Page 1 M-2000 Dispensing Systems Level 2 Maintenance Training Course Number: TR-L2-M2000 Revision B Student Guide P/N 73-0018-00 (Revision B)
Page 3: Table Of Contents
Trainee Guide TR-L2-M2000 Introduction 1. Change Record 2. Table of Contents 3. Manual/Conventions Review 4. Course Terminal Objectives 5. Course Master Schedule 6. Classroom Safety 7. Final Certification Level 2 Maintenance Training – M-2000 Dispensing Systems P/N 73-0018-00 (Revision B)
Page 5: Change Record
Trainee Guide TR-L2-M2000 Change Record Description of Change Entered By Date Revision B (New Format) Janet Ramey 09/20/01 Level 2 Maintenance Training – M-2000 Dispensing Systems P/N 73-0018-00 (Revision B)
Page 6 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M-2000 Dispensing Systems P/N 73-0018-00 (Revision B)
Page 7 Trainee Guide TR-L2-M2000 Table of Contents Contents Page Change Record ......................i Table of Contents....................... Manual/Conventions Review ..................Terminal Objectives....................Course Master Schedule....................Classroom Safety ...................... Final Certification ......................xiii MODULE 1 Equipment Safety Basic Platform and Optional Modular Components ......
Page 8 Trainee Guide TR-L2-M2000 Table of Contents (Continued) MODULE 3 Routine Maintenance (Continued) Draining the Air Regulator Water Trap..........3-2-15 XYZ Rails ..................3-2-17 Dispense Pumps/Valves..............3-2-21 Cleaning and Replacing Fans and Vents ..........3-2-49 Conveyor Belts ................. 3-2-51 Tensioning the Cables ............... 3-2-57 MODULE 4 Troubleshooting Obtaining Asymtek Technical Support ..........
Page 9: Manual/Conventions Review
Trainee Guide TR-L2-M2000 Manual/Conventions Review Manual Review: Level 1 Operations Training – M-2000 Dispensing Systems • M-2000 Operations Manual • Fluidmove for Windows Installation and User Guide • DP-3000/DV-6000/DV-7000/DJ-2000 Valve Manuals • Conventions Review: Buttons • Cautions • Commands • Filenames •...
Page 10: Course Terminal Objectives
Trainee Guide TR-L2-M2000 Course Terminal Objectives Identify M-2000 Dispensing System features and precautions. Understand the M-2000 Dispensing System Theory of Operation. Perform routine maintenance procedures on M-2000 Dispensing Systems. Perform troubleshooting procedures on M-2000 Dispensing Systems. Replace Modules and PCA’s on M-2000 Dispensing Systems. Level 2 Maintenance Training –...
Page 11: Course Master Schedule
Trainee Guide TR-L2-M2000 Course Master Schedule Lesson Topic Length Ratio Module 1 Equipment Safety Basic Platform and Optional Modular Components 15 min Safety Warning Labels 15 min Power Supply and AC Distribution 15 min Emergency Shutdown Procedure 15 min Proper Powering On and Off Procedures 15 min Safety Interlock and Light Pole/Beacon 15 min...
Page 12 Trainee Guide TR-L2-M2000 Course Master Schedule (Continued) Lesson Topic Length Ratio Module 4 Troubleshooting Obtaining Asymtek Technical Support 15 min XYZ Axis Failure 45 min Pneumatic Failure 45 min Conveyor Failure 45 min Heater Failure 45 min Scale Failure 45 min Vision System Failure 45 min Dispense Valve Failure...
Page 13: Classroom Safety
Trainee Guide TR-L2-M2000 Classroom Safety A. Student Safety Any time a student or an instructor has apprehension concerning his/her personal safety or that of another, he/she will stop the evolution to clarify the situation or procedure and receive additional instruction as appropriate. The instructor is responsible for maintaining situational awareness and shall remain alert to signs of fatigue or exhaustion that may impair safe completion of the training lesson.
Page 14 Trainee Guide TR-L2-M2000 Classroom Safety (Continued) B. Safety Review Emergency Evacuation Situations Fire or Explosion Chemical Spill Earthquake Actions to Be Taken Small Fire – Notify nearest Asymtek employee of fire, who will in turn take appropriate action. Small Chemical Spill – Supervisors will be contacted immediately. Visitors should notify nearest Asymtek employee of spill, who will in turn take appropriate action.
Page 15 Trainee Guide TR-L2-M2000 Classroom Safety (Continued) Evacuation Routes Maps are provided in Appendix A for Asymtek buildings. The instructor and students will follow local evacuation routes for training outside of Asymtek, Carlsbad. C. Building Fire Alarms Asymtek buildings are equipped with fire alarms. Follow evacuation procedures if evacuation is necessary.
Page 16 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M-2000 Dispensing Systems P/N 73-0018-00 (Revision B)
Page 17 M-2000 S ERIES EVEL AINTENANCE RAINING INAL ERTIFICATION STUDENT NAME INSTRUCTOR NAME FACTORY DATE TRAINING SITE ODULE QUIPMENT AFETY NSTRUCTOR TUDENT Basic Platform and Optional Modular Components Safety Warning Labels Power Supply and AC Distribution Emergency Shutdown Procedure Proper Powering On and Off Procedures Safety Interlock and Light Pole/Beacon Facility Requirements Safety Precautions...
Page 19 Trainee Guide TR-L2-M2000 Module 1 Equipment Safety Lesson 1 Basic Platform and Optional Modular Components Lesson 2 Safety Warning Labels Lesson 3 Power Supply and AC Distribution Lesson 4 Emergency Shutdown Procedure Lesson 5 Proper Powering On and Off Procedures Lesson 6 Safety Interlock and Light Pole/Beacon Lesson 7...
Page 21 Trainee Guide TR-L2-M2000 Module 1 Table of Contents Lesson 1 Basic Platform and Optional Modular Components ....... 1 System Description ..................2 Basic Platform ....................2 Optional Modular Components ............... 2 Basic Platform for ASPA and PCBA Applications..........3 Lesson 2 Safety Warning Labels.................
Page 22 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training - M2000 Dispensing Systems P/N 73-0018-00 (Revision B)
Page 23: Basic Platform And Optional Modular Components
Trainee Guide TR-L2-M2000 Outline Sheet 1-1-1 Basic Platform and Optional Modular Components Introduction In order to observe essential safety precautions when performing M-2000 Dispensing System maintenance, it is necessary to be familiar with both standard and optional equipment features. Enabling Objective Identify the M-2000 Dispensing System basic platform and optional modular components.
Page 24 Trainee Guide TR-L2-M2000 Information Sheet 1-1-1 Basic Platform and Optional Modular Components A. System Description The M-2000 Series dispensing system is designed primarily for Advanced Semiconductor Package Assembly (ASPA) and Printed Circuit Board Assembly (PCBA) applications. The system platform can, however be configured for various applications. B.
Page 25 Trainee Guide TR-L2-M2000 Information Sheet 1-1-2 Basic Platform and Optional Modular Components D. Basic Platform for ASPA and PCBA Applications Model Application Heating Type Valve Type Light Type Dual light Flip Chip Underfill Contact DP-3000 Light ring ASPA Dam & Fill Impingement DV-6000 Dual On-axis...
Page 26 Trainee Guide TR-L2-M2000 Information Sheet 1-1-3 Equipment Features (Front) Light Pole/Beacon – A warning device that visually and audibly warns operators of system status by displaying different colored lights and sounding an alarm. Hood – The hood allows access to the dispensing area. Lifting the hood during production activates the Interlock safety feature, which disables all dispensing head motion by putting the motors in a low-power state.
Page 27 Trainee Guide TR-L2-M2000 Diagram Sheet 1-1-1 M-2000 (1) Light Pole/ (3) Window Beacon (4) Monitor (2) Hood (5) Mouse/Trackball (10) Conveyor (6) Keyboard A N Y O M P O N C R D S A N O (7) Grounding Strap Plugs (8) Start Button (9) Emergency Machine Off...
Page 28 Trainee Guide TR-L2-M2000 Information Sheet 1-1-4 Front Cabinet Features Precision Fluid Air Gauges and Regulator – The Precision Fluid Air Gauge and Regulator supplies air to the fluid syringe. It receives air from the fluid Air Gauge and Regulator located in the rear of the dispensing system. Heat Station Timers –...
Page 29 Trainee Guide TR-L2-M2000 Diagram Sheet 1-1-2 Front Cabinet Features (1) Precision Fluid (2) Heat Station Timers Air Gauges and Regulators (3) Electronic Scale Display Inside of Cabinet (Not shown) (4) Computer Controls Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-7 P/N 73-0018-00 (Revision B)
Page 30 Trainee Guide TR-L2-M2000 Information Sheet 1-1-5 Equipment Features (Rear) Emergency Machine Off (EMO) – Allows you to quickly power down the machine in case of emergency. Main Air Gauge and Regulator - The Main Air Gauge and Regulator supplies air to all of the other system gauge and regulator sets.
Page 31 Trainee Guide TR-L2-M2000 Diagram Sheet 1-1-3 Equipment Features (Rear) (1) Emergency Machine Off (EMO) (2) Main Air Gauge and Regulator (3) Rear Access Door (6) Power Manager (4) Main Power Cord (5) Main Circuit Breaker Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-9 P/N 73-0018-00 (Revision B)
Page 32 Trainee Guide TR-L2-M2000 Information Sheet 1-1-6 Rear Cabinet Features Conveyor Controller Module – The Conveyor Controller Module receives power from the Power Manager and communicates with the system computer to control the stepper motors, which control all conveyor movement. Temperature Controller Module – The Temperature Controller Module communicates with the system computer and the Heater Relay Module to regulate the heaters.
Page 33 Trainee Guide TR-L2-M2000 Diagram Sheet 1-1-4 Rear Cabinet Features (14) Valve Air Gauge and Regulator (1) Conveyor Controller Module (201W) (13) Fluid Air Gauge and (2) Temperature Controller Module Regulator (12) Tooling Air Gauge (3) Heater Relay Module and Regulator (4) Moritex Light Source (option) (11) Tensionator Air...
Page 34 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-12 P/N 73-0018-00 (Revision B)
Page 35: Safety Warning Labels
Trainee Guide TR-L2-M2000 Outline Sheet 1-2-1 Safety Warning Labels Introduction Equipment areas that require special attention are identified with safety warning labels. All personnel should locate and identify all safety warning labels on the system before use. Enabling Objective Identify and locate all system safety warning labels. Topic Outline Introduction Overview...
Page 36 Trainee Guide TR-L2-M2000 Information Sheet 1-2-1 Safety Warning Labels SYMBOL HAZARD DESCRIPTION Warning Can cause serious injury, death, or damage to equipment. Identifies potentially hazardous areas. ECHANICAL Can cause serious injury to hands or fingers if placed OLLER in machine. Requires special attention.
Page 37: Power Supply And Ac Distribution
Trainee Guide TR-L2-M2000 Outline Sheet 1-3-1 Power Supply and AC Distribution Introduction To ensure safe operation of the M-2000 Dispensing System, all personnel working on or around the equipment should be aware of all electrical power supply sources. Enabling Objective Identify power supply and AC distribution sources.
Page 38: Main Power Inlet/Circuit Breaker
Trainee Guide TR-L2-M2000 Information Sheet 1-3-1 Power Supply and AC Distribution Main Power Inlet/Circuit Breaker The Main Power Inlet is the main source of power for the entire machine and is located on the rear bottom of the machine (See Diagram Sheet 1-3-1 on page 1-2-17).
Page 39 Trainee Guide TR-L2-M2000 Diagram Sheet 1-3-1 Main Power Inlet and Main Circuit Breaker Main Power Cord Main Circuit Breaker Main Power Inlet M-2000 Rear View Main Circuit Breaker Main Power Inlet Main Inlet and Circuit Breaker (Close-up) Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-17 P/N 73-0018-00 (Revision B)
Page 40 Trainee Guide TR-L2-M2000 Diagram Sheet 1-3-2 Start Button Start Button Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-18 P/N 73-0018-00 (Revision B)
Page 41: Emo Button
Trainee Guide TR-L2-M2000 Outline Sheet 1-4-1 Emergency Shutdown Procedure Introduction All M-2000 Dispensing Systems are, for your safety as well as those around you, equipped with an Emergency Machine OFF (EMO) Button which is located on the left side of the front panel.
Page 42: Emo Operation
Trainee Guide TR-L2-M2000 Information Sheet 1-4-1 Emergency Shutdown Features Emergency Machine Off (EMO) Button All systems have an Emergency Machine Off (EMO) button on the front panel that quickly powers down the equipment in the event of an emergency or malfunction. A second EMO is located on the back of the system.
Page 43: Exercise
Trainee Guide TR-L2-M2000 Exercise Sheet 1-4-1 Testing the Functionality of the EMO Button 1. Turn the Main Circuit Breaker ON (I). 2. Deactivate the EMO by turning the knob clockwise until it pops out. 3. Press EMO to cut power to all major system components. 4.
Page 44 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-22 P/N 73-0018-00 (Revision B)
Page 45: Proper Powering On And Off Procedures
Trainee Guide TR-L2-M2000 Outline Sheet 1-5-1 Proper Powering On and Off Procedures Introduction In order to successfully operate and safely service the M-2000 Dispensing System, you must first become familiar with the proper powering on and off procedures. Enabling Objective Demonstrate the proper procedures to properly power on and off M-2000 Dispensing Systems.
Page 46: Connecting To Facilities
Trainee Guide TR-L2-M2000 Information Sheet 1-5-1 Proper Powering On Procedures Connecting to Facilities Connect the Main Power Cord from the Main Power Inlet to the facility power source. Connect the Main Air to the facility air supply. Proceed to Section B (Service Startup). Proper Powering On Procedure Make sure that all EMO buttons are disengaged.
Page 47: Powering Down At The End Of A Shift
Trainee Guide TR-L2-M2000 Information Sheet 1-5-2 Proper Powering Off Procedures Powering Down at the End of a Shift Exit the FMW Dispensing Program. Remove workpieces from the dispensing area. Remove the syringe from the dispensing head. Clean or purge the fluid pump/valve. Exit Windows and power down the computer.
