JRT Operating Instructions SPL DSP2Typ:DSP2 Machine no.:DSP2 Year of construe:2008JRT Photovoltaics GmbH & Co. KGRobert-Bosch-Str. 1 D-79331 Teningen Tel.: +49(0)7641 / 583-0 Fax: +49(0)7641 / 583-110www.jrt-pv.deGermany Operating InstructionsSolarprinter SPLJRT Operating Instructions SPL DSP2Basic instructionsBasic instructionsThese Operating Instructions describes the JRT Solar Printer Line DSP2.This is intended as a provisional document. A detailed and thoroughversion of the technical documents will be provided on delivery of thecomplete system.These SOP are a constituent part of the system. They must always bekept in the proximity of the system. Strict observation of the SOP is aprerequisite for the correct use and handling of the system and for thesafety of the operators which depends on this.All of the supplied technical information, care and maintenanceinstructions or separate instruction manuals for parts, components oraccessories must also be observed.Flawless functioning, safety during operation, and the least possiblenumber of disturbances are ensured only when used in combination withcomponents tested and approved by JRT.Use only accessories that were tested and approved by JRT together withthis machine. If third party accessories are used JRT cannot assume anyguarantee for the safe operation or reliable function of the system.There can be no guarantee claims in the event of damages caused by theuse of third party accessories.JRT only regards itself as responsible for the system in terms of safety,reliability and function if:installation, extensions, resetting, modifications and repairs arecarried out by a party expressly authorised by JRT or by JRT itself.the system is used in compliance with these SOP.All documents correspond to the version of the system and the state of thesafety standards on which it is based on going to print. All protective rightsare reserved for the devices, switches, processes, software programs,and names mentioned in the documentation.Duplication - even of extracts - is only permitted with the writtenpermission of JRT GmbH & Co. KG.The Basic safety instructions are marked in this manual as on page 4:Version history of the operating instructionsThe changes to the operating instructions and the change date arerecorded in this section in table form. The latest changes are always at thestart of the table.Date Changes02/15/2008Key word index (page 38) and version history (page 3) extended.Table of contents updated.02/14/2008Machine name changed. All headers and footers regenerated.Basic safety instructionsThese SOP contain safety instructions which must be observed to ensurepersonal safety and to avoid damage to property.The instructions for personal safety are emphasised by several additionalwarning and hazard symbols.Instructions regarding exclusively material damage or other importantinformation are not marked by warning symbols.Depending on the degree of risk, these are treated as follows:HAZARD Means that death, serious injury or substantial material damage willoccur if the corresponding precautionary measures are not taken.WARNING Means that death, serious injury or substantial material damage mayoccur if the corresponding precautionary measures are not taken.CAUTION Means that minor injury may occur if the correspondingprecautionary measures are not taken.NOTE Without a warning triangle means that material damage can occur if thecorresponding precautionary measures are not taken. This may be animportant or an informative instruction.NOTE The information “maximum workplace concentration” can be found in:Deutsche Forschungsgesellschaft, Kennedyallee 40, D-53175 Bonn.During normal operation, the noise level is 65 dB (A).The machine and accessories must be disposed of in accordance with thelocal regulations at the end of their service life. Besides the battery in theoperating panel and the lubricants (oils and greases), the machine doesnot contain any hazardous materials.In case of doubts, questions or service requirements, please contact:JRT GmbH & Co. KG Tel.: +49 (0) 7641 / 583-0Robert-Bosch-Str. 1Fax: +49 (0) 7641 / 583-110D-79331 Teningen www.jrt-pv.deGermany1 Use and functional setup1.1 Proper useBasic principles The system is built in accordance with the state of the art and therecognised safety standards. Nonetheless, its use can result in risks to thelife and health of the users or third parties, damage to the system itself orother material damage.Only use the system in technically perfect condition and for the intendedpurpose in a safety and risk-conscious manner and in accordance with theoperating instructions. In particular, any faults which could impair safetymust be rectified immediately!The JRT solar printer SPL-ALBATROS is used exclusively for the printingof solar cells (wafers). Only materials such as pastes, lacquers andcleaning agents with a flashpoint over 40 °C may be used. The pastesand cleaning agents may not be mechanically atomised even if theirflashpoint is above 40 °C.Adequate room ventilation must be provided.The machine is intended for commercial use only.Any other or more extensive usage is improper.Correct usage also includes:Strict observation of these short operating procedures / SOP.Personnel selection.and Work on the system may only be carried out by reliable, trained or qualification instructed personnel.Clear allocation of responsibilities. Obligation to supervise personnel intraining.Work on the electrical equipment of the system may only be carried out bya qualified electrician or by instructed personnel under the direction andsupervision of a qualified electrician in accordance with the electricalengineering regulations.Work on pneumatic equipment may only be carried out by personnelqualified for this purposeNOTE The JRT screen printing machines have diverse applications. They can beused to apply the widest possible range of pastes to the widest possiblerange of print materials. As we always draw up the performance featuresindividually for our customers, please note that the use of print materials orpastes other than those used in the projection phase can alter theperformance features cited in our offers.1.2 Functional setupThe cited item nos.:-1-to-8-are in fig.1.2.2on page 9.Rotary indexing table -1-On the rotary indexing table there are four print tables – so-called printnests-2-;-3-;-4-. The table turns by 90 °on every cycle, so that it movesto 4 positions in one rotation.Inlet station -5-In the inlet station the wafers are placed on the print table.A paper is spanned over the print table onto which the wafers are placed.The paper, which is rolled off a roll-6-behind the print tables and rolledonto a roll underneath the print table, has two tasks: on the one hand itconveys the wafers after printing onto the transport belt to thedownstream dryer, and on the other hand it ensures that the cells arealways placed on a clean underlay which is free of ink or other residues.After they are placed on the print table, the wafers are fixed by a vacuum. Print station -4-Here the wafers are printed using the screen printing process. The printstation consists mainly of the print head-9-with squeegee carriage-10-and the screen rails-11-.The print head can be raised for cleaning the underside of the screen.Two vertical positions are available: an upper and a middle position. Inboth positions the print head is mechanically locked for safety reasons toprevent unintended lowering.The squeegee pressure can be adjusted separately for the right and theleft cylinder. The pre-squeegee pressure cannot be changed. Thesqueegee bar is swivelled and can be passed over a drip channel-12-.1.2 Functional setup Item no.Fig. 1.2.1Designation -9-Printing head -10-squeegee carriage -11-Screen rail -12-Drip channel -13-Squeegee pressure cylinder Printing cycle Lowering the print headPrinting the material by advancing the squeegeeRaising the print headFlooding the screen by returning the flood bar.Register setting (screen alignment) is automatic.Outlet station Item3 on the rotaryindexing table The camera over the output station (optional) checks the print quality and the condition of the wafer. Only predefined print errors are recognised by the camera. Damaged wafers are removed.To output the wafers the paper is rolled off the upper roll until the solar cells have reached the connecting transport belt.The machine is controlled via an operating panel with monitor.As required by the applicable directives, all moving or rotating parts are secured with technical protective measures.Fig. 1.2.2on page 9 shows the main components of the JRT solar printer SPL-ALBATROS.1.2 Functional setupItem no.Fig. 1.2.2Designation -1-Rotary indexing table -2-Inlet station -3-Paper control station -4-Print station -5-Paper roll -6-Outlet station with camera (optional)-7-Jockey roller on the paper transport system Fig. 1.2.2 Solarprinter Aufbau3 The operating panelThe machine is equipped with a SIMATIC control system and is operatedby mouse and keyboard. Operation is menu aided, i.e. related settings aregrouped respectively in a menu window on the screen.In all of the menu windows the lower section always shows the standardoperating keys(see page 18) with which you can execute the mostfrequent operating steps.You actuate the buttons by clicking on them with the mouse.To enter values, click on the entry field. A keyboard is displayed withwhich you can make all of the necessary entries. Use the enter key toconfirm the entry and remove the keyboard from the screen.The operating panel also contains the key to switch on the control systemand an emergency stop switch.4 The menusBasic principles This chapter briefly introduces the individual menus.Reminder:The control system is menu aided, i.e. related settings are groupedrespectively in a menu window on the screen.In the following section Machine setup(see page 20) you can read howthe machine is started up and which settings have to be made in themenusNOTE The individual menus are called up by clicking on the corresponding button;the buttons shown in the menus are actuated in the same way.To enter values or text, click on the entry field. A keyboard is displayedwith which you can make all of the necessary entries. Use the enter keyto confirm the entry and close the keyboard.In all of the menus the standard operating keys are shown on the lowersoftkey bar on the screen (see page 18), e.g.Automatic ON/OFF,Automatic START/STOP