Operating Manual

Bacher FAPS 600

Automatic Exposure Unit 8780

FAPS 600
Contents
1.
1. Technical Data and Safety Systems
1.1
1.2
1.3
1.4

Technical safety information

Technical data
Safety systems and function monitoring
Warning sign descriptions

4
5
6
8

2.

Introduction
2.1
Component description
2.2
Operating controls / control components

9
10
11

3.

Installation
3.1
Transportation and positioning
3.2
Transportation safety device
3.3
Lifting points for the hoisting equipment
Installation connection details and dimensions
3.4

12
12
12
13
14

4.

Material Requirements

18

4.1
4.2
4.3
4.4
4.5
4.6

18
18
18
19
20
21

5.

6.

Film material
Exposure material
Masking material
Mask definitions
Registration example
Registration mark specifications (for boards and film)

Operating Sequence

22

5.1

Basic principles
5.1.1 FAPS 600 co-ordination system

22
22

5.2

General
5.2.1 Switching on the Machine
5.2.2 Setting the spindle frames

23
23
23

5.3
5.4
5.5
5.6
5.7
5.8

Setting-up mode
Alignment mode
Automatic mode
Stop mode
Switching off the machine
Operational flow chart

24
24
24
24
24
25

Operating panel functions and inputing exposing parameters

28

6.1
6.2
6.3

28
29
30

Operating panel
Key board cursors functions for inputing the exposure parameters
Individual Operating Panel LCD Segment Functions

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FAPS 600
7.

8.

9.

10.

11.

The Video System and its Parameters

31

7.1
7.2
7.3
7.4
7.5
7.6
7.7

31
31
31
31
32
33
36

Basic sequence
Calling-up the video parameters
The operating panels video keypad
Exiting the video menus
Video parameter menu and sub-menus
Video Parameters
Entering the video system parameter menu during a job exposure

Video System Status Reports

36

8.1
8.2

36
36

Video system self-test status reports

Alignment report

Error Reports

37

9.1
9.2

37
38

Video system error reports

SPS error reports

Interfacing to the preceding and the succeeding inline machines

40

10.1
10.2
10.3

40
40
40

General
Interfacing to the previous inline machine
Interfacing to the succeeding inline machine

Service

41

11.1.
11.2.

Cleaning the glass plate

Lamp changes
11.2.1 POC lamp change
11.2.2 HI lamp change
11.3. Changing the exposure frame
11.4. Lubrication
11.5. Vacuum pump VCE 40 (contact vacuum)
11.6. Vacuum pump TLV 15 (film and contact vacuums)
11.7. Side channel compressor (SKP 35826.01 transport and SKP 30220-03
mask vacuums)
11.8. Air filter
11.9. Compressed-air filter
11.10. Toothed belt

41
41
41
41
42
42
42
43
43

12.

Spare parts lists

45

13.

Electrical circuit diagrams

...

14.

Pneumatic diagrams

...

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44
44

FAPS 600
1. Technical Data and Safety Systems
1.1. Technical safety information
Important:

Long term UV-radiation can result in permanent damage to health. The relevant
accident prevention regulations as well as any other acknowledged technical safety and
working medical practices must be implemented. Only personnel who have been
properly trained and informed about all the safety regulations are allowed to operate and
maintain the exposure system.

Important:

Observe the following when servicing and cleaning the system:

Important:

Exposure system must be switched off.

Exposure system has been switched off at the main switch and unauthorised
switching-on has been prevented.

When working on the compressed-air system, the supply valve must be closed
and the system made pressure free.

If settIf IIf setting-up, sevicing and error clearing work has to be carried out with the
exposure system switched on, then the following instructions must be
carried out:
-

The exposure system must only be operated in manual mode.

The work must be undertaken only by qualified personnel.

Only one person is permitted to work on the exposure system.

The side panels may only be removed after the MH lamp has been switched
off. When it is neccessary to work on the MH lamp with the panels removed,
the person undertaking the work must protect his eyes and skin from direct and
indirect UV-radiation. (Filter protection screens, safety glasses and protective
clothing).

Only qualified electricians are permitted to change the MH lamp and undertake work on the electrical
system.
The main switch must be switched off before opening the control cabinet.
The lamp must be allowed to cool down before being changed.
Only recommended specialised companies are permitted to connect up the exposure system.
Operating the exposure system without the safety panels is forbidden.

The accoustic level, measured i.a.w. DIN 45635, part 27, does not exceed 71 dB (A).
Ozone level will never build up into a hazardous quantity. However, we recommend that you ensure there
is adequate room ventilation.

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FAPS 600
1.2. Technical data
Formats
min. board thickness:
max. board thickness:
min. board format:
max. board format:
Standard layout film formats:
Standard exposure formats:

0.1 mm (0.004")
6 mm (0.25")
250 x 350 mm (10" x 14")
610 x 610 mm (24" x 24")
660 x 660 (26 x 26), 660 x 610 (26 x 24),
660 x 508 (26x 20)
610 x 610 (24x24), 640 x 580 (25,2 x 22,8),
622 x 477 (24,5 x 18,72)

Equipment data
Cooling (indirect water cooling):
Water inflow HI:
Water inflow POC:
Cooling power HI:
Cooling power POC:

with 8 - 12C, 1"; 3.4 m/h

with 8 - 12C, 3/4"; 1.6 m/h
16KW
6.6KW

Allignment tollerance:

+/- 10 m (0.0004")

Vacuum technology:

according to client specifications

Setting-up time:

<3 min

Dimensions (L x W x H)

2763 x 2182 x 1402 mm (HI)

2763 x 2074 x 1402 mm (POC)

Weight:

2000 Kg

Electrical connection HI:

Options:

400V, 50Hz, 24 KW, 3 phases, 63A

220V, 60Hz, 24 KW, 3 phases, 80A

Electrical connection POC:

Options:

400V, 50Hz, 20 KW, 3 phases, 50A

220V, 60Hz, 20 KW, 3 phases, 63A

Compressed-air supply:

6 bar, ca. 6 m3/h

Max. surface pressure:

Average ground load:

18 N/cm
5000 N/m

HI light source:

8 KW (6 KW option) air-cooled metal halogen lamp

POC light source:

3.5 KW (5 KW option) air-cooled metal halogen lamp

Illumination:
HI intensity:
POC intensity:

+/- 10%
(60 - 80) mW/cm (measuring device IL 390)
(15 - 20) mW/cm (measuring device IL 390)

Obtainable resolution (HI/POC):

Depends on the materials and

preceeding and following processes
max. 2C

Layout film heating (HI/POC):