Page 48 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-26 P/N 73-0018-00 (Revision B)
Page 49 Trainee Guide TR-L2-M2000 Outline Sheet 1-6-1 Safety Interlock and Light Pole/Beacon Introduction The Interlock is a built-in safety device activated by opening either the hood or the window while the system is ON. The Light Pole/Beacon can serve as a visual or audible warning device, indicating different Interlock status conditions either by turning on a different colored light for each condition or by issuing an alarm.
Page 50: Safety Interlock And Light Pole/Beacon
Trainee Guide TR-L2-M2000 Information Sheet 1-6-1 Safety Interlock and Light Pole/Beacon Safety Interlock The Interlock is a built-in safety device activated by opening either the hood or the window while the system is ON. Opening the hood or window while the dispensing system is ON disables all dispensing head motion.
Page 51 Trainee Guide TR-L2-M2000 Table 1-6-1 Light Pole/Beacon Color Indications Beacon Color Dispensing Status Recovery Procedures ALERT All motion, outputs, fluid pump, and motion controls are disabled. One of the following conditions exists: Solid - system in an E-stop condition. Restart machine. Remedy anomaly causing the E-stop.
Page 52: Light Pole/Beacon
Trainee Guide TR-L2-M2000 Diagram Sheet 1-6-1 Light Pole/Beacon Light Pole/Beacon Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-30 P/N 73-0018-00 (Revision B)
Page 53: Facility Requirements
Trainee Guide TR-L2-M2000 Outline Sheet 1-7-1 Facility Requirements Introduction To ensure optimal performance and safety, it is necessary to install the dispensing system in a facility that meets or exceeds recommended requirements. Failure to meet these requirements could result in serious bodily injury and damage to the dispensing system. Enabling Objective Identify facility requirements for M-2000 Dispensing Systems.
Page 54: Facility Safety Precautions
Trainee Guide TR-L2-M2000 Information Sheet 1-7-1 Facility Requirements Facility Requirements To ensure optimal performance and safety, the M-2000 dispensing system must be installed in a facility that meets or exceeds the following requirements. Facility Requirements System Footprint* 1118 X 1098 mm (44 X 43.2 in.) Power Requirements 230 VAC, 50/60 Hz, 30 A 551 kPA, 5.5 bar, 28 liter/hr, (80 PSI, 1 CFM, up...
Page 55: Safety Precautions
Trainee Guide TR-L2-M2000 Outline Sheet 1-8-1 Safety Precautions Introduction It is essential to observe safety precautions when operating and performing maintenance on M-2000 Dispensing Systems. Following safety precautions prevents injury to the operator as well as damage to the equipment. Enabling Objective Identify Safety Precautions and Electrostatic Discharge (ESD) procedures.
Page 56: Operator Safety Precautions
Trainee Guide TR-L2-M2000 Information Sheet 1-8-1 Safety Precautions Operator Safety Precautions Locate and identify safety warning labels on your system before initial use. In case of a malfunction, immediately push the Emergency Stop (E-stop, EMO) button. Do not attempt to remove the workpiece while power is ON. Do not wear loose clothing or jewelry while operating the system.
Page 57: System Protection Precautions
Trainee Guide TR-L2-M2000 Information Sheet 1-8-2 Safety Precautions (Continued) System Protection Precautions Always wear a grounding strap when operating the dispensing system. Be especially careful when dispensing with caustic or conductive fluids. Take appropriate action to immediately clean up and contain any spills. If fluid gets into internal portions of the system, call 1-800-ASYMTEK (279-6835) immediately.
Page 58 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 1-2-36 P/N 73-0018-00 (Revision B)
Page 59 Trainee Guide TR-L2-M2000 Module 2 Equipment Operation Lesson 1 Power Distribution Lesson 2 Dispensing System Modules Lesson 3 Pneumatic Distribution Lesson 4 Theory of Operation Lesson 5 Vision System Lesson 6 Dispense Pumps/Valves Lesson 7 Height Sensor Lesson 8 Linear Encoders Lesson 9 Needle Sensor Lesson 10...
Page 61 Trainee Guide TR-L2-M2000 Module 2 Table of Contents Lesson 1 Power Distribution ..................... 1 Power Manager ......................2 24/48 DC Power Supply ....................2 Interconnect PCA ....................... 2 Computer ........................3 Moritex Light Source....................3 Computer Cards ......................3 Servo Motor ....................... 4 Stepper Motor ......................
Page 62 Trainee Guide TR-L2-M2000 Module 2 Table of Contents (Continued) Lesson 7 Height Sensor ....................45 Theory of Operation for HS-Series ................46 Probe Adjustments for HS-Series................46 HS-Series Height Sensor Setup...................46 Theory of Operation for LK-Series ................47 LK-Series Height Sensor Setup ...................47 Exercises: .........................48 Setting Up the HS-Series Height Sensor ..............48 Configuring the Height Sensor................50...
Page 63 Trainee Guide TR-L2-M2000 Module 2 Table of Contents (Continued) Lesson 12 Conveyor......................89 Conveyor Configuration .....................90 Stop Pins/Clamp Bars/Lift Tables ................90 Theory of Operation ....................90 Exercises: .........................94 Conveyor Configuration..................94 Leveling the Conveyor ..................96 Lesson 13 Board Sensors....................97 Board Sensors......................98 Upward Facing Sensors....................98 Downward Facing Sensors ..................98 Exercise:........................99...
Page 64 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems P/N 73-0018-00 (Revision B)
Page 65: Power Distribution
Trainee Guide TR-L2-M2000 Outline Sheet 2-1-1 Power Distribution Introduction AC power enters the dispensing system from the facility power source at the Main Power Inlet. From there, it runs through the Main Circuit Breaker to the Power Manager. The Power Manager supplies power directly to several system components, which in turn supply power to other components.
Page 66: 24/48 Dc Power Supply
Trainee Guide TR-L2-M2000 Information Sheet 2-1-1 Power Distribution Power Manager The Power Manager supplies power to the following components: 24/48 DC Power Supply Computer Moritex Light Source(s) Conveyor Controller Module Heater Relay Module The Power Manager is also connected to the EMO (E-Stop) and the Start button. 24/48 DC Power Supply The 24/48 DC Power Supply supplies power to the following components: DC fans...
Page 67: Computer
Trainee Guide TR-L2-M2000 Information Sheet 2-1-2 Power Distribution (Continued) Computer The computer supplies power to the following components: Monitor Scale Display Interconnect PCA The Scale Display is located inside of the lower front cabinet. Moritex Light Source The Moritex Light Sources supply power to the Dual Lights mounted on the dispensing head next to the camera.
Page 68: Servo Motor
Trainee Guide TR-L2-M2000 Information Sheet 2-1-3 Power Distribution (Continued) Servo Motor A servo motor is a torque device that requires feedback in the form of a rotary/linear encoder to control position. A servo motor is a closed-loop system since it is constantly updated as to its position in the dispensing process.
Page 69 Trainee Guide TR-L2-M2000 Diagram Sheet 2-1-1 Power Distribution Main Power Inlet Main Circuit Breaker Start Button E-Stop Power Manager Start Button 24/48 DC Power Conveyor Controller Computer Moritex Light Source Heater Relay Module Supply Module Stepper Motors Dual Lights Contact Heaters Monitor DC Fans which move the...
Page 70 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 2-2-6 P/N 73-0018-00 (Revision B)
Page 71: Dispensing System Modules
Trainee Guide TR-L2-M2000 Outline Sheet 2-2-1 Dispensing System Modules Introduction Depending on your dispensing system configuration, there may be as many as four dispensing system modules installed. The number of modules depends upon the system configuration and options installed. Enabling Objective Understand the function of the Dispensing System Modules.
Page 72: Temperature Controller Module
Trainee Guide TR-L2-M2000 Information Sheet 2-2-1 Dispensing System Modules Conveyor Controller Module The Conveyor Controller Module supplies power to the stepper motors that move the conveyor rail and belt. The Conveyor Controller Module communicates with the dispensing software to coordinate conveyor operation. It is connected to the COM 2 port of the computer. If your dispensing system is equipped with a dual lane conveyor, your system platform will include two Conveyor Controller Modules.
Page 73 Trainee Guide TR-L2-M2000 Diagram Sheet 2-2-1 Dispensing System Modules Temperature Controller Module Heater Relay Module 201W Conveyor Controller Module M-2000 (Rear View) Timers Module M-2000 (Front View) Level 2 Maintenance Training – M2000 Dispensing Systems 2-2-9 P/N 73-0018-00 (Revision B)
Page 74 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 2-2-10 P/N 73-0018-00 (Revision B)
Page 75: Pneumatic Distribution
Trainee Guide TR-L2-M2000 Outline Sheet 2-3-1 Pneumatic Distribution Introduction The M-2000 Series Equipment uses compressed air at up to 120 psi of pressure for the conveyor stop pins and clamp bars, vacuum generator, dispense valve, syringe cooler and needle heater. Enabling Objective Understand the M-2000 pneumatic system and the procedure to adjust the air pressure on all pressure regulators on the M-2000 Series platform.
Page 76: Main Air Gauge And Regulator
Trainee Guide TR-L2-M2000 Information Sheet 2-3-1 Pneumatic Distribution Main Air Gauge and Regulator Air enters the dispensing system from the facility air source at the Main Air Gauge and Regulator located on the dispensing system back panel. From the Main Air Regulator, it travels to the following air gauges and regulators: Valve Pressure Fluid Pressure...
Page 77: Fluid Pressure
Trainee Guide TR-L2-M2000 Information Sheet 2-3-2 Pneumatic Distribution (Continued) Fluid Pressure The air from the Fluid Pressure Gauge and Regulator leads to the Precision Fluid Pressure Gauges and Regulators located inside of the lower front cabinet. From there, the air leads to the fluid valves located on the inside of the back panel, and then to the fluid ports on the dispensing head bulkhead.
Page 78: Cooling Pressure
Trainee Guide TR-L2-M2000 Information Sheet 2-3-3 Pneumatic Distribution (Continued) Clamp/Lifter Valve The Clamp/Lifter Valve may be used for either a clamp bar or lift table. For either device, the air leaves the valve in two separate hoses, one blue and one black, which connect directly to the pneumatic solenoid for that device.
Page 79 Trainee Guide TR-L2-M2000 Diagram Sheet 2-3-1 Pneumatic Distribution Facility Air Source Main Air Gauge Purge Valve Vacuum Control Valve Regulator Valve Pressure Fluid Pressure Tooling Pressure Cooling Pressure Tensioner Pressure Gauge Gauge Gauge Gauge Gauge Precision Fluid Dispensing Bulkhead Control Valve Pressure Gauges and Toggle Valve Tensioner Valve...
Page 80 Trainee Guide TR-L2-M2000 Diagram Sheet 2-3-2 Air Gauges and Regulators Tooling Air Gauge and Regulator Tensionator Air Gauge and Fluid Air Gauge and Regulator Regulator Valve Air Gauge and Regulator Cooling Air Gauge and Regulator (Optional) Main Air Gauge and Regulator Level 2 Maintenance Training –...
Page 81 Trainee Guide TR-L2-M2000 Table 2-3-1 Recommended Air Pressure Settings Air Gauge and Regulator Recommended Pressure Setting Cooling Application dependent. Rear gauge and regulator 40-90 psi (276-621 kPa) Precision gauges and regulators are Fluid valve dependent. Refer to the valve manual specific to the type of valve installed on your dispensing system.
Page 82 Trainee Guide TR-L2-M2000 Exercise Sheet 2-3-1 Adjusting Air Pressure This procedure can be used for all pressure regulators on the M-2000 Series platform. You must be in FmNT when adjusting the gauges and regulators. Make certain that the dispensing system is ON. The beacon system status should be yellow or green.
Page 83: Theory Of Operation
Trainee Guide TR-L2-M2000 Outline Sheet 2-4-1 Theory of Operation Introduction All M-2000 Series Dispensing Systems work in accordance with the same theory of operation demonstrating a highly developed process control. Model-specific differences may occur depending upon system configuration and options installed. The following section traces the electrical and pneumatic paths of the dispensing system.
Page 84: Theory Of Operation
Trainee Guide TR-L2-M2000 Information Sheet 2-4-1 Theory of Operation Dispense Head Dispense Head movement is controlled by the programmable PMAC card which is located inside of the computer. The dispense heads moves in the XYZ planes. X, Y-Axis (Left, Right, Front, Rear) Z-Axis (Up, Down) Home A reference point defined as (0, 0, 0,) in an X, Y, Z-axis coordinate system.
Page 85 Trainee Guide TR-L2-M2000 Diagram Sheet 2-4-1 Dispense Head Movement FmNT Command A program command is issued to the FmNT software. PMAC Card (inside of computer) Receives the command from FmNT and sends it to the Servo Interconnect PCA. Constantly polls the Linear Encoder to verify XYZ position of the Dispensing Head.
Page 86 Trainee Guide TR-L2-M2000 Diagram Sheet 2-4-2 Dispensing Head Performs a Height Sense FmNT Command A program command is issued to the FmNT software PMAC Card Sends command to lower the dispensing head to the Servo Interconnect PCA. Servo Interconnect PCA Relays command to lower the dispensing head to the Z-axis Servo Control Amplifier.
Page 87 Trainee Guide TR-L2-M2000 Diagram Sheet 2-4-3 Dispensing Head Finds Home FmNT Command A program command is issued to the FmNT software PMAC Card Relays Find Home command from FmNT to the Servo Interconnect PCA. Servo Interconnect PCA Relays Find Home command to the X, Y and Z-axis Servo Control Amplifiers.
