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Spectrum Series

S-900 Dispensing
Systems
Quick Operations
Manual

P/N 7217657 Rev B

NOTICE
This is an Asymtek publication, which is protected by copyright. Original copyright date 2007. No part
of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of Asymtek. The information contained in this publication is subject to change without
notice.
Manuals on the Internet
For the convenience of Asymtek customers and field service representatives, copies of Asymtek manuals
can be downloaded from:
http://www.asymtek.com/support/manuals.htm
Contact Us
Asymtek welcomes requests for information, comments, and inquiries about its products. Please contact
us using the information below:

Headquarters

2762 Loker Avenue West


Carlsbad, CA 92010-6603
USA
Toll Free:
Tel:

1-800-ASYMTEK (1-800-279-6835)
+1-760-431-1919

Fax:

+1-760-431-2678

E-mail:

info@asymtek.com

Website:

www.asymtek.com

USA:

1-800-ASYMTEK (1-800-279-6835)

Other regions:

www.asymtek.com/support.htm

Technical Support

Trademarks
Asymtek, DispenseJet, Fluidmove, and Heli-flow are registered trademarks of Asymtek.
Spectrum, Calibrated Process Jetting (CpJ), Rapid Response Heater, and Controlled Process Heat (CpH)
are trademarks of Asymtek.

Microsoft , Windows , and Windows XP are registered trademarks of Microsoft Corporation.

P/N 7217657, Revision B

2008

Table of Contents
1

Introduction ......................................................................................................................................... 5
1.1

Overview ..................................................................................................................................... 5

1.2

System Description ..................................................................................................................... 5

1.3

Safety First.................................................................................................................................. 5

1.4

Manuals ...................................................................................................................................... 6

1.5

Training ....................................................................................................................................... 6
1.5.1

Student Certification ...................................................................................................... 6

1.5.2

Student Registration ...................................................................................................... 6

1.6

Supported Dispensing Fluids...................................................................................................... 6

1.7

S-900N Series Standard Configurations..................................................................................... 7

1.8

Standard Equipment ................................................................................................................... 8


1.8.1

Automatic Pattern Recognition (Vision) System............................................................ 8

1.8.2

Calibrated Process Jetting (CpJ) ............................................................................... 8

1.8.3

Computer System .......................................................................................................... 8

1.8.4

Conveyor........................................................................................................................ 8

1.8.5

Fluidmove for Windows XP Software ............................................................................ 9

1.8.6

Integral Height Sensor ................................................................................................... 9

1.8.7

Light Beacon .................................................................................................................. 9

1.8.8

Low Air Pressure Alarm ................................................................................................. 9

1.8.9

Mass Flow Calibration ................................................................................................... 9

1.8.10 Precision Pneumatics .................................................................................................... 9


1.8.11 Programmable Fluid and Valve Pressure (S-92XN)...................................................... 9
1.8.12 Emergency Machine Off (EMO)..................................................................................... 9
1.8.13 Interlock ......................................................................................................................... 9
1.8.14 Service Station............................................................................................................. 10
1.8.15 System Light ................................................................................................................ 10
1.8.16 Ventilation Exhaust System ......................................................................................... 10
1.9

Introduction

Optional Equipment .................................................................................................................. 10


1.9.1

CAD Import .................................................................................................................. 10

1.9.2

Laser Height Sensor .................................................................................................... 10

1.9.3

Low Fluid Sensor ......................................................................................................... 10

1.9.4

Needle Heater.............................................................................................................. 10

1.9.5

Pre-Queue/Post-Queue Stations ................................................................................. 10

1.9.6

SECS/GEM Interface ................................................................................................... 11

1.9.7

Substrate Heaters ........................................................................................................ 11

1.10 Dispensing Valves .................................................................................................................... 11


1.11 System Features....................................................................................................................... 12
1.11.1 Dispensing Area........................................................................................................... 14
1.11.2 Service Station............................................................................................................. 16
1.11.3 Front Panel .................................................................................................................. 17
1.11.4 Front Cabinet ............................................................................................................... 18
1.11.5 Rear View .................................................................................................................... 20
1.11.6 Rear View Open........................................................................................................... 22
1.11.7 Rear Cabinet................................................................................................................ 24
1.11.8 Rear Panel Connections.............................................................................................. 25
2

Safety.................................................................................................................................................. 27
2.1

Overview ................................................................................................................................... 27

2.2

Facility Requirements ............................................................................................................... 27

2.3

Intended Use............................................................................................................................. 27

2.4

Basic Safety Precautions and Practices ................................................................................... 28

2.5

2.4.1

Safety of Personnel...................................................................................................... 28

2.4.2

Material Safety ............................................................................................................. 29

2.4.3

Preventing Dispensing System and Workpiece Damage ............................................ 30

Lifting and Transport Precautions............................................................................................. 30


2.5.1

Considerations ............................................................................................................. 30

2.5.2

Precautions .................................................................................................................. 31

2.6

Earthquake Precautions ........................................................................................................... 31

2.7

Safety Warning Labels.............................................................................................................. 32

2.8

Laser Radiation......................................................................................................................... 37
2.8.1

2.9

Laser Height Sensor Specifications............................................................................. 37

Emergency Shutdown............................................................................................................... 38
2.9.1

Emergency Shutdown Situations................................................................................. 39

2.9.2

Emergency Shutdown Recovery ................................................................................. 39

2.10 Interlock .................................................................................................................................... 39


2.10.1 Interlock Recovery ....................................................................................................... 39
2.11 Service Shutdown ..................................................................................................................... 40
2.11.1 Lockout/Tagout of Electrical and Pneumatic Energy................................................... 40
2.12 Light Beacon ............................................................................................................................. 42

Introduction

Calibration and Adjustment ............................................................................................................. 43


3.1

Overview ................................................................................................................................... 43

3.2

Safety First................................................................................................................................ 43

3.3

Record Keeping ........................................................................................................................ 43

3.4

Startup/Shutdown ..................................................................................................................... 43

3.5

Focusing the Camera................................................................................................................ 44

3.6

Calibrating the Camera ............................................................................................................. 45

3.7

Service Station Height Adjustment ........................................................................................... 47

3.8

Calibrating the Scale................................................................................................................. 48

3.9

Z-Head Counterbalance Force Adjustment .............................................................................. 51

3.10 Adjusting the Height Sensor Probe........................................................................................... 52


3.11 Adjusting the Board Sensors .................................................................................................... 53
3.11.1 Program Output for Look Down Configuration (ASPA,196581 Fiber Array) ............... 54
3.12 Initializing the Digital Gauges ................................................................................................... 55
3.13 Adjusting the Lift Table Speed.................................................................................................. 56
3.14 Adjusting Manual Airflow for Impingement Heaters (S-92X) .................................................... 58
3.15 Controlled Process Heat........................................................................................................... 60
3.15.1 CpH Configuration ....................................................................................................... 60
3.15.2 CpH Cool Down ........................................................................................................... 62
3.16 Software Controlled Light Beacon ............................................................................................ 63
4

Operation ........................................................................................................................................... 65
4.1

Overview ................................................................................................................................... 65

4.2

Safety First................................................................................................................................ 65

4.3

System Startup ......................................................................................................................... 66

4.4

4.3.1

Powering on the Dispensing System ........................................................................... 66

4.3.2

Starting Fluidmove for Windows (FmXP) .................................................................... 66

Installing the Dispensing Valve................................................................................................. 68


4.4.1

4.5

4.6

4.7

Introduction

Valve Pneumatic and Electrical Connections .............................................................. 68

Adjusting the Air Pressure ........................................................................................................ 70


4.5.1

Adjusting the Main Air Pressure .................................................................................. 70

4.5.2

Adjusting the Cooling/Coaxial, Valve, and Fluid Air Pressure..................................... 71

4.5.3

Adjusting the Vacuum Control ..................................................................................... 74

4.5.4

Setting the Low Pressure Detection Threshold ........................................................... 74

Positioning the Conveyor and Dispensing Head ...................................................................... 75


4.6.1

Using the Touchpad..................................................................................................... 75

4.6.2

Using the Keyboard ..................................................................................................... 81

Camera Operation .................................................................................................................... 82

4.8

4.9

4.7.1

Camera States ............................................................................................................. 82

4.7.2

Lighting and Color Adjustment..................................................................................... 83

Establishing Machine Offsets ................................................................................................... 85


4.8.1

Valve Offsets................................................................................................................ 85

4.8.2

Safe Z-Height............................................................................................................... 86

Creating a New Program .......................................................................................................... 88


4.9.1

Loading a Part.............................................................................................................. 88

4.9.2

Setting the Heaters ...................................................................................................... 88

4.9.3

Setting up the Fluid Manager....................................................................................... 92

4.9.4

Workpiece Alignment................................................................................................... 93

4.9.5

Opening a New Program Window ............................................................................... 94

4.9.6

Teaching Fiducials ....................................................................................................... 95

4.9.7

Machine Setup ............................................................................................................. 95

4.9.8

Attaching a Custom Fluid File...................................................................................... 96

4.9.9

Entering Program Commands ..................................................................................... 96

4.9.10 Saving the Program ................................................................................................... 102


4.9.11 Running the Program in Dry Mode ............................................................................ 103
4.10 Installing the Dispensing Fluid ................................................................................................ 103
4.11 Starting a Production Run....................................................................................................... 104
4.12 System Shutdown ................................................................................................................... 106
4.12.1 Post Production Shutdown ........................................................................................ 106
5

Maintenance..................................................................................................................................... 107
5.1

Overview ................................................................................................................................. 107

5.2

Safety First.............................................................................................................................. 107

5.3

Record Keeping ...................................................................................................................... 107

5.4

Routine Maintenance Procedures .......................................................................................... 108

5.5

Replacing Consumables......................................................................................................... 109


5.5.1

Replacing Purge and Weigh Station Cups ................................................................ 110

5.5.2

Replacing the Purge Boot.......................................................................................... 112

5.6

Draining the Water Trap.......................................................................................................... 113

5.7

Removing the Axis Covers ..................................................................................................... 114

5.8

Lubricating the Cables and Linear Guides ............................................................................. 115

5.9

5.8.1

Lubricating the Cables ............................................................................................... 115

5.8.2

Lubricating the X-Y Linear Guides............................................................................. 117

Tensioning the Cables ............................................................................................................ 119

5.10 Tensioning the Conveyor Belts............................................................................................... 120

Introduction

Introduction

1.1

Overview

The Spectrum 900N Series Systems are designed for inline production of semiconductor packaging
processes, such as underfill, cavity fill, die attach, and encapsulation. This manual is intended primarily as
a reference for production operators. However, process engineers and service technicians unfamiliar with
Asymtek products may also find this manual useful as a general introduction to the system. This section
introduces the Spectrum 900N Series (S-900N) Dispensing System and describes system configuration,
lists the standard and optional features, illustrates component location, and explains the function of the
components on the S-900N Dispensing Systems. This section covers the following topics:

1.2

System Description

Standard

Manuals

Optional Equipment

Training

Dispensing Valves

Supported Dispensing Fluids

System Features

S-900N Series Standard Configurations

System Description

The S-900N provides exceptional dispensing accuracy and repeatability, and is ideal for high-volume
manufacturing. The S-900N performs with a wide range of fluids, processes, and substrates used in
semiconductor packaging and assembly. The S-900N easily integrates with jets and valves from
Asymtek, including the DispenseJet DJ-9000.
The system utilizes Asymteks Fluidmove software, the same industry-proven software package used on
all Asymtek dispensing systems. Fluidmove and the S-900Ns flexible architecture makes it easy for
customers to upgrade as needed, and provides the portability to develop programs offline that can be
transferred to other sites or moved to inline systems.
Recommended applications include:

1.3

Underfill
BGA Solder Ball Reinforcement
Chip Scale Packaging
Cavity Fill
Die Attach

Lid Seal
Chip Encapsulation
No Flow Underfill
Conductive Adhesive
Life Sciences

Safety First

Operation of your S-900N Dispensing System involves heat, air pressure, electrical power, mechanical
devices, and the use of hazardous materials. It is essential that every person servicing or operating the
dispensing system fully understands all hazards, risks, and safety precautions. Refer to Section 2 - Safety
for additional information.

WARNING!

CAUTION!
Consult the Material Safety Data Sheet (MSDS) for all fluids used with the
dispensing system. The MSDS provides material usage instructions, disposal
instructions, and safety precautions.

Introduction

1.4

Manuals

Your Spectrum Series S-900N Dispensing System arrives with manuals for installation and operation of
major system components and software. For some system components, you may receive Original
Equipment Manufacturer (OEM) manuals. Generally, these OEM manuals are only needed for reference
and advanced troubleshooting. Consult only Asymtek manuals unless directed to do otherwise by the
manuals themselves or by Asymtek Technical Support
Below is a sample list of additional manuals that may be shipped with your Spectrum Series S-900N
Dispensing System, depending on system configuration.

1.5

Fluidmove User Guide

Dispensing Valve Owners Manual (specific to your valve)

Original Equipment Manufacturer Manuals (as applicable)

Training

Asymtek offers quality training for our dispensing platforms, valves, software, and applications both on
and off-site. The labs at our Carlsbad, California, USA corporate location are dedicated to providing a
specialized course of instruction for our customer's specific needs. With the assortment of tools available
in our labs we are able to provide a better learning experience overall. Students will rebuild machine
subassemblies, troubleshoot real problems, and learn a variety of setup techniques. In addition, your
machine's operability and production are not disturbed due to class usage.

1.5.1

Student Certification

Upon successful completion of the training course, the student is issued a Certificate of Completion.

1.5.2

Student Registration

Students can register for training at the Asymtek website www. asymtek.com/support/training or call
1-800-ASYMTEK to request information or to register for training.

1.6

Supported Dispensing Fluids

The S-900N was designed for dispensing the following materials. Contact Asymtek for materials not
listed.

"

Flip Chip & CSP Underfill materials

Dam and Fill Encapsulation materials

LED Encapsulation materials (silicon based)

Lid Seal materials

Reagent dispense materials

Silicones

NOTE

It is the responsibility of the end-user to consult the Material Safety Data Sheet (MSDS)
for all fluids used with the dispensing system. The MSDS provides material usage
instructions, disposal instructions, and safety precautions.

Introduction

1.7

S-900N Series Standard Configurations


System Features

S-91XN

S-92XN

Edge-Bond, Corner-Bonding,
SMA, Solder Paste, UV
Bonding, CMOS Imaging

Underfill, Encapsulation, Wire


Coating, Dam & Fill

In-line

In-line

Yes (S-912N)

Yes (S-922N)

1 or 2 (optional 3-6)

1 or 2 (optional 3-6)

ESD O-ring, ESD High Temp


6-mm & 4-mm Flat Belts

ESD O-ring, ESD High Temp


6-mm & 4-mm Flat Belts

Auto PR/Digital Camera

Auto PR/Digital Camera

Red/Blue

Red Blue

Mechanical
(Laser Option)

Mechanical
(Laser Option)

Tactile Z sensor

Yes

Yes

Needle Finder

No

No

Option

Yes

Yes

Yes

Heaters

No

One- to three-station heat


control, vacuum or
impingement
(up to 6 with S-922N)

Proc Dev Hot Plate

No

No

Controlled Process Heat (CpH)

No

Option

Option

Option

Yes

Yes

Option

Yes

Yes

Yes

Class 1000

Class 1000

Power Manager (10A)


Power Manager (30A)
Power Manager (Japanese)

Standard
Option
Option

Option
Standard
Option

Hatch (ESD Plastic)


Hatch (Glass)

Standard
Option

Standard
Option

Applications
Part Conveyance
Stand alone\ In-Line Conveyor
Dual Lane Option
Number of Stations
Conveyor Belt
Vision & Illumination
Vision
Part Illumination
Dispense Tip Position & Maintain
Height Sensor

Mass Flow Calibration


Purge Cup
Heater Options and Control

Miscellaneous
Low Fluid Alarm
Low Pressure Sensor
Programmable Fluid and Valve
Pressure
Beacon
Clean Room Version / Option

Introduction

1.8

Standard Equipment

1.8.1

Automatic Pattern Recognition (Vision) System

The Vision System consists of a Dalsa-Coreco Genie M640 digital 640 x 480 pixel camera, light source,
and laptop computer. The software consists of Fluidmove for Windows and its pattern recognition engine.
The vision system serves three purposes:

It allows the operator to teach dispensing locations on the substrate. The operator views a
live image of the cameras target and uses the graphical user interface to create the
dispensing sequence.

It automatically aligns the user generated dispensing sequence to the actual position of the
substrate during run operations. This is made possible by the advanced pattern recognition
system that compares expected and actual fiducial locations on the substrate. Corner finder
and bitmap model finders are supported as well as a pattern skip feature.

It is employed during the prompted setup routine to establish the vision-to-needle offsets and
service station locations.

The Dalsa-Coreco Genie M640 replaces the earlier analog cameras used with the ITI PCVision frame
grabber. It communicates bi-directionally to a host computer via Gigabit Ethernet. No frame grabber is
required. The camera is currently configured to run at 60 full frames per second which is twice as fast as
the analog PCVision cameras. A frame can be transferred in 16.67 milliseconds.
Diffuse on-axis lighting (DOAL) provides for consistent substrate illumination with color temperature and
intensity controlled through the software interface. Substrate images taught during programming (along
with the lighting levels) are stored with the program, and are automatically retrieved when loading the
program.

