Applies to

Release date: 08 Aug 2002
Type of change: Conditional

Problem

During exposure, plate ablation is produced and accumulates on the optic head lens protector, the light detector lens and other components of the machine. Over time, this causes a noticeable decline in image quality, puts a strain on the laser diodes, and may ultimately cause diode failure.

Solution

Installation of a debris removal kit that vacuums the ablative particles from where they are produced—in front of the optic head. Installation of this kit will increase reliability and reduce the need to clean ablation from the internal components of the machine.

Time needed to implement

Pre-installation site inspection: 30 minutes

Complete FCO implementation: 5 hours

Prerequisite FCOs

The Compressed Air Filtration Unit (p/n 510P1R129) must be installed.

Parts needed

FCO Kit No: 510F28983

Additional parts to order (if required)

Procedure

This procedure includes the following steps:

• Pre-installation site inspection
• Preparing the machine for installation
• Installing the debris removal kit in machines:
  • With an older chassis
  • With a newer chassis
  • With an Omron chassis

Including:

• Installing the debris collection nozzle
• Installing the Universal Debris Removal Cabinet (UDRC)
• Testing functionality

Pre-installation site inspection

Before implementing this FCO, you need to go to the customer site and verify that all site preparations have been properly completed by the customer according to the specifications listed in Universal Debris Removal Cabinet (UDRC) Site Preparation Guide (pdf), and those listed in this FCO.
Note: All electrical work must be completed by a qualified electrician.

In addition, you need to verify several details about the customer's machine and, in some situations, order additional parts. For complete information about specifications and the machine details to verify, see:

• Universal Debris Removal Cabinet (UDRC) Site Preparation Guide
• Compressed air supply specifications
• Additional details

Compressed air supply specifications

In addition to the site preparations listed in Universal Debris Removal Cabinet (UDRC) Site Preparation Guide, the following compressed air supply specifications must be met before the UDRC can be installed:
Note: Verify that Compressed Air Filtration Unit - 510P1R129 has been installed on this machine. If it has not been, order and install the compressed air filtration unit before proceeding.

• Pressure: 8 bars (~120 psi)
• Capacity: 17 CFM (minimum)
• Humidity: dew point of 3°C (37°F)
• Particles: 1 micron, 1mg/m³ (maximum)
• Oil: 0.01 mg/m³ (maximum)

Additional details

Verify the details listed below and order the required additional parts before installing the UDRC.

1. Verify the type of lens that is installed on the customer's machine by visually checking the lens. The following picture shows the differences between the three possible lens types:

   

   • If a Long Rodenstock or Zeiss lens is installed, when you implement this FCO you will install the Type I nozzle (p/n 507C3E963) that is included in this kit.
   • If a Short Rodenstock lens is installed, order a Type II Nozzle (p/n 507B4E237) before implementing this FCO.
2. Verify whether the machine includes a comp level 'O' (or higher) CTP power distribution board. If it does not, order a CTP power distribution board (p/n 503C2L049Q).
   Important: Install the CTP power distribution board before implementing this FCO.
3. Verify the PC controller software version (version 3.20.01 or higher must be installed before this FCO can be implemented). If version 3.20.01 or later is not installed, upgrade the software.
4. Verify the type of rear trapezoid panel that is installed on the machine. If it is the regular type without a vacuum tube hole, order the rear trapezoid panel, (p/n 510P1R070) before implementing this FCO. The picture below shows the section of the trapezoid panel with the vacuum tube hole.

Preparing the machine for installation

1. Verify that:
   1. All specifications have been met, as described in Pre-installation site inspection.
   2. All required, additional parts have been ordered as described in Additional details.
   3. Compressed Air Filtration Unit - 510P1R129 has been installed.
   4. The distribution board (comp level 'O' or higher) has been installed, as required.
   5. The PC controller software has been upgraded to version 3.20.01 or later, as required.
2. From the PC controller, move the carriage to the center position.
3. From the PC controller, open the front door and the rear door.
4. Manually open the right door, remove the 6 screws that secure the black laser cover in place and remove it from the machine.
5. Repeat step 3 on the left side.
6. Remove the following panels:
   • Rear trapezoid panel
   • Rear upper panel
   • Rear lower panel
7. From the rear of the machine, disconnect the three unloading tray motor connectors, remove the 6 screws that secure the unloading tray in place, and then remove the unloading tray from the machine.
8. In the PC controller, close the Lotem application.
9. Close the circuit breaker in the distribution box.
10. Unplug the main power cable from the main power supply.
11. Discontinue the air supply to the machine by closing the air pressure valve on the wall air pressure unit.
12. Remove the cable chain cover from the cable chain.
13. Remove the cable chain from the machine, as follows:
    1. Remove the two cable chain securing screws from the upper cable chain bracket (shown below).

