the track width calibration plate to verify. Press Select...
Track width should now measure 10.5 inches.
necessary..
Adjust the track width flag if necessary
Press SELECT to adjust or EXIT if done.
21. If the width is not correct, press Select to repeat the required steps.
Calibration

Motion
Training

Motion
Theta Axis Calibration

Calibration
Use the following procedure to calibrate the theta axis. On-screen prompts guide you
through the procedure and the software automatically performs all machine motions
needed to calibrate the axis. When performing this procedure, make sure that the axis
does not hit a mechanical limit.

4. Under the calibrate pull down menu SELECT the Theta Axis function.
5. Using the trackball cursor click on the power button (JOG) in the Theta Axis
calibration box. Jog the axis positive (clockwise) as far as possible.
Note: The software will prompt to check the Z axis and verify it is in the home
location. If it is not, press the trackball exit button, select the Z Axis function under
the Calibrate pulldown and then use the JOG button to move the Z axis so the
worknest is below the track height.
Note: Also verify that the X and Y axis are close to their respective home positions
or a crash with the machine covers could occur,
Axis calibration box and verify that the sensor input is active on the screen.
Note: The sensors can be access thru the rear cover. You will also have to remove
the Theta box cover to check the clearance gap of each sensor.

Motion
the sensor and the flag block. Adjust if necessary.
8. Exit the LIM function, click on the power button (PWR) in the Axis calibration box to
9. By hand, push the axis to clockwise to ensure the electrical limit sensor did stop the
10. Click on the PWR button in the Axis calibration box to re-apply stepper power.
11. Using the trackball cursor click on the power button (JOG) in the Axis calibration box.
Jog the axis negative (counter-clockwise) as far as possible. Exit the Jog function.
12. Using the trackball cursor click on the Limit button (LIM) in the Axis calibration box
the sensor and the flag block. Adjust if necessary.
14. Click on the PWR button, push the axis to the counter-clockwise to ensure the
electrical limit sensor did stop the axis before reaching the mechanical stop.
15. Locate theta bearing with theta stop block attached. Only one theta bearing has end
stops, it is the one located at the left rear corner of the theta frame.
16. Move the axis by hand so that the theta calibration block (Jig 0055/a) fits between both
left and right bearing stop blocks and the bearing evenly. Press the PWR button to
turn stepper power back on.

Motion
16a. If the THETA calibration cube does not fit equally between the stops when the
bearing wheel is centered, do the following:
a. Insert cube jig and push theta for the cube to be tight between bearing and
endstop.
c. Turn stepper power ON and remove the cube. Record the current theta position
d. Jog the Theta axis until the cube just fits on the opposite side of the bearing and
record the theta position.
e. Jog the Theta to the mid point of the two recorded positions.
f. Proceed with the calibration normally.
Z axis must be at home position.
Locate bearing with theta stops attached.
Press SELECT to Continue or EXIT to Quit.
19. Press Select...

Jog theta until block fits between stops
and bearing evenly
evenly..

Motion
20. The axis has already been set to zero position so do not jog the axis. Press the exit key
on the trackball to get out of the jog mode.
Disconnect both of Theta’s limit switches.
21. Disconnect both limit switches. Press Select to continue.

Theta will now move CW to its positive
22. Ensure the jig(s) and any tools are removed from the working areas of the machine.
Press Select to continue and the axis moves to the desired flag location.


Theta limits are being monitored...
Theta will now move CCW to its negative
26. Press Select to continue and the X axis moves to the desired flag location.
Connect the negative limit switch.


Theta limits are being monitored.

Motion
Theta axis limit to limit distance will

now be measured.

Theta axis is now calibrated.

measured range should be between 6.5 -7.75 degrees).
32. If measured value is out of range, repeat the entire procedure.
34. Refer to the Calibration chart for any follow-up calibrations. SELECT to continue
Calibration
or EXIT to quit.

Motion
Training

Motion
Y Axis Calibration
Calibration
Use the following procedure to calibrate the Y axis. On-screen prompts guide you through
mechanical limit.


4. Under the calibrate pull down menu SELECT Y Axis function.
Jog the axis positive (back) as far as possible.
Note: The software will prompt to check the track width and verify it is less than
10.5 inches. If it is not, press the trackball exit button, select the Track Width Axis
function under the Calibrate pulldown and then use the JOG button to move the
axis to 10 inches or less. Make sure no worknest is in the way.
Note: Also verify that the X and Theta axis are close to their respective home
positions or a crash with the machine covers could occur.
Note: The sensors can be access thru the rear cover, but removing the left side
panel can helpful.
Motion
when finished.
9. By hand, push the axis to the back to ensure the electrical limit sensor did stop the
Jog the axis negative (front) as far as possible. Exit the Jog function.
when finished.
14. Click on the PWR button, pull the axis to the front to ensure the electrical limit sensor
15. Install and secure the X, Y, squeegee stroke fixture (Jig 0057/a) to the base frame using
the 2 captive screws which are part of the fixture. The jig is mounted between the
front of the worknest and the X, Y & Theta frames.
Note: Make sure that the spring loaded alignment pins are pulled out and locked in
the out position before installing fixture.
Motion
Jig Location (as viewed from the top)
Note: Some machines were shipped without the mounting holes for the jig. If this is
the case, use a machinist square in place of this jig.
16. Grasp the Y frame with your hands and slowly push it towards the back of the printer
until the inside of the frame is in contact with the alignment jig. This will align the
back of the X and Y frames.
Note: If this machine does not have the mounting holes for the jig, make sure you do
not push the square back.
Note: Make sure the X and Y axis frames are also centered.
17. Using the trackball cursor, click on the power button (PWR) in the axis calibration box.
This will apply stepper power back to the drivers.
The track width should be less than 10.5 inches.

Motion
Disconnect both Y axis limit switches.
21. Disconnect only the positive limit switch. Press Select to continue.
Jog Y axis to mechanical reference point
using the fixture to set the position.
22. The axis has already been set to zero position so do not jog the axis. Press the exit key
on the trackball to get out of the jog mode.
Y axis will now move to its positive
23. Ensure the jig and any tools are removed from the working areas of the machine.
Press Select to continue and the axis moves to the desired flag location.

on its flag. Press select the view LEDs.

Y limits are being monitored...
26. Confirm that the sensor is just on by bending the sensor bracket slightly. Adjust the
Y axis will now move to its negative
27. Press Exit to quit the cal sequence. This is due to the fact that the negative sensor is
difficult to reach when the axis is at it’s negative limit.
Y calibration has been aborted !
28. Press the Exit button and then select the Limit to Limit (LTL) screen button.

Motion
The track width should be less than 10.5 inches.

29. Press Select.

About to find the limit to limit distance

measured range should be between 8.20 -9.00").
32. If measured value is out of range, confirm the Y positive location again and repeat the
entire procedure. If LTL is still out of range, adjust the negative limit sensor location
accordingly.
Calibration

Motion
Training

Motion
Z Axis Calibration
Calibration
Use the following procedure to calibrate the Z axis. On-screen prompts guide you through
mechanical limit.


4. Under the calibrate pull down menu SELECT Z Axis function.
Jog the axis positive (up) as far as possible.
Note: Make sure the camera is not above the worknest and it is recommended
that the Squeegee head be jog to the back. If required, press the trackball exit
button, select the desired Axis function under the Calibrate pulldown and then use
the JOG button to move the axis.
Note: The sensors can be access thru the front cover, but removal of the AC Plate
access cover is required.

Motion
when finished.
Jog the axis negative (front) as far as possible. Exit the Jog function.
when finished.
11. Click on the PWR button and the axis should fall slightly which will verify that the
electrical limit sensor did stop the axis before reaching the mechanical stop.
If the vacuum chucks are not installed
already
already,, install them now
now..
13. A dedicated work holder or a 4x4 board support may be used in place of the front and
rear vacuum chucks. Press Select to continue.
Camera must be parked and clear of Z movement
14. If the camera is clear of the worknest press Select to continue.

Disconnect both Z axis limit switches.
15. Disconnect ONLY the negative Z axis limit switch. Press SELECT to continue or EXIT
to quit.
Make sure the Z axis is free to move between
its electrical limits.
16. Press Select to continue.

Jog the Z axis so the top of the vacuum chucks
are parallel with the top of the tracks.

are parallel with the top of the tracks.

Motion
18. Press Select. Jog to the point where the top of the support chuck or board support
is level with the top of the transports rail caps (or the top of the belt on a Y-snugger
machine).
Z Axis Reference Height, standard tooling

Note: If you have a Y-snugger machine and are performing the Z axis calibration, you
will need to use a reference height where the Z axis raises the worknest (board
support) to a height that is equal to the TOP of the conveyor belt.
19. Press Exit when the position is achieved.

Z axis will now move to its negative limit.
20. Press Select to continue and the axis moves to the desired flag location.
Reconnect the negative Z limit switch.

off its flag. SELECT to view LEDs.

Z axis limits are being monitored...

Motion
Z axis will now move up toward its
positive limit. MAKE SURE IT IS FREE TO MOVE!
24. Press Exit to quit the cal sequence. This is due to the fact that the negative sensor is
difficult to reach when the axis is at it’s negative limit.
Z axis calibration has been aborted !
25. Press the Exit button and then select the Limit to Limit (LTL) screen button.
Camera must be parked and clear of Z movement.
26. Press Select.


measured range should be between 5.93-6.00").
29. If measured value is out of range, confirm the Z negative location again and repeat the
entire procedure. If LTL is still out of range, adjust the positive limit sensor location
accordingly.
Calibration
- Snugger Height!
- Vision Calibration!
Calibration!

Motion
Vision Y Axis Calibration

Calibration
Use the following procedure to calibrate the Vision Y axis. On-screen prompts guide you
to calibrate the axis. When performing this procedure, make sure that the axis does not hit a
mechanical limit. Also, if your machine is equipped with a Wiper, verify the wiper limit
locations before performing this procedure.


Note: Make sure the wiper is jogged all the way to the back and the Vision X is
centered. If required, select the desired Axis function under the Calibrate
pulldown and then use the JOG button to move the axis.
4. Under the calibrate pull down menu SELECT Vision Y Axis function.
Jog the axis Negative (front) as far as possible.

Motion
when finished.
8. Verify that the Vision Y forcer motors did NOT come in contact with the front squaring
stops! Adjust if necessary for 0.125” (3mm) if required.
10. By hand, pull the axis to the front to ensure the electrical limit sensor did stop the axis
before reaching the mechanical stop.
Note: Make sure the Vision X is centered !
Jog the axis positive (rear) as far as possible. Exit the Jog function.
when finished.
Note: The back (+) sensor can only be accessed by removing the lower right side
panel. Notice that the standard Vision Y park sensor is also in this area.
15. Click on the PWR button, push the axis to the rear to ensure the electrical limit sensor
Note: Make sure the Wiper is all the way to the rear!
16. Pull the Vision Y gantry to the front stops and click on the power button (PWR) in the
axis calibration box. This will apply stepper power back to the drivers and re-square the
gantry.
17. Press the Limit to Limit (LTL) screen button.

measured range should be between 26.26-27.99).
20. If the measured value is out of range, confirm the gap of the Vision Y negative stop
location again and repeat the entire procedure. If LTL is still out of range, adjust the
positive limit sensor location accordingly.
Motion
Calibration

Motion
Training

Motion
Vision X Axis Calibration

Calibration
Use the following procedure to calibrate the Vision X axis. On-screen prompts guide you
mechanical limit.


4. Under the calibrate pull down menu SELECT Vision X Axis function.
Jog the axis positive (right) as far as possible.
Note: Make sure the camera is not too far to the front of the machine, or the
camera probe could impact the front stencil support stanchion. If required, jog
the Vision Y Axis.

Motion
when finished.
9. By hand, push the axis to the right to ensure the electrical limit sensor did stop the
Jog the axis negative (left) as far as possible. Exit the Jog function.
when finished.
14. Click on the PWR button, push the axis to the left to ensure the electrical limit sensor
Note: Make sure the Vision Y is not too far forward!
16. Press the Limit to Limit (LTL) screen button.

measured range should be between 17.25-19.12).
19. If the measured value is out of range, repeat the entire procedure. If LTL is still out of
range, adjust the either limit sensor location accordingly. Using the Positive limit is
recommended first, as long as repositioning of the sensor will not allow the axis to hit
the mechanical stop. Verify that this does not occur after moving either sensor.
Calibration

Motion
Squeegee Stroke Calibration

Calibration
Use the following procedure to calibrate the Squeegee Stroke. On-screen prompts guide you
mechanical limit. Make sure no stencil is installed!


4. Under the calibrate pull down menu SELECT the Squeegee Axis function.
Jog the axis positive (back) 2/3 of the way towards the back.
Note: The home sensor can only be accessed by removing the cover over the
Squeegee stroke leadscrew. You may have to jog the axis to remove the cover.
Motion
when finished.
9. By hand, pull the axis to the front so that there is 9 7/8 inch space between the front
bearing block and the lead screw nut block. The X, Y, Squeegee stroke jig can be used
as a spacer to achieve the 9 7/8 inch dimension.
Squeegee Stroke Jig
Jog the squeegee stroke so that there is 9 7/8 inch space
between the front bearing block and the lead screw nut block.
13. Press Select to activate the jog and then press the Exit button since the axis is already
in position.
Position the sensor so that it is just on.
Press SELECT to view LEDs.

Motion
14. Press Select to activate the LIM function to monitor the input status.
Scanning the LED’s...
Press Exit to leave.
15. Confirm that the sensor is just on by bending the sensor bracket slightly. Adjust the
The squeegee will now check home.
16. Press Exit to quit the calibration routine.

Squeegee Stroke has been aborted !
17. Press the Exit trackball button twice to leave the calibration box.
18. Monitor each production program for proper Stroke +/- positions.