1.8.2

Calibrated Process Jetting (CpJ)

With this feature, volumetric repeatability can be maintained during long production runs to improve
process capability (Cpk) when dispensing fluids with one of Asymtek's DispenseJets. Dispense patterns
are programmed with a specified weight. CpJ periodically samples the dispense weight per shot, and then
computes the number of shots for each pattern. With this information, CpJ optimizes line speed based on
maximum specified shot interval.

1.8.3

Computer System

The Computer System consists of a laptop computer with an adjustable height bracket. It runs Fluidmove
for Windows XP (FmXP) software.

1.8.4

Conveyor

The Conveyor allows parts to be conveyed from upstream systems to the dispensing station, and then to
downstream systems. All conveyors are SMEMA compatible and have adjustable rear rail width. The
conveyor system uses multi-move technology which allows parts to move concurrently. This aids
throughput by minimizing conveyor time. The system is available with either a single lane or dual lane
conveyor configuration.
The Dual Lane Conveyor allows parallel processing on two lanes for continuous dispensing, eliminating
lost time in non-dispensing activities. In some applications, a 60 to 80 percent increase in throughput can
be achieved with a dual lane versus a single lane conveyor. The conveyors are independently controlled,
allowing different-sized parts to be processed in each lane for ultimate process flexibility.

Introduction

1.8.5

Fluidmove for Windows XP Software

Fluidmove for Windows XP (FmXP) is Asymtek proprietary software for use in a Windows XP
environment, developed specifically for dispensing applications.

1.8.6

Integral Height Sensor

The Integral Height Sensor allows increased positional accuracy in fluid dispensing by automatically
controlling the gap of the dispense tip to the surface of the workpiece.

1.8.7

Light Beacon

The Light Beacon is an indicator device for the operator. The beacon signals a dispensing status
condition by displaying a colored light and/or issuing an audible alarm. See 2.12 Light Beacon.

1.8.8

Low Air Pressure Alarm

The Low Air Pressure Alarm sounds when the system air pressure is too low. The low air pressure
threshold value can be set through the Fluidmove software. Refer to the Fluidmove User Guide or Online
Help for additional information.

1.8.9

Mass Flow Calibration

Mass Flow Calibration (MFC) is a patented feature that enables the user to specify the mass to be
dispensed as a separate parameter within the dispensing elements. This is made possible by using a
high precision scale to take flow rate measurements. The Fluidmove software features a fluid manager
where the user specifies how the flow rate is to be taken. This helps to ensure a statistically meaningful
flow rate value is obtained. MFC has two major benefits. First, it ensures the right amount of material is
dispensed for each part from the beginning to the end. Second, it reduces setup times on a daily basis by
automatically compensating for changes in viscosity or fluid delivery flow rate.

1.8.10 Precision Pneumatics


The S-900N features digital valve, fluid, and coax/cooling pressure gauges for high accuracy and easy
setup. They regulate the air pressure required for the fluid reservoir. See 3.12 Initializing the Digital
Gauges for additional information.

1.8.11 Programmable Fluid and Valve Pressure (S-92XN)


Electro pneumatic regulators control the valve pressure, fluid pressure and cooling/coaxial pressure.
These regulators have been integrated into the platform such that all the pressure setpoint values are set
through Fluidmove (as opposed to manual regulators). This reduces possibility of operator error when
setting the regulators manually. It also allows the user to import a recipe that includes all the pressure set
points. Programmable Fluid and Valve Pressure is standard on the S-92XN and optional on the S-91XN.

1.8.12 Emergency Machine Off (EMO)


The S-900N Series Dispensing System features an EMO button that the operator or service technician
can use to immediately stop all dispensing operations in case of emergency. This feature helps prevent
injury to personnel and damage to the dispensing system and workpieces.

1.8.13 Interlock
The Interlock is a built-in safety feature that automatically removes dispensing system servo motor power,
stopping all dispensing activity, when the hood is opened. This prevents personnel from being injured by
movement of the Dispensing Head and Conveyor.

Introduction

1.8.14 Service Station


The Service Station consists of a needle vacuum purge cup, on-board high precision scale, and a needle
calibration substrate. The Vision Assisted Prompted Setup routine enables the user to teach the service
station locations for fast and easy system setup. Refer to the Fluidmove User Guide or Online Help for
information on Vision Assisted Prompted Setup.

1.8.15 System Light


The dispensing system features a light that illuminates the dispensing area when the system is on.

1.8.16 Ventilation Exhaust System


The Ventilation Exhaust System works in conjunction with the facility exhaust system to remove excess
heat, fumes, or odors into an exhaust vent, not into the room. The system can be configured as either
down or updraft and can remove fumes lighter and/or heavier than air. It baffles direct vapor and mist to
a spill pan and is exhausted through a plenum.

1.9

Optional Equipment

1.9.1

CAD Import

CAD Import is an optional software utility used for surface mount adhesive or solder paste applications. It
enables the user to import ASCII CAD data for automated program generation. CAD Import comes
complete with a JEDEC component library.

1.9.2

Laser Height Sensor

The non-contact Laser Height Sensor provides high-speed dispense height measurement for delicate
substrates, hybrids, and integrated circuits that may be compromised by tactile sensing. Refer to 2.8
Laser Radiation for important safety information regarding the Laser Height Sensor.

1.9.3

Low Fluid Sensor

Low fluid sensing can be accomplished by installing capacitive or magnetic sensors on the fluid
reservoirs. In addition, low fluid sensing can be accomplished through the software, which features fluid
usage tracking. By inputting the fluid mass contained in the reservoir, the software can keep track of
material usage during dispensing. Both low and critically low values can be monitored. When a low fluid
condition is detected, the Light Beacon changes from green to blue. Additionally, the Fluidmove software
displays yellow (caution), and then red (critical) user warnings for low fluid conditions in the Run Window.

1.9.4

Needle Heater

The Needle Heater is an RTD-controlled heating element that provides needle heat on the DV-7000 and
DV-8000 Dispensing Valves and nozzle heat for the DJ-9000 Dispense Jet. The Needle Heater heats the
dispensing fluid to maintain a consistent viscosity and flowrate. The Fluidmove software controls the
heater temperature.

1.9.5

Pre-Queue/Post-Queue Stations

Pre-and post-queue stations without heat can be added for higher throughput or as buffer stations. In
addition, heat can be added to the S-92XN Series pre-and post-queue stations. The S-92XN Series can
be configured with pre-dispense, dispense and post-dispense heat.
The S-900N Series can be configured with single or dual-lane conveyors. A dual-lane configuration
(S-922N) can accommodate up to six (6) heaters. This configuration is ideal for applications with long
preheat cycles or long flow-out times.

10

Introduction

1.9.6

SECS/GEM Interface

SECS/GEM is the protocol used for linking several factory equipment units together via a host computer.
The GEM standard defines useful conventions for designing the communications interface on a unit of
factory equipment to improve operations with a host computer

1.9.7

Substrate Heaters

Dedicated, heated tooling is often required to enable proper fluid flow once dispensed on the substrate.
The S-92XN Series provides for either contact or non-contact impingement heating. Heated tooling is
custom designed depending on the substrate and carrier type. The S-92XN Series can be configured with
pre-dispense, dispense and post-dispense heat. Temperature values are stored in the program recipe,
and are automatically retrieved when loading the program. For additional information, refer to the
Fluidmove User Guide or Online Help.
1.9.7.1 Rapid Response Heater System
Asymteks new Rapid Response Heaters with low-mass design rapidly ramp to temperature for uniform
material flow and quick cool-down for fast tool change out. An advanced hole pattern provides highly
uniform impingement heat across the entire part surface.
1.9.7.2 Controlled Process Heat (CpH)
Asymteks optional Controlled Process Heat (CpH) software increases functional control that eliminates
operator interaction altogether: software-managed heat levels (e.g., warm up, process ramp, cool down,
etc.) with programmable shut-off timers and step-down or no-heat capability when a part is not present.
CpH control improves both yield and thermal footprint efficiency by requiring less power.

1.10 Dispensing Valves


The Spectrum Series S-900N Dispensing Systems support the following Asymtek jets and valves:

DJ-9000 Series DispenseJet


DJ-2200 Series DispenseJet
DV-7000/DV-8000 Heli-Flow Pumps
DV-01 Syringe Dispensing Valve
DV-02 Pinch Tube Valve
DV-03 High-Pressure Valve with Suckback
DV-05 Diaphragm Valve with Suckback
DV-07 Adjustable Liquid Valve
DV-09 Needle Valve

Refer to the appropriate dispensing valve manual for additional information.

Introduction

11

1.11 System Features


The figures in this section show views and features of the dispensing system. Callouts locate major
components, options, and switches seen in each illustration. Detailed operating instructions for some of
these features are treated in other sections of this manual. System features are shown in Figure 1-1 to
Figure 1-9.
1
5

Figure 1-1A S-920N

12

Introduction

6
7

Figure 1-1B S-920N with Optional Pre- and Post-Queue Stations


Item

Name

Description

Light Beacon

The Light Beacon is a device that displays system status and can warn
the operator when fault conditions exist.

Dispensing Area

The Dispensing Area is where all dispensing operations take place.


See 1.11.1 Dispensing Area.

Front Panel

Digital Valve, Fluid and Coax/Cooling Pressure Gauges, ON and OFF


Buttons, Emergency Stop, and Grounding Strap Jacks are located on
the Front Panel. See 1.11.3 Front Panel.

Computer

The Dispensing System features a laptop computer which runs the


Fluidmove for Windows XP (FmXP) dispensing software.

Exhaust Vent

The Ventilation Exhaust System works in conjunction with the facility


exhaust system to remove excess heat, fumes, or odors.

Pre-Queue Station

The optional pre-queue station can be added for higher throughput or


as a buffer station. In addition, the S-92XN Series can be configured
with pre-dispense heat.

Post-Queue Station

The optional post-queue station can be added for higher throughput or


as a buffer station. In addition, the S-92XN Series can be configured
with post-dispense heat.
Figure 1-1 S-920N Front View

Introduction

13

1.11.1 Dispensing Area

Figure 1-2A S-920N Front View (Open Dispensing Area)

14

Introduction

3
Figure 1-2B Dispensing Area Close-Up (Dual Conveyors shown)

Item

Name

Description

Dispensing Valve

The Dispensing Valve (DJ-9000 shown) controls or regulates the


flow of material from a pressurized reservoir, such as a syringe.
Devices include valves and jets.

Conveyor

The Conveyor transports the workpiece from an upstream system to


the dispensing station and then to downstream systems. All
Conveyors are SMEMA compatible and have adjustable rear rail
width. The Dual Lane Conveyor allows parallel processing on two
lanes for continuous dispensing.

Service Station

The Service Station consists of the Dispense Tile, Tactile Needle


Sensor, Purge Station, and Scale. See Figure 1-3.

Vision System

The compact, high resolution, black and white camera and lens are
part of the Vision System. They are mounted on the Dispensing
Head and are used to view work surfaces.

Height Sensor
(NOT SHOWN)

The Height Sensor is a device that measures substrate height and


sends a signal to the system computer. The height information is
used to position the dispensing needle at an exact distance above
the workpiece surface.

Figure 1-2 Dispensing Area

Introduction

15

1.11.2 Service Station

3
4

Item

Name

Description

Dispense Tile

The Dispense Tile is a ceramic tile dispensed upon during system


offset routines.

Tactile Needle Sensor

The Tactile Needle Sensor measures needle/nozzle position in the


Z-axis.

Purge Station

The Purge Station consists of a small reservoir that contains a


disposable plastic cup and is attached to a vacuum generator. Air
flowing through the purge boot into the cup removes excess fluid on
the dispensing valve needle/nozzle.

Scale

The scale measures the weight of dispensed fluid and sends the
information to the Fluidmove software for mass flow calibration. The
scale is standard on S-92X systems and an option on S-91X
systems.

Figure 1-3 Service Station

16

Introduction

1.11.3 Front Panel


2

Item

Name

Description

Grounding Strap Jack

Grounding straps worn by the operator plug into this jack to prevent
electrostatic discharge (ESD) damage to workpieces during
dispensing operations.

ON/OFF Buttons

The green ON (l) button illuminates and switches ON power to the


dispensing system mechanics. The black OFF (0) button shuts down
the dispensing activity and vents the air pressure. The laptop
computer power remains ON.

Front EMO (Emergency


Machine Off)

The Front EMO is a built-in safety feature located on the front panel
of the dispensing system. Activating the EMO vents all pressure in
the pneumatic system, de-energizes the servo power, and cuts
power to all system components except the computer and monitor.

Fluid Pressure Gauge

The Fluid Pressure Gauge displays the air pressure supplied to the
fluid syringe.

Valve Pressure Gauge

The Valve Pressure Gauge displays the air pressure supplied to the
dispensing valve.

Cooling/Coaxial Air
Pressure Gauge

The Cooling/Coaxial Gauge displays the air pressure supplied to


either the valve cooling air port or the DJ-2200 coaxial air assist,
depending on machine configuration.

Computer Connection

Connects the dispensing system to the laptop computer.

Figure 1-4 Front Panel

Introduction

17

1.11.4 Front Cabinet

3
4

5
Figure 1-5A Front Cabinet (S-912N Dual Conveyor System)

18

Introduction

"

Figure 1-5B Front Cabinet (S-922N Dual Conveyor System - Dispense Heat Only)

NOTE

Item

The S-92XN Series features programmable fluid and valve pressure. Air pressure is set
through the FmXP software. This feature is an option on the S-91XN Series Systems.

Name

Description

Vacuum Air
Regulator

Controls the vacuum level applied to fluid pressure air line when pressure
is turned off. The vacuum helps prevent residual pressure buildup in the
syringe that may cause fluid drip.

Cooling/Coaxial Air
Regulator

Controls the air pressure supplied to either the valve cooling air port or
the DJ-2200 coaxial air assist, depending on machine configuration.

Valve Pressure
Regulator

Controls the air pressure supplied to the dispensing valve.

Fluid Pressure
Regulator

Controls the air pressure supplied to the fluid syringe.

Conveyor/Heater
Modules

Controls all conveyor functions (motors, sensors, pneumatics, etc.). It


receives power from the Power Manager and supplies AC power to the
substrate heaters in the dispensing area. If your system is equipped with
dual conveyors, two Conveyor/Heater Modules are required.

Impingement
Flowmeters (S-92X)

Controls the airflow through the impingement heaters in the dispensing


chamber. A manual shut-off valve controls the air going to the flowmeters.
NOT USED ON THE S-91X.

Tooling Air
Regulator

Controls the air pressure supplied to the stop pins and lift tables. The
regulator receives air from the main air regulator located on the back of
the dispensing system.
Figure 1-5 Front Cabinet

Introduction

19

1.11.5 Rear View

1
2

Figure 1-6A Rear View (30A Power Manager shown)

20

Introduction

Conveyor/Heater
Pneumatics
Fluid/Valve
Pneumatics

6
Figure 1-6B
Main Air Regulator and Gauge Sets (Close-up)

Item

Name

Description

Main Air Regulator


and Gauge

The system is equipped with two Main Air Regulators and Gauges. They
control the air pressure supplied to all other system regulators. The
regulators contain built-in air filter and water traps to ensure that only
clean, dry air enters the system. Refer to 4.5 Adjusting the Air Pressure
for the recommended pressure settings and other important information.

Rear EMO

The Rear EMO is a built-in safety feature located on the rear panel of the
dispensing system. Activating the EMO vents all pressure in the
pneumatic system, de-energizes the servo power, and cuts power to all
system components except the computer.

Main Circuit Breaker

The Main Circuit Breaker is the main power switch for the dispensing
system. It protects the dispensing system from facility power surges and
controls the flow of facility AC power supplied to the Power Manager. A
flange to the right of the Main Circuit Breaker allows it to be locked in the
OFF position during servicing. Switching OFF the Main Circuit Breaker
cuts power to all dispensing system electrical components.

Main Power Cord

The Main Power Cord connects the dispensing system to the facility
power supply (30A power cord shown).

Rear Panel
Connections

See 1.11.8 Rear Panel Connections.

Water Trap

The facility air supply may contain moisture that can damage the
dispensing system. The Water Trap condenses this moisture before it
enters the dispenser pneumatic system.

Figure 1-6 Rear View

Introduction

21

1.11.6 Rear View Open

Figure 1-7A Rear View Open (S-910N)

22

Introduction

3
4

Figure 1-7B Rear View Open (S-920N with Pre-Queue and Post-Queue Stations)
Item

Name

Description

Upper E-Pan

The Upper E-Pan houses the Dispense Head Controller, Z-Axis Servo
Amp, and Applicator Pneumatics.

Lower E-Pan

The Lower E-Pan houses the Mainboard, X-Y Axis Servo Amps, Main Air
Pneumatic Valves, and Conveyor Pneumatic Valves.

Rear Cabinet

The Rear Cabinet houses the Power Manager and the Conveyor/Heater
Module(s). See 1.11.7 Rear Cabinet.

Rear Panel
Connections

See 1.11.8 Rear Panel Connections.


Figure 1-7 Rear View Open

Introduction

23

1.11.7 Rear Cabinet


1

Item
1

Name

Description

Power Manager
(30A shown)

The Power Manager is located inside the rear cabinet. It houses the
Main Circuit Breaker and the Main Power Inlet. It also contains the
EMO circuitry. The EMO button, the green ON (I) button, and the black
OFF (0) button are directly connected to the Power Manager.