    

    2. Carefully remove all cables and fibers from the inside of the cable chain.
    3. Remove the 2 cable chain securing screws from the lower cable chain bracket, and then remove the black cable chain from the machine.
14. Remove the two cable chain bracket securing screws from the upper bracket, and remove the bracket from the machine.
15. Repeat step 14 on the lower bracket.
16. Install the new upper cable chain bracket (p/n 280A9L160) and the lower cable chain bracket (p/n 280A9L161B) in the machine. Secure them in place using the screws that you removed in steps 14 and 15.
    Note: Be sure to apply Loctite™ to each screw.
17. Verify chassis type and then continue as follows: 
    • If the chassis is an older type, proceed to Installing the debris removal kit in machines with an older type chassis.
    • If the chassis is a newer type, proceed to Installing the debris removal kit in machines with a newer type chassis.
    • If the chassis is an Omron type, proceed to Installing the debris removal kit in machines with an Omron chassis.

Installing the debris removal kit in machines with an older type chassis

1. From the rear of the machine, locate the black plastic tray that divides the upper and lower portions of the machine (just under the Optomec).
2. Drill a 25 mm hole in the left side of the tray (on your right), just behind the laser fiber tube, as shown below.



3. Insert the 3/4 inch vacuum hose (p/n 344F10115) into the 25 mm hole that you just drilled, thread it through the hole to the lower compartment of the Lotem, and route it over the L-box and the D-box to the middle of the machine as shown below.



4. Locate the 3/4 inch - 1 1/2 inch fitting (p/n 290B2M813), attach it to the lower end of the 3/4 inch vacuum tube (the one that you just routed over the D-box), and then secure it in place using the supplied hose clamp (p/n 388L10035).
5. Locate the 1 1/2 inch vacuum hose (p/n 344F10120) and attach it to the 1 1/2 inch end of the fitting that you installed in the previous step. Secure it in place using the supplied hose clamp (p/n 388B28000).
6. Locate the nipple out assembly (p/n 291A2N219), and then secure it to the lower right rear corner of the machine (on your left), as shown below.
   Note: Use the supplied 1/4 inch screws, spring, and flat washers. Be sure to apply Loctite to each screw.



7. Attach the other end of the 1 1/2 inch vacuum hose to the upper part of the nipple you just installed and secure it in place using the supplied hose clamp (p/n 388B28000), as shown above.
8. Install the debris collection nozzle as described in Installing the debris collection nozzle.

Installing the debris removal kit in machines with a newer type chassis

1. Locate the 3/4 inch vacuum hose (p/n 344F10115), and then, from the rear of the machine, attach one end to the metal nipple on the chassis (shown below) and secure it in place using the supplied hose clamp (p/n 388B2800).
   Note: If you cannot attach the vacuum hose to the metal nipple, remove the nipple from the machine by removing the two securing screws, attach the vacuum hose to the nipple and secure it in place using the hose clamp, and then reinstall the nipple. Be sure to apply Loctite to each screw.



2. Locate the 1 1/2 inch vacuum hose (p/n 344F10120), and attach it to the 1 1/2 inch nipple underneath the mainframe. Secure the vacuum hose to the nipple using the supplied hose clamp (p/n 388B28000), as shown below.

   

3. Locate the nipple out assembly at the lower-right rear corner of the machine (on your left). Attach the other end of the 1 1/2 inch vacuum tube to this nipple and secure it in place using the supplied hose clamp (p/n 388B28000), as shown below.
   Note: If the nipple out assembly is not installed, locate the nipple out assembly (p/n 291A2N219), and use the supplied 1/4 inch screws, spring, and flat washers to  secure it to the lower-right rear corner of the machine (on your left), as shown below. Be sure to apply Loctite to each screw.



4. Install the debris collection nozzle as described in Installing the debris collection nozzle.

Installing the debris removal kit in machines with an Omron chassis

1. From the rear of the machine, locate the prepared hole in the mainframe, and remove the plastic plug from this hole (shown below).



2. Locate the plastic sleeve (p/n 290F9B892), place the sleeve in the prepared hole, and use a plastic hammer to tap the sleeve into the hole.



3. Insert the 3/4 inch vacuum hose into the plastic sleeve in the mainframe and pass it through the sleeve to the lower compartment.
4. Use a plastic tie to secure the 3/4 inch vacuum hose to the other cables, as shown below.



5. Locate the 3/4 inch - 1 1/2 inch fitting (p/n 290B2M813), attach it to the lower end of the 3/4 inch vacuum tube, and secure it in place using the supplied hose clamp (p/n 388B2800), as shown below.