Motion
Training

Motion
Squeegee Height C alibration

Calibration
Use the following procedure to calibrate the Squeegee Height. On-screen prompts guide you


4. Under the calibrate pull down menu SELECT the Squeegee Stroke Axis function.
Jog the axis negative (front) 3/4 of the way towards the front. Press Exit to leave the
Squeegee stroke calibration function.
Note: The home sensor is on the back of the Squeegee Head.

Motion
6. Under the calibrate pull down menu SELECT the PSqueegee function.
7. Select the cal button from the calibration box.
Disable the limit switch and jog the Squeegee.
height positive, until the mech. stop is hit.
Press Select to Continue or Exit to quit.
8. Disconnect the sensor.
9. Press Select to open the jog function and jog the axis up until it just contacts the
upper mechanical limit. Press Exit to continue.
The squeegee will now travel a -0.0500 inches from
its mechanical stop.
10. Press Select and the head move down to the flag position.
Connect the switch. Position the flag just
on the limit switch.
Press SELECT to view LED.
11. Reconnect the switch and press Select to activate the LIM monitor function.
Scanning limit LEDs.

Motion
12. Verify the sensor is just on by loosening the two bolts holding the flag (near the right
float sensor, under the ProHead cover). Position the flag in the just On position and
retighten the bolts. Press Exit to continue.
The squeegee will now go home.

The squeegee will now test its negative
software limit. Make sure the squeegee
Press Select...
is free to travel down 3 inches.
14. Press Select and the head moves to the lower software limit.
The squeegee will now test its positive
software limit.
15. Press Select and the head moves to the upper software limit.
Next, adjust the weighing sensors.
16. Press Select and the following prompt appears:

Pressure will now be set for adjusting the weighing sensors.
17. Press Select to continue and pressure is applied.

Raise both sides up 1/16 of an inch and adjust
the sensors so they just make.
Press Select to see the next set of instructions.

Press SELECT to view the float sensors.
18. Press Select to activate the LIM status function.

Scanning limit LEDs...
P ress EXIT to leave.
19. Use a 1/16 allen wrench installed between the downstop block and the lower bearing
block to verify that the float sensor is On. Use a 0.050” allen wrench and verify that
the float sensor is Off. Check both sides.

Motion
20. If adjustment is necessary, make sure you keep a clearance gap of 0.008 to 0.012”
between the sensor and the flag block.
21. Press Exit when adjustment is complete.

PSqueegee is now calibrated.
Press Exit to leave.
22. Press Exit twice to leave the calibration box.

23. Squeegee Level will have to be done for each board file.

Motion
Camera to Track C
Track alibration
Calibration
Use the following procedure to calibrate the Camera to Track. On-screen prompts guide you
to calibrate the axis.


4. SELECT ‘cam to track’ from the calibration pull down menu.
5. Select the CAL button on the screen. The following prompt is displayed:
System will now home the VY and Y axes.
If Y and VY are not calibrated, exit and do now!
6. Press Select to continue, if the conditions are met.

Make sure the VY axis is free to move
between its limits.
7. If there is clearance, press Select to continue.

Jog the VY axis so the inside lip of the fixed
track is seen through the top of the camera.
8. Jog the axis so that the camera is positioned over the inside lip of the fixed rail the
following message will appear.
Rail Cap
(or snugger finger)
CRT Live Video Display
Note: Look down thru the top cube to do the preliminary alignment of the camera.
Sliding a piece of white notebook paper under the rail cap will give better contrast.

Motion
9. Press Exit to continue.

About to alter the CAL file.
10. Press Select to save changes to the machine calibration file.

CAL file is updated.
Press SELECT to continue.
Note: The new camera to track calibration will not be introduced until the
machine application is restarted.
11. Press Select.

Camera to track is now calibrated.
12. Press the Exit button to leave the calibration box.

13. Perform any remaining calibrations.
14. Go to Supervisor user level and load an existing board file (or teach a new program).
15. Perform a Stencil Adjust and check for errors.
16. Enter the Teach Vision function under the Teach pulldown menu. The fiducials should
be centered in the Y direction.
17. Repeat the Calibration if required.
18. Perform a System Backup to save the changes to the calibration file.

Motion
Tactile Calibration
Calibration
Use the following procedure to calibrate the Tactile sensor. On-screen prompts guide you
to calibrate the axis.


4. SELECT the Tactile function from the calibrate pull down menu.
5. Select the CAL button on the screen. The following prompt is displayed:
The tactile axis will now go to home.

The tactile will now test its negative
software limit. Make sure the tactile
Press Select to view the rest of the prompt:

is free to travel 0.5 inches.

Motion
7. Press Select to continue and the tactile should extend.

The tactile axis will now return to home.
8. Measure with a ruler to verify that the tactile extended properly.
9. Press Select when done.

If the tactile did not move freely adjust
the flag up and re-calibrate the tactile.

The tactile is now calibrated.
11. Press Exit button twice to leave the calibration box.

12. Perform any remaining calibrations.
13. Go to Supervisor user level and load an existing board file (or teach a new program).
14. Perform a Stencil Height (or Level Squeegee) and check for errors.
15. Repeat the Calibration if required.

Motion
Motion Calibration Checkout

Calibration
Since most motion calibrations do not store any values in the machine .CAL file, an alternate
method is required to test the calibration of each motion axis.
Base axis checkout procedure
Each axis’ positioning is controlled via the hardware limit or homing sensors. It is very
important that each sensor is in the desired location for the machine to operate to factory
specifications. The easiest way to determine if the sensors are located properly is to use
the software calibration routines to test the sensor locations. Below is a generic
procedure that can be used as a general guideline:
– Power on the printer, log in to WindowsNT and when prompted, RESET the printer normally
– Change the user mode to Calibrate
– From the Calibrate pulldown, select the desired axis to be tested
– Postion the axis to it’s known mechical reference position using the required jig or other
means
– Select the CAL button in the axis calibration dialog box
– Follow the prompts thru the calibration routine to the point where the machine engages the
flag and sensor for the axis, and states that the sensor at this position is either just ON or OFF
– Write down the desired sensor state (ON or OFF) and also the current axis position displayed
in the jog list as the ‘Cal Sensor Pos’
– Abort the calibration by pressing the EXIT button
– With the sensor plugged in, select the JOG button in the axis calibration dialog box
– Slowly jog the axis until the input just goes to the desired state and note the current axis
position displayed in the jog list
– Slowly jog the axis on/off the sensor several times to ascertain the average position and record
this position as the ‘Actual Flag Position’
– Compare this position to that of the recorded ‘Cal Limit Pos’
– If adjustment(calibration) is required, jog to the ‘Cal Sensor Pos’ and relocate the flag/sensor
to the desired just ON/OFF postion and retest the ‘Actual Flag Position’ until the a desirable
position is achieved
– For axis’ with two Limit sensors, proceed as described as above for the first sensor. Reenter
the CAL button routine and skip any adjustments for the sensor. Follow the prompts thru the
calibration routine to the point where the machine engages the flag and sensor for the axis,
and states that the sensor at this position is either just ON or OFF. Write down the desired
sensor state (ON or OFF) and also the current axis position displayed in the jog list as the ‘Cal
Sensor Pos’. Abort the calibration by pressing the EXIT button. With the sensor plugged in,
select the JOG button in the axis calibration dialog box. Slowly jog the axis until the input just
goes to the desired state and note the current axis position displayed in the jog list. Slowly jog
the axis on/off the sensor several times to ascertain the average position and record this
position as the ‘Actual Flag Position’. Compare this position to that of the recorded ‘Cal Limit
Pos’. If adjustment(calibration) is required, jog to the ‘Cal Sensor Pos’ and relocate the flag/
sensor to the desired just ON/OFF postion and retest the ‘Actual Flag Position’ until the a
desirable position is achieved
– From the axis calibration dialog box, select the LTL button for any two sensor axis and confirm
that the results are within the desired range
– Adjust as necessary

Motion
Base axis checkout worksheet
X+ On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
X- On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Y+ On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Y- On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
THETA+
THETA+ On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
THETA-
THETA- On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Z+ On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Z- On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Wiper+ On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Wiper- On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
VY+ On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
VY- On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Track+ On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Sq. Hgt+ On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Dispense On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
Sq. Strke On/Off:_______ Cal Sensor Pos:_______ Actual Sensor Pos:_________
X+/- LTL:_______
Y+/- LTL:_______
THETA+/-
THETA+/- LTL:_______
Z+/- LTL:_______
VX+/- LTL:_______
VY+/- LTL:_______

Motion
Boardstop Sensor Calibration

Calibration
1. Enter the MAINTENANCE user mode and reset the machine
2. Remove any tooling from the worknest area
3. Jog the track width to 7.025 inches to accommodate the boardstop sensor calibration
board, JIG0178.
4. Ensure that the board moves smoothly and does not bind the entire length of the tracks.
5. Place a standard board supports into worknest area ensuring that the supports will not
encroach the window portion of the calibration board.
6. Jog the Z axis so there is 3/8 (9.5mm) inch between the top of the supports and the
bottom of the board.
7. Jog the Vision Y so that it is centered over a board support between the tracks.
8. Remove the two screws retaining the camera cover and remove the cover to gain access to
the boardstop sensor.
9. Using the potentiometer located above the LED, adjust to the point where the sensor just
turns OFF when over the board support.
Note: Newer ultrasonic sensors (blue) do not have a potentiometer to adjust.

Motion
10. Place the calibration board on the track belts and slide the board under the sensor. The
sensor should turn ON. Adjust as necessary to achieve the desired results.
11. Repeat the test with the customer’s maximum thickness board.
12. When sensor adjustment is complete, replace the camera cover.
13. Remove any boards from the tracks and jog the Z axis to it’s home position.
14. Place the calibration board on the tracks over the left board input sensor.
15. From the TEACH pulldown menu select the ‘Calibrate Boardstop’ function. Follow the
prompts to teach the load left and load right Boardstop to camera X offsets.
16. When prompted to jog the camera’s horizontal crosshair to the front edge of the board
cutout, position the cube so it is left side of the window.
Y image is inverted!
CRT Live Video Display
17. When complete, follow the prompts to finish the calibration.

18. Restart the application and load an existing board program.
19. Use the load board function to test the calibration. A small offset is acceptable, but if the
machine reports a “Software Limit” reperform the calibration. Retest the new calibration.
20. Perform a ‘Backup System’ to update the backup copy to the calibration file.

Motion
Camera Park Position Adjustment and Calibration

Calibration
Camera Park Sensor Mounting
Note: This procedure has been performed at the factory and need only be done if the
bracket (with sensor) was removed for track repair or was removed prior to
installation. The sensor must be calibrated using a procedure later in this document.
1. Install the camera park sensor bracket.

2. Reconnect the sensor connector (if disconnected).
Note: If camera park sensor was removed, re-calibrate the camera park sensor. Refer
to Camera Park Position Calibration.

Motion
Training

Motion
Camera Park Position Calibration

Calibration
1. Reset the printer.

2. Change user mode to Calibration.
3. Select Camera Park Position from the Test pull-down menu.
4. If the PARK SENSOR LED is OFF, using the jog button in the control box, jog the camera
in either X or Y axes until the PARK SENSOR LED in the control box comes ON.
Note: Use of an inspection mirror will aid in moving the camera in the correct
direction.
5. Select CAL in the CAMERA PARK control box.

6. Check that the values of VX and VY (determined by the CAL function and displayed in the
Measured boxes) are within the Position Range (Inches) values given to the right in the
control box. If either measured value exceeds a range value, that axis must be adjusted.
For example, in Figure 38, VX is -2.2500 which exceeds the range value -2.043. Therefore,
the base reflector mount bracket in the vision probe must be moved in the (+) direction at
least 0.208".
Note: The base reflector mount bracket in the vision probe is adjusted for making X-
axis corrections. The park sensor itself is adjusted for making Y-axis corrections.
7. If the checks in step 7 above show a need for an X axis adjustment, carefully remove the
vision probe cover.
Caution: Use care not to disturb any components inside the vision probe.
8. Adjust the X axis position by loosening the mounting screws and moving the base
reflector mount bracket in the appropriate direction.
9. Re-select the CAL function and re-check the measured VX value against its range values
until it does not exceed either.

Motion
10. If the Y axis is out-of-range, using an 7mm open end wrench, loosen both jam nuts
securing the park sensor to its bracket. Slide the sensor to the front (-) or to the rear (+) to
correct a Y axis measurement that is out-of-range.
Note: When selecting the CAL function, the track width must be set at 16.000".
11. Re-select the CAL function and re-check the measured VY value against its range values
until it does not exceed either.

Motion
12. Reset the printer, Verify that the camera parks properly and the Camera Not Parked
message is not displayed. If the message is displayed, refer back to the Camera Park
Position Calibration and re-calibrate the camera park position.
13. Jog the track width to 2.00" and select CLEAR FAULT. Verify that the camera parks behind
the rail at 2" and the Camera Not Parked message is not displayed. Only if the message is
displayed, should you perform the following steps:
Note: The following procedure should rarely be required to be performed in the field.
a. Select the TEST pull down menu. Select Camera Park Position from the menu.(The
PARK SENSOR LED in the control box should not be ON.)
b. Using an inspection mirror, determine which direction (in the X direction) that the
vision probe should be jogged to turn ON the PARK SENSOR LED.
c. Read and record on paper the value of VX AXIS on the main screen.
d. Select JOG in the camera park control box. Jog the vision X axis (VX AXIS) until the
PARK SENSOR LED in the control box turns ON.
e. Read and record the new value of VX AXIS. Calculate the difference of this value from
the original value read in step c. above.
f. Select CLEAR FAULT. The camera (VX AXIS) should return to the value recorded in
step c.
g. Loosen the two mounting screws securing the base reflector mount bracket. Move the
bracket (in the same direction as in step d.) until the PARK SENSOR turns ON. It
should move the same amount as the difference calculated in step e.
h. Secure the bracket mounting screws.
i. Select JOG in the camera park control box. Jog VX AXIS until the PARK SENSOR LED
turns OFF. Record the value of VX AXIS from the main screen.
j. Jog the PARK SENSOR LED back ON and record the new value of VX AXIS. The
difference between the OFF and ON value should be 0.005" to 0.010". If it is greater
than this, repeat step g.
k. Jog the track width back to 16.000" and select CLEAR FAULT. Verify that the camera
parks correctly and the Camera Not Parked message is not displayed.
l. Re-install the camera probe cover.
Note: If the camera does not park correctly, DO NOT RE-CALIBRATE CAMERA
PARK POSITION AGAIN. You MUST go back and repeat step 13 on page 43 again.

