Asymtek Spectrum Series

Spectrum Series
S-920 Dispensing
System
Installation
Operations
Maintenance
Manual
P/N 7212417 Rev A

Spectrum™ Series
S-920
Dispensing System
Installation, Operations, and

Maintenance Manual
P/N 7212417, Revision A

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

Tel: +1-760-431-1919
Fax: +1-760-431-2678
E-mail: info@asymtek.com
Website: www.asymtek.com
Technical Support
USA: 1-800-ASYMTEK (1-800-279-6835)
Other regions: www.asymtek.com/support.htm
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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.
Txt. P/N 7212418, Revision A ©2007

Manual Conventions
Bold Text Dispensing system labels, buttons and switches, and software menu selections
and commands appear in this text style.
[Bracketed Text] [Bracketed Text] indicates a single key or key combination to press on a
computer keyboard, such as [Enter] or [Alt + Tab].
Text > Text Refers to a series of menu bar commands in Fluidmove for Windows XP (FmXP)
software.
WARNING! Personnel Safety Warning. This symbol appears in a shaded text block to warn
you about actions that could cause personal injury or death.
CAUTION! Property Damage Caution. This symbol appears in a shaded text block to warn
you about actions that could cause serious damage to the machinery, software,
parts being processed, and facilities.
" NOTE This symbol appears next to helpful information relating to text that precedes it, or
information you must know before proceeding.
TIP This symbol appears next to a timesaving or technique tip.

Table of Contents
1 Introduction ...................................................................................................................................... 1-1
1.1 Overview .................................................................................................................................. 1-1
1.2 System Description .................................................................................................................. 1-1
1.3 Safety First............................................................................................................................... 1-1
1.4 Manuals ................................................................................................................................... 1-2
1.5 Training .................................................................................................................................... 1-2
1.5.1 Student Certification ................................................................................................... 1-2
1.5.2 Student Registration ................................................................................................... 1-2
1.6 Supported Dispensing Fluids................................................................................................... 1-2
1.7 Standard Equipment and Features.......................................................................................... 1-3
1.7.1 Automatic Pattern Recognition (Vision) System......................................................... 1-3
1.7.2 Calibrated Process Jetting (CpJ™) ............................................................................ 1-3
1.7.3 Computer System ....................................................................................................... 1-3
1.7.4 Conveyor..................................................................................................................... 1-3
1.7.5 Fluidmove for Windows XP Software ......................................................................... 1-4
1.7.6 Integral Height Sensor ................................................................................................ 1-4
1.7.7 Light Beacon ............................................................................................................... 1-4
1.7.8 Low Air Pressure Alarm .............................................................................................. 1-4
1.7.9 Mass Flow Calibration ................................................................................................ 1-4
1.7.10 Needle Heater............................................................................................................. 1-4
1.7.11 Precision Pneumatics ................................................................................................. 1-4
1.7.12 Safety Features........................................................................................................... 1-5
1.7.13 Service Station............................................................................................................ 1-5
1.7.14 System Light ............................................................................................................... 1-5
1.7.15 Ventilation Exhaust System ........................................................................................ 1-5
1.8 Optional Equipment ................................................................................................................. 1-5
1.8.1 CAD Import ................................................................................................................. 1-5
1.8.2 Laser Height Sensor ................................................................................................... 1-5
1.8.3 Low Fluid Sensor ........................................................................................................ 1-6
1.8.4 SECS/GEM Interface .................................................................................................. 1-6
1.8.5 Substrate Heaters ....................................................................................................... 1-6
1.9 Dispensing Valves ................................................................................................................... 1-7
1.10 System Features...................................................................................................................... 1-8
1.10.1 Dispensing Area........................................................................................................1-10
1.10.2 Service Station..........................................................................................................1-11
1.10.3 Front Panel ...............................................................................................................1-12
1.10.4 Front Cabinet ............................................................................................................1-13
1.10.5 Rear View .................................................................................................................1-14
1.10.6 Rear View Open........................................................................................................1-16
1.10.7 Rear Cabinet.............................................................................................................1-17
1.10.8 Rear Panel Connections...........................................................................................1-18
2 Safety ......................................................................................................................................... 2-1
2.1 Overview .................................................................................................................................. 2-1
2.2 Facility Requirements .............................................................................................................. 2-1
2.3 Intended Use............................................................................................................................ 2-1
2.4 Basic Safety Precautions and Practices .................................................................................. 2-2
Table of Contents v
2.4.1 Safety of Personnel..................................................................................................... 2-2
2.4.2 Material Safety ............................................................................................................ 2-3
2.4.3 Preventing Dispensing System and Workpiece Damage ........................................... 2-3
2.5 Lifting and Transport Precautions............................................................................................ 2-4
2.5.1 Considerations ............................................................................................................ 2-4
2.5.2 Precautions ................................................................................................................. 2-4
2.6 Earthquake Precautions .......................................................................................................... 2-5
2.7 Safety Warning Labels............................................................................................................. 2-6
2.8 Laser Radiation......................................................................................................................2-11
2.8.1 Laser Height Sensor Specifications..........................................................................2-11
2.9 Emergency Shutdown............................................................................................................2-12
2.9.1 Emergency Shutdown Situations..............................................................................2-13
2.9.2 Emergency Shutdown Recovery ..............................................................................2-13
2.10 Interlock .................................................................................................................................2-13
2.10.1 Interlock Recovery ....................................................................................................2-13
2.11 Service Shutdown ..................................................................................................................2-14
2.11.1 Lockout/Tagout of Electrical and Pneumatic Energy................................................2-14
2.12 Light Beacon ..........................................................................................................................2-16
3 Installation ........................................................................................................................................ 3-1
3.1 Overview .................................................................................................................................. 3-1
3.2 Safety First............................................................................................................................... 3-1
3.4 Tools and Materials Needed.................................................................................................... 3-1
3.5 Uncrating and Placing the Dispensing System........................................................................ 3-2
3.6 Unpacking the Dispensing Chamber ....................................................................................... 3-4
3.7 Leveling the Dispensing System.............................................................................................. 3-8
3.8 Leveling the Scale..................................................................................................................3-10
3.9 Setting Up the Service Station...............................................................................................3-11
3.10 Installing the Light Beacon.....................................................................................................3-12
3.11 Installing the Laptop Computer..............................................................................................3-12
3.12 Installing the Camera .............................................................................................................3-15
3.12.1 Installing the Genie Framework Software.................................................................3-15
3.12.2 Connecting the Camera............................................................................................3-15
3.13 Anchoring the Dispensing System.........................................................................................3-16
4 Power-Up and Testing ..................................................................................................................... 4-1
4.1 Overview .................................................................................................................................. 4-1
4.2 Safety First............................................................................................................................... 4-1
4.4 Connecting the Power and Air Supply ..................................................................................... 4-2
4.5 Powering on the Dispensing System ....................................................................................... 4-4
vi Table of Contents
4.6 Starting Fluidmove for Windows (FmXP)................................................................................. 4-4
4.7 FmXP Configuration................................................................................................................. 4-6
4.7.1 Conveyor Setup .......................................................................................................... 4-6
4.7.2 Scale Setup................................................................................................................. 4-8
4.7.3 Vision Setup................................................................................................................ 4-9
4.8 Exiting Fluidmove for Windows (FmXP) .................................................................................. 4-9
4.9 Preliminary System Check.....................................................................................................4-10
4.10 Component-Level Functional Tests .......................................................................................4-10
4.10.1 EMO..........................................................................................................................4-11
4.10.2 Pneumatic Regulators and Gauges..........................................................................4-11
4.10.3 Impingement Air Flowmeters ....................................................................................4-13
4.10.4 Light Beacon .............................................................................................................4-14
4.10.5 Conveyor and Conveyor Pneumatics .......................................................................4-15
4.10.6 Dispensing Head and Accessories ...........................................................................4-23
4.10.7 Vision System ...........................................................................................................4-27
4.10.8 Dispensing Valve Pneumatics ..................................................................................4-28
4.10.9 Tactile Sensor ...........................................................................................................4-30
4.10.10 Purge Station ............................................................................................................4-32
4.10.11 Scale .........................................................................................................................4-33
4.10.12 Heater Tooling and Needle Heaters .........................................................................4-35
4.11 System-Level Functional Test ...............................................................................................4-38
5 Calibration and Adjustment ............................................................................................................ 5-1
5.1 Overview .................................................................................................................................. 5-1
5.2 Safety First............................................................................................................................... 5-1
5.3 Record Keeping ....................................................................................................................... 5-1
5.4 Startup/Shutdown .................................................................................................................... 5-1
5.5 Focusing the Camera............................................................................................................... 5-2
5.6 Calibrating the Camera ............................................................................................................ 5-3
5.7 Service Station Height Adjustment .......................................................................................... 5-5
5.8 Calibrating the Scale................................................................................................................ 5-6
5.9 Z-head Counterbalance Force Adjustment.............................................................................. 5-9
5.10 Adjusting the Height Sensor Probe........................................................................................5-10
5.11 Adjusting the Board Sensors .................................................................................................5-11
5.11.1 Program Output for Look Down Configuration (ASPA,196581 Fiber Array) ............5-12
5.12 Initializing the Digital Gauges ................................................................................................5-13
5.13 Software Controlled Light Beacon .........................................................................................5-14
6 Operation ......................................................................................................................................... 6-1
6.1 Overview .................................................................................................................................. 6-1
6.2 Safety First............................................................................................................................... 6-1
6.3 Startup ..................................................................................................................................... 6-1
6.4 Installing the Dispensing Valve................................................................................................6-2
6.4.1 Valve Pneumatic and Electrical Connections ............................................................. 6-2
Table of Contents vii

6.5 Adjusting the Air Pressure ....................................................................................................... 6-4
6.5.1 Adjusting the Main Air Pressure ................................................................................. 6-4
6.5.2 Adjusting the Cooling/Coaxial, Valve, and Fluid Air Pressure.................................... 6-5
6.5.3 Adjusting the Vacuum Control .................................................................................... 6-6
6.5.4 Setting the Low Pressure Detection Threshold .......................................................... 6-6
6.6 Establishing Machine Offsets .................................................................................................. 6-7
6.6.1 Valve Offsets............................................................................................................... 6-7
6.6.2 Safe Z-Height.............................................................................................................. 6-8
6.7 Positioning the Conveyor and Dispensing Head ...................................................................6-10
6.7.1 Using the Touchpad..................................................................................................6-10
6.7.2 Using the Keyboard ..................................................................................................6-14
6.7.3 Dual Conveyor Systems ...........................................................................................6-14
6.8 Camera Operation .................................................................................................................6-16
6.8.1 Camera States ..........................................................................................................6-16
6.8.2 Lighting and Color Adjustment..................................................................................6-17
6.9 Creating a New Program .......................................................................................................6-19
6.9.1 Loading a Part...........................................................................................................6-19
6.9.2 Setting the Heaters ...................................................................................................6-19
6.9.3 Setting up the Fluid Manager....................................................................................6-22
6.9.4 Workpiece Alignment................................................................................................6-23
6.9.5 Opening a New Program Window ............................................................................6-24
6.9.6 Teaching Fiducials ....................................................................................................6-25
6.9.7 Machine Setup ..........................................................................................................6-25
6.9.8 Entering Program Commands ..................................................................................6-26
6.9.9 Saving the Program ..................................................................................................6-32
6.9.10 Running the Program in Dry Mode ...........................................................................6-33
6.10 Installing Fluid on the Dispensing Valve ................................................................................6-33
6.11 Starting a Production Run......................................................................................................6-34
6.12 System Shutdown ..................................................................................................................6-36
6.12.1 Post Production Shutdown .......................................................................................6-36
7 Maintenance...................................................................................................................................... 7-1
7.1 Overview .................................................................................................................................. 7-1
7.2 Safety First............................................................................................................................... 7-1
7.3 Record Keeping ....................................................................................................................... 7-1
7.4 Routine Maintenance Procedures ........................................................................................... 7-2
7.5 Replacing Consumables..........................................................................................................7-3
7.5.1 Replacing Purge and Scale Cups............................................................................... 7-4
7.5.2 Replacing the Purge Boot........................................................................................... 7-6
7.6 Draining the Water Trap........................................................................................................... 7-7
7.7 Removing the Axis Covers ...................................................................................................... 7-8
7.8 Lubricating the Cables and Linear Guides .............................................................................. 7-9
7.8.1 Lubricating the Cables ................................................................................................ 7-9
7.8.2 Lubricating the X-Y Linear Guides............................................................................7-11
7.9 Tensioning the Cables ...........................................................................................................7-13
7.10 Tensioning the Conveyor Belts..............................................................................................7-14
viii Table of Contents