Conveyor/Heater
Module

The Conveyor/Heater Module receives power from the Power Manager


and supplies AC power to the substrate heaters in the dispensing area.
It also controls all conveyor functions (motors, sensors, pneumatics,
etc.). If your system is equipped with dual conveyors, there will be two
Conveyor/Heater Modules.
Figure 1-8 Rear Cabinet (S-920N)

24

Introduction

1.11.8 Rear Panel Connections

1
2
3
4

Item

Name

Description
Allows for SMEMA communication between Conveyor 2 and a
downstream machine such as an unloader.
Allows for SMEMA communication between Conveyor 2 and an upstream
machine such as a loader.

CV2 Downstream

CV2 Upstream

Loader/Up

Allows the dispensing system to communicate with an upstream loader


for programming purposes only.

Loader/Down

Allows the dispensing system to communicate with a downstream


unloader for programming purposes only.

Network

Allows the dispensing system to communicate with a host computer on a


local area network. Necessary for SECS/GEM functionality.

CV1 Downstream

CV1 Upstream

"
Introduction

Allows for SMEMA communication between Conveyor 1 and a


downstream machine such as an unloader.
Allows for SMEMA communication between Conveyor 1 and an upstream
machine such as a loader.
Figure 1-9 Rear Panel Connections

NOTE

CV2 connectors are only present on S-912N and S-922N dual conveyor
dispensing systems.

25

Safety

2.1

Overview

This section is intended to provide basic safety information necessary for operating and servicing the
Spectrum S-900N Series Dispensing System. This section covers the following topics:

Intended Use

Laser Radiation

Basic Safety Precautions and Practices

Emergency Shutdown

Lifting and Transport Precautions

Interlock

Earthquake Precautions

Service Shutdown

Safety Warning Labels

Light Beacon

To further optimize safe dispensing system operation, precautions and recommended practices are
included with the procedures throughout this manual.

WARNING!

CAUTION!
Unsafe equipment conditions can result in personal injury or property damage.
Failure to properly operate and maintain the system in accordance with this
manual could cause the built-in safety features to be ineffective.

"
2.2

NOTE

Safety is considered a joint responsibility between the original equipment manufacturer


(Asymtek) and the end-user (owner). All safety precautions and practices should be in
accordance with local regulations and facility policy.

Facility Requirements

To ensure optimal performance and safety, it is necessary to install the dispensing system in a facility that
meets the necessary requirements. Refer to the S-900 Installation, Operations, and Maintenance Manual
for details. If you have any questions, please contact Asymtek Technical Support.

2.3

Intended Use

Use of Asymtek equipment in ways other than those described in the documentation supplied with the
equipment may result in injury to persons or damage to property. Some examples of unintended use of
equipment include:

Safety

Using incompatible materials

Making unauthorized modifications

Removing or bypassing safety guards or interlocks

Using incompatible or damaged parts

Using unapproved auxiliary equipment

Operating equipment in excess of maximum ratings

27

2.4

Basic Safety Precautions and Practices

Compliance with the following recommended precautions and practices reduces the risk of personal injury
or damage to property during S-900N Series Dispensing System operation and maintenance.

WARNING!

CAUTION!
Failure to comply with any of the safety recommendations could cause serious
injury to the user or damage to the dispensing system.

2.4.1

28

Safety of Personnel

Only trained personnel should be permitted to perform operation, maintenance, and


troubleshooting procedures

There should always be a second person present when performing maintenance on a system
under power.

Locate, identify, and obey all safety warning labels on your system before initial use. Refer to
2.7 Safety Warning Labels for details.

Immediately push the red Emergency Machine Off (EMO) button if personnel are in danger of
being injured.

Lock out and tag out power and disconnect facility air to the dispensing system before
performing service or maintenance on the dispensing system. Refer to 2.11 Service
Shutdown for details.

Lock out and tag out power to upstream and downstream machines before performing
service or maintenance on the dispensing system.

When using conveyorized machines as stand alone equipment (not inline), make sure the
machine is configured with the optional Conveyor Closeout Kit (P/N 7214478) to prevent
personal injury and equipment/workpiece damage.

Do not wear loose clothing or jewelry while operating the system. Tie back long hair to
prevent it from being caught in moving parts.

Do not touch the dispensing head or other moving parts while the dispensing system is
operating.

To prevent burn injury, wear thermal gloves when working around heater tooling and fluid
heaters.

If your system is equipped with a laser height sensor, use extreme care to avoid looking
directly at the laser beam or its reflection off of mirror-like surfaces. Refer to 2.8 Laser
Radiation for details.

Make sure the main power cable and main air supply hose are securely connected before
operating the dispensing system.

If in a confined room, ensure adequate and uninterrupted air ventilation, and heating and
cooling meet environmental stress limits of personnel and the dispensing system.

Safety

2.4.2

Safety

Where volatile organic compound (VOC) emissions can exceed safe limits, facility ventilation
and filtration systems must be operational.

Provide adequate space around the dispensing system to allow for movement of
maintenance and service personnel. Allow space for access doors and service panels to
open fully.

Make sure all facility power sources are safely grounded.

Routinely inspect all air hoses and electrical cables for damage.

Make sure power cords and air supply hoses do not cross a walkway or aisle.

Before attempting to lift a load, take into consideration facility lifting and transport
precautions. See 2.5 Lifting and Transport Precautions.

Maintain a clean and orderly work area.

Material Safety

Follow Material Safety Data Sheet (MSDS) recommendations for the proper handling,
cleanup, and disposal of all materials and fluids and their containers (i.e., syringes, cups,
reservoirs, etc.) used with the dispensing system.

Follow MSDS recommendations for the proper handling and disposal of all materials when
cleaning dispensing equipment and spills.

Make sure the dispensing system ventilation is ON during handling and cleanup of all
materials used with the dispensing system.

Know the MSDS recommendations for treatment of injury resulting from exposure to
hazardous materials.

Always wear appropriate personal protective equipment (PPE) as recommended by facility


safety practices and the material manufacturers MSDS.

When working with multiple fluids, refer to the MSDS to ensure the materials are compatible.

If possible, save or recycle unused materials. Refer to the MSDS before saving or recycling
unused materials.

29

2.4.3

Preventing Dispensing System and Workpiece Damage

Immediately push the EMO button if dispensing system or a workpiece is in danger of


being damaged.

Use standard Electrostatic Discharge (ESD) precautions when working near sensitive
components. Always wear a grounding strap and connect it to the ESD ground before
handling workpieces.

Immediately contain and clean up any caustic or conductive fluid spills as recommended in
the material manufacturers MSDS. If fluid gets into internal portions of the machine,
immediately contact Asymtek Technical Support.

Follow all recommended system maintenance procedures.

Always keep the dispensing area clear of any fallen workpieces or obstacles.

Ensure that no air intakes or exhaust grilles are blocked when the system is in operation.

2.5

Lifting and Transport Precautions

2.5.1

Considerations

Before attempting to lift a load, personnel should take into consideration the following factors:

30

Does the load display a lift hazard warning label as shown below?

Is lifting and transporting equipment available that might make the task safer and easier?

Do you need to use personal protective equipment such as back supports and work gloves?

Do you need an assistant to help you lift or guide the load?

Do you know the destination for the load and the route you have to follow?

Has the load been prepared for lifting (doors closed, facility cables/air lines disconnected,
loose items secured, earthquake-bolts removed)?

Safety

2.5.2

Precautions

When lifting, transporting, and lowering heavy or large loads, personnel should observe the following
precautions:

2.6

Stand close to the load to be lifted and place your feet at shoulder width.

Firmly grip the load and bring the load close to your body.

Lift your head and shoulders first and with your back straight, use the strength of your legs to
slowly and smoothly raise yourself up.

DO NOT twist your body. Change direction by first moving your feet.

When transporting the load on a cart or a lifting device, reduce back strain by pushing rather
than pulling the load.

When lowering the load, bend your knees, lower it slowly and smoothly, and keep your
fingers out from under the load.

Earthquake Precautions

In the event of an earthquake, your dispensing system must be secured to prevent movement that
could cause injury to personnel and damage to the dispensing system and facility. Each dispensing
system leveler (foot) should be anchored to the floor. Refer to the S-900 Installation, Operations, and
Maintenance Manual for details.
As a safety precaution, all hazardous electrical and pneumatic energy is automatically bled out of the
system if electrical power is lost.

WARNING!

Safety

All personnel should follow facility earthquake safety guidelines.

31

2.7

Safety Warning Labels

Safety warning labels on the S-900N Series Dispensing System point out potentially hazardous areas and
remind personnel to take necessary safety precautions. Table 2-1 describes safety warning labels that
may be on the dispensing system.

WARNING!

CAUTION!
Comply with all safety warning labels or serious injury to personnel or damage to
the dispensing system may occur. Worn or damaged labels should be replaced
with new labels having the same part number.

Table 2-1 Safety Warning Labels


Warning Type
Electrical
(Shock Hazard)

Symbol

Part
Number (1)
70-0116-00
or
70-0050-00

General
Warning

Heavy Object
(Lifting Hazard)

70-0055-00
70-0118-00
or
196666

Moving Parts
Present
Hand
Entanglement/
Moving Material

Hot Surface

Consult
Operators
Manual
Notes:

(2)

(2)

70-0120-00
or
198883 (2)
7214364

7206858

(1)

(1)

(2)

(2)

7206854

This label identifies a component that requires special


attention. Can cause serious bodily harm to the user.
Disconnect and lock out power before servicing.
This label warns that the labeled component is heavy
and can cause muscle strain or back injury to
personnel trying to lift it.

(1)

70-0121-00
or

This label warns of a high-voltage component that can


cause shock, burn, or death. Use extreme caution
when working in or around these areas.
Disconnect and lock out power before servicing.

(1)

(2)

70-2150-00
Laser

(1)

Hazard

This label warns of moving parts that can cause


serious injury to hands or fingers. Keep hands away
from moving parts.
Disconnect and lock out power before servicing.
This label warns of moving parts that can cause
serious injury to hands and fingers.
Disconnect and lock out power before servicing.
Thermal warning labels identify potentially hot
components and surfaces. Use extreme caution when
working on or around these areas.
Can cause severe burns.
Warns personnel of the possibility of hazardous
radiation exposure if your system is equipped with a
Laser Height Sensor or other laser device.
Warns personnel to read Operators Manual before
operating machine.

(1) Rectangular labels with symbols and text. These labels are placed on machines that are shipped anywhere but the
European community.
(2) Triangular labels with symbols only. These labels are placed on machines that are shipped to the European
community, referred to as CE labeled machines.

32

Safety

Item
1

Description
Read Manual Label
Figure 2-1 Safety Warning Labels (Front Cover)

Item
1

Description
Laser Radiation Warning Label (if Laser Height Sensor present)
Figure 2-2 Safety Warning Labels (Front Inside Panel)

Safety

33

Item

Description

Laser Radiation Warning Label (if Laser Height Sensor present)

Hot Surface Label (if heaters present)


Figure 2-3 Safety Warning Labels (Dispensing Area)

34

Safety

Item

Description

Hot Surface Label (if heaters present)

Moving Parts Present Label


Figure 2-4 Safety Warning Labels (Conveyor)

Item

Description

Hand Entanglement Label

Hot Surface Label


Figure 2-5 Safety Warning Labels (Rear))

Safety

35

Item
1

Description
Electrical Warning Label
Figure 2-6 Safety Warning Labels - Power Manager

36

Safety

2.8

Laser Radiation

WARNING! The Height Sensor contains a Class 2 laser. DO NOT look directly at the laser
beam. Looking directly at the laser beam may result in serious eye injury.
If your S-900N Series Dispensing System is equipped with the optional laser height sensor, the following
safety precautions should be observed in addition to the basic system safety precautions:

"
2.8.1

Operate the laser height sensor in accordance


with the operators manual included with the
equipment. Failure to do so may result in injury
due to exposure to the laser beam.

DO NOT disassemble the sensor head. Laser


emission from the height sensor is not
automatically stopped if the sensor head is
disassembled.

DO NOT look directly at the laser beam or its


reflection.

Wear protective goggles when using the laser


height sensor.

Check the laser beam path. DO NOT install the


height sensor in such a way that the laser beam
passes at eye level.

DO NOT open the hood while the laser is on.

NOTE

The laser beam is not harmful to the skin so


there is no danger in exposing arms or hands
to the beam. The only possible health hazard
is in exposing the eyes to the laser beam,
which could result in serious eye injury.

Figure 2-7 Laser Height Sensor

Laser Height Sensor Specifications

Table 2-2 contains Laser Height Sensor specifications.


Table 2-2 Laser Height Sensor Specifications
Classification
Light Source
Maximum Output
Emitted Wavelength
Spot Diameter
Reference Distance and Range
Environmental Range
Ambient Light

Safety

Class 2 Laser Product


Red semiconductor laser ( = 670 nm)
1.0 mW
670 nm
110 m at reference distance
70 mm 15 mm (2.75 in. 0.6 in.)
0 to 55 C
0 to 85% RH
4,000 lux max

37

2.9

Emergency Shutdown

In the event of an emergency or malfunction, press the EMO button. The S-900N Series has two EMO
buttons. The EMO buttons are the large red buttons located on the front panel and the rear of the
dispensing system (Figure 2-8). Activating the EMO vents all pressure in the pneumatic system and cuts
power to all components except the laptop computer, the camera, the interior light, and the light beacon.

TIP

If the operator or technician is unable to reach the EMO button, the main circuit
breaker (Figure 2-8), which is located on the back of the system, can be used for
emergency shutdown.

Front Panel

Item
1

Rear View

Description
Front EMO button

EMO Guard

Rear EMO button

Main Circuit Breaker


Figure 2-8 EMO/Main Circuit Breaker Locations

WARNING!

38

In an emergency, failure to completely shut down power to the dispensing


system with the EMO can cause serious injury to the user and/or damage to the
dispensing system.

Safety

2.9.1

Emergency Shutdown Situations

As a minimum, activate the EMO in the following situations:

2.9.2

If anyone is in immediate danger of being injured by moving parts, hazardous materials, or


electrical shock.

If valuable dispensing system components or the workpieces are in danger of


being damaged.

Emergency Shutdown Recovery

WARNING!

"

NOTE

Do not restart the dispensing operation until the condition that caused the
emergency shutdown has been corrected. Failure to comply could cause serious
injury to the user and/or serious damage to the dispensing system.

If the main circuit breaker has been tripped, you will need to restart the dispensing
system. Refer to 4.3 System Startup for instructions.

To recover after an Emergency Shutdown:


1.

Locate and remedy the cause of the emergency shutdown. If necessary, refer to the S-900
Installation, Operations, and Maintenance Manual..

2.

If applicable, close the dispensing area doors.

3.

Turn the EMO knob clockwise until it pops back into position.

4.

Press the ON (I) button on the front panel.

5.

Restart your dispensing program.

2.10 Interlock
The Interlock is an electronic connection that immediately cuts the power to any motion and pneumatic
actuators. If the dispensing area hood is opened during dispensing, the interlock is activated and all
dispensing activity immediately stops to protect the operator from injury.

2.10.1 Interlock Recovery


When the Interlock has been triggered, FmXP will display an Interlock Active message (Figure 2-9). To
recover from an interlock shutdown, close the dispensing area hood. When the FmXP Message 32691
appears (Figure 2-10), click OK to continue dispensing or Cancel to abort.

Figure 2-9 Interlock Active Message

Safety

Figure 2-10 Clear Interlock Message

39

2.11 Service Shutdown


Before performing any service or parts replacement, the dispensing system should be shut down
as follows:
1.

Shutdown the dispensing system as described in 4.12 System Shutdown.

2.

Perform a Lockout/Tagout of Electrical and Pneumatic Energy as described below.

2.11.1 Lockout/Tagout of Electrical and Pneumatic Energy


Companies may differ in their Lockout/Tagout (LOTO) procedures and requirements, and it is the
responsibility of the end user to determine compliance with local safety procedures. The purpose of any
LOTO effort is to help avoid injury or dispensing system damage due to unexpected energizing of
equipment, start up, or the release of stored energy during repair, maintenance, and operation of
equipment. Situations where LOTO practices may be employed on the S-900N Series include:

Adjusting cables, belts, pulleys, or moving parts

Servicing bearings or motors

Troubleshooting, servicing, or replacing electronic components or assemblies

Troubleshooting, servicing, or replacing pneumatic components or assemblies

Situations where LOTO practices might not be required are when troubleshooting electrical, pneumatic, or
hydraulic components or assemblies that make de-energizing the whole system impractical.
Troubleshooting or servicing the S-900N Series while powered up and operating should only be
accomplished by fully trained and qualified personnel. There should always be a second person present
when performing maintenance on a system under power.
To lockout/tagout the electrical and pneumatic energy:
1.

Turn the main circuit breaker on the rear of the system to the OFF (0) position.

2.

Unplug the main power cable from the back of the Power Manager.

3.

Rotate the main air pressure knob counterclockwise until the gauge reads 0 psi and then
disconnect the main air supply by the quick release fitting.

4.

Install an approved, keyed lock on the locking flange of the main circuit breaker so it cannot
be turned on; tag it with an approved tag.
!

5.

Install an approved lockout clamp and keyed lock onto the power connector so it cannot be
reconnected to the power manager, and attach an approved tag.
!

6.

40

Ensure that the owner, date, reason, and estimated time for repair are clearly marked on
the tag.