Motion
Camera Park Sensor Amplifier Set-Up
Perform this procedure only if replacing the amplifier.

1. Select Input/Output Test from the Maintenance menu. Disable Stepper Power.
2. Manually position the vision gantry so that the reflective tape window on the bottom of
the vision probe is centered (X and Y) over the sensor light spot.
3. On the camera park sensor amplifier, change the Mode Selection Switch from RUN to SET.
4. Manually pull the vision gantry fully forward.
5. Pull the stencil wiper assembly forward until the wiper paper (under the carriage) is over
the park sensor so that the sensor light spot strikes the paper.
6. Press the OFF button on the camera park sensor amplifier.
7. On the sensor amplifier, change the Mode Selection Switch from SET to RUN.
Note: As a check, run the wiper over the sensor. Check the VISION Y PARK input
on the Input/Output Test from the Maintenance menu. It should be OFF. If it turns ON
(by sensing the paper or the underside of the vision gantry or wiper carriage) repeat
this procedure.

Motion
8. Re-square the vision gantry against the forward hard stops.

9. Select Input/Output Test from the Maintenance menu. Enable Stepper Power.

Motion
Training

Motion
Stencil Wiper Calibration

Calibration
Use the following procedure to calibrate the stencil wiper. On-screen prompts guide you


4. Under the calibrate pull down menu SELECT the Vision Y axis function.
5. Using the trackball cursor click on the jog button (JOG) in the Axis calibration box. Jog
the axis negative (front) just short of the front stops. Make sure the camera probe
remains in the center of it’s travel! Press Exit twice to leave the axis calibration
function.
6. Under the calibrate pull down menu SELECT the Wiper function.
7. Click on the jog button (JOG) in the Axis calibration box. Jog the wiper axis negative
(front) just short of the vision gantry. Press Exit to leave the jog function.
8. Select the PWR (power) button from the calibration box to remove stepper power from
all the drivers.
9. Pull the Vision Gantry to the front end stops to square the gantry. Select the PWR
(power) button from the calibration box to re-apply stepper power to all the drivers.
10. Click on the jog button (JOG) in the Axis calibration box. Jog the wiper axis negative
(front) slowly until the limit sensor stops motion of the axis. Press Exit to leave the jog
function.
11. Verify that wiper assembly is square to the vision gantry. If not, the newer style wipers
have eccentric screws on the wiper roller bearings to help square the wiper. The roller
bearings ride on the inside of the vision platens.

Motion
12. Click on the calibration button (CAL) from the calibration control box. The following
messages and instructions will appear in the text box.
Disconnect both wiper limit switches.

Motion
13. Disconnect the switches as prompted. It is easier to unplug the negative limit at the
connection panel above the pneumatics tray. It is the only yellow (older machines
were orange) cable that plugs into the connection panel. Press Select:
Jog the vision Y forward to a good
position. BE CAREFUL NOT TO CRASH VISION Y Y..
Press EXIT when done jogging.
14. Since we brought the Vision Y to the front stops earlier, press Exit:
Install the wiper/vision spacer on vision Y
Y..
Press Select to see the rest of the message:

Jog the wiper forward until it just
contacts the spacer

Motion
15. Jog the wiper while holding a 7/64 allen wrench (used as a spacer) between the wiper
and the vision gantry. Stop jogging where the space just passes the entire length of the
Vision gantry without getting caught.
16. Press Exit:

Connect the wiper negative limit switch.

Now adjust the wiper’s negative limit switch
just on its flag. Press SELECT to view LEDs.
18. Press Select to activate the LIM function to monitor the input status.
The wiper limits are being monitored...
19. Adjust the sensor so it is just On at this position.

20.Press Exit to Continue.
Install the wiper / limit spacer
spacer..
Press Select to see the rest of the message:

Jog the wiper back until it just
contacts the spacer
spacer..

Motion
21. Jog the axis towards the rear of the printer until the wiper roller bearing is 0.030” from
the end of travel stop.
22. Press Exit when positioning is complete.

Connect the wiper positive limit switch.

Now adjust the wiper’s positive limit switch
just off its flag. Press SELECT to View LEDs.
24. Press Select to view the LED status:

The wiper limits are being monitored.
25. Bend the flag slightly to test the position. When adjustment is complete, press Exit
The wiper will now move home.

Wiper is now calibrated.
27. Press EXIT twice to leave the calibration box.

28. Complete any other remaining calibrations.
29. Perform a RESET to ensure that the wiper limit does not interfere with the proper
operation of the Vision Y axis.

Motion
Training

Motion
Winder Setup and Calibration

Calibration
Tools
Digital Multimeter
Small straight slot screwdriver for potentiometer adjustment
Full roll of paper
Empty paper roll
Procedure
Verify and adjust if necessary the following potentiometer settings:

MIN SPEED
SPEED: full counter-clockwise
IR COMP
COMP: full clockwise
SIG ADJ
ADJ: full clockwise
CURR LIMIT
LIMIT: full clockwise
CURR MIN
LIMIT SPEED
IR SIG
COMP ADJ
1. With power off, open the rear access doors on the machine.
2. Remove the cover for the winder driver card.
3. Power on and reset the printer.
4. From the maintenance pulldown, select the user mode function.
5. Select the MAINTENANCE user mode and enter the required password.
6. From the maintenance pulldown, select the ‘Change Paper’ function to bring the wiper to
the front of the machine.
7. Remove any existing paper rolls and install the empty wiper roll into the payout position.
8. Confirm that the roll size fiber optic sensor is approximately 1.2 inches (30mm) from the
roll core. This would put the sensor tip 0.5 inches (13mm) from a full 2.4 inch (61mm)
paper roll. Adjust the sensor position if required. The sensor amplifier should be set to L-
ON.

Motion
9. Connect the digital multimeter to the winder motor driver card for DC volts at the
terminals DC Voltage Positive (POS +) and BUS Negative (BUS-).
BUS-
POS +
10. Remove the empty roll core and install the full paper roll on the pay out position
11. From the Maintenance pulldown menu, select the ‘Input / Output Test’ screen. Activate
the winder motor with the output ‘WMR Winder’.
12. On the sensor amplifier mounted on the wiper assembly, confirm that the operation
potentiometer is set to 1.0 and the gain is approximately 1.5.
13. Use the gain adjust potentiometer to adjust the voltage displayed on the multimeter to a
value between 9.8 and 10 VDC. If 9.8 is not achievable, recheck all previous steps. If the
setting is close (9.5-9.7VDC), turn the potentiometer to the point where the maximum
value is just achieved.
14. Turn of the winder output and remove the full roll core. Install the empty paper roll on the
pay out position and turn the winder output on.
15. Install the multimeter probes on A1 and A2. Adjust the MIN SPEED potentiometer until
the meter reads around 6 VDC.
MIN
SPEED
A2
A1

Motion
16. Turn off the winder output and remove the empty roll core. Install the full paper roll on
the pay out position and turn the winder output on. Verify the voltage displayed is around
22VDC.

Motion
Training

Motion
Paste Dispenser Calibration

Calibration
Use the following procedure to calibrate the Pate Dispenser. On-screen prompts guide you
mechanical limit. Make sure no paste is in the dispenser and remove the stencil!


4. Under the calibrate pull down menu SELECT the Dispenser axis function.
5. SELECT the CAL button located in the calibration control box.
Jog the dispenser so its limit switch is
half on the limit bar
bar..

Motion
6. Press Select to activate the jog, but jogging is unnecessary. Press Exit and the axis will
home itself.
The dispenser will now cycle between its
plus and minus limits.
7. Press Select.
If the dispenser hits a mechanical limit
recalibrate the dispenser
8. Press Select and watch/listen to the axis movements.

Dispenser is now calibrated.
9. Reset the machine.

10. Enter Setup menu 2 and select the dispenser parameter ‘Profile.
11. Change the Dispense position limits (yellow lines) to their maximum value. Press the
Exit button to return to Setup Menu 2.
12. Return to the main view screen and Cycle the dispenser using the Utilities pulldown
function. Press Next to continue the dispense cycle. Watch/listen to the axis
movements.
Cycle the Dispenser a 2nd time. Watch/listen to the axis movements.
13. If the dispenser struck a mechanical limit, RESET the machine again.
Jog the Dispenser to position 0.000”.
With a ruler measure whether or not the dispenser is centered in the machine.
Adjust the dispenser home flag accordingly.

Motion
Snugger H eight C
Height alibration
Calibration
Note: The Z axis must be calibrated and the vacuum chucks put in place before
calibrating snugger height.
Note: If the Calibrate and Test user modes are not displayed, you will have to: Exit the
application, change the keylock parameter in the Option Editor to ‘Extended’ and
restart the application.

4. Under the maintenance pulldown menu, select the RESET function to make sure the
camera is out of the way.
5. Under the calibrate pull down menu SELECT the Snugger Height function.
6. The following message is displayed:
Z axis MUST be calibrated and chucks MUST be
in place before calibrating Snugger Height.
7. Press SELECT button on the trackball controller.

Z axis will now home.
8. Press SELECT to home the axis.

are parallel to the top of the snuggers.
Press SELECT again.

are parallel to the top of the snuggers.
9. The Z axis jog function is now active. Jog the Z axis up until the top of the vacuum
chucks are even (horizontally) with the top surface of the snuggers fingers. A standard
support bridge can also be used.
Note: To avoid possible contact with the stencil, most engineers will jog the worknest
0.008” higher than the snugger fingers.
10. Press EXIT.

This is the snugger height position.
Press SELECT to save or EXIT to quit.

Motion
11. Press SELECT to save the height to the machine CAL file.
Snugger height is now calibrated.
12. Press EXIT.

13. Go to the Supervisor user level and RESET the machine.
14. Load an existing board file and test the snugger height calibration by loading the
boardwith the load board function.
15. If the board is not slightly above the snugger fingers, check the accuracy of the board
thickness parameter in Setup menu 1. Test Again.
16. If problems still persist, repeat the calibration and test again.
17. When finished, perform a System Backup.

Vision
Tab 6. Vision System

Course
Calibrate the vision csystem
Calibrate the optional 3D verification System *
Perform automated diagnostic tests
MPM Series Printers

Vision
Training
MPM Series Printers

Vision
Calibration Chart
Whenever you calibrate, refer to the chart below for any followup calibrations that need to
be re-verified.
– Remember to do a Backup System after completing the vision calibration!
User Menu
Motion


Vision

Utilities /
ProHead

Vision
Vision Calibrations Jig & T

Calibrations ool List
Tool
Jig/tool Part # OptionDescription

JIG0112 Vision alignment fixture, C-tool
1000743 2D histogram board
AP25OPT-55 Calibration board and stencil ( for Rear Fixed rail machines, you will need to
use the UP2500 Vision calibation board and stencil - APOPT74)
Loctite 222 thread sealer
Pot tweeker
X30 magnifiers (radio shack)
Flash light

Vision
Vision System C alibration Checkout

Calibration
Tools Required
· Production board program, board and stencil

· Flashlight
· Vision Alignment Jig (C-tool)
· Good production Stencil
How to Determine if Vision Calibration is necessary

Calibration
Under normal circumstances there should not be a need for an offset to be added to the
setup menu, unless that offset is being added to compensate for Board to Stencil Stretch.
(Stretch is defined as a difference that exists between the artwork on a board and on the
stencil. Stretch differs from board to board; the vision system automatically splits the
difference between ‘trained’ board targets during it’s alignment process.)
If offset values are needed to get the board to match the stencil, the machine may be out of
alignment. To test for vision mis-alignment, perform the following steps:
a. Select a circuit board and stencil with pads or fiducials located to the left and right front
edges. Place a mark on the board that will distinguish it from any other board.
b. Use this board to generate a new Vision Teach profile. Select a pad/aperture as close as
possible to the front-left and front-right sides of the board and stencil.
c. On the Setup Menu, enter a ‘Snapoff’ figure of 0.00, enter an accurate board thickness
figure, and enable the vision system (leave it enabled throughout this entire procedure).
d. Once the board is taught, use the Load Board to Stencil Height utility from the main
menu.
Use a microscope scope to inspect the stencil-to-board alignment at the two taught targets.
Remember how closely the alignment appears, as well as exactly how any offset of board-to-
stencil appears.
Note: Do not lean on or against the stencil during any portion of this procedure.
Movement may occur even with the frame clamps on.
e. Use the Load Board to Stencil Height utility to cycle the board in and out of the machine
10 times, inspecting the alignment each time to verify that it appears exactly the same.
Figure 1 illustrates examples of ‘board stretch’. The substrate pads in Example A are
physically closer together than the stencil openings. Example B shows the type of stretch
where the substrate pads are physically further apart than the stencil openings .

Vision
Figure 1
If vision calibration is needed, it is possible that the Probe Assembly (or the X-Platen) has
been disturbed, causing mis-alignment. Figure 2 illustrates this effect:
Figure 2
If the alignment is not repeatable, this is an indication of three other potential problems:
a. Backlash exists. Check the drive rods and couplers of the axis in question .
b. Loose camera or vision cube is shifting during the vision gantry movements.
c. The targets that were trained during vision teach are not clearly defined and/or made
unique during teach. Re-teach vision, consulting your manual for assistance in properly
training targets. Following the steps properly in the Vision Teach segment is critical; if you
have doubts as to the proper method of defining the targets after reading your manual,
call Technical Support for advice.