Page 88 Trainee Guide TR-L2-M2000 Diagram Sheet 2-4-4 Conveyor Belt Movement FmNT Command A program command is issued to the FmNT software Optional Configuration for Dual Lane Conveyor COM1 on Computer System COM2 on Computer System Com Port through which the If your system is equipped with a computer communicates with the dual-lane conveyor, the system will Conveyor Controller Module.
Page 89 Trainee Guide TR-L2-M2000 Diagram Sheet 2-4-5 Stop Pin/Clamp Bar/Lift Table Raises Board Sensor Detects a part entering the system. Triggers output to Interconnect PCA. Interconnect PCA Receives Board Sensor input. Relays message to Conveyor Controller Module and Interface PCA. Conveyor Controller Module Interface PCA Receives Board Sensor input.
Page 90 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 2-2-26 P/N 73-0018-00 (Revision B)
Page 91: Adjusting The Av-2550
Trainee Guide TR-L2-M2000 Outline Sheet 2-5-1 Vision System Introduction The AV-2250 Pattern Recognition System is an advanced vision system with a choice of light sources. The built-in light ring and camera on the vision system may occasionally require adjustments to the brightness and focus. Enabling Objective Identify steps necessary to adjust and test the vision system.
Page 92 Trainee Guide TR-L2-M2000 Information Sheet 2-5-1 AV-2550 Vision System AV-2550 The AV-2550 Pattern Recognition System (PRS) is an advanced vision system with a choice of light sources to accommodate edge detection and fiducial detection. There are three light source options available. Light Ring Dual Light NER diffused On-Axis Light...
Page 93 Trainee Guide TR-L2-M2000 Diagram Sheet 2-5-1 AV-2550 Vision System ITI Card NER Diffused On Axis Lighting and Camera Video Card Light Ring and Camera Light Ring or     Moritex Control Card (optional) Dual Light Source and Camera Level 2 Maintenance Training –...
Page 94 Trainee Guide TR-L2-M2000 Exercise Sheet 2-5-1 Calibrating the Camera In the Main Window, click on Configuration. From the Configuration menu, select Setup Vision. The Vision Parameters dialog box opens and displays the parameters configured for your system at installation. Click on Calibrate in the Hardware segment of the dialog box. A Teach Window opens.
Page 95 Trainee Guide TR-L2-M2000 Diagram Sheet 2-5-2 FmNT - Vision Parameters Dialog Box Level 2 Maintenance Training – M2000 Dispensing Systems 2-2-31 P/N 73-0018-00 (Revision B)
Page 96 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 2-2-32 P/N 73-0018-00 (Revision B)
Page 97: Dispense Pumps/Valves
Trainee Guide TR-L2-M2000 Outline Sheet 2-6-1 Dispense Pumps/Valves Introduction There are various pumps and valves available for the M-2000 Series Equipment. Pump/Valve selection is generally based on the viscosity of the fluid as well as the dispensing program goals. Enabling Objective Describe the dispense valve theory of operation and make adjustments as necessary.
Page 98: Pump/Valve Types
Trainee Guide TR-L2-M2000 Information Sheet 2-6-1 Pump/Valves Pump/Valve Types Time/Pressure Air pressure forces fluid through needle. Amount dispensed is dependent on time, viscosity, temperature, pot life and needle size and shape. Auger Air pressure feeds fluid to Auger. Auger turns in closed cylinder and fluid is extruded through needle. Piston Material is pushed from syringe into pump chamber through stopcock.
Page 99 Trainee Guide TR-L2-M2000 Information Sheet 2-6-2 DP-3000 Series Description The DP-3000 is a servo-controlled, piston type pump. It is capable of dispensing a specified amount of fluid at relatively high flow rates. It is also capable of accurate volume repeatability, regardless of fluid viscosity. Operation Fluidmove commands signal the pneumatic module to supply air pressure to the actuator, forcing the stopcock to open and close.
Page 100 Trainee Guide TR-L2-M2000 Information Sheet 2-6-3 DV-6000 Series Description The DV-6000 Rotary Auger Pump is designed to accurately dispense high-viscosity, single-component fluids and pastes. It can be specially programmed for high degree of accuracy when dispensing very small dots. Operation The DV-6000 dispenses fluid by the controlled rotation of a rotary feedscrew.
Page 101 Trainee Guide TR-L2-M2000 Information Sheet 2-6-4 DV-7000 Series Description The DV-7000 Series Heli-Flow Pump is a rotary positive displacement auger pump. The DV-7000 can be used as a floating head valve for dispensing dots, or as a standard valve for dispensing lines and/or patterns. It is good for small dot dispensing with high viscosity materials.
Page 102 Trainee Guide TR-L2-M2000 Information Sheet 2-6-5 DJ-2000 Series Description The DJ-2000 Dispense Jet is a high throughput, air-actuated, dispensing jet. These devices are referred to as “jets”, because they use an air-activated needle to force a jet of fluid from the fluid chamber. The DJ-2000 employs a non-contact dispensing method in which individual drops of material are formed and shot from the nozzle to the substrate.
Page 103 Trainee Guide TR-L2-M2000 Diagram Sheet 2-6-1 Dispense Pumps/Valves DV-6000 Series DV-7000 Series The DP-3000 Series DJ-2000 Series Level 2 Maintenance Training – M2000 Dispensing Systems 2-2-39 P/N 73-0018-00 (Revision B)
Page 104 Trainee Guide TR-L2-M2000 Information Sheet 2-6-6 Priming/Purging the Pump/Valve Purging Purging the pump/valve prepares it and the needle for dispensing. The purge procedure should be performed after changing a syringe or at the end of a dispensing process. During a purge, residual fluid is forced out of the pump/valve. Purge Process The purge process can be invoked manually or programmed during a production run.
Page 105: Pump/Valve Purging/Priming
Trainee Guide TR-L2-M2000 Exercise Sheet 2-6-1 Pump/Valve Purging/Priming To Purge the Pump/Valve: Check that the valve pressure is at normal operating level (50-80psi). Check that the purge station location has been properly taught in FmNT. Click on Configuration in the Main Window. Click on Setup Purge Station.
Page 106: Valve Setup
Trainee Guide TR-L2-M2000 Exercise Sheet 2-6-2 Valve Setup Click on Configuration in the Main Window. Click on Setup Valves. The Setup Valves window opens. To select a different valve: Highlight the appropriate valve from the list. Click on OK. You must restart FmNT in order for the change to be implemented. To edit valve setup: Click on Edit in the Setup Valves Window.
Page 107 Trainee Guide TR-L2-M2000 Diagram Sheet 2-6-2 Setup Valve Window Setup Valves Setup Valves Valve 1 Valve 1 Valve 2 Valve 2 Valve 2 Valve 2 Valve 2 Valve 2 Active Configuration: Active Configuration: Active Configuration Active Configuration Active Configuration Active Configuration Valve 2 Valve 2 Valve 2...
Page 108 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 2-2-44 P/N 73-0018-00 (Revision B)
Page 109: Height Sensor
Trainee Guide TR-L2-M2000 Outline Sheet 2-7-1 Height Sensor Introduction M-2000 Dispensing Systems are equipped with a height sensor to ensure that the dispensing system maintains a constant dispensing height during production runs. There are two types of sensors available for the M-2000, the Retractable Adjustable Height Sensor (HS-Series RT) and the LK-Series Laser Height Sensor.
Page 110: Theory Of Operation For Hs-Series
Trainee Guide TR-L2-M2000 Information Sheet 2-7-1 HS-Series RT Height Sensor Theory of Operation for HS-Series This sensor uses a stainless steel probe to contact the dispensing surface. When the dispensing head lowers and the probe tip contacts the substrate, it triggers an I/O in the Height Sensor.
Page 111: Theory Of Operation For Lk-Series
Trainee Guide TR-L2-M2000 Information Sheet 2-7-2 LK-Series Laser Height Sensor Theory of Operation for LK Series The LK-Series Laser Height Sensor uses a semiconductor laser beam and triangulation measurement to determine the substrate height. As the dispensing head lowers, the laser beam reflects off the substrate surface back up to sensing array inside of the Height Sensor.
Page 112: Setting Up The Hs-Series Height Sensor
Trainee Guide TR-L2-M2000 Exercise Sheet 2-7-1 Setting Up the HS-Series Height Sensor Check the locating of the Micrometer Locking Screw (See Diagram Sheet 2-7-1 on page 2-2-49). Loosen the Micrometer Locking Screw. Adjust the Micrometer Adjustment until the Micrometer Locking Screw is centered in the slot.
Page 113 Trainee Guide TR-L2-M2000 Diagram Sheet 2-7-1 Height Sensors LED Indicator Probe Set Screw Micrometer Locking Screw Micrometer Adjustment Mounting Bracket Probe Solenoid HS-Series Height Sensor LK-Series Laser Height Sensor Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-49 P/N 73-0018-00 (Revision B)
Page 114: Configuring The Height Sensor
Trainee Guide TR-L2-M2000 Exercise Sheet 2-7-2 Configuring the Height Sensor In the Main Window, click on Configuration. Select Setup Height Sensor from the Configuration Menu. Click on the arrow under Height Sensor Type and select RT or LK Laser. Select a Mode. You have three options available, Height sense always, Selective height sense and Height sense on command.
Page 115 Trainee Guide TR-L2-M2000 Diagram Sheet 2-7-2 Configuring the Height Sensor Note: These parameters are different for the Laser Height Sensor. Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-51 P/N 73-0018-00 (Revision B)
Page 116: Probe Height Adjustments For Hs-Series
Trainee Guide TR-L2-M2000 Exercise Sheet 2-7-3 Probe Height Adjustments for HS-Series To make small adjustments to the probe height: 1. Install the needle you will be using 2. Loosen the micrometer locking screw (See Diagram Sheet 2-7-1 on page 2-2-49). 3.
Page 117 Trainee Guide TR-L2-M2000 Diagram Sheet 2-7-3 Probe-to-Needle Alignment – HS Series Needle Height Sensor Probe 1 mm (0.04 in.) 1.78–2.54 mm (0.07–010 in.) Important Alignment Point Probe-to-Needle Alignment Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-53 P/N 73-0018-00 (Revision B)
Page 118: Adjusting Probe/Needle Distance And Gu Stroke Length
Trainee Guide TR-L2-M2000 Exercise Sheet 2-7-4 Adjusting Probe/Needle Distance and GU Stroke Length – HS Series To adjust the GU stroke length: 1. Using the Z-axis controls, raise the dispensing head so that neither the needle tip nor the probe tip is touching the work surface. 2.
Page 119 Trainee Guide TR-L2-M2000 Diagram Sheet 2-7-4 GU Adjustment Locations – HS Series Adjustment GU Adjust Screw Locking Screw (near stem of GU adjust screw Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-55 P/N 73-0018-00 (Revision B)
Page 120: Probe Removal And Replacement
Trainee Guide TR-L2-M2000 Exercise Sheet 2-7-5 Probe Removal and Replacement – HS Series Tools and Materials Needed: 1/16-inch hex key New Height Sensor probe Make sure the probe is in the GD position. Using the 1/16-inch hex key, loosen the Probe Set Screw. Be careful not to loosen the screw too much or it may fall out.
Page 121: Linear Encoders
Trainee Guide TR-L2-M2000 Outline Sheet 2-8-1 Linear Encoders Introduction Linear encoders are mounted on each axis and keep track of the actual dispensing head position. If the dispensing head starts and then stops, or loses its position, it may be necessary to adjust the encoders.
Page 122 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-58 P/N 73-0018-00 (Revision B)
Page 123 Trainee Guide TR-L2-M2000 Information Sheet 2-8-1 Linear Encoders Linear Encoders The Linear Encoder assembly consists of an encoder head and an encoder strip. They are mounted on each of the three axes on the dispensing head. They keep track of the actual dispensing head position in all three axes. This information is supplied as positional feedback on a constant basis to the PMAC by way of the Servo Interconnect PCA.
Page 124: Adjusting The X Or Y Axis Linear Encoder Height
Trainee Guide TR-L2-M2000 Exercise Sheet 2-8-1 Adjusting the X or Y-Axis Linear Encoder Height Tools and Materials Needed: 0.8-mm gauge (included with linear encoder) 3-mm hex key Loctite thread locker 242 In the Main Window, click on Tools. In the Tools Window, click on Terminal. Click on Dispenser.
Page 125 Trainee Guide TR-L2-M2000 Diagram Sheet 2-8-1 Y-Axis Linear Encoder Y-Axis Encoder (right side of dispensing system on l-beam) Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-61 P/N 73-0018-00 (Revision B)
Page 126: Adjusting The Z-Axis Linear Encoder
Trainee Guide TR-L2-M2000 Exercise Sheet 2-8-2 Adjusting the Z-Axis Linear Encoder Tools and Materials Needed: 0.8-mm gauge (included with linear encoder) 3-mm hex key Loctite thread locker 242 In the Main Window, click on Tools. In the Tools Window, click on Terminal. Click on Dispenser.
Page 127 Trainee Guide TR-L2-M2000 Diagram Sheet 2-8-2 X and Z-Axis Linear Encoders X-Axis Encoder Z-Axis Encoder Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-63 P/N 73-0018-00 (Revision B)
Page 128 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-64 P/N 73-0018-00 (Revision B)
Page 129: Needle Sensor
Trainee Guide TR-L2-M2000 Outline Sheet 2-9-1 Needle Sensor Introduction The needle sensor locates the XYZ position of the needle. It is also used to determine the XYZ location of the Height Sensor Probe in relation to the needle. These locations are sent to the dispensing software, which uses them during the programming process and during production runs.
Page 130: Needle Sensor Setup
Trainee Guide TR-L2-M2000 Information Sheet 2-9-1 NSZ Needle Sensor Needle Sensor When used as part of the Prompted Setup routine, the needle sensor automatically compensates for XYZ changes in needle position due to a needle change or bent needle so that you can change needles and continue production without reprogramming the system.
Page 131 Trainee Guide TR-L2-M2000 Diagram Sheet 2-9-1 NSZ Series Needle Sensor LED Indicator Tactile Sensor Place for Calibration Substrate Needle Slot Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-67 P/N 73-0018-00 (Revision B)
Page 132: Needle Sensor Configuration
