Nordson Asymtek X-1000 Series Manuals

Nordson Asymtek X-1000 Series Manuals

Manuals and User Guides for Nordson Asymtek X-1000 Series. We have 1 Nordson Asymtek X-1000 Series manual available for free PDF download: Training Manual

Nordson Asymtek X-1000 Series Training Manual

Nordson Asymtek X-1000 Series Training Manual (500 pages)

Dispensing Systems

Brand: Nordson | Category: Dispenser | Size: 17.02 MB

Table of Contents

Table of Contents
5
Manual/Conventions Review
17
Course Terminal Objectives
18
Classroom Safety
19
Final Certification
21
Lesson 1-1 System Features
23
- System Description
  26
- System Feature Summary
  26
- Basic Platform
  28
- Optional Equipment
  28
Module 1 Equipment Safety
23
Lesson
29
- Safety Warning Labels
  29
  - Safety Warning Label Description
    29
Lesson
33
- Startup/Shutdown Procedures
  33
Lesson
39
- Emergency Shutdown Procedure
  39
  - Emergency Machine off (EMO) Buttons
    39
  - EMO Operation
    40
  - Emergency Shutdown Situations
    40
  - Emergency Shutdown Recovery
    40
  - EMO Circuit Diagram
    42
  - Exercise
    43
    
    Testing the Functionality of the EMO Button
    43
Lesson
45
- Safety Interlock and Light Beacon
  45
  - Light Beacon
    46
  - Safety Interlock
    46
  - Light Beacon Color Indications
    47
Lesson
49
- Facility Requirements
  49
  - Facility Safety Precautions
    50
Lesson
53
- Safety Precautions
  53
Lesson 2-1 Theory of Operation
57
- System Mechanics
  60
- Dispense Head
  60
- Conveyor
  61
- Fmnt
  61
- Theory of Operation
  62
- Operations Flow Chart
  63
Module 2 Equipment Operation
57
Lesson
65
- Dispensing System Components
  65
  - Power Manager
    66
  - Conveyor Controller
    66
  - Dispense Head Controller
    68
  - Computer
    69
    
    Main Interface PWA
    69
    
    ITI Vision Card
    69
    
    ATI Graphics Card
    70
    
    PIO96-J Card
    70
    
    PMAC Card
    70
  - Servo Shelf
    73
    
    Servo Power Transformer
    73
    
    XY Servo Interface PWA
    73
    
    Servo Amplifiers
    73
    
    Low Pressure Sensor
    73
    
    DC Cooling Fan
    74
    
    Main Air Solenoid
    74
    
    Dual Action Solenoid
    74
  - Positional Sensors
    76
    
    Linear Encoders
    76
    
    Hall Sensors
    76
  - Dispense Head
    77
    
    Dispense Head Mechanics
    77
    
    Z Servo Interface
    77
Lesson
79
- Power Distribution
  79
  - Power Manager
    79
  - Main Interface PWA
    79
  - XY Servo Interface
    79
  - Computer Power Supply
    81
  - Conveyor Controller
    81
Lesson
83
- Pneumatic Distribution
  83
  - Main Air Regulator and Gauge
    83
  - Main Air Solenoid
    83
  - Fluid Pressure Regulator and Gauge
    83
  - Valve Pressure Regulator and Gauge
    83
  - Tooling Air Pressure Regulator and Gauge
    83
  - Dual Action Solenoid
    85
  - Low Pressure Sensor
    86
  - Stop Pin Valve
    86
  - Clamp/Lifter Valve
    86
    
    Adjusting the Main Air Pressure Regulator
    90
  - Exercises
    90
    
    Adjusting Impingement Flowmeters
    93
    
    Digital Pressure Gauge Configuration
    95
Lesson
97
- Electrical and Pneumatic Paths
  97
Lesson
105
- Vision System
  105
  - Vision System Description
    106
  - Theory of Operation
    106
    
    Focusing the Camera
    108
  - Exercises
    108
    
    Calibrating the Camera
    110
Lesson
113
- Dispense Valves
  113
  - Dp-3000
    114
  - DV-7000
    116
  - Dj-2000
    118
Lesson
121
- Conveyor Operations
  121
  - Conveyor Configuration
    121
  - Stop Pins/Clamp Bars
    121
  - SMEMA Communication
    121
  - Detailed Operation
    121
    