Vision
Checking the vertical Alignment of the Vision Cube
1. Reset the machine.

2. On the Main Menu’s control panel, enable the Board Light, and turn off the Stencil Light.
3. Jog the vision system out over a clear are of the worknest base plate. Ensure the surface is
clean.
4. Jog the Z-axis up slowly until it makes its software limit, while maintaining a watch on the
vision probe to ensure that no contact is made.
5. Place the C-Tool on the workholder to ‘bracket’ the camera, and place a small flashlight on
the top of the C-Tool, as shown in Figure 3.
Figure 3
6. At the Main Menu, select Live Video. Two dots are visible on the monitor; one dark and
one light. If needed, jog the vision system to center the dots on the screen.
Note: It may be not be possible to see the dark dot if the intensity of the light source
is too high. Diffuse the light source if needed; placing a sheet of paper between the
light source and the C-Tool may help.
C-Tool
Also, if the alignment is already accurate, you may not see the two dots separated;
manually angle the C-Tool a small amount while watching the monitor to view the dots.
Place the C-Tool back when finished.
7. If adjustment is needed to align the dots over each other, refer to the vision calibration
procedure.
8. Remove the C-Tool and light from the machine.
9. Turn off the board light.
10. Select Clear Fault on the Main Menu.

Vision
Checking the Rotational Alignment and the Focus of the CCD C

Focus amera
Camera
1. Install a regular production stencil in the machine, and clamp it in place.

2. On the Main Menu control panel, turn on the Stencil light, and select Live Video.
3. Jog the camera to a horizontal row of pads (QFP or BGA).
4. The monitors shown in Figure 4 provide a reference for correct and incorrect settings for
the rotational alignment.
Note
Note: Ensure that the three white dots on the camera body (older cameras only) are facing
towards the front of the machine when finished.
Figure 4
5. If the image is off, try re-timing the vision gantry assembly and reconfirm (AP and
UP3000’s only).
7. If the image is off and you suspect the stencil image is not square to the frame, try jogging
the camera in the Vision X axis only while watching a single aperature on the monitor. If
the aperture seems to travel non-linear, then re-calibration is required.
8. Push up and down on the stencil while watching the monitor. The relaxed position should
be the most focused.
9. Return to the Main Menu and select the Clear Fault button.
10. If adjustment is required, refer to the vision calibration procedure.

Vision
Vision System Calibration Procedure

Calibration
Attention: The steps contained in this procedure are critical to the accuracy of the vision
system’s automatic alignment correction. Damage to the equipment may result if the steps
are not followed properly. It is recommended that the person performing this calibration
thoroughly read and understand these steps before attempting the calibration procedure. If
there are any questions concerning any portion of this procedure, contact Technical Support.
Pre-Requisite Calibrations
Calibrations
Before proceeding, make sure that the Z axis and Snugger Height Calibrations are complete.
CREATING A PRE-CALIBRA
CREATING TION BACKUP
PRE-CALIBRATION
1. Select Backup System from the File pull-down menu.

2. Place a blank disk in the floppy drive of the machine’s computer.
3. Follow the prompts to make a new set backup disk(s). Write the machine’s model, serial
number, software revision, current date and disk number on the new backup disk(s).
Also write ‘PRE-CAL’ on each diskette
4. From backup Disk 1, make a harcopy printout of the following files with a regular PC that is
printer capable:
AP.CAL
AP.LIM
UP.OPT
5. Discard any old hardcopy backups and write the machine’s model, serial number, software
revision and current date on the new hardcopy backups printouts.
Also write ‘PRE-CAL’ on each printout.
TOOLS REQUIRED FOR THIS PROCEDURE
• An MPM Vision Cal Board and Stencil (MPM part # AP25Opt-55 or APOPT74 for rear fixed
rail machines)
• A Vision Calibration ‘C’-Tool (MPM part # Jig0112)
• A standard production stencil
• An illuminated microscope or pocket-scope
• A Volt/Ohmmeter
• A flashlight (or the illumination source for your microscope?)

Vision
PREPARE THE MACHINE FOR CALIBRATION

CALIBRATION
Re-timing the vision gantry:

1. Re-time the vision gantry by performing the following steps:
a.) Select Output Test from the Maintenance section of the Main Menu.
b.) Move your cursor to the Stepper_Power block, and select it. (Stepper motor power is
now disabled to the entire machine; the vision assembly can now be manually moved
in the Y-Axis.).
c.) Manually grasp the left and right ends of the Vision X-axis gantry, and pull the gantry
forward until it gently touches the two hard stops at the front of the machine.
d.) Hold the gantry in place with one hand, and select the Stepper_Power block again to
enable stepper power.
e.) Move to the Main Menu, and select Reset from the Maintenance pull down menu.
2. Remove any stencils or adaptor frames from the machine.
3. Remove the tactile sensor, and any vacuum chamber components and board supports
from the workholder.
Clean the surface of the workholder thoroughly. Remove any raised surfaces or burrs with
a machinist’s stone if needed.
4. Jog the vision gantry to the approximate center of it’s travel.
5. Jog the squeegee carriage to the rear of the machine.
Cleaning the Camera Lens:

Warning: The camera system should never be doused with any type of solvent. Solvents can
degrade the adhesives that hold the cube components together.
Clean the cubes with lens cleaning paper or a cotton swab lightly dipped in alcohol. Remove
any residual alcohol film with a clean dry swab or tissue paper.

Vision
ADJUSTING FOCUS AND ALIGNING PATTERNS

PATTERNS
1. Install a regular production stencil in the machine, and clamp it in place.

2. On the Main Menu control panel, turn on the Stencil light, and select Live Video.
3. Jog the camera to a horizontal row of pads.
4. Loosen the screws in the Camera Clamp Bracket, as shown in the Figure.
Rotate the camera head to adjust the horizontal alignment, and move the camera in and
out to focus the image. The monitors shown in the Figure provide a reference for correct
and incorrect settings.
5. Tighten the camera clamp screws, watching the monitor for any shift while the screws are
tightened.
6. Return to the Main Menu and select the Clear Fault button.
7. Open the frame clamps, and remove the stencil from the machine.
8. Using the chart on the next page, check for proper zero degree rotation of the camera
assembly. You should see the message ‘Camera Correct’ on the live video screen.

Vision
Vision Probe
Machine Front
Board Lamp ON
This Page

Vision
ALIGNING THE VISION CUBES
1. Select Jog-Vision from the Main Menu and move the vision gantry to the front of the
machine.
2. Move to page 1 of the Setup menu, and set the Board Thickness parameter to zero.
3. On the Main Menu’s control panel, turn ON the Board Light and turn OFF the Stencil
Light.
4. Jog the vision system out to it’s approximate center of travel.
5. Jog the Z-axis up slowly until it makes its software limit, while maintaining a watch on the
vision probe to ensure that no contact is made.
6. Verify that the workholder is still clean.
7. Place the C-Tool on the workholder to ‘bracket’ the camera, and place a small flashlight on
the top of the C-Tool, as shown in the Figure.
8. At the Main Menu, select Live Video. Two dots are visible on the monitor; one dark and
one light. If needed, jog the vision system to center the dots on the screen.
Note: It may be not be possible to see the dots clearly if the intensity of the flashlight is
too high. Diffuse the flashlight if needed; placing a sheet of paper between the light source
and the C-Tool may help.
Also, if the alignment is already accurate, you may not see the two dots separated;
manually angle the C-Tool a small amount while watching the monitor to view the dots.
Place the C-Tool back when finished.

Vision
9. If adjustment is needed to align the dots over each other:

In the Y-axis:
a.) Use the two cube adjustment set-screws (items #1 in Figure 5.2) to tilt the center
cube holder. When loosening one set-screw, tighten the other one against it.
b.) Ensure that the set-screws are locked against each other when the desired setting is
achieved.
In the X-axis:
Use the Tuning Lever Adjustment Screw (item #3) to position the light and dark dots
over each other. Switch back and forth between items #2 and #3 while watching the
monitor.
Note: The Center Cube Clamp screw (item # 2 in Figure 5.2) is used to maintain the cube
in a stable position once the adjustment is set. If the cube ‘rattles’ in it’s holder while
adjustments are being made, use the #2 screw to eliminate the rattle. Do not tighten the
screw; use it only to maintain the cube in position.
If loosening the Tuning Lever Adjustment Screw (item #3) doesn’t allow the spring to
enough adjustment, loosen the Center Cube Clamp screw. Access is possible by removing
the Laser Power Supply (item #4 -be careful to not lose the standoff washer under the top
screw). When finished with adjustments, replace the power supply, and ensure that all
screws are gently snugged.
10. Remove the C-Tool and light from the machine.
11. Turn off the board light.
12. Replace the cover on the vision probe.

Vision
VISION CALIBRATE
CALIBRATE
1. Set up the machine and perform Teach using the MPM Test Board and Stencil. Use board
supports and the stock vacuum chamber assembly.
Note: You will only need to Teach up to the ‘Stencil’ module in the Teach Board function.
2. Enter Setup Menu #1.
Set the Snapoff setting in the Board Parameters box to 0.0201 .
Set the FP Mode setting in the Vision Parameters box to 1 .
Ensure that the Vacuum parameter is set to On.
3. Jog the squeegee head to the rear of the printer.

4. Use Load Board from the Utilities pull-down menu to load the board to stencil height.
5. Align the two square stencil openings over their corresponding board pads. Use the X, Y
and Theta Jog buttons to move the stencil over the board while looking through the
openings.
6. On the Main Menu, select Vision Adjust from the Maintenance pull down menu to save
the coarse alignment position.
7. When finished, save the program and assign an easily-remembered name to the board
profile. Press the Clear Fault button on the main operation screen.
8. On the Main Menu for the Maintenance User, select Calibrate Vision from the Teach pull
down menu. The board exits and is re-loaded into the machine to Vision Height.
9. Follow the step-by-step instructions on the screen, teaching the four corner fiducials as
targets when prompted .

Vision
10. Select EXIT after the fourth target is trained. When the save prompt appears, select NEXT
to continue.
11. The Vision Calibration routine automatically starts and the system makes a number of
moves to calculate it’s geometry.
If no problems are encountered, a Vision Calibration Complete message appears.
If problems occured, a Vision Calibration Terminated message appears. To correct for this
problem:
a.) Clean the stencil
b.) Clean the board targets
c.) Repeat all steps

Vision
Histogram Test Procedure

Test
The Histogram only needs to be performed when replacing the camera power supply, camera
controller, CCD camera or the board lamp.
1. Power On and reset the machine.

2. Enter the Test User Level and select Reset from the Maintenance pull-down menu.
3. Enter Setup Menu 1 and set the PCB thickness to that of the Histogram card.
4. Place a standard tooling block on the worknest and jog camera over the tooling block.
5. Jog Z axis up to it’s software limit.
6. Place the Histogram card on the tooling with the white area under the camera.
7. Switch the board lamp ON.
8. From the Test menu select Histogram.
9. With the board lamp ON and the white area under the camera, press NEXT.
10. When prompted, place the Histogram card on the tooling with the white area under the
camera.
11. When the screen message says Remove Card - it means move the black area under the
camera. Press NEXT and then NEXT again.
12. From the Reports menu, click on Histogram Data.
13. You should see something like the graph below.
The aim of this test is to set the illumination from the lamps to achieve the correct
separation between dark and light levels encountered in production. Varying the voltage to
the lamps will shift the position of the white peaks. Clockwise adjustment of the voltage
control potentiometer on the lamp power supply (pneumatics tray) will increase the
voltage and move the white peak to the right of the graph.
14. If necessary, adjust the voltage and repeat the test steps until the peaks are centered in the
green areas of the chart.
Make small adjustments only and repeat the test

Vision
SETTING THE LEARNED OFFSET
1. Re-load the file previously saved.

2. If you saved the board file after fiducials were taught, enter the Teach Vision function and
delete ALL fiducials.
3. Use the Board Load utility to load the board to stencil height. Select the Exit button when
finished.
4. Ensure that there is approximately 0.020 clearance between board and stencil (snapoff
distance) to allow the stencil to move over the board without touching.
6. Select Learn Offset from the Teach pull-down menu on the Main Menu.
7. Teach the two front board targets as multi-model fiducials as directed by the on-screen
instructions.
8.) Press EXIT after the second target is trained and Save the file under a new name. The
machine will reload the board, inspect the fiducials and raise the board to the stencil.
9. When the printer has raised the board to the stencil, set up a microscope so that you can
view the 1st and 2nd targets by placing the microscope on the stencil target.
Check both targets for correct offset. If targets are off center, adjust X-axis, Y-axis, or Theta
axis (or a combination of all three axes) to center both targets on top of each other.
Note: It is critical that both targets are centered and that once centered, both targets are
repeatable.
10. Press reload several times. View targets through the microscope to check that both targets
are aligned.
11. Click on Done.
12. Select Clear Fault from the Main Menu.

Vision
CAMERA TO TRACK CALIBRATION

CALIBRATION
1. Select Reset from the Maintenance pull-down menu.