Trainee Guide TR-L2-M2000 Exercise Sheet 2-9-1 Needle Sensor Configuration Start FmNT. In the Main Window, click on Configuration. Select Machine Offsets from the Configuration menu. Select Machine Offsets Parameters from the drop-down menu. The Machine Offsets Parameters dialog box opens. Click on the arrow next to the Sensor Type text box to view all available configuration options.
Page 133 Trainee Guide TR-L2-M2000 Diagram Sheet 2-9-2 Needle Sensor Setup Window Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-69 P/N 73-0018-00 (Revision B)
Page 134: Tactile Sensor Error
Trainee Guide TR-L2-M2000 Exercise Sheet 2-9-2 Tactile Sensor Error Gently lift the “hat” off of the tactile sensor. Use isopropyl alcohol and a soft cloth to remove any residual fluid from around the circumference of the “hat” and around the tactile sensor opening. Carefully remove any residual fluid from the sensor tip as well.
Page 135 Trainee Guide TR-L2-M2000 Diagram Sheet 2-9-3 Tactile Sensor Error Tactile Sensor Hat Tactile Sensor NSZ Series Needle Sensor FmNT Dispenser I/O Inputs Screen Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-71 P/N 73-0018-00 (Revision B)
Page 136: Leveling The Needle Sensor
Trainee Guide TR-L2-M2000 Exercise Sheet 2-9-3 Leveling the Needle Sensor 1. Use the jog controls, move the dispensing head over one of the three leveling screws on the Needle Sensor. 2. Be sure to use one of the leveling screws and not the Needle Sensor cover plate. 3.
Page 137 Trainee Guide TR-L2-M2000 Diagram Sheet 2-9-4 Needle Sensor Leveling Screws Leveling Screws Leveling Screw Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-73 P/N 73-0018-00 (Revision B)
Page 138 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-74 P/N 73-0018-00 (Revision B)
Page 139: Needle Heater
Trainee Guide TR-L2-M2000 Outline Sheet 2-10-1 Needle Heater Introduction The Needle Heater consists of a temperature controller and a heating element that attaches to the dispensing needle. On M-2000 Dispensing Systems equipped with heaters, the temperature controller is an integrated feature. The heating element plugs into outlets on the dispensing head and the temperature is controlled through the FmNT software.
Page 140: Heating Element Compatibility
Trainee Guide TR-L2-M2000 Information Sheet 2-10-1 Needle Heaters Heating Element Compatibility Heating Element Valve Compatibility HT-04 Asymtek DV-04 valve only HT-06 All Asymtek valves except DV-04 HT-10N All Asymtek valves using metal needles Temperature Controllers The HT-1000 is a temperature controller for a needle heater. The HT-2000 is made up of two independent temperature controllers.
Page 141 Trainee Guide TR-L2-M2000 Diagram Sheet 2-10-1 Heating Elements and Temperature Controllers Heating Element J-Type Thermocouple Cable Thumbscrew Power Cable HT-04 HT-1000 Temperature Controller HT-06 On/Off Switch Control Panel Close-up HT-10N HT-2000 Temperature Controller Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-77 P/N 73-0018-00 (Revision B)
Page 142: Installing A Needle Heater
Trainee Guide TR-L2-M2000 Exercise Sheet 2-10-1 Installing a Needle Heater Loosen the thumbscrew on the front of the heating element. Do one of the following, depending on your type of heating element: For the HT-04, slide the heating element onto the needle and onto the valve tip. For the HT-06, slide the heating element onto the needle and onto the luer lock fitting.
Page 143 Trainee Guide TR-L2-M2000 Diagram Sheet 2-10-2 Needle Heater Connections (not to scale) J-Thermocouple or RTD Dispense Microcontroller Head J-Thermocouple 120/220 VAC From DC Power or RTD AC Power Source DC Power Needle Heater Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-79 P/N 73-0018-00 (Revision B)
Page 144: Operations, Controls And Adjustments
Trainee Guide TR-L2-M2000 Exercise Sheet 2-10-2 Operations, Controls and Adjustments Setting Up the Needle Heater: Start FmNT. In the Main window, click on Tools. In the Tools window, click on Terminal. Click on Heaters. The Heater Control window opens. Refer to Online Help for heater loop setup information. Turning the Temperature Controller ON: Follow proper procedures to turn ON your dispensing system.
Page 145: Heater Modules
Trainee Guide TR-L2-M2000 Outline Sheet 2-11-1 Heater Modules Introduction Some M-2000 Dispensing Systems are equipped with underboard substrate heating systems. There are two types of heaters currently available on the M-2000 systems: contact heaters and impingement heaters. Both types of heaters are capable of independent temperature regulation in pre-heat, dispense heat, and post-heat zones.
Page 146 Trainee Guide TR-L2-M2000 Information Sheet 2-11-1 Contact Heaters Overview A Contact Heater is a plate of individual heater modules that act as a single unit. Each plate is equipped with a vacuum that holds the part in place. Contact Heaters are used for applications in which the part being dispensed upon may need to come in contact with the heating element, or applications in which contact with the heating element is not an issue.
Page 147 Trainee Guide TR-L2-M2000 Diagram Sheet 2-11-1 Contact Heaters Contact Heaters Vacuum Hole Close-up of Individual Heater Contact Heater Configuration Loop 1 Loop 2 Loop 3 Pre-Heat Zone Dispense Heat Zone Post-Heat Zone Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-83 P/N 73-0018-00 (Revision B)
Page 148 Trainee Guide TR-L2-M2000 Information Sheet 2-11-2 Impingement Heaters Overview Impingement Heaters are similar to Contact Heaters except that they blow hot air up at the part rather than use a vacuum to hold the part in place. The determining factor when choosing between Contact and Impingement heat is the part carrier being used for the application.
Page 149 Trainee Guide TR-L2-M2000 Diagram Sheet 2-11-2 Impingement Heaters Impingement Heaters Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-85 P/N 73-0018-00 (Revision B)
Page 150: Removing And Replacing Heater Modules
Trainee Guide TR-L2-M2000 Exercise Sheet 2-11-1 Removing and Replacing Heater Modules Turn the Main Power Switch OFF (O). Unplug all power cords. Unplug the Heating Module Thermocouple Cable. Disconnect the module airflow hose. Unplug the Heating Module Power Cable. Remove the module by gently lifting up on it. Place the new module in the proper location.
Page 151: Testing Heater Loops
Trainee Guide TR-L2-M2000 Exercise Sheet 2-11-2 Testing Heater Loops In the Main Window, click on Tools. In the Tools Window, click on Terminal. Click on Heaters. The Heater Controls Window opens. In the On/Off column of the dialog box are heater coil icons. Use the mouse or trackball to position the cursor over the heater icon next to the loop name that you wish to activate, and double-click directly on the icon.
Page 152 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-88 P/N 73-0018-00 (Revision B)
Page 153: Conveyor
Trainee Guide TR-L2-M2000 Outline Sheet 2-12-1 The Conveyor Introduction The conveyor is used to move parts into and out of the dispensing area. All M-2000 Dispensing Systems are equipped with a Surface Mount Equipment Manufactures Association (SMEMA) compatible belt conveyor. Enabling Objective 2.12 Understand the conveyor theory of operation and setup and level the conveyor.
Page 154 Trainee Guide TR-L2-M2000 Information Sheet 2-12-1 Conveyor Operations Conveyor Configuration Conveyor configuration varies depending upon the application requirements and the type of heaters installed. Conveyor width is controlled by moving the rear conveyor towards the front or towards the rear of the dispensing system. Stop Pins/Clamp Bars/Lift Tables Stop pins and clamp bars are used to index parts in the dispensing area and hold them in place during dispensing procedures.
Page 155 Trainee Guide TR-L2-M2000 Information Sheet 2-12-2 Conveyor Operations (Continued) Part enters the dispense zone. Stop pins in the dispense zone raise to stop the part. A lift table underneath the heating plate raises up to the part. For systems with impingement heaters, a clamp bar raises, lifting the part off the conveyor belt.
Page 156 Trainee Guide TR-L2-M2000 Diagram Sheet 2-12-1 Common Conveyor Configuration (Contact Heaters) Part Sensor Stop Pin Part Sensor Stop Pin Lift Table (Underneath Heater Plates) Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-92 P/N 73-0018-00 (Revision B)
Page 157 Trainee Guide TR-L2-M2000 Diagram Sheet 2-12-2 Common Conveyor Configuration (Impingement Heaters) Stop Pin Stop Pin Tooling Pin Tooling Pin Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-93 P/N 73-0018-00 (Revision B)
Page 158: Conveyor Configuration
Trainee Guide TR-L2-M2000 Exercise Sheet 2-12-1 Conveyor Configuration Select Setup Conveyors from the Configuration menu. The Setup Conveyors dialog box opens. Click on the arrow next to the Type box and select the type of conveyor installed on your system. Most M-2000 Series Dispensing Systems use Automove to communicate with the conveyor.
Page 159 Trainee Guide TR-L2-M2000 Diagram Sheet 2-12-3 FmNT Conveyor Setup and Configuration Dialog Boxes Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-95 P/N 73-0018-00 (Revision B)
Page 160: Leveling The Conveyor
Trainee Guide TR-L2-M2000 Exercise Sheet 2-12-3 Leveling the Conveyor Place the level in the center of the front conveyor rail, along the length of the rail. Observe the position of the bubble within the level window. Determine if the dispensing system is level from side to side.
Page 161: Board Sensors
Trainee Guide TR-L2-M2000 Outline Sheet 2-13-1 Board Sensors Introduction Board sensors are sensors located along the length of the conveyor rail that detect the presence of a board or part. Board sensors should be adjusted after initial installation and when the sensors are failing to sense the presence of a board. Enabling Objective 2.13 Describe the procedure to adjust board sensors.
Page 162 Trainee Guide TR-L2-M2000 Information Sheet 2-13-1 Board Sensors Board Sensors Board sensors are optic sensors located along the length of the conveyor rails. They detect the presence of a board or part and report the detection to the dispensing software. Depending upon system configuration, your dispenser may have as many as three board sensors.
Page 163: Adjusting The Board Sensors
Trainee Guide TR-L2-M2000 Exercise Sheet 2-13-1 Adjusting the Board Sensors Tools and Materials Needed: Flat head screwdriver Phillips head screwdriver 1/8-inch hex key Sample board identical to one used during production run. Use the Philips head screwdriver to remove the four screws holding down the clear plastic cover over the sensor sensitivity adjustments.
Page 164 Trainee Guide TR-L2-M2000 Exercise Sheet 2-13-1 Adjusting the Board Sensors (Continued) Push down on the thumbwheel. This sets the OFF condition for output 2. GOOD should display for 2 seconds, indicating the ON-OFF threshold is identifiable. If HARD is displayed, then the sensor may not be able to tell the difference between ON and OFF.
Page 165 Trainee Guide TR-L2-M2000 Diagram Sheet 2-13-1 Board Sensor Locations Sensor Sensitivity Adjustments Optic Sensor Optic Sensor Front Conveyor Rail (may vary depending on system configuration) Upward Facing Sensor Location Optic Sensor Sensor Sensitivity Adjustments Optic Sensor Front Conveyor Rail (may vary depending on system configuration)
Page 166 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-102 P/N 73-0018-00 (Revision B)
Page 167: Tooling Flow Controls
Trainee Guide TR-L2-M2000 Outline Sheet 2-14-1 Tooling Flow Controls Introduction When a part is conveyed into the system, a sensor detects its presence and indexes the part. Stop pins are raised to stop the board transport. Clamp bars or lift tables raise to hold the part in place.
Page 168: Stop Pins
Trainee Guide TR-L2-M2000 Information Sheet 2-14-1 Tooling Flow Control Adjustment Lift Tables/Clamp Bars The lift tables or clamp bars raise to hold the part in place when it is being dispensed upon. For optimum operation, the lift tables and/or clamp bars should raise and lower at the same time and at the same rate.
Page 169: Adjusting The Tooling Flow Controls
Trainee Guide TR-L2-M2000 Exercise Sheet 2-14-1 Adjusting the Tooling Flow Controls Determine the location of your tooling flow controls. If the dispensing area front plate needs to be removed, remove it now. In the FmNT Main Window, click on Tools. Click on I/O Test.
Page 170 Trainee Guide TR-L2-M2000 Diagram Sheet 2-14-1 Tooling Flow Controls Clamp Bar Clamp Bar Flow Control Flow Control Clamp Bar Flow Controls Lift Table Front Conveyor Rail Rear Conveyor Rail Lift Table Tooling Flow Controls Lift Table Flow Controls Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-106 P/N 73-0018-00 (Revision B)
Page 171: Smema Transfer
Trainee Guide TR-L2-M2000 Outline Sheet 2-15-1 SMEMA Transfer Introduction SMEMA (Surface Mount Equipment Association) is an equipment interface standard. SMEMA handshaking is an exchange of input and output signals between two systems. Enabling Objective 2.15 Describe the principle of SMEMA Transfer. Topic Outline Introduction Overview...
Page 172 Trainee Guide TR-L2-M2000 Information Sheet 2-15-1 SMEMA Transfer SMEMA Handshaking with Upstream Machine When the dispensing system is ready to accept a board, it outputs a SMEMA signal to the upstream machine requesting a board. The upstream machine receives the signal as an input. If the machine is ready to send a board, it responds with an output signal back to the dispensing system, which receives the signal as an input.
Page 173 Trainee Guide TR-L2-M2000 Diagram Sheet 2-15-1 SMEMA Transfer Detailed Operation SMEMA handshaking with upstream machine A board is conveyed into the pre-dispense zone. The board is heated. Dispensing preparations are performed. The dispensing pattern is executed. SMEMA handshaking with downstream machine Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-109 P/N 73-0018-00 (Revision B)