    Conveyor Configuration
    126
  - Exercises:
    126
    
    Checking Adjustable Width Conveyor Clearance
    128
    
    Checking Fixed Width Conveyor Clearance
    129
    
    Leveling the Conveyor
    130
    
    Rough Adjusting the Conveyor Rail Width
    132
    
    Checking Upstream/Downstream SMEMA Communication
    133
    
    Checking Overall Conveyor Component Operations
    135
Lesson
137
- Dispensing Calibration Module
  137
Lesson 2-10 Linear Encoders
143
- Linear Encoder Calibration
  144
  - Linear Encoder Gap Adjustment
    146
  - Adjusting the Encoder Scanner to Encoder Scale Gap
    146
  - Exercises:
    146
Lesson 2-11 Height Sensor
149
- Theory of Operation
  149
- Height Sensor Setup
  149
- Probe Adjustments
  151
- Laser Height Sensor
  151
  - Configuring the Height Sensor
    152
  - Exercises:
    152
    
    Centering the Micrometer Locking Screw
    154
    
    Probe Removal and Replacement
    156
    
    Minor Probe Height Adjustments
    158
    
    Major Probe Height Adjustments
    160
    
    Probe Travel Adjustment
    162
Lesson 2-12 Needle Sensor
165
- Theory of Operation
  165
- Needle Sensor Setup
  165
- Needle Sensor Maintenance
  166
  - Needle Sensor Configuration
    168
  - Exercises:
    168
    
    Functional Testing of Needle Sensor
    170
Lesson 2-13 Needle Heater
171
- Needle Heater
  172
- Theory of Operation
  172
- Needle Heater Installation
  172
- Needle Heater Maintenance
  172
  - Installing a Needle Heater
    174
  - Exercises:
    174
    
    Adjusting Needle Heater Settings
    176
Lesson 2-14 Part Heaters
179
- Theory of Operation
  179
- Contact Heaters
  180
- Impingement Heaters
  182
- Heater Calibration
  182
  - Electrically Testing Part Heaters and Needle Heaters
    184
  - Exercises:
    184
    
    Temperature Testing Part Heaters and Needle Heaters
    186
    
    Checking Contact Heater Vacuums
    187
    
    Impingement Heater Airflow Adjustment
    188
    
    Checking the Function of Impingement Air Valve and Flowmeters
    189
    
    Heater Calibration
    190
Lesson 2-15 Board Sensors
193
- Upward Facing Sensors
  193
- Downward Facing Sensors
  194
- Sensitivity Adjustments
  194
  - Board Sensors
    194
  - Exercises:
    195
    
    Adjusting the Upward-Facing Board Sensors
    196
    
    Adjusting the Downward-Facing Board Sensors
    201
  - Testing the Board Sensors
    195
Lesson 2-16 Stop Pins/Lift Tables/Clamp Bars
203
- Stop Pins
  204
- Lift Tables/Clamp Bars
  204
- Airflow Adjustment
  204
  - Checking Stop Pin, Lift Table and Clamp Bar Operation
    205
  - Exercises:
    205
    
    Leveling the Lift Tables
    206
Lesson
211
- Pmac
  211
  - PMAC Initialization Files
    212
  - PMAC Watchdog
    213
  - Reinitializing the PMAC
    213
  - PMAC Commands
    214
Lesson 2-18 PMAC Plot
217
- Gathering Data
  219
- Plotting Data
  221
- Analyzing Data
  222
- Saving and Printing Data
  222
Module 3 Routine Maintenance
225
Lesson
227
- Routine Maintenance Procedures
  227
  - Routine Maintenance Procedure Schedule
    228
Lesson
231
- Purge Boot and Weigh Station Maintenance
  231
  - Replacing Purge/Weigh Station Cups, Banjo Wipe and Cleaning the Purge Boot
    232
  - Exercises:
    232
    
    Replacing the Purge Boot
    234
Lesson
237
- Scale Leveling and Calibration
  237
  - Digital Scale
    238
  - Scale Leveling and Calibration
    238
    
    Leveling the Scale
    239
  - Exercises:
    239
    
    Calibrating the Scale
    242
Lesson
245
- Draining the Water Trap
  245
  - Draining the Water Trap
    246
  - Exercise:
    246
Lesson
249
- Lubricating the X-Beam and Y-Rail Linear Bearings
  249
  - Lubricating the X-Beam and Y-Rail Linear Bearings
    250
  - Exercise:
    250
Lesson
253
- Lubricating and Tensioning the Positioner Cables
  253
  - Lubricating the Positioner Cables
    254
  - Exercises:
    254
    