2. Select User Mode from the Maintenance pull-down menu and enter the Calibrate user
level.
3. Turn on the Board Light.
4. Select Cam to Track from the Calibrate menu. When prompted, jog the camera to the front
of the machine. Look down through the lens onto the track. Center the inside lip of the
front track in the lens, and press Exit when finished.
CREATE A NEW SYSTEM BACKUP

CREATE

3. Follow the prompts to make a new set backup disk(s). Discard the old backup disk(s) and
write the machine’s model, serial number, software revision, current date and disk number
on the new backup disk(s).
Also write ‘POST-CAL’ on each diskette
printer capable:
AP.CAL
AP.LIM
UP.OPT
5. Discard old backups and write the machine’s model, serial number, software revision and
current date on the new hardcopy backups printouts.
Also write ‘POST-CAL’ on each Hardcopy printout

Vision
Training

Vision
3D Post Print Verification, Laser Setup and C

Verification, alibration
Calibration
The 3D system option measures the height of solder deposits after being printed. Use the
following procedure to setup and calibrate the system to optimum performance standards.
Laser Voltage Set-Up

Voltage
Tools, Equipment, and Materials

• Digital Voltmeter
Procedure
1. Apply system power (if OFF).
2. After boot-up and machine RESET, change user mode to Maintenance.
3. Jog vision probe forward to gain access to it.
4. Open rear door to gain access to pneumatic tray area.
5. Open front covers and remove vision probe cover to gain access to the laser connectors,
P78 and P79.
6. Turn on both lasers using the I/O Test screen.
7. Connect the (–) lead of the DVM to XT9-10 or the (–) terminal on power supply GS4 in the
pneumatic tray. Using either P78 or P79, connect the (+) lead of a DVM to pin 1 of the
connector.
8. Check for +5.00 VDC ±0.010VDC.
9. If 5.00 VDC is not within tolerance, adjust PS2 in pneumatic tray for +5.00 VDC ±0.01 VDC
at the vision probe with both lasers ON.
10. After the measurement (and adjustment if necessary) is done, turn off both lasers.
11. Exit out of I/O Test.
- See the graphic on the next page -

Vision

Vision
Laser Alignment Check
Tools, Equipment, and Materials

• Micrometer caliper
• Board support (P/N A2-789)
• Laser calibration plate (P/N 1000812)
• Set of Imperial Allen wrenches
WARNING! Do not allow the laser beam to enter the eye directly. Possible eye injury
could result.
1. Jog track width for maximum width.

2. Adjust vacuum chucks for maximum width.
3. Measure the thickness of the laser calibration plate (P/N 1000812) with a micrometer
caliper. The thickness must be 0.125 ± 0.002 inch (3.18 ± 0.0508 mm).
4. Enter Set Up menu 1 and enter the thickness you measured in step 3.
5. EXIT to main menu and save it to a file, e.g., 3-D Check.
6. Jog vision system back to home position.
7. Place board support (P/N A2-789) as close to the forward vacuum chuck as possible.
8. Put the laser calibration plate on top of the board support. Make sure the plate is centered
and sits flat on the board support.
9. Enter Utilities sub menu and click on Check Lasers. The printer will prompt to you to
check board thickness. (It was already set to 0.125 ± 0.002 inch (3.18 ± 0.0508 mm) in
step 3).
10. Press SELECT and use your hand to trigger the upstream track sensor and board stop
sensor.
11. Z Tower will raise to vision height. Jog the vision gantry so it indicates a position of
0.0000 for VX AXIS and -16.0000 for VY AXIS. Both lasers should be ON with cross hairs
displayed on monitor.

Vision
12. Leave the VX AXIS and VY AXIS Jog active so that the board light will remain on. (It will
turn off if Jog is deselected.)
13. Loosen one 6-32 1/4 SHCS and remove other 6-32 1/4 SHCS so the vertical laser power
supply can be swung out of the way to gain access to the vertical laser.
14. Loosen the 6-32 x 1-1/8 SHCS, the 6-32 x 3/4 SHCS, and the 6-32 x 1/2 SHCS on the
vertical laser support. To adjust the vertical laser, snug the 6-32 x 1-1/8 SHCS and leave the
6-32 x 3/4 SHCS loose. Loosening the 6-32 x 1-1/8 and 6-32 x 3/4 SHCS, enables laser line
rotational adjustments and focusing. Loosening the 6-32 x 1/2 enables fine tuning the
lasers vertical position.
15. Adjust the vertical laser so that its line is centered in cross hairs and is has the thinnest
line possible. Tighten hardware.
Equipment Damage! Use extreme caution when tightening the screws. Over-tightening
the 6-32 x 1-1/8 and 6-32 x 3/4 SHCS will warp the laser housing, causing the laser line to
bow and causing irreversible damage to the laser.
16. Horizontal laser adjustments are made by loosening the 6-32 x 5/8 SHCS in the horizontal
laser support. Adjustments can now be made for focus, rotation, and horizontal position.
Be aware that this one screw controls all three axis. After the correct focus and rotational
positions are obtained, snug the 6-32 x 5/8 SHCS.

Vision
17. Using light to moderate finger pressure, adjust the mirror support beam to set the
horizontal laser line in the cross hairs. Tightening the 6-32 x 5/8 SHCS will probably cause
the laser to move up or down, so compensate the position prior to tightening the screw.
18. Check laser line thickness by pressing NEXT. It should be close to 4.3 to 4.6. However,
laser line thickness will be fine-tuned in laser calibration.
19. Jog the vision gantry out of the way so you can move the board support.
20. Move the board support to the second location. Jog the vision probe to the new board
support location.
21. Test the six test positions shown in the figure in sequence, 1 to 6.
22. When testing all six positions, the lasers should fall into the cross hairs. If, at any position,
the lasers fall off the cross hairs, the vision frame is not leveled to laser specs and must be
leveled. Use the cross hairs as a guide to adjust the vision frame.
23. After all positions test satisfactorily, the Lasers Alignment Check procedure is complete.
The next step is to calibrate the lasers.

Vision
Laser Calibration
Calibration
1. You should still be in the Maintenance utility.

2. Set up the track width and vacuum chucks for the test board. (Use a regular MPM
demonstration board or a customer’s production board).
3. Under Set Up menu, set test board thickness, detent, and board size (X and Y).
4. Under utilities sub menu, test the detent setting and adjust as needed.
5. After all is set, save it to a file (e.g., 3-D Cal).
6. Use utility sub menu “Load Board”. Install board on track and load board to vision height.
Click on EXIT.
7. Jog vision probe to position VX AXIS = 0.0000, V Y AXIS = -16.0000. Board must be free
from surface defects, pads, or dirt/grease/paste. Clean the board if dirty. If area is
obstructed, find a position on the board that is satisfactory (VX AXIS and VY AXIS position
is not critical).
8. Select Calibrate Lasers and follow the prompts.
9. After the test is finished, a graph will be displayed on screen.
10. The criteria is as follows:
The trace must be flat over at least four divisions and the flat portion must be
immediately to right of the vertical center line. If the horizontal and vertical laser traces
do not meet this criteria, the lasers will have to be re-adjusted using the Laser
Alignment Check procedure.
Acceptable
Ideal
Two examples of incorrect laser adjustment and the corrective procedures follow.

Vision
In example #1 , the horizontal laser trace correctly has a “flat line” that covers four screen
divisions immediately to the right of the vertical black line. However, the vertical laser’s
“flat line” portion is two divisions to the right the vertical black line and is only three
divisions in length. To correct this fault, go back to the Laser Alignment Check procedure
and adjust the vertical laser by pulling the laser further out from its current position.
In example #2, the horizontal flat line portion is four divisions in length, but is to the left
of the center line. The vertical laser flat line portion is too short (only three divisions) and
is two divisions from the center line. The correction is as follows:
1. Go back to the Laser Alignment Check procedure, and with the horizontal laser still in
the cross hairs, push the laser in. Adjust the vertical laser by pulling it out.
2. After adjustments, both the horizontal and vertical laser must have four-division “flat
line” portions immediately to the right of the vertical black line.
3. After successful completion of the laser voltage setup, laser alignment check, and laser
calibration, replace the cover on the vision head.

Vision
Training

Advanced Operations
Using the Diagnostic Test

Test
The Diagnostic Test is a tool used to check the repeatability and backlash of the critical
alignment axis’ of the machine. This should be run after all axis and vision calibrations are
complete.
1. Using the Trackball; from the “drop down” menu under Maintenance, select USER MODE
2. Select the TEST User Mode; Login by typing the password: qmpm and then selecting
ENTER.
3. From the Maintenance pulldown menu, select the RESET function. Press NEXT to allow
the machine to reset.
4. From the File pulldown menu, select the LOAD FILE function and load in an existing
board file.
5. Follow the prompts to allow the machine to reconfigure for the new board file.
NOTE: The track will change size to the required Y dimension for the new board file.
Make sure the worknest is clear of any obstuctions!
6. From the main operation screen, select the TRANSPORT button to jog the Printed Circuit
Board “full travel” several times to ensure the Tracks are parallel and the Board transports
freely.
7. Remove the Printed Circuit Board from the Conveyor Tracks.
8. Install the proper board supports in the worknest to achieve reliable results in the test.
9. From the File pulldown menu, select the LOAD BOARD function, select the TOOLING
HEIGHT radio button and the select the BEGIN button.
10. Verify that the board is centered properly on the worknest. Use Detent to modify the
board load location if required and select the BEGIN button to reload the board to tooling
height. When the board loads centered on the worknest, select the EXIT button.
11. Select the CLEAR FAULT button to unload the board from the worknest.
12. Before running the Diagnostic Test, tour the machine and check for any loose parts.
Remove all paperwork, notebooks, pens and pencils, etc. from the machine. Hang a
Display sign on the machine:
WARNING! DIAGNOSTIC TESTING, DO NOT TOUCH !
13. From the TEST pulldown menu, select DIAGNOSTICS and then select the SHORT TEST.
14. The board will load automatically, and if fiducials are taught, the vision system will display
of of the targets on the LIVE VIDEO display.
15. Check the monitor and Jog, as required, to center the “TARGET” on the cross-hairs shown
on the display. When positioning is done. select the EXIT button on the trackball.
16.The test will start automatically. The test will run for approximately 50 minutes.
17. At the conclusion of Diagnostic Testing, the machine will Transport the Board to its exit
position. The display will show the first of two (2) pages of test results.
18. Verify the test results to determineif all the Diagnostic Tests have passed, an Asterisk
indicates failure. Select NEXT to see the second page.
Advanced Operations
19. If any test fails, re-run the Diagnostic Test for the specific module that failed. This is done
by retrurning to the main operation screen and from the TEST pulldown menu, select the
DIAGNOSTICS function again. Instead of short test, select the desired test that previosly
failed.
The sub-tests take approximately 10~20 minutes.
20. If the test fails again, check:

a. The axis coupler for slipping or timing belts for excessive play or wear.
b. Check the lubrication of the axis
c. Check to see if the axis is binding mechanically
d. Make sure the machine is level and all leveling feet are contacting the floor solidly
e. Check the continuity of the motor cabling with machine power off
21. Rerun the test and if the test fails again:

a. Replace the motor driver and/or motor
22. Rerun the test. If the test fails, the machine may still run in production without problems
arising due to the fine tolerance that is required when the machine was built is longer
achieavable due to wear in the system. The machine may require the bearings and/or
leadscrews replaced.

ProHead
Tab 7. ProHead System

Course
Perform basic Prohead setup
Calibrate the Pneutronics style control system *
Calibrate the ProAir style control system *
MPM Series Printers

ProHead
Training
MPM Series Printers

ProAir ProHead
Calibration Chart
Whenever you calibrate, refer to the chart below for any followup calibrations that need to
be re-verified.
– Remember to do a Backup System after completing the calibration!
User Menu
Motion


Vision

Utilities /
ProHead

ProAir ProHead
ProAir ProHead C alibration Jig & T

Calibration ool List
Tool
Part # Description
P2947 Pressure gauge
1001546/a Pressure gauge adapter hoses
P6028 Push/pull; gauge
JIG 0148 Blade leveler
Medium straight slot screwdriver
Pot tweeker

ProAir ProHead
ProHead Lift C ylinder System T

Cylinder est
Test
Tools required:
• Digital Pressure Gauge
Lift Cylinder T
Cylinder est Procedure
Test
1. Insert the pressure gauge in line with either the left or right lower cylinder.
2. Locate the Pressure Regulator and Sequence V alve on the rear of the Prohead. (They are
Valve
mounted together on a bracket; the Sequence Valve on the left and the Regulator on the
right.)
3. The pressure gauge should read 34 PSIPSI.

4. Manually grasp the left and right sides of the Prohead float mechanism with both hands.
Pull it down while watching for change on the pressure gauge reading. The change should
be no greater than 0.3 PSI
PSI.
5. Check for a small amount of air flow out of the Sequencer’s exhaust port.
6. If any of the above tests have not passed, then re-calibration is required.

ProAir ProHead
Training

ProAir ProHead
ProHead Squeegee System Test F

Test or ProAir Style MPM Printers
For
Tools required:
• Digital Ammeter
• Test Leads
• Digital Pressure Gauge
• Force Gauge
Control Cards T
Cards est Procedure
Test
1. Ensure that the system air pressure to the machine is set to 90 PSI.
2. Enter the Calibrate User Level and select Reset from the Maintenance pull-down menu.
3. Select Jog-Squeegee Stroke and jog the squeegee to the front of the machine.
4. Select the DAC Board Test from the Test pull down menu.
5. Connect a digital pressure gauge in line with one of the upper air cylinders by removing
the Air Output hose from the ProAir Control Card.
6. At the ProAir card, connect an Ammeter in series on the (–) or (C-) wire of the card.

ProAir ProHead
7. Select the desired channel button on the CRT to start the test procedure.
8. Follow the prompts in the software test, but do not adjust any potentiometers. The results
of your test should match as follows:
a.) When at 4mA (+/- .01mA) the expected air pressure is 0 PSI.
b.) When at 12mA (+/- .01mA) the expected air pressure approximately 32.5 PSI.
Newer DAC card software routines will also prompt for the 20mA check, the
expected air pressure is approximately 65 PSI.
Only if the current is not correct, then re-calibration of the DAC board in the
computer is required.
If the expected output Air pressure is off, then replace the ProAir Card.
9.) Repeat the test for the other channel.

