Easy Coat for Windows XP Version 3.
NOTICE This is an Asymtek publication, which is protected by copyright. Original copyright date 2006. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Asymtek. The information contained in this publication is subject to change without notice. Manuals on the Internet For the convenience of Asymtek customers and field service representatives, copies of Asymtek manuals can be downloaded from: http://www.asymtek.com/support/manuals.
Manual Conventions Bold Text Dispensing system labels, buttons and switches, and software menu selections and commands appear in this text style. [Bracketed Text] [Bracketed Text] indicates a single key or key combination to press on a computer keyboard, such as [Enter] or [Alt + Tab]. Text > Text Refers to a series of menu bar commands in Easy Coat for Windows XP (ECXP) software. WARNING! CAUTION! " iv Personnel Safety Warning.
Table of Contents 1 Introduction ...................................................................................................................................... 1-1 1.1 Overview .................................................................................................................................. 1-1 1.2 Getting Started......................................................................................................................... 1-1 1.3 Safety First.........................
4.10 Beacon Configuration ............................................................................................................4-14 4.11 Fan Width Configuration ........................................................................................................4-16 4.11.1 FWC Sensor Setup ...................................................................................................4-19 4.12 Needle Finder Configuration...........................................................................
5.8 Properties................................................................................................................................. 5-9 5.9 Creating a Program................................................................................................................5-10 5.9.1 5.9.2 5.9.3 5.9.4 5.9.5 5.9.6 5.9.7 5.9.8 Creating Product Programs ......................................................................................5-10 Creating Macro Programs.................................
Table of Figures Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 System Configuration ......................................................................................................... 2-3 Tools Configuration............................................................................................................. 2-4 ID Systems Configuration................................................................................................... 2-5 ECXP Operator Screen ...............
Figure 5-18 Figure 5-19 Figure 5-20 Figure 5-21 Figure 5-22 Figure 5-23 Figure 5-24 Figure 5-25 Figure 5-26 Figure 5-27 Figure 5-28 Figure 5-29 Figure 5-30 Figure 5-31 Figure 5-32 Figure 5-33 Figure 5-34 Script Instruction ...............................................................................................................5-20 Selecting a Pattern ...........................................................................................................5-21 Calling a Procedure ....................
1 Introduction 1.1 Overview Welcome to Easy Coat® for Windows XP (ECXP). Easy Coat for Windows software is a Windows XP application specifically designed for use with Asymtek's Century selective conformal coating systems. This manual is an instructional guide designed for system operators, computer programmers, and process engineers. It provides a complete tour of the Easy Coat for Windows software with detailed explanations of all features. This section covers the following topics: 1.
1.5 ECXP Overview Easy Coat for Windows XP (ECXP) is Asymtek proprietary software for use in a Windows XP environment, developed specifically for conformal coating applications. Before the dispensing process can begin, the ECXP software must be installed and programmed to perform the necessary procedures. ECXP controls both the dispensing head (robot) movements and the dispensing operation in the conformal coating process. ECXP features include: 1.
Asymtek offers an automated solution to the conformal coating process by offering Automated Selective Coating. Unlike other methods, Automated Selective Coating achieves high throughput, dispensing consistency, and material savings with little or no masking. Asymtek Conformal Coating Systems are listed in Table 1-1.
2 Installation 2.1 Overview In most cases, ECXP should arrive already installed and configured for your dispensing system from the Asymtek factory. The installation process is a typical Windows XP installation with user prompts. " NOTE Refer to this section for first time installation only. Upgraded versions of ECXP include separate installation instructions. This section covers the following topics: 2.
2.4 ECXP Installation Procedure Most of the standard installation process is automated. You will be prompted to approve file locations and accept defaults. Since ECXP is a true Windows XP software package, installing ECXP follows standard Windows installation procedures. CAUTION! The ECXP installation procedure should be performed by trained personnel only. CAUTION! DO NOT attempt to install ECXP on a Windows 95 or Windows 98 Operating System. To install ECXP: 1.
2.5 ECXP Configuration The first time ECXP is run, a setup procedure runs, asking you to define your system hardware. Responses to each question are written to the ECW.INI file. If you change your system hardware or reinstall the software, use the Reconfigure feature to re-run the setup procedure. See 2.5.2 Reconfigure. " NOTE 2.5.1 " In most cases, ECXP arrives already installed and configured for your dispensing system from the Asymtek factory. Initial Setup Procedure NOTE 2.5.1.
2.5.1.2 Tools Configuration After you have defined your system, you will be prompted to define your tool (fluid applicator). See Figure 2-2. Figure 2-2 Tools Configuration Depending on the applicator and options selected, you will be prompted to respond to some or all of the following questions. 1. Does this applicator have tilt? 2. Does this applicator have rotate? 3. Does this applicator have incremental rotate (0, 90, 180, and 270 degrees)? 4. Does this applicator have a nozzle extension? 5.
2.5.1.3 Conveyor Configuration If you selected a conveyorized system, you will be prompted to answer the following questions about the conveyor. 1. Is your conveyor left to right? 2. Is this a chain conveyor? 3. Does this conveyor have clamps or pins in the dispense station? 4. Is there a sensor to detect that the product pins or clamps are engaged? 5. Do you have an inverter? 6. Is your inverter upstream? 7.
2.5.2 " Reconfigure NOTE If you change your system hardware or reinstall the software, use the Reconfigure feature to run the setup procedure. To reconfigure ECXP: 1. If necessary, install the ECXP software as instructed in 2.4 ECXP Installation Procedure. 2. Double-click the ECXP ! " icon on the Windows desktop to start ECXP. The ECXP Operator Screen shown in Figure 2-4 opens. NOTE The product program from the previous session opens when you start ECXP. Figure 2-4 ECXP Operator Screen 3.
Figure 2-5 ECXP Edit Screen 4. Select Configure > Reconfigure from the ECXP Edit Screen. ! The Configure Dialog box opens. See Figure 2-6. Figure 2-6 ECXP Configure Dialog Box 5. Select the item to be configured by clicking on it. ! To select more than one item, hold down the CTRL key while selecting additional items. 6. When you are finished, click on OK.