or Starting position.JRT Operating Instructions SPL DSP2Once the system is booted up, the system start window appears. Click on The control system is booted up and theappears.the function of the individual stations pending error messages and warnings The other menus for printer, dryer etc. can be called up with the buttonsbelow the header.On page 15 you will find a detailed description of the individual functionsin correspondence to the numbers on this page (14).JRT Operating InstructionsSPL DSP21In the system overview window you can call up the other individual menus on the menu bar at the top. These are: printer, dryer, statistics, miscellaneous and fault reports2List with fault reports. Fault reports cause a shutdown of the machine.3List with warning reports.4To select the machine setting.5To load the corresponding machine settings in the machine control system.6Diagram of rotary indexing table (middle) and the four stations: print station, inlet station, paper control station, outlet station; the red panel symbolises the switched-on camera lighting. Numbers displayedrepresent the individual print nests. When the rotary indexing table turns, the print nest numbers turn with it.7Diagram of the trapdoor (to remove rejected parts).8Diagram of the synchronising belt.9Extreme left: result for the last wafer, then the result for the second last etc.10List of pending reports (fault or warning reports).11To confirm reports.12Control lamps dryer, cooling zone green: temperature OKyellow: heating/cooling red: fault13Control lamps dryer, heating zone. green: temperature OKyellow: heating/cooling red: fault14Control lamps dryer belt. green: speed OKred: fault15To switch the dryer belt on and off.16Standard operating keys.17Function control inlet, print and outlet station as well as paper control and rotary indexing table. yellow: station working green: station has workedred: fault18To start automatically (e.g. after a change of screen) the machine moves to the basic position, automatic mode is switched on and the machine starts up.19To call up the camera image (screen centering) on the separate monitor. 20To initiate a change of screen. Automatic operation stops. Squeegee carriage is raised and passes over the drip channel. The screen frame clamp opens.21To start the automatic screen alignment process.22Last fault occurringDisplay of the information You can display detailed information for the individual stations.windowA window appears in each case with two lines:The first line shows the current action.The second line shows the conditions for the next action.The control lamps below indicate the function of the step chain.To display the information window, click on the symbol of the station andselect Open / close information. Use the same procedure to close theinformation window.Fig. 4.2 SYSTEM OVERVIEW Open /close informationSwitch step mode on / off You can switch on step mode to make settings at the individual stations.The buttons Reset and Step forwards are displayed.To switch step mode on, click on the icon for the station and select Stepmode on /off. You can switch the step mode off in the same wayFig. 4.3 Menu SYSTEM OVERVIEW Switch step mode on / off Attention!If step mode is activated you have to continue through the individual stepson the step chain by individual clicks on the corresponding button.The machine comes to a standstill after every step.Standard operating keys. The lower standard operating keys bar is the same in all menu windows1 Automatic ON/OFF.To switch from manual to automatic mode.You can only switch to automatic mode if the machine is in the startingposition. In automatic mode, pressing Automatic START/STOP triggersthe print cycles automatically until the machine is stopped by pressingAutomatic START/STOP2 Automatic START/STOP For starting and stopping the machine in automatic mode.3 Squeegee forwards / back To move the squeegee in manual operation (Automatic START/STOP is not pressed). The squeegee carriage moves forwards to the end position and then back again.4 Screen cleaning.To activate the screen cleaning (before the print head can be raised withFrame UP / DOWN,Clean screen must be pressed). To lower the printhead you must press either the button Starting position or Frame UP /DOWN.The function ”Clean screen” is automatically deactivated5 Swivel squeegee Use this to swivel the squeegee bar upwards and pass it over the dripchannels.When you press key5:the squeegee carriage moves to the centre of the print headthe squeegee bar swivels upwardsthe squeegee carriage waits for the drip-off timethe squeegee carriage passes over the drip channelWhen you press the key again:the squeegee carriage moves to the centre of the print headthe squeegee bar swivels downward6 Starting positionBrings the machine to the starting position. While approaching the startingposition, the key flashes green. As soon as starting position is reached,the key is permanently lit in green.7 Dryer ON/OFF To switch the dryer on and off.8 Screen clamp To open and close the screen frame clamp.9 Squeegee forward Causes the squeegee carriage to remain in the position “print end” afterevery print (screen open).10 Frame UP / DOWN To raise or lower the print head