LPKF ZelFlex Z4P User manual

USER MANUAL
Pneumatic 4-side quick release
stretching frame
LPKF ZelFlex®Z4P

Rev.: 13.01.2014 3User Manual v2.11
INTRODUCTION
LPKF Laser & Electronics d.o.o.
LPKF d.o.o.
Polica 33
SI-4202 Naklo
Slovenia
[phone]
[phone]
www.lpkf.com; www.lpkf.si; www.zelex.com
[email protected], [email protected]
Company name:
Abbreviated name:
Address:
Telephone:
Fax
Internet:
E-mail:
Trade-mark:
1 INTRODUCTION
1.1 LPKF ZelFlex Z4P
ZelFlex frames are designed for holding SMT metal stencils tensioned during the SMT printing
process.
The ZelFlex frame size should be selected according to printer data, either for direct inserting,
or using adapters.
When the printer supports various sizes of frames, frame holders must be adjusted to the
ZelFlex frame size.
The ZelFlex patented stretching system uses compressed air for perfect and uniform tensioning
all over the working area. Two major ZelFlex Z4P types are available - standard and slim.
Standard frame has thickness of 33 mm, whereas Slim of 25 mm. This type was designed
especially to t into smaller printers with height limit of 25 mm. Thinner frame acumulates less
air inside and for this reason it needs ll up time at least every 24 h.
Compressed air is kept inside the frame and provides optimum tensioning for the next 24/48 h
depending on the frame type.
Different supplied air pressure levels allow optimum tensioning of stencils from 100 microns
(4 mil) to 250 microns (10 mil). Details can be found inside the manual.
When stencil is mounted, air supply is disconnected. A frame can be inserted into the printer,
and used for at least 24 hours without the need for air connection.
LPKF ZelFlex Z4P is available in many different sizes and with different adapters suitable for
almost all printing machines.

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INTRODUCTION
1.2 Warnings
Copyright© 2010-2013 LPKF d.o.o.
Copying and distributing these instructions in their entirety or in part is only permitted by LPKF
approval in writing.
Note: Data can be altered without prior notice.
Original Instructions
LPKF is not liable for damage occurring due to improper use of these instructions.
The owner of the LPKF system is obligated to:
• Ensure that the system is used only for its intended purpose.
• Ensure that the system is used only under the specied operating conditions.
• Regularly check for safety, and control systems.
• Ensure that only authorized and qualied personnel operate the system.
• Ensure that all operators of the system have ready access to these instructions.
• Ensure that the system always has safety labels in place.
Remove the packaging and check the general state of the equipment, and check the contents
against the enclosed packing list.
In the event of any damage immediately inform the transport agent!
Before starting-up the system, remove all packaging, which served as protection of the system
during transport, otherwise severe damage could be caused to the system!
Please note: unauthorized repairs or modications to the equipment will void the warranty!
In case of problems with the system, please immediately contact us, giving the serial number
of the system!
[phone]
[phone]
Telephone:
Fax:
E-mail: [email protected]
[email protected]

Rev.: 13.01.2014 5User Manual v2.11
CONTENTS
2 CONTENTS
1 INTRODUCTION 3
1.1 LPKF ZelFlex Z4P 3
1.2 Warnings 4
2 CONTENTS 5
2.1 Symbols, etc. used in this manual 6
2.1.1 Registered trademarks
3 BASIC DATA 7
3.1 Name and address of the manufacturer 7
3.2 Relevant model 7
3.3 Intended use 7
3.4 Technical data 7
3.4.1. LPKF ZelFlex - standard
3.4.2. LPKF ZelFlex - slim
3.5 Noise level/vibration/emission of hazardous chemicals 9
4 SAFETY NOTES 10
4.1 General 10
4.2 Hazards 10
4.3 Safety measures 11
4.4 Procedures in the event of injury or other emergencies. 11
5 DEVICE DESCRIPTION 12
5.1 Basic parts 12
5.1.1 Air connector
5.1.2 Pins
5.1.4 Return springs
5.2 Compressed Air 13
5.3 Optional equipment 14
5.3.1 Adapters
5.3.2 Air pressure measuring gauge
5.3.3 Air supply unit
6 DEVICE INSTALLATION 15
6.1 Opening the packaging 15
6.2 Inspection of the frame 15
7 USE OF ZELFLEX Z4P 16
7.1 Process of inserting the stencil 16
7.1.1 Compressed Air
7.2 Process of removing the stencil 19
8 MAINTENANCE 20
8.1 General 20
8.2 Cleaning the frame 20
8.3 Cleaning the stencil – Washing Frame (optional) 20
8.4 Stencil care 21
9 TROUBLESHOOTING 22
10 APPENDICES 23