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FAPS 600
1.3. Safety systems and function monitoring
a) Safety systems
Main Switch (1)
The main switch (1) switches off all phases to all activated devices (excepting the power supply and power
filter). N will be mechanically switched off first. The main switch is located in the middle of the panel on the
operators side of the machine. Access to the lamp unit is possible only after the main switch has been
switched off. This ensures that the operator will not be exposed to direct UV radiation.
Emergency-Off unit (2)
The Emergency-Off unit is designed according to VDE 0113 and IEC 204-1 and switches all phases
(including N.) to the active devices off, excluding the Emergency-Off switching unit itself. All movement will
be immediately stopped. The Emergency-Off switch is located on the control panel on the operators
side (2). The Emergency-Off unit is reset by pulling the switch upwards. The Emergency-Off switch is a
red push-button against a yellow background.
Safety switches/ interlocks (3, 4)
Both plexi-glass and metal covers protect the operator from the machines moving parts. They are fitted
with safety interlocks (S34 and S35) and retainers (K20 and K21) and position monitoring. It is only
possible to open the covers during setting-up and fault elimination.
If one of the covers is open, the connection to the gearing motor FU drive is broken, the motor brake is
activated and the transport rollers are switched off. This ensures that there is no movement of potentially
dangerous parts when the covers are open. "COVER OPEN" is shown on the display.
b) Function monitoring system
Transport shuttle safety monitoring (5)
Transport shuttle movement is only possible when the transport frames are closed. If the frames are open,
all movement is prevented by both soft and hardware.
Compressed-air monitoring (6)
The machine can only be operated when air with a pressure of >6 bar
(operating pressure is 6 bar) is available.
Transport and removal shuttle safety valve(7)
In case of a sudden pressure loss, the safety valve prevents the transport shuttle from dropping.
Water inflow and outflow safety valve (8)
Machine off = valve closed, machine on = valve open
Machine too hot = valve open, machine too cold = valve closed
Additional mechanical valves are also available.
Overloading breakdowns (9-13)
If one of the transport motors is overloaded, an over-voltage protection switch is activated (9-13).
The equipment is then switched off. The over-voltage protection switch can be reset to its normal position
after a cooling phase of about 1 min. The locations of the over-voltage protection switches are shown in
the following drawing.
Warning lamps (14)
RED indicates a breakdown, see display error report
YELLOW indicates a bad board, registration marks unknown or not within tolerance
GREEN indicates equipment is ready for operation

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FAPS 600
Figure 1:

Safety and function monitoring systems

14

13

10-12
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Main switch
Emergency-Off unit
Plexiglass cover safety switch
Metal cover safety switch
Transport shuttle safety monitor
Compressed-air monitor
Transport and removal shuttle safety valves
Water inflow and outflow safety valve
Warming-up over-voltage protection switch (or integrated in the CLEANER)
X-Axis pre-centering over-voltage protection switch
Y-Axis pre-centering over-voltage protection switch
Roller transport over-voltage protection switch
End of run over-voltage protection switch
Warning light

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FAPS 600
1.4. Warning sign descriptions
a)

Beware! High Voltage! Even with the main switch off, the supply lines are still live.

-Mains filter cover

-Mains filter
b)

Beware! High Voltage!

-all vacuum pump terminal boxes

-monitor cover shields
-right rear panel
-exposure area paneling
-main switch case
Only qualified electricians are permitted to remove the covers.
c)

Beware! Danger of burns!

-Lamp housing
Lamp change can only be carried out after it has cooled down.
d)

Switching off the main switch

-Lamp housing
The main switch must be switched off before changing the lamp
e)

Switch off the main switch before opening the housing

Switch the main switch off before opening the housing.

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FAPS 600
2. Introduction
The FAPS 600 exposure system is a fully automatic exposure system for the production of printed circuit
boards, based on single side exposure. Please refer to the Technical Data (chapter 1) for information
regarding the authorised materials.
It is made for the exposure of common photosensitive photo resists and solder masks.
The registration of the photographic layout to the exposing material is achieved by aligning suitable
registration marks by means of one of the X-Y--tables controlled by the image processing system.
Photographic layout and exposing material are registered in succession and are taken first to the
exposing level in the contacter by means of a suitable transport system.
The equipment can be divided into three parts regarding the throughput direction. The alignment station is
located on the left. The operator places the film here, the boards are fed in, in succession, and both film
and board are aligned in the correct exposure position.
Next comes the exposure station. Here a vacuum from a surrounding groove fixes the film to a glass plate.
The boards are placed on top of the film with the side to be exposed facing downwards, and pressed
firmly onto the film by means of the contact vacuum. The board is then exposed.
To the right of the operator is the output station, where the boards are outputted from the machine.
The film and board transportation is achieved by means of a vacuum transport system (Shuttle). This
consists of a frame, that is driven by a motorised belt and two vacuum plates. One of these vacuum plates
is responsible for transporting film and boards between the alignment and exposing stations and the other
transports the exposed boards to the output station.
Precise film and board registration is achieved by pilot pins, which are located in the alignment and
exposure stations, and the vacuum plate responsible for transportation is lowered onto these pins.
The machine is supplied with two different light technologies.
POC light technology (Practice-Orientated Collimation) ensures minimal heating of the layout, a small
collimation angle, a very high resolution and is especially suitable for exposure of photo resists.
HI light technology (High Intensity) ensures short exposure times for the highest resolutions. If required, a
special IR reflector may also be supplied with this light technology, made from specially coated glass that
prevents most of the lights infra-red segment from reaching the exposure area.
In case of further questions or urgent repairs please contact:
B. Bacher, Graphische Gerte GmbH
Eisenbahnstrae 84
Postfach 7
D-78573 Wurmlingen
Tel: +49-7461-177-0
Fax: +49-7461-177-110
Internet: http://www.b-bacher.com
Important: The exposure system must only be used as described above.
Any other use is strictly prohibited.
The manufacturer is not responsible for any damage resulting from wrong use. It is entirely at
the customers own risk.

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FAPS 600
Diagram 2.1

Component description

Input and pre-alignment

CCD-camera for PCB
registration

Monitoring display
Vacuum tranport system

Board output

Precision
centering
CCD-camera
for PCB registration

POC

Control prealignment station

Video slide-in unit

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Exposure unit

Vacuum
technology
Electro-cabinets

HI

10

FAPS 600
Diagram 2.2

Operating controls / control components

8
16

1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

17

18

4 5

10 11 12 13 14

7 15

Camera positioning
Camera system
Operating panel
On/Off switch
Emergency-Off
Temperature display
Monitor
Warning light
Main switch
Lamp power display
Operating-hours counter
Film-vacuum display
Removal-vacuum display
Contakt-vacuum display
Spindle frame selection switch

Rear side
16
Compressed-air display
17
Water inflow and outflow valve
18
Water inflow and outflow,
pressure and temperature displays
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FAPS 600
3. Installation
Pre-conditions:

The exposure system must be placed in a room protected against UV radiation.

UV radiation would pre-expose the PC boards making them unusable for further
processing.
Ensure that this room has sufficient floor space for the machine and surrounding
free space for operating and servicing.
The installation site must have a solid foundation,
(permitted surface pressure 18N/cm; average ground load 5000N/m)
to ensure a perfect alignment.

The machine consists of two components, the actual exposure unit and the the vacuum tower, which
contains up to 4 side channel compressors for the transport vacuum as well as the pump for the contacter
vacuum. Tower and machine are connected together with flexible vacuum tubes. Maximum length 10 m.
3.1 Transportation and positioning
First the machine is transported to the selected site.
Attention: Observe the lifting points for the hoisting equipment in the drawing overleaf.

Ensure that there is sufficient space (minimum of 50 cm) between the rear of the machine and the wall to
allow for service work. If the vacuum tower is to be placed behind the machine (behind the plexi-glass
cover), it must be positioned at least 20 cm from the machine.
3.2 Transportation safety device
Now remove the red transportation safety device fitted to the left of the shuttle, in order to do this open the
cover.

Attention: Prior to opening the machine, ensure that the compressed-air pressure meets
the specifications.
When the machine is in position at the site, it must be aligned by using a spirit-level. Firstly the load on the
4 feet that are not at the corners of the machine must be removed. By using the remaining corner feet the
machine can be adjusted so that the transport gliding bars upon which the transport shuttle slides, are horizontal. Both gliding bars must be set to the same height. Check this with a suitable spirit-level. When this
has been achieved, the four inner feet can be readjusted to take the load.
As soon as the machine is horizontal, the cooling water connections (the inflow and outflow each have 1"
connectors) as well as the mains power connection can be made.
Attention: Only a qualified electrician is permitted to make the mains power connection.
The electricity phase sequence can be checked against the side channel compressor phase sequence
and be corrected if neccessary.