Page 174 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training - M2000 Dispensing Systems 2-2-110 P/N 73-0018-00 (Revision B)
Page 175 Trainee Guide TR-L2-M2000 Module 3 Routine Maintenance Lesson 1 Routine Maintenance Procedures Lesson 2 Purge Boot and Weigh Station Lesson 3 Scale Leveling and Calibration Lesson 4 Draining the Water Trap Lesson 5 XYZ Rails Lesson 6 Dispense Pumps/Valves Lesson 7 Cleaning and Replacing Fans and Vents Lesson 8 Conveyor Belts...
Page 177 Trainee Guide TR-L2-M2000 Module 3 Table of Contents Lesson 1 Routine Maintenance Procedures ..............1 Routine Maintenance Schedule..................2 Lesson 2 Purge Boot and Weigh Station ................3 Disposables........................ 4 Tools and Materials Needed ..................4 Exercises: ........................5 Replacing the Purge and Weigh Station Cups and Banjo Wipe ........5 Replacing the Purge Boot..................
Page 178 Trainee Guide TR-L2-M2000 Module 3 Table of Contents (Continued) Lesson 7 Cleaning and Replacing Fans and Vents............49 Exercise:........................50 Cleaning the Fans and Vents .................50 Lesson 8 Conveyor Belts....................51 Conveyor Belt Maintenance ..................52 Cleaning the Belts .....................52 Exercise:........................53 Removing and Replacing Conveyor Belts ..............53 Lesson 9 Tensioning the Cables ..................
Page 179: Routine Maintenance Procedures
Trainee Guide TR-L2-M2000 Outline Sheet 3-1-1 Routine Maintenance Procedures A. Introduction Performing routine maintenance is necessary to prevent part degradation and to ensure high quality dispensing performance. There are several procedures that should be performed on a regular basis to optimize system performance. B.
Page 180 Trainee Guide TR-L2-M2000 Information Sheet 3-1-1 Routine Maintenance Schedule Maintenance Recommended Est. Instructions Procedure Frequency Time Remove the purge station lid. Clean purge boot Daily 3 minutes Clean the boot with isopropyl alcohol (IPA) and a small bottlebrush. Remove the purge station and weigh station lids. Replace purge Daily 3 minutes...
Page 181: Purge Boot And Weigh Station
Trainee Guide TR-L2-M2000 Outline Sheet 3-2-1 Purge Boot and Weigh Station A. Introduction The plastic cups in the Purge Boot and Weigh Station should be replaced on a daily basis. In addition the purge boot must be cleaned and the banjo wipe replaced. B.
Page 182: Disposables
Trainee Guide TR-L2-M2000 Information Sheet 3-2-1 Purge Boot and Weigh Station A. Disposables Disposables are items that are discarded and replaced on a regular basis. The following items are common disposables for M-2000 Dispensing Systems and should be replaced as recommended. Purge Boot Purge Station Cup Weigh Station Cup...
Page 183: Replacing The Purge And Weigh Station Cups And Banjo Wipe
Trainee Guide TR-L2-M2000 Exercise Sheet 3-2-1 Replacing the Purge and Weigh Station Cups and Banjo Wipe Remove the Purge and Weigh Station cups (Refer to diagram below). Remove the plastic cups inside of each station and discard them. Discard the banjo wipe inside of the Weigh Station cup. Place new plastic cups inside of each station.
Page 184: Replacing The Purge Boot
Trainee Guide TR-L2-M2000 Exercise Sheet 3-2-2 Replacing the Purge Boot Remove the purge station lid. Grip the top of the purge boot with a pair of needle-nosed pliers and pull it out of the lid from the top. See table below for size verification). Obtain a new boot ( Push the new boot into the top of the lid until it starts to come out of the bottom Grip the bottom of the boot with a pair of needle-nosed pliers and gently pull until it...
Page 185: Scale Leveling And Calibration
Trainee Guide TR-L2-M2000 Outline Sheet 3-3-1 Scale Leveling and Calibration A. Introduction Some M-2000 Dispensing Systems include a digital scale capable of recording the weight of dispensed fluid. The scale must be leveled and calibrated in order to record an accurate weight.
Page 186: Digital Scale
Trainee Guide TR-L2-M2000 Information Sheet 3-3-1 Scale Leveling and Calibration A. Digital Scale The weigh station is a small reservoir containing a metal pedestal resting on an electronic balance. It contains a plastic disposable cup with a removable lid. During a production run, the needle tip is inserted into the top of the weigh station lid and fluid is dispensed into the plastic cup and weighed by the scale.
Page 187 Trainee Guide TR-L2-M2000 Diagram Sheet 3-3-1 Dispensing Area Front Plate Removal e n s ig h ti le T a c ri e s -S e Level 2 Maintenance Training - M2000 Dispensing Systems 3-2-9 P/N 73-0018-00 (Revision B)
Page 188: Leveling The Scale
Trainee Guide TR-L2-M2000 Exercise Sheet 3-3-1 Leveling the Scale Tools and Materials Needed: 3-mm hex key 4-mm inch hex key 9/64-inch hex key Level Lab gloves Tweezers Set of calibrated weights Use the 3-mm hex key and the 4-mm hex key to remove the screws in the dispensing area front plate.
Page 189 Trainee Guide TR-L2-M2000 Diagram Sheet 3-3-2 Leveling the Scale Scale Base Cut-out Showing Scale Leveling Screw (one screw on the underside of each corner) Scale Leveling Screws Purge Station Weigh Station Scale Base Close-up of Scale Level Scale Level Location Level 2 Maintenance Training - M2000 Dispensing Systems 3-2-11 P/N 73-0018-00 (Revision B)
Page 190: Calibrating The Scale
Trainee Guide TR-L2-M2000 Exercise Sheet 3-3-2 Calibrating the Scale Both the dispensing system and the scale need to be leveled prior to performing this procedure. See Diagram Sheet 3-3-1 on Remove the dispensing area front plate using a 1/8-inch hex key. page 3-2-9.
Page 191: Configuring The Scale
Trainee Guide TR-L2-M2000 Exercise Sheet 3-3-3 Configuring the Scale Open the lower front storage cabinet Press Menu to access Menu 3. and locate the scale. Press 1.Serial Port Setup. Press Menu to access Menu 1. Press 2.Cal. Data. Press 2.Units. Press 1.Automatic Output.
Page 192: Setting Up The Scale
Trainee Guide TR-L2-M2000 Exercise Sheet 3-3-4 Setting Up the Scale In the FmNT Main Window, click on Configuration. Select Setup Scale to open the Setup Scale dialog box. Follow the On-line help instructions to set up the scale. Level 2 Maintenance Training - M2000 Dispensing Systems 3-2-14 P/N 73-0018-00 (Revision B)
Page 193: Draining The Air Regulator Water Trap
Trainee Guide TR-L2-M2000 Outline Sheet 3-4-1 Draining the Air Regulator Water Trap A. Introduction Because the facility air supply may contain moisture that can damage the dispensing system, the M-2000 is equipped with a water trap that condenses this moisture. The water trap condenses this moisture before it enters the dispenser pneumatic system.
Page 194 Trainee Guide TR-L2-M2000 Exercise Sheet 3-4-1 Draining the Air Regulator Water Trap Tools and Materials Needed: Box wrench Container for waste water Locate the water trap at the rear of the system. Shut off facility air pressure. Using a box wrench, disconnect the facility air supply from the Main Air Inlet. Hold a container under the water trap to catch the water.
Page 195: Xyz Rails
Trainee Guide TR-L2-M2000 Outline Sheet 3-5-1 XYZ Rails A. Introduction Lubricating the XYZ rails on a monthly basis will ensure smooth dispensing head movement and prolong the life of the bearing housing. B. Enabling Objective Perform necessary steps to lubricate the XYZ rails and check them for wear. C.
Page 196: Routine Maintenance
Trainee Guide TR-L2-M2000 Information Sheet 3-5-1 Lubricating the XYZ Rails XYZ Rails The XYZ Rails support the dispense head and allow it to travel within the dispensing area. The dispense head is the portion of the machine that moves during dispensing operation.
Page 197: Lubricating The X-Axis
Trainee Guide TR-L2-M2000 Exercise Sheet 3-5-1 Lubricating the X-Axis Using an ammonia-based cleaner and a soft cloth, clean and wipe the X-Axis shafts. Load the grease cartridge into the grease gun. Pull back on the handle at the bottom of the grease gun cylinder until the locking tabs are visible.
Page 198 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training - M2000 Dispensing Systems 3-2-20 P/N 73-0018-00 (Revision B)
Page 199: Dispense Pumps/Valves
Trainee Guide TR-L2-M2000 Outline Sheet 3-6-1 Dispense Pumps/Valves A. Introduction Performing the recommended maintenance procedures at regular intervals is an essential factor in maintaining maximum performance from the valve. Cleaning involves the removal and disassembly of the dispensing cartridge, and the removal and replacement of several disposable parts.
Page 200 Trainee Guide TR-L2-M2000 Information Sheet 3-6-1 Dispense Valve Maintenance A. DP-3000 Maintenance Procedure Recommended Frequency Instructions Before the expiration of the pot life of the fluid. See Exercise Sheet 3-6-2 Clean pumping chamber. Immediately when on page 3-2-26. changing from one type of fluid to another.
Page 201 Trainee Guide TR-L2-M2000 Information Sheet 3-6-2 Valve Maintenance (Continued) C. DV-7000 Maintenance Procedure Recommended Frequency Instructions Clean exterior and interior Clean daily. See Exercise Sheet 3-6-8 exposed surfaces of the Clean before using new pump. fluid. on page 3-2-38. Clean immediately after using curable material.
Page 202: Disconnecting The Dp-3000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-1 Disconnecting the DP-3000 Tools Needed: 4-mm hex key Disconnect the DP-3000 black pneumatic hose from the manifold. Disconnect the DP-3000 blue pneumatic hose from the manifold. Disconnect the syringe receiver head hose from the manifold. Disconnect the power cable from the dispense head.
Page 203 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-1 DP-3000 Blue Pneumatic Hose Upper Knob (Detachable) Power Cable Indicators Black Pneumatic P R IM F U L L L IM IT Hose S T O P C O C K 1 /1 3 /4 Stopcock 1 /2 Cylinder...
Page 204: Cleaning The Dp-3000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-2 Cleaning the DP-3000 Tools and Materials Needed: Soft cloth Scribe Cleaning step bottle brush (provided with DP-3000) Mild solvent or isopropyl alcohol (IPA). Compatible solvent for your fluid (see the MSDS for fluid compatibility) Wipe off the piston with a soft cloth and mild solvent or IPA.
Page 205 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-2 DP-3000 Chamber Assembly Black O-Ring Urethane O-Ring Metal Luer Prime Port Priming Chamber Pumping Chamber Seal (insert ring-side down) Pumping Chamber High Pressure Chamber Assembly Priming O-Ring Plastic Prime Port Priming Chamber Pumping Chamber Seal Static O-Ring (insert ring-side down)
Page 206: Reconnecting The Dp-3000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-3 Reconnecting the DP-3000 Open the swinging bracket by pressing up on the red swinging bracket latch and gently pulling out on the swinging bracket. Flip the yellow stopcock lever forward to release the stopcock. Flip the green chamber retention lever up 90°.
Page 207 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-3 Closing the DP-3000 Stopcock Actuator Green Chamber Retention Lever Mating Point of Stopcock and Pumping Chamber Blue Detent Lever Level 2 Maintenance Training - M2000 Dispensing Systems 3-2-29 P/N 73-0018-00 (Revision B)
Page 208: Disconnecting The Dv-6000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-4 Disconnecting the DV-6000 Tools and Materials Needed: 3/32-inch hex key 4-mm hex key  Adjustable Jaw (Crescent ) Wrench Seal Removal Tool (P/N 48-8105) Disconnect the DV-6000 Interface Cable from the dispense head. Disconnect the blue air pressure line on the manifold. Remove the syringe by loosening the nylon thumbscrew and turning the luer elbow counter-clockwise.
Page 209 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-4 DV-6000 – Partially Disassembled Amp Connector Valve Motor Valve Body Luer Fitting Check Valve (optional) Luer Elbow Needle Level 2 Maintenance Training - M2000 Dispensing Systems 3-2-31 P/N 73-0018-00 (Revision B)
Page 210: Cleaning The Dv-6000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-5 Cleaning the DV-6000 Tools and Materials Needed: Ultrasonic cleaner Bottle Brush Seal Removal Tool Fill an ultrasonic cleaner with an appropriate cleaning solvent for the dispensing fluid to be dissolved. Check with the fluid formulator for recommended cleaning solvents. Remove the seal, clean with solvent, and dry with pressurized air.
Page 211 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-5 DV-6000 – Disassembled Valve Motor Check Valve Amp Connector (optional) Needle Feedscrew (DO NOT REMOVE) Motor Mount Teflon Seal Cleats Stainless Steel Luer Lock Fitting Lower Luer Lock (DO NOT REMOVE) Luer Elbow Black Shield Level 2 Maintenance Training - M2000 Dispensing Systems 3-2-33 P/N 73-0018-00 (Revision B)
Page 212: Reassembling And Reconnecting The Dv-6000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-6 Reassembling and Reconnecting the DV-6000 Tools and Materials Needed: KC-01 conditioning fluid 4-mm hex key Apply a small amount of conditioning fluid (KC-01) to the seal shoulder at the base (Solder Paste applications only). of the motor/feedscrew assembly on the DV-6000 Apply a small amount of conditioning fluid (KC-01) to the feedscrew on the DV-6000 (Solder Paste applications only).
Page 213 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-6 DV-6000 Installation Syringe Nylon Thumbscrew DV-6000 Height Sensor Level 2 Maintenance Training – M2000 Dispensing Systems 3-2-35 P/N 73-0018-00 (Revision B)
Page 214: Disconnecting The Dv-7000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-7 Disconnecting the DV-7000 Tools and Materials Needed: 3/8-inch wrench 3/10-inch wrench Small bottle brush Use the Position Controls, either on the front panel or in the Jog Controls in FmNT, and move the dispensing head to the front and center of the dispensing area. Disconnect the feed tube from the barbed cartridge fitting on the valve.