    Tensioning the Positioner Cables
    256
Lesson
259
- Cleaning and Replacing Conveyor Belts
  259
  - Conveyor Belt Maintenance
    260
  - Cleaning the Belts
    260
    
    Removing the Conveyor Belts
    261
  - Exercises:
    261
    
    Installing a Conveyor Belt
    262
Lesson
265
- Dispense Pump/Valve Maintenance
  265
  - Dp-3000
    266
  - Dj-2000
    267
    
    Disconnecting the DP-3000
    268
  - Exercises:
    268
    
    Cleaning the DP-3000
    270
    
    Reconnecting the DP-3000
    272
    
    Disconnecting the DV-7000
    274
    
    Cleaning the DV-7000
    276
    
    Reassembling and Reconnecting the DV-7000
    278
    
    Disconnecting the DJ-2000
    280
    
    Cleaning the DJ-2000
    282
    
    Reassembling the DJ-2000
    285
    
    Reconnecting the DJ-2000
    286
Module 4 Troubleshooting
287
Lesson
289
- Obtaining Asymtek Technical Support
  289
  - Describing Machine Faults
    290
  - Request for Technical Support Form
    290
  - Ordering Replacement Parts
    290
Lesson
293
- Power Failure
  293
Lesson
317
- Testing the I/O Functions of the Dispenser and Conveyor
  317
  - Testing I/O Functions
    318
  - Conveyor I/O Test
    318
  - Dispenser I/O Test
    319
    
    Conveyor I/O Testing
    320
  - Exercises:
    320
    
    Using the TS-03 Test Kit to Test the Conveyor Controller
    322
    
    Dispenser I/O Testing
    324
Lesson
327
- Troubleshooting XY-Axis Motion
  327
Lesson
341
- Troubleshooting Z-Axis Motion
  341
Lesson
355
- Troubleshooting the Servo Controller (PMAC)
  355
  - PMAC Fault Isolation Procedure
    355
  - PMAC Troubleshooting Summary
    356
  - Troubleshooting Guidelines
    357
Lesson
377
- Troubleshooting Pneumatics
  377
Lesson
385
- Troubleshooting the Conveyor
  385
Lesson
407
- Troubleshooting the Scale
  407
  - Scale Fault Isolation Procedure
    408
  - Scale Troubleshooting Summary
    408
  - Troubleshooting Guidelines
    408
Lesson 4-10 Troubleshooting the Height Sensor
415
Lesson 4-11 Troubleshooting the Tactile and Needle Sensors
423
Lesson 4-12 Troubleshooting the Vision System
431
- Vision System Troubleshooting Summary
  432
Lesson 4-13 Troubleshooting Dispense Valves
433
- DP-3000 Troubleshooting
  433
- DJ-2000 Troubleshooting
  433
Module 5 Parts Replacement
445
Lesson
447
- Removing and Replacing Fuses
  447
  - Replaceable Fuses
    448
  - Board Mounted Fuses
    448
  - Panel Mounted Fuses
    448
  - Box Mounted Fuses
    448
  - Fuse Replacement Precautions
    448
    
    Replacing Board and Panel-Mounted Fuses
    449
  - Exercises:
    449
    
    Replacing Box Mounted Fuses
    450
Lesson
451
- Removing and Replacing Conveyor Belts
  451
  - Removing a Conveyor Belt
    451
  - Installing a Conveyor Belt
    454
Lesson
455
- Removing and Replacing Pneumatic Solenoid Valves
  455
  - Removing a Pneumatic Solenoid Valve
    456
  - Exercises:
    456
Lesson
461
- Removing and Replacing the Scale
  461
  - Removing the Scale
    461
  - Installing the Scale
    469
Lesson
471
- Removing and Replacing the Dispensing Head
  471
  - Removing the Dispensing Head Assembly
    472
  - Exercises:
    472
    
    Installing the Dispensing Head Assembly
    476
Lesson
479
- Removing and Installing the Computer and Computer Cards
  479
  - Removing and Installing the Computer
    480
  - Exercises:
    480
    
    Removing the PMAC Card
    482
    
    Installing the PMAC Card
    484
    
    Removing and Replacing the Image Capture or Video Card
    486
Lesson
487
- Removing and Replacing the Main Interface PWA
  487
  - Removing/Installing the Main Interface PWA
    488
  - Exercises:
    488
    
    Removing the XY Servo Interface PWA
    491
    
    Installing the XY Servo Interface PWA
    491
  - Exercises:
    492
Lesson
497
- Removing a Servo Amplifier
  497
- Installing a Servo Amplifier
  499

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