Chapter 4

Troubleshooting/Messages

Table of Contents
How to Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Basic Techniques – Operational Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Basic Techniques – Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Maintenance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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AP HiE Series Maintenance/Troubleshooting Guide

How to Troubleshoot
This chapter contains information on troubleshooting your AP HiE Series printer. Many
problems are of an operational nature. Therefore, this chapter contains both operational
troubleshooting and maintenance troubleshooting information.
Operational Troubleshooting is done by the machine operator and primarily helps him/her
correct problems that may be corrected without the aid of maintenance department
personnel. A section of this chapter is devoted to this level of troubleshooting.
Maintenance troubleshooting is done when the operator cannot correct a problem or an
obvious machine fault exists. Detailed information and aids are include in the Maintenance
Troubleshooting section of this chapter.

Basic Techniques – Operational Troubleshooting

Troubleshooting is basically a two-step process. First, the problem must be clearly defined and
understood. Next, procedures to isolate the problem to a particular operation or part of the
machine are performed. A problem can often be cleared by the operator alone or with a
supervisor’s assistance.
If the fault cannot be found or is not correctable without machine repair, the malfunction is
referred to the Maintenance Department. Twelve troubleshooting tables are included in this
chapter to aid in quickly locating and correcting the fault. Using the tables, the maintenance
technician isolates the fault to a repairable or replaceable part and repairs or corrects the
problem. Finally, he/she should perform an operational test to verify that the problem has
been corrected and does not repeat.
To start troubleshooting:
1. Identify a fault by first carefully noting the symptoms of the problem. A written Failure
Report is strongly recommended. Failure reports should be filed for future reference.
2. Use all available troubleshooting aids to quickly pinpoint the fault.
The AP HiE Series printer continuously monitors printer status and displays faults in error
messages. The messages are displayed on the bottom right-hand corner of the main operating
screen. Error messages may indicate the action the machine was undertaking as the fault
occurred. Operational Troubleshooting Message Table 4–1 lists and describes some of the
messages that can be displayed.
Error messages are grouped in the table as follows:
• Communications
• Operational
• File Management
• Verification
Table 4–2 contains troubleshooting aids for printing problems.

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 Chapter 4: Troubleshooting/Messages

Note
Most of the printer setup parameters that are mentioned in Table 4–2 have default access
privileges for the supervisor and maintenance only. If the operator is to be able to change
these, either the default access entries must be changed or the operator must be allowed to
change the access mode (with a password) to Supervisor or Maintenance.

Table 4–1. System Error Messages

Message Description of Condition Remedy/Action

Communications
Cognex is not responding • Communication processor not • Check Cognex operation.
responding.
Cognex software version will • Wrong Cognex version loaded. • Load correct Cognex version.
not work

GEM initialization failed • Host Communications board • Notify maintenance.

does not respond.
Operational
Air Pressure Fault • The system air pressure is low. • Notify Maintenance Dept.
• Ruptured hose. • Notify Maintenance Dept.
• Air pressure regulator • Notify Maintenance Dept.
(measures pressure) error.
“Axis” - Hardware Limit! • An assembly traveled beyond • Visually inspect for damage.
acceptable limit. If recoverable, reset the
machine.
“Axis” - Software Limit! • May occur in Teach Vision or • Jog away from the software
print mode when system finds limit.
that moving an axis for
alignment would put axis into
software limit.
Board stop sensor not made • Board did not make it to • Check worknest for board.
print area. • If present, sensor may be bad.
Notify Maintenance Dept.
(They should check/replace
sensor.)
• If board is stuck on tracks,
check for correct track width.
Inspect board travel path for
obstructions or bent track.
Notify Maintenance Dept. if no
obstructions.
Board Model NOT Found • System cannot find taught • Ensure that correct board is
board model. loaded in print area.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–1. System Error Messages (continued)

Message Description of Condition Remedy/Action
Board Profile not LOADED • File load aborted. • Reload profile.
Calculation error • Contact MPM Field Service.
CAMERA IS NOT PARKED! • Camera did not make park • Check for obstructions and
sensor when homing. notify Maintenance Dept.
Can’t find the STENCIL • Tactile sensor malfunction • Notify Maintenance Dept.
during Stencil Height/Level
Squeegee operations.
Can’t leave the STENCIL • Tactile sensor malfunction • Notify Maintenance Dept.
during Stencil Height/Level
Squeegee operations.
Deleting all Vision Models • An error has occurred during • Check detent values and reteach
Vision Teach. vision.
Dispenser is not present • Contact MPM Field Service.
DMR error • Serial error. • Contact MPM Field Service.
Down Stop not positioned • Notify Maintenance Dept.
correctly

Downstream Board not • Downstream machine did not • Check both machines, lower
received! receive board. track speed, or increase track
width if necessary.
Exit sensor not made • Board did not make it to end of • Check exit tracks for board.
exit tracks. • If present, sensor may be bad.
Notify Maintenance Dept.
• If board is stuck on tracks,
inspect board travel path for
obstructions or increase track
width if necessary.
Frame Clamps MUST be Set • The frame clamps need to be set • Press NEXT to allow clamps
for current process. to set.
HARDWARE LIMIT • The printer has hit one of its • Check for interference on all
WARNING! hardware limits. axes, then reset printer.
ID Targets Not Loaded • There was an error loading • Try to reload file.
the file. • Try to reboot printer.
• Contact MPM Field Service.
Machine must be RESET • To operate the machine, • Reset the machine.
perform reset.
Machine power off • Machine is about to shut down. • N/A

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 Chapter 4: Troubleshooting/Messages

Table 4–1. System Error Messages (continued)

Message Description of Condition Remedy/Action
Out of wiper paper • The wiper paper empty sensor • Install a new roll of paper.
indicates there is no paper left. If roll is not empty, notify
Maintenance Department.
Pressure not set • Pressure in prohead is off. • Notify Maintenance Dept.
Remove BOARD from • Board detected on tracks when • Remove board from tracks and
TRACKS utility requiring cleared tracks press NEXT to continue.
was selected.
Reset has been aborted! • The user has aborted the reset • Check for any interferences and
process, or the printer was reset again.
unable to reset.
SOFTWARE LIMIT • May occur in Teach Vision or • N/A.
WARNING! print mode when system finds
that moving an axis for
alignment would put axis into
software limit.
Squeegee Clamps • Squeegee blades are required for • Install blades and run Squeegee
MUST be SET this operation. Height utility.
Squeegee Height • You must run Squeegee Height • Run Squeegee Height utility.
MUST be run utility before operation.
Squeegee not positioned • Contact MPM Field Service.
correctly

Squeegee too light • Weigh Squeegee utility not • Notify Maintenance Dept.
operating properly.
Squeegee not up free (L) • Weigh Squeegee utility not • Notify Maintenance Dept.
operating properly.
Squeegee not down free (L) • Weigh Squeegee utility not • Notify Maintenance Dept.
operating properly.
Squeegee not up free (R) • Weigh Squeegee utility not • Notify Maintenance Dept.
operating properly.
Squeegee not down free (R) • Weigh Squeegee utility not • Notify Maintenance Dept.
operating properly.
Stencil Model NOT Found • System cannot find taught • Ensure that proper stencil is
stencil model. loaded in print area. Perform
Stencil Adjust utility if required.
Stencil Sensor is STUCK ON • Tactile sensor is stuck on. • Notify Maintenance Dept.
Wipe In and Wipe Out are Off • Cycle Wiper utility selected, but • Enable Wipe In or Wipe Out
neither Wipe In or Wipe Out is field in Stencil Wiper
enabled. parameter box
(SETUP MENU PAGE # 2).