Ensure the owner, date, reason, and estimated time to repair are clearly marked on the
tag.

Install an approved lockout clamp and keyed lock onto the pneumatic fitting so it cannot be
reconnected to the main air regulator, and attach an approved tag. Ensure the owner, date,
reason, and estimated time to repair are clearly marked on the tag.

Safety

"

NOTE

Warning tags document the name of the technician taking the equipment out of operation,
the date, and other facility-required information. It is a warning that the equipment cannot be
put back into operation until the authorized technician has removed the tag.

WARNING!

If your dispensing system is equipped with a heater, allow sufficient time for the
heater to cool prior to performing maintenance or service. Failure to do so may
result in serious burn injury.

Figure 2-11 Electrical/Pneumatical Lockout/Tagout

Safety

41

2.12 Light Beacon


The Light Beacon is a device that displays system status and can warn the operator when fault conditions
exist. The beacon has red, yellow, green, and blue lights that can be solid or flashing. The beacon also
has an audible alarm. Table 2-3 provides possible reasons for each color indication.
Software and hardware share control of the beacon lights. Sometimes, hardware-driven displays override
those caused by software conditions and sometimes software-driven displays override. Safety critical
conditions always have priority. Flashing light software commands have priority over solid light
commands.

"

NOTE

Light beacon action can be custom configured using the beacon control feature. See
3.16 Software Controlled Light Beacon.
Refer to the S-900 Installation, Operations and Maintenance Manual for suggested
recovery from common fault conditions.
Table 2-3 Beacon Color Indications

Beacon Color

System Status
ALERT
All motion, outputs, dispensing valve, and motion controls are disabled until
the fault is cleared.
One of the following conditions may exist:
A. Solid Emergency stop condition or heater error.

RED

B. Flashing General error or vision error. Software driven error message is


displayed on the computer monitor.
C. Solid or Flashing - Software has been configured to display a solid or
flashing red light.
CAUTION
System in a low power state or lacks sufficient air pressure.
One of the following conditions may exist:
A. Solid Hood is open (Interlock activated).

YELLOW

B. Solid or Flashing - Software has been configured to display a solid or


flashing yellow light.
OPERATION
One of the following conditions may exist:
A. Solid The system is fully operational with the hood closed.
B. Solid or Flashing Software has been configured to display a solid or
flashing green light.

GREEN
USER DEFINED
A. Solid Software has been configured to display a solid blue light.
B. Flashing Software has been configured to display a flashing blue light.
BLUE

42

Safety

3
3.1

Calibration and Adjustment


Overview

After initial installation or if any hardware changes have been made, certain dispensing system
components may need to be calibrated or adjusted. This section covers the following topics:

Focusing the Camera

Adjusting the Board Sensors

Calibrating the Camera

Initializing the Digital Gauges

Service Station Height Adjustment

Adjusting the Lift Table Speed

Calibrating the Scale

Adjusting Manual Airflow for Impingement Heaters


(S-92X)

Z-Head Counterbalance Force Adjustment

Controlled Process Heat

Adjusting the Height Sensor Probe

Software Controlled Light Beacon

Refer to Section 4 - Operation for the following routine setup and adjustment procedures:

"

Installing the Dispensing Valve

Adjusting the Air Pressure

Setting the Heaters

NOTE

Refer to the Fluidmove User Guide for information on Fluidmove programming and
fluid setup.

CAUTION!

3.2

The procedures in this section should only be performed by a trained


service technician.

Safety First

Operation of your S-900N Series Dispensing System involves heat, air pressure, electrical power,
mechanical devices, and the use of hazardous materials. It is essential that every person servicing or
operating the dispensing system fully understands all hazards, risks, and safety precautions. Refer to
Section 2 - Safety for important safety information.

3.3

Record Keeping

The type of calibration or adjustment performed should be recorded in maintenance records for the
dispensing system along with names of technicians and other pertinent data.

3.4

Startup/Shutdown

Refer to Section 4 - Operation for details on system and Fluidmove startup/shutdown procedures.

Calibration and Adjustment

43

3.5

"

Focusing the Camera


NOTE

This procedure assumes that the dispensing system has been powered on and FmXP is
running, and that a representative substrate is available to teach the focal plane.

To focus the camera:


1.

In the FmXP Programming Window, click the Load a Board

The conveyor will transport the substrate to the dispense station and the lift mechanism
will lift it off the conveyor belt. This establishes the focal plane for dispensing as well as
for the Service Station.

2.

In the FmXP Main Window, click on Jog.


The Jog Window opens.

!
3.

icon.

Click on Video.
The Video Window opens.

!
4.

Position the camera over a fiducial or an easily recognized feature on the substrate.

5.

Hold the camera and use a 7 mm hex key to loosen the upper and lower screws on the
bracket (Figure 3-1).

6.

Use a 3 mm hex key to loosen the screw above the camera.

7.

Slowly move the camera bracket up and down.

8.

When a sharp image is obtained in the Video Window, lock the upper screw.

9.

Tighten the lower screw on the camera bracket.


3
1

Item

"
44

Description

Upper screw

Lower screw

Item
3

Description
Screw (not shown)

Figure 3-1 Focusing the Camera

NOTE

A machine offsets routine must be performed after focusing the camera. For more
information, refer to the FmXP User Guide or Online Help.

Calibration and Adjustment

3.6

Calibrating the Camera

"

NOTE

"

This procedure assumes that the dispensing system has been powered on, that FmXP is
running, that a substrate is available, and that the camera has been focused. The camera
is self-calibrating when using the calibrate button from the Setup Vision Window. The
software makes a pixel count comparison to machine units by moving away from the
taught image by a known value, finding the image again, and assigning a pixel-count-tomachine-unit value. With this value established, the vision system can accurately find the
substrate and dispense at the correct location (provided the vision target image is within
the field of view).

NOTE

If the camera is ever refocused to accommodate a different part height, the calibration
routine MUST be run again.

To calibrate the camera:


1.

In the FmXP Programming Window, click the Load a Board


!

2.

icon.

The conveyor will transport the substrate to the dispense station and the lift mechanism
will lift it off the conveyor belt.

In the FmXP Main Window, click on Configuration > Setup Vision.


!

The Setup Vision Window opens (Figure 3-2).

Figure 3-2 FmXP Setup Vision

Calibration and Adjustment

45

3.

Click on Calibrate.
!

The Calibration Window (Figure 3-3) opens.

Figure 3-3 FmXP Calibration Window


4.

Position the camera over a fiducial and adjust the light level to obtain a good image contrast.
See 4.7.2 Lighting and Color Adjustment.

5.

If the image is not in focus, focus the camera as described in 3.5 Focusing the Camera.

6.

Click on Next.

7.

Verify that the fiducial image is centered and click on Next.


!

"

8.

"

46

If the fiducial is acceptable, select Next. If not, select Prev and define a new fiducial.

NOTE
9.

10.

The Vision System will take a snap image of the fiducial.

The fiducial should fit inside the green square on the camera image.

After the camera calibration sequence is complete, verify that the X and Y values are
relatively close to each other. If there is a large difference, repeat the calibration process and
define a new fiducial.
If the results are satisfactory, select Done to save the calibration results.

NOTE

Machine Offsets must be performed after calibrating the camera. For more information,
refer to the FmXP User Guide or Online Help.

Calibration and Adjustment

3.7

Service Station Height Adjustment

After the camera position has been adjusted for the part set height, the service station height must be
adjusted to bring the ceramic square into focus. The service station can be adjusted upward 1-inch
(25 mm) from the factory set position by performing both rough and fine height adjustments. Each
adjustment will allow 1/2-inch (12.7 mm) of vertical adjustment.
To adjust the service station height:
1.

Loosen the three mounting screws holding the service station to the bracket (Figure 3-4).

2.

Move the camera over the ceramic tile and adjust the three leveling feet to bring the ceramic
tile into focus.

3.

Continue to adjust the leveling feet until all corners of the ceramic square are in focus.

4.

Tighten the three mounting screws.

5.

If the leveling feet do not provide enough vertical adjustment to bring the service station
into focus:
a. Remove the 3 side mounting screws.
b. Slide the service station forward to gain access to the bracket mounting screws.
c.

Loosen these screws, adjust the bracket upwards, and retighten the screws.

d. Repeat steps 1-4 above.


2

1
2

Item

Description

Ceramic Tile

Mounting Screws

Leveling Feet (not shown)


Figure 3-4 Adjusting the Service Station Height

Calibration and Adjustment

47

3.8

Calibrating the Scale

Tools and Materials Needed:

Calibration Weight Set (P/N 193758)

Latex gloves or tweezers

Screwdriver

Level

To calibrate the scale:


1.

Remove the scale cover.

2.

Verify that the scale is level by


checking the scale level bubble.
a. If the bubble is not centered, the
scale must be leveled.
b. If the bubble is centered, the
scale is level.

3.

If necessary, adjust the scale


leveling screws until the scale is level
(Figure 3-6).

Figure 3-5 Scale Cover Removal

Leveling Screws

Bubble

Figure 3-6 Leveling the Scale


4.

When finished, replace the scale cover.

5.

Start FmXP.

6.

Select Configuration > Setup Scale from the Main Window.


!

48

The Scale Setup Window (Figure 3-7) opens.

Calibration and Adjustment

Figure 3-7 Setup Scale - Scale Operations Tab


7.

Select SART-WZ from the Type pull-down menu.

8.

Click on the Advanced tab (Figure 3-8).

Figure 3-8 Setup Scale - Advanced Tab

Calibration and Adjustment

49

9.

Verify that the calibration weight is set to 50 and click on Calibrate.


!

FmXP will prompt you to place the weight on the scale.

10.

Using gloves or tweezers, place the 50 g calibration weight on the pedestal.

11.

Replace the scale cover and click OK.


!

FmXP will display the following message (Figure 3-9):

Figure 3-9 FmXP Calibrating Scale Message


12.

Upon completion, FmXP displays the following message:

Figure 3-10 FmXP Calibration Complete Message


13.

50

Remove the weight from the scale and click OK.

Calibration and Adjustment

3.9

Z-Head Counterbalance Force Adjustment

The Z-head Counterbalance Force prevents the Z-head (dispensing head) from crashing down upon
disengagement of the motor. There are three settings to accommodate various payloads.
To adjust the Z-head counterbalance (Figure 3-11):
1.

Loosen the Z-head counterbalance force adjustment screw (Figure 3-11).

2.

Slide the screw assembly to the desired position. See Table 3-1.
!

3.

In order to slide the screw up and down, you may need reach behind the Z-slide and pull
on the small bracket with your finger or an Allen wrench.

Tighten the Z-head counterbalance force adjustment screw.

To test counterbalance tension:


1.

Place valve on Z-head and move it to middle of dispense area.

2.

Open machine hood.


!

3.

The Z-head should not drop more the 25.4 mm (1-inch).

Readjust tension if necessary.

Item
1

Description
Adjustment Screw
Figure 3-11 Z-Head Counter Balance Force Adjustment
Table 3-1 Counterbalance Spring Settings

"

NOTE

Z-payload
(kg)

Counterbalance
Spring Setting

0 - 1.7

top

1.7 - 2.2

middle

Dual action
Dual action with laser height sensor

2.2 - 3

bottom

Any custom tooling exceeding 2.2-kg

Typical Applications
Standard (i.e. single valve)
Standard with laser height sensor

The settings in Table 3-1 are for reference purposes only. Certain applications may
require different settings.

Calibration and Adjustment

51

3.10 Adjusting the Height Sensor Probe


The Height Sensor Probe must be adjusted each time a different type of dispensing valve or a different
length of needle is installed.
To adjust the Height Sensor Probe:
1.

Power down the system as described in 4.12 System Shutdown.

2.

Manually move the dispensing head down.

3.

Loosen the Height Sensor Probe locking screw (Figure 3-12).

4.

Move the probe to the desired location (approximately 6 mm below the needle tip in the gear
down position).

5.

Tighten the height sensor locking screw. Do not over-tighten.

3
2

6 mm

Figure 3-12A Height Sensor Probe (Front View)


Item

"
52

Figure 3-12B Probe-to-Needle Alignment

Description

Height Sensor Probe Locking Screw

Height Sensor Probe

Needle
Figure 3-12 Adjusting the Height Sensor Probe

NOTE

For additional information on dispensing valve-to-height sensor offsets, see 4.8


Establishing Machine Offsets.

Calibration and Adjustment

3.11 Adjusting the Board Sensors


Board Sensors are optical sensors located along the length of the front conveyor rail. The sensors detect
the presence of the workpiece and report it to the Conveyor Controller. Board sensor sensitivity should be
adjusted after initial installation and if the sensors fail to sense the presence of a workpiece. Depending
on whether the system has a single-lane or dual-lane conveyers, there may be as many as six downwardfacing board sensors (pre-dispense, dispense, and post-dispense station for each conveyor). Sensitivity
adjustments for downward-facing board sensors are made on Fiber Optic Amplifiers mounted under the
dispensing area front cover.
To adjust downward-facing sensor sensitivity:
1.

Unlock the fiber lock (UP position). Insert ferrule ends until the fibers cords are fully seated.
Lock the fiber lock down into position (Figure 3-13).

"
2.

NOTE

Fiber ends are not designated as send or receive. Each ferrule can be used in
either amplifier position.

Verify that the digital value of the amplifier is less than 100 with the fiber array pointed away
from any objects (within 6-inches). This insures array cross-talk will not significantly degrade
the signal.

Figure 3-13 Board Sensor - Side View


3.

Move the SET-ADJ-RUN switch to the SET position (Figure 3-14). Press and hold the MODE
button for 2 sec or until the Sensing Function menu is displayed.
!

The Standard sensing function ( F St ) is default.


1
2

3
Item

Description

Item

4
Description

TEACH Button

SET-ADJ-RUN Switch

MODE Button

MODE Switch

Figure 3-14 Board Sensor - Top View

Calibration and Adjustment

53

4.

Press the TEACH button until the Long Distance sensing function (F Ld ) is displayed.
See Figure 3-14.

5.

Move the SET-ADJ-RUN switch to the RUN position to implement this setting.

3.11.1 Program Output for Look Down Configuration (ASPA,196581 Fiber Array)
1.

Ensure no part is under the sensor lens. The sensor leading edge should remain parallel to
the rail insert.
!

2.

Move the MODE switch to L (Light On).

3.

Move the SET-ADJ-RUN switch to the SET position.

4.

Slide the carrier/board under the sensor. Momentarily press the Teach button (1 sec) to
teach the board present condition.

5.

Slide the carrier/board out from under the sensor. Momentarily press the Teach button
(1 sec) to teach the board not present condition.

6.

Move the SET-ADJ-RUN switch to the RUN position to implement this setting.

"

NOTE

Low contrast applications (low-reflectivity, dark color substrates) may require the
amplifier to be re-taught for the board present condition. Alternatively, a manual
adjustment of the amplifier can be done. If required, move the SET-ADJ-RUN
switch to ADJ. Change the digital threshold level DOWN to detect the board.

7.

Digital threshold is the reflected value at which the sensor turns ON to detect the
carrier/board.

8.

As a general rule, the "Board Present" digital value should be a minimum of 5% higher than
the background digital value. For example, if the background digital value (no board under
sensor) is 350, the "Board Present" minimum digital value must be 350 *1.05 = 368 for
reliable detection.

9.

Verify that the SET-ADJ-RUN switch is in the RUN position.

10.

54

The reference digital value should be less than 250 (approximate value).

Test the sensor by moving the carrier/board into the fiber array. Verify that the output turns on
and is stable when the carrier/board is against the stop pin.
!

The orange output LED should light when the carrier/board is in the path of the fiber
array.

The LED should go off when the carrier/board is moved out of the array.

Calibration and Adjustment

3.12 Initializing the Digital Gauges


The S-91XN Series Dispensing System is equipped with Cooling/Coaxial, Valve and Fluid Pressure Digital
Gauges. If the system is configured with the optional Electronic Pressure Control Utility, the digital gauges
will not be present.
To initialize the digital gauge:
1.

Make sure the air pressure to the pressure gauge is OFF by turning the appropriate regulator
knob counterclockwise until it stops. See Figure 1-5 and Figure 1-6.

2.

To configure the gauge, press and hold down the SET button for at least 2 seconds
(Figure 3-15).

3.

Select the Measuring Unit by pressing the Up button or Down button until the desired
measuring unit is displayed and then press SET.
Available units are kPa or MPa (PA), kgf/cm2 (GF), bar (bAr), and psi (PSi).

!
4.

Verify the Output 1 type is set on the normally open (1no) setting. If it is not displayed, press
the Up or Down button until 1no is displayed and then press SET.

"

NOTE

The output function of the digital gauge is not used on your dispensing system.

5.

Verify the Response Time is set at 192 ms. If it is not displayed, press the Up or Down button
until 192 is displayed.

6.

Verify the Setting Mode is set on the manual setting (nAn). If the manual setting is not
displayed, press the Up or Down button until nAn is displayed and then press SET.
!

The gauge will now be in the pressure-measuring mode.

7.

Zero the gauge by holding down both arrow buttons simultaneously until zeros (00.0) are
displayed on the screen.

8.

Set the pressure to the desired level for your application by turning the knob on the pressure
regulator knob clockwise until the correct pressure is displayed on the screen.