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FAPS 600
3.3 Lifting points for the hoisting equipment

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11/99 BA-FAPS600-e

Cleaning drawer

Maximum distance between FAPS 600 / vacuum tower when

using flexible tubes = 10m,
if distance is more than 10m, fixed tubing is required.
Recommende diameter = 100 mm.

Throughput direction

A1/A2

A3
Vacuum tower
Machine operating area

A1 = 400V, 50 Hz, 16 KW, 3 phases, 35A

Options:
A2 = 220V, 60 Hz, 6 KW, 3 phases, 50A
A3 = 220V, 60 Hz, 14 KW, 3 phases, 80A for vacuum tower
B = Compressed-air 6 bar, connection R1/4"
C = Water inflow R1", Temp.= 8C
D = Water outflow R1", Temp.= 12C
E = Vacuum tube external diameter 33 mm, internal 25 mm
F = Vacuum tube external diameter 60 mm, internal 50 mm

Hepa-Box
Clean room class 1000
or 100

FAPS 600
3.4 Installation connection details and dimensions

FAPS POC - Tower - HEPA projection from above

14

Air output
1000 m3 /h
60-80C

11/99 BA-FAPS600-e

Vacuum tower

A3

A1 = 400V, 50 Hz, 16 KW, 3 phases, 35A

Options:
A2 = 220V, 60 Hz, 6 KW, 3 phases, 50A
A3 = 220V, 60 Hz, 14 KW, 3 phases, 80A for vacuum tower
C = Water inflow R1", Temp.= 8C
D = Water outflow R1", Temp.= 12C

A1/A2

Hepa-Box
Clean room class 1000
or 100

FAPS 600
3.4 Installation connection details and dimensions

FAPS POC - Tower - HEPA side projection

15

11/99 BA-FAPS600-e

Cleaning drawer

Maximum distance between FAPS 600 / vacuum tower when

using flexible tubes = 10m,
if distance is more than 10m, fixed tubing is required.
Recommende diameter = 100 mm.

Throughput direction

A1/A2

A3
Vauumturm

Machine operating area

A1 = 400V, 50 Hz, 19 KW, 3 phases, 50A

Options:
A2 = 220V, 60 Hz, 9 KW, 3 phases, 50A
A3 = 220V, 60 Hz, 14 KW, 3 phases, 80A for vacuum tower
B = Compressed-air 6 bar, connection R1/4"
C = Water inflow R1", Temp.= 8C
D = Water outflow R1", Temp.= 12C
E = Vacuum tube external diameter 33 mm, internal 25 mm
F = Vacuum tube external diameter 60 mm, internal 50 mm

Hepa-Box
Clean room class 1000
or 100

FAPS 600
3.4 Installation connection details and dimensions

FAPS HI - Tower - HEPA projection from above

16

Air output
1000 m3 /h
60-80C

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Vacuum
tower

A3

A1 = 400V, 50 Hz, 19 KW, 3 phases, 50A

Options:
A2 = 220V, 60 Hz, 9 KW, 3 phases, 50A
A3 = 220V, 60 Hz, 14 KW, 3 phases, 50A for vacuum tower
C = Water inflow R1", Temp.= 8C
D = Water outflow R1", Temp.= 12C

A1/A2

Hepa-Box
Clean room class 1000
or 100

FAPS 600
3.4 Installation connection details and dimensions

FAPS HI - Tower - HEPA side projection

17

FAPS 600
4. Material Requirements
4.1. Film material
All well known black and diazo films may be used in the FAPS 600 exposure system.
The exposure layout can be up to a maximum of 660 x 660 mm. This is neccessary, to ensure that the
vacuum from the surrounding vacuum tracks fixes the layout film firmly onto the exposing area. If no film
of this format is available, then clear mounting foil of the correct size may also be used.
When using clear mounting foil, ensure that the original film is mounted so that it conforms to the
registration mark specifications.

4.2. Exposure material

Standard format rigid boards from 250 x 350 mm up to 610 x 610 mm can be exposed with this equipment.
Permitted board thickness lies between 0.1 and 6 mm. The register marks must correspond with the film
register marks and also the registration specifications.

4.3. Masking material

The FAPS 600 exposure systems strong vacuum holds the boards very firmly down onto the layout film
on the glass plate when exposing. In order to prevent any light undercutting due to warping of the glass
plate, or even the glass breaking, the resulting pressure must be as evenly distributed as possible across
the glass plate.
In order to achieve this, the space around the exposure material is covered with masking material.
This masking material must conform precisely to the exposure materials shape.(see 4.4)
After aligning the first (master) board for exposure, the masks are laid on the alignment table and remain
fixed to the film transport system until the next film change.
The masks must correspond to the parameters, outlined on the following page.
Important: Please observe the co-ordination system definitions.

Mask

Resist

Basic material
Shuttle

Glass

Film
Mask thickness calculation:
PCB single side lamination
PCB basic material thickness
+ Resist thickness
+ Resist protection foil thickness
+ Film thickness & possible carrier
+ Addition = 0.20 mm
= Mask thickness
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Exposing
frame

Resist
PCB double side lamination
PCB basic material thickness
+ 2 x Resist thickness
+ 2 x Resist protection foil thickness
+ Film thickness & possible carrier
+ Addition = 0.20 mm
= Mask thickness
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FAPS 600
4.4

Mask definitions

Important: Please observe the co-ordination system definitions.

Format L=200-440 x W=300-440

Throughput direction

Format L=440-510 x W=510-560

Throughput direction

Format L=200-440 x W=440-510

Throughput direction

Format L=510-560 x W=510-560

Throughput direction

Format L=440-510 x W=440-510

Throughput direction

Format L=510-560 x W=560-610

Throughput direction

No mask

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FAPS 600
4.5 Registration mark examples

Electroplated edge

Throughput direction

20 mm free area
(no drilled holes)

Register mark :
good

Register mark : with

identification hole

Register mark :
reduced option

Register mark :
poor

Lamination edge

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Dirt

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FAPS 600
4.6 Registration mark specifications (for exposure material and Film)
Depending on the application, the following components can be used for register mark definition:

1.

Hole recognition
Around the actual hole in the PCB.
Application: Internal layers, external layers and soldering masks.

2.

Pad recognition
Basic round, oval and rectangular copper track structures.
Application: Soldering masks.

3.

Structure recognition
A section of the PCB layout is aligned to the
to the exposure film
Application: Soldering masks

4.

Resit colour contrast recognition

The alignment is made from the
colour contrast in the "A" side exposure film.
Application: Post-etching inner layers

General guidelines and parameters:

1.

The registration marks are located at the middle of the boards length, if not then they should be
matched in the X plane to be the same distance from the outer edge of the blank board.

2.

In order to achieve the highest possible registration accuracy, the register mark diameter should
lay between 2 and 4 mms.

3.

The registration marks surrounding areas should be free of any other drilled holes or similar
register marks within a radius of 10mm. If this is impossible to achieve, then further tests must be
carried out.
a) ensure that there are the minimum obstructions within the image area, and
b) if possible, any obstruction should be smaller than the register mark

4.

The film registration marks may be either black or transparent.

5.

It is advantageous to locate the registration marks inside the galvanised border. It is not
recommended to have any copper around the registration holes as this will reduce the
contrast.

6.

By using reduction, it is possible to work with register marks that have been laminated.
- The register marks should be as large (i.e. 4mm) as possible.
- The processing depends on the type of resist being used (tenting, contrast etc.).
- The space between the hole and the edge of the lamination should be as large as possible.
- The register holes must never be part-laminated.
- The board should be used as soon as possible after being laminated.
- In any case tests should be carried out.

7.

Boards that have soldering masks, must either be completely varnished or not at all.

8.

Ensure that there is always sufficient contrast between the register marks and the surrounding
areas.