Rev.: 13.01.20146 ZelFlex Z4P
CONTENTS
2.1 Symbols, etc. used in this manual
Bolded text emphasises the importance of the information.
Symbols that you will notice in some chapters have the following meaning:
Good advice and instruction
“Rapido” warns the user about possible faults, and recommends simple and effective
solutions.
Caution!
The symbol warns of circumstances that could threaten the safety and health of the
device operator or cause a serious device defect.
Danger!
The symbol is used to highlight danger to life or health.
2.1.1 Registered trademarks
The LPKF logo and all LPKF product brand names are registered trademarks of LPKF Laser &
Electronics AG and LPKF Laser & Electronics d.o.o.
All other trademarks are property of their respective owners.

Rev.: 13.01.2014 7User Manual v2.11
BASIC DATA
LPKF Laser & Electronics d.o.o.
LPKF d.o.o.
Polica 33
SI-4202 Naklo
Slovenia
+ 386 (0) 592 08 800
+ 386 (0) 592 08 820
www.lpkf.si
[email protected], [email protected]
Company name:
Abbreviated name:
Address:
Telephone:
Fax
Internet:
E-mail:
Trade-mark:
3 BASIC DATA
3.1 Name and address of the manufacturer
3.2 Relevant model
ZelFlex Z4P
3.3 Intended use
Professional quick-release SMT stencil frame.
3.4 Technical data
Compressed air supply: Clean and dry air only!
Pressure depends on the thickness of the stencil:
Stencil thickness 80 μm 100 μm 120 μm or thicker
Recommended air supply 4,5 bar 5,0 bar 6,0 bar
Fill-up time: Every 48 hours
Size: Width & length (outer dimension) are dened in the frame name
LPKF ZelFlex Z4P 584 x 584= width 584 mm x length 584 mm
Thickness: 33 mm
Weight: 4,3 – 8 kg
(depends on the model & size, without adapters)
Ambient conditions: temperature: 5 – 35ºC
humidity: 30 - 95 %
3.4.1. LPKF ZelFlex - standard

Rev.: 13.01.20148 ZelFlex Z4P
BASIC DATA
Compressed air supply: Clean and dry air only!
Pressure depends on the thickness of the stencil:
Stencil Thickness 80 μm 100 μm 120 μm
Recommended air supply 5,0 bar 5,5 bar 6,0 bar
Fill-up time: Every 24 hours
Size: Width & length (outer dimension) are dened in the frame name
LPKF ZelFlex Z4P 584x584= width 584 mm x length 584 mm
Thickness: 25 mm
Weight: 3,4 – 5 kg
(depends on the model & size, without adapters)
Ambient conditions: temperature: 5 – 35ºC
humidity: 30 - 95 %
ZelFlex Z4P 406x508
ZelFlex Z4P 457x584
ZelFlex Z4P 508x508
ZelFlex Z4P 508x584/584x584
ZelFlex Z4P 540x540
ZelFlex Z4P 558x558
ZelFlex Z4P 558x558/584x558
ZelFlex Z4P 558x558/736x736
ZelFlex Z4P 584x508
ZelFlex Z4P 584x584
ZelFlex Z4P 584x584 manometer
ZelFlex Z4P 584x584/736x736
ZelFlex Z4P 584x584/736x736 manometer
ZelFlex Z4P 636x636
ZelFlex Z4P 636x636 manometer
ZelFlex Z4P 636x636/650x680
ZelFlex Z4P 636x636/736x736
ZelFlex Z4P 636x636/736x736 manometer
ZelFlex Z4P 636x736/736x736
ZelFlex Z4P 650x550
ZelFlex Z4P 736x636/736x736
ZelFlex Z4P 736x736
ZelFlex Z4P 381x381x25 Slim
ZelFlex Z4P 508x508x25 Slim
ZelFlex Z4P 540x540x25 Slim
ZelFlex Z4P 559x559x25 Slim
ZelFlex Z4P 584x584x25 Slim
ZelFlex Z4P 584x584x25 Slim manometer
ZelFlex Z4P 600x550x25 Slim manometer
ZelFlex Z4P 650x550x25 Slim manometer
ZelFlex Z4P 650x680x25 Slim
3.4.2. LPKF ZelFlex - Slim
When the frame is equipped with adapters, its outside dimensions are part of the name:
ZelFlex Z4P 636x636 / 736x736 (dimensions with adapters).
ZelFlex Z4P, most common product range:

Rev.: 13.01.2014 9User Manual v2.11
BASIC DATA
Check product data, both on the packaging and on any safety data sheets, for any
harmful characteristics.
Soldering pastes may contain lead and hazardous chemicals!
Please take into account the prescribed safety measures, and the prescribed
personal protective equipment stated in the paste manufacturer’s instruction
The device does not cause any noise or vibration.
Contact with chemicals (soldering pastes) is possible during the process of printing.
3.5 Noise level/vibration/emission of hazardous chemicals
Please nd further information about LPKF ZelFlex stretching frames on our web
site:
www.zelex.com

Rev.: 13.01.201410 ZelFlex Z4P
SAFETY NOTES
4 SAFETY NOTES
Before using the device, carefully read this chapter on health and safety. Familiarise
yourself with potential risks and prescribed safety precautions.
4.1 General
1. The device must be installed in accordance with the installation instructions.
2. The device should only be used for its designated purpose.
3. A suitable working environment must be ensured.
4. The device may only be operated by qualied personnel.
5. Servicing can only be performed by authorised and qualied personnel.
6. Ready access to the “User Manual” must be provided to all device operators.
4.2 Hazards
CHEMICAL
HAZARDS Soldering pastes may contain substances hazardous to health.
MECHANICAL
HAZARDS
A risk of cuts is present during the process of clamping the
stencil (use protective gloves).
MECHANICAL
HAZARDS
Inating the frame without holding bars mounted could cause
serious injury (uncontrolled moving parts).

Rev.: 13.01.2014 11User Manual v2.11
SAFETY NOTES
4.3 Safety measures
Before operating the device a full visual inspection should be carried out. In the event of any
defects or malfunctions, work may not begin before removing all faults!
It is of vital importance that the area around the device is maintained clean and tidy.Adisorganised
workplace can cause occupational injuries (e.g. a person can fall, slip or incur an injury).
Holding bars must always be mounted on the frame during printing.
Do not push sharp edges of the stencil through the notches on the prole.
Do not use air pressure over 6 bars (87 PSI). It can damage the frame permanently. Make sure
to use clean and dry air only. Exceeded air pressure may damage the stencil permanently.
Consider recommended compressed air supply according to the frame type and stencil thickness.
Please ensure, that the environment in which the equipment is going to be used, conforms to
that specied in this document.
While working with the device, complete attention of the operator is required. A person who is
feeling unwell or is having difculties concentrating should not operate the device!
Only equipment, which has been approved by LPKF, can be used in conjunction with the device.
The use of unsuitable equipment could endanger the operator!
Repairs can only be carried out by authorised service personnel. The service personnel should
ensure that the safety of the equipment is not compromised by the repair.
The storing or consuming of food and beverages in the work area is forbidden!
Smoking in the work area and while working is forbidden!
When using hazardous substances, safety data sheet instructions and advice should be followed!
Recommended personal protective equipment: protective gloves!
4.4 Procedures in the event of injury or other emergencies.
In the event of a work-related injury, stop working immediately, and if necessary, seek professional
medical assistance.