7. To close the ECXP Edit Screen and return to the Operator Screen, click on File > Exit from the Edit Screen menu bar. 8. To exit ECXP, click on or select or select File > Exit from the Operator Screen menu bar. 9. Restart ECXP to perform the configuration procedure. ! 2-8 Depending on the items to be reconfigured, you will be prompted to answer a series of questions. See 2.5.1 Initial Setup Procedure.
3 Tour of Easy Coat 3.1 Overview This section provides a tour of the unique Windows Graphic User Interface (GUI) of ECXP. In this section, you will learn how to start and exit ECXP. Both the Operator Screen and Edit Screen will be visited and explained in detail, along with all icons, toolbars, and message areas. You will find that the ECXP user interface was designed to utilize the simplicity and intuitiveness of Windows-based software. This section covers the following topics: 3.
3.4 Starting/Exiting ECXP To start/exit ECXP: 1. Double-click the ECXP icon on the Windows desktop. ! As an alternative, you may click on the Windows Start menu and select Programs > ECXP to start the ECXP software. ! The dispenser will find Home in the Z-axis, Y-axis, and X-axis, respectively. ! The ECXP Operator Screen shown in Figure 3-1 will open. " NOTE The Operator Screen will vary slightly depending upon system configuration (batch or conveyor).
3.5 Operator Screen The Operator Screen (Figure 3-2) contains all tools necessary to run production. You can load a program, run a program, and stop a program through the Operator Screen. In addition you can monitor events and system status. A brief description of the items on the Operator Screen is contained in Table 3-1. Detailed descriptions are addressed in other sections of the manual.
Table 3-1 Operator Screen Commands (continued) Command Run Product Exit Description Click to run program. Only present when ECXP is configured for a nonconveyorized (batch) system. Click to shut down ECXP software. Fault Monitor Displays warning or error messages with the last message received at the top. Silence Alarm Click to silence an alarm activated by a fault. Clear Faults Begin Idle Click to clear fault(s). Only clearable faults, such as a board failing to load, can be cleared.
3.5.1 Operator Screen Menu Bar Each item on the Operator Screen menu bar activates a drop-down menu (Figure 3-3). Some drop-down menu selections open dialog boxes. Drop down menus, along with a brief explanation of each menu, are listed in Table 3-2. If a menu item is light gray, it is not available at the present time. " NOTE File Exit Menu choices will vary depending on system configuration.
3.6 Edit Screen The Edit Screen (Figure 3-4) is used for creating and editing programs, configuring system hardware, and testing and adjusting system settings. The Edit Screen menu bar is shown in Figure 3-5. Menu bar options are described in Table 3-3. " 3.6.1 NOTE Menu choices will vary depending on system configuration. Opening the Edit Screen To open the Edit Screen from the Operator Screen: 1. If production is running, click on the Stop button to stop production.
3.6.2 Edit Screen Menu Bar File Edit Cut Copy Paste Del Run Import Board Images ► Print … Print Preview English Units Graphic Display Language Data Utilities Help Help … >Show Hints Copy Configuration to Disk ► ► Run Step Pause Stop F9 F8 Run Pattern Procedure F6 >Test Mode Exit Configure Macro Program Product Program Ctrl+X Ctrl+C Ctrl+V Ctrl+Del New Product Program Open Product Program … Save Product Program Save Product Program As … View Production . . . Product Map . . . Tools . .
Table 3-3 Edit Screen Menu Options (Continued) Menu Edit Item Cut Cuts the selected item and places it on the clipboard. The last item cut or copied to the clipboard can be pasted in another location in a program, pattern, or procedure. Copy Copies the selected item to the clipboard. The last item cut or copied to the clipboard can be pasted in another location in a program, pattern, or procedure. Paste Pastes the contents of the clipboard at the cursor location. Delete Deletes the selected item.
Table 3-3 Edit Screen Menu Options (Continued) Menu Item Description Log Click on Configure > Log to display the Log Configuration dialog box. This dialog box allows you select the Event, Warning, and Error messages displayed on the Event Monitor and written to the log file. Fixtures Configure Fixture refers to the location where products are physically constrained in the workcell. Click on Configure > Fixture to set the fixture constraint coordinates.
3.6.3 Edit Screen Toolbar The Edit Screen toolbar contains frequently used commands. The commands associated with each icon on the toolbar are identified in Figure 3-6. If the “Show Hints” option on the Help Menu is on, a tip will appear below each button as you move the mouse cursor over the toolbar. Toolbar commands are described in Table 3-4.
Table 3-4 Edit Screen Toolbar Commands (Continued) Button Create Mask Region Description Allows you to create a new Mask Region. A Mask Region is an area of the board that will not be coated. Refer to 5.5 Mask Regions for detailed instructions. Run Runs the loaded program. Step Steps through the loaded program. Each click of the button performs one instruction. Pause Stop Silence Alarm Pauses the current program. If a program is not running, this choice will be grayed-out (non-functional).
3.6.4 Edit Screen Tabs The Edit Screen is divided into a series of tabs. Tabs will vary depending upon your system configuration. Basic groups include: • • • • Conformal Coating Control General Motion Depending on your system hardware, additional tabs include: • • • • • A201 Conveyor Inverter Fan Width Control Needle Finder A201 Robot Each tab contains related buttons to assist you with inserting program commands into your conformal coating program. Basic tabs are shown in Figure 3-7.
4 Configuration and Characterization 4.1 Overview Your dispensing system is configured at the Asymtek factory prior to shipping. However, if any components have been changed or moved, it may be necessary to reconfigure them in ECXP. This section contains the following procedures: 4.
4.4 Tool Configuration A tool consists of a fluid dispensing applicator and nozzle. The Tool Configuration dialog box allows you to set the offset for each tool and perform a characterization. 4.4.1 Tool Offset Tool Offset is the X, Y, and Z distance from the lower tooling pin on the Z-slide (also called the tool flange, or tool arm) to the tool tip (end of nozzle). See Figure 4-1.