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FAPS 600

5. Operating sequence
5.1. Basic principles
5.1.1. FAPS 600 co-ordination system
The FAPS 600 co-ordination system is as shown:

FAPS 600
Durchlaufrichtung
Bedienerseite

X
Correspondingly the film and exposure material co-ordinating system is also defined.

Register
marks

Board

Width

Length
Throughput direction

Attention: The board "length is always the X-axis dimension, i.e. in

throughput direction.
The board "width is always the Y-axis dimension, and lies parallel to the
input width.

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FAPS 600
5.2 General
When operating the machine has 3 different operational modes.
5.2.1 Switching on the machine
After switching on the main switch press the green " I switch. The display now shows "B. Bacher
Graph... or "Operating station ready. Pressing the POWER (7) key activates the system checks. The
mechanical and video self tests will now run. The lamp will be switched on. During the mechanical tests
each tested component is displayed in the operating panels LCD. If a malfunction occurs the defective
unit name is displayed.
-Compressed-air monitoring
-FU drive
-Cover/transport plate opened
-Pre-centering X-axis
-Pre-centering Y-axis
-Input belt below
-Transport plate movement
After the system checks (approx. 60 sec), the machine is now in the setting up mode.
Setting the spindle frames
The spindle frames are used for improving the contact pressure. Fitted to the front door is a selection
switch with 4 different setting positions. Each switch position has been assigned a spindle position, which is
interrogated via sensors [1-4].Position 1 indicates the cycle runs without using the spindles. Switch settings 2 4 differentiate between the 4 spindle settings at the highest level, whereas position 2 indicates
the least space between the film and the board and position 4 signifies the largest space. The selection of
the switch position depends on the thickness of the board and is set in accordance with the specific customer requirements. The selection of the switch position must be carried out before the alignment operation
and a safe procedure is to reset the switch back 1 at the end of every production run.
Attention: Glass can brake when spindle set-up too high.
Setting up mode
In setting-up mode a film is placed on the alignment table and then moved, under the control of the video
system, into a position which will be used to align all the susequent boards in this job batch. This position
is defined by the register marks described in section 3.4. The setting-up mode is terminated when the
FAPS 600 transport system removes the film from the alignment table and places it onto the exposure area
glass plate, where the film will be held securely in place by the vacuum from the surrounding vacuum
channel.
Automatic mode
In automatic mode the boards are passed, when demanded, individually to the alignment table, where they
are aligned and transported to the exposing area. There the board is laid on top of the film and held in
place by the contact vacuum. The board is then exposed. After being exposed, the board is transported
out of the exposure area. At the same time the next board to be exposed is moved into the exposure area.
If a board can not be aligned (due to missing or dirty register marks), it will also be transported into the
exposure area, however neither the vacuum or exposing systems will operate. When outputting such an
unexposed board the exposure unit sends a signal which will be interpreted by one of the succeeding
machines (turning/sorting machine).
Stop mode
The stop mode is used to terminate a job batch. When stop mode is selected, the mask, if present, is
transported to the alignment table, the last board in the machine will be outputted and the film will be laid
on the alignment table.
Now the machine is ready for the next setting-up.
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FAPS 600
Operating with 2 cameras above (standard model) for hole recognition.
5.3 Setting-up mode
In order to start a new job, the film must first be aligned. Open the plexi-glass cover. Lay the film on the
alignment table corresponding to the blue engraved markings. The film emulsion must be upwards.
Press START (15) button to switch the video system on and the accompanying camera images will be
seen on the monitor. The register marks must be brought into the middle of the video camera image. The
upper cameras can be moved alopg the Y axis (loosen clamps). A final correction can be made by
moving the film very slightly.
Close the plexi-glass cover and confirm the film alignment with the ENTER (5) button.
Thereupon the alignment process now begins, determining the position and size of the register marks etc.

5.4 Alignment mode

When the alignment process is completed, the video parameter menu is displayed on the monitor, in
which the operator can change the parameters as described in section 7.5. The selected parameters are
confirmed by pressing the "Ready" function ENTER (5) button.
Special feature: Pad/Structure recognition offers a suggestion for film alignment, which can be manually
altered by the cursors in the video system key-pad.
When the selected parameters have been confirmed with the ENTER (5) button, the film will be
transported into the machine and fixed in place by the vacuum system.
The system now switches into automatic mode and awaits the first board to be exposed.

5.5 Automatic mode

During automatic mode the boards are moved into the machine consecutively, aligned on the alignment
table, transported into the exposure area, exposed and transported out of the machine.
An exception to this is the first board. Firstly this board is aligned. When the alignment has finished, the
following report is shown on the display "Mask ? Start. Wether a mask is required or not, is decided by
the application. This report is the insert masking (see section 3.3.) demand. Open the plexi-glass cover
and place the mask on the corresponding marks engraved in red. Close the cover, and the system will
check the alignment. When this has finished, press the START (15) button and the first board together
with the mask will be transported into the exposure station. The mask remains in the transport system for
the duration of the job batch, and is only moved out when the stop mode is activated.

5.6 Stop mode

When a job batch has been competed, press the STOP (17) button first and afterwards the STOP (17)
and SHIFT (13) buttons simultaneously. The mask, last board and the film are then consecutively moved
out by the machine. After having pressed the START (15) button, open the plexi-glass cover and remove
the mask and film. Now the machine can either be prpared for the next job batch or switched off.

5.7 Switching off the machine

To switch off the machine first press the POWER (7) button. This button switches of the lamp. The 90 second cooling down period, which must be adhered to, is shown on the display. After this cooling down
period has expired, press the red " O switch and turn the main switch to the "O" position.

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FAPS 600
5.8. Operational flow chart Button description page 28

POWER ON

Setting-up mode

Orientation option:
Hole, structure, pad...?

First make certain, that the machine is fully unloaded.

Switch on the main switch, press button I (22), wait for Info B. Bacher
etc. (approx. 5 sec), and after the report "Operating station ready"
press POWER (7) button on the control panel.
The automatic system test runs (60 sec.), then "Setting-up mode" is
shown in the display.
Select exposure program: Set-up new program (see 6.3) or change
video parameters (see 7.1-7.3).
Then press START (15) button.If no exposure value has been entered,
the report "No exposure value!" will be displayed.

Has the orientation been selected? (see chapter 7)

START

START (15) button switches the video system into the active setting-up
mode.

Setting-up mode

Open cover, place film onto the table corresponding to the blue format
markings. The register marks should now be displayed on the monitor,
if not, loosen the locks and readjust the cameras. Afterwards relock
the cameras. It is possible to position (up / down) the cameras electromechanically.

ENTER

Acknowledge by using the video control panel left ENTER button (5)
(Ready report) and the alignment process will start.

Setting-up mode

The film is aligned automatically (it is possible to change the alignment

parameters, see 7.5).

ENTER

Move the cursor to the "Ready" position to acknowledge the selected

parameters, after pressing the left ENTER (5) button the transport
frame delivers the film to the exposing level.
When the film vacuum is correct, the machine switches to the
AUTOMATIC MODE

1
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FAPS 600
5.8. Operational flow chart

Automatic-mode

New board

Board enters system

Adjust tolerances?
(Video 7.)

1st. board
aligned?

No

Remove
board

1st. board not

aligned

Yes
Film output

Mask?

Yes
Position
mask

No

When a mask is required, lay this on the corresponding

red markings (display: "Automatic 1st. PCB mask? =
START") and after closing the cover the board will be
newly aligned. Afterwards acknowledge by pressing the
Start (15) button.
Attention! If the cover was opened, although no mask
was required, use ENTER (21) to de-select the mask
vacuum.

START

next board

Board
in order?