8 Troubleshooting ............................................................................................................................... 8-1
8.1 Overview .................................................................................................................................. 8-1
8.2 Safety First............................................................................................................................... 8-1
8.3 Record Keeping ....................................................................................................................... 8-1
8.4 Basic System Troubleshooting ................................................................................................ 8-2
8.4.1 System Power............................................................................................................. 8-2
8.4.2 System Accuracy ........................................................................................................ 8-3
8.4.3 Pneumatic ................................................................................................................... 8-4
8.4.4 FmXP Startup ............................................................................................................. 8-5
8.4.5 Dispense Head Controller Connections and Functions.............................................. 8-6
8.4.6 Height Sensor ............................................................................................................. 8-7
8.4.7 Laser Height Sensor ................................................................................................... 8-7
8.4.8 Vision System ............................................................................................................. 8-8
8.4.9 Scale ........................................................................................................................... 8-9
8.4.10 Needle Heater...........................................................................................................8-12
8.4.11 Tactile Sensor ...........................................................................................................8-12
8.4.12 Substrate Heaters .....................................................................................................8-14
8.4.13 Conveyor...................................................................................................................8-14
9 Parts Replacement ........................................................................................................................... 9-1
9.1 Overview .................................................................................................................................. 9-1
9.2 Record Keeping ....................................................................................................................... 9-1
9.3 Parts Ordering Information ...................................................................................................... 9-2
9.3.1 Placing Your Order ..................................................................................................... 9-2
9.3.2 Shipping Instructions .................................................................................................. 9-2
9.3.3 Warranty ..................................................................................................................... 9-2
9.3.4 Credit and Exchanges ................................................................................................ 9-2
9.3.5 Return Material Authorization ..................................................................................... 9-2
9.4 Cleaning and Inspection .......................................................................................................... 9-3
9.5 Unpacking and Inspecting Replacement Parts........................................................................ 9-3
9.6 Gaining Access to Dispensing System Components .............................................................. 9-4
9.7 Replacing the Conveyor Belts ................................................................................................. 9-5
9.8 Replacing the Camera Lens .................................................................................................... 9-8
9.9 Replacing the Height Sensor Probe ........................................................................................ 9-9
9.10 Replacing Fuses ....................................................................................................................9-11
9.10.1 Fuse Mounting ..........................................................................................................9-11
9.10.2 Replacement Fuses ..................................................................................................9-11
9.10.3 Board-Mounted Fuses ..............................................................................................9-11
9.10.4 Panel-Mounted Fuses...............................................................................................9-13
10 Specifications .................................................................................................................................10-1
10.1 Overview ................................................................................................................................10-1
10.2 Facility Requirements ............................................................................................................10-1
10.2.1 System Dimensions ..................................................................................................10-1
10.3 Specifications.........................................................................................................................10-2
10.4 Stability Analysis ....................................................................................................................10-3
Table of Contents ix
Appendix A Material Safety Information.......................................................................................... A-1
A.1 Introduction ..............................................................................................................................A-1
A.2 MSDS - MULTEMP PS NO 2-A 07-350...................................................................................A-1
A.3 MSDS Moly-Graph® Extreme Pressure Multi-Purpose Grease..............................................A-4
Appendix B Block Diagrams ............................................................................................................. B-1
B.1 Safety First...............................................................................................................................B-1
B.2 List of Pneumatic and Electrical Diagrams ..............................................................................B-1
B.3 Power Manager Connections ..................................................................................................B-2
B.4 Conveyor/Heater Module Connections....................................................................................B-3
Appendix C Parts List........................................................................................................................ C-1
C.1 Overview ................................................................................................................................. C-1
C.2 Safety First.............................................................................................................................. C-1
C.3 Spare Parts List ...................................................................................................................... C-1
Glossary ................................................................................................................................................... G-1
Index ........................................................................................................................................................... I-1
x Table of Contents
Table of Figures
Figure 1-1 Front View........................................................................................................................... 1-8
Figure 1-2 Front View (Open Dispensing Area - Dual Conveyors)...................................................... 1-9
Figure 1-3 Dispensing Area ...............................................................................................................1-10
Figure 1-4 Service Station..................................................................................................................1-11
Figure 1-5 Front Panel .......................................................................................................................1-12
Figure 1-6 Front Cabinet (Dual Conveyor System shown) ................................................................1-13
Figure 1-7 Rear View .........................................................................................................................1-15
Figure 1-8 Rear View Open ...............................................................................................................1-16
Figure 1-9 Rear Cabinet (Dual Conveyor Configuration Shown).......................................................1-17
Figure 1-10 Rear Panel Connections...................................................................................................1-18
Figure 2-1 Safety Warning Labels (Front Cover) .................................................................................2-7

Figure 2-2 Safety Warning Labels (Front Inside Panel)....................................................................... 2-7
Figure 2-3 Safety Warning Labels (Dispensing Area) ......................................................................... 2-8
Figure 2-4 Safety Warning Labels (Conveyor)..................................................................................... 2-9
Figure 2-5 Safety Warning Labels (Rear)) ........................................................................................... 2-9
Figure 2-6 Safety Warning Labels - Power Manager.........................................................................2-10
Figure 2-7 Laser Height Sensor .........................................................................................................2-11
Figure 2-8 EMO/Main Circuit Breaker Locations ...............................................................................2-12
Figure 2-9 Interlock Active Message..................................................................................................2-13
Figure 2-10 Clear Interlock Message...................................................................................................2-13
Figure 2-11 Electrical/Pneumatical Lockout/Tagout ............................................................................2-15
Figure 3-1 Removing the Shipping Brackets ....................................................................................... 3-2

Figure 3-2 Adjusting the Levelers ........................................................................................................ 3-3
Figure 3-3 Dispensing Head Stopper Locations .................................................................................. 3-5
Figure 3-4 Removing the Z-Head Bracket ........................................................................................... 3-5
Figure 3-5 Removing the Service Station Packing Tape ..................................................................... 3-6
Figure 3-6 Removing the Front Cover ................................................................................................. 3-6
Figure 3-7 S-920 Dispensing System Scale Stem............................................................................... 3-7
Figure 3-8 Leveling the Dispensing System – X-Axis .......................................................................... 3-8
Figure 3-9 Dispensing System Levelers (Feet).................................................................................... 3-8
Figure 3-10 Leveling the Dispensing System – Y-Axis .......................................................................... 3-9
Figure 3-11 Leveling the Scale ............................................................................................................3-10
Figure 3-12 Replacing the Scale Cover ...............................................................................................3-10
Figure 3-13 Setting up the Weigh Station ............................................................................................3-11
Figure 3-14 Purge Station ....................................................................................................................3-11
Figure 3-15 Installing the Light Beacon ...............................................................................................3-12
Figure 3-16 Windows Explorer - FmXP Directory ................................................................................3-13
Figure 3-17 Dispensing System Serial Number Label .........................................................................3-13
Figure 3-18 Aligning the Laptop Computer to the Tray........................................................................3-14
Figure 3-19 Camera (Rear View) .........................................................................................................3-15
Figure 3-20 Anchoring the Dispensing System....................................................................................3-16
Figure 4-1 Main Power Circuit Breaker and Cable .............................................................................. 4-2
Figure 4-2 Connecting the Power and Air Supply..................................................................................... 4-3
Figure 4-3 FmXP Message 30416 ....................................................................................................... 4-5
Figure 4-4 FmXP Main Window ........................................................................................................... 4-5
Figure 4-5 Setup Conveyor Window .................................................................................................... 4-6
Figure 4-6 FmXP - Setup Configuration - Conveyor ............................................................................ 4-7
Figure 4-7 FmXP Scale Setup ............................................................................................................. 4-8
Figure 4-8 FmXP - Setup Vision .......................................................................................................... 4-9
Figure 4-9 Air Regulator and Gauge Locations .................................................................................4-13
Figure 4-10 Dispenser I/O (Outputs 32-63) .........................................................................................4-14
Figure 4-11 Conveyor Jog Commands Dialog Box..............................................................................4-16
Figure 4-12 SMEMA Connections........................................................................................................4-18
Table of Contents xi
Figure 4-13 Conveyor I/O (Outputs 0-31) ............................................................................................4-19
Figure 4-14 Conveyor I/O (Inputs 0-31) ...............................................................................................4-20
Figure 4-15 Setup Conveyors ..............................................................................................................4-23
Figure 4-16 Dispenser I/O (Outputs 0-31) ...........................................................................................4-24
Figure 4-17 FmXP Jog Window ...........................................................................................................4-25
Figure 4-18 Vision and Reticles Set-up Dialog Boxes .........................................................................4-27
Figure 4-19 Machine Offsets Parameters Dialog Box..........................................................................4-30
Figure 4-20 Dispenser I/O (Inputs 0-31) ..............................................................................................4-31
Figure 4-21 Dispenser I/O Test (Outputs 32-63) .................................................................................4-32
Figure 4-22 Service Station..................................................................................................................4-33
Figure 4-23 Scale Setup ......................................................................................................................4-34
Figure 4-24 Heater Control Window ....................................................................................................4-36
Figure 4-25 Valve Offset Dialog Boxes................................................................................................4-39
Figure 4-26 Machine Setup Dialog Box ...............................................................................................4-40
Figure 4-27 Program Open Window ....................................................................................................4-41
Figure 4-28 Run Window .....................................................................................................................4-41
Figure 5-1 Focusing the Camera ......................................................................................................... 5-2

Figure 5-2 FmXP Setup Vision............................................................................................................. 5-3
Figure 5-3 FmXP Calibration Window.................................................................................................. 5-4
Figure 5-4 Adjusting the Service Station Height .................................................................................. 5-5
Figure 5-5 Scale Cover Removal ......................................................................................................... 5-6
Figure 5-6 Leveling the Scale .............................................................................................................. 5-6
Figure 5-7 Setup Scale - Scale Operations Tab ..................................................................................5-7
Figure 5-8 Setup Scale - Advanced Tab.............................................................................................. 5-7
Figure 5-9 FmXP Calibrating Scale Message......................................................................................5-8
Figure 5-10 FmXP Calibration Complete Message ............................................................................... 5-8
Figure 5-11 Z-head Counter Balance Force Adjustment ....................................................................... 5-9
Figure 5-12 Adjusting the Height Sensor Probe ..................................................................................5-10
Figure 5-13 Board Sensor - Side View ................................................................................................5-11
Figure 5-14 Board Sensor - Top View .................................................................................................5-11
Figure 5-15 Initializing the Digital Gauge .............................................................................................5-13
Figure 5-16 Beacon Configuration Dialog Box.....................................................................................5-14
Figure 5-17 Beacon Configuration Dialog Box.....................................................................................5-15
Figure 5-18 Dispenser I/O Dialog Box .................................................................................................5-15
Figure 6-1 Valve Pneumatic and Electrical Connections (DV-8000 shown)........................................ 6-2
Figure 6-2 Valve Pneumatic and Electrical Connections (DJ-9000 shown) ........................................ 6-3
Figure 6-3 Main Air Pressure Regulator and Gauge Sets ................................................................... 6-4
Figure 6-4 Adjusting the Valve and Fluid Pressure Regulators ........................................................... 6-5
Figure 6-5 Low Air Pressure Detection Window .................................................................................. 6-6
Figure 6-6 Setup Valve Offsets Dialog Box ......................................................................................... 6-7
Figure 6-7 FmXP Error Message 30694 .............................................................................................. 6-8
Figure 6-8 Production Window - Teaching Safe Z Height ................................................................... 6-9
Figure 6-9 Teaching Safe Z Height...................................................................................................... 6-9
Figure 6-10 Conveyor Position Controls ..............................................................................................6-10
Figure 6-11 Dispensing Head Position Controls ..................................................................................6-12
Figure 6-12 Conveyor Position Controls ..............................................................................................6-15
Figure 6-13 Camera LED's (Rear View) ..............................................................................................6-16
Figure 6-14 Camera Lighting Adjustment ............................................................................................6-18
Figure 6-15 Fluidmove Production Window .........................................................................................6-20
Figure 6-16 Heater Control Window ....................................................................................................6-21
Figure 6-17 FmXP Fluid Manager........................................................................................................6-22
Figure 6-18 Workpiece Alignment Options ..........................................................................................6-23
Figure 6-19 Create Workpiece .............................................................................................................6-24
Figure 6-20 Machine Setup Window....................................................................................................6-25
Figure 6-21 Programming Window ......................................................................................................6-26
Figure 6-22 Program Commands Toolbar ...........................................................................................6-27
xii Table of Contents