To define Tool Offsets: " NOTE Before defining tool offsets, see the warning on Page 4-2 1. Click on Configure > Tools from the Edit Screen menu bar. ! The Tool Configuration dialog box opens. See Figure 4-2. Figure 4-2 Tool Configuration Dialog Box 2. Select the tab for the tool to be configured. 3. Enter the appropriate Tool Offsets for the X, Y, and Z fields. ! 4.4.1.1 Since the tool tip is in front of and below the tooling pin, the Y and Z offsets are always negative.
4.5 " Characterization NOTE A characterization must be performed for each tool and each coating material used or as required to ensure quality and consistent dispensing. Many variables, such as material type, temperature, viscosity, substrate type, robot velocities, and dispenser response times affect the coating process. Characterization improves coating placement accuracy and repeatability. The Characterization Wizard helps you adjust program values to compensate for these variables.
2. Click Clear Positions and then click OK to confirm. • If you have performed a characterization before, the old test area coordinates are used unless you clear them. 3. Click Next. 4. Click Yes when prompted to teach the substrate height. 5. Teach the substrate height. a. Install a nozzle on the fluid dispensing applicator and lower the tool until the tip just touches the substrate. b. Click Teach Z. c. Click OK. 6. Enter the dispense height.
10. Position the tool tip over the left intersection of the dotted lines and click Next. 11. Position the tool over the right intersection of the dotted lines and click Next. 12. Position the tool tip over the right dotted line and the back line and click Next. ! Remove any teaching devices before continuing. 13. Click Next. ! The Wizard will now apply three stripes of material to the test area (See Figure 4-5).
4.6 Fixture Configuration Fixture refers to the location at which products are physically constrained in the workcell. It consists of both position (XYZ) coordinates and a corner constraint (Front Left, Front Right, Back Left, or Back Right). On conveyorized systems, the fixture is typically the combination of a clamp and a stop. On nonconveyorized systems, it is usually a manual fixture. 4.6.
To configure a fixture: " NOTE Before configuring the fixture, you must configure the Tool Offsets. Refer to 4.4 Tool Configuration for detailed instructions. 1. To configure a fixture, click on Configure > Fixtures from the ECXP Edit Screen. ! The Fixture Configuration dialog box shown in Figure 4-7 opens. Figure 4-7 ECXP Fixture Configuration 2. Click on the tab for the fixture you are configuring. ! There will be a separate tab for each fixture configured in ECXP.
5. Install the nozzle on the fluid dispensing applicator. The nozzle must be installed in order to accurately teach the Z-coordinate. See Figure 4-8 for coordinate location. a. To teach the Z-coordinate, carefully lower the nozzle until it is just touching the surface of the board (Z-coordinate on the Side View). b. Click on the Teach Z button. X-Axis X Y-Axis Top View Z-Axis Y Z Side View Figure 4-8 Teaching XYZ Coordinates 6. Click on Close when done.
4.7 Conveyor Configuration To configure the conveyor: 1. Click on Configure > Conveyor Settings from the ECXP Edit Screen. ! " The Conveyor Settings dialog box shown in Figure 4-9 opens. NOTE The Conveyor Settings dialog box also contains inverter configuration settings. See 4.8 Inverter Configuration later in this section. 2. Enter the desired property values. ! See Table 4-1 for a description and default value for each property. 3. Click OK when done.
Table 4-1 Conveyor Settings Property Description Default Value Belt Acceleration Rate at which the conveyor belt accelerates. 98.4 in./sec Belt Speed Speed at which the conveyor belt moves. 98.4 in./sec Blind Unload If True, only one attempt is made to unload the board to the downstream machine. If no SMEMA acknowledgement is received, then production continues. If False and no SMEMA acknowledgement is received, an error occurs and production stops.
4.8 " Inverter Configuration NOTE You may configure the Inverter through the Conveyor Configuration dialog box or through the Reconfigure function. The recommended method is through the Conveyor Configuration dialog box. If you use the Reconfigure function, all conveyor settings are reset to the factory defaults. You will need to restore any customized settings. The following procedure uses the Conveyor Configuration dialog box. The Reconfigure method is detailed in 4.14 Reconfiguring System Hardware.
4.9 Robot Configuration The Home position of the robot is a known position within its workspace defined by X, Y, and Zcoordinate limit switches. When the robot is at the Home position, the coordinates of the tool flange in the Base Frame are X=0, Y=0, Z=3.5 inches. The Z-axis is all the way up in the Home position, and all the way down when at the origin position. See 5.7 Reference Frames for additional information.
4.10 Beacon Configuration The behavior of the light beacon can be customized to respond to the I/O states of customer equipment added to the system. Beacon configuration is only turned on if both Custom System and Configurable Beacon options are chosen during initial system configuration or reconfiguration. A separate beacon.ini file is used to store the beacon configuration settings. The operation of the beacon depends on the machine firmware.
d. Click on the Fault Color field and select a color. ! This is the color of the Fault Message displayed on the Fault Monitor. e. Click on the Trigger Message field and select a trigger for the fault from the dropdown menu or type in a fault log message. f. Click on the Clear Message field and select the event that clears the message from the dropdown menu or type in a fault log message. 4. Create a Subsystem. a. Click on Configure > Status Monitoring > Beacon Configuration > Subsystems. b.
4.11 Fan Width Configuration If your system is equipped with the optional Laser Fan Width Control feature, you will need to perform a Fan Width Setup. For additional information, refer to the manual for your Fan Width Control System or contact your Asymtek representative. To perform a fan width setup: 1. Select Configure > Fan Width Setup > Toolname from the ECXP Edit Screen. ! The Fan Width Control configuration window (Figure 4-13) opens. 2. Enter the desired values.
Table 4-3 Fan Width Control Configuration Window Options Category Item Sensor Fixture Rotation Use 0 degrees for laser beam parallel to Y-axis, 90 degrees for laser beam parallel to X-axis. XYZ Values Displays the X, Y, and Z-coordinate captured during the Find Nozzle End routine. These values CANNOT be typed in manually. Sensor Setup Establishes the threshold of the amplifier that is used for detecting the edge of the fan pattern. This button runs the FWC Sensor Setup macro in the Macro1.ecm file.
Table 4-3 Fan Width Control Configuration Window Options (Continued) Category Item Description Control Width Pressing this button will first run the Locate Nozzle End instruction and update the XYZ nozzle position. After the nozzle is successfully located, the Control Width algorithm will start to run. The Control Width will automatically adjust the fluid pressure until the target width (Width In Air) is achieved.