Rev.: 13.01.201412 ZelFlex Z4P
DEVICE DESCRIPTION
5 DEVICE DESCRIPTION
5.1 Basic parts
5.1.1 Air connector
Fast connector enables a fast and effective air connection
with your air supply unit.
Make sure to use clean and dry air only.
5.1.2 Pins
Stencil supporting pins on the stretching bar enable a
fast and easy placement of stencils onto the ZelFlex
frame.
5.1.3 Protective holding bars
Protective bars have multiple functions:
• holding the stencil down while air is supplied
• providing good contact between pins and perforation
• providing an adequate stencil level
• protecting the stencil and operator from mechanical
hazards
5.1.4 Return springs

Return springs are factory adjusted for optimum
operation.
Do not adjust or change return springs position.
Wrong settings may damage the frame and the stencil.
Under moderate stress ZelFlex Z4P requires relling every 48 h, whereas ZelFlex
Z4P Slim requires relling every 24 h.

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DEVICE DESCRIPTION
5.2 Compressed Air
ZelFlex frames must be relled with compressed air for
5 – 10 s to provide the necessary stretching force.
Stretching force is related to compressed air pressure.
Always use dry and clean air only! Particles and humidity can damage the frame or
the air connector.
For easy and reliable air distribution use an air suppy unit with a water separator and
5 μm air lter (option).
Always use original air connectors to protect the valve (fast connector) on the frame
side!
The connection hose is equipped with a fast connector
for fast and effective air connection with the air supply
unit.
Exceeding the pressure of 6 bar (87 PSI) may damage the stencil and the frame.
LPKF recommends:
ZelFlex Z4P
Stencil thickness 80 μm 100 μm 120 μm or thicker
Recommended air supply 4,5 bar 5,0 bar 6,0 bar
ZelFlex Z4P Slim
Stencil thickness 80 μm 100 μm 120 μm or thicker
Recommended air supply 5,0 bar 5,5 bar 6,0 bar

Rev.: 13.01.201414 ZelFlex Z4P
DEVICE DESCRIPTION
5.3 Optional equipment
5.3.1 Adapters
Many different adapters have been designed to t
most of the customer’s demands for different printer
requirements.
Please nd additional information on: www.zelex.com
5.3.2 Air pressure measuring gauge
The optional manometer can be integrated into the
frame for a fast check of the pressure – stencil tension.
5.3.3 Air supply unit
• water separation
• 5 μm air lter for particles removal
• pressure regulation
• fast clamping to the working table

Use of Air supply unit with water separator and 5 μm air lter is strongly recommended,
as it prevents damage caused by particles or humidity in the air or by exceeded air
pressure. It is particularly important to use it with the thinnest stencils.

Rev.: 13.01.2014 15User Manual v2.11
INSTALLATION
6 DEVICE INSTALLATION
6.1 Opening the packaging
Carefully open the packaging by cutting the belts.
6.2 Inspection of the frame
Inspect the ZelFlex frame for transport damage.
If any transport damage is discovered, immediately notify the forwarding agent!
Please inspect the ZelFlex frame immediately after unpacking it:
• check the enclosed packaging list
• check the general state of the device
In an event of damage immediately contact your ZelFlex representative, providing
the SN and type of the frame.
ZelFlex frames may be repaired by an authorized ZelFlex partner only.

Rev.: 13.01.201416 ZelFlex Z4P
INSTRUCTIONS FOR USE
7 USE OF ZELFLEX Z4P
7.1 Process of inserting the stencil
Remove the protective holding bars side by side: press down, slide to the left and lift
them.
Before tensioning the stencil, always CHECK your system’s air supply characteristics!
Use of Air supply unit (available as an option) with 5 μm air lter and water separator
is advised.
Make sure there is no pressure in the frame.
1.
Always use dry and clean air only! Particles and humidity can damage the frame or
the air connector.
LPKF recommends:
ZelFlex Z4P
Stencil thickness 80 μm 100 μm 120 μm or thicker
Recommended air supply 4,5 bar 5,0 bar 6,0 bar
ZelFlex Z4P Slim
Stencil thickness 80 μm 100 μm 120 μm or thicker
Recommended air supply 5,0 bar 5,5 bar 6,0 bar