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–1. System Error Messages (continued)

Message Description of Condition Remedy/Action
Tracks touching the vacuum • Transport tracks have hit the • Reposition vacuum chuck and
chuck vacuum chuck. reset the machine.
Verification requires stencil • Verify Stencil utility looking for • No stencil targets taught.
models stencil targets Refer to Teach Vision procedure
in the System Support Guide.
Vision Targets Not Loaded • EXIT button on trackball • Reload board file.
controller pressed while system
was loading vision targets.
WIPER IS NOT PARKED! • Wiper did not make park sensor • Check for obstruction and
when homing. notify Maintenance Dept.
WIPER VACUUM LOW • Vacuum in wiper system is • Clean off vacuum plenum and
low (printers with Vacuum try again. If problem persists,
wiper only). notify Maintenance Dept.
Z BRAKE IS ENGAGED • The user tried to jog after • Turn Z-brake off in I/O screen.
turning the Z-brake ON in the
I/O screen.
File Management
Disk space error • There is not enough space • Insert a blank diskette.
available on the diskette to
complete the operation.
Drive not ready • Diskette drive not readable. • Insert floppy diskette into drive.
• Verify drive door is closed.
• Check integrity of floppy drive.
Error creating file • Contact MPM Field Service.
Error deleting file • Contact MPM Field Service.
Error processing data • Contact MPM Field Service.
Error reading file • Contact MPM Field Service.
Error setting window • Contact MPM Field Service.
Error with vision system • Contact MPM Field Service.
Error writing file • Contact MPM Field Service.
Incorrect password, access • Password entered incorrectly • Retype the correct password.
denied

Invalid Directory path • Retry. If message repeats,

contact MPM Field Service.
Maximum file limit reached • Attempting to store more than • Perform backup or delete files to
400 parameter files. make room for new file.

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 Chapter 4: Troubleshooting/Messages

Table 4–1. System Error Messages (continued)

Message Description of Condition Remedy/Action
New password not retyped • Password entered is invalid • Retype the new password.
correctly when using the Change
Password utility.
New password same as old • When using the Change • Enter a new password different
password Password utility the new from the current.
password entered is exactly the
same as the current password.
Not enough memory • Contact MPM Field Service.
Software version mismatch • All installed software must be • Reinstall correct software
the same version number. version.
Unknown error • Floppy diskette error or floppy • Check diskette at another PC.
drive malfunction. Check functionality of floppy
drive. If bad, contact MPM
Field Service.
Verification
Can’t Auto Contrast, • Not enough contrast for device. • N/A.
deactivating device Post Print will not check.
Can’t find spacing HORZ pad • Problem encountered • Refer to Device Layout Teach
during Teach. procedure in the System Support
Guide.
• Try different corner.
• Try teaching different board.
Can’t find spacing VERT pad • Problem encountered • Refer to Device Layout Teach
during Teach. procedure in the System Support
Guide.
• Try different corner.
• Try teaching different board.
Can't update 2D SPC info • Contact MPM Field Service.
Device is too big • Too many pads on device • N/A.
(max=400).
Device not level • Board not level. • Improve board support using
snuggers, support pins.
Error while searching for pad • System could not find pad. • Refer to Device Layout Teach
procedure in the System Support
Guide.
• Reteach with new board.
HORZ pad count error • System could not find one or • Reteach with new board.
more pads on horizontal row.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–1. System Error Messages (continued)

Message Description of Condition Remedy/Action
Insufficient pads to define • Operator error during teach • Refer to Device Layout Teach
device procedure. procedure in the System Support
Guide.
Laser too far out • Board is not level or laser is not • Verify board is being held flat.
aligned properly. Contact MPM Field
Service.MPM Field Service.
Maximum Number of Panels • Contact MPM Field Service.
Reached

No devices to DELETE • Delete Devices selected, but none • Perform Device Teach utility.
have been taught. See System Support Guide.
Must Teach Devices First • Cannot select Edit Devices if • Perform Teach Vision utility.
none have been taught. See System Support Guide.
Pad contrast is too low • Bad board. • Reteach with new board.
See System Support Guide.
Pad count error • Bad board. • Reteach with new board.
See System Support Guide.
Panel Target Not Loaded • Contact MPM Field Service.
Panel Model Not Found • Contact MPM Field Service.
Panels Must NOT Overlap • Contact MPM Field Service.
Unknown device corners • Contact MPM Field Service.
VERT pad count error • System could not find one or • Reteach with new board.
more pads on vertical row.

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 Chapter 4: Troubleshooting/Messages

Table 4–2. Operational Troubleshooting – Printing Problems

Problem Cause Remedy

Poor print quality

Incomplete print • Insufficient paste on stencil. • Check for proper amount of paste on the
(partial pad coverage) stencil. One ounce (28g) per inch of PCB
length (X axis) is recommended.
• Clogged stencil. • Clean stencil. Increase wipe frequency; use
solvent with wiping. See Paste Clogging
Apertures.
• Particle size distribution in paste • Replace paste
inconsistent or too large.
• Excessive snap off. • Reduce Snap off; (Snap Off is normally
0.000 with stencil printing.)
• Thickness set incorrectly. • Check that Thickness matches PCB
substrate thickness.
• Slow Snap Off set too fast or • Choose slower Slow Snap Off and/or add
insufficient down delay. Down Delay.
• Paste sticking to squeegee. • Paste is too viscous or has lost solvent due
to infrequent use. Replace paste.
• Insufficient downstop (large PCB). • If printing large boards, down stop may
need to be increased beyond default value
of 0.075 inch.
• Squeegee pressure too low. • Increase squeegee pressure (Total Force).
• Squeegee balance incorrect. • Balance squeegee.

Irregular print thickness • Stencil not parallel to PCB surface. • Check worknest and stencil installation.
(thickness varies over • Irregular flood thickness. • Check paste bead for uniformity.
PCB) • Squeegee pressure not even. • Check squeegee balance, squeegee wear.
• Warped stencil. • Check that stencil is flat.
• Paste buildup on bottom of stencil. • Clean stencil bottom surface.
• Legends on PCB have irregular • Check PCB legend layout and
thickness or are too close to pads. thicknesses.
• Solder mask was irregular
• Irregular solder thickness on PCB • Check quality of solder mask.
• Snugger clamping pressure incorrect. If • Check PCB soldering operation.
air pressure is set too high, snuggers • Verify that all the snuggers are firmly
can warp the board. clamping substrate. Adjust as necessary
(see System Support Guide).
Excessive paste on pads • Incorrect Snap off setting (too high). • Check Snap off setting. (Snap Off is
normally 0.000 with stencil printing.)
• Incorrect squeegee pressure (too high). • Reduce squeegee pressure (Total Force)
value.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–2. Operational Troubleshooting – Printing Problems (continued)