6. Locate the 1 1/2 inch vacuum hose (p/n 344F10120) and attach it to the 1 1/2 inch end of the fitting that you installed in the previous step. Secure it in place using the supplied hose clamp (p/n 388L10035), as shown above.
7. Locate the nipple out assembly on the lower-right rear corner of the machine (on your left, shown below).



8. Attach the other end of the 1 1/2 inch vacuum hose to the upper part of the nipple that you just installed and secure it in place using the supplied hose clamp (p/n 388B28000), as shown above.
9. Install the debris collection nozzle as described in Installing the debris collection nozzle.

Installing the debris collection nozzle

1. From the rear of the machine, remove the two fufu nozzle bracket securing screws (shown below), and remove the bracket from the optic head.
   Note: Leave the fufu tube in place.



2. Install the new cable chain (p/n 203C10085).
   Note: Do not put the cover onto the chain.
3. Locate the relevant nozzle according to the type of lens on the optic head:
   • Long Rodenstock: Type I nozzle (p/n 507C3E963)
   • Zeiss: Type I nozzle (p/n 507C3E963)
   • Short Rodenstock: Type II nozzle (p/n 507B4E237)
4. Install the relevant nozzle on the end of the optic lens, as follows:
   1. From above, place the nozzle over the lens, and press the nozzle toward the optic head until it is flush with the lens protector.
   2. Secure the nozzle in place by tightening the two nozzle securing screws on top of the nozzle (shown below).

   

   3. Insert the two supplied 8-32 x 3/8 inch screws and flat and spring washers into the additional nozzle securing holes (shown above) and tighten them.
      Note: Be sure to apply Loctite to each screw.
   4. Attach the end of the 3/4 inch vacuum hose to the 3/4 inch nipple on the nozzle, as shown below, and then secure it in place using the supplied hose clamp (p/n 388B2800).
      Note: The 3/4 inch vacuum hose is the one that you previously installed.

   

   5. Attach the fufu tube to the fitting on the air pressure regulator that is attached to the nozzle (shown below).
      Note: If the fufu tube is too long, cut it, as required.

   

   6. Verify whether the machine supports a vacuum sensing option. Then:
      • If the machine supports a vacuum sensing option, attach the vacuum sensing tube to the vacuum sensing tube nipple on the top of the nozzle (shown below).

      

      • If the machine does not support a vacuum sensing option, remove the nipple and plug the inlet with the supplied plug (p/n: 344B13050, included with the ablation nozzle assembly, p/n 507C3E963).
5. Place the following items into the cable chain according to the diagram below:
   • Blue 1/4 inch fufu tube
   • 3/4 inch air hose
   • Power cable
   • Vacuum sensor tube, if supported
   
   

   Note: The components in the cable chain should lay flat and not be tangled.

6. Place the cable chain cover on the cable chain, and press it down to secure it in place (it should snap into place).
7. Manually rotate the drum and make sure there is sufficient clearance between the tail grippers and the nozzle.
8. Inspect the right-most spoiler (on your left) and verify whether it is the same as the spoiler supplied with this FCO kit (p/n 290B2P030A). If it is, proceed to the next step. If it is not, remove it and install the new one, as follows:
   1. Remove the two spoiler securing screws (one Philips™ round-head screw and one Allen™ screw, shown below), and remove the spoiler from the machine.

   

   2. Secure the supplied spoiler (p/n 290B2P030A) in place using the two screws previously removed. Be sure to apply Loctite to each screw.
9. Install the light detector hood (p/n 280B2M807) supplied with this FCO kit, as follows:
   1. Disconnect the connector on top of the light detector (shown below).

   

   2. Remove the four light detector securing screws (shown above), and carefully remove the light detector assembly from the machine.
      Note: Do not drop the light detector or touch the light detector lens.
   3. Remove the light detector hood (cover) from the light detector.
   4. Clean the light detector lens using one of the following, soaked with alcohol:
      • Rice paper
      • Special lens-cleaning paper
      • Q-tip
   5. Clean the light detector lens again, using a clean piece of paper or Q-tip (as described in the previous step) soaked with acetone.
   6. Place the supplied light detector hood on the light detector, and secure the light detector assembly to the machine using the four screws that you previously removed.
      Note: Be sure to apply Loctite to each screw.

Installing the Universal Debris Removal Cabinet (UDRC)

1. Position the UDRC (p/n 506A01506A) as close to the rear of the machine as possible.
2. Attach the 1 1/2 inch vacuum hose that is connected to the UDRC to the nipple at the lower-right rear of the machineand secure it in place using a hose clamp (p/n 388L10035), as shown below.