Page 215 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-7 DV-7000 Syringe Air Hose Receiver Head F L O W H E L I - Syringe Syringe Bulkhead Fitting D V - 7 0 Cartridge Release Lever Feed Tube Barbed Cartridge Fitting Level 2 Maintenance Training – M2000 Dispensing Systems 3-2-37 P/N 73-0018-00 (Revision B)
Page 216: Cleaning The Dv-7000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-8 Cleaning the DV-7000 Tools and Materials Needed: Cleaning solution (MSDS recommended) Cotton swabs Reamer Use MSDS recommended cleaning solution and a small bottle brush or cotton swab to thoroughly clean the feed screw, the upper bearing, the seal, the needle cap, and the inside of the dispensing cartridge.
Page 217 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-8 DV-7000 Dispensing Cartridge Feed Screw Lower Bearing Dispensing Seal Cartridge Level 2 Maintenance Training – M2000 Dispensing Systems 3-2-39 P/N 73-0018-00 (Revision B)
Page 218: Reassembling And Reconnecting The Dv-7000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-9 Reassembling and Reconnecting the DV-7000 Tools and Materials Needed: 3/10-inch wrench 4mm hex key 2mm hex key Phillips Head screwdriver 3mm hex key Inspect the seal and the lower bearing for wear. If they are worn, replace them. Insert the seal spring-side down into the top of the dispensing cartridge.
Page 219 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-9 DV-7000 with Valve Bracket and Height Sensor DV-7000 and Valve Bracket s o r S e n g h t H e i t i l e T a c ri e s -S e DV-7000 with Height Sensor Level 2 Maintenance Training –...
Page 220: Disconnecting The Dj-2000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-10 Disconnecting the DJ-2000 Tools and Materials Needed: Spanner Wrench Torque Wrench 3-mm hex key Disconnect the solenoid connector on the DJ-2000 from the dispensing head bulkhead connector. Disconnect the pneumatic hoses (jet pressure and fluid pressure) from the dispensing head manifold.
Page 221 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-10 DJ-2000 Black Pneumatic Hose Micrometer Assembly Outer Micrometer Collar Micrometer Lock Nut Height Sensor Solenoid Preload Connector Preload Screw Bracket Upper Body 3-mm Bolts Syringe Cable Luer Lock Heater Heater Extension Cable Nozzle Purge Screw Lower Body...
Page 222: Cleaning The Dj-2000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-11 Cleaning the DJ-2000 Tools and Materials Needed: Solvent .050-inch hex key Ultrasonic Cleaner 7/64-inch hex key Small spanner wrench Kimwipes Cotton swabs (mid-size and mini) Slotted screwdriver O-ring removal tool Spray Solvent Magnifying Glass Pin vise Flashlight Air gun...
Page 223 Trainee Guide TR-L2-M2000 Diagram Sheet 3-6-11 DJ-2000 – Disassembly for Cleaning Micrometer Micrometer Assembly Lock Nut Preload Screw Dispense Preload Lock Solenoid Valve Upper Body Syringe Luer Lock Purge Screw Needle U-Cup Seal Lower White Body ® (Chemraz O-Ring Fillister Screw Black (Kalraz) O-Ring...
Page 224 Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-11 (Continued) Cleaning the DJ-2000 If adhesive appears on the needle within 0.25 mm (0.1in.) of the upper body, place the o- ring removal tool in the center of the U-cup seal, and lift it out. Inspect the needle for excessive wear.
Page 225: Reassembling The Dj-2000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-12 Reassembling the DJ-2000 Tools and Materials Needed: Ring and seal insertion tool .050-inch hex key 7/64-inch hex key Spanner Wrench Conductive Grease Kimwipes If you removed the U-cup seal, place it into the bottom side of the lower body, spring side outwards.
Page 226: Reconnecting The Dj-2000
Trainee Guide TR-L2-M2000 Exercise Sheet 3-6-13 Reconnecting the DJ-2000 Tools Needed: 3-mm hex key Place the bracket mount into the slot of the Z-head. The top of the bracket mount should be approximately 2” down from the top of the Z-head slot.
Page 227: Cleaning And Replacing Fans And Vents
Trainee Guide TR-L2-M2000 Outline Sheet 3-7-1 Cleaning and Replacing Fans and Vents A. Introduction There are two fans located on the floor underneath the modules in the rear of your dispenser. The function of these fans is to regulate the internal temperature of the dispenser and prevent the modules from over-heating.
Page 228 Trainee Guide TR-L2-M2000 Exercise Sheet 3-7-1 Cleaning the Fans and Vents Tools and Materials Needed: 1/8 inch hex key Pliers Philips head screw driver Turn the Main Power Switch OFF (O). Switch the Main Power Circuit Breaker to OFF (O). Open the lower access panel on the back of the dispensing system.
Page 229: Conveyor Belts
Trainee Guide TR-L2-M2000 Outline Sheet 3-8-1 Conveyor Belts A. Introduction Checking the condition of the conveyor belts should be a part of the routine maintenance schedule of the dispensing system. B. Enabling Objective Perform the procedure to remove and replace the conveyor belts. C.
Page 230: Conveyor Belt Maintenance
Trainee Guide TR-L2-M2000 Information Sheet 3-8-1 Conveyor Belts A. Conveyor Belt Maintenance To maintain optimum system performance, it is recommended that you change the conveyor belts every six months. Belts may need to be changed more frequently or less frequently, depending upon the volume of part handling.
Page 231: Removing And Replacing Conveyor Belts
Trainee Guide TR-L2-M2000 Exercise Sheet 3-8-1 Removing and Replacing the Conveyor Belts Tools and Materials Needed: 1/8 -inch hex key 3/32-inch hex key 7/64-inch hex key Pliers New conveyor belts Move the dispensing head to the home position. Use the Jog Controls to move the rear conveyor rail to the extreme back of the dispensing area.
Page 232 Trainee Guide TR-L2-M2000 Exercise Sheet 3-8-1 (Continued) Removing and Replacing the Conveyor Belts Remove the old belt by sliding it off the conveyor wheels. Use alcohol and clean swabs to clean all metal surfaces that make contact with the belt, including pulleys and rails. Compare the new conveyor belt to the old conveyor belt still on the dispenser to determine which side of the new belt should face up and which side should face down when you install it.
Page 233 Trainee Guide TR-L2-M2000 Diagram Sheet 3-8-1 Conveyor Belt Replacement Level 2 Maintenance Training – M2000 Dispensing Systems 3-2-55 P/N 73-0018-00 (Revision B)
Page 234 Trainee Guide TR-L2-M2000 Diagram Sheet 3-8-2 Conveyor Drive Shaft Locking Pin Drive Shaft Drive Shaft and Locking Pin Drive Shaft Upper Rear Access Door M-2000 Drive Shaft Assembly Level 2 Maintenance Training – M2000 Dispensing Systems 3-2-56 P/N 73-0018-00 (Revision B)
Page 235: Tensioning The Cables
Trainee Guide TR-L2-M2000 Outline Sheet 3-9-1 Tensioning the Cables A. Introduction The Auto Tensioner is a pneumatic device employed to maintain proper tension on the dispenser cables. Proper cable tension is essential for accurate dispensing. You should perform an Auto Tension procedure at least once a month, or whenever you experience accuracy problems in your dispensing process.
Page 236: File Select
Trainee Guide TR-L2-M2000 Information Sheet 3-9-1 Tensioning the Cables A. Auto Tension Procedure FmNT includes auto tension procedure that allows you to tighten the dispenser cables. This is essential in order to achieve and maintain an accurate and consistent dispensing. The Tensioner Setup dialog box allows you to setup and run an Auto Tension procedure.
Page 237: Run
Trainee Guide TR-L2-M2000 Information Sheet 3-9-2 Tensioning the Cables (Continued) Burn-in Frequency You will need to run the Tensioner procedure multiple times during the Burn-in Period. Burn-in Frequency is the number of hours between Tensionings. When the Burn-in Frequency expires, FmNT issues a message telling you to rerun the Auto Tensioner procedure.
Page 238 Trainee Guide TR-L2-M2000 Exercise Sheet 3-9-1 Tensioning the Cables In the Main Window, click on Run a Program. In the Production Window, click on Setup. Select Auto Tensioner from the list of available options. The Tensioner Setup dialog box opens. Select desired options.
Page 239 Trainee Guide TR-L2-M2000 Module 4 Troubleshooting Lesson 1 Obtaining Asymtek Technical Support Lesson 2 XYZ Axis Failure Lesson 3 Pneumatic Failure Lesson 4 Conveyor Failure Lesson 5 Heater Failure Lesson 6 Scale Failure Lesson 7 Vision System Failure Lesson 8 Dispense Valve Failure Lesson 9 Height Sensor Failure...
Page 241 Trainee Guide TR-L2-M2000 Module 4 Table of Contents Lesson 1 Obtaining Asymek Technical Support ..............1 Describing Machine Faults................... 2 Request for Technical Support (RTS) Form ..............2 Ordering Replacement Parts..................2 Lesson 2 XYZ Axis Failure....................5 Symptoms and Causes of XYZ Axis Failure ..............6 Lesson 3 Pneumatic Failure....................
Page 242 Trainee Guide TR-L2-M2000 Module 4 Table of Contents (Continued) Lesson 13 Testing the I/O Functions of the Dispenser and Conveyor ......49 Testing I/O Functions ....................50 Conveyor I/O Test.....................50 Dispenser I/O Test ....................51 Exercises: .........................52 Conveyor I/O Testing....................52 Using the TS-03 Test Kit to Test the Conveyor Controller Module ......54 Dispenser I/O Testing ...................56 Lesson 14 Reinitializing Conveyor Controller Memory .............
Page 243: Obtaining Asymek Technical Support
Trainee Guide TR-L2-M2000 Outline Sheet 4-1-1 Obtaining Asymtek Technical Support Introduction Although this course will help you identify and correct many problems you may encounter with your dispensing system, there may be times when it is necessary to contact Asymtek Technical Support.
Page 244: Request For Technical Support (Rts) Form
Trainee Guide TR-L2-M2000 Information Sheet 4-1-1 Contacting Asymtek Technical Support Describing Machine Faults Summarize the problem, and describe when it started. Write down all of the details of the symptom. This information will be required if replacement parts are needed to resolve the issue. Tell what you believe is causing the problem, and how you isolated it to this problem.
Page 245 Trainee Guide TR-L2-M2000 Diagram Sheet 4-1-1 Request for Technical Support Request for Technical Support Section 1 COMPANY INFORMATION Section 2 EQUIPMENT INFORMATION Date: Originator: Model: (required): Company Software: Firmware: Ship To Addr1: Voltage Requirements: Ship To Addr2: Light Camera: Source: City: Country/ State:...
Page 246 Trainee Guide TR-L2-M2000 Diagram Sheet 4-1-2 Return Material Authorization (RMA) Form Return Material Authorization Date: RMA Type Legend RMA Type: Originated By: Ship To: RW = Warranty Replace Part RN = Non-warranty Replace Part Customer: FW = Warranty Repair Address: FN = Non-Warranty Repair Address: CC = Credit Return...
Page 247: Xyz Axis Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-2-1 XYZ Axis Failure Introduction The dispense head moves to the left, right, back and front on the X/Y-Axis rods. The dispense head moves up and down on the Z-axis rod. Axis failure can be attributed to a variety of causes.
Page 248 Trainee Guide TR-L2-M2000 Information Sheet 4-2-1 Symptoms and Causes of XYZ-Axis Failure Symptom Possible Cause Recovery Hood or window open Close hood or window +48V power supply down Call Service Technician EMO activated Rotate EMO clockwise until in pops back into position. Servo amps failed Call Service Technician Limits not cleared...
Page 249: Symptoms And Causes Of Xyz Axis Failure
Trainee Guide TR-L2-M2000 Information Sheet 4-2-2 Symptoms and Causes of XYZ-Axis Failure (Continued) Symptom Possible Cause Recovery Mechanical interference along X or Y Visually inspect cable for cable anything that may be restricting movement. Call Service Technician Jerky Movement Z brake (to test: m214=1) Call Service Technician Mechanical interference along Z Visually inspect cable for...
Page 250 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-8 P/N 73-0018-00 (Revision B)
Page 251: Pneumatic Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-3-1 Pneumatic Failure Introduction Pneumatic failure symptoms include loss of fluid pressure, loss of valve pressure and a leaky regulator. It may be necessary to make appropriate adjustments to the air pressure settings to correct this problem. Enabling Objective Identify necessary steps to isolate pneumatic failure and perform appropriate recovery procedures.
Page 252: Symptoms And Causes Of Pneumatic Failure
Trainee Guide TR-L2-M2000 Information Sheet 4-3-1 Symptoms and Causes of Pneumatic Failure Symptom Possible Cause Recovery Main Air Switch is Off. Turn Main Air Switch On. No Fluid Pressure Air Pressure Make sure that the Fluid Pressure Regulator is set to the proper air pressure.
Page 253: Conveyor Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-4-1 Conveyor Failure Introduction Occasionally you may experience conveyor problems. Conveyor failure can have numerous symptoms as well as causes, and it will be necessary to isolate these factors in order to effectively troubleshoot conveyor problems. Enabling Objective Identify steps to isolate conveyor failure and perform appropriate recovery procedures.
Page 254: Symptoms And Causes Of Conveyor Failure
Trainee Guide TR-L2-M2000 Information Sheet 4-4-1 Symptoms and Causes of Conveyor Failure Symptom Possible Cause Recovery Conveyor Controller Module Cannot Adjust Replace fuse Fuse Width/Belt Does Not Call Service Technician Main PCA Move Conveyor Motor Call Service Technician Check cable connections. Conveyor Controller Module Fails to Find Width Call Service Technician...
Page 255: Heater Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-5-1 Heater Failure Introduction Occasionally the technician may need to solve minor heater related problems. Although causes may vary depending on the type of heater installed, the following section outlines some common heater problems and their recovery. Enabling Objective Identify steps to isolate heater failure and perform appropriate recovery procedures.