Figure 6-23 Dispensing Elements Toolbar...........................................................................................6-28
Figure 6-24 Programming Window - Conveyor Block Commands ......................................................6-29
Figure 6-25 Sample Dual Conveyor Program......................................................................................6-30
Figure 6-26 Creating a Pattern.............................................................................................................6-30
Figure 6-27 Create Pattern Dialog Box................................................................................................6-31
Figure 6-28 Selecting a Pattern ...........................................................................................................6-31
Figure 6-29 Placing Patterns................................................................................................................6-32
Figure 6-30 Dry Run.............................................................................................................................6-33
Figure 6-31 Production Window – Setup Scripts .................................................................................6-34
Figure 6-32 FmXP Open Window ........................................................................................................6-35
Figure 6-33 Run Window .....................................................................................................................6-35
Figure 7-1 Replacing the Purge and Weigh Station Cups ................................................................... 7-5
Figure 7-2 Replacing the Purge Boot................................................................................................... 7-6
Figure 7-3 Draining the Water Traps ................................................................................................... 7-7
Figure 7-4 Removing the X-Axis Covers.............................................................................................. 7-8
Figure 7-5 Removing the Y-Axis Covers.............................................................................................. 7-8
Figure 7-6 Removing the Rear Cable Covers......................................................................................7-9
Figure 7-7 Lubricating the X-Axis Linear Guides ...............................................................................7-12
Figure 7-8 Lubricating Y-Axis Linear Guides .....................................................................................7-12
Figure 7-9 Tensioning the Cables......................................................................................................7-13
Figure 7-10 Tensioning the Conveyor Belts.........................................................................................7-14
Figure 8-1 Scale Flex Circuit Orientation ............................................................................................. 8-9

Figure 8-2 Scale Dip Switch Configuration ........................................................................................8-10
Figure 8-3 FmXP Scale Setup Menu .................................................................................................8-11
Figure 8-4 Scale Error Message ........................................................................................................8-11
Figure 8-5 Tactile Sensor Exposed....................................................................................................8-13
Figure 9-1 Gaining Access to Dispensing System Components ......................................................... 9-4

Figure 9-2 Conveyor Belt Removal/Installation.................................................................................... 9-6
Figure 9-3 Camera Lens Replacement................................................................................................ 9-8
Figure 9-4 Removing the Z-Head Panels ............................................................................................ 9-9
Figure 9-5 Height Sensor Probe ........................................................................................................9-10
Figure 9-6 Replacing the SDHC Board-mounted Fuse .....................................................................9-12
Figure 9-7 Replacing a Panel-mounted Fuse ....................................................................................9-13
Figure B-1 Power Manager Connections .............................................................................................B-2

Figure B-2 Conveyor/Heater Module Connections...............................................................................B-3
Table of Contents xiii

Table of Tables
Table 2-1 Safety Warning Labels ....................................................................................................... 2-6
Table 2-2 Laser Height Sensor Specifications..................................................................................2-11
Table 2-3 Beacon Color Indications..................................................................................................2-16
Table 4-1 SMEMA Communication Test Matrix................................................................................4-19

Table 4-2 Heater Set Points..............................................................................................................4-37
Table 6-1 Conveyor Position Controls: Jog Distance(1) ....................................................................6-11

Table 6-2 Dispensing Head Position Controls: Jog Distance and Velocity(1) ...................................6-12
Table 6-3 Position Control Commands.............................................................................................6-13
Table 6-4 Position Control Keyboard Commands ............................................................................6-14
Table 6-5 Genie Camera States .......................................................................................................6-16
Table 6-6 Camera Status Indicators .................................................................................................6-16
Table 7-1 Routine Maintenance Procedures ...................................................................................... 7-2

Table 7-2 Purge Boot Colors, Sizes, and Compatible Needles.......................................................... 7-3
Table 8-1 System Power Troubleshooting.......................................................................................... 8-2

Table 8-2 System Accuracy ................................................................................................................ 8-3
Table 8-3 Pneumatic Troubleshooting................................................................................................ 8-4
Table 8-4 FmXP Startup ..................................................................................................................... 8-5
Table 8-5 Dispensing Head Troubleshooting ..................................................................................... 8-6
Table 8-6 Height Sensor Troubleshooting .......................................................................................... 8-7
Table 8-7 Laser Height Sensor Troubleshooting ................................................................................ 8-7
Table 8-8 Vision System Troubleshooting .......................................................................................... 8-8
Table 8-9 Scale Troubleshooting........................................................................................................ 8-9
Table 8-10 Needle Heater Troubleshooting........................................................................................8-12
Table 8-11 Tactile Sensor Troubleshooting........................................................................................8-12
Table 8-12 Substrate Heater Troubleshooting....................................................................................8-14
Table 8-13 Conveyor Troubleshooting ...............................................................................................8-14
Table 9-1 Replaceable Fuses ...........................................................................................................9-11
Table 10-1 Facility Requirements .......................................................................................................10-1

Table 10-2 System Dimensions Diagram ...........................................................................................10-1
Table 10-3 Specifications....................................................................................................................10-2
Table 10-4 Stability Analysis...............................................................................................................10-3
Table B-1 Block Diagrams...................................................................................................................B-1

Table C-1 Spare Parts List ................................................................................................................. C-1
xiv Table of Contents

1 Introduction
1.1 Overview
The Spectrum™ 920 Series system is 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 920 Series (S-920) 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-920 Dispensing System. This section covers the following topics:
• System Description • Standard Equipment and Features

• Manuals • Optional Equipment
• Training • Dispensing Valves
• Supported Dispensing Fluids • System Features
1.2 System Description

The S-920 provides exceptional dispensing accuracy and repeatability, and is ideal for high-volume
manufacturing. The S-920 system performs with a wide range of fluids, processes, and substrates used in
semiconductor packaging and assembly. The S-920 easily integrates with jets and valves from Asymtek,
including the DispenseJet DJ-9000.
The system utilizes Asymtek’s Fluidmove® software, the same industry-proven software package used on
all Asymtek dispensing systems. Fluidmove and the S-920’s 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:
• Underfill • Lid Seal
• BGA Solder Ball Reinforcement • Chip Encapsulation
• Chip Scale Packaging • No Flow Underfill
• Cavity Fill • Conductive Adhesive
• Die Attach • Life Sciences
1.3 Safety First

Operation of your S-920 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 1-1
1.4 Manuals
Your Spectrum Series S-920 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-920
Dispensing System, depending on system configuration.
• Fluidmove User Guide
• Dispensing Valve Owner’s Manual (specific to your valve)
• Original Equipment Manufacturer Manuals (as applicable)
1.5 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-920 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.
1-2 Introduction
1.7 Standard Equipment and Features
1.7.1 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 camera’s 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 which 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.
1.7.2 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.
1.7.3 Computer System

The Computer System consists of a laptop computer with an adjustable height bracket. It runs Fluidmove
for Windows XP (FmXP) software.
1.7.4 Conveyor
The Conveyor allows parts to be conveyed by a flat belt from upstream systems, to the dispensing station,
and then to downstream systems. The system is available with either a single lane or dual lane conveyor
configuration. 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. Previous technology only allowed one part to move at a time.
1.7.4.1 Single Lane
The Single Lane Conveyor provides continuous part processing.
Introduction 1-3
1.7.4.2 Dual Lane
The Dual Lane Conveyor allows parallel processing on two lanes for continuous dispensing, eliminating
lost time in non-dispensing activities, such as material flow-out and substrate loading and unloading. 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.
1.7.5 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.
1.7.6 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.
1.7.7 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.
1.7.8 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.
1.7.9 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.
1.7.10 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.
1.7.11 Precision Pneumatics
1.7.11.1 Digital Gauges

The S-920 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 5.12 Initializing the Digital
Gauges for additional information.
1-4 Introduction
1.7.11.2 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 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.
1.7.12 Safety Features
1.7.12.1 Emergency Machine Off (EMO)

The S-920 Series Dispensing System features two EMO buttons 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.
1.7.12.2 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.
1.7.13 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.
1.7.14 System Light

The dispensing system features a light that illuminates the dispensing area when the system is on.
1.7.15 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.
1.8 Optional Equipment

1.8.1 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.
1.8.2 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.
Introduction 1-5
1.8.3 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.
1.8.4 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.
1.8.5 Substrate Heaters
Dedicated, heated tooling is often required to enable proper fluid flow once dispensed on the substrate.
The S-920 provides for either contact or non-contact impingement heating. Heated tooling is custom
designed depending on the substrate and carrier type. 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.
1.8.5.1 Rapid Response Heater™ System
Asymtek’s 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.
1.8.5.2 Controlled Process Heat (CpH™)
Asymtek’s 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.
1-6 Introduction
1.9 Dispensing Valves
The Spectrum Series S-920 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 1-7
1.10 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 1-10.
1
Figure 1-1 Front View
1-8 Introduction
4
Figure 1-2 Front View (Open Dispensing Area - Dual Conveyors)
Item Name Description

The Light Beacon is a device that displays system status and can warn
1 Light Beacon
the operator when fault conditions exist.
The Dispensing System features a laptop computer which runs the
2 Computer
Fluidmove for Windows XP (FmXP) dispensing software.
Digital Valve, Fluid and Coax/Cooling Pressure Gauges, ON and OFF
3 Front Panel Buttons, Emergency Stop, and Grounding Strap Jacks are located on the
Front Panel. See 1.10.3 Front Panel.
The Ventilation Exhaust System works in conjunction with the facility
4 Exhaust Vent
exhaust system to remove excess heat, fumes, or odors.
The Dispensing Area is where all dispensing operations take place. See
5 Dispensing Area
1.10.1 Dispensing Area.
Introduction 1-9
1.10.1 Dispensing Area
3
4

The compact, high resolution, black and white camera and lens are
1 Vision System part of the Vision System. They are mounted on the Dispensing
Head and are used to view work surfaces.
The Dispensing Valve (DJ-9000 shown) controls or regulates the
2 Dispensing Valve flow of material from a pressurized reservoir, such as a syringe.
Devices include valves and jets.
The Conveyor transports the workpiece from an upstream system to
the dispensing station and then to downstream systems. All
3 Conveyor
Conveyors are SMEMA compatible and have adjustable rear rail
width.
The Service Station consists of the Dispense Tile, Tactile Needle
4 Service Station
Sensor, Purge Station, and Scale. See Figure 1-4.
The Height Sensor is a device that measures substrate height and
Height Sensor sends a signal to the system computer. The height information is
(NOT SHOWN) used to position the dispensing needle at an exact distance above
the workpiece surface.
Figure 1-3 Dispensing Area
1-10 Introduction
1.10.2 Service Station
1 2
3
4

The Dispense Tile is a ceramic tile dispensed upon during system
1 Dispense Tile
offset routines.
The Tactile Needle Sensor measures needle/nozzle position in the
2 Tactile Needle Sensor
Z-axis.
The Purge Station consists of a small reservoir that contains a
disposable plastic cup and is attached to a vacuum generator. Air
3 Purge Station
flowing through the purge boot into the cup removes excess fluid on
the dispensing valve needle/nozzle.
The scale measures the weight of dispensed fluid and sends the
4 Scale
information to the Fluidmove software for mass flow calibration.
Figure 1-4 Service Station
Introduction 1-11
1.10.3 Front Panel
2
7
6 5
4

Grounding straps worn by the operator plug into this jack to prevent
1 Grounding Strap Jack electrostatic discharge (ESD) damage to workpieces during
dispensing operations.
The green ON (l) button illuminates and switches ON power to the
dispensing system mechanics. The black OFF (0) button shuts down
2 ON/OFF Buttons
the dispensing activity and vents the air pressure. The laptop
computer power remains ON.
The Front EMO is a built-in safety feature located on the front panel
Front EMO (Emergency of the dispensing system. Activating the EMO vents all pressure in
3
Machine Off) the pneumatic system, de-energizes the servo power, and cuts
power to all system components except the computer and monitor.
4 Computer Connection Connects the dispensing system to the laptop computer.
The Fluid Pressure Gauge displays the air pressure supplied to the
5 Fluid Pressure Gauge
fluid syringe.
The Valve Pressure Gauge displays the air pressure supplied to the
6 Valve Pressure Gauge
dispensing valve.
The Cooling/Coaxial Gauge displays the air pressure supplied to
Cooling/Coaxial Air
7 either the valve cooling air port or the DJ-2200 coaxial air assist,
Pressure Gauge
depending on machine configuration.
Figure 1-5 Front Panel
1-12 Introduction
1.10.4 Front Cabinet
2 3 4
1