4.11.1 FWC Sensor Setup As part of the Fan Width Setup procedure, you will need to perform a FWC Sensor Setup. ECXP contains a macro to automate this procedure. See Figure 4-15. Refer to the Laser Fan Width Control Users Guide for step-by-step instructions. Figure 4-15 FWC Sensor Setup Procedure in Macro1 The FWC Sensor Setup procedure in Macro1.ECM is used to set the trip point of the amplifier. The routine moves the applicator to an appropriate X, Y, and Z position over the drain pan.
4.12 Needle Finder Configuration Needle-type nozzles are easily damaged or frequently changed. The Needle Finder option locates the current location of the needle tip, compares the current location with the last measured location, and adjusts the tool offset to maintain consistent dispensing results, prevent quality problems, and reduce scrap. The needle finder support in ECXP includes two programming instructions, Find Needle and Check Needle.
4.12.2 Dual Applicators (Only One Fits in Needle Finder) 1. Click on Configure > Needle Finder Setup to open the Needle Finder Setup dialog box (Figure 4-16). 2. Set the Tool Offset for the applicator that doesn't fit into the needle finder (large applicator) to a nominal value. 3. Click on the Teach Relative button on the Tool Configuration dialog box to set the offset for the small applicator, using the large applicator as the reference tool. See 4.4.1.1 Dual Applicators/Needle Finder. 4.
4.13 Bar Code Scanner Configuration Bar code scanners can be used to load product programs. If your system is equipped with the optional bar code scanner, you will need to perform a scanner configuration. For additional information, refer to the manual for your particular scanner or contact your Asymtek representative. 4.13.
8. Click on the Protocol tab. 9. Set Selected Protocol to Point-to-Point and check the RTS/CTS box. 10. Enable the Postamble and set it CR and LF. 11. Click on the Output tab. 12. Set the Beeper status to On Noread. Choose Volume Level 5. 13. Click on the Apply button on the bottom of the window. ! The Save window opens. 14. Click on Send/Save. 15. Click on OK. 16. Click the Send/Recv button and then on the Receive From Scanner button to obtain the scanner's settings.
4.13.3.2 Wildcard Multiple Match Scoring When wildcards are used, ECXP scores multiple matches depending on the number of characters matched. The match with the highest score is selected. When the scoring results in a tie, an error is generated. " NOTE Wildcard characters are configurable. To change the wildcard characters, you must edit the following entries in the [IDSystemManager] section of the ECW.INI file. MultipleLetterWildCard = * SingleLetterWildCard = ? 4.
4.15 Production Configuration 4.15.1 Setting Idle Timers Idle procedures are Begin Idle, During Idle, and End Idle. These procedure names are reserved. They are executed based on the Idle Timer settings in the Production Configuration dialog box. These procedures allow a sequence of maintenance operations to be performed whenever products are not being coated. Only an error or operator-initiated stop prevents the idle procedures from executing.
To add Periodic Timers: 1. Click Configure > Production from the ECXP Edit Screen. ! The Configure Production dialog box opens. 2. Click on the Add Periodic Task button. ! A new sequentially numbered Periodic Timer will be added to the list. To set Periodic Timers: 1. Click on Configure > Production from the ECXP Edit Screen. ! The Production Configuration dialog box opens. See Figure 4-17. Figure 4-17 Production Configuration Window 2. Click on the Periodic Timer you wish to set from the list.
4.15.3 AutoStart The AutoStart feature allows ECXP to start production without operator intervention. The AutoStart Delay Timer starts when ECXP finishes loading and prevents production from starting until the timer runs out, giving the operator a chance to cancel the AutoStart. To enable AutoStart and set a delay: 1. Click on Configure > Production. ! The Configure Production dialog box appears. See Figure 4-17. 2. Click on AutoStart. ! A check mark appears in the box when AutoStart is enabled. 3.
4.17 Product Map Configuration The Product Map is a file manager that makes only production-ready product programs available to the operator. The actual file names and paths are hidden. Only part numbers or names assigned to the program files are displayed. The Product Map (Figure 4-18) appears when you click the Change Product button on the Operator Screen.
4.17.1 New Group A group appears as a folder in the Product Map. To create a new group: 1. Select the Product Map folder. 2. Click on the New Group button (Figure 4-19) and enter the group name in the New Group field. To create a new group inside a group: 1. Select a group folder. 2. Click on the New Group button and enter the new group name in the New Group field. 4.17.2 New Part This allows you to assign a logical name to a product program. This is the name the operator will see when loading a program.
4.18 Maintenance Manager To ensure that required maintenance is done on schedule, programmers can create a maintenance program and configure the Maintenance Manager in ECXP to remind the operator of the required maintenance. The Maintenance Manager displays a reminder for the operator at the beginning of the next production run following the expiration of the configured time period.
Figure 4-21 Adding/Deleting Maintenance Procedures Table 4-5 Maintenance Manager Menu Options Command Time Period Units Delete Add Message Name Section Key Description Recommended frequency of selected procedure. Procedure frequency may be entered in weeks, days, hours, minutes, or seconds. Deletes the selected procedure from the Maintenance Manager. Adds a new procedure to the Maintenance Manager. Message displayed to operator when timer has expired. Procedure name. Identifies the section of the ECW.
To add a procedure to the Maintenance Manager: 1. In the ECXP Edit Screen, select Configure > Maintenance Manager. 2. Click on Advanced. 3. Click on the Name drop-down list and select New Item. 4. Enter the time period, units, message, name, section, and key. 5. Click on OK. Table 4-6 Adding a Maintenance Procedure To delete a maintenance procedure: 1. In the ECXP Edit Screen, select Configure > Maintenance Manager. 2. Click on Advanced. 3. Select the procedure from the Name drop-down list. 4.
4.19 Custom Buttons This feature allows you to add custom buttons to the Operator Screen and Edit Screen to execute procedures you create. To create a custom button: 1. Start ECXP and select Edit > Edit Mode to open the Edit Screen. 2. Select Configure > Custom Buttons from the menu bar. 3. Select Operator Screen or Edit Screen to choose where you want the button to appear. ! A dialog box opens that allows you to enter the text you want to appear on the button. See Figure 4-22.