10. Exit to the main menu and identify which is the selected blade in the Squeegee Stroke ID
box. If the front blade is selected, use CYCLE SQUEEGEE to select the desired blade for
the force gauge adapter you are using.
11. Enter setup menu 1 and change the FORCE setting for the desired blade to 10Lbs.
12. Return to the main menu and jog the printhead to the front software limit.
13. Press the Squeegee UP/DOWN button at the bottom of the main menu to have the
system update the program change to the ProAir Cards. In Calibrate mode, the blades will
lower. Press the Squeegee UP/DOWN button to raise the blades.
14. With a Force gauge, measure the downward print force.
15. Check several different FORCE settings to see if the Calibrated down force is accurate
(+/- 2Lbs).
16. If any of the above tests have not passed, then re-calibration is needed.

ProAir ProHead
ProAir ProHead System Calibration Procedure

Calibration
Attention: The steps contained in this procedure are critical to the accuracy of the vision
system’s automatic alignment correction. Damage to the equipment may result if the steps
are not followed properly. It is recommended that the person performing this calibration
thoroughly read and understand these steps before attempting the calibration procedure. If
there are any questions concerning any portion of this procedure, contact Technical Support.
CREATING A PRE-CALIBRA
CREATING TION BACKUP
PRE-CALIBRATION

3. Follow the prompts to make a new set backup disk(s). Write the machine’s model, serial
number, software revision, current date and disk number on the new backup disk(s).
Also write ‘PRE-CAL’ on each diskette.
4. From backup Disk 1, make a hardcopy printout of the following files with a regular PC that
is printer capable:
AP.CAL
AP.LIM
UP.OPT
5. Discard any old hardcopy backups and write the machine’s model, serial number, software
revision and current date on the new hardcopy backups printouts.
Also write ‘PRE-CAL’ on each printout.
TOOLS REQUIRED FOR THIS PROCEDURE
• Force Gauge
• Milliamp Meter
• Air Pressure Gauge and adapter hoses
• Straight slot screwdriver
• Potentiometer screwdriver
LIFT CYLINDER CALIBRATION

CALIBRATION
1. Ensure that the system air pressure to the machine is set to 90 PSI
3. Remove the Prohead cover.
4. Disconnect the left side lower cylinder air line.

ProAir ProHead
5. Connect an air pressure gauge in line with the left side lower cylinders.
Attention: Mounted together on a bracket on the back of the ProHead are the
sequence valve and the balance regulator. Support.
6. Close the sequencer so that no air is escaping.

7. Set the balance regulator to 34.5 PSI with the sequence valve closed (no air escaping).
Attention: For Rheopumps longer than 16”, it may be necessary to set this to 37.5
PSI.
8. Pull the float mechanism down by hand and release. When released, it should return to
the upper stops by itself.
9. Adjust the sequencer to bleed pressure back to 34 PSI.
Attention: For Rheopumps longer than 16”, it may be necessary to set this to
37 PSI.
Attention: For When the float mechanism is pushed up and down, the meter should read
within +/- 0.2 PSI of the desired value. If this is not achieved, increase the regulator
pressure output by 0.2 PSI and use the sequencer to reset the pressure to 34 PSI.

ProAir ProHead
DAC CARD AND PROAIR CARD SETUP
1. Ensure that the system air pressure to the machine is set to 90 PSI.
2. Enter the Calibrate User Level and select Reset from the Maintenance pull-down menu.
4. Select the DAC Board Test from the Test pull down menu.
5. Connect a digital pressure gauge in line with one of the upper air cylinders by removing
the Air Output hose from the ProAir Control Card.
6. At the ProAir card, connect an Ammeter in series on the (–) or (C-) wire of the card.
7. Select the desired channel button on the CRT to start the test procedure.

ProAir ProHead
8. Follow the prompts in the software test, but do not adjust any potentiometers. The results
of your test should match as follows:
a.) When at 4mA (+/- .01mA) the expected air pressure is 0 (zero) PSI.
b.) When at 12mA (+/- .01mA) the expected air pressure approximately 32.5 PSI.
c.) Repeat the test for the other channel.
Newer style DAC boards will have an additional step for 20mA @ approximately 65PSI.
If the current is not correct, then re-calibration of the DAC board in the computer is
required.
If the expected output Air pressure is off, then replace the ProAir Card. Repeat the
testing of the new card.
If the expected output Air pressure and mA values are okay, then proceed to downward
force calibration.
9. If adjustment of the mA value from the DAC board is required, open the upper drawer and
remove the computer cover to gain access to the DAC card.
10. Re-enter the desired channel’s calibration. Adjust the required DAC card potentiomer until
the mA value is correct. Exit the the DAC board test screen.
11. Replace the computer cover when finished.

ProAir ProHead

ProAir ProHead
DOWNWARD FORCE CALIBRATION

CALIBRATION
1. Clean all areas around the worknest. Enter the Calibrate user level and reset the printer.
2. Zero out the force gauge and place the force gauge and jig onto the worknest in the center
of the pump head or squeegee head assembly.
Note: Be sure not to place the force gauge under the pump head blades. Place the force
gauge just in front of the front blade.
3. Jog the Z-axis up until the gauge is just short of touching the squeegee head assembly
(The gauge should not be supporting the head at this time).

ProAir ProHead
4. Select the DAC Board Test function under the Test pulldown menu. From the Select
Calibrate Prohead (Lbs) from the DAC Board Calibration screen.
5. Press the SELECT button on the trackball controller.

ProAir ProHead
6. Follow the prompts and increase the DAC steps until the force gauge scale reads 10.0 lbs.
Note: After performing each step, verify that there is .010 to .050 between the hard stop
and the downstop block. By pressing the NEXT button, you can jog the Z axis up/down to
achieve the proper height.
7. Press the EXIT button on the trackball controller to accept.

8. Press the SELECT button on the trackball controller.
9. Increase the DAC steps until the scale reads 20.0 lbs. Verify there is the proper downstop
gap and press the EXIT button on the trackball controller to accept.
10. Continue with the preceding steps for values of: 30, 40, and 50 lbs.
11. After accepting all five values, select DONE from the DAC Board C Calibration
alibration screen.
12. Remove the force gauge from the worknest.

ProAir ProHead
Calibration Testing
Testing
1. Reset the machine and enter the Calibrate user mode.

2. Identify which is the selected blade in the Squeegee Stroke ID box. If the front blade is
selected, use CYCLE SQUEEGEE to select the rear blade (starting in back).
3. Enter setup menu 1 and change the FORCE setting for the rear blade to 10Lbs (4.5 Kg).
4. Place the force gauge back onto the worknest and align under the head as done in the
calibration steps.
Note: Make sure the force gauge will make contact with the flat part of the pump head and
not the blades.
5. Press the Squeegee UP/DOWN button at the bottom of the main menu to have the
system update the program change to the ProAir Cards (In Calibrate mode, the blades will
lower without having to do a Level Squeegee).
6. Press the Squeegee UP/DOWN button to raise the blades.
7. Raise the Z-axis up until the force gauge reads 10.0 lbs (4.5Kg). If calibration was done
properly, the hard stop should start to rise.
Note: If calibration is off by more than two pounds (plus or minus), the down force
calibration procedure will have to be redone.
8. Lower the Z-axis so the head is unsupported.

9. From Setup Menu 1, set the Total Force for the Front/Rear to 50.0Lbs (22.7Kg) and press
EXIT on the trackball controller to accept.
10. Repeat the preceding steps to ensure that the calibrated down force is accurate.

ProAir ProHead
CREATE A NEW SYSTEM BACKUP

CREATE

3. Follow the prompts to make a new set backup disk(s). Discard the old backup disk(s) and
write the machine’s model, serial number, software revision, current date and disk number
on the new backup disk(s).
Also write ‘POST-CAL’ on each diskette.
printer capable:
AP.CAL
AP.LIM
UP.OPT
5. Discard old backups and write the machine’s model, serial number, software revision and
current date on the new hardcopy backups printouts.
Also write ‘POST-CAL’ on each Hardcopy printout

ProHead
Crush Bearing Adjustment

Critical for reliable performance of the Rheopump, the crush bearings need to be checked to
avoid backlash in the system.
1. Check that there is no play in the left and right bearing blocks and adjust if necessary.
Ensure that the bearing blocks do not bind.
To check the bearings:

a. Remove air from the printer.
b. Grab the new swing arm bar near the vertical shaft and try to move forward and
backward in the y-axis direction. The entire ProHead assembly will move a little
when you do this.
c. If no play is detected in either end, bearing blocks are fine. If you feel some play,
tighten the adjusting screws.
d. Push one end of the swing arm up to the top of travel. Tighten the adjusting screw
until the bearing holds the shaft. Loosen until the arm drops smoothly.
Repeat for the other side.
Note: Be sure not to over tighten the bearing blocks. This will cause excessive friction
and will not allow the system to apply the correct pressure when printing.

ProHead
Training

ProHead
Swing Arm Bar Leveling Procedure

Critical for reliable performance of the Rheopump, the swing arm bar needs to be checked to
ensure proper blade to stencil engagement.

2. Perform a reset.
3. Raise the Z-tower and jog squeegee stroke to its mid point.
4. Select Squeegee Height from the main operating screen and jog squeegee height to it’s
mid point.
5. Change the user mode to Maintenance (password: SVC).
6. Select Setup Menu 1 from the main screen.
7. Change the Total Force for both Pump Front and Pump Rear to: 20.0 lbs
lbs.
8. Select Pump Up/Down from the operator control panel of the main screen.
Note: Verify that both the right and left balance cylinder brackets are in the down position
resting on both lower bearing blocks.
9. Place the indicator onto the worknest.

ProHead
10. Indicate the swing arm bar parallel, left to right, to the worktable by adjusting the right
side of the swing arm bar allowing for no more than 0.003 inches TIR.

ProHead
11. Indicate the swing arm bar from the front to rear allowing no more than .003 inches TIR
(shimming the back of the ProHead (both sides) to where it mounts if necessary).
Note: Place shims between the back of the ProHead and ProHead mount and through
the 1/4-20. The amount of shims required will be approximately twice the TIR measured.
Note: If the front to back TIR is less than 0.010 inches TIR, the adjustment can usually be
performed with the swing arm bar’s right side mounting bolts.

ProHead
Training

ProHead
Checking Level of the Mount Bar

1. Mount the pump head assembly onto the swing arm bar with two wing screws.
2. Remove the paste cover, if installed.
3. Remove both end caps from the pump head. This will prevent any influence on the blades.
5. Reset the printer.
6. Change the user mode to Calibrate user.
7. Raise the Z-tower and jog the squeegee stroke to its mid point.
8. Select Setup Menu 1 from the main screen.
9. Change the Total Force for both Pump Front and Pump Rear to: 15.0 lbs.
10. Select Pump Up/Down from the operator control panel of the main screen.
Note: Verify that both the right and left balance cylinder brackets are in the down
position resting on both lower bearing blocks.
11. Select Squeegee Height from the main operating screen and jog the squeegee height to
it’s mid point.
12. Place the indicator onto the worknest.
13. Indicate the bottom of each blade (left and right sides) staying about 1/2 inch from the
ends.
If the blades are out more than 0.003 inches from each other, remove the pump head
from the swing arm and loosen the blade backup bar to verify that the blades are properly
seated.

ProHead
14. Re-install the pump head and re-indicate the blades.
Note: If the blades are still out, perform the Re-level procedure on the swing arm.
Remember that the blades will bend. If the Swing Arm bar is leveled properly and the
blades are still out, check the mounting of the pump on the swing arm bar.
If it is still out, it may be the pump. Run the pump in production and determine if there
are any problems printing.
Also, if there is sufficient downstop in the programs, the left to right TIR is less of an issue
than a front to back TIR issue.

ProHead
Refurbishing the Programmable Squeegee Head

This procedure provides directions for disassembling, cleaning, reassembling and adjustment of
the Programmable Squeegee Head (ProHead) assembly. The ProHead should be calibrated in
accordance with the Preventative Maintenance schedule, however, a heavy production schedule
or accidental jarring of the assembly may require adjustment outside of planned calibration.
This procedure can be used to mechanically adjust the Programmable Squeegee if problems
occur during the following sequences of operation:
• Squeegee Clamping
• Squeegee Flip
• Squeegee Leveling
This procedure can also be used if the following problems occur:

• Attack Angle shifts or changes while printing
• Attack Angle settings are difficult to adjust
• Paste is being left behind on the front or the rear of the stencil after printing
• Squeegee holders are difficult to install or remove
• Squeegee holders fall out of the clamps before the clamps are energized
Materials required:
• Loctite 222
• Isopropyl Alcohol
Tools required:
• Hex wrenches: 5/32", 3/32", 1/16"

• External snap-ring pliers
• Flat-blade screwdrivers (small to large)
Section 1: Disassembly and Cleaning the Prohead
1. Close the front load cover. Select the Jog-Squeegee Stroke button on the Main Menu, and
jog the squeegee carriage to the front of the machine.
2. Remove the front cover from the Prohead.
3. On the Main Menu, select the Jog-Squeegee Height button on the Control Panel, and jog
the squeegees all the way down.
4. Tag or mark the Squeegee Clamp air hoses to identify the front and rear lines for
reinstallation. Remove the incoming (supply) airline from each T-fitting.
5. For non-quick change heads, disconnect the squeegee flip cylinders by removing the
cotter and guide pins on the bottom of each cylinder.

ProHead
6. Use a 5/32 hex wrench to remove the two rear Bearing Block mounting screws.
7. Support the bottom of the squeegee assembly to prevent it from falling. Loosen the two
upper Bearing Block mounting screws (shown in Figure 1: these screws are installed
vertically from the top and cannot be completely removed). Move back and forth between
the screws until the assembly falls.
8. Place the assembly on a work bench.
With a felt-tip pen, mark the following parts for identification
• Left and right Bearing Mounts
• Left and right End Plates
• Front and rear Clamp assemblies
9. Slide the Bearing Mounts from their dowels. Remove the washers from the dowels.
10. Inspect each Bearing Mount assembly for cleanliness, wear, or binding of parts. Clean
solder paste or other contaminants using isopropyl alcohol.
Inspect the black roller bearings; replace them if they do not turn easily. (To replace them,
tap them out from the inside with a brass rod. Use a bench press to install the
replacement bearings.)
Inspect the entire Bearing Mount assembly for burrs. Remove all burrs using a file or
stone.