Controls the vacuum level applied to fluid pressure air line when pressure
Fluid Vacuum
1 is turned off. The vacuum helps prevent residual pressure buildup in the
Suckback
syringe that may cause fluid drip.
Cooling/Coaxial Air Controls the air pressure supplied to either the valve cooling air port or
2
Regulator the DJ-2200 coaxial air assist, depending on machine configuration.
Valve Pressure
3 Controls the air pressure supplied to the dispensing valve.
Regulator
Fluid Pressure
4 Controls the air pressure supplied to the fluid syringe.
Regulator
Controls all conveyor functions (motors, sensors, pneumatics, etc.). It
Conveyor/Heater receives power from the Power Manager and supplies AC power to the
5
Modules substrate heaters in the dispensing area. If your system is equipped with
dual conveyors, two Conveyor/Heater Modules are required.
Impingement Control the airflow through the Impingement Heaters in the dispensing
6
Flowmeters chamber. A manual shut-off valve controls the air going to the flowmeters.
Controls the air pressure supplied to the stop pins and lift tables. The
Tooling Air
7 regulator receives air from the main air regulator located on the back of
Regulator
the dispensing system.
Figure 1-6 Front Cabinet (Dual Conveyor System shown)
Introduction 1-13
1.10.5 Rear View
Figure 1-7A Rear View
1-14 Introduction
Conveyor/Heater
Pneumatics
Fluid/Valve
Pneumatics
6
Figure 1-7B
Main Air Regulator and Gauge Sets (Close-up)

The system is equipped with two Main Air Regulators and Gauges. They
control the air pressure supplied to all other system regulators. The
Main Air Regulator
1 regulators contain built-in air filter and water traps to ensure that only
and Gauge
clean, dry air enters the system. Refer to 6.5 Adjusting the Air Pressure
for the recommended pressure settings and other important information.
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
2 Rear EMO
pneumatic system, de-energizes the servo power, and cuts power to all
system components except the computer.
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
3 Main Circuit Breaker
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.
The Main Power Cord connects the dispensing system to the facility
4 Main Power Cord
power supply.
Rear Panel
5 See 1.10.8 Rear Panel Connections.
Connections
The facility air supply may contain moisture that can damage the
6 Water Trap dispensing system. The Water Trap condenses this moisture before it
enters the dispenser pneumatic system.
Figure 1-7 Rear View
Introduction 1-15
1.10.6 Rear View Open

The Upper E-Pan houses the Dispense Head Controller, Z-Axis Servo
1 Upper E-Pan
Amp, and Applicator Pneumatics.
The Lower E-Pan houses the Mainboard, X-Y Axis Servo Amps, Main Air
2 Lower E-Pan
Pneumatic Valves, and Conveyor Pneumatic Valves.
The Rear Cabinet houses the Power Manager and the Conveyor/Heater
3 Rear Cabinet
Module(s). See 1.10.7 Rear Cabinet.
Rear Panel
4 See 1.10.8 Rear Panel Connections.
Connections
Figure 1-8 Rear View Open
1-16 Introduction
1.10.7 Rear Cabinet
1

The Power Manager is located inside the rear cabinet. It houses the
Main Circuit Breaker and the Main Power Inlet. It also contains the
1 Power Manager
EMO circuitry. The EMO button, the green ON (I) button, and the black
OFF (0) button are directly connected to the Power Manager.
The Conveyor/Heater Module receives power from the Power Manager
Conveyor/Heater
and supplies AC power to the substrate heaters in the dispensing area.
2 Module (Dual Conveyor
It also controls all conveyor functions (motors, sensors, pneumatics,
Configuration shown)
etc.).
Figure 1-9 Rear Cabinet (Dual Conveyor Configuration Shown)
Introduction 1-17
1.10.8 Rear Panel Connections

Allows for SMEMA communication between the dispensing system and
1 SMEMA 1 Upstream
an upstream machine such as a loader.
SMEMA 1 Allows for SMEMA communication between the dispensing system
2
Downstream and a downstream machine such as an unloader.
Allows the dispensing system to communicate with an upstream loader
3 Loader Upstream
for programming purposes only.
Allows the dispensing system to communicate with a downstream
4 Loader Downstream
unloader for programming purposes only.
Allows the dispensing system to communicate with a host computer on a
5 Network
local area network. Necessary for SECS/GEM functionality.
Allows for SMEMA communication between the dispensing system and a
6 SMEMA 2 Upstream
second upstream machine such as a loader.
SMEMA 3 Allows for SMEMA communication between the dispensing system
7
Downstream and a second downstream machine such as an unloader.
Figure 1-10 Rear Panel Connections
1-18 Introduction
2 Safety
2.1 Overview
This section is intended to provide basic safety information necessary for operating and servicing the
Spectrum S-920 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.
" 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.
2.2 Facility Requirements

To ensure optimal performance and safety, it is necessary to install the dispensing system in a facility that
meets the necessary requirements. See 10.2 Facility Requirements. 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:
• 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
Safety 2-1
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-920 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 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.
• Where volatile organic compound (VOC) emissions can exceed safe limits, facility
ventilation and filtration systems must be operational.
2-2 Safety
• 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.
2.4.2 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 manufacturer’s 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.
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 manufacturer’s 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.
Safety 2-3
2.5 Lifting and Transport Precautions
2.5.1 Considerations
Before attempting to lift a load, personnel should take into consideration the following factors:
• 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)?
2.5.2 Precautions
When lifting, transporting, and lowering heavy or large loads, personnel should observe the following
precautions:
• 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.
2-4 Safety
2.6 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. See 3.13 Anchoring the Dispensing System.
All personnel should follow facility earthquake safety guidelines. The S-920 Dispensing System is
designed to automatically go into safe mode if electrical power is lost. All hazardous electrical and
pneumatic energy is bled out of the system.
For additional information, see 10.4 Stability Analysis.
Safety 2-5
2.7 Safety Warning Labels
Safety warning labels on the S-920 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

Part
Warning Type Symbol Hazard
Number (1)
(1) This label warns of a high-voltage component that can
70-0116-00
Electrical cause shock, burn, or death. Use extreme caution
or
(Shock Hazard) (2) when working in or around these areas.
70-0050-00 Disconnect and lock out power before servicing.
This label identifies a component that requires special
General (2)
attention. Can cause serious bodily harm to the user.
Warning 70-0055-00
Disconnect and lock out power before servicing.
(1)
70-0118-00 This label warns that the labeled component is heavy
Heavy Object or and can cause muscle strain or back injury to
(Lifting Hazard) (2)
196666 personnel trying to lift it.
(1) This label warns of moving parts that can cause
70-0120-00
Moving Parts serious injury to hands or fingers. Keep hands away
or from moving parts.
Present
198883 (2) Disconnect and lock out power before servicing.
Hand This label warns of moving parts that can cause
(1)
Entanglement/ 7214364 serious injury to hands and fingers.
Moving Material Disconnect and lock out power before servicing.
(1) Thermal warning labels identify potentially hot
70-0121-00
components and surfaces. Use extreme caution when
Hot Surface or
(2) working on or around these areas.
70-2150-00 Can cause severe burns.
Warns personnel of the possibility of hazardous
(2)
Laser 7206858 radiation exposure if your system is equipped with a
Laser Height Sensor or other laser device.
Consult
Warns personnel to read Operator’s Manual before
Operator’s 7206854
operating machine.
Manual
Notes: (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.
2-6 Safety
1
Item Description
1 Read Manual Label
Figure 2-1 Safety Warning Labels (Front Cover)
Item Description
1 Laser Radiation Warning Label (if Laser Height Sensor present)
Figure 2-2 Safety Warning Labels (Front Inside Panel)
Safety 2-7
1
Item Description
1 Laser Radiation Warning Label (if Laser Height Sensor present)
2 Hot Surface Label (if heaters present)
Figure 2-3 Safety Warning Labels (Dispensing Area)
2-8 Safety
1 2
Item Description
1 Hot Surface Label (if heaters present)
2 Moving Parts Present Label
Figure 2-4 Safety Warning Labels (Conveyor)
Item Description
1 Hand Entanglement Label
2 Hot Surface Label
Figure 2-5 Safety Warning Labels (Rear))
Safety 2-9
2
Item Description
1 Electrical Warning Label
2 General Warning Label
Figure 2-6 Safety Warning Labels - Power Manager
2-10 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-920 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:
• Operate the laser height sensor in accordance with

the operator’s 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
2.8.1 Laser Height Sensor Specifications
Table 2-2 contains Laser Height Sensor specifications.
Table 2-2 Laser Height Sensor Specifications

Classification Class 2 Laser Product
Light Source Red semiconductor laser (λ = 670 nm)
Maximum Output 1.0 mW
Emitted Wavelength 670 nm
Spot Diameter 110 μm at reference distance
Reference Distance and Range 70 mm ± 15 mm (2.75 in. ± 0.6 in.)
0 to 55 °C
Environmental Range
0 to 85% RH
Ambient Light 4,000 lux max
Safety 2-11
2.9 Emergency Shutdown
In the event of an emergency or malfunction, press the EMO button. The S-920 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.
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.
2
1
Item Description
1 Front EMO
2 Rear EMO
Figure 2-8 EMO/Main Circuit Breaker Locations
WARNING! 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.
2-12 Safety
2.9.1 Emergency Shutdown Situations
As a minimum, activate the EMO in the following situations:

• 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.
2.9.2 Emergency Shutdown Recovery
WARNING! 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.
" NOTE If the main circuit breaker has been tripped, you will need to restart the dispensing
system. Refer to 6.3 Startup for instructions.
To recover after an Emergency Shutdown:

1. Locate and remedy the cause of the emergency shutdown. If necessary, refer to Section 8 -
Troubleshooting.
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 Figure 2-10 Clear Interlock Message
Safety 2-13
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 6.12 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-920 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-920 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.
! Ensure that the owner, date, reason, and estimated time for repair are clearly marked on
the 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.
! Ensure the owner, date, reason, and estimated time to repair are clearly marked on the
tag.
6. 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.
2-14 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 2-15
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. Refer
to the Fluidmove User Guide or Online Help for details.
Refer to Section 8 - Troubleshooting 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.
B. Flashing – General error or vision error. Software driven error message is
displayed on the computer monitor.
RED
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.
A. Solid – Hood is open (Interlock activated).
B. Solid or Flashing - Software has been configured to display a solid or
YELLOW flashing yellow light.
OPERATION
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
2-16 Safety
3 Installation
3.1 Overview
This section describes installation procedures for the Spectrum Series S-920 Dispensing System and
covers the following topics:
• Uncrating and Placing the Dispensing System
• Unpacking the Dispensing Chamber
• Leveling the Dispensing System
• Leveling the Scale
• Setting Up the Service Station
• Installing the Light Beacon
• Installing the Laptop Computer
• Installing the Camera
• Anchoring the Dispensing System
3.2 Safety First

CAUTION! Installation procedures should only be performed by a trained service technician.

meets the requirements. If you have any questions about facility requirements, please contact Asymtek
Technical Support. See 10.2 Facility Requirements for detailed information.
3.4 Tools and Materials Needed

• 3 mm hex key • 1/2-inch wrench
• 9/16-inch wrench • Phillips Screwdriver (included in tool kit)
• Band Cutter • 1 ½-inch wrench (included in tool kit)
• Personal Protective Equipment • Diagonal-cut pliers
• Hammer • Forklift
• Flat Bar • Box Level
Installation 3-1
3.5 Uncrating and Placing the Dispensing System
To uncrate and place the dispensing system:
1. Check the “Tip & Tell” and "Shockwatch" devices, both on the outside of the shipping crate
and on the dispensing system, to make sure that the dispensing system has not been dropped
or tipped. If any of these devices has been activated, contact Asymtek.
" NOTE If the dispensing system is being installed in a clean room, uncrate the system,
remove all packaging material, including wrapping paper and tape from all parts
and components, before moving into the clean room.
2. Locate and remove the envelope on the outside of the shipping crate. Open the envelope and
locate the shipping list.
! As you unpack each item inside of the box, identify the item, locate it on the shipping list,
and place a checkmark next to the item.
3. Referring to the uncrating instruction sheet, use the flat bar and hammer to remove the lid and
sides of the crate.
WARNING! CAUTION!
Personnel should wear gloves and safety glasses while removing the top and
sides of the crate. Sufficient personnel should be used to lift and control the crate
to prevent serious injury to personnel or damage to the dispensing system.
4. Remove the four machine-to-crate shipping brackets attached to the pallet using a 1/2-inch
wrench and 9/16-inch wrench (Figure 3-1).
6
8
1
3
4
Item Description Item Description