Problem Cause Remedy

Printed pads are not the • Machine out of alignment. • Contact the MPM Field Service.
same height on opposite
sides of board

Solder spikes (dog ears) • Slow Snap-Off set too fast • Choose slower Slow Snap-Off (Speed).
• Snap off excessive (off contact) • Reduce Snap off distance.(Snap Off is
normally 0.000 with stencil printing.)
• Poor stencil design • Replace stencil
• Poor quality paste • Replace paste
• Loose tension of stencil in frame • Replace stencil
• Vacuum pulling stencil down during • Reduce or eliminate worknest vacuum.
slow snap off. (PCB has apertures)
Peaking • Snap off excessive (off contact) • Reduce Snap off distance. (Snap Off is
(multiple dog ears) normally 0.000 with stencil printing.)
• Temperature /humidity too high • Correct environment or use thicker paste
• Paste clinging to bottom of stencil or • Clean stencil; increase stencil wiping
clogging in apertures actions; use solvent wipes.
• Thickness board parameter set wrong. • Set Thickness to equal PCB thickness.
• Squeegee Print Speed set too high. • Reduce squeegee Print Speed.
• Squeegee pressure too low • Increase squeegee pressure (Total Force).
• Inadequate board support • Add more bridges/pins to support board.
Bridging • Poor quality paste (slumping) • Change paste
(smudging/shorts)
• Paste on bottom of stencil. • Clean stencil; increase stencil wiping
actions; use solvent wipes.
• Snap off too high. • Reduce Snap off. (Snap Off is normally
• Use of multiple squeegee strokes 0.000 with stencil printing.)
• Poor stencil to board alignment. • Use Altern print strokes.
• Poor HAL (Hot Air Leveling). • Re-teach the board.
• Squeegee pressure too high or Down • Check quality of substrate.
Stop excessive. • Reduce squeegee pressure (Total Force);
check Down Stop and adjust if needed.

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Table 4–2. Operational Troubleshooting – Printing Problems (continued)

Problem Cause Remedy

Paste Clogging Apertures • Dry paste • Knead paste or replace with fresh paste.
• Incorrect paste selection (solder ball • Change paste.
size too large.
• Poor quality paste. • Change paste.
• Slow Snap Off set too fast. • Select slower Slow Snap Off Speed.
• Slow Snap Off distance too small. • Increase Slow Snap Off Distance.
• No slow snap off. • Enable and set Slow Snap-Off parameters.
• Vacuum pulling stencil down during • Reduce or eliminate vacuum.
slow snap off.
• Poor stencil design (bad aspect ratio) • Check stencil for aperture design.
Insufficient paste on pads • Incorrect print pressure setting too low • Increase print pressure setting.
(or too high with soft squeegees). (Note: If pressure is too high, scooping
can result if using non-metal squeegees.
• If a large PCB, Down Stop may be too Also, “coining” of the stencil can occur.)
shallow. • Increase Down Stop may help if a large
• Clogged stencil apertures PCB.
• Increase wiper frequency, number of
cycles, solvent priming time, number of
vacuum cycles, or reduce wipe speed. See
Paste Clogging Apertures, this table.
• Misaligned board to stencil • Perform Teach Vision procedure; retry.
• Paste viscosity too high for wipe speed. • Check temperature and age of paste.
• Incorrect print speed setting (too fast).
• Stencil thickness too thin (or worn) • Check Print Speed setting. Try one inch/
• Poor flooding second to start.
• Check stencil thickness.
• Check paste bead quantity, quality.
Poor pad edge definition • Temperature or humidity too high. • Check print environment. Check paste
viscosity.
• Plating too thick or HASL. • Check plating and HASL (Hot Air Solder
Leveling) operation.
• Worn or damaged stencil. • Check stencil for wear, damage.
• Snap off too large. • Reduce Snap off distance. (Snap Off is
normally 0.000 with stencil printing.)

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–2. Operational Troubleshooting – Printing Problems (continued)

Problem Cause Remedy

Poor registration of print • Print image moved during print stroke. • Verify that the print image is not moving
during print stroke due to stencil mesh
being overly “elastic.”
• Printer out of alignment. • Verify printer alignment is within factory
specifications.
• Frame clamp problem. • Check integrity of frame clamps.
• Improper side snugger pin height • Verify that the side snugger pins are set
setting. properly for the thickness of substrate.
Adjust as necessary (see System Support
Guide).
• Snugger clamping pressure incorrect. • Verify that all the snuggers are firmly
If air pressure is set too high, snuggers clamping substrate. Adjust as necessary
can warp the board. (see System Support Guide).
If set too low, snuggers may not
maintain correct registration.
Squeegee not wiping • Squeegee problem. • Check that blades are securely attached.
cleanly
• Squeegee problem. • Verify that squeegee material is flat in
holder.

• Check squeegee edge for wear/nicks.

• Check for freedom of motion on squeegee
pivots. (Look for paste accumulation.)
• Check for correct squeegee attack angle
(normally 45°).
Paste sticking to squeegee • Poor quality paste; paste viscosity too • Change paste; check for low paste
high. temperature.
• Incorrect squeegee attack angle. • Change front and rear squeegee attack
angle. Attack Angle is normally 45° during
the print stroke.

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Basic Techniques – Maintenance Troubleshooting

The first step is to receive from the operator a description of all the observed symptoms and
any unsuccessful troubleshooting efforts that the operator or others may have made.
The next step is to isolate the problem to a particular operation or part of the machine.
If possible, start by performing an operational test on the machine and attempt to duplicate
and verify the operator’s reported problem. After verifying the fault, refer to the Maintenance
Troubleshooting Tables 4–3 to 4-14 for tips on likely causes and possible remedies.
A source of information could be a Preventive Maintenance (P/M) log maintained for the
printer. If P/M procedures have been done on a regular schedule, most of the common
failures caused by poor P/M can be eliminated from consideration. Also, some types of failure
are caused by gradual wear or fatigue and may have been detected and noted in the P/M log.
If severe wear is discovered, a scheduled replacement is usually far preferable over an
unscheduled one.
There are six general causes of machine failure. The failure types and affected parts are:
• Foreign material (usually paste) accumulation on working mechanisms and sensors.
• Vibration-induced failure of connections, wiring, or other printer components.
• Heat-induced failure of power supplies, driver boards, fuses, or transformers.
• Electrical noise-induced failures of the computer, circuit boards and components.
• Motion-induced wear of parts such as belts, bearings, motors, and couplings.
• Software fault either from incorrectly entered data or a fault in the control program.
Misalignment of parts due to rough handling if the printer is moved or shipped to a different
location could be added to this list.
Down-time from many these causes can be either eliminated or greatly reduced by a dedicated
PM program. By far, experience has shown that scheduled cleaning and inspections are the
most important factors for eliminating down-time in an MPM printer. Refer to the AP HiE
Series Preventive Maintenance Guide for recommended procedures and PM logs.