TIP

To ensure accurate pressure measurement, allow the gauge to warm up for 20 to 30


minutes before adjusting pressure level.
1

SMC

PRESSURE

MPa

35.4

OUT 1

SET
4

Item
1
2
3

Description
LED Display
Switch Output Indicator
Up Button

Item
4
5

Description
Set Button
Down Button

Figure 3-15 Initializing the Digital Gauge

Calibration and Adjustment

55

3.13 Adjusting the Lift Table Speed


1.

From the FMXP Main Menu, select Configuration>Conveyor Setup>Test I/O.

2.

Select the tab labeled Outputs 0-31 and locate the Lift output buttons for the station to be
adjusted ( Left Center- Right ).

3.

Use these buttons to lift and lower the table to test the speed adjustment setting.

Figure 3-16 Conveyor I/O Test Dialog


4.

Open the dispensing system hood.

WARNING!

"

5.

Locate the Flow Control Valves (FCVs) for the appropriate Lift Table.

NOTE

6.

Do not reach into the dispensing chamber until yellow beacon light is displayed
and all system motion has stopped. If the Heaters are hot, use extreme caution
when performing this operation.

Flow Control Valve locations are shown in Figure 3-17 to Figure 3-19. If the system has
dispense heat only, the FCVs are located under the lift table. To gain access to the
FCVs, it may be necessary to move the Dispensing Head to the rear of the machine.

Adjust the FCVs as follows:


a. For lift tables, adjust FCV with the black hose for upward speed, and FCV with the blue
hose for downward speed.
b. After adjusting the FCVs test the lift/lower speed as follows:

56

7.

Close the hood and use the output buttons to test. If more adjustment is required, repeat
adjustment and test from Step 2.

8.

Once you are satisfied with the operation of the Lift Tables, exit Conveyor setup and return to
the Main Window.

Calibration and Adjustment

Figure 3-17 Pre-Dispense Lift Table Controls

Figure 3-18 Post-Dispense Lift Table Controls

Figure 3-19 Dispense Lift Table Controls

Calibration and Adjustment

57

3.14 Adjusting Manual Airflow for Impingement Heaters (S-92X)

"

NOTE

This procedure applies to systems equipped with impingement heat and manual flow
controls.

Airflow to Impingement Heaters is adjusted by turning the applicable flowmeter adjustment knob located
in the lower front cabinet door. Airflow is read on the gauge on the front of the flowmeter (Figure 3-20).
Factors to be considered when determining the airflow include the following:

Maximum airflow is 4.0 SCFM.

Size, weight, and securing of the workpiece (high airflow can cause
movement/misalignment).

Effect of airflow on the time it takes to heat the workpiece to dispensing temperature.

Effect of airflow on how fast the heat tooling reaches/maintains steady-state temperature.

Ambient temperature of the dispensing area and its effect on dispensing fluid properties (pot
life, viscosity, cure time).

To Adjust the Flowmeters:


1.

Locate the Impingement Air Valve and Flowmeters in the front cabinet of the dispensing
system.

"
2.

NOTE

If the system is equipped with Pre-Queue and Post-Queue stations, there will be
additional flowmeters located on the Pre-Queue and Post-Queue stations to
control the heat for that station.

Open the Impingement Air Valve by turning the handle counterclockwise so that it is parallel
with the airline. Listen for leaks.

! If there is an air leak, identify the source, shut off the air valve, and fix the leak before
proceeding.
3.

While monitoring the readouts on all Flowmeters, turn the Flowmeter Adjustment Knobs
counterclockwise until maximum airflow is achieved.

! The flow indicators should show an increase in airflow.


4.

While monitoring the readouts on all Flowmeters, turn the Flowmeter Adjustment Knobs
clockwise to lessen the flow.

! The flow indicators should show a decrease in airflow.

58

5.

Restore maximum airflow and open the dispensing system hood. Verify air is coming out of
the holes in Impingement Heater at each conveyor station.

6.

If air is not flowing out of the heater, check the pneumatic connections.

Calibration and Adjustment

1
3

2
Item

Description

Flowmeter Adjustment Knob (Conveyor 1)

Flowmeter Adjustment Knob (Conveyor 2)

Impingement Air Valve

Figure 3-20 Adjusting the Impingement Heater Airflow (S-922 Dual Conveyor)

Calibration and Adjustment

59

3.15 Controlled Process Heat

"

NOTE

This procedure applies to systems equipped with impingement heaters and Controlled
Process Heat (CpH) only.

3.15.1 CpH Configuration


If the dispensing system is equipped with (CpH), make sure that option is selected in the FmXP Heater
Setup Window. See Figure 4-7.
To configure CpH:

"

NOTE

CpH can be added to any station and each station is configured independently.

1.

In the FmXP Main Window, select Tools > Terminal.

2.

Select Heater 2 (Conveyor 1) or Heater 3 (Conveyor 2).


!

3.

The Heater Control Window opens. See Figure 4-28.

Double click on the station that you want to configure.


!

The Heater Control Loop Parameters Window opens. See Figure 3-21.

Figure 3-21 Heater Control Loop Parameters Window - Main Tab

60

4.

Enter the desired settings on the Main tab.

5.

If you want to set ramp and standby options, skip to Step 6, otherwise skip to Step 9.

6.

Click on the Controlled Process States tab.

Calibration and Adjustment

7.

Enter the desired ramp temperature, airflow, and time.


!

8.

Enter the desired standby temperature, airflow, and time.


!

9.
10.

The ramp temperature is generally higher than the dispense station temperature and is
used to quickly heat a part in the pre-dispense station.

The standby temperature is generally lower than the dispense station temperature and is
used to reduce energy when a board is not received for a specified amount of time.

Click on OK to close the Heater Control Window.


Click on Main to return to the FmXP Main Window.

Figure 3-22 Heater Control Window - Controlled Process States


11.

You may press Ctrl + A in any FmXP Window to toggle the Current Air Flow toolbar ON
and OFF. See Figure 3-23.

2
1
Item

Description

Conveyor 1 Impingement Airflow

Conveyor 2 Impingement Airflow


Figure 3-23 Current Air Flow Toolbar

Calibration and Adjustment

61

3.15.2 CpH Cool Down


The Cool Down feature will allow the operator to select which stations should be cooled down before
working on or removing a heater module. The heater will be shut off and maximum air flow will be applied
for a given amount of time specified by the operator.
To cool down the heaters:
1.

In the FmXP Main Window, click on Run a Program.


!

2.

The Production Window opens.

Click on Shutdown.
!

The Cool Down button (Figure 3-24) appears.

Figure 3-24 FmXP Main Window - Cool Down Button


3.

Click on Cool Down.


!

The Heater Cool Down Window opens.

Figure 3-25 Heater Cool Down Window

62

4.

Select the desired stations and enter a cool down time.

5.

Click Start to begin the cooling process.

6.

Click on Cancel to stop the cooling process before the time expires.

Calibration and Adjustment

3.16 Software Controlled Light Beacon


Beacon Configuration allows you to easily configure beacon and audible alarm states for various
FmXP/dispensing system operational conditions.
To configure the desired beacon state and audible alarm:
1.

In the Main Window, select Configuration > Setup Runtime Preferences > Beacon
Control.
!

"

The Beacon Configuration dialog box (Figure 3-26) opens.

Figure 3-26 Beacon Configuration Dialog Box

NOTE

Click on the desired tab to select one of the following categories: See Figure 3-27.
Error Conditions
Program States 1
Program States 2
FmXP States

Calibration and Adjustment

63

Figure 3-27 Beacon Configuration Dialog Box


2.

"
64

Click the Configure button next to the desired condition to display the Dispenser I/O dialog
box where you can select the desired beacon state. See Figure 3-28.

Figure 3-28 Dispenser I/O Dialog Box

NOTE

Refer to the Fluidmove User Guide or Online Help for detailed instructions.

Calibration and Adjustment

Operation

4.1

Overview

At this point, we have installed the S-900N Series, connected it to the necessary facilities, performed the
sub-system checks, calibrated and adjusted the options, and are ready to begin final configuration for
program generation. The sections that follow describe the general sequence of actions necessary to write
and run a new dispensing program. References to FmXP are included as a guide. For detailed
information on FmXP, please consult the Fluidmove User Guide. It is assumed the system has been
powered up and FmXP is running. This section covers the following topics:

"

System Startup

Establishing Machine Offsets

Installing the Dispensing Valve

Creating a New Program

Adjusting the Air Pressure

Installing the Dispensing Fluid

Positioning the Conveyor and Dispensing Head

Starting a Production Run

Camera Operation

System Shutdown

NOTE

Refer to Section 3 - Calibration and Adjustment for the following procedures:

Focusing the Camera

Adjusting the Height Sensor Probe

Calibrating the Camera

Adjusting the Board Sensors

Adjusting the Service Station Height

Adjusting the Lift Table Speed

Z-head Counterbalance Force Adjustment

Adjusting Impingement Heat Airflow

WARNING!

CAUTION!
DO NOT operate the Spectrum Series S-900N Series Dispensing System unless
you have been trained to do so. Operating the dispensing system without proper
training may result in personal injury or dispensing system damage.

4.2

Safety First

Operation of your S-900N Series Dispensing System involves heat, air pressure, electrical power, heat,
mechanical devices, and the use of hazardous materials. It is essential that every person servicing or
operating the dispensing system fully understands all hazards, risks, and safety precautions. Refer to
Section 2 - Safety for important safety information.

Operation

65

4.3

System Startup

4.3.1

Powering on the Dispensing System

"

NOTE
1.

Verify that the main power cord is connected to the main power inlet and the facility power
source.

2.

Verify that the facility air is at the recommended pressure level and connected to the main air
pressure regulator inlets. Refer to the S-900 Installation, Operations and Maintenance
Manual for additional information.

3.

Turn the main circuit breaker on the back of the system to the ON (I) position.

4.

Check the EMO buttons to see if they have been activated. If one has been activated,
deactivate it by turning the red knob clockwise until the knob pops out.

5.

Make sure the interlock signal is not interrupted. Close the dispensing system hood if
applicable.

6.

Turn the laptop computer power button ON.


!

7.

4.3.2

If necessary, refer to the figures in Section 1 - Introduction to identify system


components.

The system computer should begin the boot up sequence.

Press the ON (l) button on the front panel.


!

The dispensing system should be in a powered-up state and the digital gauges and green
power button should be on. If not, make sure the power cord is properly connected to the
dispensing system and to an active facility power source.

It may take several minutes for the camera to acquire a connection with the laptop
computer. DO NOT attempt to run FmXP or DALSA programs during this time.

An icon image of a blue camera will be displayed on the Windows taskbar with a red X
crossing it. After the camera has connected, the red X will be removed and a balloon
message will pop up stating that the Device has limited or no functionality. This is
normal. The limited or no functionality means that you cannot connect to the Internet
with this device. See 4.7.1 Camera States.

Starting Fluidmove for Windows (FmXP)

The FmXP startup procedure assumes that the computer is turned ON and running Windows XP.
1.

Click on Start > Programs > FmXP or double-click the FmXP icon
desktop.
!

When FmXP starts, it will check to see that all the Input and Output (I/O) devices for your
dispensing system are communicating properly with FmXP.

CAUTION!

66

on the Windows

Do not press any keys or the touchpad while FmXP is starting unless prompted
to do so.

Operation

2.

If the FmXP Message 30416 - Dispenser Motor References Not Found appears, click OK to
home the dispenser (Figure 4-1).

Figure 4-1 FmXP Message 30416


!

The FmXP Main Window (Figure 4-2) will open.

Figure 4-2 FmXP Main Window

"

3.

Check to make sure the dispensing head is in the proper home position.

NOTE

Operation

If you receive any error messages, refer to the Fluidmove User Guide or Online Help.

67

4.4

Installing the Dispensing Valve

To install the dispensing valve, slide the dovetail bracket (included with the dispensing valve) into the
valve mounting bracket on the Z-axis face plate. Secure by turning the lever on the valve mounting
bracket to the upward position. Refer to the applicable dispensing valve manual for additional information.

4.4.1

Valve Pneumatic and Electrical Connections

Valve pneumatic and electrical connections are shown in Figure 4-3 and Figure 4-4. Refer to the manual
for your particular dispensing valve for additional information.
2

Item

Description

Fluid Air Pressure (Clear)

Valve Electrical Connection

Item
3

Description
DV-Series Valve

Figure 4-3 Valve Pneumatic and Electrical Connections (DV-8000 shown)

68

Operation

Item

Description

Item

Description

Cooling Air (Green)

Valve Electrical Connection

Valve Air Pressure (Black)

DJ-9000 Valve

Fluid Air Pressure (Clear)


Figure 4-4 Valve Pneumatic and Electrical Connections (DJ-9000 shown)

Operation

69

4.5

Adjusting the Air Pressure

4.5.1

Adjusting the Main Air Pressure


1.

Verify that the facility air is connected to the Main Air Pressure Regulator Inlet.

TIP For accurate pressure adjustment, lower the pressure below the desired level
and then increase to the desired pressure.
2.

Rotate the knob on the Main Air Pressure Regulator counterclockwise until the Main Air
Gauge registers 0 psi.

3.

Rotate the knob clockwise until the Main Air Pressure Gauge registers 90 to 100 psi (621 to
689 kPa).

4.

If the Main Air Gauge fails to register pressure, verify that the dispensing system is connected
to the facility air source.

5.

Monitor the Main Air Gauge to make sure that pressure builds at a steady rate. Watch for
dropping pressure indicating an air leak.
!

If there is an air leak, identify the source, shut off the facility air, and fix the leak before
proceeding.
1

Item

Description

Main Air Pressure Regulators

Main Air Pressure Gauges


Figure 4-5 Main Air Pressure Regulator and Gauge Sets

70

Operation

4.5.2

Adjusting the Cooling/Coaxial, Valve, and Fluid Air Pressure

4.5.2.1 S-91X Series Systems


1.

Locate the Cooling/Coaxial, Valve, and Fluid Pressure Regulator adjustment knobs in the
front cabinet (Figure 4-6).
TIP For accurate pressure adjustment, lower the pressure below the desired level
and then increase to the desired pressure.

2.

Rotate the adjustment knob counterclockwise until the gauge registers 0 psi.

3.

Rotate the adjustment knob clockwise until the associated gauge registers the air pressure
value (psi or kPa) required by your dispensing application.

"
4.

NOTE

Pressure settings depend on the fluid being dispensed and dispensing valve
being used. Refer to the applicable dispensing valve manual for additional
information.

Monitor the pressure gauge on the front panel to make sure that pressure builds at a steady
rate. A drop in air pressure can indicate an air leak.
!

If there is an air leak, identify the source, shut off the facility air, and fix the leak before
proceeding.

Item
1
2

Description
Vacuum Control Regulator
Cooling/Coaxial Air Regulator

Item
3
4

Description
Valve Air Regulator
Fluid Air Regulator

Figure 4-6 Adjusting the Valve and Fluid Pressure Regulators (S-910)

Operation

71

4.5.2.2 S-92X Series Systems


The S-92XN features programmable fluid and valve pressure. Electro pneumatic regulators control the
valve pressure, fluid pressure and cooling/coaxial pressure. These regulators have been integrated into
the platform. All the pressure setpoint values are set through Fluidmove (as opposed to manual
regulators). This reduces possibility of operator error when setting the regulators manually. It also allows
the user to import a recipe that includes all the pressure set points. Programmable fluid and valve
pressure is standard on the S-92XN and optional on the S-91XN.
There are two locations in FmXP where air pressure can be adjusted:

Electronic Pressure Control Utility (E/P)

Fluid Manager

The values set through the Electronic Pressure Control Utility are the default settings and are only used
when a fluid file without the E/P settings is loaded for use. FmXP will initialize the E/Ps to these values at
FmXP startup. The E/P Utility selection also allows you to test the E/P.
Settings established through the Fluid Manager Menu are applicable whenever a fluid file is loaded.
These settings will override the defaults established in the E/P Utility.

"

NOTE

The following procedures assume the dispensing system is on and FmXP is running.

Using the Electronic Pressure Control Utility:


1.

From the FmXP Main Menu select Configuration>Setup Runtime Preferences>Electronic


Pressure Control Utility (Figure 4-7).

2.

Position the mouse to the appropriate SET button and type in the desired settings:

Figure 4-7 E/P Utility

72

Operation

Using the Air Pressure Settings in the Fluid Manager:


1.

In the FmXP Main Menu select Configuration>Setup Fluid Manager>Air Pressure


Settings tab (Figure 4-8).

2.

Click to select the appropriate setting and enter the desired value.

3.

Click Save to save the settings in the fluid file.

Figure 4-8 Fluid Manager - Air Pressure Settings


To view the Current Air Pressure Settings:
1.

You may press Ctrl + P in any FmXP Window to toggle the Current Pressure toolbar ON
and OFF. See Figure 4-9.

1
2
3

Item

Description

C = Cooling/Coaxial Air Pressure

V = Valve Air Pressure

F = Fluid Air Pressure


Figure 4-9 Current Air Pressure Toolbar

Operation

73

4.5.3

Adjusting the Vacuum Control

The Vacuum Control (Figure 4-6) allows low viscosity fluids to be consistently dispensed without dripping
between cycles. The vacuum exerts a negative pressure (suckback) on the fluid, thereby decreasing
dripping.
To adjust the Vacuum Control:

4.5.4

1.

Rotate the knob counterclockwise to increase vacuum pressure and decrease dripping.

2.

Rotate the knob clockwise to decrease vacuum pressure.