ProHead
11. Remove the left and right End Plates.

Notice that the right End Plate has two Attack Angle Ball Plungers. Verify that the Attack
Angle Ball Plungers turn easily.
Inspect the condition of the ball-tips on the Attack Angle Ball Plungers. Press down on
the tips to test the internal springs. Replace the Plungers if the balls are missing, the
springs are defective, or the threads are damaged. (Do not use a thread sealer on the
Plungers.)
Inspect and clean each End Plate.
Note: Perform the following steps on the front clamp assembly only. Set aside the
rear assembly for reference.
ProHead
12. Inspect the condition of the nylon tips on the Cam Pivot Ball Plungers.
Press down on the nylon tips to test the internal springs. Replace them if necessary.
13. Inspect the entire Clamp assembly for cleanliness, wear, or binding. Clean any solder
paste or other contaminants with isopropyl alcohol. Pay particular attention to the
following components:
a. Squeegee Clamp Bar: Use a 3/32 hex wrench to remove the button heads from the
Shaft Clamp Block. Note the orientation of the “chamfers” on the Shaft Clamp Block
and the Clamp Bar before removing them.
Place the washer and guide pin aside for reassembly.
b. Pressure Plate: clean and deburr the plate.
c. Squeegee Clamp Ball Plungers: Ensure that the springs in each plunger are operating
correctly; replace them if necessary.
d. Traction Plates (with blue traction material ): Replace the plates as follows:
d1) Remove the screws using a 1/16" hex wrench and remove the plates.
Note: If hardened accumulated solder paste prevents removal of the screws, use
a Dremel tool (or a file) to cut a slot across the surface of the screw head. Remove
the screw with a flat-blade screwdriver. Remove any resulting burrs.
d2) Install new plates and screws. Do not use Loctite on the screws.
d3) With a polishing stone, burnish (smooth) the BLUE abrasive surface of the
traction material to remove any high spots. (High spots can interfere with removal
and replacement of the squeegee holders.)
14. Reassemble the Clamp Bar, Shaft Clamp Block, washer, and guide pin. Ensure that the
orientation of the chamfer on the block is correct before assembling.
15. Repeat steps #11 through #15 for the rear clamp assembly.

ProHead
Section 2: Reassembling the Prohead
1. Apply Loctite 222 on the threads and adjust the Squeegee Ball Plungers so that the tip of
the ball extends beyond the traction plate, but the ball plunger’s threaded housing does
not.
Ball Plunger Friction Pad /Plate
Frame
2. Repeat for the other squeegee clamp.

3. Install the front squeegee blade holder. Ensure that the blade holder installs easily and
that blade is able to float left and right in the blade clamp assembly.
Note: Adjustment screws to increase or decrease clamping force are located on each
ProHeads clamp assembly. These two screws are located on the left and right face of
each squeegee clamp assembly.
4. Adjust only one squeegee clamp at a time. Turn the screws clockwise for greater clamping
force, adjust until the blades will not fall out, but rock side to side (float) with ease.
5. Hold the entire Squeegee clamp assembly over a soft surface and shake it. If the
squeegee holder falls out, reconfirm the position of the squeegee ball plungers and re-
adjust the clamp force adjusting screws as necessary.
6. Repeat for the other squeegee clamp.
7. Remove the squeegee holders.
8. If the blades bind or grate as they are removed, burnish the blue traction material.
Note
Note: New traction plates are no longer blue and should not be burnished.
9. Place the front and rear Clamp Assemblies together with the clamp bars touching.
10. Install the right End Plate (with the Attack Angle Ball Plungers) on the right end of the
front and rear Squeegee Clamp assemblies.
11. Install the left End Plate on the left end of the front and rear Squeegee Clamp assemblies.
12. Ensure that both plates are fully seated.
13. Install the special washers on the left and right dowels.
14. Install the left and right Bearing Mounts.
15. Mount the squeegee head back onto the machine.
16. Manually grasp each clamp assembly and turn it to test all five detent settings (-5, -2.5, 0,
+2.5 and +5 degrees). Adjust the setting of the Ball Plungers in or out as needed to verify
that they engage in the detents properly, but do not bind as the degree of attack angle is
changed.
17. Ensure that the four end plate screws are loose.

ProHead
Flip Levers Adjustment

This procedure needs to be performed after rebuilding the Squeegee Head.
1. Grasp the bottom portion of each of the Squeegee Flip Levers, and manually flip them.
Check for a smooth and balanced feel between the two Bearing Mounts.
If adjustment is needed, set the front and rear Cam Pivot Ball Plungers until both sides
move the same. The plungers should gently hold the Squeegee Flip Levers in position at
any of their detent positions.
Press Here
2. When finished with adjustments, ensure that neither Cam Pivot Ball Plunger is turned in
as far as it will go; if this happens, turn both screws out and begin the adjustments again.
3. Push against the top of the right Squeegee Flip Lever. Tighten the End Plate Lock screws
while holding the lever in place. Repeat for the left Squeegee Flip Lever.

ProHead
Squeegee Flip Cylinders Adjustment

Both squeegee flip cylinders should extend and retract at identical rates. Balance the speed of the
squeegee flip cylinders as follows:
WARNING! When performing maintenance procedures, you may need to reposition

printer components to gain better access. Stay clear as components move. Failure to
comply could result in personal injury.
Equipment Damage! Before resetting the printer or jogging any printer component,
ensure the printer is free of objects that may interfere with or obstruct movement. Failure
to comply may result in equipment damage.
1. If the printer has not already been reset, select Reset from the Maintenance pull-down
menu.
2. Select the NEXT button on the RESET menu.
3. Select the Jog button from the main operating screen.
4. Select Squeegee Stroke on the JOG CONTROL screen to jog the print head to the
negative software limit.
5. Press the EXIT button once to return to the main operating screen.
6. Open the front hood and doors.
7. Open the print head cover. Remove the clevis pins that attach the cylinders to the flip
levers of the ProHead.
8. Select the Squeegee Flip button on the operator control panel several times. Watch the
squeegee flip cylinders as they extend and retract to verify that they complete full strokes.
Both cylinders should extend and retract at identical rates.
9. Make required adjustments as follows:
a. Turn the adjustment screws on the
lower flow control valve clockwise to
slow the rate of cylinder extension, or
counter-clockwise to speed extension.
Select the Squeegee Flip button on
the operator control panel after every
adjustment to check the effect of your
adjustment on performance.
b. Turn the adjustment screws on the
upper flow control valve clockwise to
slow the rate of cylinder retraction, or
counter-clockwise to speed
retraction. Select the Squeegee Flip
button on the operator control panel
after every adjustment, to check the
effect of your adjustment on
performance.

ProHead
10. Lower the print head cover and replace the two thumbscrews.
11. Close the front doors and hood.
12. Select the Jog button again from the main operating screen.
13. Jog the print head carriage to the rear to its positive software limit.

ProHead
Setting the Attack Angle (45 degrees)

The following procedure describes the steps required to set the attack angle to 45 degrees (zero).
1. Inspect and clean the worktable with isopropyl alcohol.

2. Select Squeegee Stroke from the main operating screen and jog the squeegee over the
center of the worktable.
3. Place a bridge onto the worktable.
4. Place the machinist square onto the bridge as shown:
5. Lower the squeegee completely to its down position using SQUEEGEE HEIGHT
6. Select Z AXIS from the main operating screen and jog the Z-tower in the positive direction
(up) until the machinist square is directly in front of the squeegee clamp mechanism.
Note: Refer to the figure when raising the Z-tower for the proper positioning.
7. Press the SQUEEGEE FLIP button from the operator control panel and flip the squeegee
so the front blade is in the downward position.

ProHead
8. If the machinist square is not flush with the front squeegee clamp mechanism, loosen the
two attack angle screws.
9. Adjust the squeegee clamp mechanism until it is flush against the machinist square as
shown in the figure.
10. Tighten the two attack angle screws.
Note: Do not overtighten the two attack angle screws.
11. Press the SQUEEGEE FLIP button from the operator control panel and flip the squeegee
so the rear blade is in the downward position.
12. Reposition the machinist square to the rear of the squeegee.
13. Perform the same steps that were used for the front attack angle adjustment.

Pneutronics
Pneutronics Programmable Squeegee Calibration Procedure

Calibration
Tools required:
· Digital Voltmeter
· Digital Pressure Gauge
· Trimpot Adjustment tool
· Calibration Software Disk
· Flashlight
Note
Note: Addendum A of this document provides the appropriate Engineering Drawing
needed for this procedure. Before starting this procedure, note C14 and C16
C16, the
capacitors across terminals 3 and 4 of each pressure controller. Verify that the pressure
controllers on the machine to be calibrated have only one capacitor per controller and are
installed in the same location as shown in Addendum A. Remove or install capacitors as
needed.
Procedure
1. Ensure that the system air pressure to the machine is set to 80 PSI (90 PSI on machines
equipped with the Enhanced Ultra style wiper system).
2. If you are using machine software prior to Version 5, insert the Calibrate software diskette
into the computer and press the reset button to reboot.
If you are using later version of software, you must enter the Calibrate user mode by
selecting the Maintenance pulldown menu and then the function User Mode.
Using the trackball, select the CALIBRATE user and then enter the password qmpm.
Note: If the Calibrate and Test users do not appear in the list, alter the KEYLOCK
Note
parameter in the machine’s Option Editor.
Pneutronics
3. Select Reset from the Maintenance pulldown menu.
4. Select Jog-Squeegee Stroke and jog the squeegee to the front of the machine. Clear the
worknest of board supports and jog the track to approximately 10 inches (250mm). Jog
the Y axis to approximately 2 inches (50 mm).
5. Select Psqeeg I/O Test from the Test pull down menu. The monitor displays left and right
Set Point and Feedback bit values.
6. Position the cursor over the on-screen Left button, and press the Select button on the
trackball. The left Set Point window becomes active.
a.) Set the left Set Point to 000.

(To change the setting, roll the trackball or select the Next button on the trackball to
toggle between 000 and 255.) Press the Exit button on the trackball when finished.
b.) Set the right Set Point to 000. Press the Exit button on the trackball when finished.
7. Locate the Pneutronics Pressure Controller C

Controller ards (MPM part # P1666). These cards
Cards
are mounted on the Electro/Pneumatics tray (the top shelf on the rear of the machine).

Pneutronics
Note: On earlier model machines the Controller Cards are stacked, the right card is on
top. On later model machines the cards are mounted side-by-side. Check the wire tags
(or “Brady” markers) on the wires to identify left and right controllers.
8. Use the voltmeter to measure the voltage across terminals #33 and #4
4 of the left
Pneutronics card. The correct voltage reading is 1VDC.
If adjustment is needed, use trim potentiometer P1 (the top left pot) on the Analog Buffer
Card. (This card is mounted vertically behind the computer on the upper control drawer.)

Pneutronics
P1 - Left side 1VDC Adjustment P2 - Left side 5VDC Adjustment
P3 - Right side 1VDC Adjustment

P4 - Right side 5VDC Adjustment
9. Check for 1VDC across terminals #33 and #4

4 of the right Pneutronics card.
- If adjustment is needed, use trim potentiometer P3 (bottom left pot) on the Analog
Buffer Card.
10. Set both left and right Set Points to 255

255.
11. Check for 5VDC across terminals #3 and #4 of the left Pneutronics card.
- If adjustment is needed, use trim potentiometer P2 (top row, second from left) on the
Analog Buffer Card.
12. Check for 5VDC across terminals #3 and #4 of the right Pneutronics card.
- If adjustment is needed, use trim potentiometer P4 (bottom row, second from left) on
the Analog Buffer Card.
13. Set both left and right Set Points to 000
000.
14. Remove the hose from the left upper cylinder fitting
fitting. Connect a digital pressure gauge in
line with the cylinder.
Pneutronics
Right
Upper Air
Left Upper
Fitting
Air Fitting
Left Pneutronics
Card
Air Pressure
Gauge
Position the pressure gauge so it can be read from the rear of the machine while making
adjustments to the Analog Buffer Card and Pressure Controllers.
15. Adjust the potentiometer labeled Zero (R38) on the left pressure controller to achieve a
reading of 0.5 PSI on the pressure gauge.
16. Set the left and right Set Points to 255

255.
Adjust the potentiometer labeled Span (R36) on the left pressure controller to achieve a
Zero
Span
17.)Repeat the process, toggling back and forth between Set Points 000 and 255 while
adjusting the appropriate Zero and Span potentiometers until the desired values are
consistent and stable.
Pneutronics
18. Remove the pressure gauge from the left cylinder, and connect the original hose.
19. Remove the hose from the right upper cylinder fitting
fitting. Connect a digital pressure gauge
in line with the cylinder.
- Position the pressure gauge so it can be read from the rear of the machine while
making adjustments to the Analog Buffer Card and Pressure Controllers.
20. Adjust the potentiometer labeled Zero (R38) on the right pressure controller to achieve a

255.
- Adjust the potentiometer labeled Span (R36) on the right pressure controller to
achieve a reading of 51.0 PSI on the pressure gauge.
22. Repeat the process, toggling back and forth between Set Points 000 and 255 while
adjusting the appropriate Zero and Span potentiometers until the desired values are
consistent and stable.
23. Set the left and right Set Points to 005 (roll the trackball upwards from the 000 setting).
Press the exit button when finished.
- Make adjustments on the Analog Buffer Card (PC103) to make the left and right
Feedback set points equal to 005
005. (Tolerance is ± 001 bit.)
· Adjust P5 on the card (top row, third from left) for the left Pneutronics card
· Adjust P7 on the card (bottom row, third from left) for the right Pneutronics card
24. Set the left and right Set Points to 250 (roll the trackball downwards from the 255 setting).
Press the exit button when finished.
- Make adjustments on the Buffer Card (PC103) to make the left and right Feedback set
point equal to 250
250. (Tolerance is ± 001 bit.)
· Adjust P6 (top row, 4th from left) for the left Pneutronics card
· Adjust P8 (bottom row, 4th from left) for the right Pneutronics card
000. Select the Done button at the bottom of the

screen to return to the Main Menu.