Yes

No

STOP

Correct video
parameters (7.5)

START

last board

Activate STOP-mode
(last board still in machine)
Stop-mode description see 6.2 point 7

2
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FAPS 600
5.8. Operational flow chart

STOP

Press STOP (17) button

Stop process
activated

Press SHIFT (13) and STOP (17) simultaneously

SHIFT + STOP

Mask and film are transported to the alignment table,

the last board is transported out of the system.
Report: " PCB being transported / exposed PCB"

Mask, film
output

START

Remove film, remove mask

Yes
Continue?

New job

No
POWER

11/99 BA-FAPS600-e

The MH lamp switches off after a 10 sec. delay.

Wait (90 sec.) for the cooling down period,
then switch button 0 (24), then switch the main switch off.

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FAPS 600
6. Operating panel functions and inputing exposing parameters

6.1.The O perating Panel

1 2

Video keypad
for inputing video parameters

8 9 10 11 12 13 14 15 16 17 18 19 20 21

22

23

24

Keypad for inputing exposure parameters

Key assignments:
"POWER (7)
The POWER button switches the machine controls on and off.
"UNASSIGNED BUTTON (8)
The left unassigned button is used simultaneously with the ENTER (9) button in order to save the
exposure program.
When used simultaneously with the other unassigned button (18) this button acknowledges that
reported errors have been manually cleared and the machine can continue its operation.
"INTENSITY (11)
Use this button to select whether semi or full exposure power should be used.
The "INTENSITY button also resets to the default values when used simultaneously with the
ENTER button (21).
"SHIFT (13)
The SHIFT button, when used in conjuction with another button, initiates a special function.
When used in conjuction with the STOP button (17) the stop mode is activated.
"START (15)
This button is used to start a specific function i.e. restarting the automatic mode after an
interruption (inputing new video parameters) or to start the setting-up mode.
"STOP (17)
This button is used to stop a specific function i.e. to interrupt the automatic mode to input new
video parameters.
"ENTER (21)
The "Enter button is used to acknowledge error reports, saving programs as well as reloading the
default settings (in conjuction with the INTENSITY button).

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Displays:

"PROGRAM
Shows the number of the selected exposure program (3 in total).
An exposure program is comprised of the vacuum time parameters and illumination cycle power
(energy required).

"VACUUM
The vacuum time is the time between starting the vacuum (contact vacuum) and start of
exposure.
The upper part of the LCD shows the time required, and the lower part shows the actual time
taken so far.

"COUNTER
The counter shows the number of boards that have entered the machine. The upper part of the
LCD shows the number of boards that have been inputed. The lower part shows the number of
boards that have been exposed.

"EXPOSURE
The light details are shown here, (the illumination cycle duration depends on the intensity and
time). The target value is shown in the upper part of the LCD and the actual value in the lower
part.

6.2. Key board cursors functions for inputing the exposure parameters
Additional cursors are to be found on the key board, these are marked with up and down arrows. There
are two keys for each of the functions "FUNCTION, "PROGRAM, "VACUUM, or "EXPOSURE.
The cursors are also used for increasing or decreasing required values, or selecting the required option.
0.1 must always be given as the minimum value.

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6.3.

Individual Operating Panel LCD Segment Functions

"FUNCTION
The current program status is displayed here. The displays options are:
1. Setting-up mode
This is displayed as long as the machine is in the setting-up mode.
2. Exposure program-Saving
Pressing the STOP button (17), interupts the current function. Then press one of the cursor buttons under
"FUNCTION (6 or 9) until the report "SAVE PROGRAM is displayed. Now the corresponding parameters
may be entered. Pressing the UNASSIGNED button (8) and ENTER (2) assigns the new exposure
parameters to the selected exposure program and then saves them. Afterwards press one of the cursors
again (6 or 9), until the previously activated mode is displayed again. Use the START (15) button to restart
the normal operation.
3. Video parameters.
Pressing the STOP button (17), interupts the current function. Then press one of the cursor buttons under
"FUNCTION (6 or 9) until the report "VIDEO PARAMETERS" is displayed. The video parameters can now
be altered (see section 7). Afterwards press one of the cursors again (6 or 9), until the previously
activated mode is displayed again. Use the START (15) button to restart the normal operation.
4. Measurement function
The measurment function is an alternative program to the machines automatic mode. Here you can
compare the films and /or the boards to one another. The machine will be in the setting-up mode! Pressing
the STOP button (17), interupts the current function. Then press one of the cursor buttons under
"FUNCTION (6 or 9) until the report "MEASUREMENT FUNCTION" is displayed. Press the SHIFT
(13) button and left unassigned (8) button to switch the video system on. The film or the board is laid
against the corresponding marks, the cameras must be positioned on the register marks. If neccessary
position the measurement window by means of the cursors (1-4). The cover will be closed.
Attention! Press the unassigned button (18) to use the vacuum to fix the film or board in position. Now use
the ENTER (5) button that corresponds to the display. After the video system has finished the scanning
cycle, confirm the parameters by pressing the Ready function ENTER (5) button. Now the film/board can
be removed and the comparison film placed in position.
Press the START (15) button to begin the alignment. The comparison values will be displayed on the
monitor. The cycle can be repeated. After pressing the STOP (17) button an alignment statistic will be
displayed. Afterwards press on of the cursor (6 or 9) until the previously activated mode is displayed. Use
the START (15) button to restart the normal operation.
5. Default settings
Pressing the STOP button (17), interupts the current function. Press one of the cursor buttons under
"FUNCTION (6 or 9) until the report "DEFAULT SETTINGS" is displayed. Simultaneously pressing the
INTENSITY (11) and ENTER (21) buttons will now reload the default settings. This gives the basic settings
to the exposure control which is dependent on the intensity. This is neccessary after a lamp change. After
loading the defaults new tests to determine the exposure time must be made. Therefore resetting the
defaults does not offer a concrete solution. Afterwards press one of the cursors (6 or 9) until the
previously activated mode is displayed. Use the START (15) button to restart the normal operation.
6. Automatic mode
Displayed as long as the machine remains in automatic mode.
7. STOP mode
Press STOP and then SHIFT + STOP together. The machine will then load the mask first, the board second and thirdly the film.

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7. The Video System and its Parameters
7.1 Basic sequence
The video system is controlled by a PC, that communicates with the machine SPS.
The video system is responsible for aligning the register marks as well as controlling the X, Y, table, so
that the film and board are perfectly registered one above the other.
The corresponding board or film components are used for every register mark recognition application.
The video system is controlled by a series of operator defined parameters. These parameters are found
together in one menu displayed on the monitor. When this parameter menu is activated, help information
is displayed on the monitor for the operator regarding the relevent options available for the selected
parameter. The video system menu is displayed after the film is placed in the machine and can always be
called up even during machine operations.

7.2 Calling-up the video parameters

When in setting-up mode press button (6) until the function parameters are shown in the display.
The parameter selection is displayed on the monitor.

7.3 The operating panels video keypad

The left (smaller) part of the operating panels keyboard controls the video operations. The (2) and
(3) buttons are used to move within the parameter menus. The (1) and (4) buttons are used to
select the options. The "Enter button saves the new inputs.

1 2

7.4 Exiting the video menus

After inputing the corresponding parameters and saving with ENTER after selecting "Ready", use the
FUNCTION (9) button to return to the setting-up mode.