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AP HiE Series Maintenance/Troubleshooting Guide

Maintenance Troubleshooting
This section contains troubleshooting tables to aid in quickly finding faults that are not
operational in nature. The tables are as follows:
• Table , Base Machine – (power, air, vacuum, and motion problems)
• Table , Programmable Print Head
• Table , Tactile Sensor
• Table , Vision System
• Table , Worknest/Stencil
• Table , Environmental Control Unit Option
• Table , Paste Dispenser Option
• Table , Snuggers, Side (X-Axis) Option
• Table Y-Axis Tooling (snuggers/flippers) Option
• Table , Stencil Wiper Option
• Table , Solvent Bar Option
• Table 4–15, 3-D Option

Fuses
There are up to 46 power-related fuses in a fully-configured AP HiE Series printer.In addition,
there are up to 39 additional fuses in the digital input/output cards (output circuits). Most
fuses are located in the four major electrical assemblies in the printer (AC plate, pneumatic
tray, upper drawer, and lower drawer).
Refer to Table 4–16 for a quick reference to fuses and circuit breakers, grouped by assembly
location and by function.

Note
Remember that fuses can fail (open) solely due to fatigue and/or vibration, not necessarily
from an over-current fault condition.

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Table 4–3. Troubleshooting - Base Machine

Problem Cause Remedy

No Power • Main Power cable unplugged, • Check power in cable; press Power On
(no lights on front panel) switched off remotely or defective. switch.
• Circuit breaker QF1 (Main Circuit • Check circuit breakers; reset breaker if
Breaker) or QF2, AC Plate, tripped. tripped. Verify there is no repeat trip.
• Main Disconnect OFF. • Turn Main Disconnect ON.
• Main AC power source failure. • Check in-house AC power.
• Blown fuse or transformer (TV1 or • Check power Supply voltages.
TC1) defective. Check fuse 1FU (2A) on AC plate.
Check fuse 2FU (4A) on AC plate
Check both transformer’s input/output
A front panel indicator does not • Bulb blown. • Inspect for blown bulb. Replace bulb if
illuminate defective.
• Perform continuity check on indicator.
Power is available, but machine • Interlocks not enabled. • Check interlock switches.
will not start
• Emergency Stop switch open. • Pull all three E-stop switches out.
Power is available, but machine • Power On button will not stay on. • Main power relay (KM1) loop open
will not start (cont’d.) circuit. Check:
a. Fuses 4FU (2A) and 9FU (4A) on AC
plate
b. GS1 on AC plate for 24V
c. General wiring
d. Main power relay, KM1
e. Power off relay (KP9, upper drawer)
and all connectors.
f. KP9 output control (I/O rack,
module # 3-4)

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–3. Troubleshooting - Base Machine (continued)

Problem Cause Remedy

No high pressure air to printer • In-house air supply faulty. • Check in-house air supply.
• Air pressure regulator misadjusted or • Check incoming air regulator. Adjust to
defective. 90 psi (620kPa).
• Air filter blocked. • Inspect/replace air filter.
• Air pressure switch SP1 defective. • Check air pressure switch at I/O rack,
module #2-8, pin 18 to XT9-13.Voltage
should be 0V with air switch SP1 “ON”.
• Y1 solenoid/valve defective. • Check LED on Y1 solenoid/valve. If OFF,
check if relay KP6 is energized.
• If relay KP6 is ON, check for 24 VDC at
Y1. If OK, manually activate Y1. If air is
enabled, replace Y1.
“Air Pressure Fault” message • Bad air pressure sensor SP1 switch • Do voltage check XT9-5 to XT9-13
(air pressure is normal). (located on pneumatics tray). Voltage
should be 0V with air switch “ON”.
• Relay KP6 or solenoid Y1 defective • Check relay KP6 and solenoid valve Y1.
(no air pressure).
Computer does not • No power to computer or monitor. • Check all cables.
boot up • If monitor only is OFF; • Check 3FU (2A)
• No power to computer only. • Check 5FU (5A) in upper drawer
Check internal fuse in computer.
Defective power supply in computer.
Contact the MPM Field Service.
Turn power OFF, install keyboard, turn
power ON.
• Invalid configuration: “Press F1 key • Press F1 key. If MPM logo appears,
to continue” computer battery is bad. Contact the
MPM Field Service.
“Trackball not responding” • Trackball not connected. • Check in-line connection and
message connections on side of machine.
• Trackball defective. • Replace trackball.
• Serial I/O card defective. • Contact the MPM Field Service.
Cursor moving erratically • Trackball dirty. • Remove power from printer. Remove the
ball from the trackball assembly. Clean
ball with alcohol. Clean the rollers inside
with alcohol on a Q-tip. Re-insert ball.
Refer to Trackball Assembly Cleaning in
Chapter 3.

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Table 4–3. Troubleshooting - Base Machine (continued)

Problem Cause Remedy

Machine will not power off • Random error. • Save changes to file. Try again.
• Open connector; OFF push-button • Press SB5 and check LED on input
SB5, or input module #2-0 module #2-0. If LED OFF, check cables
defective. and switch SB5. If all OK, replace
module #2-0.
• If LED for module #2-0 is ON, check
output circuit below.
• Check LED for I/O module #3-4. If ON,
• Bad relay KP9, output fuse or check if relay KP9 is energized. If
module #3-4. energized, replace relay (contact frozen
ON). If relay is OFF, check fuse at output
module #3-4. If OK, replace module
#3-4.
Reset problem • Electrical problem. • Visually inspect for blockage; remove
blockage and retry Reset.
• See “Problem: No air to printer.”
• No voltages to drivers. Check all fuses
associated with 24VDC and stepper drive
main power.
• Check associated switch.
• See “Problem: No Motion (all axes)” and
“Problem: No motion (one axis).”
• Cover switch defective. • Check all cover interlock switches.
No motion (all axes) • Covers open. • Close all machine covers.
Check interlock switches.
• Obstruction/mechanical jam. • Inspect for blockage. Remove obstruction
and select Reset.
• Electrical fault. • Check drive power relays KP3 and KP5
(lower drawer). If not closed, check LED
on output module, #3-0.
• If ON check fuse FU48, lower drawer.
• If OK, check output fuse for module
#3-0 (on IO board #3).
Check 10FU (5A, upper drawer).
Check 6FU (1A, upper drawer).
Check 37FU (6A), 38FU (8A), 39FU
and 40FU (15A), 41FU and 42FU (20A)
(All in lower drawer).

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–3. Troubleshooting - Base Machine (continued)

Problem Cause Remedy

No motion (one or more axes) • Stepper driver malfunction. • Check fuses feeding driver (39FU, 40FU,
41FUand 42FU).
Check voltage to driver.
• Check DIP switch/current setting on
driver.
• Check wiring and drive power connector.
• Replace driver. If still not resolved, check
stepper motor as follows:
• Stepper motor or coupler defective. • Check tightness/condition of shaft
mechanical coupling.
• Replace motor.
Axis travel rough • Loose pin in driver connector • Replace/reinstall pin.
• Driver defective. • Replace driver.
• Motor defective • Replace motor.
Axis hammers or chatters at end • Proximity switch problem • Check alignment of proximity switch flag,
of travel if used.
• Check proximity switch.
Single tower light does not • Light defective • Check bulb. Replace as necessary.
illuminate • Defective I/O module • Check ODC5 #9 (red), 10 (green), or 11
(amber) on I/O #3.
• Fuse defective • Check 1FU (2A) on AC plate
• Check 2FU (4A) on AC plate.
Tower lights do not illuminate • Cable problem • Check cables and connector.
• Electrical problem. • Check 24VAC (XT1-8 to XT1-18) on AC
plate.
• Check 1FU (2A) on AC plate
• Check 2FU (4A) on AC plate.
Interior light does not • On/Off switch defective • Replace switch.
illuminate
• Bulb blown • Replace bulb.
• Bad electrical connection • Check connector.
• Fuse or power supply failure. • Check 4FU (2A) on AC plate.
• Check 9FU (4A) on AC plate
• Check 8FU (2A) on AC plate.
• Check power supply GS1 output
(24VDC).

