MDC/Manncorp/Mekko ECM97 Cheat Sheet

1. Open front right door. Confirm that circuit breaker and isolator are both in the OFF position and the green light is OFF
2. Power on the PC. Wait for the “Machine Run?” prompt.
3. Switch on the circuit breaker and isolator. Green light on isolator panel should light.
4. At the “Machine Run?” prompt, enter Y <Enter>.
5. The “U” (up/down) and “TH” (theta, rotation) axes will be moved to their home positions.
6. PC will prompt: “Homing OK?”. Enter Y <Enter>. The head will move to the home position (X=0, Y=0).

From the main menu, select:

• (2) Data Input
• Starting Step Number: 1

The computer will display the Bias Point. This is the offset from which all measurements are made and is normally a fiducial mark at the corner of the PCB closest to the machine's home position (the origin, or front left corner; X=0, Y=0).

Press F8 to enter Teach mode. Use the cursor keys to set the bias point.

The movement increment applied when the cursor keys are pressed can be increased with the “*” key and decreased with the “/” key.
Available increments are: 0.01mm, 0.1mm, 0.5mm, 5mm.

When the bias point has been set, press <ESC> then press <Enter> to confirm the new bias point.

1. Press F8 to switch to Teach mode.
2. Press “U” to move the head down until it touches the PCB surface.
3. (TO DO)

The incoming air pressure should be set to 60 psi (4.14 bar or 4.22 kgf/m²).

The first regulator (Norgren Olympian) should be set slightly higher than this value, and the second regulator inside the machine used to regulate down to the required pressure shown above.

A vacuum sensor (Keyence AP-31A) is mounted on the back of the ECM97. This is used to detect the increase in vacuum pressure which occurs when a component is successfully picked up. If this sensor is set up incorrectly, the machine may report one of two errors:

• NOZZLE CHOKED indicates that the vacuum sensor output is stuck on (the set point is too low – the machine thinks the nozzle is blocked).
• PICKUP MISSED (even though a component was successfully picked up). This indicates that the vacuum sensor output is stuck off (the set point is too high).

The sensor output must be “off” until the vacuum is present and a component has been successfully picked up.

To calibrate the vacuum sensor:

1. Use Teach mode to load the smallest nozzle. Exit to the main menu.
2. Select Diagnostics, (1) VAC CHK
3. Turn the vacuum on. Confirm that the nozzle is clear and no parts have been picked up.
4. Note the reading on the vacuum sensor display.
5. Place a component under the nozzle. Note the new reading.
6. Take the mid-point (average) of the two pressure readings. This is the small nozzle set point.
7. Switch to the largest available nozzle, then repeat the above steps to obtain the large nozzle set point.
8. Take the small and large nozzle set points and average them. Set the sensor set point to this value.
9. Confirm that the sensor works correctly with a variety of pick-up nozzles. Adjust the set point until the sensor operates correctly.

1. At the ECM97 main menu, select:
   • (1) Data List
   • (4) Nozzle changer
   • (2) Edit
   • (2) Change Data
2. Move the cursor to POS 1.
3. Press F8 to enter Teach mode (Move Head). The status line indicates whether the Camera, Nozzle or Eye (fiducial sensor, red light) is at the specified co-ordinate.
4. If there is no nozzle mounted on the head:
   1. Press N.
   2. The machine will ask for the Head number.
      • Enter 1 as the ECM97 only has one placement head.
   3. You will then be prompted for the current nozzle number.
      • If unsure, enter the number of an empty nozzle holder.
      • The nozzle holders are numbered 1 to 6 in order, counting from the front of the machine to the back.
   4. You will then be asked which nozzle to load.
      • Select the smallest nozzle loaded in the nozzle holder; this will typically be nozzle 1.
      • Entering “0” will prevent the machine from loading a new nozzle.
   5. A nozzle must be loaded for the calibration process to succeed.
5. Press 9 for “Nozzle”. Use the cursor keys to move the nozzle to a convenient location on the machine bed.
6. Tape a piece of paper to the machine base (under the nozzle) and place a sheet of carbon paper on top.
   • A thin piece of Blu-tak may be used instead
7. Press the “U” key to lower the nozzle, then press Shift-U to raise the nozzle.
   • If using carbon paper, repeat this four times.
8. Press 5 for “Camera”. The head will move the camera to the specified co-ordinate using the existing camera offset.
9. Press 0 to start calibration. (the computer will beep)
10. Use the cursor keys to move the head until the centre cross-hair on the camera display is directly over the centre of the nozzle dot.
11. Press C to store the calibration. (the computer will beep)
12. At the CALIB Y/N prompt, enter Y <ENTER>. The new camera offset will be stored in memory.
13. Press F2 to save the parameters to disk.
14. Press: <ESC> <ENTER> <ESC> <ESC> to return to the Data List menu. Press <ESC> again to return to the main menu.