in setup mode or to raise and lower theprint head for cleaning the screen or changing the paper roll.5 Adjusting the machine5.1 Referencing, bringing the machine to the starting positionWARNING Risk of injury due to moving machine parts.Serious physical injury to head and hands by crushing or severingof body parts.Before switching on (start-up) the machine (system), make surethat nobody is working on or in the machine.Close the protective doors.Apply safety and protection covers.After actuating the main switch, the drives for print head, squeegeecarriage and screen lift have to execute a reference motion.Only then can the machine be brought to the starting position.Switch on compressed air supply.Actuate main switch.First the start information window appears.The system is booting up! Please wait.After booting up, the start window appears on the screen.The system overview window is opened by mouse click on the softkeySystem loaded!Fig. 5.1.1 System loaded5.1 Referencing, bringing the machine to the starting positionFig. 5.1.2 SYSTEM OVERVIEW Switch on the control system at the control panel. The illuminated button must be lit up.Click on the Starting position key.The machine now carries out a reference motion with the print head, i.e. the print head is raised to the end position where it remains. During the reference motion the button Starting positionflashes. Click on Starting position once more.The print head. is lowered and remains in the position “raised”.Click on Starting position once more.Now the squeegee carriage and the screen lift carry out a reference motion.Click on Starting position once more.The squeegee carriage moves forward to the position “print end”. The machine has reached its starting position and the button Starting position is lit permanently in green5.2 Inserting screenClick on the button Printer in the system overview window. The windowPRINTER – print parameters appears. Click on the button Setup in theupper standard operating key bar and the window PRINTER – setupappears(Fig. 5.2.1).Fig. 5.2.1 PRINTER - setupOpen the screen clamp.Insert screen.Close the screen clamp again. The screen frame is alignedautomatically.5.3 Inserting the squeegee Press the softkey Squeegee forwards / back on the lower standard operating key bar to move the squeegee carriage to a favourable position for inserting the squeegee.Select a squeegee of the appropriate length.The squeegee should extend beyond both sides of the printed image by approximately 20 mm.The maximum length of the squeegee depends on the size of the screen frame.. Maintain a distance of at least 100 mm between the end of the squeegee and the screen frame. Make sure that the two swivel plates are set at the same squeegeeangle. If not, this can be corrected using the clamp lever.Insert the flood bar (front) and the printing squeegee (rear) into theclamping receivers and tighten the clamping levers (6).Make sure that the squeegee is under symmetrical tension and does not protrude to the right and left more than 25% of the total lengthBefore switching on (start-up) the machine (system), make sure that nobody is working on the squeegee cylinders.If the controller fails, the cylinders may raise or lowerunpredictably. For this reason, switch off the main switch before performing adjustment work that requires a longer amount of time.If the cylinders were moved manually while the power wasswitched off (like when the main switch is switched off), they will return to the previously selected position when the power is turned back on.WARNING Risk of injury due to moving machine parts.Serious physical injury to head and hands by crushing or severing of body parts.5.4 Setting the print parametersEntering the print and Click on the softkey Print parameters in the upper softkey bar to flood speed.open the PRINTER - print parameters windowClick on the entry panel-1- print speed and used the keyboarddisplayed to enter the starting value 100 mm/s (input range 100 (400)mm/s).Press the enter key J+to confirm the entry. This also closes thekeyboard.Proceed in the same way for-2- flood speed.Fig. 5.4.1 PRINTER – print parameters Print speed / Flood speed5.4 Setting the print parametersAdjusting the SqueegeeYou can set the squeegee path in two ways:Stroke . 1. By driving the squeegee carriage to the front and back end positionand then storing the respective position by pressing a key.2. By entering the front (print start) and rear (print end) end position as anumerical value in the squeegee menu NOTERisk of the squeegee arm colliding with the screen frame.Damage to the squeegee and the screen frame. Whenever possible, always set the squeegee path by moving the squeegee carriage.1. Moving the squeegeecarriage and storingthe end position (Fig. 5.4.1) Move the squeegee carriage with -3- Squeegee forwards /back to the print start and press-4- Teach In Start.Then move the squeegee carriage to the print end and press -5-Teach In End .Fig. 5.4.1 PRINTER – print parameters Teach In Start / End HAZARD Insufficient minimum distance at the end positions betweensqueegee and screen frame.Increased risk of crushing injury to hands.The distance between the squeegee and the screen framemust not be less than 25 mm.5.4 Setting the print parameters2. Entering end positions Click on the entry panel-6- Position print start end enter the value (theas numerical values value is entered in mm and measured from the rear end stop of the (Fig. 5.4.2)squeegee carriagePress the enter key J+to confirm the entry.Proceed in the same way for-7- Position print endFig. 