Page 256: Symptoms And Causes Of Heater Failure
Trainee Guide TR-L2-M2000 Information Sheet 4-5-1 Symptoms and Causes of Heater Failure Symptom Possible Cause Recovery Turn EMO button clockwise to System is in Emergency Stop. release and restart machine. Activate the heater loops. See Exercise Sheet 4-5-1, Testing Heater loops are not active. Heater Loops, on page 4-2-15.
Page 257: Testing Heater Loops
Trainee Guide TR-L2-M2000 Exercise Sheet 4-5-1 Testing Heater Loops 1. In the Main Window, click on Tools. 2. In the Tools Window, click on Terminal. 3. Click on Heaters. 4. The Heater Controls Window opens. 5. In the On/Off column of the dialog box are heater coil icons. 6.
Page 258: Resetting Heater Thermostat
Trainee Guide TR-L2-M2000 Exercise Sheet 4-5-2 Resetting Heater Thermostat 1. Turn the Main Circuit Breaker OFF and lock it out with a padlock. 2. If a Main Power Switch is present, turn the Main Power Switch OFF and lock it out with a padlock.
Page 259: Checking Zone Sensor
Trainee Guide TR-L2-M2000 Exercise Sheet 4-5-3 Checking Zone Sensor If the heaters are functioning normally, but do not turn on when a part enters that zone, it is possible that the sensor is burned out or not turned on. Perform the following procedure to check the zone sensor: 1.
Page 260 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-18 P/N 73-0018-00 (Revision B)
Page 261: Scale Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-6-1 Scale Failure Introduction Occasionally you may experience scale failure. Scale failure has several symptoms and causes. This section will identify common scale problems and their recovery. Enabling Objective Isolate possible causes of scale failure and perform recovery procedures. Topic Outline Introduction Overview...
Page 262 Trainee Guide TR-L2-M2000 Information Sheet 4-6-1 Symptoms and Causes of Scale Failure Symptom Possible Cause Recovery Power Connector Connect Power Cable Blank Display Screen Scale Display Call Service Technician Check surrounding area for any equipment that may be causing vibration. Vibration If problem cannot be resolved, call Service Technician.
Page 263: Vision System Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-7-1 Vision System Failure Introduction There are some troubleshooting procedures that an operator may perform when experiencing problems with the Vision System. However, some symptoms that appear to be problems with the Vision System may actually have other causes. Enabling Objective Perform steps to isolate Vision System failure and perform appropriate recovery procedures.
Page 264 Trainee Guide TR-L2-M2000 Information Sheet 4-7-1 Vision System Failure Symptom Check/Correction Dispensing program • Reboot the computer and do not press [Esc] or [Enter] while in a ® freezes Cognex menu. • If you moved the camera to refocus it, you must reestablish the Camera-to-needle camera-to-needle offset.
Page 265: Dispense Valve Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-8-1 Dispense Valve Failure Introduction Troubleshooting dispense pump/valves varies depending on the type. This section describes some common troubleshooting techniques for the DP-3000, DV-6000, DV-7000, and DJ-2000 pumps. Enabling Objective Identify troubleshooting procedures for various pumps and perform recovery procedures.
Page 266 Trainee Guide TR-L2-M2000 Information Sheet 4-8-1 DP-3000 Troubleshooting Intermittent or No Fluid Dispensing Possible Cause Recovery Pump poorly primed Perform a priming sequence. Replace tip. Clogged dispensing tip Plugged pump Clean pump. Empty fluid reservoir Replace fluid reservoir. Speed Control set to 0 rpm Increase Valve Speed.
Page 267 Trainee Guide TR-L2-M2000 Information Sheet 4-8-2 DP-3000 Troubleshooting (Continued) Pump Unable To Complete Reset Routine Possible Cause Recovery Set valve pressure to 40-80 psi. Pump air pressure too low (For encoded models, set the fluid pressure to 40 psi). Speed Control too slow Make sure Speed Control is greater than 1.
Page 268 Trainee Guide TR-L2-M2000 Information Sheet 4-8-3 DP-3000 Troubleshooting (Continued) No Material Comes Through Priming Port When Priming Possible Cause Recovery Priming port clogged Clean pumping chamber. Valve or fluid pressure set Set the valve pressure (non-encoded models) or fluid too low pressure (encoded models) to 40-80 psi.
Page 269 Trainee Guide TR-L2-M2000 Information Sheet 4-8-4 DV-6000 Troubleshooting Intermittent Or No Fluid Is Dispensing Possible Cause Recovery 1. Valve pressure off or too low 1. Set pressure. 2. Clogged dispensing tip 2. Replace tip. 3. Plugged valve 3. Clean valve. 4.
Page 270 Trainee Guide TR-L2-M2000 Information Sheet 4-8-5 DV-6000 Troubleshooting (Continued) Material Drips For A Short Time And Eventually Stops Possible Cause Recovery 1. Air in Fluid 1. Purge thoroughly or use degassed material. 2. Valve set too high 2. Lower valve pressure. 3.
Page 271 Trainee Guide TR-L2-M2000 Information Sheet 4-8-6 DV-7000 Troubleshooting Intermittent Or No Fluid Dispensing Possible Cause Recovery 1. See “Priming the DV-7000” in the Valve Operations 1. Pump poorly primed Manual. 2. Clogged needle 2. Clean or replace the needle. 3. Clean pump. See “Cleaning the DV-7000” in the Valve 3.
Page 272 Trainee Guide TR-L2-M2000 Information Sheet 4-8-7 DV-7000 Troubleshooting (Continued) Inconsistent Shot Sizes Possible Cause Recovery 1. Syringe air pressure set too 1. Increase syringe air pressure (20 psi max.). Refer to the system Operations Manual for instructions. 2. Drive mechanics do not have 2.
Page 273 Trainee Guide TR-L2-M2000 Information Sheet 4-8-8 DJ-2000 Troubleshooting Nozzle Is Capping Over (tip is covered with fluid) Possible Cause Recovery 1. Raise the temperature. Refer to Section 4 – Heater 1. Heat setting is too low Control for Windows (HCW) of the Fluidmove for Windows Installation and User Guide.
Page 274 Trainee Guide TR-L2-M2000 Information Sheet 4-8-9 DJ-2000 Troubleshooting (Continued) Satellite Dots Possible Cause Recovery 1. Preload screw too tight 1. Adjust Preload screw to reduce tension. 2. Reduce the shooting height by adjusting the Safe Z-Axis 2. Dispensing head too high from height.
Page 275 Trainee Guide TR-L2-M2000 Information Sheet 4-8-10 DJ-2000 Troubleshooting (Continued) Fluid Not Escaping Through Nozzle Possible Cause Recovery 1. Micrometer or Preload screw is 1. Adjust the Micrometer to the proper setting. tightened all the way down 2. Cutout windows in extension 2.
Page 276 Trainee Guide TR-L2-M2000 Information Sheet 4-8-11 DJ-2000 Troubleshooting (Continued) Not Dispensing Properly Possible Cause Recovery 1. Perform “Cleaning Procedure” in DJ-2000 Operations 1. Jet may need to be cleaned Manual. Dispenser Does Not Cycle Possible Cause Recovery 1. Check that the solenoid cable is securely fastened to the 1.
Page 277 Trainee Guide TR-L2-M2000 Information Sheet 4-8-12 DJ-2000 Troubleshooting (Continued) Dots Are Stringing Or Stitching Possible Cause Recovery 1. Clean the nozzle with solvent and cleaning wire 1. Dirty nozzle (provided in Spare Parts Kit, shipped with DJ-2000). 2. Inspect the interface between the nozzle and extension. Clean so that they are free of adhesive and debris.
Page 278 Trainee Guide TR-L2-M2000 Information Sheet 4-8-13 DJ-2000 Troubleshooting (Continued) Dots Are Too Flat Possible Cause Recovery 1. Reduce temperature 2°C (3.6°F) at a time. Refer to 1. Dispenser heater temperature Section 4 – Heater Control for Windows (HCW) of the too high Fluidmove for Windows Installation and User Guide.
Page 279: Height Sensor Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-9-1 Height Sensor Failure Introduction The HS-Series RT Height Sensor uses a stainless steel probe to contact the dispensing surface. The probe tip is machined to minimize surface contact. The LK-Series Laser Height Sensor uses a semiconductor laser beam and triangulation measurement to determine the substrate height.
Page 280: Height Sensor Troubleshooting
Trainee Guide TR-L2-M2000 Information Sheet 4-9-1 Height Sensor Troubleshooting Symptom Possible Cause Recovery Check probe function: Push the probe up with Call a Service Probe does not drop or your finger Technician. retract (HS-Series) If the green LED light on the side does not turn ON, the probe is not working.
Page 281: Needle Sensor Failure
Trainee Guide TR-L2-M2000 Outline Sheet 4-10-1 Needle Sensor Failure Introduction The Needle Sensor allows you to change needles and continue production without reprogramming the dispensing system. It can automatically compensate for XYZ changes in needle location due to a needle change or a bent needle, therefore minimizing operator error and eliminating wasted time spent manually adjusting the needle.
Page 282: Needle Sensor Troubleshooting
Trainee Guide TR-L2-M2000 Information Sheet 4-10-1 Needle Sensor Troubleshooting Symptom Possible Cause Recovery During Setup routine, error See Exercise Sheet 2-9-2, Tactile sensor “hat” is stuck in indicates that the tactile sensor Tactile Sensor Error, on the down position. is already engaged. page 2-2-70.
Page 283: Removing And Replacing Fuses
Trainee Guide TR-L2-M2000 Outline Sheet 4-11-1 Removing and Replacing Fuses Introduction There are approximately fifteen fuses on most M-2000 Series Dispensing Systems, depending upon your system heater configuration. Occasionally, you may need to replace a fuse. Enabling Objective 4.11 Locate fuses on the M-2000 Series Systems and perform the procedure to replace them.
Page 284: Board Mounted Fuse
Trainee Guide TR-L2-M2000 Information Sheet 4-11-1 Fuses Removing and Replacing Fuses The number of fuses on M-2000 Series Dispensing Systems varies depending upon the system configuration. There are 2 types of fuses: Board Mounted Fuses Panel Mounted Fuses Make sure that all system power is OFF when replacing fuses or serious bodily injury and/or damage to the dispensing system will occur.
Page 285: Removing And Replacing Main Line Fuses
Trainee Guide TR-L2-M2000 Exercise Sheet 4-11-1 Removing and Replacing Main Line Fuses Turn the Main Circuit Breaker OFF (0). Unplug all power cords. Determine which fuse needs to be replaced. Insert the small flat head screwdriver into the slot at the top or on the side of the fuse box and gently pry it open.
Page 286 Trainee Guide TR-L2-M2000 Diagram Sheet 4-11-1 Main Line Fuses - Conveyor Controller Module (Box Mount) M ai n P ow er Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-44 P/N 73-0018-00 (Revision B)
Page 287: Removing And Replacing Panel Mounted Fuses
Trainee Guide TR-L2-M2000 Exercise Sheet 4-11-2 Removing and Replacing Panel Mounted Fuses Turn the Main Circuit Breaker OFF (0). Unplug all power cords. Determine which fuse needs to be replaced. Use the small flat head screwdriver to turn the fuse ¼ turn counter clockwise. Gently push in on the fuse while turning it.
Page 288 Trainee Guide TR-L2-M2000 Diagram Sheet 4-11-2 Panel Mounted Fuses – Conveyor Controller Module Fuse Fuse Cap Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-46 P/N 73-0018-00 (Revision B)
Page 289: Communications Error
Trainee Guide TR-L2-M2000 Outline Sheet 4-12-1 Communications Error Introduction No computer interface is the result of a communications error. The possible causes include faulty COM ports or the Conveyor Controller Module. Enabling Objective 4.12 Identify necessary steps to isolate communication failure and perform appropriate recovery procedures.
Page 290: Module
Trainee Guide TR-L2-M2000 Exercise Sheet 4-12-1 No Computer Interface Be sure that the following Modules and components are connected to the computer as follows: COM 1 to the Conveyor Controller Module 2 (if system is equipped with Dual Lane Conveyor) COM 2 to the Conveyor Controller Module COM 3 to the Scale Display COM 4 to the Heater Relay Module...
Page 291: Testing The I/O Functions Of The Dispenser And Conveyor
Trainee Guide TR-L2-M2000 Outline Sheet 4-13-1 Testing the I/O Functions of the Dispenser and Conveyor Introduction When troubleshooting the dispensing system, it may be necessary to test the input and output (I/0) functions of the Dispenser and Conveyor. Enabling Objective 4.13 Perform procedure to list and test the I/O functions of the Dispenser and Conveyor.
Page 292 Trainee Guide TR-L2-M2000 Information Sheet 4-13-1 Testing the I/O Functions of the Dispenser and Conveyor Testing I/O Functions The TS-03 test kit is a device used to test the internal and external communications (I/O) of the system modules. It contains a TS-01 test box and TS-03 cables (See Diagram Sheet 4-13-2 on page 4-2-55).
Page 293 Trainee Guide TR-L2-M2000 Information Sheet 4-13-2 Testing the I/O Functions of the Dispenser and Conveyor (Continued) Dispenser I/O Test The Dispenser I/O Test window lists all of the Inputs and Outputs associated with the Dispenser. This window can be accessed, and these functions performed from the I/O Test button in the Tools Window.
Page 294: Conveyor I/O Testing
Trainee Guide TR-L2-M2000 Exercise Sheet 4-13-1 Conveyor I/O Testing Check that conveyor belt forward and backward movement is smooth and controlled using the Position Controls. Use the Jog Commands to open the Position Control dialog box for the conveyor. Press Home to send the conveyor home. Press Reinitialize to reset the conveyor.
Page 295 Trainee Guide TR-L2-M2000 Diagram Sheet 4-13-1 Conveyor I/O Window Input Tab Output Tab Control Tab Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-53 P/N 73-0018-00 (Revision B)
Page 296: Using The Ts-03 Test Kit To Test The Conveyor Controller Module