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7.5
Video parameter menu and sub-menus
Select the parameters using cursor keys 1-4, and confirm with ENTER (5)
Parameter
Alignment method:
Measuring standard:
Alignment trials:
Alignment tolerance:
Spacing tolerance:
Positioning test:

setting options (depending on version)

Holes
high
3
20 m
100 m
none

off, holes, pad, structure

low, normal, high, maximum
0, 1, 2, 3, 1 to 2, 1 to 3, 2 to 3
20 m, 40 m, ..., 200 m
50 m, 100 m, ... , 5000 m
none, Register 1, Register 2

Reset
Save
Ready
Options
Offsets
Parameter 2

Options

setting options

Measurement area: normal

Alignment prediction:off
Reference 1st. PCB: off

reduced, normal, enlarged

off, on
off, on

Language

German, English, French, Italian

English

Reset
Ready

Offset sub-menu
Total X:
Total Y:
Register 1 X:
Register 1 Y:
Register 2 X:
Register 2 Y:

setting options
0 m
0 m
0 m +
0 m +
0 m +
0 m +

0 m
0 m
0 m
0 m

-1000, -995 ... 995, 1000

-1000, -995 ... 995, 1000
-1000, -995 ... 995, 1000
-1000, -995 ... 995, 1000
-1000, -995 ... 995, 1000
-1000, -995 ... 995, 1000

Reset
Ready

Parameter 2
Measuring standard:
Alignment trials:
Alignment tolerance:
Spacing tolerance:
Positioning test:

high
3
20 m
100 m
none

Reset
Ready
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7.6 Video Parameters
The following contains a description of the video parameters. Each of these parameters occupies a position
in the video parameter menu.

Menu option

Option

Alignment mode

Corresponds to the installed video components and the

complete system requirement. You may select from various
alignment options. An alignment option involves the video
system in the following situations:- film placement and
measurement area settings, - film centering, - measuring
and aligning the 1st. board, - light settings, - aligning the
following boards. The following basic option descriptions
are shown as examples. Other function names might be
used.
off

The PCB will simply be mechanically aligned, an optical

positioning correction option is not available.

Drilled hole

Circular register marks are to be found on both film and

PCBs. The video system searches for and tries to align on
the centre of the hole.

Structure

Circular registration marks are located in the films and on

the boards for the pre-alignment and freely located
structures for the fine-alignment. After the pre-alignment
the video system searches for layout film structures for the
fine - alignment. Due to the reduced matching of the track
layout structures with the layout film, the 1st. board is used
as the reference. Additionally after the alignment of the
first PCB the alignment record must be confirmed by the
operator, or manually optimized by means of an offset
adjustment. The pre-alignment settings are to be found in
parameter menu 2.

Pad

Simple registration marks are to be found on the film and

on the boards, e.g. circular or square. The board
registration marks are located on the upper side. The
video system matches the PCB structure against the film
structure in order to make the most accurate alignment
possible.

Measurement
quality

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Description

The measuring quality is the degree of matching between

the register marks defined in the film and those found on
the boards.
Low

The measurement requirements are minimal, so that fewer

suitable register marks will be listed as unsuitable. This
setting is only useful when used in conjunction with a
coarse tolerance.

Normal

The register mark requirements are higher than those of

the "Low" option. Correspondingly, a higher accuracy is
acheived.

High

The register mark requirements are higher than those of

the "Normal" option. Correspondingly, an even higher
accuracy is acheived than before.

Maximum

The highest register mark requirements are set and

because of the minimum tolerance settings, the highest
accuracy is ensured.

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FAPS 600

Menu option

Option

Alignment search

Description

The number of alignment searches that has been entered,

tells the video system how often it must search, in order to
improve on the present alignment. The setting controls the
accuracy and the alignment time. If the required accuracy
can not be acheived within the selected cycle count,
neither the contact vacuum or the exposure will be
allowed.
1, 2, 3

The completing of the selected number of alignment

searches does not depend on the already achieved
accuracy.

1 - 2, 1 - 3, 2 - 3

After the required minimum number of alignment cycles

have been completed, it will be decided from the accuracy
that has been achieved, if further alignments are
necessary..

Alignment
tolerance

20 - 200 m in 20 m
increments

The alignment tolerance sets the maximum allowed

divergence between the PCB register mark positions and
the register mark positions in the film. If the alignment
tolerance can not be acheived, the board will not be
exposed. The difference between the film and PCB
register mark positions will be taken from this examination
and entered in the menu option Spacing tolerance".

Spacing tolerance

50 - 5000 in 50 m
increments

The spacing tolerance sets the maximum difference

between the film and PCB register marks. If the spacing
remains exceeds the tolerance, then the board will not be
exposed.

Positioning check

The positioning check prevents the film or board from

being rotated or being processed with the wrong side
uppermost. Also after the alignment or film centering has
been checked, it will see if a control mark can be located
in the indicated registration.
none

No positioning check will be undertaken.

Register 1, Register 2

Alongside one of the registration marks, is located another,

although smaller, mark, which prevents the film from being
rotated when it is being positioned. After the board has
been aligned, the corresponding cameras image area will
check for the availability of the required mark.

Options

Goes to option menu.

Offsets

Goes to offset menu.

Parameter 2

Goes to parameter menu 2 This menu option is only

displayed when the selected alignment option works with 4
cameras. The settings in parameter menu 2 are simply for
pre-centering.

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Sub-menu options
Menu option

Option

Measuring area

Description

Measuring area marks a section of the camera image,

where a search for register marks will take place.
normal

The complete camera image area will be used as the

measuring area.

limited

The cameras image area is reduced. When placing the

film you are required to set the measurement area. This
option should be selected, when there are other similar
registration structures close by the registration mark.

enhanced

The camera image area will be artificially enhanced. If the

video system does not find a registration mark in the
normal image area, the alignment table will be moved in
the picture centre resolution direction, in order to locate a
register mark in the surrounding areas.

Alignment
prediction

off, on

When the alignment prediction is activated, the video

system will pre-position the board. This position will be
calculated from the average of the previous alignment
positions and compensate for the resulting deviations. If
there are strong conturing deviations requiring an enlarged
measurement area, this option can reduce the alignment
time, as it does not have to search the complete enhanced
area first.

Reference: 1st.
board

off, on

With this option you can select, wether the spacing

tolerance is relevant to the first board or the film.
Alignment options (i.e. structures), that will use the first
boards register marks as a reference, work automatically
with "Reference: 1st. board" and do not need this setting.

Language

German, English, French,

Italian

After selecting the language, all reports and menu entries

will be in the selected language.

Option

Description

Offset sub-menu
Menu option

If the exposure results are not optimum, there could be

various reasons for this.A fine correction to the alignment
position can be made by entering an offset, without
unloading the machine.
Complete X/Y

The following boards will be aligned to the entered values,

relative to the film. This correction concerns both register
marks and can not compensate for a rotation error.

Register 1/2, X/Y

Rotation errors give different offsets to both register marks.

This sort of error can be corrected by entering the
corrections in this box.

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7.7 Entering the video system parameter menu during a job exposure
(button description page 28)
Pressing the "Stop button interupts the automatic mode. Press the 9 button three times in "FUNCTION" and
the video parameter menu will be displayed on the monitor. After you have entered your inputs and used
"Ready" and ENTER to confirm them, press the 6 button three times in "FUNCTION". The display will now
show the "Automatic mode report. Press the "Start button, and the automatic mode will be continued.

8. Video System Status Reports

8.1. Video system self-test status reports
After the exposure system has been switched on the video system components are tested. The systems
individual component status reports will be diplayed on the monitor. The number of integrated cameras
depends on which video system has been installed.
System report
Camera 1: +/Camera 2: +/Camera 3: +/Camera 4: +/Table: +/If - is displayed against a component, then the video system is not ready to be operated. The system
displays Video system not ready error report and must be acknowledged with ENTER (also see 91.).
8.2. Alignment report
During alignment the following reports are displayed:
Alignment report
Trial:
Spacing error:
Remaining error X1:
Y1:
X2:
Y2:

Alignment trial number

0m

measured spacing distance

0m
0m

Camera 1 X-direction alignment error

Camera 1 Y-direction alignment error

0m
0m

Camera 2 X-direction alignment error

Camera 2 Y-direction alignment error

If a displayed value is greater than the video menu setting, then the relevant line in the alignment report is
marked with a red *. The alignment status is displayed on the last line and Alignment finished is
displayed in green when the alignment is correct.