Pneutronics
P5 - Left side 005 Adjustment P6 - Left side 250 Adjustment
P7 - Right side 005 Adjustment P8 - Right side 250 Adjustment
26. Insert the pressure gauge in line with either the left or right lower cylinder.
27. Locate the Balance Pressure Regulator and Sequencer V alve on the rear of the Prohead.
Valve
(They are mounted together on a bracket; the Sequencer Valve is on the left and the
Regulator is on the right.)
Regulator
Sequencer
Air Pressure
Gauge
Lower Air
Fittings
28. Use a small flat-blade screwdriver to adjust the screw on top of the Sequencer Valve in a
clockwise direction until it is fully closed (so that no air escapes from the bottom).
29. Turn the adjustment screw on top of the Balance Pressure Regulator until the pressure
gauge reads 34.5 PSI
PSI.

Pneutronics
30. Turn the Sequencer Valve adjustment screw until the pressure gauge reads 34.0 PSI
PSI.
31. Manually grasp the left and right sides of the Prohead float mechanism with both hands.
Pull it down while watching for change on the pressure gauge reading (the “change” to
watch for means a variation from 34.0 PSI).
Release the float mechanism; it should return to the upper stops by itself. If the change is
PSI, adjust the Sequence Valve until the change is within 0.3 PSI.
greater than 0.3 PSI
Pull the float mechanism down again a few times while adjusting the Sequence Valve as
needed. When satisfied that the change is within 0.3 PSI, adjust the Balance Pressure
Regulator until the pressure gauge reads 34.0 PSI
PSI.
Note: Adjusting the Regulator setting affects the Sequence Valve setting. Conversely,
Note
changing the Sequence Valve setting affects the Regulator setting.
Repeat adjustments to the Sequence Valve to achieve a change of .3 PSI or less, and
adjustments to the Regulator to maintain the 34.0 PSI reading. Pull the Prohead down
between each step to monitor the changes.
When satisfied that the change is 0.3 PSI or less and the Pressure setting is 34.0 PSI,
remove the pressure gauge from the cylinder and replace the airline.
Note
Note: the sound of air escaping from the Sequencer Valve is normal.
32. Remove the Calibrate diskette and reboot the computer.

Pneutronics
Addendum A: Programmable Squeegee C ontrol Engineering Drawing

Control
ANALOG I/O CONTROLLER (P1416)
GATE
GATE
OUT
OUT
CLK
CLK
DIF F1
*
CTR2 CTR1 1a mp
CLK/ 16
CLK/ 4
CLK/ 8
CLK/ 2 SE
J2
GATE
CLK
OUT
ADDRESS SELECT
(340h)
OSC
CLK
CTR0 6 5 4 3 2 1
SW1
NO INTERRUPT USED. ON
ANALOG BUFFER CARD (PC-103)

J3 * J1 * FU1 J2 *
OFFSET GAIN OFFSET GAIN OFFSET GAIN

#1 #3 #5
P10
VR1
P2
P5
P6
P9
P1
C13
LED1LED2
1IC 2IC 3IC
T1 BR1
115VAC
P12
P11
P3
P4
P7
P8
#2 #4 #6
C14 OFFSET GAIN OFFSET GAIN OFFSET GAIN
TB2 VR2
1
2
TB1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
C14
6 5 4 3 2 1
1mfd P1666
50V cer
CMD (RED)
LEFT
COM (BLK)
FDBK (WHT)
PRESSURE
CONTROLLER
(W10 removed)
+24VDC
COMMON
C16
6 5 4 3 2 1
1mfd P1666
50V cer
CMD (RED)
RIGHT
COM (BLK)
FDBK (WHT)
PRESSURE - +
CONTROLLER 6P S
(W10 removed) 24VDC

Pneutronics
Training

Appendix
Appendix
List of critical machine backup files
Newer Style Vision Probe Calibration
Calibration
AP -20/24 Vision C alibration
Calibration
AP -20/24 Laser Calibration
Calibration
MPM Series Printers

Appendix
Training
MPM Series Printers

Appendix
AP.CAL File
Below is a copy of the settings stored in the machine calibration file. It is always a good
idea to have a hardcopy backup along with the software backup of this file.
Version 8.0a, C:\apnt\ap.cal
[GENERAL]
MPP BOARD = 0.000655
MPP STENCIL = 0.000655
PROBE ANGLE = 0.000699
BASE ANGLE = 0.005357
X CENTER = -0.038172
Y CENTER = -11.276294
TOOLING = 1.02520
VISION = 2.54724
X CAL = 0.00463
Y CAL = 0.00423
T CAL = 0.00022
HEIGHT SW = 0.250000
PSQ_INIT_HT = -2.100000
OFFSET_3D_X = 0
OFFSET_3D_Y = 0
VY_TO_FTRACK = 19.118000
LASER_MPP_V = 0.000697
LASER_MPP_H = 0.000663
CAM_GAIN = 137
CAM_OFFSET = 7
X_PARK_POS = -1.708000
Y_PARK_POS = -0.386000
SNUGGER_HGTH = 1.00000
X_BSS_OFF_RT = 1.27000
X_BSS_OFF_LT = 1.02200
Y_BSS_OFFSET = -1.15400
FORCE_STEPS_SLOPE =49.080000
STEPS_INTERCEPT =225.800000
L_HEAD_WEIGHT = 0.000000
R_HEAD_WEIGHT = 0.000000
Z_TOWER_HT_ADJ = 0.625000
DEFAULT_ZERO = 120
DEFAULT_LOW_THRESH_ZERO = 136
MPM Excel Series Printers B-1

Appendix
AP.LIM File
Below is a copy of the settings stored in the machine Limit to Limit file. It is always a
good idea to have a hardcopy backup along with the software backup of this file.
Version 8.0a, C:\apnt\ap.lim
[GENERAL]
X_AXIS = 1.253947240 ;
Y_AXIS = 8.259861494 ;
Z_AXIS = 5.952753072 ;
THETA_AXIS = 7.599777018 ;
VX_AXIS = 18.222050000 ;
VY_AXIS = 27.378000000 ;
Strings.RSC File
The strings.rsc file is used to hold the current native MPM software language file. It is
always a good idea to have a software backup of this file.
Version 8.0a, C:\apnt\strings.rsc
B-2 MPM Excel Series Printers

Appendix
UP.OPT File
Below is a copy of the settings stored in the machine configuration file. It is always a good
idea to have a hardcopy backup along with the software backup of this file.
Version 8.0a, C:\apnt\up.opt
[OPTIONS]
MACHINE TYPE = 16;<MACHINE_TYPE>
VERSION = 8000
SERIAL # = 10339
HANDSHAKE = 1;<HANDSHAKE>
SEREMAP = 0;<BOOL>
SPECIAL = 0;<KEYBOARD>
CODE PAGE = 0;<iCODEPAGE>
IO = 1;<BOOL>
MOTION = 1;<BOOL>
WIPER = 4;<WIPER>
SOLV BAR = 1;<BOOL>
VACUUM = 1;<BOOL>
VISION = 2;<VISION>
DISPENSER = 2;<DISPENSER>
TRACK MTR = 1;<BOOL>
PROG HEAD = 1;<SQUEEGEE>
AUTO HGT = 3;<TACTILE>
SNUGGERS = 2;<SNUGGERS>
TOOL PINS = 0;<BOOL>
ECU PRESENT = 1;<BOOL>
BOARD STOP = 1;<BSTOP>
HARD STOP = 1;<BOOL>
STAGING = 1;<BOOL>
POST 2D = 1;<BOOL>
POST 2D CODE = 8761
POST 2D RECD DATA = 0;<BOOL>
POST 3D = 0;<BOOL>
POST 3D CODE = 0
POST 3D RECD DATA = 0;<BOOL>
CALIBRATE = 0;<BOOL>
KEYLOCK = 1;<KEYLOCK>
TBPW ENABLED = 0;<BOOL>
SCRN SAVER = 1;<BOOL>
METRIC = 0;<BOOL>
GEMCOMM = 0;<BOOL>
GEMCOMM CODE = 0

Appendix
FIXED TRACK = 0;<FIXED_TRACK>

AUTO IN = 0;<TRACK_DIRECTION>
AUTO OUT = 1;<TRACK_DIRECTION>
MANUAL IN = 0;<TRACK_DIRECTION>
MANUAL OUT = 0;<TRACK_DIRECTION>
AP 2x COMP UPGRADE = 0;<BOOL>
BACKUP PATH = A:;<KEYBOARD>
TO FROM PATH = A:;<KEYBOARD>
CAMERA PARK = 3;<CAMERA_PARK>
COVER INTERLOCKS = 2;<INTERLOCKS>
UNLATCH ON TEACH = 0;<BOOL>
CAMERA POS PAPER CHG = 0;<CAMERA_POS_PAPER_CHANGE>
[MACHINE_TYPE]
"UP-2000 HiE" = 17
"AP25A or AP27A HiE" = 16
[HANDSHAKE]
"SMEMA" = 0
"Extended SMEMA" = 1
"Extended SMEMA-2" = 2
"SIEMENS" = 3
[BOOL]
"FALSE" = 0
"TRUE" = 1
[iCODEPAGE]
"English/French/German/Spanish" = 0
"Japanese" = 1
[WIPER]
"No Wiper" = 0
"Standard Wiper" = 1
"Enhanced Vacuum Wiper" = 4
[VISION]
"No Vision System" = 0
"Vision with Single Offsets" = 1
"Vision with Dual Offsets" = 2
"Single Offsets and Z Lockout" = 5
"Dual Offsets and Z Lockout" = 6
"No vision and Z Lockout" = 9

Appendix
[DISPENSER]
"None" = 0
"Single Dispenser" = 1
"Dual Dispenser" = 2
[SQUEEGEE]
"AP-25 Programmable Squeegee" = 1
"UP-2000 Squeegee" = 4
"UP-2000 Programmable Squeegee" = 5
"Closed Loop Pump" = 9
[TACTILE]
"Not Present" = 0
"Above Mounted" = 3
[SNUGGERS]
"Not Present" = 0
"Side Snuggers" = 2
"Y with Flippers" = 3
[KEYLOCK]
"Standard" = 0
"Extended" = 1
[FIXED_TRACK]
"Front Fixed" = 0
"Rear Fixed" = 1
[TRACK_DIRECTION]
"Left" = 0
"Right" = 1
[BSTOP]
"Track Mounted" = 0
"Camera Mounted" = 1
"Camera Mounted/Park" = 2
[CAMERA_PARK]
"Rear Mounted" = 0
"Moveable Track Mounted" = 1
"Rear Mounted/Home when idle" = 2
"Moveable Track Mounted/Home when idle" = 3

Appendix
[INTERLOCKS]
"Standard Cover Interlocks" = 0
"Enhanced Cover Interlocks" = 1
"AP Excel Cover Interlocks" = 2
[CAMERA_POS_PAPER_CHANGE]
"RIGHT (Default)" = 0
"LEFT = 1
[KEYBOARD]

MPM Calibration Crash Course

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COOKSON ELECTRONICS EQUIPMENT

COOKSON ELECTRONICS EQUIPMENT

COOKSON ELECTRONICS EQUIPMENT

COOKSON ELECTRONICS EQUIPMENT

COOKSON ELECTRONICS EQUIPMENT

COOKSON ELECTRONICS EQUIPMENT

MPM | AP Series Printers

COOKSON ELECTRONICS EQUIPMENT

COOKSON ELECTRONICS EQUIPMENT

COOKSON ELECTRONICS EQUIPMENT

COOKSON ELECTRONICS EQUIPMENT

580-A Tollgate Road

Elgin, Illinois 60123

All Rights Reserved

Tab 1. Factory User Levels

Tab 3. Advanced Operations

Tab 4. General Calibrations

Tab 5. Motion System

Tab 6. Vision System

Tab 7. ProHead System

Objectives: Given an AP Series MPM Printer, Documentation, Boards, Stencil, Instructor

Enable factory user levels

The student will perform these functions to MPM standards.

Prerequisites: 30 days operational experience with the equipment ; Have attended an AP

Length: 3 Days Start: Monday 9 am End: Wednesday 5 pm

STUDENT SKILLS PERFORMANCE CHECK LIST

SKILL Student Initials Instructor Initials

Student Signature Instructor Signature

Cookson Electronics Equipment xi

xii Cookson Electronics Equipment

2 -Crowne Plaza by Holiday Inn

- Bennigan’s at the Crowne Plaza

-Towne Place Suites by Marriott

6 - La Zaza Cucina Restaurant

-Famous Dave’s Bar-B-Que

Cookson Electronics Equipment xiii

12 - Emmett’s Micro Brewery & Restaurant

13 - El Faro Mexican Restaurant

15 - Prairie Rock Micro Brewery & Restaurant

- Grand Victoria Riverboat C asino

16 - Port Edward’s Seafood Restaurant

17 - Country Inn & Suites

18 -C adillac Ranch (music, dancing)

xiv Cookson Electronics Equipment

Tab 1. Factory User Levels

Enable the factory user levels

MPM Series Printers

MPM Series Printers

Accessing the Factory User Modes (DOS)

MPM Series Printers 1-3

9. The machine should display “C:\AP>” .

1-4 MPM Series Printers

Accessing the Factory User Modes (NT)

Enabling/Disabling this Feature

MPM Series Printers 1-5

• After making the change:

1-6 MPM Series Printers

The C alibrate and T

• Never enter these menus unless you are qualified!

MPM Series Printers 1-7

Cookson Electronics Equipment

1-8 MPM Series Printers

Navigate the operation screens and user levels