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 Chapter 4: Troubleshooting/Messages

Table 4–3. Troubleshooting - Base Machine (continued)

Problem Cause Remedy

“Access Denied” message • Front panel PROGRAM ACCESS • Use access key to place the PROGRAM
switch in the LIMITED position ACCESS switch in the FULL position.
• Electrical problem • Check LED for I/O module #2-12 input.
If ON with PROGRAM ACCESS switch
on FULL, replace switch and retry.
“Cover not Closed” message • Covers open • Close all machine covers.
• Cover not making proper contact on • Re-align cover.
interlock switch
• Relay KP13 defective. • Check LED for input module #2-15.
If OFF, check if relay KP13 energized.
If not, check cabling, continuity through
interlock switches.
• If LED for #2-15 ON, replace module.
Poor vacuum • Gate valve malfunction. • Check gate valve (may be partially closed).
• Vacuum tunnel screen blocked. • Check vacuum tunnel screen for excessive
paste build-up.

No vacuum in worknest. • Vacuum blower motor will not turn • Check fuses 7FU and 34FU (240 VAC
on. machines only) on AC plate.
• Motor overload contact open. Wait a few
minutes and retry with gate valve open.
• Check contactor KP8 on AC plate
(240VAC systems only). If deenergized,
• Check LED on I/O rack module #3-2.
If ON, check module fuse (24 VDC at
output or 0 VDC across fuse). If OK,
replace relay KP8 (AC rail on AC plate).
• Gate valve will not open. • Check that VACUUM GATE button on
Operator Control Panel is ON.
• Check LED on Y13 solenoid on
pneumatics tray. If ON, press manual
override button. If gate opens, replace
solenoid valve Y13. If not, check tubing
and gate valve actuator.
• If Y13 LED is OFF, check LED on output
module #3-3. If ON, check module fuse.
If OK, check cable/connector. If OK,
replace module #3-3.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–3. Troubleshooting - Base Machine (continued)

Problem Cause Remedy

Transport belts fall off rollers • Incorrect belt tension. • Adjust belt tension.
“Tracks not cleared” message • Board on tracks. • Remove board from tracks.
• Incorrect board dimensions • Ensure that the correct board dimensions
specified. are entered on SETUP menu.
• Input/Output sensors defective. • Check sensitivity setting of input/output
sensors.

Insufficient vacuum • Air loss through channels on board. • Re-arrange board on vacuum chamber to
hold-down minimize air loss, or use dedicated fixture.
• Defective vacuum gate. • Check that vacuum gate is wide open.

Cannot align board to stencil • Board positioned incorrectly on • Verify that the board is centered on
workholder. workholder.
• Stencil image not centered. • Verify that the stencil image is centered in
stencil frame.
• Stencil not positioned correctly. • Verify that the stencil is properly seated
and clamped.
• Defective camera-mounted board • Repeat the Boardstop Teach procedure.
stop sensor. If problem persists, contact MPM Field
Service.
• Vision system problem. • See Vision System table.

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 Chapter 4: Troubleshooting/Messages

Table 4–4. Print Head

Problem Cause Remedy

Front blade does not flip • Paste accumulation. • Remove paste accumulation.
• Electrical or pneumatic problem. • Check LED on Y8 solenoid/valve on
pneumatics tray. If ON, manually override
the output. If flips OK, replace Y8. If still
no flip, check tubing/fittings for leak.
• If Y8 LED OFF, check LED on module
#4-14. If ON, check output for 24 VDC.
If O VDC, check fuse. If fuse OK, replace
module #4-14.
Rear blade does not flip • Paste accumulation. • Remove paste accumulation.
• Electrical or pneumatic problem. • Check LED on Y9 solenoid/valve on
pneumatics tray. If ON, manually override
the output. If flips OK, replace Y9. If still
no flip, check tubing/fittings for leak.
• If Y8 LED OFF, check LED on module
#4-15. If ON, check output for 24 VDC.
If O VDC, check fuse. If fuse OK, replace
module #4-15.
Front blade does not clamp • Clamp assembly clogged with • Clean paste off clamp assembly/clear
paste/mechanical obstruction. mechanical obstruction.
• Electrical or pneumatic problem. • Check LED on Y6 solenoid/valve on
pneumatics tray. If ON, manually override
the output. If clamps OK, replace Y6.
If still no flip, check tubing for leak, open
connector.
• If Y6 LED OFF, check LED on module
#4-12. If ON, check output for 24 VDC.
If O VDC, check fuse. If fuse OK, replace
module #4-12.
• Leak or front clamp module • Check tubing/fittings for leaks. Check front
bladders malfunctioning. clamp module bladders for leaks.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–4. Print Head (continued)

Problem Cause Remedy

Rear blade does not clamp • Clamp assembly clogged with • Clamp assembly clogged with paste/
paste. mechanical obstruction.
• Mechanical obstruction. • Remove obstruction.
• Electrical or pneumatic problem. • Check LED on Y7 solenoid/valve on
pneumatics tray. If ON, manually override
the output. If clamps OK, replace Y7.
If still no flip, check tubing/fittings for
leak, open connector.
• If Y7 LED OFF, check LED on module
#4-13. If ON, check output for 24 VDC.
If O VDC, check fuse. If fuse OK, replace
module #4-13.
• Leak or rear clamp module • Check tubing/fittings for leaks. Check rear
bladders malfunctioning. clamp module bladders for leaks.
Unable to seat blade holder into • Clamping bladders in clamp • Disassemble clamping assembly and re-seat
clamping assembly modules over-extended bladders in clamp modules. Refer to Clamp
(popped out). Assembly Bladder Resetting in Chapter 3.
Blade(s) fall out when • Ball plungers require adjustment. • Adjust ball plungers. Refer to Squeegee
unclamped. Holder Ball Plungers Adjustment, Chapter 3.
Blade(s) are loose or fall out • Pivot bar requires adjustment. • Refer to Clamp Force Adjustment,
when clamped. Chapter 3.