1 Foot Restraint Bracket 5 Lag Bolts and Washers
2 Hex Head Screws and Washers 6 Hex Nuts and Washers
3 Leveler (foot) 7 Post Nut
4 Machine-to-Crate Shipping Bracket 8 Lock Nut
Figure 3-1 Removing the Shipping Brackets
3-2 Installation
5. Remove the two 1/2-inch hex head screws clamping the four shipping brackets to the levelers.
6. When the four shipping brackets have been removed, slide the forklift forks under the front of
the dispensing system between the levelers (feet). Use the forklift to gently lift the dispensing
system off of the crate.
! You may use the shipping crate for future shipping purposes or dispose of according to
local regulations.
! Save the shipping brackets. They can be used later for seismically securing the dispensing
system. See 3.13 Anchoring the Dispensing System.
CAUTION! Lift the dispensing system from the front only. Attempting to lift the dispensing
system from the back or sides may cause serious damage. Place forks between
the front feet, making sure that the blades reach from front to back.
WARNING! CAUTION!
The dispensing system has a high center of gravity causing sensitivity to tipping.
Use extreme caution when lifting and moving the dispensing system.
7. Move the dispensing system over the location where it will be installed.
8. Slowly lower the forklift until the dispensing system conveyor rail is at the approximate
height of the mating upstream and downstream equipment.
9. Raise or lower each leveler (foot) as follows until they all touch the floor:
a. Loosen the 1½-inch lock nut on the leveler. See Figure 3-2.
b. Adjust the 1½-inch post nut to raise or lower each leveler as required.
! Turning the post nut clockwise raises the leveler. Turning the post nut
counterclockwise lowers the leveler.
c. Tighten the lock nut finger tight.
4
2

1 Post 4 Post Nut
2 1 1/2-inch Wrench 5 Lock Nut
3 Leveler (foot)
Figure 3-2 Adjusting the Levelers
Installation 3-3
10. Remove bag and plastic wrap from the machine.
" NOTE Location of packaging materials to be removed is indicated by the presence of

red warning tags.
11. Remove all shrink-wrap and other packing material from the perimeter of the dispensing
system.
12. Remove all perimeter packaging material from the dispensing area.
" NOTE Remove all shrink wrap and packing foam from the system prior to moving it to
a clean room. Also, remove the protective plastic film from the front door. If
necessary, clean the system thoroughly.
3.6 Unpacking the Dispensing Chamber
CAUTION! If the dispensing system is being installed in a clean room, remove all packaging
material and follow facility-recommended procedures before moving components
into the clean room.
To unpack the Dispensing Chamber:
1. Remove all tie wraps, tape, foam packing material, and warning tags from the following
areas:
• Dispensing Head
• Conveyor
• Service Station
" NOTE Location of packaging materials to be removed is indicated by the presence of

red warning tags. The amount, type, and arrangement of packaging materials will
depend on your system’s configuration.
2. Use a 3 mm hex key to loosen the setscrews on the X- and Y-axis Dispensing Head Stoppers.
See Figure 3-3.
3. Remove the stoppers and retain them in a safe place.
3-4 Installation
1
2 3 4

1 Y-Axis Stopper 3 X-Axis Stopper
2 Y-Rail (right side) 4 X-Beam
Figure 3-3 Dispensing Head Stopper Locations
4. Remove the shipping bracket and warning tag attached to the Z-Head by loosening the
screws. See Figure 3-4.
! Retain bracket and hardware for future shipping purposes.
Item Description
1 Allen Head Screws
Figure 3-4 Removing the Z-Head Bracket
Installation 3-5
5. Remove the tape covering the Service Station.
Figure 3-5 Removing the Service Station Packing Tape
6. Remove the front cover by first removing the two screws from the ends of the cover. See
Figure 3-6.
7. Lift the cover up and away from the machine.
CAUTION! The scale stem is extremely sensitive. Hitting or applying pressure to the scale
stem may damage the scale stem. See Figure 3-7.
Figure 3-6 Removing the Front Cover
3-6 Installation
8. Loosen the strap covering the scale and remove the warning tag from the scale unit.
" NOTE Do not remove the strap. The strap may be needed when moving or shipping
machine.
9. Leave the scale uncovered until it has been leveled. See 3.8 Leveling the Scale.
Scale Stem
Figure 3-7 S-920 Dispensing System Scale Stem
Installation 3-7
3.7 Leveling the Dispensing System
WARNING! CAUTION!
This procedure should only be performed by a trained service technician. The
system should be shutdown for service before performing this procedure. Refer
to 2.11 Service Shutdown.
1. Place the box level on the conveyor rail along the X-axis (Figure 3-8).
2. Observe the position of the bubble within the level’s window.
! The bubble should be centered, indicating the dispensing system is level from
side-to-side.
Figure 3-8 Leveling the Dispensing System – X-Axis
3. If necessary, adjust the levelers (Figure 3-9) of the dispensing system as follows:
a. Loosen the 1 1/2-inch lock nut on the leveler.
b. Turn the 1 1/2-inch post nut in the desired direction until the level’s bubble is centered,
indicating that the system is level from side-to-side.
! Turning the post nut clockwise raises the dispensing system. Turning the post nut
counterclockwise lowers the dispensing system.
c. Tighten the 1 1/2-inch lock nut on the leveler.
Lock Nut Post Nut
Leveler
Figure 3-9 Dispensing System Levelers (Feet)
3-8 Installation
4. Place the box level between the front and rear conveyor rails along the Y-axis (Figure 3-10).
5. Observe the position of the bubble within the level’s window.
! The bubble should be centered, indicating dispensing system is level from front-to-back.
Figure 3-10 Leveling the Dispensing System – Y-Axis
6. If necessary, adjust the levelers (Figure 3-9) of the dispensing system as follows:
a. Loosen the 1 1/2-inch lock nut on the leveler.
b. Turn the 1 1/2-inch post nut in the desired direction until the level’s bubble is centered,
indicating that the system is level from front-to-back.
! Turning the post nut clockwise raises the dispensing system. Turning the post nut
counterclockwise lowers the dispensing system.
c. Tighten the 1 1/2-inch lock nut on the leveler.
7. Check the system for stability by putting your hands on top of the dispensing system in one
corner and pressing down. If one leveler is lower or higher than the others, the dispensing
system will rock back and forth. Adjust the levelers so that they are all bearing the weight
equally.
8. Re-level the dispensing system from side-to-side and from front-to-back, if necessary.
CAUTION! The scale stem is extremely sensitive. Be careful not to hit or apply pressure to
the scale stem (Figure 3-7).
Installation 3-9
3.8 Leveling the Scale
1. Check the scale level bubble.
! If the bubble is not centered, the scale must be leveled. If the bubble is centered, the scale
is level.
2. Adjust the scale leveling screws until the scale is level (Figure 3-11).
Leveling Screws
Bubble
Figure 3-11 Leveling the Scale
3. Replace the scale cover and reinstall the two mounting screws (Figure 3-12).
Figure 3-12 Replacing the Scale Cover
3-10 Installation
3.9 Setting Up the Service Station
The Service Station consists of both the weigh station and purge station.
1. Place the scale lid, cup, pedestal and breeze shield on the weigh station (Figure 3-13).
Figure 3-13 Setting up the Weigh Station
2. Place the purge cup inside of the purge station (Figure 3-14).
3. Replace the purge station lid.
Figure 3-14 Purge Station
Installation 3-11
3.10 Installing the Light Beacon
1. Remove the two screws holding the top panel in place.
2. Open the top panel.
3. Feed the electrical wiring of the light beacon through the top of the light beacon base.
4. Attach the light beacon to the base using the supplied set screws.
5. Insert the light beacon assembly in the top back right corner of the dispensing system.
6. Tighten the screws.
7. Make the beacon electrical connections.
8. Close the top panel, and reinstall and tighten the screws that hold the top panel in place.
Figure 3-15 Installing the Light Beacon
3.11 Installing the Laptop Computer

1. Remove the laptop computer from its packaging.
2. Power on the laptop computer.
! The laptop computer is shipped from the factory fully charged.

3. Open Windows Explorer.
4. Follow the steps below to verify the serial number of the dispensing system and the laptop
computer are the same.
a. Locate C:\FMXP\SNXXXXX.ACL (Figure 3-16).
b. Compare the serial number located in the name of the ACL file with the serial number on
the dispensing system (see Figure 3-17).
! If the numbers are not the same, contact Asymtek Technical Support.
3-12 Installation
Figure 3-16 Windows Explorer - FmXP Directory
Serial Number Label
Figure 3-17 Dispensing System Serial Number Label
5. Power off the laptop computer.

6. Move the laptop tray arm bracket on the dispensing system so that the laptop tray is facing
forward.
7. Attach both the USB and Network cables to their respective ports on the left side of the
computer.
" NOTE The laptop is adhered to the tray with a hook and loop fastener. Align the laptop
computer before placing it on the tray.
Installation 3-13
8. Align the computer flush with the front of the tray.
9. Offset the left side of the computer 3/8-inch to the right of the two locking screws located on
the left side of the tray.
10. Gently press the laptop onto the base.
11. Attach the power cable to its port on the back of the computer.
12. Attach the locking cable to the laptop.
Figure 3-18 Aligning the Laptop Computer to the Tray
3-14 Installation
3.12 Installing the Camera
3.12.1 Installing the Genie Framework Software
" NOTE The Genie Framework Software is installed at the factory prior to shipping. Follow the
instructions below to reinstall the software.
1. Insert the DALSA Genie CD-ROM.
! If AUTORUN is enabled on your computer, the Genie installation menu opens. If it is not
enabled, use Windows Explorer and browse to the root directory of the CD-ROM.
2. Select launch.exe to start the Genie installation menu and install the software components.
3. Click to install the Genie Framework Software which includes the Network Imaging Driver,
and the Sapera GigE server.
! The procedure will prompt for acceptance of the installation folder for the Genie files.
4. If desired, click to install Sapera LT run-time which includes CamExpert.
5. Follow the on screen prompts and reboot when the installation is complete.
3.12.2 Connecting the Camera

1. Connect a power supply to the Genie camera (Figure 3-19).
2. Connect an RJ45 Ethernet cable from the camera to the laptop computer.
1 2
Item Description
1 Power Connection
2 Ethernet Connection
Figure 3-19 Camera (Rear View)
Installation 3-15
3.13 Anchoring the Dispensing System
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 with two bolts (Figure
3-20). The anchor joint (the point between each anchor bolt and the floor) must be able to withstand at
least 220 lbs (100 kg) of pullout force. For additional information, see 10.4 Stability Analysis.
Item Description
1 Bolt
2 Leveler (Foot)
Figure 3-20 Anchoring the Dispensing System
" NOTE You may also use the shipping brackets to anchor the dispensing system.
WARNING! CAUTION!
The S-920 Dispensing System is designed to be used as an inline system. When
using the dispensing system for batch operations, make sure it is configured with
the optional Conveyor Closeout Kit (P/N 7214478) to prevent personal injury and
equipment/workpiece damage.
3-16 Installation
4 Power-Up and Testing
4.1 Overview
Once you have performed installation of the accessories, you are ready to power up and functionally test
the dispensing system. This section covers the following topics:
• Safety First
• Facility Requirements
• Connecting the Power and Air Supply
• Powering on the Dispensing System
• Starting Fluidmove for Windows (FmXP)
• FmXP Configuration
• Exiting Fluidmove for Windows (FmXP)
• Preliminary System Check
• Component-Level Functional Tests
• System-Level Functional Test
4.2 Safety First


meets the requirements. If you have any questions about facility requirements, please contact Asymtek
Technical Support. See 10.2 Facility Requirements for detailed information.
Power-Up and Testing 4-1

4.4 Connecting the Power and Air Supply
CAUTION! The following procedures should only be performed by a trained

service technician.
Tools and Materials Needed

• Main Power Cable
• Facility Air Hose
To connect the system to facility power:

1. Locate the main power cable, included in the accessories crate.
2. Plug the female end of the power cable into the main power inlet on the rear of the dispensing
system (Figure 4-1).
CAUTION! Make sure that the Main Circuit Breaker is in the OFF (0) position before
connecting the dispensing system to the facility power source.
3. After making sure the main circuit breaker is OFF, plug the male end of the power cable into
the facility power source.
Item Description
2 Main Power Cable
Figure 4-1 Main Power Circuit Breaker and Cable
4-2 Power-Up and Testing

To connect the system to the facility air supply:
CAUTION! Make sure that facility air pressure meets the requirements specified in
10.2 Facility Requirements. Higher pressures will damage the dispensing
system.
1. Locate the facility quick-disconnect air hose (Figure 4-2).