Trainee Guide TR-L2-M2000 Exercise Sheet 4-13-2 Using the TS-03 Test Kit to Test the Conveyor Controller Module Verifying Conveyor I/O: With the system powered down, remove the I/O Cable from the 201 (W) Controller. Use the TS-01 Box and cables to verify each of the 24 I/O bits available. Set the TS-01 test box to I/O Mode (not Drivers) and set the bottom switches to Independent so that the Inputs will be independent of the Outputs.
Page 297 Trainee Guide TR-L2-M2000 Diagram Sheet 4-13-2 TS-01 Test Box Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-55 P/N 73-0018-00 (Revision B)
Page 298: Dispenser I/O Testing
Trainee Guide TR-L2-M2000 Exercise Sheet 4-13-3 Dispenser I/O Testing 1. Click on Tools in the FMW Main Window, then on I/O Test in the Tools Window, then on Dispenser. 2. Click the Control tab to access the Jog commands. 3. Move the dispensing head left and right, backward and forward. Check for slipping, stuttering and vibrating.
Page 299 Trainee Guide TR-L2-M2000 Diagram Sheet 4-13-3 Dispenser I/O Window Input Tab Output Tab Control Tab Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-57 P/N 73-0018-00 (Revision B)
Page 300 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-58 P/N 73-0018-00 (Revision B)
Page 301: Reinitializing Conveyor Controller Memory
Trainee Guide TR-L2-M2000 Outline Sheet 4-14-1 Reinitializing Conveyor Controller Memory Introduction The Conveyor Controller Module contains operating instructions that control various aspects of the dispensing system’s major components. If the memory is erased, it will need to be reinitialized. Enabling Objective 4.14 Understand the procedure to reinitialize memory and download the conveyor atom.
Page 302 Trainee Guide TR-L2-M2000 Information Sheet 4-14-1 Reinitializing Conveyor Controller Memory Conveyor Atom The conveyor atom is an Automove Control Language (ACL) file that contains the software commands that control your conveyor. Personality Parameters are values contained in the conveyor atom. They control various aspects of the dispensing system’s major components.
Page 303: Reinitializing Conveyor Controller Memory
Trainee Guide TR-L2-M2000 Exercise Sheet 4-14-1 Reinitializing Conveyor Controller Memory Using the Calibration Restoration Diskette, located inside of the front door of the system, you can erase and reinitialize the memory of the 201 W Conveyor Controller Module. Note: System calibration should only be performed by a trained service technician . In the FMW Main Window, click on Tools.
Page 304 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-62 P/N 73-0018-00 (Revision B)
Page 305: Reinitializing The Pmac
Trainee Guide TR-L2-M2000 Outline Sheet 4-15-1 Reinitializing the PMAC Introduction The PMAC Card (Programmable Multi Axis Controller) connects to the X, Y, and Z Servo Amplifiers and provides positional information to the robot. PMAC is a computer, capable of stand-alone operation with its own stored programs. PMAC Commands are used on M-2000 Series dispensing system to control the dispensing head.
Page 306: Pmac Initialization Files
Trainee Guide TR-L2-M2000 Information Sheet 4-15-1 PMAC Initialization PMAC Initialization Files There are several FmNT files that contain configuration variables for the PMAC. These files are downloaded to the PMAC upon FmNT startup and include the following: PMACINI.PMC This file contains several servo parameters and PMAC configuration variables.
Page 307: Pmac Watchdog
Trainee Guide TR-L2-M2000 Information Sheet 4-15-2 PMAC Initialization (Continued) PMAC Watchdog The PMAC motion control board has an on-board “watchdog timer” circuit whose job it is to detect a number of conditions that could result in a dangerous malfunction of the equipment. It provides a fail-safe shutdown to guard against: Software or hardware malfunction.
Page 308: Pmac Commands
Trainee Guide TR-L2-M2000 Information Sheet 4-15-3 PMAC Terminal Commands PMAC Commands Saving Downloads In the terminal Mode type: Save [enter]. Clearing Memory In the Terminal Mode type: $$$*** [enter]. Home Commands Enables amplifiers. M214-[enter] Closes the servos, powers the motors. a [enter] Homes the Z-axis.
Page 309 Trainee Guide TR-L2-M2000 Information Sheet 4-15-4 PMAC Terminal Commands (Continued) Running XY Motion Programs Where x is in terms of micrometers. M900=x [enter] Where y is in terms of micrometers. M901=y [enter] b-buffer, r-run. b100r [enter] Aborting a Program How to abort a program. a [enter] Stopping a Program / Opening a Servo Loop Motors will be disabled.
Page 310 Trainee Guide TR-L2-M2000 Exercise Sheet 4-15-1 Reinitializing the PMAC Restart the system in Windows NT. Click the Start button, select Programs and PEWIN32. Type the commands in column 1 below in the terminal window to reset the PMAC to factory defaults. Column 2 explains the commands. Command Explanation $$$***...
Page 311: Pmac Plot
Trainee Guide TR-L2-M2000 Outline Sheet 4-16-1 PMAC Plot Introduction One of the diagnostic tools available is a built-in tool called PMAC Plot. PMAC Plot is used to measure and gather position, velocity and acceleration profiles of the dispense head for dispensing programs written in FmNT that are installed on Asymtek servo systems.
Page 312 Trainee Guide TR-L2-M2000 Information Sheet 4-16-1 PMAC Plot PMAC Plot PMAC Plot is a program that plots the electrical signals of the dispense head path on the screen. The information can be saved and printed. This program is generally used by Service Technicians as a diagnostic tool to measure and gather position, velocity and acceleration profiles.
Page 313: Gathering Data
Trainee Guide TR-L2-M2000 Diagram Sheet 4-16-1 Gathering Data Process FmNT Programming Window Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-71 P/N 73-0018-00 (Revision B)
Page 314 Trainee Guide TR-L2-M2000 Information Sheet 4-16-2 PMAC Plot (Continued) Plotting Data Open the PMAC Plot Program. Press [Ctrl]-ESC Select Programs, Pmac Plot, PmacPlot. Click on the Quick Plot tab. Click on Motors to Gather. Select motors (commanded and actual) to be analyzed. 1 = x-motor, 2 = y-motor, 3 = z-motor.
Page 315: Plotting Data
Trainee Guide TR-L2-M2000 Diagram Sheet 4-16-2 Plotting Data Motors to Gather Clears Gather buffer Choices Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-73 P/N 73-0018-00 (Revision B)
Page 316: Saving And Printing Data
Trainee Guide TR-L2-M2000 Information Sheet 4-16-3 PMAC Plot (Continued) Saving and Printing Data Load Word Pad. Press [ctrl]-[Esc] keys. Select Start, Programs, Accessories, Word Pad. {Alt]-[Tab] back to PMACPLOT window. Maximize plot window. Press [Alt]-Print Screen. (This performs a screen capture). Select Word Pad on toolbar.
Page 317 Trainee Guide TR-L2-M2000 Diagram Sheet 4-16-3 Printing Data Starting WordPad Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-75 P/N 73-0018-00 (Revision B)
Page 318 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 4-2-76 P/N 73-0018-00 (Revision B)
Page 319 Trainee Guide TR-L2-M2000 Module 5 Module and PCA Replacement Lesson 1 Removing and Replacing the Power Manager Module Lesson 2 Removing and Replacing the Conveyor Controller Module Lesson 3 Removing and Replacing the Temperature Controller Module Lesson 4 Removing and Replacing the Heater Relay Module Lesson 5 Removing and Replacing the PCA’s Level 2 Maintenance Training –...
Page 321 Trainee Guide TR-L2-M2000 Module 5 Table of Contents Lesson 1 Removing and Replacing the Power Manager Module......1 Exercise: ...................... 2 Removing and Replacing the Power Manager Module........2 Lesson 2 Removing and Replacing the Conveyor Controller Module....5 Exercise: ...................... 6 Removing and Replacing the Conveyor Controller Module ......
Page 322 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems P/N 73-0018-00 (Revision B)
Page 323: Removing And Replacing The Power Manager Module
Trainee Guide TR-L2-M2000 Outline Sheet 5-1-1 Removing and Replacing the Power Manager Module Introduction Occasionally a technician may find it necessary to replace the Power Manager Module. The following section describes in detail how to remove and replace the Power Manager Module.
Page 324: Removing And Replacing The Power Manager Module
Trainee Guide TR-L2-M2000 Exercise Sheet 5-1-1 Removing and Replacing the Power Manager Module Tools and Materials Needed: 1/8-inch hex key 1. Press the Emergency Stop (EMO) button. 2. Turn the Main Circuit Breaker OFF (O). 3. Unplug all power cords. 4.
Page 325 Trainee Guide TR-L2-M2000 Diagram Sheet 5-1-1 Power Manager Module Level 2 Maintenance Training – M2000 Dispensing Systems 5-2-3 P/N 73-0018-00 (Revision B)
Page 326 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 5-2-4 P/N 73-0018-00 (Revision B)
Page 327: Removing And Replacing The Conveyor Controller Module
Trainee Guide TR-L2-M2000 Outline Sheet 5-2-1 Removing and Replacing the Conveyor Controller Module Introduction Occasionally a technician may find it necessary to replace the Conveyor Controller Module. The following section describes in detail how to remove and replace the Conveyor Controller Module.
Page 328 Trainee Guide TR-L2-M2000 Exercise Sheet 5-2-1 Removing and Replacing the Conveyor Controller Module Tools and Materials Needed: 4-mm hex key Press the Emergency Stop (EMO) button. Turn the Main Circuit Breaker OFF (O). Unplug all power cords. Open the lower back access door. Identify the Conveyor Controller Module.
Page 329 Trainee Guide TR-L2-M2000 Diagram Sheet 5-2-1 Conveyor Controller (201W) Module Level 2 Maintenance Training – M2000 Dispensing Systems 5-2-7 P/N 73-0018-00 (Revision B)
Page 330 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 5-2-8 P/N 73-0018-00 (Revision B)
Page 331: Removing And Replacing The Temperature Controller Module
Trainee Guide TR-L2-M2000 Outline Sheet 5-3-1 Removing and Replacing the Temperature Controller Module Introduction Occasionally a technician may find it necessary to replace the Temperature Controller Module. The following section describes in detail how to remove and replace the Temperature Controller Module. Enabling Objective Identify steps required to remove and replace the Temperature Controller Module.
Page 332 Trainee Guide TR-L2-M2000 Exercise Sheet 5-3-1 Removing and Replacing the Temperature Controller Module Tools and Materials Needed: 1/8-inch hex key 1. Press the Emergency Stop (EMO) button. 2. Turn the Main Circuit Breaker OFF (O). 3. Unplug all power cords. 4.
Page 333 Trainee Guide TR-L2-M2000 Diagram Sheet 5-3-1 Temperature Controller Module 4CH Temperature Controller Module 16CH Temperature Controller Module Level 2 Maintenance Training – M2000 Dispensing Systems 5-2-11 P/N 73-0018-00 (Revision B)
Page 334 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 5-2-12 P/N 73-0018-00 (Revision B)
Page 335: Removing And Replacing The Heater Relay Module
Trainee Guide TR-L2-M2000 Outline Sheet 5-4-1 Removing and Replacing the Heater Relay Module Introduction Occasionally a technician may find it necessary to replace the Heater Relay Module. The following section describes in detail how to remove and replace the Heater Relay Module. Enabling Objective Identify steps required to remove and replace the Heater Relay Module.
Page 336: Removing And Replacing The Heater Relay Module
Trainee Guide TR-L2-M2000 Exercise Sheet 5-4-1 Removing and Replacing the Heater Relay Module Tools and Materials Needed: 4-mm hex key 1. Press the Emergency Stop (EMO) button. 2. Turn the Main Circuit Breaker OFF (O). 3. Unplug all power cords. 4.
Page 337 Trainee Guide TR-L2-M2000 Diagram Sheet 5-4-1 Heater Relay Module Heater Relay Module Level 2 Maintenance Training – M2000 Dispensing Systems 5-2-15 P/N 73-0018-00 (Revision B)
Page 338 Trainee Guide TR-L2-M2000 Level 2 Maintenance Training – M2000 Dispensing Systems 5-2-16 P/N 73-0018-00 (Revision B)
Page 339: Removing And Replacing Pca's
Trainee Guide TR-L2-M2000 Outline Sheet 5-5-1 Removing and Replacing PCA’s Introduction Occasionally a technician may find it necessary to replace one of the Printed Circuit Assemblies (PCA). The following section describes in detail how to remove and replace the main interface board, circuit boards and servo boards. Enabling Objective Identify steps required to remove and replace PCA’s.
Page 340 Trainee Guide TR-L2-M2000 Exercise Sheet 5-5-1 Removing and Replacing the Main Interface Board Tools and Materials Needed: Phillips Head screwdriver Power down and lock out/tag-out the M-2000. Remove all power cables to the equipment. Pull open the front access panel. Remove the two retaining screws on the computer bay.
Page 341 Trainee Guide TR-L2-M2000 Exercise Sheet 5-5-2 Removing and Replacing Circuit Boards Tools and Materials Needed: Phillips Head screwdriver Power down and lock out/tag-out the M-2000. Remove all power cables to the equipment. Pull open the front access panel. Remove the two retaining screws on the computer bay. Gently remove the computer bay by pulling on the handles.
Page 342: Removing And Replacing The Servo Boards
Trainee Guide TR-L2-M2000 Exercise Sheet 5-5-3 Removing and Replacing the Servo Boards Tools and Materials Needed: Phillips Head screwdriver Power down and lock out/tag-out the M-2000. Remove all power cables to the equipment. Using a 2.5mm hex key, remove the two bolts on the rear upper access panel, exposing the servo boards.
Page 343 Trainee Guide TR-L2-M2000 Appendices Asymtek, Carlsbad Site Map – Building 1 Site Map – Building 2 – 1 Floor Site Map – Building 2 – 2 Floor Site Map – Building 3 Level 2 Maintenance Training – M2000 Dispensing Systems P/N 73-0018-00 (Revision B)

Nordson Asymtek M-2000 Maintenance Training

Introduction

Table of Contents

Table of Contents

Table of Contents

Table of Contents

Needle Sensor Failure

Removing and Replacing Fuses

Communications Error

Testing the I/O Functions of the Dispenser and Conveyor

Reinitializing Conveyor Controller Memory

Reinitializing the PMAC

PMAC Plot

Quick Links

Chapters

Troubleshooting

Related Manuals for Nordson Asymtek M-2000

Summary of Contents for Nordson Asymtek M-2000