Setting the Low Pressure Detection Threshold

This feature allows the user to set the air pressure level at which the software will issue an on-screen low
air pressure error message.
To set the low pressure threshold:
1.

In the FmXP Main Window, select Configuration > Setup Runtime Preferences >
Calibrate Low Air Pressure Detect.
!

2.

The Low Air Pressure Detection Configuration Window (Figure 4-10) opens.

Adjust the dispensing systems Main Air Pressure Regulator to the pressure at which you
want the software to issue a low pressure error message.
!

This should be a value that would result in dispensing variations. The typical set value is
65 psi, but this may vary depending upon the sensitivity of the application.

3.

In the Low Air Pressure Detection Configuration dialog box, click the Set button to set the
current Main Air Pressure Regulator reading as the low air pressure threshold value.

4.

Click on OK.

5.

Restore the air pressure to the normal setting.

Figure 4-10 Low Air Pressure Detection Window

74

Operation

4.6

Positioning the Conveyor and Dispensing Head

When necessary, an operator can use Fluidmove Position (Jog) Controls to reposition the dispensing
head in the X-, Y-, and Z-axes, adjust conveyor rail width, and reposition the workpiece X-axis location
on the conveyor. These position controls can be operated using the touchpad to click on-screen buttons,
or by pressing key combinations on the keyboard. Both methods are described below.

"

NOTE

4.6.1

These procedures assume that the dispensing system and computer have been turned
on as specified in 4.3 System Startup.

Using the Touchpad

To operate position controls with the touchpad:


1.

In the Fluidmove Main Window, click on Jog.


!

"

The FmXP Jog Window (Figure 4-11) opens.

Figure 4-11 FmXP Jog Window

NOTE

Operation

The Jog Window can be accessed from the Main Window, the Production Window, the
Run Window, the Programming Window, and the Tools Window. The selected jog device
is indicated in the bottom right-hand corner of all major windows.

75

4.6.1.1

"

Dispenser Position Controls


1.

Click on the Dispenser Radio button to activate the dispensing head position controls.

2.

Dispensing head position controls (Figure 4-12) operate as follows:


!

On the X-Y control panel, the arrows pointing to the Left move the dispensing head to the
left and the arrows pointing to the Right move it to the right.

On the X-Y control panel, the arrows pointing Up move the dispensing head toward the
back of the dispensing area and the arrows pointing Down move it toward the front of the
dispensing area.

On the Z-axis control panel, the arrows pointing Up move the dispensing head upward
and the arrows pointing Down move it downward.

Clicking on a Locations button, sends the dispensing head to a pre-defined location, i.e.
purge station, weigh station.

Clicking on Home sends the dispensing head to its home position. The home position is
the extreme left front corner of the dispensing area, where the Dispensing Head X, Y, Zaxis coordinates are set to (0, 0, 0).

NOTE

move the dispensing head different


The single arrows
and double arrows
distances and different velocities per mouse click. See Table 4-1.
Table 4-1 Dispensing Head Position Controls: Jog Distance and Velocity(1)

Movement
Axis

Velocity
mm/sec (in/sec)

X-Y

0.0254 (0.001)

2.54 (0.100)

2.54 (0.100)

88.9 (3.500)

0.0254 (0.001)

1.27 (0.050)

2.54 (0.100)

10.16 (0.400)

Notes: (1)
(2)

76

Distance
mm (inch)(2)

Default distances and velocities. Refer to the Fluidmove User Guide or Online
Help to modify jog distances and velocities.
Distance per mouse click on the arrow button.

Operation

Item

"

Description

Target Box

Y-axis Controls (forward and back movement)

X-axis Controls (side to side movement)

Radio Button (Dispenser selected)

Locations (moves the dispensing head to pre-defined locations, purge,


scale, etc.)

Home (moves the dispensing head to its home location)

Z-axis Controls (up and down movement)


Figure 4-12 Dispensing Head Position Controls

NOTE(s) The selected jog device is indicated in the bottom right-hand corner of all major FmXP
windows.
Refer to Table 4-3 for a detailed explanation of position control commands for both the
dispensing head and conveyor.

Operation

77

4.6.1.2

Conveyor Position Controls


1.

Click on the Conveyor 1 radio button to activate the Conveyor 1 position controls.

Item

"

78

Y-axis Controls (rear rail forward and backward movement)

X-axis Controls (belt left and right movement)

Radio Buttons (Conveyor 1 selected)


Figure 4-13 Conveyor Position Controls

NOTE
2.

"

Description

See 4.6.1.2.1 Dual Conveyor Systems for systems equipped with dual conveyors.

Conveyor position controls (Figure 4-13) operate as follows:


!

On the X-Y control panel, the arrows pointing to the Left move the conveyor belt to the
left and the arrows pointing to the Right move it to the right.

On the X-Y control panel, the arrows pointing Up move the rear rail toward the back of
the dispensing area and the arrows pointing Down move the rear rail toward the front of
the dispensing area.

NOTE

move the conveyor rail or belt different


The single arrows
and double arrows
distances per mouse click as specified in Table 4-2.

Operation

Table 4-2 Conveyor Position Controls: Jog Distance(1)


Movement
Axis

Distance
mm (inch)(2)

0.0254 (0.001)

1.27 (0.0500)

0.0254 (0.001)

1.27 (0.0500)

Notes: (1) Default distances. Refer to the Fluidmove User Guide or


Fluidmove Online Help to modify jog distances.
(2) Distance per mouse click on the arrow button.

4.6.1.2.1

Dual Conveyor Systems

If the dispensing system is equipped with dual conveyors, the Conveyor 2 radio button will be active. Click
on the Conveyor 1 radio button to activate the Conveyor 1 position controls, click on the Conveyor 2
radio button to activate the Conveyor 2 position controls.
1.

2.

"

Conveyor 1 position controls operate as follows:


!

On the X-Y control panel, the arrows pointing to the Left move the Conveyor 1 belt to the
left and the arrows pointing to the Right move it to the right.

On the X-Y control panel, the arrows pointing Up move the Conveyor 1 rear rail toward
the back of the dispensing area and the arrows pointing Down move the rear rail toward
the front of the dispensing area.

Conveyor 2 position controls operate as follows:


!

On the X-Y control panel, the arrows pointing to the Left move the Conveyor 2 belt to the
left and the arrows pointing to the Right move it to the right.

On the X-Y control panel, the arrows pointing Up move the Conveyor 2 rear rail toward
the back of the dispensing area and the arrows pointing Down move the rear rail toward
the front of the dispensing area.

NOTE(s) The selected jog device is indicated in the bottom right-hand corner of all major FmXP
windows.
Refer to Table 4-3 for a detailed explanation of position control commands for both the
dispensing head and conveyor.

Operation

79

Table 4-3 Position Control Commands


Name
Target Box

Y-axis Controls
(move front/back)

Dispensing Head Response


Clicking in the Target Box moves the
Dispensing Head to the corresponding
position in the dispensing area.

N/A

Moves the Dispensing Head as follows:

Moves the rear Conveyor rail as follows:

Slow Backward (small increments)

Slow Backward (small increments)

Fast Backward (large increments)

Fast Backward (large increments)

Slow Forward (small increments)

Slow Forward (small increments)

Fast Forward (large increments)

Fast Forward (large increments)

Moves the Dispensing Head as follows:


X-axis Controls
(move left/right)

Conveyor Response

Moves the Conveyor Belt as follows:

Slow Right (small increments)

Slow Right (small increments)

Fast Right (large increments)

Fast Right (large increments)

Slow Left (small increments)

Slow Left (small increments)

Fast Left (large increments)

Fast Left (large increments)

Moves the Dispensing Head as follows:


Slow Upward (small increments)
Z-axis Controls
(move up/down)

Fast Upward (large increments)

N/A

Slow Downward (small increments)


Fast Downward (large increments)
Device
Radio Buttons

80

Click the Dispenser radio button to


activate jog controls for the Dispensing
Head.

Click the Conveyor 1 radio button to


activate jog controls for the conveyor. On
dual conveyor systems, click Conveyor
2 to activate the jog controls for the
second conveyor.

Click to Video open a Video Display in


which you can see a close-up of the
Dispensing Area.

Click to Video open a Video Display in


which you can see a close-up of the
Dispensing Area.

Click to open a dialog box where you can


configure Dispensing Head jog distance
and speed.

Click to open a dialog box where you can


configure conveyor jog distance and
speed.

Click to access Fluidmove Online Help.

Click to access Fluidmove Online Help.

Click to reinitialize the dispenser. Use


this button if you are experiencing
communication problems with the
Dispensing Head.

Click to reinitialize the conveyor. Use this


button if you are experiencing
communication problems with the
conveyor.

Clicking on Home sends the Dispensing


Head to its Home position. The home
position is the extreme left front corner of
the dispensing area, where the
Dispensing Head X, Y, Z-axis
coordinates are set to (0, 0, 0).

Clicking on Home sends the conveyor


rear rail to its Home position. The home
position is the extreme rear of the
dispensing area.

Operation

4.6.2

Using the Keyboard

To operate position controls using Keyboard commands:


1.

Press [Ctrl + J] to open the FmXP Jog Window.

2.

Using the mouse, click on the Dispenser radio button to activate the dispensing head
position controls, the Conveyor 1 radio button to activate the Conveyor 1 position controls or
the Conveyor 2 radio button to activate the Conveyor 2 position controls.

3.

Press the appropriate keys shown in Table 4-4 to jog the selected device (conveyor or
dispensing head).
Table 4-4 Position Control Keyboard Commands

Speed of
Movement

Slow(2)

(3)

Fast

Command(1)

Dispensing Head
Response

Conveyor
Response

Ctrl + H

Moves to front left corner of


dispensing chamber

Rear rail moves all the way


to the back of dispensing
chamber

Ctrl +

Moves left

Belts move left

Ctrl +

Moves backward

Rear rail moves to back

Ctrl +

Moves right

Belts move right

Ctrl +

Moves to front

Rear rail moves to front

Ctrl + Z +

Moves downward

N/A

Ctrl + Z +

Moves upward

N/A

Ctrl + Shift +

Moves left

Belts move left

Ctrl + Shift +

Moves backward

Rear rail moves to back

Ctrl + Shift +

Moves right

Belts move right

Ctrl + Shift +

Moves forward

Rear rail moves to front

Ctrl + Shift + Z +

Moves downward

N/A

Ctrl + Shift + Z +

Moves upward

N/A

Note: (1) Simultaneously press the keys shown.


(2) Slow is the same as clicking on a single arrow

in the Position Control dialog box.

(3) Fast has the same effect as clicking on a double arrow

"

in the Position Control dialog box.

NOTE(s) The selected jog device is indicated in the bottom right-hand corner of all major FmXP
windows.
Keyboard commands are the same for both single and dual conveyor systems.

Operation

81

4.7

Camera Operation

The S-900N Series features a Dalsa-Coreco Genie M640 digital 640 x 480 pixel camera. It communicates
bi-directionally to the laptop computer via Gigabit Ethernet. The camera is configured to run at 60 full
frames per second, twice as fast as the analog PCVision cameras. A frame can be transferred in 16.67
milliseconds.

4.7.1

Camera States

After the Dalsa-Genie software package has been installed, the GigE Server icon will be visible in the
desktop taskbar tray area. The icons and descriptions are shown in Table 4-5.

"

NOTE

The Dalsa-Genie software is installed at the factory prior to shipping.


Table 4-5 Genie Camera States

Icon

State

Description

Device Available

The GigE server tray icon when the Genie device is found. It will
take a few seconds for the GigE Server to refresh its state after the
Genie has obtained an IP address.
The GigE server tray icon shows a warning when a device is
connected but there is some type of IP error.

Device IP Error

A red X will remain over the GigE server tray icon when the Genie
device is not found. This indicates a major network issue.

Device Not
Available

The Genie has one multicolor LED to provide a simple visible indication of camera state. Additionally the
RJ45 has two LEDs for network status conditions (Figure 4-14). LED Status indicators are described in
Table 4-6.
2

Table 4-6 Camera Status Indicators


LED Status

Item

Description

LED is OFF

No power to camera

Steady Red

Camera Not Initialized

Slow Flashing Red

Camera Initialization Problem

Fast Flashing Red

Camera Overheating

Steady Blue

IP Address Assigned

Slow Flashing Blue

Waiting for an IP Address

Camera Status LED

Fast Flashing Blue

Ethernet Cable Disconnected

Network Status LED

Steady Green

Application Linked to the Camera

Slow Flashing Green

Trigger Acquisition in Progress

Figure 4-14 Camera LED's (Rear View)

82

Description

Operation

4.7.2

Lighting and Color Adjustment

The light intensity and color level can be adjusted to optimize the view of your workpiece. See Section 3 Calibration and Adjustment for instructions on focusing and calibrating the camera.

CAUTION!

Except for lighting adjustments and lens replacement, all other configuration and
adjustments should only be performed by a trained service technician.

To adjust lighting intensity and color level:

"

1.

Open the hood, place a workpiece on the heated vacuum tooling plate, and close the hood.

2.

Access the Jog Window using one of the following methods:

Select Jog

Select the Jog

Press [Ctrl]+[J] on the keyboard.

from the Main Menu.


button in the Production Window.

3.

At the bottom of the Jog Controls, click on Video and when the video display screen appears,
click on Reticles. See Figure 4-15.

4.

In the Reticles Setup Window, use the Jog Controls to move the dispensing head over the
sample workpiece so that the video display reticles are aligned with a fiducial. See
Figure 4-15.

5.

View the fiducial in the video display screen while adjusting the two lighting controls until you
get the highest contrast between the fiducial and substrate or between the part being
dispensed upon and the surrounding area.

6.

Adjust the brightness and red/blue color balance by vertically moving the control slides on the
toggles the light control slide
right side of the dialog box. Clicking on the light bulb icon
from a linked mode to an unlinked mode that permits up to 255 independent color
level/brightness levels.

NOTE

Operation

For more information concerning fiducials and video display contrast, refer to the
Fluidmove User Guide or Online Help.

83

1
2
3

Item

Description

Blue Light Adjustment Slide (in unlinked mode)

Red Light Adjustment Slide (in unlinked mode)

Color/Brightness Control Mode Button

Jog Controls
Figure 4-15 Camera Lighting Adjustment

84

Operation

4.8

Establishing Machine Offsets

Programming a dispensing sequence and running production involve the use of the camera. Dispensing
is accomplished with a needle or nozzle. To ensure accurate dispensing and to avoid damage to the
dispensing system or parts, offsets between the camera and needle and camera and height sensor must
be defined prior to dispensing.

4.8.1

Valve Offsets

FmXP provides a semi-automated routine called Valve Offsets to establish machine offset parameters.
This setup procedure is vision assisted to ensure the front door remains closed. The user proceeds
through a list of steps to teach the camera offset, the safe Z- height and the locations for the scale, purge
cup, and test substrate. Valve offsets must be run when installing a new needle or nozzle to provide for
the highest possible dispense accuracy.
Offset procedures may also be tailored to suit the specific environment. Please consult the Fluidmove
User Guide for Scripted Valve Offsets.
To perform a Valve Offsets routine:

"

NOTE

Make sure the Vision System has been calibrated before performing this routine. See
3.6 - Calibrating the Camera.

1.

Clear the work area of any obstacles that might interfere with dispensing head movement.

2.

In the Main Window, select Configuration > Machine Offsets > Valve Offsets or Scripted
Valve Offsets.
!

The selected offsets dialog box opens. See Figure 4-16.

Valve Offsets

Scripted Valve Offsets

Figure 4-16 Machine Offsets

Operation

85

3.

Make sure Valve 1 is selected.

4.

Click on Run to End.


A Teach Window opens.

"
5.

6.

"

NOTE

When using the Valve Offsets setup procedure, click on the Run button next to
the desired task. You will need to repeat this step for each task in the dialog box
(as desired). When setup tasks are complete, click End in the Setup Valve
Offsets dialog box.

Follow the on-screen prompts. Click on Help if you have questions.


!

The Teach Window content and appearance may vary depending on your system
configuration.

When the task has been completed, a check mark appears next to the task.

If your dispensing system is equipped with dual valves, repeat the above procedure for
Valve 2.

NOTE(s)

Any tasks not applicable to your system configuration will be skipped.


If you end the routine prematurely, you will receive an error message similar to the
one shown in Figure 4-17. Click on OK to exit the routine and save the completed
tasks or click on Cancel to continue.

Figure 4-17 FmXP Error Message 30694

4.8.2

Safe Z-Height

Safe Z-Height is determined by choosing a height that ensures the needle, height sensor, or any part of
the dispensing head does not collide with any obstacles while traveling around the dispensing area. Safe
Z-Height is the height below which the tip of dispensing head cannot go when moving from one set of
coordinates to another during operation. This value is taught within the Valve Offsets procedure, but can
be taught independently if needed as follows:
To set the Safe Z-Height:
1.

In the FmXP Main Window, click on Run a Program.


!

2.

In the Production Window, click on the Setup button.

3.

Click on Teach Safe Z Height (Figure 4-18).


!

86

The Production Window opens.

The Teach Safe Z Height Window (Figure 4-19) opens.

Operation

Figure 4-18 Production Window - Teaching Safe Z Height

Figure 4-19 Teaching Safe Z Height


4.

Move the dispensing head over a workpiece fiducial.

5.

Raise or lower the dispensing head until it reaches a Safe Z-Height.

6.

Click on Teach.
!

7.

The Safe Z-Height value will be recorded in the value textbox.