5 Programming 5.1 Overview This section introduces you to the fundamental dispensing commands that form the foundation for all conformal coating programs. Program commands are accessed from the ECXP Edit Screen. " NOTE You should complete Section 4 - Configuration and Characterization before attempting the exercises in this section. This section covers the following topics: • • • • • • 5.
5.3.2 Opening a Product Program When you start ECXP, the product program from the previous session opens. Follow the instructions below to open a new product program. To open a product program: 1. Start ECXP and select Edit > Edit Mode to open the Edit Screen. 2. Click on View > Product Program to make sure you are in the product program view. ! A check mark next to an item indicates the current view. 3. Click on Open ! or select File > Open Product Program from the menu bar.
5.3.4 Opening a Macro Program When you start ECXP, the macro program from the previous session opens. Follow the instructions below to open a new macro program. To open a macro program: 1. Start ECXP and select Edit > Edit Mode to open the Edit Screen. 2. Click on View > Macro Program to make sure you are in the macro program view. ! A check mark next to an item indicates the current view. 3. Click on Open ! or select File > Open Macro Program from the menu bar.
5.4.1 Main Pattern When you create a new product program, the Main Pattern is automatically created. When you run a product program, the Main Pattern is executed. Each program must have a Main Pattern, and each Main Pattern must have at least one instruction. To execute other patterns in the program, insert Place Pattern instructions in the Main Pattern. See 5.9.7 Placing Patterns. 5.5 Mask Regions Mask Regions are areas on the board that should not be coated.
The Begin Idle, During Idle, End Idle, and Periodic procedures are used in product or macro programs to program idle and periodic behavior. They are executed by the Begin Idle, End Idle, and Periodic buttons on the Operator Screen and Edit Screen. See 5.6.1.1 Idle Behavior and 5.6.1.3 Periodic Behavior for additional information. Periodic1 to PeriodicN procedures execute based on their timers only. To use Periodic1 to PeriodicN procedures, you must create procedures with the same names.
5.6.1.1 Idle Behavior Idle behavior is defined by the instructions in the Begin Idle, During Idle, and End Idle procedures. These procedures allow a sequence of operations to be performed whenever products are not being coated. These procedure names are reserved and can only be used for idle behavior. Only an error or operatorinitiated stop prevents the idle procedures from executing. " • The Begin Idle procedure is executed when the Idle Timer expires. The timer starts when production stops.
5.6.1.3 Periodic Behavior Periodic behavior is defined by the instructions in the Periodic procedures. These procedures allow a sequence of operations to be performed periodically during production. The procedure names are reserved and can only be used for periodic behavior. Periodic procedures are named Periodic, Periodic1, Periodic2, Periodic3, etc. A Periodic procedure is executed when its periodic timer expires.
5.7 Reference Frames All positioning in the workcell is done with reference to sets of position coordinates, called Reference Frames. In ECXP, three different sets of reference frames are used: Base Frame, Product Frame, and Pattern Frame. See Figure 5-4. As you face the front of the workcell, the X-axis is left to right, the Y-axis is front to rear, and the Z-axis is up and down. The X, Y, and Z limit switches at the front left corner of the Base Frame define the Home or Origin position of the robot.
5.7.3 Pattern Frame The origin coordinates of patterns (See Figure 5-4, Rectangle C) other than the Main Pattern are expressed as a set of coordinates in the Product Frame. The pattern origin coordinates are stored in the Pattern Edit Frame when the pattern is created. 5.8 Properties Every program, pattern, procedure, mask region, and instruction has properties. Properties include items such as the fixture, pattern coordinates, and instruction approach height, etc.
5.9 Creating a Program All programming is done in the ECXP Edit Screen. The Edit Screen is used to create and edit both product and macro programs. 5.9.1 Creating Product Programs To create a new product program: 1. Start ECXP and select Edit > Edit Mode to open the Edit Screen. 2. Click on View > Product Program to make sure you are in the product program view. 3. Click on New ! or select File > New Product Program. The New Program dialog box shown in Figure 5-6 opens.
" NOTE Every program contains a Main Pattern, which consists of an Edit Frame and a Mask Regions pattern. See Figure 5-7. Figure 5-7 Untitled Program 7. Make sure the Main Pattern Edit Frame was calculated correctly: a. Expand the properties of the Main Pattern, then click on the Main Pattern Edit Frame. b. Click on the GoTo " button. ! The applicator should travel to the front left corner of the product or pallet if the length and width and fixture configuration is correct.
5.9.2 Creating Macro Programs To create a new macro program: 1. Start ECXP and select Edit > Edit Mode to open the Edit Screen. 2. Click on View > Macro Program to make sure you are in macro program view. ! A sample macro program named Macro1.ECM is furnished with ECXP. It contains blank, programmable Begin Idle, During Idle, End Idle and Periodic procedures, plus preprogrammed Go to Front and Z Home procedures. See Figure 5-8. Figure 5-8 Creating a Macro Program 3. To create a copy of Macro1.
5.9.3 Creating a Pattern All coating and maintenance instructions must be placed in patterns and procedures. To create a new pattern: 1. Move the tool tip to the desired origin point of the pattern (preferably at the front left corner of the board, so all the coordinates are positive). ! The origin point will establish the 0,0,0 coordinates of the pattern for editing and teaching purposes and should be easily recognized for Step and Repeat purposes. 2.
5.9.3.1 Inserting Program Instructions To insert a program instruction into a pattern: 1. Make sure the pattern name is highlighted. ! Available patterns are listed in the left pane of the Edit Screen. If patterns are not displayed, click on the plus (+) sign next to Patterns. 2. Click on the desired instruction button to insert the instruction into your pattern. " ! NOTE The instruction will be inserted above the cursor location. Coating instructions are categorized by tabs on the Edit Screen.
" NOTE When you create an instruction, the tool shown in the Current Tool Selector is entered into the tool property of the instruction. The current tool tip coordinates are entered into the first set of coordinate properties (Begin X and Y properties) with the exception of the Spot instruction. See Figure 5-11. 3. To change tools, click on List button in the Tool Property field and select a new tool. 4.