5.4.2 PRINTER – print parameters Position print start / print end5.5 Changing the paper rollTo change the paper roll, the corresponding print nest must be in the printstation.When the system demands a change of paper, click on the softkey-1-Request paper change in the menu PRINTER – print parameters (Fig.5.5.1).The machine continues running until the corresponding print nest is in theprint station. The machine stops and the print head moves upwards intothe cleaning position.-1-Fig. 5.5.1 PRINTER – print parameters Request paper change5.5 Changing the paper rollOpen the holder for the take-up roll. To do this lift the locking lever and slide itto the right (Fig 5.5.1). Remove the roll to be changed.Fig. 5.5.1 Locking lever to open the holderPlace the new roll on the lower tray (Fig. 5.5.2).Fig. 5.5.2 Inserting the new roll5.5 Changing the paper rollStick the end of the paper (Fig. 5.5.3) to the end of the take-up roll withadhesive tape and wind on some paper with a few turns.Insert the take-up roller. and close the holderFig. 5.5.3 Sticking the end of the paper to the take-up roll.Wind on paper with a few turns.Now grip the new roll and lead the paper under the jockey roller and overthe print head (Fig. 5.5.4).Place the new roll into the holder after the print head and close the lockinglever.Fig. 5.5.4 Thread paper under the jockey roller Fasten the roll on the rear holder.5.5 Changing the paper rollSwitch to the submenu Manual control.Use the symbol key at-1- Take-up roll in the paper transport window to windon paper until the jockey roller has reached the upper position (Fig. 5.5.5).Fig. 5.5.5. PRINTER – Manual control Take-up roll5.6 Working on the underside of the screen To carry out work on the underside of the screen, the whole print head can be raised.There are two positions to choose from: one at the top and one around the middle. You can select the position in the submenu print parameters.Make sure that the print head reaches this position and stops automatically. Only in these positions is the print head mechanically locked and is thus secured against unintentional lowering. Click onStarting position. Click on Clean screen . Click on Frame UP / DOWN .The print head is raised into the cleaning position. Wait until the print head reaches its end position and all movement has stopped. Move the print head to the end position. Then the print head is mechanically locked and thus prevented from unintentional lowering.Now you can open the door and begin work.After work is completed you must close the door and either press Starting position or Frame UP / DOWN . The Clean screen function is automatically deactivated.If you would like to clean the screen during automatic mode you only have to click on Clean screen : the machine stops. the squeegee carriage stops in the forwards position (screen notflooded). The print head is raised into the cleaning position.When work is completed, press: Basic position Automatic ON/OFF Automatic START/STOP HAZARDPrint head not in end position.Increased crushing risk for head, neck and hands.5.7 Storing and loading machine settingsIn the menu PRINTER – print parameters you can store machine settingsunder a data set name or reload them using this data set name.In the window Recipe administration Printer you can enter thecorresponding data.Storing settings Make all of the machine settings.Click on key-1-(see Fig. 5.7.2on page 33).Load the data from the machine control system with the key-4-.Enter a data set name in the entry panel-6-.Store the data with one of the keys-2-.Load settings Enter the data set name under which the settings are stored in theentry panel-6-or select it with-7-.Use key-5-to load the data in the machine control system.The loaded settings appear in the table column Value(see item no.-8-onpage 32).Delete stored machine settingsEnter the data set name under which the settings are stored in the entry panel-6-or select it with-7-.Use the key-3-to delete the settings.Fig. 5.7.1 PRINTER – print parameters Recipe administration Printer5.7 Storing and loading machine settingsFig. 5.7.2 Recipe administration Printer5.8 Selecting a languageThe language of the display texts can be selected in the Miscellaneous menuby clicking on key-1- Select language(Fig. 5.8.1).Fig.5.-1-8.1MISCELLANEOUFig. 5.8.1.MISCELLANEOUS Select language6 Automatic mode 6.1PrintingSet up the machine (see Chapter 5, page 20). Add paste.Click on the softkey -1- Start position .Select automatic mode with -2- Automatic ON/OFF . Start automatic mode with -3- Automatic START/STOP .You can also start the machine by simply clicking on-4- Machine START . With this key the starting process is executed automatically:The machine moves to the starting position. Automatic mode is selected. The machine starts running.-Fig. 6.1.1 SYSTEM OVERVIEW Print-4--3--2--1-。
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