Click on Done.

WARNING!

Operation

Safe Z-Height should never be taught lower than the tallest component on the
unit to be dispensed on.

87

4.9

Creating a New Program

This section briefly covers the steps required to create a new dispensing program. For detailed
instructions, refer to the Fluidmove User Guide or Online Help.

"
4.9.1

NOTE

Loading a Part
1.

In the FmXP Main Window, click on Teach a Program


!

Place the substrate on the conveyor.

3.

Click on the Load

4.

icon to load the substrate into the dispense station.

The substrate will be lifted off the conveyor and clamped into place. The substrate should
be evenly clamped and level.

Adjust the clamping mechanism as necessary to achieve a level dispensing plane.


!

4.9.2

The Programming Window opens.

2.

"

The following procedures assume that the dispensing system is on and FmXP is running.

NOTE

When using heated tooling with pedestals, the parts are NOT clamped but held in place
with vacuum and the tool itself must be leveled.
The dispensing sequence MUST be taught with the part raised and clamped as
necessary. Failing to load the substrate in this manner results in the camera being out of
focus.

Setting the Heaters

Heater tooling temperature is set in the Fluidmove software and saved with the dispensing program. The
Heater Controller in the lower front cabinet monitors the Resistance Temperature Detector (RTD),
compares it to the heat parameters set in Fluidmove, and regulates the voltage going to the heating
element to maintain the set temperature.

88

Operation

4.9.2.1 Heater Setup


1.

In the Fluidmove Main Window, click on Configuration.

2.

Select Setup Heaters.


!

The Heater Setup Window (Figure 4-20) opens.

Figure 4-20 Heater Setup Window


3.

Select desired settings and click on OK.

4.9.2.2 Heater Tooling

CAUTION!

"

NOTE

Operation

The operator can turn the heaters ON and OFF and monitor their function.
However, only authorized personnel should set heater parameters.

Contact your applications engineer or Asymtek Technical Support for information about
setting heater parameters for your particular application.

89

To setup the Heater Tooling in Fluidmove:

WARNING!

The heater may be hot. Avoid touching heater surfaces or burn injury may occur.

1.

In the Fluidmove Main Window, click on Run a Program

2.

In the Production Window (Figure 4-21), click on Setup and in the list box select Setup
Heater 2.
!

The Heater Control Window (Figure 4-22) will open.

Figure 4-21 Fluidmove Production Window


3.

In the Heater Control Window (Figure 4-22), locate the loop (channel) for the desired heater.

"

90

NOTE

See 3.15 Controlled Process Heat for systems equipped with Controlled Process
Heat (CpH).

Operation

Item

Description

Item

Description

Heater Loop - ON

Temperature Set Point Column

Heater Loop - OFF

Present Temperature Value Column

Channel (Loop) Name Column

Message Column

Figure 4-22 Heater Control Window


4.

Activate the heater by double clicking the icon in the On/Off column until the heater loop icon
turns yellow and red.

"
!

NOTE

To change heater temperature, double click on the heater loop name. The heater
parameters dialog box will open.

The heater is operating properly if both of the following are observed:


- The Message column contains any message except T/C Break.
- The Present Value (PV) column indicates the heater is heating up to, and stabilizing at,
the set point (SP).

5.

If the heater is operating properly, click on Exit to close the Heater Control Window. If it is not
operating properly, refer to the S-900 Installation, Operations and Maintenance Manual or call
a trained service technician.

4.9.2.3 Needle Heater


If your system is equipped with a needle heater, select Setup Heater 1 and follow the steps under 4.9.2.2
Heater Tooling to set up the needle heater.

"

NOTE

Operation

The heater file is attached to the program file and is automatically loaded each time the
program file is loaded. This helps to ensure the correct heating profile.

91

4.9.3

Setting up the Fluid Manager

The Fluid Manager is a powerful tool that contains information about the dispensing fluid, such as line,
dot, and mass parameters; purge duration; and pot life. It also contains flow rate setup parameters for the
Mass Flow Calibration System. Mass Flow Calibration makes it possible to dispense the proper amount of
fluid every time and helps to reduce setup time on a daily basis by eliminating trial-by-error guesswork for
the various input parameters.
Parameters are set up through the FmXP Fluid Manager. To open the Fluid Manager, select
Configuration > Setup Fluid Manager from the FmXP Main Menu. Depending on the valve selected, the
Fluid Manager may contain the following tabs:

Purge Parameters

Flow Rate Parameters (DV-Series, DP-Series Valves)

Dot Weight Parameters (DJ-Series Valves)

Weight Verification

Pot Life/Low Fluid Check

Attach Script Files

Click on the appropriate tab to set the fluid parameters for your particular dispensing program. The Fluid
Manager information is recorded in a fluid file (.FLU ) that is attached to the program file and
automatically loaded with the program. This helps to ensure that the correct dispensing parameters are
used each time the program is run.
For example, through the Fluid Manager, the user can describe how a flow rate is to be taken and provide
for a statistically meaningful approach to the measurement (i.e., 30 samples of virtually any shot
duration). The S-900N Series uses these flow rate parameters to calculate the required on-time during
dispensing to achieve the specified mass. After you have defined all fluid parameters, enter the fluid
name and click on Save (Figure 4-23).

"
92

Figure 4-23 FmXP Fluid Manager

NOTE

For additional information on the Fluid Manager, refer to the Fluidmove User Guide or
Online Help.

Operation

4.9.4

Workpiece Alignment

Prior to creating your dispensing program, you should setup workpiece alignment and define the number
of fiducials to be used in your program. Workpiece alignment refers to the position of the board or part in
relation to the Dispensing Head X- and Y-axes. Even if the board is slightly askew, FmXP can use
workpiece alignment to adjust the patterns and dispense correctly. Once you have established workpiece
alignment parameters, workpiece alignment will be performed at the beginning of each production run
and at the beginning of each new board in the run. Checking for workpiece alignment can be eliminated if
speed is a factor. In that case, correct workpiece alignment and symmetry are assumed.
To Setup Workpiece Alignment:
1.

"

Select Setup Workpiece Alignment from the Configuration menu and make sure there is a
checkmark in the box next to Workpiece Angle first. See Figure 4-24.
!

If you select Learn Workpiece Angle first, you will be prompted to define the workpiece
orientation in the X- or Y-axis when you begin programming.

FmXP compares the defined axis to the dispensing head axis to adjust for workpiece
alignment.

NOTE

If Setup Workpiece Alignment is not activated, you will be asked if you want to Learn
Workpiece Angle first? each time you begin a new programming session. However, to
ensure workpiece alignment, it is a good idea to activate this feature in the Configuration
Menu.

Figure 4-24 Workpiece Alignment Options

Operation

93

2.

Indicate the number of fiducials to be used in your program.


!

3.

4.9.5

If No Fiducials is selected, you have the option of confirming the workpiece origin when
opening an existing program. To activate this feature, make sure there is a checkmark in
the textbox next to Confirm Origin location

All dispensing locations on the workpiece are defined in reference to the


workpiece origin.

The workpiece origin is defined as the point where the position counters are reset to
(x0, y0) or (0, 0).

Click OK.

Opening a New Program Window

To create a new program:


1.

Select Teach a Program from the Main Menu.


!

The FMXP Programming Window (Figure 4-25) opens.

The last saved program opens when you start FmXP.

Pattern Name

Program Name
Fluid File
Pattern End
Instruction

Figure 4-25 Programming Window

94

Operation

2.

To create a new program, select File > New from the menu bar or click on the Program
Wizard
icon on the toolbar.
!

This action clears the work area, loads the default fluid and heater files, and opens the
Create Workpiece Window (Figure 4-26).

You will be prompted to define the number of fiducials and skip marks.

Figure 4-26 Create Workpiece


3.

Enter the desired information and click OK.


!

4.9.6

You will be prompted to teach the workpiece origin and fiducial locations, if applicable.

Teaching Fiducials

Depending on the options you have selected for vision use, you may be prompted to teach the workpiece
and two vision targets.
If your programming options are set to have two global fiducials, then FmXP will prompt you to teach two
target points on the workpiece. Choose images that are identical from part to part and in the same
location. With the Vision System Teach screen you can specify a search window size. This helps when
there are multiple identical images within the field of view. You then teach the actual fiducial image and
size using the on-screen controls. The slider bars for lighting control can be adjusted as necessary to
provide optimum lighting and contrast. A found score is available if there is any question about the quality
of the vision target.
Once the vision targets are defined, the program sequence is ready to be inserted.

4.9.7

Machine Setup

If Valve Offsets have not been defined, you will be prompted to do so now. Follow the instructions under
4.8 Establishing Machine Offsets.

Operation

95

4.9.8

"

Attaching a Custom Fluid File


NOTE

4.9.9

The default fluid file is automatically attached to the program when you open the new
program window. To attach a different fluid file, follow the instructions below. The fluid file
is saved with the program. See 4.9.3 Setting up the Fluid Manager.

1.

In the Programming Window, Select File > Fluid Table > Load from the pull-down menu.

2.

If your systems is equipped with dual dispensing valves, you will be prompted to select
Valve 1 or Valve 2.

3.

Select the new fluid file.

4.

Click on Open.

5.

If necessary, repeat Steps 1-4 for Valve 2.

Entering Program Commands

With FmXP there is no syntax to learn. You simply select commands from the Dispensing Commands
Toolbar, teach the appropriate coordinates and click done. FmXP inserts the dispensing commands into
the program sequence for you. By using the dispensing pallet and the host of features from FmXP, simple
or complex programs can be quickly and easily written. Dispense gaps, retract distances, velocities, and
special dispense instructions are accessed from the Edit Menu. Parameters entered for line or dot control
are saved with the fluid file. Consult the Fluidmove User Guide or Online Help for further information.

4.9.9.1

1.

To enter a new program command, position your cursor at the beginning of Line 1 and
press enter to insert a blank line.

2.

Select the desired program command from the Program Commands Toolbar at the right of
the Programming Window and follow the prompts. See. Figure 4-27.
Dispensing Commands

Dispensing commands dictate the actions to be performed. They may consist of maintenance functions
as well as dispensing instructions. Each command has a line number and is executed sequentially. You
may rearrange program commands by cutting and pasting them. Ultimately, you want to program the
workpiece so that the commands are executed in the fastest way possible.
To enter a dispensing command, click on the appropriate icon on the Program Commands toolbar
(Figure 4-27). A Teach Window opens prompting you through the remainder of the process.

96

Operation

Dispensing
Elements

Inserts a Program
Comment

Disable/Enable
Instruction

Inserts a Send
Command into your
program

Create a Pattern

Inserts Process
Commands into
your program

Inserts Procedures into


your program

Inserts Motion
Commands into
your program

Inserts timer-related
functions into your
program

Conveyor

Step and Repeat

Figure 4-27 Program Commands Toolbar

Operation

97

4.9.9.1.1

Dispensing Elements

There are several fundamental dispensing elements and patterns that form the foundation for all
dispensing applications. These include lines, dots, circles, rectangles, area fill, etc. When you select
from the Program Commands Toolbar, a Teach Window opens. The Teach
Dispensing Elements
Window contains the Dispensing Elements toolbar (Figure 4-28). Select the desired Dispensing Element
by clicking on it. You will then be prompted through the remainder of the programming process for the
dispensing element selected.

"

NOTE

Some Dispensing Elements are platform and valve specific and may not be available for
your particular system configuration.

Dot

Line

Arc

Circle

Rectangle

Pot

Area Fill

Spiral Fill

Weight Control Fill

Weight Control
Line
Delta Z Line

Find Substrate
Height

Pattern

Select Valve

Multipass

Coat Dot

Coat Line

Coat Grid

Dot Grid

Figure 4-28 Dispensing Elements Toolbar


4.9.9.2 Dual Conveyor Programming
Fluidmove programming differs slightly for Dual Lane Dispensing Systems. There is only one program
(workpiece) origin for both conveyors. In addition, all program commands must be placed in a Conveyor
Block. Program commands for both conveyors may be placed directly in the Workpiece pattern. When
placing the commands directly in the Workpiece pattern, there is only one origin and one set of fiducials
for both conveyors. However, for more precise dispensing, you may create separate patterns for
Conveyor 1 and Conveyor 2. This allows you to define an origin and fiducials for each pattern in addition
to those defined for the Workpiece pattern. Both methods are explained in the following sections.

"
98

NOTE

For detailed information about programming, refer to the Fluidmove User Guide or
Online Help.

Operation

To place a program command in a Conveyor Block:


1.

In the Fluidmove Main Window, select Teach a Program.


!

2.

The Programming Window opens.

Click on the Conveyor


!

button on the Program Commands toolbar.

The Conveyor drop-down menu (Figure 4-29) opens.

Figure 4-29 Programming Window - Conveyor Block Commands


3.

Select Use Conveyor 1 Block or Use Conveyor 2 Block depending on where you want
to dispense.
!

A Conveyor Block command similar to the one below will be inserted into your program.
1
2

USE CONVEYOR 1:
END USE CONVEYOR:

4.

Move the cursor to the beginning of the END USE CONVEYOR command.

5.

Click on the Dispense Elements

6.

A Teach Window opens.

7.

Select the element you want to program from the Dispensing Elements toolbar and follow the
screen prompts.

8.

Click on Done when you are finished.


!

9.

The dispensing command should be inserted between the Use Conveyor 1 and
End Use Conveyor commands.

Save the program.


!

Operation

button on the Program Commands toolbar.

A sample program is shown in Figure 4-30.

99

Dual_Lane.fmw

1
2
3
4
5
6
7

Workpiece

USE CONVEYOR 1:
LINE: 1, START: (15.139, 12.971), End: (1.139, 11.370)
END USE CONVEYOR:
USE CONVEYOR 2:
DOT: 1, (4.964, 24.501)
END USE CONVEYOR:
END:

Figure 4-30 Sample Dual Conveyor Program


To create additional patterns:
1.

Click on the Pattern

button on the Program Commands toolbar. See Figure 4-31.

Figure 4-31 Creating a Pattern


2.

Select Create Pattern.


!

100

The Create Pattern dialog box (Figure 4-32) opens.

Operation

Figure 4-32 Create Pattern Dialog Box


3.

For this example, enter C1Line as the name for the new pattern.

4.

In the Fiducial section of the window, select None for no fiducials and click OK.

5.

Repeat Steps 1 to 4 and create a pattern called C2Dot.

To add program commands to your pattern:


1.

Click on the arrow


See Figure 4-33.

in the Pattern textbox and select C1Line.

Figure 4-33 Selecting a Pattern


2.

Insert program instructions into the C1Line pattern by clicking the appropriate icons on the
Program Commands Toolbar and following the screen prompts. Refer to the Fluidmove User
Guide or Online Help for programming instructions.

3.

Repeat Steps 1 and 2 to insert program instructions for the C2Dot pattern.

Operation

101

To place a pattern:
1.

Make sure the Workpiece pattern is selected. Follow the steps above for instructions on
selecting a pattern.

2.

Click on the Pattern

3.

Select Place Pattern.


!

4.

button on the Program Commands toolbar. See Figure 4-31.

A Teach Window opens prompting you to select a pattern and teach the placement point.

Follow the screen prompts and click on Done when finished.


!

Sample program screens are shown in Figure 4-34.

dual_lane.fmw

1
2
3
4
5
6
7

Workpiece

USE CONVEYOR 1:
DO: C1Line AT (1.543, 3.567)
END USE CONVEYOR:
USE CONVEYOR 2:
DO: C2Dot at (0.382, 5.198)
END USE CONVEYOR:
END:

dual_lane.fmw

1
2

C1Line

LINE: 1, START: (0.300, 0.300), End: (4.861, 2.118)


END:

dual_lane.fmw

1
2

"

C2Dot

DOT: 1, START: (2.454, 2.110)


END:

Figure 4-34 Placing Patterns

NOTE

Conveyor Block Commands can only be placed in the Workpiece Pattern.

4.9.10 Saving the Program


It is helpful to save the program file frequently as it is developed. Revision conventions are a convenient
way to save programming steps without losing previously entered sequences. When the save icon is
clicked, the program sequence, vision, heater, and fluid files are also saved.

102

Operation

4.9.11 Running the Program in Dry Mode


Once the sequence is written, it is helpful to run the camera through the program first (dry run) to visualize
where the needle tip will go when dispensing. The Vision Window will open and show a live image of the
dispensing path the system will make during a wet run.
To run the program in dry mode:
1.

Select Run > Dry Run from the Programming Window.


!

Alternately, you may click on Dry Mode

icon and then on Run

Figure 4-35 Dry Run

4.10 Installing the Dispensing Fluid


When you are confident the program is going to dispense in the appropriate locations and in the correct
sequence, fluid can then be installed on the valve, pump, or jet. Follow the instructions in the applicable
dispensing valve manual to install the fluid reservoir and make the electrical and pneumatic connections.

Operation

103

4.11 Starting a Production Run


You are now ready to run the program with fluid. Ensure that dry mode on the Run menu is not checked
(Figure 4-35) and click the run button. The system will find the vision targets, height sense, and dispense
in exactly the manner you have specified. All system functions from purging to measuring flow rates will
be performed.
To start a production run:
1.

Verify that the main air, valve, and fluid pressures are set to the desired levels.

2.

If not, adjust pressure as described in 4.5 Adjusting the Air Pressure.

3.

If applicable, turn on the heaters.


!

4.

In the FmXP Main Window, click on Run a Program.