Exercise 5-3: Creating a Pattern and Inserting Program Instructions 1. Create a new product program as described in 5.9.1 Creating Product Programs. 2. Create a new pattern named “Rectangle” as described in 5.9.3 Creating a Pattern. 3. Make sure the Rectangle pattern is highlighted. If not click on it. 4. Click on the Conformal Coating tab. 5. Click on the Area Coat button. 6. Move the tool to the starting point of the rectangle and click the Teach ! button.
5.9.4 Creating a Mask Region To create a Mask Region: 1. Start ECXP and select Edit > Edit Mode to open the Edit Screen. 2. Make sure the desired product program is open. If not, open it. 3. Move the tool tip to the first corner of the mask region you are going to create. 4. Highlight the pattern where you want to create a Mask Region. 5. Click on the Create Mask Region ! button on the toolbar. A mask region is created in the pattern's Mask Regions section, with the name New Mask Region.
5.9.5 Creating a Procedure To create a procedure: 1. Start ECXP and select Edit > Edit Mode to open the Edit Screen. 2. Make sure the desired product or macro program is open. If not, open it. 3. Click the New Procedure ! button on the toolbar. A new blank procedure will be created. See Figure 5-14. Figure 5-14 Creating a Procedure 4. Enter a procedure name in the property section. ! DO NOT use reserved procedure names. See 5.6.1 Reserved Procedures. 5.
Exercise 5-4: Creating a Procedure 1. Click the New Procedure ! button on the toolbar. A new blank procedure will be created. See Figure 5-14. 2. Click on the Name Property Field and name the procedure “Abort Program.” See Figure 5-15. Figure 5-15 Naming a Procedure 3. Insert an Abort Program instruction. a. Make sure the Abort Program procedure on the left panel of the screen is highlighted. If not click on it. b. Click on the General tab. c. Click on the Abort Program ! instruction.
5.9.6 Creating a Maintenance Procedure When creating a new maintenance procedure, you should first define it in the Maintenance Manager, setting the name, time period, section, and key. See 4.18 Maintenance Manager. A maintenance procedure is created like any other procedure, however an Ini File Write instruction must be included in the Main Pattern (Figure 5-17). This instruction writes the key and the time and date stamp to the ECW.ini file.
5.9.7 Placing Patterns All patterns except the Main Pattern are executed by the Place Pattern instruction. The Main Pattern is executed when the program is run and all program instructions are executed from the Main Pattern. Mask Regions do not need to be placed since they are associated with a particular pattern. The Main Pattern is placed at the Product Frame origin, which is the front left corner of the workpiece. See 5.7 Reference Frames. To place a pattern: 1. Highlight the Main Pattern.
5.9.8 Calling Procedures After you have created your procedures, you must place a Call Procedure instruction in a pattern to run a procedure. To call a procedure: 1. Highlight the pattern or procedure in which you want to place the Call Procedure instruction. ! One procedure can call another. 2. Click on the Call Procedure button to create the instruction. 3. Click on the List button in the Procedure Name property field, and select the procedure you want to call.
5.11 Editing Programs You can make the following modifications to programs: " • Create new patterns or procedures. • Create new instructions. • Create New Mask Regions or modify Mask Region coordinates. • Modify existing instructions by teaching new coordinates or altering values in instruction property fields. • Cut, copy, paste, delete, and move patterns, procedures, and instructions. NOTE You cannot delete the Main Pattern from a product program.
5.12 Printing Programs If you have a printer connected to your computer, you can print loaded product and macro programs. To view the print results before sending a program to print, click on File > Print Preview. To print from the Print Preview window, click on the printer icon at the top of the window. To print a program, click on File > Print.
5.13.2 Creating Images The Graphic Display supports JPEG and BMP formats only. Image files can be created with a digital camera or exported from CAD programs. Bitmap resolutions of 640 x 480 or 800 x 600 are sufficient for most purposes. Higher resolutions result in larger file sizes, which could cause slow refresh rates in ECXP. If you use a digital camera to create board images, place the boards on a light background before taking pictures.
To crop an image: 1. Drag three corner handles to their respective corners of the board, aligning the cursor crosshairs with the corners. For more precise handle placement, click inside the magnified crosshair window. See Figure 5-21. Clicking near the corner of the board will snap it to the crosshairs. Each time you drag a handle to a corner of the board, the image of the board is redrawn. 2. Hold down the [Ctrl] key before clicking and dragging the last corner.
5.13.5.2 Zooming 1. To zoom in, left-click on the image and drag down and to the right. ! The area surrounded by the marquee will be magnified. 2. To zoom out, left-click on the image and drag up and to the left. Figure 5-22 Zooming In Figure 5-23 Zooming Out 5.13.5.3 Resizing The Graphic Display can be resized without undocking it from the Edit Screen by left-clicking and dragging the top and left edges. Drag the edges of the undocked Graphic Display to resize it. To resize an image: 1.
5.13.5.4 Undocking/Redocking Undocking places the image in a separate window and provides greater flexibility for enlarging and zooming in on the image. To undock an image: 1. Move the cursor to the undocking bar. ! The undocking bar is represented by the two vertical lines on the left border of the Graphic Display. See Figure 5-25. 2. Left-click and drag to undock the Graphic Display from the Edit Screen. 3.
To redock the Graphic Display: 1. Click on the title bar and drag it toward the bottom left corner of the Edit Screen. ! When positioned correctly, a gray receiving area appears. See Figure 5-28. 2. Move the title bar toward the upper-left corner of the receiving area until the Graphic Display snaps into place.
5.13.6 Using the Graphics Display for Programming After you have imported your image, you can use it to create your dispensing program. This is useful when you are creating programs on a computer that is not connected to a coating system. To create a program using graphics display: 1. Start ECXP and select Edit > Edit Mode to open the Edit Screen. 2. Click on View > Product Program to make sure you are in the product program view. 3. Click on New or select File > New Product Program from the menu bar. 4.