Squeegee Z-brake does not • Solenoid valve Y2 defective. • Check LED on solenoid valve Y2. If ON,
operate manually actuate valve. If brake operates,
replace Y2.
• If LED is OFF, check LED for output
module #3-0. If OFF, check 5 VDC input
to module. If ON, check for 24 VDC
output. If 0 VDC, check fuse. If fuse OK,
replace module #3-0.
• Brake cylinder defective. • Replace brake cylinder.
Leveling works; weighing • Calibration needed. • Contact the MPM Field Service.
does not

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 Chapter 4: Troubleshooting/Messages

Table 4–4. Print Head (continued)

Problem Cause Remedy

Weighing works; leveling • Clamp assembly clogged with • Clean paste from clamp assembly.
does not paste.
• Spring-loaded plungers too tight. • Adjust spring-loaded plungers.
• Electrical problem.
Refer to Rear blade does not clamp, this table.
• Rear clamp module or tubing
• Check rear clamp module, fittings for leaks.
leaking.
• Defective Airpot® cylinder, fuse
• Contact the MPM Field Service or isolate
28FU, pressure controller AV1 or
fault to a listed component.
AV2, fuse 27FU, buffer card, or
D/A converter in computer.

Table 4–5. Tactile Sensor

Problem Cause Remedy

Board-to-stencil distance is not • Tactile sensor assembly out of • Calibrate tactile sensor assembly.
the same as on Setup menu calibration. Contact the MPM Field Service.
Sensor does not extend down • Electrical/pneumatic problem. • Check LED on Y17 solenoid valve
(on pneumatics tray). If OFF,
• Check LED for output module #3-18.
If ON, check fuse. If fuse OK, check for
24 VDC on output. If OK, check wiring.
• If wiring OK, replace Y17.
• If LED on Y17 solenoid valve ON,
manually override valve. If sensor lowers,
replace Y17. If not,
• Air leak; internal air cylinder • Check the tubing/fittings, internal air
defective. cylinder.

Tactile switch malfunctioning • Switch actuator (or switch) clogged • Clean switch actuator. Refer to Tactile
with paste. Sensor Inspection/Cleaning –Daily in the AP
HiE Series Preventive Maintenance Guide.
If the actuator still does not move freely,
refer to Tactile Sensor Switch Cleaning/
Replacement in the chapter 3 of this
manual.
• Electrical problem. • With the tactile switch on the stencil, check
LED for module #2-20. If OFF check
continuity through switch. If open, check
wiring. if OK, replace tactile switch.
Tactile sensor does not move Driver card malfunction • Check fuse 26FU in lower drawer.
down CAUTION: The tactile sensor motor • Check DIP switch settings on driver.
has a special 180mA output driver. • Measure voltage input at driver.
Do not attempt to swap with other • Contact the MPM Field Service.
drivers during troubleshooting.
Burnout of the motor will result. Use
only the same type driver card.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–6. Vision System

Problem Cause Remedy

Poor Correction • Poor placement of printed pads. • Verify that the stencil targets are properly
matched to the correct board targets.
• Vision system out of alignment. Contact
the MPM Field Service.
Illumination problems • Board camera lamp does not • Check for blown bulb.
illuminate. Check LED for I/O module #3-16. If ON,
check fuse. If fuse is OK, replace module.
• Stencil camera lamp does not • Check for blown bulb.
illuminate. Check LED for I/O module #3-17. If ON,
check fuse. If fuse is OK, replace module.
• Neither camera lamp illuminates. • Check fuse 44FU (1A) 110VAC
• Check fuse 23FU (2A).
• Check GS3 for 13VDC output.
• Check for loose connector J65.
No camera image on • Monitor not turned on. • Check monitor on/off button.
monitor (camera lamps OK) • Monitor power fuse blown. • Check fuse 3FU.
• Vision system cable not connected. • Check condition of vision cable.
• Camera power supply GS3 • Check for 13VDC from XT9-9(+) to
inoperative or blown fuse. XT9-16 (comm.)
• Check power to camera power supply (all
fuses are located on the pneumatics tray):
44FU (1A, 120VAC input)
23FU (2A, 13VDC output to lamps)
21FU (2A, 13VDC to camera control
unit)
X platen skews on gantry during • Incorrect vision system air • Check vision system air pressure setting.
travel pressure. (Set air regulators to labeled value.)
X platen forcers (linear drive • Dirty platen. • Clean platens.
motors) do not float freely
• Dirty bearing on X-forcer and • Inspect/clean bearings on X forcer, and
Y-left forcer. Y-left forcer.
• Insufficient air to vision system. • Increase air to vision system.
• Clogged orifices on forcer (motor). • Contact the MPM Field Service

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 Chapter 4: Troubleshooting/Messages

Table 4–7. Worknest/Stencil

Problem Cause Remedy

Frame clamps do not operate • Electrical problem. • Check LED at I/O Rack #3-13. If ON,
check fuse for mod
• Check Y16 solenoid on pneumatics tray.
Vacuum gate sluggish to open/ • Faulty cylinder/air line. • Verify condition of cylinder/airline.
close • Gate clogged with paste • Clean gate.
• Faulty solenoid. • Check Y13 solenoid on pneumatics tray
(may be sticking during shutoff ). Contact
the MPM Field Service.
Z axis brake does not release or • KT2 (on Z-axis tower) not • Check delay time setting of KT2
is sluggish energizing properly. (relay should energize in 5 seconds).
• Electrical problem. • Check for 24V to brake.

Table 4–8. Environmental Control Unit (ECU)

Problem Cause Remedy

Totally inoperative • External power source OFF. • Check power cable, ON/OFF switch,
external disconnects.
• Internal circuit breaker tripped • Reset internal breaker and retry. If repeats,
check for clogged filters or other blockage.
Check motor currents.
• ECU enable signal fault • Check I/O Rack #4-8 and KI in ECU with
ECU ON/OFF from operators control
panel
Printer temperature is too high • ECU filters clogged • Clean filters
• Compressor inoperative • Check that compressor is running
• Temperature controller setpoint • Check temperature controller setpoint and
too high, in wrong mode, or has mode (should be in Auto).
failed
Printer temperature is too low • Temperature controller setpoint • Check temperature controller setpoint and
too low, is in wrong mode, or has mode (should be Auto).
failed • Check ECU heater.
• ECU heater has failed

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–9. Paste Dispenser Option

Problem Cause Remedy

No paste is being dispensed • Paste cartridge empty • Install new paste cartridge
(dispenser downward and cross- • No air pressure to dispenser head • 1. Check air tubes for leak/open
travel motions are OK) 2. Check LED for output
I/O Rack module #3-19. If ON, check
fuse. If fuse is OK, check LED on solenoid
valve Y3. If ON, manually actuate valve.
If paste dispenses, replace valve Y3.
• Cut-off solenoid valve, tubing or • Check LED for I/O Rack module #3-21; if
cut-off cylinder defective. ON check solenoid valve Y19 LED.
• If ON manually actuate valve. If fault
persists, check pneumatic tubing and paste
tube cut-off air cylinder.
• Defective dispenser head up sensor • Check up sensor switch SQ63; I/O Rack
module #2-22.
Dispenser won’t travel; • Defective center limit sensor or • Check center limit sensor SQ62; I/O Rack
“Machine Must be Reset” I/O module module #2-21.
message
• Blown fuse in drive power circuit • Check 25FU in XT7 of lower drawer
• Bad driver card or motor. • Check stepper driver card E23; check
motor M23.
Dispenser won’t drop down to • Defective I/O module or solenoid • Check LED on I/O Rack module #3-20.
dispense position valve. If ON, check fuse. If fuse OK, check LED
• Defective air cylinder or tubing on solenoid valve Y18.
• If LED on Y18 is ON, manually actuate
valve. If dispenser drops down, replace
valve Y18. If LED is OFF, check wiring.
• If fault persists, check air cylinder and air
connections

Table 4–10. Side Snuggers (X-Axis) Option

Problem Cause Remedy

Snuggers do not operate • Electrical/pneumatic problem. • Check LED on module #3-23 in I/O rack
#3. If ON, check fuse.
• If fuse OK, LED on solenoid valve Y4.
If ON, manually actuate valve.
• If snugger operates, replace valve. If fault
persists, check pneumatic tubing and
connectors.
• Flow controls set incorrectly. • Check setting of flow controls.