2. Make sure each dispensing system Main Air Regulator is closed. Verify facility air pressure
is at 0 psi.
3. Connect the facility air hose(s) to the quick-disconnect(s) on the Main Air Regulator(s).
4. If not already connected, also connect the air hose(s) to the facility air supply.
! Use pliers to tighten the connections.
5. Slowly open the facility air valve and listen for leaks.
! If there is an air leak, identify the source, shut off facility air, and fix the leak before
proceeding.
1
Item Description
1 Main Air Pressure Regulator and Gauge Sets
2 Quick-Disconnect Fittings
Figure 4-2 Connecting the Power and Air Supply

4.5 Powering on the Dispensing System
" NOTE If necessary, refer to the figures in Section 1 - Introduction to identify system
components.
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. See 4.4 Connecting the Power and Air Supply.
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.
! The system computer should begin the boot up sequence.
7. 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 stated 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 6.8.1 Camera States.
4.6 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 on the Windows
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! Do not press any keys or the touchpad while FmXP is starting unless prompted
to do so.

2. If the FmXP Message 30416 - Dispenser Motor References Not Found appears, click OK to
home the dispenser (Figure 4-3).
Figure 4-3 FmXP Message 30416
! The FmXP Main Window (Figure 4-4) will open.
Figure 4-4 FmXP Main Window
3. Check to make sure the dispensing head is in the proper home position.
" NOTE If you receive any error messages, refer to Section 8 - Troubleshooting or to the

4.7 FmXP Configuration
The FmXP software is configured at the factory prior to shipping. The following section identifies FmXP
configuration for standard components. Your configuration may vary depending on system configuration.
4.7.1 Conveyor Setup
To set up the conveyor:
1. In the FmXP Main Window, select Configuration > Setup Conveyors.

! The Setup Conveyors window opens (Figure 4-5).
Figure 4-5 Setup Conveyor Window
2. Verify that Conveyor 1 Type is CCACLPlus. If not, click on the and select CCACLPlus
from the drop-down list.
3. Click on Configure.
! The Setup Configuration - Conveyor dialog box opens. Default settings are shown in
Figure 4-6.

Figure 4-6 FmXP - Setup Configuration - Conveyor
4. Click on OK to close the configuration dialog box.
" NOTE If your dispensing system is equipped with a dual-lane conveyor, repeat steps 1-4
for Conveyor 2.
5. In the Setup Conveyors dialog box, click on OK.

4.7.2 Scale Setup
1. In the FmXP Main Window, select Configuration > Setup Scale.

! The Scale Setup window opens (Figure 4-7).
2. Verify that Scale Type is SART-WZ. If not, click on the and select SART-WZ from the
drop-down list.
3. Click on OK to exit the Scale Setup window.
Figure 4-7 FmXP Scale Setup

4.7.3 Vision Setup
1. In the FmXP Main Window, select Configuration > Setup Vision.

! The Setup Vision window opens (Figure 4-7).
2. Verify that the Vision System and Video Mixer are GENIE. If not, click on the and select
GENIE from the drop-down list.
3. Click on OK to exit the Setup Vision window.
Figure 4-8 FmXP - Setup Vision
4.8 Exiting Fluidmove for Windows (FmXP)
To exit FmXP, close all open FmXP windows and click Exit in the FmXP Main Window. For
additional information, refer to the Fluidmove User Guide or Online Help.

4.9 Preliminary System Check
Before powering up the dispensing system, follow the steps below to make sure there is sufficient
clearance for the dispensing head to operate in the dispensing chamber.

service technician.
To check Dispensing Head clearance:

1. With the hood still open, manually move the dispensing head throughout the entire
dispensing chamber making sure that it does not encounter any obstacles during its travel.
2. Make sure the pneumatic and electrical cables do not impede the dispensing head travel and
are not in danger of being pinched or snagged.
3. Check the dispensing valve and bracket to make sure that it is mounted securely.
4. Close the dispensing system hood.
4.10 Component-Level Functional Tests

After initially powering up your dispensing system, all major subsystems must be tested to ensure that
they are ready for operation. This section includes functional tests for the following components:
• EMO
• Pneumatic Regulators and Gauges
• Impingement Air Flowmeters
• Light Beacon
• Conveyor and Conveyor Pneumatics
• Dispensing Head and Accessories
• Vision System
• Dispensing Valve Pneumatics
• Tactile Sensor
• Purge Station
• Scale
• Heater Tooling and Needle Heaters

service technician.

• Production Sample Workpieces (3) • Metal Ruler

• Multimeter • 24-bit I/O Tester (P/N TS-03)
• ¾-inch Wrench • Syringe Receiver Heads (2)
• 1½ -inch Wrench • Small Box Level
• 1.5 mm Hex Key • Calibrated Temperature Probe, Digital
• Pen • Removable Thread Locker (P/N 40-0019)
4.10.1 EMO
To check EMO function:

1. Press the EMO button on the front of the dispensing system.
2. Verify that all pneumatic pressure has been vented and power to all components cut, except
the laptop computer.
3. Restart the dispensing system.
a. Turn the EMO knob clockwise until it pops back into position.
b. Press the ON (l) button on the front panel.
4. Repeat Steps 1 and 2 using the Rear EMO.
4.10.2 Pneumatic Regulators and Gauges
Perform the following procedures to check the function of the pneumatic regulators and gauges.
To check the function of the Main Air Pressure Regulator and Gauge:
1. Locate the Main Air Pressure Regulator at the rear of the dispensing system (Figure 4-2).
2. Unlock the regulator by pulling the knob upward and increase the air pressure to 100 psi
(689 kPa) by turning the knob clockwise.
3. Monitor the Main Air Pressure Gauge to make sure that pressure builds at a steady rate.
Listen for any air leaks as the pressure builds.
! If there is an air leak, identify the source, shut off the facility air, and fix the leak
before proceeding.
4. Bleed the air pressure to 0 psi by turning the regulator knob counterclockwise. Verify the
Main Air Pressure Gauge settles at 0 psi.
5. Turn the regulator knob clockwise to increase the air pressure to 100 psi (689 kPa). Lock the
knob by pushing it downward.

To check the function of the Valve Air Pressure Regulator and Digital Gauge:
1. Locate the Valve Air Pressure Regulator inside the front cabinet of the dispensing system
(Figure 4-9).
2. Verify the LED display screen on the front panel is illuminated.
! If the LED is not working, check electrical connections. If still not working, contact
Asymtek Technical Support.
3. Initialize the gauge as specified in 5.12 Initializing the Digital Gauges.
4. After the digital gauge has been initialized, shut off air pressure by turning the Valve Air
Pressure Regulator counterclockwise. Make sure the gauge settles at 0 psi.
5. Increase air pressure to 90 psi (621 kPa) by turning the Valve Air Pressure Regulator
clockwise.
! Valve air pressure may vary depending on dispensing valve used.
6. Monitor the gauge display to make sure that the pressure builds at a steady rate. Listen for
any air leaks as the pressure builds.
! If there is an air leak, identify the source, shut off the facility air, and fix the leak before
proceeding.
! If the gauge is not working properly, contact Asymtek Technical Support.
To check the function of the Fluid Air Pressure Regulator and Digital Gauge:
1. Locate the Fluid Air Pressure Regulator inside the front cabinet of the dispensing system
(Figure 4-9).
2. Verify the LED display screen on the front panel is illuminated.
! If the LED is not working, check electrical connections. If still not working, contact
3. Initialize the gauge as specified in 5.12 Initializing the Digital Gauges.
4. After the Fluid Digital Gauge has been initialized, shut off air pressure by turning the Fluid
Air Pressure Regulator counterclockwise. Make sure the gauge settles at 0 psi.
5. Increase air pressure to 30 to 40 psi (206 to 275 kPa) by turning the Fluid Air Pressure
Regulator clockwise.
6. Monitor the gauge display to make sure that the pressure builds at a steady rate. Listen for
any air leaks as the pressure builds.
proceeding.
! If the gauge is not working properly, contact Asymtek Technical Support.

1 2 3
6
7

1 Vacuum Air Regulator 5 Impingement Air Valve
2 Cooling/Coaxial Air Regulator 6 Tooling Air Regulator and Gauge
3 Valve Air Regulator 7 Impingement Flowmeters
4 Fluid Air Regulator
Figure 4-9 Air Regulator and Gauge Locations
4.10.3 Impingement Air Flowmeters
Perform the following procedure to check function of the Impingement Air Valve and Flowmeters.
To check function of Impingement Air Valve and Flowmeters:

1. Locate the Impingement Air Valve and Flowmeters in the front cabinet of the dispensing
system (Figure 4-9).
2. 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 the 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 the Flowmeters, turn the Flowmeter Adjustment Knobs
clockwise to lessen the flow.
! The flow indicators should show a decrease in airflow.
5. Restore maximum airflow and open the dispensing system hood. Verify air is coming out of
the holes in the impingement heaters at each conveyor station.
! If air is not flowing out of the heater, check the pneumatic connections.

4.10.4 Light Beacon
Perform the following procedures to check function of the Light Beacon.
To test the Light Beacon:

1. Close the dispensing system hood, make sure the EMO is deactivated, and press the green
ON (l) button on the front panel.
! The green beacon light should be ON.
2. Open the hood.
! The yellow beacon light should come ON and the green beacon light should go OFF.
! The green beacon light should come ON and the yellow beacon light should go OFF.
4. In the FmXP Main Window, click on Tools.
5. In the Tools Window, click on I/O Test.
6. Click on Dispenser.
! The I/O Test Dialog screen opens.
7. Locate the tab (Figure 4-10) with the beacon color outputs (BEACON_YELLOW, etc.).
8. Make sure the SOFTWARE_ACTIVE bit is ON (l). If not, the beacon lights will not toggle.
Figure 4-10 Dispenser I/O (Outputs 32-63)
9. Toggle the button next to the desired output ON (l) and OFF (0) to test the beacon signal.
10. Click on OK to return to the Tools Window.
11. Click on Main to return to the Main Window.

4.10.5 Conveyor and Conveyor Pneumatics
Perform the following procedures, as applicable to your system configuration, to check the function of the
conveyor and its associated components.
To check adjustable-width conveyor clearance, Safety Interlock, and X- and Y-axis movement:
CAUTION! Perform this procedure only if your dispensing system has been configured for an
application that requires an adjustable conveyor width. DO NOT perform the
procedure for fixed-width conveyor configurations.
1. Verify electrical cables and pneumatic lines near the conveyor are not in danger of being
pinched or snagged during conveyor operation.
2. If not already started, start FmXP as described in 4.6 Starting Fluidmove for Windows (FmXP).
3. Click on Tools .
! The FmXP Tools Window opens.
4. In the FmXP Tools Window, click on the Jog icon .

5. In the Jog Commands dialog box, click on Conveyor 1 (Figure 4-11).
6. Click on Home in the Jog Commands dialog box and make sure that the rear conveyor rail
moves to the home position at the rear of the dispensing system.
! The rear conveyor rail should start moving to the rear of the dispensing system.
! Rear conveyor rail movement should be smooth and not damage any electrical lines or
pneumatic hoses.
7. While the conveyor rail is moving, lift the hood.
! The green beacon light should go OFF, the yellow beacon light should come ON, and the
conveyor rail should stop moving.
! The yellow beacon light should go OFF, the green beacon light should come ON, and the
conveyor rail should continue moving to the Home position.
9. In the Jog Commands dialog box, click on both the slow and the fast X-axis jog
buttons to move the conveyor belt in both directions (Figure 4-11).
! The conveyor belt should move smoothly in both directions with no slipping on
its pulleys.
10. In the Jog Commands dialog box, click on both the slow and the fast Y-axis jog
buttons to move the rear conveyor rail backward and forward (Figure 4-11).
! The conveyor rail should move smoothly in both directions.
11. If your system is equipped with dual conveyors, repeat Steps 5-9 for Conveyor 2. Conveyor 2
Jog Commands are described in 6.7.3 Dual Conveyor Systems.
12. Close the Jog Commands dialog box to return to the Tools Window.
13. Click on Main to return to the Main Window.

1
Item Description
1 Y-Axis Control
2 X-Axis Control
3 Home Button
Figure 4-11 Conveyor Jog Commands Dialog Box
" NOTE For dual conveyor systems, the Conveyor 2 front rail is manually adjustable to allow
pitch variations between Conveyor 1 and Conveyor 2. Both of the rear rails move
synchronously toward the back or front of the machine.
To check fixed-width Conveyor clearance, Safety Interlock, and X-axis movement:
CAUTION! Perform the following procedure only if your dispensing system has been
configured for an application that requires a fixed conveyor width. DO NOT
perform the procedure for adjustable-width conveyor configurations.
" NOTE This procedure assumes that you are already in the FmXP Tools Window. If not, refer to
Steps 2 and 3 in 4.10.5 Conveyor and Conveyor Pneumatics.