Exercise 5-5: Creating a Program with Graphics Display 1. Open the ECXP Edit Screen and click on View > Product Program to make sure you are in the product program view. 2. Click on New or select File > New Product Program from the menu bar. 3. Enter the length and width of the product in the New Program dialog box as shown in Figure 5-30 and click OK. Figure 5-30 Entering Product Length and Width 4. Import and crop the board image entitled Sample12.jpg. See 5.13.3 Importing Images and 5.13.
7. Click OK. 8. Undock the Graphic Display as described in 5.13.5.4 Undocking/Redocking. 9. Click on the “Side 1” pattern. 10. Click on the Conformal Coating tab and then on the Area Coat ! button. The Graphics Display reappears. 11. Move the cursor to the start point of the area on the graphics image to be coated and press the key and left-click the mouse. 12. Move the cursor to the end point and press left-click again. 13. Repeat Steps 10 through 12 and coat another section of the board.
5.13.7 Using Graphics Display to Program Both Sides of a Board Program images are imported with File > Import Board Image > First Side > Second Side. The Second Side is used when the board or pallet is inverted. If you import both First Side and Second Side images, both images will be displayed in the Graphics Display simultaneously only when you have the Main Pattern selected and an Invert instruction is present in the Main Pattern. Only the First Side image is displayed on the Operator screen.
5. Undock the image and enter pattern instructions for “Side 1.” See 5.13.6 Using the Graphics Display for Programming. 6. Click on Save . 7. Repeat Steps 2 to 6 for the second side of the board. Replace “Side 1” references with “Side 2”. " NOTE For most applications, you will only use one image, imported with the Image Name 1 property. The only time you will import an image with the Image Name 2 property field is if you have an Invert instruction in the pattern. 5.13.7.
5.14 Advanced Programming Concepts 5.14.1 Delta Changes A Delta Change is an incremental change to a floating-point (numerical) value in a program. To make a Delta Change to a property value, select the value, then enter the change symbol twice, plus the incremental value, and press Enter. • • • • Add: ++ Subtract: -- (two hyphens) Multiply: ** Divide: // For example, to add 2 to a value of 2. 1. Select the property value (highlight the value). 2. Type ++2. 3. Press Enter. 5.14.
6 Troubleshooting 6.1 Overview If you have difficulty running your coating programs, use this section to identify a possible solution to the problem. If you have difficulties not listed in this section, or the suggested solution does not correct the problem, contact Asymtek Technical Support. This section covers the following topics: 6.
6.3 " 6.3.1 Programming Errors NOTE Most errors usually take place during programming, with the exception of conveyor errors and Fan Width Control errors. Program Does Not Run With the Edit Screen open, an error will cause a dialog box to display “Program had Error.” See Figure 6-3. In most cases ECXP will toggle to the procedure or pattern with the error and will mark the instruction that caused the error with a blue arrow. Click OK and then switch to the Operator Screen to view the Event Monitor.
6.3.2.1 Not Found Errors If ECXP fails to find a procedure or pattern, it displays an error message that includes the name of the procedure or pattern not found. This error message occurs: • If the procedure called by a Call Procedure instruction is not in the loaded macro program. • If a Place Pattern or Call Procedure instruction was not included in a pattern or procedure. • If a Place Pattern or Call Procedure instruction was inserted without selecting a pattern or procedure to place or call.
6.4 GoTo Errors If the applicator will not perform a GoTo command: 1. Check the system Safe Z Height (Utilities > Robot). The system Safe Z Height is used before executing anything while in the Edit Screen. The Safe Z Height value in most configurations will be a negative number. 2. Check to make sure the Tool Flange is not selected in the Current Tool Selector. The Tool Flange is the Tool 0,0,0. If the Tool Flange is selected, select another tool, then click GoTo again. 3.
6.7 Fan Width Control Errors The Fan Width Control option has sensors that detect and measure the fan pattern and fluid pressure controls to adjust fan width and keep it within programmed tolerances. The fan width instructions can be included in procedures or programs to periodically measure and control the fan width. Fan width tolerances are set by the programmer with Error and Warning offsets during the Fan Width configuration procedure (Configure > Fan Width Setup).
Appendix A Instruction Quick Reference Overview This appendix provides a brief description of all ECXP program instructions grouped by category. Refer to Appendix B for detailed information on program instructions, instruction properties, and syntax. Tab A-201 Conveyor Button Instruction Description Send ACL Sends an ACL command to the Conveyor Controller. Coat Specifies a single coating pass, in a straight line. Begin and end coordinates must be specified.
Tab Button Instruction Repeat Control (Continued) Fan Width Control Inverter Instructions between Repeat and End instructions are executed a set number of times. Creates a loop between the Repeat instruction and the End instruction. While Instructions between a While and an End instruction are executed as long as the While condition is True. Creates a loop between the While instruction and the End instruction. Pattern Array Repeatedly places a pattern on a rectangular grid.
Tab Button Instruction Description Terminate Program Ends program with error (returns False to Robot Controller). Can be used to stop program. If this instruction is executed during production, production will be stopped with a "Coating program had error" message. Add Fault Use this instruction to add a clearable fault message to the operator display. This instruction is typically used in user-created error handling procedures, which have no pre-programmed fault messages.
A-4 Appendix A - Instruction Quick Reference
Appendix B Instruction Properties Overview This appendix alphabetically lists all ECXP program instructions, descriptions, syntax (if applicable) and instruction properties. Abort Program Description: Ends program with error (returns False to Robot Controller). If this instruction is executed during production, production will be stopped with a "Coating program had error" message. Properties: Property Log Message Description Enter the text message to appear in the Log.
Property Description Begin Y Y coordinate where dispensing begins. End X X coordinate where dispensing ends. End Y Y coordinate where dispensing ends. Midpoint X X coordinate that determines radius of arc. Midpoint Y Y coordinate that determines radius of arc. Depart Height Depart end motion position with tool tip no lower than this height. If Depart Height is greater than dispense height, then tool tip is moved to Depart Height after dispensing is completed.
Property Description Depart Height Depart end motion position with tool tip no lower than this height. If Depart Height is greater than Dispense Height, then tool tip is moved to Depart Height after dispensing is completed. Use to avoid collisions with components on board. Dispense Height Distance from tool tip to substrate while dispensing.