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9. Error reports
9.1. Video system error reports
Video error reports are displayed on both monitors. If the error will influence the complete process, then
the error report is passed to the SPC, which will also generate an error report.

Error report

Meaning

Solution

Alignment interupted.

During the alignment an interupt

was demanded.

Repeat the alignment.

Register not found.

The minimal measuring accuracy

has not been achieved.

Change the present board or re-align

using a lesser measuring accuracy.

Register unsuitable.

No corresponding registers were

found in the film.

Re-align the film and the cameras.

Positioning check error.

The positioning check has not

recognised a control mark.

Check the positioning of the board or

the the check positioning settings in
the parameter menu.

Un-alignable.

The alignment can not be

completed with the required
accuracy.

Change the present board or re-align

using a lesser alignment accuracy.

Not set-up.

Alignment search without having

placed a film in the machine.

Check the run, re-place the film in the

machine.

Light can not be set.

The exposure lighting can not be

set on the board or film.

Check the selected alignment option

and the positioning of the film or
board.

Table can not be set.

The alignment table is in the end

stop position or has been stopped
by the cover being opened.

Repeat the operation or run a new

system check.

System not ready.

The system check has failed.

Check the component that the system

check has reported as defect.

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9.2 SPS error reports
SPS error reports are, as opposed to the video system, not displayed on one of the monitors but on the
operating panels LCD.
All errors, with the exception of those from the video system, are displayed here. If the video system
generates an error that will influence the complete system, then this error report is passed onto SPS.

Error report

Meaning

Solution

Over temperature MH lamp

Lamp temperature too high

Switch off the machine, check the cooling

(M1 ventilator, fuse F4, ventilatorcut-out)

Film vacuum not reached

Vacuum too low or no film vacuum

Are the register marks located in the

correct position?
Is the film the correct size?
Vacuum valve Y10 defect?
Vacuum switch S30 defect?
Is the glass plate broken?
Is the M3 vacuum pump OK?

Contact vacuum ot reached

Vacuum too low or no contact

vacuum

Is the mask the correct size and form, and

in the correct position?
Is the sealing lip defect?
How was the board laid on the glass plate?
Is the glass plate defect?
Check the vacuum meter, if wrong, re-set
the reduction valve to 0.65 bar. Check the
M4.1 and M4.2 vacuum pumps, switch the
machine off.

FU failure

Frequency converter failure

(Transport drive) due to, overcurrent, over-voltage, low voltage,
overloading or over-heating.

Switch off the machine, if it happens again

inform the service department.

Succeeding machine not

ready

Succeeding machine ready report

not available.

Is the succeeding machine switched on?

Are the FAPS and the succeeding machine
correctly cabled?
Is there a succeeding machine error
report?
Is the succeeding machine not yet ready to
accept the next PCB?

No calibration factor

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Calibration factor missing in the

defaults register

Run a default set-up (press "Intensity" and

"Enter" simultaneously)

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FAPS 600

Error

Meaning

Solution

No exposure value

No exposure value entered in the

corresponding register

Enter values for the illumination cycle,

vacuum time etc.

Cover open

Plexi-glass cover, metal cover or

shuttle have been recognised as
open.

Close the covers, check that the shuttle

latches are turned correctly.

Video system
communications error

Communication error between the

video system and SPS.

Switch the machine off.

Video system not ready

The video system is not ready.

Switch the machine off.

Video system calibration

false

Error in the setting-up process.

Press the "Enter" button and wait for

approx. 60 seconds.

PCB on the alignment table

The board can not be transported

away from the alignment table.

Is the fixing vacuum (Q8, K4) still switched

on? Is the transport vacuum (Q4, K5, M6)
still switched off? Switch off the machine.

Alignment station not in startup position.

X and / or Y axis pins are not in

their outer start positions.

Switch the machine off.

PCB output transport failure

PCB is still on the exposure table

Remove the PCB, and manually place it on

the output shuttle, close the machine and
press both hidden buttons.

PCB output transport failure

PCB stuck on transport plate 2.

Transport vacuum still active. (check K6)

PCB is still stuck on the transport

plate.

Remove PCB

PCB pressurising board output

control sensor B 20

OutOutput band does not move (check

M21

PCB jammed

Remove PCB

PCB format is not correct for the

controlling suction area.

Switch off machine

Alignment table fixing vacuum not

switched off.

Check the vacuum (Q8 and M2), switch off

the machine

Masking vacuum is switched on,

without there being a mask on
transport plate 1.

Check the masking vacuum (Q3, M5 and

K8), switch off the machine.

Transport vacuum 1 is still switched

on.

Check Q4, K5 and M6, switch off the

machine.

Masking vacuum is still switched on,

without there being a mask on
transport plate 1.

Check the masking vacuum (Q3, M5 and

K8), switch the machine off.

Shuttle 1 not above (shuttle

over pre-centering)

Shuttle 1 not above (shuttle

over exposure table.)

Contact vacuum still available during Check Q2 and K9, switch off the machine.
film transporation.
No air flow to the exposure table.

11/99 BA-FAPS600-e

Check output Y24 (master) (air flow from

above) or output Y25 (air flow from below)
and switch off the machine.

39

FAPS 600
10. Interfacing to the preceding and the succeeding inline machines
10.1. General
FAPS 600 automatically exposes boards as they are passed through the machine. In order to achieve an
improvement in quality as well as the utmost efficiency, it is highly recommended that the transporting of
boards to and from the machine is also fully automated. Furthermore boards that are inadequately
registered or others that could not be exposed, can be automatically selected and diverted.
The basic communication is made by signals that are passed onto the corresponding machine by means
of potential-free change-over switches, i.e. relays.

10.2. Interfacing to the previous inline machine

A suitable preceding inline unit would be an automatic board feeder machine. In a production line having
two exposure machines you could have a turning unit (WD 600) as the feed-in machine for the second
exposure unit. The exposure unit sends two signals back to the preceding unit as well as receiving "Bad
board signals from the preceding unit.
a)

"Ready
The "Ready" signal indicates that the exposure unit is switched on and that no errors have been
reported. When the ready signal has been sent, the preceding unit can prepare a board, which
is then ready to be passed immediately into the exposure unit.

b)

"Board required
The signal "Board required indicates that the exposure unit is waiting for a board. This signal
remains set until another board passes through.

c)

"Bad board
The signal "Bad board indicates to the exposure unit that the next board to arrive should not be
aligned or exposed. This signal is also sent to the succeeding machine.

10.3. Interfacing to the succeeding inline machine

Two signals are also required for interfacing to the succeeding machine. One of these is the "Ready"
signal that the succeeding machine sends to the exposure unit, and the other is the "Bad board" signal
that the FAPS 600 sends to the succeeding machine.
a)

"Ready
The "Ready" signal indicates to the exposure unit that the succeeding machine is switched on and
is waiting for a board to be inputed. If this signal is not sent, then only one board can be
outputted from the exposing unit.

b)

"Bad board
The "Bad board signal is sent from the FAPS 600 to the succeeding machine and indicates that
the next board to arrive was not exposed (missing register marks etc.). Prior to the outputing of
the next unexposed board this signal must be reset to "0" for at least 1 second.