!

5.

Make sure the heaters have reached the desired set point temperature before running
production.

The Production Window opens.

In the Production Window, click on the Setup button and then click on Setup Scripts and
then on Prompted Setup. See Figure 4-36.

Figure 4-36 Production Window Setup Scripts


6.

"
104

Follow the on-screen prompts and when finished, click on Exit to return to the
Production Window.
!

NOTE

If necessary, refer to the FmXP User Guide or Online Help for assistance.
If the program shown in the upper left corner of the Production Window is not the desired
program, proceed with Step 7. Otherwise, skip to Step 9.

Operation

7.

In the Production Window, click on Load


!

8.

The Open Window (Figure 4-37) opens.

Select the program you wish to run and click on Open.


!

The current program name will appear in the Production Window.

Figure 4-37 FmXP Open Window


9.

In the Production Window, click on Run


!

and then click on the Run Production button.

The Run Window opens (Figure 4-38).

10.

Load the workpiece.

11.

Click on Go

to start the dispensing process.

Figure 4-38 Run Window


Operation

105

4.12 System Shutdown


Routine shutdown may vary depending on your particular requirements. However, it is recommended that
you incorporate the following procedures into your post production shutdown routine.

4.12.1 Post Production Shutdown


To shut down at the end of a production shift:
1.

Wait for the dispensing program to complete and verify that all motion has stopped.

2.

Unload all workpieces.

3.

Move the dispensing head to the front center of the system for easy access.

WARNING!

CAUTION!
Follow MSDS recommendations for the proper handling, cleanup, and disposal of
all fluids used with the dispensing system.

4.

Remove the valve, pump or jet and clean it as instructed in the appropriate valve manual.

5.

Clean the dispenser of any spilled fluids.


!

6.

Cured epoxy is exceptionally difficult to clean!

Exit FmXP.

"

NOTE

When FmXP closes, the machine will remain powered but the main air
solenoid will close and relieve all air pressure to the system.

7.

Exit Windows XP by clicking on the Windows Start button, and then on Shutdown.

8.

Make sure Windows XP completely shuts down before turning off the computer.

9.

Press the black OFF button on the S-900N Series front panel to de-energize the system.

WARNING!

CAUTION!
Before performing any servicing or parts replacement, the system must be shut
down for service. Failure to do so could cause serious injury to the user and/or
serious damage to the dispensing system. See 2.11 Service Shutdown.

106

Operation

Maintenance

5.1

Overview

Following a routine maintenance schedule and procedures can prevent part degradation and ensure high
quality performance for every production run. This section covers the following topics:

Routine Maintenance Procedures

Lubricating the Cables and Linear Guides

Replacing Consumables

Tensioning the Cables

Draining the Water Trap

Tensioning the Conveyor Belts

Removing the Axis Covers

WARNING!

5.2

Maintenance procedures should be performed by trained personnel only.

Safety First

Operation of your S-900N Dispensing System involves heat, air pressure, electrical power, mechanical
devices, and the use of hazardous materials. It is essential that every person servicing or operating the
dispensing system fully understands all hazards, risks, and safety precautions. Refer to Section 2 - Safety
for important safety information.

WARNING!

CAUTION!
Consult the Material Safety Data Sheet (MSDS) for all fluids used with the
dispensing system. The MSDS provides material usage instructions, disposal
instructions, and safety precautions.

WARNING!

CAUTION!
If the dispensing system is equipped with a ventilation system, make sure the
dispensing system ventilation is ON during handling and cleanup of all materials
used with the dispensing system.

5.3

Record Keeping

The type of procedure performed should be recorded in maintenance records for the dispensing system.
Dates, part numbers/serial numbers of replaced parts, names of technicians, and other pertinent data
should be recorded.

Maintenance

107

5.4

Routine Maintenance Procedures

WARNING!

CAUTION!
Before performing any of the maintenance procedures in this section, perform a
service shutdown described in 2.11 Service Shutdown.

"

NOTE

The following maintenance procedures are for the S-900N Series Dispensing Systems
only. Refer to the appropriate manual for recommended maintenance procedures for your
specific fluid dispensing applicator.

Routine maintenance procedures and required intervals are listed in Table 5-1.
Table 5-1 Routine Maintenance Procedures
Task

Frequency

Instructions
Remove spilled fluids with the manufacturers
recommended solvent and a soft cloth. Remove any
foreign objects from the dispensing area and tooling plate.

Clean Dispensing Area

Clean Purge Station


Boot

Daily

Daily

Replace Purge Station


Cup

Daily

Replace Scale Cup

Daily

"

NOTE

Make sure the dispensing system


ventilation is ON during handling and
cleanup of all materials used with the
dispensing system.

1. Remove the Purge Station cover.


2. Carefully clean the boot and Purge Station cover with
a small brush or soft cloth and the cleaning agent
recommended by the fluid manufacturer. Inspect the
rubber boot for damage. Replace if needed. See 5.5.2
Replacing the Purge Boot.
3. Replace Purge Station cover.
See 5.5 Replacing Consumables.
See 5.5 Replacing Consumables.

Clean Dispensing
System

Weekly

Clean all surfaces using a clean cloth and isopropyl


alcohol.

Drain Water Trap

Weekly

Check water level and empty if necessary. See 5.6


Draining the Water Trap.

Check Air Cylinders

Monthly

Check for leakage.

Lubricate XYZ Axis


Linear Guides

Every three
months

See 5.8.2 Lubricating the X-Y Linear Guides.

Clean Encoder Strips


and Read Heads

Every three
months

Using lint-free cotton pads or swabs wetted with alcohol,


wipe the encoder strips for their full length and inspect for
damage. Similarly, clean the read heads to remove dirt,
dust, or foreign material.

108

Maintenance

Table 5-1 Routine Maintenance Procedures (Continued)


Task

Frequency

Instructions

Lubricate Mechanical
Drive Cables

Every three
months

See 5.8.1 Lubricating the Cables.

Tension Mechanical
Drive Cables

Every 6-12
months

See 5.9 Tensioning the Cables.

Clean Camera Lens

As Needed

Use the cleaning kit provided.

Tension Conveyor Belts

As Needed

See 5.10 Tensioning the Conveyor Belts.

Replace Conveyor Belts

As Needed

Refer to the S-900 Installation, Operations and


Maintenance Manual.

5.5

Replacing Consumables

Consumables are items that are discarded and replaced on a regular basis. The following items are
common consumables and should be replaced at the intervals recommended in Table 5-1.

Purge Boots

Scale and Purge


Cups

Tools and Materials Needed

Needle-nosed Pliers

Replacement Purge Boot (see Table 5-2)

Isopropyl Alcohol

Replacement 1 oz. (29 ml) Plastic Cups (P/N 58-0030)

Clean Shop Cloth

Small Brush

Rubber Gloves

Personal Protective Equipment (as required)

Table 5-2 Purge Boot Colors, Sizes, and Compatible Needles


Purge Boot Color

Inside Diameter

Compatible Needle Gages

Asymtek P/N

Orange

0.5 mm (0.020-in.)

26, 27, 30, 32

01-0019-00

Pink

0.8 mm (0.031-in.)

22, 23, 24, 25

01-0021-00

Green

1.1 mm (0.045-in.)

19, 20, 21

01-0018-00

Olive*

3.0 mm (0.120-in.)

14, 15, 16, 18

01-0022-00

*Recommended size for nozzles on DJ-2000 and DJ-9000 Series Dispensing Valves.

Maintenance

109

5.5.1

Replacing Purge and Weigh Station Cups

The cups in the purge and weigh stations should be replaced at the intervals recommended in Table 5-1.
To replace the Purge and Scale cups:

WARNING!

"

NOTE

The Fluidmove Valve Offsets routine does not need to be performed after replacing the
Purge Station and Weigh Station cups.

1.

When the dispensing system is idle, open the dispensing system hood.

2.

Remove the covers on the Purge Station and Weigh Stations (Figure 5-1).

3.

Remove and discard the plastic cups inside the Purge and Weigh Stations and inspect the
interior surfaces for spilled fluid.
!

If the interior of the Purge Station has spilled fluid, clean with the recommended cleaning
agent and a soft cloth.

If the interior of the Weigh Station has spilled fluid, call a service technician.

CAUTION!

110

Follow all local regulations, the material manufacturer MSDS, and facility
practices concerning personal protective equipment and disposal of
hazardous materials.

Avoid putting downward pressure on the scale or damage to the sensitive


weighing mechanism will occur.

4.

Place a new plastic cup inside of each station.

5.

Clean the covers using isopropyl alcohol and a soft cloth.

6.

Reinstall the covers and close the hood.

Maintenance

Item

Description

Weigh Station

Weigh Station Cup

Purge Station Cup

Purge Station Lid


Figure 5-1 Replacing the Purge and Weigh Station Cups

Maintenance

111

5.5.2

Replacing the Purge Boot

To replace the purge boot:

WARNING!

Follow all manufacturer MSDS, facility requirements, and local ordinances


concerning personal protective equipment and disposal of hazardous materials.

1.

When the dispensing system is idle, open the dispensing system hood.

2.

Remove the Purge Station cover.

3.

Using needle-nosed pliers, grip the top of the purge boot and pull it out from the top of
the cover. Discard the used purge boot.

4.

If the cover is dirty, clean it with the recommended cleaning agent and a soft cloth.

5.

Obtain a new boot. See Table 5-2 for compatibility information.

6.

Insert the new boot, narrow end first, into the top of the cover.

7.

Push the boot downward through the hole in the cover until it starts to emerge from
the bottom.

8.

Using fingers or needle-nosed pliers, grip the bottom of the boot and pull gently through the
hole until it is fully seated. Slight scoring on the bottom end of the boot is acceptable, but the
top of the boot must be undamaged.

9.

Reinstall the cover onto the Purge Station.

10.

Close the hood.

Item

Description

Purge Boot

Purge Station Cover


Figure 5-2 Replacing the Purge Boot

112

Maintenance

5.6

Draining the Water Trap

Because the facility air supply may contain moisture that can damage the dispensing system, the S-900N
is equipped with two water traps that condense this moisture before it enters the pneumatic system. The
operator or technician must drain the water trap weekly or whenever it is full.
Tools and Materials Needed:

Container for waste water

To drain the Water Trap:


1.

Locate the Water Traps at the rear of the system.

2.

Shut off facility air pressure and disconnect the facility air supply from the Main Air Pressure
Regulator Inlet.

3.

Hold a container under the Water Traps to catch the water and open the water drain knob by
turning counterclockwise.

4.

After the trap has been drained, close the Water Trap drain knob by turning clockwise.

5.

Reconnect the facility air supply to the Main Air Pressure Regulator Inlet.

2
Item

Description

Water Trap

Drain Knobs
Figure 5-3 Draining the Water Traps

Maintenance

113

5.7

Removing the Axis Covers

In order to lubricate the cables and linear guides and to tension the cables, it will be necessary to remove
the axis and rear cable covers.
To remove the X-axis covers:
1.

Use a 5 mm hex key to loosen the four (4) M-6 screws (Figure 5-4).

2.

Lift off the covers and set aside.

Figure 5-4 Removing the X-Axis Covers


To remove the Y-axis covers:
1.

Use a 5 mm hex key to loosen the five (5) M-6 screws (Figure 5-5).

2.

Slide out the covers and set aside.

Figure 5-5 Removing the Y-Axis Covers

114

Maintenance

To remove the rear cable covers:

1. Use a 5 mm hex key to loosen the eight (8) M-4 screws (Figure 5-6).
2. Remove the covers and set aside.

Figure 5-6 Removing the Rear Cable Covers

5.8

Lubricating the Cables and Linear Guides

The XYZ-Axes support the dispensing head and allow it to travel within the dispensing area. To ensure
smooth dispensing head movement, the cables and linear guides must be lubricated approximately every
three months.

"
5.8.1

"

NOTE

To perform the following procedures, you will need Asymtek Grease Kit (P/N 7203262).
The kit contains a grease syringe.

Lubricating the Cables


NOTE

The following procedure is a two-man operation.

To lubricate the cables:


1.

Perform a service shutdown as specified in 2.11 Service Shutdown.

2.

Remove the axis and cable covers as described above.

3.

Open the dispensing system hood and move the dispensing head to the front middle of the
dispensing area.

WARNING!

Maintenance

Use Personal Protective Equipment when working with cleaning and lubrication
materials. Refer to the applicable MSDS. Remove all spills and properly dispose
of contaminated materials.

115

4.

Wearing gloves, clean all accessible cables using a soft lint-free cloth and isopropyl alcohol.

WARNING!

5.

Visually inspect the cleaned cables for uneven and excessive wear. Run a lint-free cloth over
cables while feeling for breaks in sheathing or swollen spots.

"

NOTE

If the cables show signs of wear, skip this procedure and contact Asymtek. If the
cables show no signs of wear, proceed with the next step.

6.

Wearing rubber gloves, manually apply an adequate but not excessive amount of grease to
the exposed portion of all mechanical cables.

7.

Move the X-beam to the rear of the machine and apply grease to all exposed cables on the
left and right sides of the machine.

8.

Move the X-beam to the front of the machine and apply grease to all exposed cables on the
left and right sides of the machine.

9.

Move the Z-head to the left side of the X-beam and apply grease to all exposed cables on the
X-beam.

10.

Move the Z-head to the right side of the X-beam and apply grease to all exposed cables on
the X-beam.

11.

While an assistant is moving the X-beam SLOWLY in the Y-direction from bump stop to
bump stop, apply grease to the exposed cables near the Y-motor drive pulley.

12.

While an assistant is moving the X-beam SLOWLY in the X-direction from bump stop to
bump stop, apply grease to the exposed cables near the X-motor drive pulley.

"

116

Fingers may be pinched if the dispensing head is moved while cleaning and
lubricating the cables.

NOTE

Do not apply grease directly to the drive pulleys or cable pulleys as this will over
grease the mechanics.

13.

Manually exercise the X/Y mechanics fully in all directions.

14.

Wipe excess grease off drive pulleys, motor pulleys, cables, and frame.

15.

When finished, replace the axis and cable covers.

16.

Ensure adequate clearance between the pulley assemblies and side covers.

Maintenance

5.8.2

Lubricating the X-Y Linear Guides

To load the grease gun:


1.

Pull back on the handle at the bottom of the grease gun cylinder until the locking tabs
are visible.

2.

Twist the lock into position.

3.

Unscrew and remove the top of the grease gun.

4.

Remove the blue cap from the grease cartridge and place it, open end down, into the grease
gun cylinder.

5.

Remove the seal from the bottom of the grease cartridge by pulling the tab.

6.

Replace the top of the grease gun.

7.

Screw the extension into the front side at the top of the grease gun.

8.

Release the handle from the locked position.

9.

Purge the air from the grease gun cartridge by dispensing grease into a waste receptacle
until a solid stream flows from the gun.

To lubricate the linear guides:


1.

Perform a service shutdown as specified in 2.11 Service Shutdown.

2.

Manually move the dispensing head to the front of the dispensing area.

3.

Remove the X- and Y-axis covers. See 5.7 Removing the Axis Covers.

4.

Using an ammonia-based cleaner and a soft cloth, clean and wipe the X- and Y-rails.
!

Manually move the dispensing head as necessary to reach all parts of the rails.

5.

Locate the grease fitting on each of the four X-beam Linear Bearing Cars and four Y-rail
Linear Bearing Cars (Figure 5-7 and Figure 5-8).

6.

Attach grease gun to each fitting and pull the grease gun lever one time to squirt grease into
the bearing.

7.

Use a soft cloth to clean up any excess grease.

8.

Replace the X- and Y-axis covers

9.

Power on the dispensing system.

10.

Use the Fluidmove position controls to move the dispensing head back and forth in both the
X-axis and the Y-axis.

11.

Open the hood and use a soft cloth to remove any excess grease along the rails.

Maintenance

117

Figure 5-7 Lubricating the X-Axis Linear Guides

Figure 5-8 Lubricating Y-Axis Linear Guides

118

Maintenance

5.9

Tensioning the Cables

To tension the cables:


1.

Perform a service shutdown as specified in 2.11 Service Shutdown.

2.

Loosen the X-Axis and two (2) Y-axis tensioner screws.

3.

Move the Z-head in a circle around the entire length and width of the dispensing area
approximately 5 times.

4.

Stop in the center of the dispensing area.

5.

Retighten the tensioner screws.

1
Figure 5-9A Tensioning the X-Axis Cables

Item

Figure 5-9B Tensioning the Y-Axis Cables

Description

X-Axis Tensioner Screw

Y-Axis Tensioner Screw


Figure 5-9 Tensioning the Cables

Maintenance

119

5.10 Tensioning the Conveyor Belts


To tension the conveyor belts:

1. Perform a service shutdown as specified in 2.11 Service Shutdown.


2. Loosen the belt tensioner screw located on the back of the Motor Mount Tensioner
(Figure 5-10).

3. Move the Motor Mount Tensioner right and left until the desired tension is obtained.
4. Tighten the tensioner screw.
5. Repeat Steps 2-4 for the other belt.
6. If the dispensing system is equipped with dual conveyors, perform steps 2-5 for the other
conveyor.
1
2

Item

"
120

Description

Conveyor Belt

Motor Mount Tensioner


Figure 5-10 Tensioning the Conveyor Belts

NOTE

If the conveyor belts need to be replaced, refer to the S-900 Installation, Operations and
Maintenance Manual.

Maintenance