1. Verify electrical cables and pneumatic lines near the conveyor are not in danger of being
pinched or snagged during conveyor operation.
2. In the FmXP Tools Window, click on the Jog icon .

3. In the Jog Commands dialog box, click on Conveyor 1 (Figure 4-11).
4. Open the dispensing system hood.
! The green beacon light should go OFF and the yellow beacon light should come ON.
5. In the Jog Commands dialog box, click on both the slow and the fast Y-axis jog
buttons to try to move the conveyor rail backward and forward.
! There should be no movement of the conveyor rail.
7. In the Jog Commands dialog box, click on both the slow and the fast X-axis jog
buttons to move the conveyor belt in both directions.
! The conveyor belt should move smoothly in both directions with no slipping on
its pulleys.
8. If your system is equipped with dual conveyors, repeat Steps 5-7 for Conveyor 2. Conveyor 2
10. Click on Main to return to the FmXP Main Window.
To rough-adjust Conveyor Rail width:

1. When the rails are determined to be level with dispensing system mechanics, obtain a sample
workpiece identical to the one that will be used during production.
2. Narrow or widen the spacing between the conveyor rails to fit the sample workpiece
as follows:
a. In the Jog Commands dialog box, click on Conveyor 1.
b. Use the Y-axis fast jog buttons to adjust the rail width to the approximate width of the
sample workpiece.
c. When the rails are at the approximate distance apart, open the hood and place the
workpiece on the conveyor belts.
d. Close the hood and use the Y-axis slow jog button to finish adjusting the rail width.
! Rail width should allow the workpiece to rest on the belts as close to the rails as
possible, allowing space for smooth, non-binding movement along the conveyor and
for heat expansion of the workpiece.
3. If your system is equipped with dual conveyors, repeat Step 2 for Conveyor 2. Conveyor 2
5. Click on Main to return to the FmXP Main Window.
6. Remove the workpiece from the conveyor.

To check Conveyor upstream and downstream SMEMA communication:
1. Perform a Service Shutdown as specified in the 2.11 Service Shutdown.
2. Attach the TS-01 upstream and downstream cable adapters to the TS-01 I/O Test Box.
3. Attach the TS-01 upstream and downstream cables to the appropriate SMEMA connectors at
the rear of the dispensing system (Figure 4-12).
Figure 4-12 SMEMA Connections
4. Make sure that all of the I↔O/INDEP switches along the edge of the TS-01 I/O Test Box are
all set to INDEP.
5. Start the dispensing system as described in 4.5 Powering on the Dispensing System.
6. Make sure that the DRIVERS/OPTO I/O switch in the corner of the TS-01 I/O Test Box is set
to OPTO I/O.
7. In the FmXP Main Window, click on Configuration and then select Setup Conveyors.
8. Click on I/O Test and then on the Outputs 0-31 tab (Figure 4-13).
9. Locate the upstream and downstream bits. Perform the actions specified in Table 4-1.

Table 4-1 SMEMA Communication Test Matrix
Action Result
In dialog box, press Request Board No. 2 LED on TS-01 comes ON.
from Upstream Tool output button.
Press TS-01 button No. 3. Dialog box “Board Available from
Upstream Tool” input changes to ON.
In dialog box, press Board Available No. 4 LED on TS-01 comes ON.
to Downstream output button.
Press TS-01 button No. 5. Dialog box “Downstream Tool
Requests Board” input changes to
ON.
Figure 4-13 Conveyor I/O (Outputs 0-31)
10. If results are not as specified, check all TS-01 connections and retest. If results are still
negative, refer to Section 8 - Troubleshooting.

To check Board Sensor operation:
" NOTE This procedure assumes the following:

• Each conveyor station has a board sensor that is positioned to sense
the workpiece.
• The conveyor rail width has been adjusted to fit a production sample workpiece.
Perform this procedure as applicable to the configuration of your dispensing system.

2. Place a production sample workpiece on the conveyor to the left of the dispense station board
sensor.
3. In the Conveyor I/O Diagnostic dialog box (Figure 4-14), locate the board sensor inputs.
Figure 4-14 Conveyor I/O (Inputs 0-31)
4. Manually move the workpiece under or over (depending upon system configuration) the
dispense station board sensor and monitor the dialog box SENSOR_CTRA input.
! The SENSOR_CTRA input should change from OFF (0) to ON (1).
5. Move the workpiece out of Board Sensor sensing range and monitor the dialog box
SENSOR_CTRA input.
! The SENSOR_CTRA input should change from ON (1) to OFF (0).
6. Repeat Steps 4 and 5 for the pre-dispense station and post-dispense station, as applicable.

! If a bit does not toggle ON and OFF check the following:
- Board Sensor connections.
- Sensitivity of the Board Sensor. See 5.11 Adjusting the Board Sensors.
! If the bit still does not toggle, refer to Section 8 - Troubleshooting.
To check Lift Table operation:
" NOTE This procedure assumes that the dispensing system hood is open and the FmXP
Conveyer I/O Test Dialog Box is open.
1. Check under and around all lift tables and heater tooling to make sure that no electrical or
pneumatic lines are in danger of being pinched or snagged.
2. Make sure that no electrical or pneumatic lines are touching the scale or scale base.
3. Manually place production sample workpieces on the conveyor in the pre-dispense, dispense,
and post-dispense stations, as applicable to your dispensing system configuration.
4. In the Conveyor Test I/O dialog box (Figure 4-13), locate the Lifter output buttons
(Lift_Up_Left, Lift_Up_Ctr, etc.).
5. Raise the lift table by toggling the output buttons ON (1).
6. Lower the lift table by toggling the output buttons OFF (0).
7. Repeat Steps 4 through 6 for the pre-dispense station and the post-dispense station lift tables,
if applicable.
! The lift tables should raise and lower smoothly and no parts should shift during the lifting
and lowering process.
! If the lift tables do not operate as specified, the air pressure may need to be adjusted as
specified in Section 5 - Calibration and Adjustment.
! If air adjustment does not remedy the problem, refer to Section 8 - Troubleshooting.
To check Stop Pin operation:
" NOTE This procedure assumes that the dispensing system hood is open and FmXP Conveyer
I/O Test Dialog Box is open.
1. Locate the stop pin output buttons (Stop_Hold_Left, Stop_Hold_Ctr, etc.).
2. Raise and lower the stop pins by toggling the stop pin buttons ON (1) and OFF (0).
! The stop pins should raise and lower smoothly.
3. If the stop pins do not operate as specified, refer to Section 8 - Troubleshooting.

To check vacuum for Contact Heaters:
WARNING! The heaters may be hot. Use caution when working in the area of the heaters or
serious burns may result.
" NOTES This procedure assumes the following:

• Sample workpieces are on the conveyor in the pre-dispense, dispense, and
post-dispense stations as applicable to your system configuration.
• The dispensing system hood is open.
• The FmXP Conveyer I/O Test Dialog Box is open.
1. Raise all lift tables as described in the previous procedure.
2. In the Conveyer I/O Test dialog box, (Figure 4-13) locate the vacuum output buttons
(Vac_Hold_Left, Vac_Hold_Ctr., etc.).
3. Activate the vacuum in each conveyor station by toggling the vacuum buttons ON (1).
4. Test the vacuum for each heater by clicking on the vacuum button in each conveyor station
and trying to move the sample workpiece.
! The workpieces should not be easily moved off of the contact heaters.
5. Click on OK in the Conveyer Test I/O dialog box to return to the Main Window.
6. Manually unload all of the sample workpieces.
To check overall Conveyor component operation:

1. Place a sample workpiece in the dispense station without activating the board sensor.
3. In the FmXP Main Window, click on Teach a Program.
4. In the Programming Window, click on the Load a Board icon .
5. Make sure that the stop pins, lift tables, and heater tooling function correctly during the
loading process as follows:
! The stop pins and lift tables should all raise and lower smoothly.
! The workpiece should contact the stop pins gently without bouncing off.
! The heater tooling should come on and go off at the proper times.
! If applicable, the contact heater vacuums should come on and go off at the proper times.
6. In the Programming Window, click on the Unload a Board icon .
7. Make sure that the stop pins and lift tables all function correctly during the unloading
process.
" NOTE If the stop pins or lift tables do not function correctly, refer to Section 8 -
Troubleshooting.

4.10.6 Dispensing Head and Accessories
Perform the following procedures to check function of the dispensing head, its accessories, and the
Safety Interlock.
To check Dispensing Head clearance:
" NOTE The following procedures assume the dispensing system is on and FmXP is running.
1. Open the hood, place a production sample workpiece in the dispense station of the conveyor,
and then close the hood.
2. In the FmXP Main Window, click on Configuration and then select Setup Conveyors
(Figure 4-15).
Figure 4-15 Setup Conveyors
3. In the Setup Conveyors dialog box, click on the Test I/O button.
4. Click on the Outputs 0-31 tab (Figure 4-13).
5. In the Conveyor I/O Test dialog box, click on the dispense station lifter button (Lift_Up_Left,
Lift_Up_Ctr., etc.) to raise the lift table.
! This action clamps the workpiece in place at its actual dispense height.
6. Click on OK twice to return to the Main Window.
7. If your system is equipped with a retractable height sensor, follow the steps below:
a. In the Tools Window, click on I/O Test.
b. Click on Dispenser.
! The I/O Test Dialog screen opens.

c. Locate the tab (Figure 4-16) with the height sensor probe output
(HS_PROBE_EXTEND).
d. Click the button next to HS_PROBE_EXTEND to toggle the bit ON (1).
! The height sensor probe should be in the down position.
Figure 4-16 Dispenser I/O (Outputs 0-31)

8. In the Main Window, click on the Jog icon
.
! The Jog Window (Figure 4-17) opens.
6 1
5
2
4

1 XYZ Position Indicator 4 X-Axis Controls
2 Z-Axis Controls 5 Y-Axis Controls
3 Home Button 6 Target Box
Figure 4-17 FmXP Jog Window
9. In the Jog Commands dialog box, click on Dispenser.

10. Using the position controls, move the height sensor probe just above the sample production
workpiece that is clamped in the dispense station.
11. Using the X- and Y-axis position controls only, move the dispensing head around the
dispensing chamber.
! The dispensing valve needle tip and height sensor probe should not contact any board
sensor, stop pin, electrical line, or pneumatic line in the dispensing chamber.
12. Close the Jog Commands dialog box.
13. To retract the height sensor, repeat Steps 7.a through 7.c above and then click the button next
to HS_PROBE_EXTEND to toggle the bit OFF (0).
! The height sensor probe should be in the retracted position.

To test the Safety Interlock effect on the Dispensing Head:
1. In the Main Window, click on the Jog icon .
2. In the Jog Commands dialog box (Figure 4-17), verify the Dispenser radio button is selected
and then click on the Home button.
3. While the dispensing head is moving toward its home position, open the hood.
! The green beacon light should go OFF, the yellow beacon light should come ON, and the
dispensing head should stop moving.
! The yellow beacon light should go OFF, the green beacon light should come ON, and the
Dispensing Head should continue moving toward its home position.
To test Dispensing Head movement:

1. In the Jog Commands dialog box (Figure 4-17), click inside of the target box in three or more
locations.
! The dispensing head should smoothly move to the chosen locations.
2. Click on the slow and the fast X-and Y-axis jog buttons to move the dispensing head
to the extreme X and Y limits of travel.
! No unusual vibrations should occur during dispensing head motion.
! The dispensing head should move freely about the dispensing chamber.
! The cable cat track should not impede dispensing head motion.
3. Click on the slow and the fast Z-axis jog buttons to move the dispensing head up and
down.
CAUTION! The downward travel of the dispensing head must not exceed 3.5 inches
(88 mm) or damage to components will occur.
! No unusual vibrations should occur during dispensing head motion.

! Pneumatic and electrical cables should not impede the Z-axis motion or be in danger of
being snagged or cut.
4. Close the Jog Commands dialog box to return to the Main Window.

4.10.7 Vision System
Perform the following checks to make sure that the Vision System is ready for operation.
" NOTE The following procedure assumes the dispensing system is on and FmXP is running.
1. In the FmXP Main Window, click on Teach a Program .