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 Chapter 4: Troubleshooting/Messages

Table 4–11. Y-Axis Tooling Option

Problem Cause Remedy

Snugger does not operate • Paste has accumulated between the • Clean out the paste accumulation with
(partial or totally inoperative) snuggers and the tracks. solvent and a brush.
• Electrical problem. • Test operation with Y SNUGGER digital
output on the Digital Input/Output
Screen. If snugger is inoperative:
• Check solenoid valve Y11 LED. If OFF,
check I/O module #5-8 LED.
• If #5-8 LED is ON, check voltage across
associated “pico-fuse”. If 24 VDC, replace
fuse (fuse can be pulled out of socket).
If 0 VDC (fuse OK), replace output
module #5-8.
• If #5-8 LED is OFF, check cables and
connectors.
• If solenoid valve Y11 LED is ON, press
manual override button on valve Y11.
If snuggers actuate, replace valve Y11.
• Pneumatic tubing /connector • If snuggers don’t actuate, check for open
problem. tubing or connector. If fault persists, check
• Air cylinder defective snugger cylinders.
Flippers do not operate • Electrical problem. • Check solenoid valve Y21; I/O module
#5-10.
• Pneumatic tubing /connector • Check for open line or connector.
problem.
• Air cylinders defective • Check operation of cylinders.
Flippers do not clamp boards 1. Board thickness is thinner than 1. Enter correct board thickness in SETUP
tightly the Board Thickness MENU PAGE #1.
parameter.
2. Flipper shafts are out of 2. Check Flipper Shaft Alignment per
alignment. procedure in the Repair section.
Check for loose belt or pulley.
3. Flipper shafts are “out of sync” 3. Check Flipper Shaft Alignment per
(one or more groups of procedure in the Repair section. If out of
flippers are not fully actuated). sync, check for loose belt or pulley.
Snuggers do not grip board 1. Paste has accumulated between 1. Clean out the paste accumulation with
tightly the snuggers and the tracks. solvent and a brush.
2. Low air pressure to snugger 2. Check air pressure and air lines for leak.
cylinders or leaky line.
3. Defective air cylinder. 3. Check both air cylinders. Replace bad
cylinder if needed.
4. TRK WIDTH incorrectly set. 4. Reenter correct Y size in SETUP MENU
PAGE or jog TRK WIDTH.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–11. Y-Axis Tooling Option (continued)

Problem Cause Remedy

Printing halted and 1. Paste buildup has occurred. 1. See Messages section in this document for
Front Snugger Not Down or procedures.
Rear Snugger Not Down 2. Paste has accumulated on the 2. Clean and lubricate brake shafts.
message displayed on screen brake shafts.
3. Brakes out of alignment. 3. See Brake Alignment in the Repair
section.
Half of flippers on one side do 1. Loose or broken clamp on belt 1. Inspect pulley clamp. Tighten or replace
not actuate pulley. pulley as indicated. See Flipper Shaft
Alignment for repair and re-alignment.
2. Loose belt 2. Tighten belt. See Flipper Actuator Belt
Tension Adjustment.
3. No air to flipper actuator. 3. Check air lines for leak.
4. Defective flipper actuator. 4. Test flipper actuator with FLIPPERS
digital output. See Flipper Actuator
Replacement if replacement is needed.

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 Chapter 4: Troubleshooting/Messages

Table 4–12. Stencil Wiper Option

Problem Cause Remedy

Wiper carriage will not operate • Wiper not enabled. • Enable on Setup Menu.
• Wiper binding. • Check for binding, remove fault, reset
machine.
• Wiper carriage will not move. • Check wiper carriage stepper motor.
• Check fuse (22FU) lower drawer.
• Check motor coupling condition.
• Wiper paper not loaded properly. • Load wiper paper properly. See Chapter 3.
Paper winder does not operate • Electrical problem. • Check LED on I/O rack #3, module #3-1.
• If ON, check fuse. If open, replace fuse and
re-test. (Fuse unplugs from board; use spare
fuse from board.)
• Winder motor relay defective. • If fuse for #3-1 OK, check winder motor
relay (KP7). If deenergized, replace relay
and retry.
• Defective motor drive unit, E3 or • If energized, check output of DC drive
fiber optic winder sensor, ES87. unit, E3 (A1+ to A2-). If 0VDC, check
• Defective motor (rare). current output of fiber optic winder sensor,
ES87. If 0mA, replace sensor. If OK,
replace DC drive unit.
• If drive unit and sensor OK, check motor
for open winding. Replace motor if open.
• Drive chain broken. • Check integrity of drive chain.
Vacuum/wiper plenum does not • Mechanical obstruction • Check for paste accumulation.
rise up (paste accumulation).
• Electrical/pneumatic problem. • Check LED on I/O module #3-7. If ON,
check output fuse. If open, replace and
retry.
• If fuse is OK, check LED on solenoid valve
Y15. If OFF, check cable/connector.
If ON, manually actuate valve. If plenum
lifts, replace valve Y15. If not, check for
leak in pneumatic tubing; check plenum
actuators.
• Flow controls out of calibration. • Contact the MPM Field Service.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–13. Stencil Wiper Solvent Faults

Problem Cause Remedy

Solvent pump motor does not • Fuse blown. • Check fuse 29FU (2A, near solvent pump)
run for 110VAC.
• Solvent motor relay KP12 • Check KP12 for activation
defective. • Check
• Defective timing relay, KP11. operation of timing relay, KP11.
Solvent not pumping • Solvent tank empty. • Fill solvent tank. See Chapter 3.
(motor runs)
• Solvent pump not primed. • Prime pump. (Press Dispense Solvent on
Operator’s Control Panel.)
• In-line filter clogged. • Replace in-line filter.
• Solvent shutoff valve malfunction. • Check solvent shutoff valve (YV1).
• Electrical problem. • Check I/O Rack #4-18.
“Solvent Empty” warning • Solvent tank empty. • Fill solvent tank. See Chapter 3.
message
• Electrical problem (tank not • Check I/O Rack #4-2.
empty).
“Solvent Empty” warning • Solvent level switch • Check solvent level switch.
message - cont’d. malfunctioning (tank not empty).
Solvent pump motor does not • Fuse blown. • Check fuse 29FU (2A, near solvent pump)
run for 110VAC.