11/99 BA-FAPS600-e

40

FAPS 600
11. Service
11.1 Cleaning the glass plate
The glass plate should be frequently cleaned from above.
We recommend cleaning the glass plate prior to each new job run.
Open the metal cover. If neccessary move the transport shuttle (Attention: You are only permitted to
move the shuttle, when compressed-air is supplied to the machine!) to the correct end position (up
to the drive motor stop). Now turn the four clamps to the left and open the shuttle. (Attention: You are
only permitted to open the shuttle, when compressed-air is supplied to the machine!). Then press
the latches on both handles and lift the shuttle. The shuttle is held open by pressurised gas lid support.
Now you can clean the glass plate with an ordinary glass cleaner.
Then close the shuttle again (Attention: You are only permitted to close the shuttle, when
compressed-air is supplied to the machine!). Turn the clamps to the right and close the cover.
If it is neccessary to clean the glass plate from beneath, switch off the main switch and open the machine
with the two-way key supplied with the machine. You can now clean the glass plate with an ordinary glass
cleaner. (Attention: You now have access to the lamp and reflector. Be very careful not to damage
the machine components or to hurt yourself!).
11.2. Lamp changes
11.2.1 POC lamp change
Attention:

Switch the machine off and and leave it to cool down until you are absolutely
certain that there is no danger of being burnt.

Switch the main switch off, remove the POC housing rear door and take off the lamp housing rear panel.
Remove the lamp connection slotted screws. Lift the lamp out of the clamping spring and lift out of the
reflector from above. Use a safety cloth when fitting the new lamp and install from above. Ensure that
neither the refector surface or the lamps glass bulb are touched by bare hands. Make certain that you fit
the lamp so that the unevenly formed part in the middle of the lamp faces upwards inside the machine.
Reconnect using the M5 slotted screws again. Turn the reflector by hand and check the lamp connection
cable. Do not touch the cable. Refit the covers in the reverse order.

11.2.2 HI lamp change

Attention:

Switch the machine off and and leave it to cool down until you are absolutely
certain that there is no danger of being burnt.

Switch off the main switch and open the machine with the two-way key supplied with the machine. Remove
the connection and carefully pull out the lamp. Place this on a suitable work top so that you have access
to the lamp and the screwed-on contacts. Unscrew the contacts and remove the lamp. Install the new
lamp. Ensure that you touch neither the reflector surface or the lamps glass bulb. Make certain that you
fit the lamp so that the unevenly formed part in the middle of the lamp faces upwards inside the machine.
Re-mount the lamp in the machine. Ensure that the draw is secured in the correct position.

11/99 BA-FAPS600-e

41

FAPS 600
11.3 Changing the exposure frame
Open the metal cover. If neccessary move the transport shuttle (Attention: You are only permitted to
move the shuttle, when compressed-air is supplied to the machine!) to the correct end position (up
to the drive motor stop). Now turn the four clamps to the left and open the shuttle. (Attention: You are
only permitted to open the shuttle, when compressed-air is supplied to the machine!). Press the
latches on both handles and lift the shuttle. The shuttle is held open by pressurised gas lid support.
If the frame that is to be changed is defective, switch the main switch off and open the machine with the
two-way key supplied with the machine. If necessary clean any glass splinters from the lamp using a
suitable cleaning method (e.g. vacuum cleaner). Also use a suitable material (e.g. cardboard) to protect
the lamp from any bits of glass that may fall down.
After removing the machine front panels (by the main switch), pull off the air connections.
Then use an Allen key to remove the screws that are located on the upper side of the exposure frame.
When all of the screws have been removed, exchange the exposure frame for a new one.
Replace and tighten all the screws, reconnect the air pipes and close the machine again. (Attention: You
are only permitted to close the shuttle, when compressed-air is supplied to the machine!).

11.4 Lubrication
Every 8 weeks, or after 500 operating hours, it is neccessary to lubricate the machine at five different
points. Use the lubricant and the grease gun that were supplied with the machine.
Three of the grease nipples are located behind the cover to the left of the operator at the front of the
machine. These three nipples supply the X, Y, & table drives.
The other two nipples lubricate the shuttle drive shaft. One of the nipples is located externaly, close to the
shuttle drive motor. The other is located inside the machine and can be found as follows:

Attention:

You are only permitted to move the shuttle, when compressed-air is supplied to
the machine!
Open the metal cover.
Remove the shuttle cover (remove the 4 screws)
Loosen the drive motor brake.
Move the shuttle to the middle position.
The grease nipple is now accessable, and should be lubricated.
Move the shuttle back to the right end position.
Tighten the motor brake.
Replace the shuttle cover (4 screws)
Close the metal cover.

11.5 Vacuum pump VCE 40 (contact vacuum)

Please refer to the enclosed service information leaflet regarding vacuum pump servicing.
We recommend filling with "Special oil 1.5l, Art. No: 0086.038", or alternatively the following may be used:
BP Energol RC 100, ESSO Nvto 100, ARAL Montanol ME 100.
The contact vacuum pump is located in the vacuum tower.

11/99 BA-FAPS600-e

42

FAPS 600
Please check the oil level weekly. The oil level can be seen in the pumps indicator glass.
Change the oil every 500 operating hours (even though the vacuum pump only operates for a part of the
total machine operating time). Oil specifications are contained in the enclosed service leaflet.
Periodically use compressed-air to blow the gas balast valve filter components clean (depending on the
cleanliness of the air that is sucked through).
Periodically use compressed-air to blow the gauze filter clean (depending on the cleanliness of the air that
is sucked through).
It is recommended to change the air-oil separator components every 2000 operating hours (even though
the vacuum pump only operates for a part of the total machine operating time).
The coupling seals are subject to wear. If you hear a knocking noise as the machine starts up, then the
seals must be changed, as worn seals could cause the rotor shaft to snap.

11.6. Vacuum pump TLV 15 (film and contact vacuums)

Please refer to the enclosed service information leaflet regarding vacuum pump servicing.
These pumps are located on the exposure unit output side and can be accessed by removing the panels
from the front of the machine.
These pumps do not require lubrication.
The air filter system cartridges must be cleaned monthly and changed anually.
The carbon lamellas must be checked every 6000 operating hours and changed if neccessary.

11.7 Side channel compressor (SKP 35826.01 transport and SKP 30220-03
mask vacuums)
Please refer to the enclosed service information leaflet regarding the side channel compressor servicing.
These side channel compressors do not require sevicing. The pressure limiting valve should be cleaned
every 500 operating hours, and also be checked for corrosive damage.
Nevertheless in order to ensure full vacuum power the suction side filters must be checked at regular
intervals.

11.8 Air filter

The filters in the monitor cover and the video PC should be changed when they are dirty.

11/99 BA-FAPS600-e

43

FAPS 600
11.9 Compressed-air filter
The scale filter in the maintenance unit must be changed (compressed-air connection) in the event of a
loss of air pressure.

11.10 Toothed belt

The toothed belt tension (transport systems drive) must not exceed a maximum bowing of 15 mm. If
neccessary adjust the tension.

11.11 Required material list

No.
1
2
3
4
5
6
7
8
9
10
11

Description
MH-lamp for HI
MH-lamp for HI
MH-lamp for POC
Lubricating grease, Isoflex, special
Special oil for vacuum pumps VCE 40, 1.5l
Rubber cleaner for frame seals
Cleaning cloth, greeen
Cleaning cloth, orange
Monitor cover filter
PC filter
Cleaner adhesive rollers

11/99 BA-FAPS600-e

Model/Manufacturer
Z 1 (Galium)
Z 4 (Eisen)
LDS 18/Klber
Caramba
Bacher
Bacher

M/E Order-No.
E
9602.561
E
9602.562
E
9602.566
3250.351
0086.038
0086.039
0096.031
0096.032
8780.500.005
8780.500.008
8780.328.003

44

FAPS 600
12. Spare parts lists and relevant part position

11/99 BA-FAPS600-e

45

FAPS 600
13. Electrical circuit diagrams

11/99 BA-FAPS600-e

46

FAPS 600
14. Pneumatic diagrams

11/99 BA-FAPS600-e

47