3. Verify whether the machine you are working on is a LOCAL2 or a LOCAL3 machine. Then, connect the relevant control cable, as follows:
   • In LOCAL2 machines, connect the control cable (p/n 504L3E849) to the two-pin J5 Molex connector on the distribution box (the connector is labeled J5 SOLENOID).
     Note: Route the control cable along the vacuum hose.
   • In LOCAL3 machines, connect the control cable (p/n 504L3E848A) to the Molex cable near the E-box (the cable is labeled ABL).
4. Connect the Vacuum Unit to the power supply.
5. Reconnect the main power supply.
6. Open the air supply valve on the wall air supply unit.
   Note: Verify that the air pressure level is at least 6 bar.
7. Perform start up.
8. In the PC controller, set the values for the following parameters:
   Note: Click Utilities > Hardware to access these parameters.
   1. Others/LOTEM800V/I/O Objects/Distribution card/Solenoid Switch/Optical Head Suction:
      • Hold Pwn Value = 250 (Default 150)
      • Max Allowed Sol Activation Time =255 (Default 3)
      • Open = 0 (Default 0)
      • App Auto Off Time = 0 (Default 1)
   2. Others/LOTEM800V/EXPOSE:
      • Lens Air Suction Enable = 1 (Default 0)
   3. In addition, if the machine you are working on is a LOCAL3 machine, set these values for the following parameters:
      • Others/LOTEM800V/I/O OBJECTS/LOCAL 3/VALVE/Lens Air suction:
        • Make sure the Valve Number is 8 and it's connection to the Left Local Card
        • Lens Air Suction App HP Detector = None
        • Lens Air Suction App End Detector Name = None
      • Others/LOTEM800V/IO OBJECTS/LOCAL 3/DETECTORS/Lens Air Filter OK Detector/Detector Active State = 0 (Default = 1).
      • Others/LOTEM800V/IO OBJECTS/LOCAL 3 DETECTORS/Lens Air Vacuum OK Detector/Detector Active State = 0 (Default = 1).
      • Others/LOTEM800V/PROTECTORS/Drum Motor Protector/Open = 1

Testing functionality

1. Insert cheaters into interlocks, as required.
2. From the PC controller, activate the valve that supplies air to the debris collection nozzle.
3. Verify that the air pressure regulator on the nozzle is set to 40–45 psi.
4. From the PC controller, activate the UDRC vacuum system and verify that suction occurs at the debris collection nozzle.
5. Feel for leaks at all vacuum hose unions.
6. From the PC controller, move the carriage to HP. Watch the nozzle as the optic head passes the light detector and verify that there is adequate clearance and that they do not collide.
7. Adjust the focus mechanical stopper by sending the motor to position 500, attaching the stopper to the optic tube and tightening the screws.
8. From the PC controller, move the carriage from HP to EP. Watch the optic head as it moves, and verify that there is adequate clearance between the optic head and the unloading tray, that they do not collide, and that the vacuum hose does not come into contact with the tray at any point.
9. From the PC controller, move the carriage to the middle of the drum. Then, manually rotate the drum and verify that the spoilers do not touch the nozzle.
   Note: It is extremely important that the head gripper and tail gripper spoilers do not come into contact with the nozzle.
10. Load a 0.3 mm plate and repeat step 9.
    Note: Do not remove the plate.
11. Remove all cheaters and complete the following:
    Note: Be sure to apply Loctite to each screw.
    1. Replace the unloading tray.
       Note: Be sure to reconnect the three unloading tray motor connectors.
    2. Replace the black laser covers on the right and left sides of the machine.
    3. Replace all panels.
       Note: Remember to install the correct rear trapezoid panel (p/n 299A9B172).
    4. Close all doors.

    IMPORTANT! Do not proceed until all panels are properly replaced and all doors are closed.

12. From the PC controller, rotate the drum at a rate of 900 RPM.
    IMPORTANT! Be prepared to stop the machine immediately either from the PC controller, or using the main circuit breaker.
13. While the drum is rotating, move the carriage from HP to EP. While the carriage is moving, listen carefully for any sounds that may indicate malfunction, such as the nozzle colliding with something. If you hear anything of this sort:
    • Stop the machine immediately.
    • Open the rear door and check the clearance between the debris collection nozzle and other machine parts.

Logistics

Approved quantities:

Schedule supplies for first lots:

Lead time for extra kits: 6 weeks

Material Disposition

See also

UDRC Overview

Technical contact

Itai Peperovich

Project Manager: Stefan Kleinman
Support Manager: Assaf Zach

Revision A

Date submitted