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 Chapter 4: Troubleshooting/Messages

Table 4–14. Stencil Wiper - Vacuum Option

Problem Cause Remedy

Weak vacuum at stencil wiper Clogged filters, line or plenum at vac- Check filters. Replace if dirty. Refer to
plenum uum pump. Vacuum Stencil Wiper Inspection/Cleaning -
Monthly in the AP HiE Series Preventive
Maintenance Guide.
No vacuum at stencil wiper • No air to pump. • Check regulator output gauge for 80 PSI.
plenum • Clogged or open vacuum line. • Check vacuum pump output gauge.
• No air through pump. If higher than -15 to -17 in. Hg, check
for clogged line. If -15 to -17 in. Hg,
check for an open vacuum line.
• If vacuum output gauge reads 0 in Hg,
check LED on solenoid valve Y10.
• If Y10 LED is ON, press manual output
button on Y10. If vacuum increases,
replace Y10. If not, check air line to
pump solenoid; if OK, replace solenoid
valve on vacuum pump.
• If Y10 LED is OFF, check LED for
output module #4-22. If OFF, fault is
upstream in computer/interface. If LED
is ON, replace fuse in module. If fault
persists, replace module #4-22.

Table 4–15. 3-D Option

Problem Cause Remedy

3D verification inoperable • Vertical laser off. • Check I/O Rack #4-16.

• Horizontal laser off. • Check I/O Rack #4-17.
• Both lasers off. • Close all machine covers.
• Check position of Safety keylock switch
SW1 on PC-107 laser interlock board
(located on pneumatics tray)
• Check interlock switches.
• Check fuse 45FU, 1A, 120VDC to GS4.
• Check fuse 30FU, 1A, 5VDC output from
power supply GS4)
3D verification inoperable • Vertical laser off. • Check I/O Rack #4-16.

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AP HiE Series Maintenance/Troubleshooting Guide

Table 4–16. Fuse / Circuit Breaker List

Voltage/Function Location Fuse No. Amps Class Part No.
115 VAC to 24V transformer AC Plate Contactor bulk. 1FU 2A CC P5010
24 VAC AC Plate - FUB-1 2FU 4 250V Slo-Blo P5245
120 VAC to video monitor AC Plate - FUB-1 3FU 2 250V Slo-Blo P0887
120 VAC to 24 VDC P.S. AC Plate - FUB-1 4FU 2 250V Slo-Blo P0887
Vacuum Blower Motor - AC power AC Plate contactor block 7FU 12 (120V) CC P4860
10 (240V) CC P4859
24 VDC to machine lamp AC Plate - FUB-1 8FU 2 250V Slo-Blo P0887
24 VDC to relays AC Plate - FUB-1 9FU 4 250V Slo-Blo P5245
240 VAC Vacuum Blower Motor AC Plate contactor block 34FU 10 CC P4859
(only if 240 VAC is used)

120 VAC to cooling fans AC Plate - FUB-1 36FU 1 Glass body P1992
“Busy” signal 24VDC excitation AC Plate - FUB-1 49FU 1 Glass body P1992
“Board Avail” 24VDC excitation AC Plate - FUB-1 50FU 1 Glass body P1992
240 VAC to transformer TV1 AC Plate Contactor block QF2 10 240V breaker P5114
120 VAC to transformers (Alternate) AC Plate Contactor block QF2 15 120V breaker P5115

12 VDC to Camera Control Unit Pneumatic Tray - XT9 21FU 2 250V Slo-Blo P0887
12 VDC to vision unit lamps Pneumatic Tray - XT9 23FU 2 250V Slo-Blo P0887
24 VDC to L&R pressure controllers Pneumatic Tray - XT9 28FU 1 Glass body P1992
5 VDC to 3-D option Pneumatic Tray - XT9 30FU 1 Glass body P1992
120VAC to GS3 (12 VDC P.S.) Pneumatic Tray - XT9 44FU 1 Glass body P1992
120 VAC to GS4 (3-D option P.S.) Pneumatic Tray - XT9 45FU 1 Glass body P1992
+24 VDC for relays, solenoids, etc. Pneumatic Tray - XT9 46FU 3 250V Slo-Blo P0704

120 VAC to AT computer Upper Drawer - XT5 5FU 5 250V Slo-Blo P0703
120 VAC to GS2, 5 VDC P.S. Upper Drawer - XT5 6FU 1 Glass body P1992
+5 VDC to Motion Mother Bd. MUX Upper Drawer - XT5 10FU 5 250V Slo-Blo P0703
120 VAC to PC-103 Analog Buffer Bd. Upper Drawer - XT5 27FU 1 Glass body P1992
24 VDC to solenoid valves & relays Upper Drawer - XT5 47FU 3 250V Slo-Blo P0704

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 Chapter 4: Troubleshooting/Messages

Table 4–16. Fuse / Circuit Breaker List

Voltage/Function Location Fuse No. Amps Class Part No.
40 VDC X axis stencil stepper drive Lower drawer - XT8 11FU 5 250V Slo-Blo P0703
40 VDC Y axis stencil stepper drive Lower drawer - XT8 12FU 5 250V Slo-Blo P0703
40 VDC theta stencil stepper drive Lower drawer - XT7 13FU 5 250V Slo-Blo P0703
70 VDC Z axis stepper drive Lower drawer - XT8 14FU 8 250V Slo-Blo P0869
70 VDC to squeegee stepper drive Lower drawer - XT8 15FU 8 250V Slo-Blo P0869
40 VDC to bd. xport stepper drive Lower drawer - XT8 16FU 8 250V Slo-Blo P0869
40 VDC to track width stepper drive Lower drawer - XT8 17FU 5 250V Slo-Blo P0703
70 VDC - vision X axis stepper drive Lower drawer - XT7 18FU 5 250V Slo-Blo P0703
70 VDC - vision Y left stepper drive Lower drawer - XT7 19FU 5 250V Slo-Blo P0703
70 VDC - vision Y right stepper drive Lower drawer - XT7 20FU 5 250V Slo-Blo P0703
40 VDC wiper carriage stepper drive Lower drawer - XT7 22FU 5 250V Slo-Blo P0703
40 VDC -squeegee down stop drive Lower drawer - XT7 24FU 5 250V Slo-Blo P0703
40 VDC paste dispenser step. drive Lower drawer - XT7 25FU 5 250V Slo-Blo P0703
40 VDC tactile axis stepper drive Lower drawer - XT7 26FU 1 250V Slo-Blo P2559
120 VAC to cooling fans Lower drawer - XT6 35FU 1 250V Slo-Blo P1992
120VAC to TV2 transf. (70 VDC P.S.) Lower drawer - XT6 37FU 6 CC P5011
120 VAC to TV3 trans. (40VDC P.S.) Lower drawer - XT6 38FU 8 CC P5012
70 VDC to vision, Z, squeegee drives Lower drawer - XT6 39FU 15 CC P4806
70 VDC to vision, Z, squeegee drives Lower drawer - XT6 40FU 15 CC P4806
40 VDC to all other drivers Lower drawer - XT6 41FU 20 CC P4861
40 VDC to all other drivers Lower drawer - XT6 42FU 20 CC P4861
24 VDC to YB1, KP3, KT4, KP5 Lower drawer - XT6 48FU 2 250V Slo-Blo P0887

120 VAC to solvent pump motor PCB near pump 29FU 2 250V Slo-Blo P0887
120/240 VAC to vacuum blower Motor switch box — 250V Slo-Blo
motor

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