Property Description Depart Height Default = None. Depart end motion position no lower than this height. If value is set to None or less than Dispense Height, it is ignored. Use to avoid collisions with components on board. Dispense Height Default = Height determined while running characterization for tool selected for this instruction. Distance from tool tip to substrate while dispensing.
Check Needle Description: Checks if a needle has moved. This could be in a periodic procedure to detect collisions with out-of-place components or improperly loaded boards. Properties: Property Description Error Procedure Name Name of the procedure to call if the preset error tolerance is exceeded. Click on the List button in the property field to select from a list of the procedures in the currently loaded programs.
Property Description End Y Y coordinate where dispensing ends. Ignore Masks Default = False (No). If True (Yes), then material dispensed even if specified coordinates fall within a Mask Region. Pass Width How wide the pass will be. Rotate Default = Rotate position when instruction created. Number of degrees to rotate tool before dispensing. Not supported by all tools. Start Distance Default = Automatic. Distance to accelerate after dispensing.
End Flow Measurement Description: This instruction stops measuring the flow of coating through the flowmeter, and checks the flowmeter counts against the minimum and maximum volume property settings. This instruction is only available if the flowmeter option is installed and configured in ECXP. The amount dispensed is logged and stored in the production database, which can be accessed by selecting View > Data > Flow Monitoring from the Edit Screen.
Fan Width Description: Measures and controls fan pattern width. Because this process takes time, this instruction should only be included in a periodic procedure in a macro program. A faster alternative is the Fan Quick Check instruction. Properties: Property Control Width Description Default = True. If set to True, the fan width is measured and controlled by adjustments to fluid pressure. Warning or error messages are only be generated if fan width cannot be adjusted to within tolerances.
Find Needle Description: Updates the offsets of a needle. This would normally be done after a needle change so ECXP can learn the position of the new needle. Properties: Property Description Error Procedure Name Name of the procedure to call if the preset error tolerance is exceeded. Click on the List button in the property field to select from a list of the procedures in the currently loaded programs.
Log Message Description: Allows programmer to send a message to the log file when a specified event occurs. May be used to log product completion times to evaluate production timing and lapse times. Properties: Property Description Event Level Event, Warning, Error. Log Message Message string. Move Relative Description: Moves the tool the specified X, Y, and Z distances from current position. Properties: Property X, Y, Z Description Target coordinates, expressed as relative to current position.
Property Description Rows Number of rows in grid. Serpentine Default = True. If set to True, move in a serpentine pattern. If set to False, begin each pass (across row or column) on same side of grid. X Placement X coordinates of first pattern placement. Y Placement Y coordinates of first pattern placement. Z Placement Z coordinates of first pattern placement. Pause Description: Allows the programmer to pause a program and display a message on the screen while waiting for user input.
Prompted Log Description: Allows programmer to stop production and request that the operator enter a message. This message is written to the log file and displayed in the Event Monitor, just like a regular log message. The request is displayed as a dialog box, with OK and Cancel buttons. For example, if you want the operator to enter the serial number of each board coated, create a Prompted Log instruction as the first instruction in the Main Pattern.
Rotate Tool Description: Rotates the tool in 90-degree increments. Only supported by the Select Coat 4-axis or 5-axis dispenser. Properties: Property Description Rotate (deg) Number of degrees to rotate the tool. Rotation is in 90-degree increments. If a value less than 90 but greater than 45 is entered, the tool is rotated 90 degrees. If a value less than 45 degrees is entered, the tool is not rotated. The rotate cycle is absolute, not relative.
Set Outputs Description: Sets digital outputs. Properties: Property Outputs Description Output number and condition setting. Positive = True, Negative = False. A More button appears in the property field. Clicking on this button displays the Set Outputs Conditional Edit dialog box for the instruction. Use the dialog box to set outputs for the Set Output instruction. True is on, False is off, Don't Care leaves the output in its current state. Outputs for each tool are set in the ECW.INI file.
Property Description Ignore Masks Default = False (No). If set to True (Yes), then material is dispensed even if specified location falls within a Mask Region. Rotate Default = Rotate position when instruction created. Number of degrees to rotate tool before dispensing. Not supported by all tools. Tilt Default = Tilt position when instruction created. Number of degrees to tilt tool before dispensing. Not supported by all tools.
While Description: Pauses program for a specified period of time. Syntax: WHILE [Instructions] END Properties: Property Condition Description The condition to evaluate can only be True, False, or IOState. If True, execute instructions. This is used for testing the dispensing program. If False, either do nothing or execute conditional Else instructions. Also used for testing product programs.
Glossary AutoStart: The AutoStart feature allows ECXP to start production without operator intervention. Bar Code Recognition System: The Bar Code Recognition System uses a bar code label mounted on the workpiece to select a coating sequence. Beacon Configuration: The behavior of the light beacon can be customized to respond to the I/O states of customer equipment added to the system.
Home: The Home position of the Robot is a known position within the workspace defined by X, Y, and Z coordinates. It is generally located at the front left of the Workcell. Icons: Small buttons on a Computer screen with a symbol representing the function that they perform. Used to execute a menu shortcut.
SC-200 Slim Swirl Applicator: Asymtek Fluid Applicator that uses slim swirl 12-hole nozzles to apply materials that do not required heating in a bead, monofilament, or swirl pattern. System Status LEDs: Located on the Control Panel, the LED’s are color coded for each System Status condition. The colors correspond with the colored lights on the Light Beacon.
IIndex A AutoStart....................................................................... 4-27 B Bar Code Scanner configuration............................................ 2-5, 4-20–4-24 MS810 ..................................................................... 4-22 PSC5312 .................................................................. 4-22 Bar Codes wildcard characters .................................................. 4-23 Base Frame ..................................................................
Main Pattern ................................................................... 5-4 Maintenance Manager.......................................... 4-30–4-32 adding procedures .................................................... 4-32 deleting procedures .................................................. 4-32 Maintenance Procedure................................................. 5-20 creating .................................................................... 5-20 Mask Regions ...............................
T Timers idle .................................................................... 4-25, 5-6 periodic .................................................................... 4-25 Toggle Breakpoint ........................................................ 5-35 Tool configuration....................................................... 2-4, 4-2 Tool Offset............................................................... 4-2–4-3 dual applicators ..........................................................