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INSTRUCTIONS FOR USE
Carefully put the stencil onto the pins.
Pay special attention to the orientation of the stencil.
Mind the upper and lower sides of the stencil!
2.
Put the protective holding bars back onto the frame side by side:3.
Press down and slide to the right:

Rev.: 13.01.201418 ZelFlex Z4P
INSTRUCTIONS FOR USE
Connect the frame with your air supply.
Remove the air connection tube from the frame. Insert the frame into the printer according to
printer instructions.
The ZelFlex size should be selected according to printer data, either for direct inserting or using
adapters. When the printer supports various sizes of the frame, frame holders must be adjusted
to the ZelFlex frame size.
Fill-up time is every 24/48 hours to guarantee the tensioning of the stencil > 35 N/cm.
When using a stencil with sharp edges, use of protective gloves is recommended.
Under moderate stress ZelFlex Z4P requires relling every 48 h, whereas ZelFlex
Z4P Slim requires relling every 24 h.
7.1.1 Compressed Air
ZelFlex frames must be supplied with compressed air for 5 – 10 s to provide the necessary
stretching force. Stretching force is related to compressed air pressure; the recommended
pressure is 4,5 – 6 bar (65 – 87 PSI) for 100 – 200 µm stencils.
Exceeding the pressure of 6 bars (87 PSI) may damage the stencil and frame.
Always use dry and clean air only! Particles and humidity can damage the frame or
air connector.
LPKF recommends:
ZelFlex Z4P
Stencil thickness 80 μm 100 μm 120 μm or thicker
Recommended air supply 4,5 bar 5,0 bar 6,0 bar
ZelFlex Z4P Slim
Stencil thickness 80 μm 100 μm 120 μm or thicker
Recommended air supply 5,0 bar 5,5 bar 6,0 bar

Rev.: 13.01.2014 19User Manual v2.11
MAINTENANCE
When using a stencil with sharp edges, use of protective gloves is recommended.
An air supply unit with a pressure regulator, water separation and 5 µm air lter is
available as an option.
• Release air from the ZelFlex frame:
use the air connector (connection hose) push
the female thread towards the male thread just
enough to release the clamp (do not connect)
7.2 Process of removing the stencil
• Remove the protective holding bars (for details see chapter 7.1).
• Remove the stencil.
• Place the protective holding bars back onto the frame (for details see chapter 7.1).
Always use dry and clean air only! Particles and humidity can damage the frame or
air connector.

Rev.: 13.01.201420 ZelFlex Z4P
MAINTENANCE
8 MAINTENANCE
8.1 General
ZelFlex frames are designed to be operated maintenance free, except for cleaning.
Always use clean and dry compressed air to avoid particles and humidity entering into the
ZelFlex frame.
Most soldering pastes and glues can be cleaned using isopropyl alcohol.
Never clean ZelFlex frames using cleaning devices or dipping them into cleaning
solvents!
8.2 Cleaning the frame
No cleaning solvent should enter the ZelFlex frame!
Pastes, solders or adhesives must be cleaned in accordance with the manufacturer’s instructions
regarding each individual substance.
Take care to follow manufacturer’s instructions for each individual substance!
8.3 Cleaning the stencil – Washing Frame (optional)
Matching the respective to sizes of the ZelFlex frames/stencils, two special washing frames for
stencils with ZelFlex perforation are available:
• LPKF ZelFlex Washing frame 584x584:
For stencils with Z4P perforation with frame width of up to 584 mm (23”) and frame length of 508 - 584 mm
(20” - 23”)
• LPKF ZelFlex Washing frame 736x736:
For stencils with Z4P perforation with frame width of up to 610 mm (24”) and frame length of 610 - 736 mm
(24” - 29”)
The stencil is easily clamped onto the washing frame,
which provides support and protection of the stencil
during washing.
The washing frame is designed to be inserted into
a cleaning agent solution or/and ultrasonic cleaning
system.