2. In the Programming Window, click on the Load a Board icon .
3. In the FmXP Main Window, click on Configuration and then select Setup Vision.
4. In the Setup Vision dialog box, click on the Setup Reticles button (Figure 4-18).
5. Using the target box and position controls, move the camera over the production sample
workpiece clamped in the dispense station. Locate a production fiducial on the workpiece.
6. In the Reticle Setup dialog box (Figure 4-18), use the lighting controls to vary the light
intensity and red-blue color balance (if applicable).
! For diffuse on-axis lighting (DOAL) systems, the brightness should range from 0 to 255.
! If your system has red and blue LEDs, they should adjust from all red to all blue and all
combinations of the two colors.

1 Video Display 4 Position Controls
2 Reticles Set-up Box 5 Target Box
3 Lighting Controls
Figure 4-18 Vision and Reticles Set-up Dialog Boxes

7. In the Reticles Setup dialog box, enter the following sample settings:
• Circle 1 (0.050) • Crosshair graduations (0.025)
• Circle 2 (0.10) • Red reticle color
• Rectangle (0.10 x 0.10)
8. Click on the Apply changes button and view the display.
! If any of the reticles are not visible on the screen, contact Asymtek Technical Support.
9. Turn off all of the reticle selections and click on the Apply changes button.
10. View the image in the video display.
! The reticles should not be visible.
! If the image is focused, the camera does not need to be adjusted.
! If the image is not focused, the camera focus must be adjusted. See 5.5 Focusing the
Camera.
11. Verify the bottom of the lighting module is approximately 1.1 inches (27.9 mm) above the
workpiece surface to be viewed with a metal ruler.
! If the lighting is not at the correct height, grasp the light with your hand and loosen the
adjustment screw. Then slide the light up or down on its bracket until it is at the proper
distance and retighten the adjustment screw. Refer to 5.5 Focusing the Camera.
12. Calibrate the camera. See 5.6 Calibrating the Camera.
4.10.8 Dispensing Valve Pneumatics
Perform the following procedure to check function of the dispensing valve pneumatic system.
1. If a dispensing valve is currently installed on your dispensing system, disconnect all air hoses
connected to the dispensing valve.
2. Connect a syringe receiver head to the silver-colored fluid pressure fitting on the pneumatic
bulkhead located on the right-hand side of the dispensing head.
3. In the FmXP Main Window, click on Tools .
4. In the Tools Window, click on I/O Test and then on Dispenser .

! The Dispenser I/O Test Window opens (Figure 4-16).
5. Locate the bit labeled V1_FLUID_AIR.
6. Toggle the bit ON (1).
! This should turn ON air at the Fluid Pressure port. You should hear air coming out of the
syringe receiver head.

7. With V1_FLUID_AIR ON, adjust the Fluid Air Regulator so that pressure increases and
decreases.
! The air pressure coming from the syringe receiver head should vary with regulator
adjustment.
8. Toggle the V1_FLUID_AIR bit until it reads OFF (0).
9. This should turn OFF air at the fluid pressure port.
10. Disconnect the syringe receiver head from the fluid pressure port and connect it to the blue
fitting on the pneumatic bulkhead. Also connect a syringe receiver head to the black fitting on
the bulkhead.
! Air should be coming out of the syringe receiver head connected to the black fitting. No
air should be coming out of the syringe receiver head connected to the blue fitting.
11. Locate the bit labeled V1_VALVE_AIR and toggle the bit until it reads ON (1).
! This should turn OFF the air coming out of the syringe receiver head on the black fitting
and turn ON the air coming out of the syringe receiver head that you connected to the
blue fitting.
12. With V1_VALVE_AIR ON, adjust the Valve Air Regulator so that pressure increases and
decreases.
! The air pressure coming from the syringe receiver head should vary with
regulator adjustment.
13. Toggle the V1_VALVE_AIR bit again until it reads OFF (0).
! This should turn OFF the air coming from the blue fitting and turn ON the air coming
from the black fitting on the bulkhead.
14. Disconnect the syringe receiver heads from the blue and black fittings on the pneumatic
bulkhead.
15. If previously disconnected, reconnect all air hoses to the dispensing valve.
16. Close the Dispenser I/O Test dialog box to return to the Tools Window.

4.10.9 Tactile Sensor
Perform the following procedures to make sure that the Tactile Sensor is functioning properly.
1. Verify your dispensing system has been configured for the type of Needle Sensor installed
as follows:
a. In the FmXP main Window, click on Configuration > Machine Offsets > Machine
Offsets Parameters.
b. In the Machine Offsets Parameters dialog box (Figure 4-19), verify the sensor type
installed on your system.
! If necessary, click on the arrow in the Sensor Type box and select the correct
sensor type.
c. Click on OK to return to the Main Window.
Figure 4-19 Machine Offsets Parameters Dialog Box
3. In the Tools Window, click on I/O Test and then on Dispenser .

! The Dispenser I/O Test dialog box (Figure 4-20) opens.
Figure 4-20 Dispenser I/O (Inputs 0-31)
4. Locate the bit labeled TACTILE_SENSOR.

5. Lightly press on the Tactile Needle Sensor.
! The TACTILE_SENSOR bit should toggle to ON (1) when the Tactile Needle Sensor is
pressed and return to OFF (0) when pressure is released.

4.10.10 Purge Station
Perform the following procedure to check function of the purge station.
1. Locate the bit labeled PURGE_CUP and toggle the bit until it reads ON (1) to turn the purge
vacuum ON (Figure 4-21).
Figure 4-21 Dispenser I/O Test (Outputs 32-63)
2. Place your finger on the purge boot opening and try to lift the purge cup cover.
See Figure 4-22.
3. If the purge station is working properly, it should be difficult to lift the purge cup cover.
4. Toggle the bit until it reads OFF (0) to turn the purge vacuum OFF.

2 3 4
1

1 Ceramic Tile Substrate 3 Purge Station
2 Tactile Needle Sensor 4 Scale
Figure 4-22 Service Station
4.10.11 Scale
Perform the following procedure to make sure that the scale is ready for operation.
2. Remove the scale cover.
3. Inspect the scale pedestal area to see if fluid has been spilled around the scale.
CAUTION! Fluid spilled in and around the Scale Pedestal may seriously affect Scale
accuracy. Excessive pressure on the Pedestal while attempting to clean spilled
fluid may cause damage to sensitive Scale mechanics. Contact Asymtek
Technical Support before attempting to clean the Pedestal area.
4. Check the scale level bubble.

! If the bubble is not centered, the scale needs to be leveled. See 3.8 Leveling the Scale.
! If the bubble is centered, the scale is level. Go to Step 5.

5. In the FmXP Main Window, click on the Configuration button and select Setup Scale.
6. In the Scale Setup dialog box (Figure 4-23), click on the Scale Operations tab.
7. In the Scale Operations dialog box, click on the Zero Scale button and monitor the Current
Reading portion of the dialog box.
! The current reading should be 0.000 mg.
Figure 4-23 Scale Setup
8. Replace the cup and scale cover.

! The current reading should indicate an increase in weight. If not, refer to
Section 8 -Troubleshooting.
9. Calibrate the scale in accordance with the procedure in 5.8 Calibrating the Scale.

4.10.12 Heater Tooling and Needle Heaters
Perform the following electrical and temperature tests, as applicable to your system configuration, to
make sure that the heaters are functioning properly.
To electrically test Heater Tooling:
WARNING! Make sure that the Heater Tooling is cool before performing this procedure or
serious injury may occur.
2. In the Tools Window, click on Terminal .
3. Click on Heaters .
4. In the Heater Control Window (Figure 4-24), locate the loops (channels) for the heater
tooling installed on your system.
5. Verify the icons in the On/Off column indicate that each heating tool is OFF (gray). If any of
the tools are ON, double click on the yellow and red icon next to the loop name
to turn them OFF. Wait until the tools are cool (35 °C or less) as indicated by the value in the
PV (present value) column.
6. Turn off power to the dispensing system by pressing OFF (0) on the Front panel and
switch the Main Circuit Breaker OFF (0). Lock out and tag out the power as specified in
Section 2 - Safety.
7. Open the hood and disconnect the electrical cable to each heater module.
8. Measure and record resistance between connector pins 1 and 2 for each heater module.
! The resistance for a heater should be 56 ohms.
! If the heater tooling does not meet the resistance requirements, it should be repaired or
replaced before proceeding.
9. Measure and record resistance between connector pins 5 and 6 for each heater module (RTD).
! The resistance for the RTD at ambient temperature should be approximately 110 ohms.
10. Reconnect the electrical cables, and close the hood.
11. Restore power to the dispensing system by turning the red EMO knob clockwise until it pops
out and then pressing the green ON (l) button on the front panel.

2 3 4 5
Item Description
1 Heater On/Off Column
2 Channel (Loop) Name Column
3 Temperature Set Point Column
4 Present Temperature Value Column
5 Message Column
Figure 4-24 Heater Control Window

To temperature test Heater Tooling and Needle Heaters:
WARNING! The Heaters will be hot and can cause serious injury. Use extreme caution when
measuring Heater temperature and checking connections.
" NOTE This procedure assumes that FmXP is in the Heater Control Window. If not, refer to
Steps 1 through 3 of the previous procedure.
1. Check all air and electrical connections to the heaters.
2. In the Heater Control Window (Figure 4-24), locate the loops (channels) for the heaters
installed on your system and verify the messages for all the heaters read OK.
! If the Heater Control Window shows an open loop message (T/C Break), open the
dispensing system hood and recheck all heater connections. Then, close the hood
and repeat this step. If the open loop message still appears, refer to Section 8 -
Troubleshooting.
3. Set the heater temperature to the set point (SP) specified in Table 4-2.
! Make sure mode column is set to Auto. If not, the heater may respond inadequately.
Table 4-2 Heater Set Points
Set Point Set Point

Heater Type
(°C) (°F)
Impingement and Contact 80 176
Needle 40 104
4. When all loops have been configured, go to the On/Off column and double click on the
gray-shaded icon next to each loop.
! The icon will become yellow and red indicating that it is in the ON state.
5. Wait for the temperature in the present value (PV) column to reach the set point (SP)
temperature.
6. Measure the temperature of the heaters as follows:
a. For heater tooling, use a calibrated temperature probe on the top surfaces of each heater
to verify it is achieving the set point temperature. Read and record temperatures at both
ends and the middle of each Heater.
! The variance in temperature from left end of the heater to the right end should be
±5 °C (±9 °F).
b. For needle heaters, insert a calibrated temperature probe into the fluid-heating chamber of
the dispensing valve.
! The temperature should ramp up and achieve a steady state temperature within ±1 °C
(±1.8 °F) of the set point.
7. Calibrate the heaters as specified in Section 5 - Calibration and Adjustment.

To test EMO effect on Heater Tooling and Needle Heaters:
" NOTE This procedure assumes that FmXP is in the Heater Control Window and that the Heaters
are at their set temperatures.
1. With the heater tooling and needle heaters at their set temperatures (SP), press the red EMO
knob on the front panel.
2. Monitor the temperature values shown in the PV column of the Heater Control Window.
! The temperature values in the PV column should indicate that the heaters are cooling.
This may take several minutes to verify.
3. Restore power to the dispensing system by turning the red EMO knob clockwise until it pops
out and then pressing the green ON (l) button on the front panel.
4. Monitor the temperature values shown in the PV column of the Heater Control Window.
! The temperature values in the PV column should indicate that heater temperature
is rising.
5. Repeat Steps 1 through 4, except use the EMO switch on the back of the dispensing system.
6. Turn the heaters OFF by double clicking on the icons in the On/Off column of the Heater
Control Window.
7. Click on Exit to return to the Tools Window.
4.11 System-Level Functional Test
CAUTION! Provide a means to catch workpieces/carriers exiting the dispensing system or

they will fall on the floor and be damaged.
" NOTE This procedure assumes that a production program has been created in accordance with
the FmXP User Guide.
1. If applicable to your system, turn on the Heater Tooling as follows.
a. In the FmXP Main Window, click on Tools .
b. In the Tools Window, click on Terminal .
c. Click on Heaters .
d. In the Heater Control Window (Figure 4-24), locate the loops (channels) for the Heater
Tooling installed on your system.
e. Double-click on the heater icon in the On/OFF column to turn the heater on.
! A yellow and red heater icon indicates the heater is on.

2. Perform a Valve Offsets routine as follows. See Figure 4-25.
a. In the FmXP Main Window, click on Configuration.
b. Select Machine Offsets from the Configuration menu.
c. In the dropdown menu, select Scripted Valve Offsets.
Figure 4-25 Valve Offset Dialog Boxes
! The Machine Setup dialog box opens (Figure 4-26).

Figure 4-26 Machine Setup Dialog Box
3. Click on Run to End to perform the offsets routine.

4. Once you have completed the Scripted Valve Offsets routine, perform a simulated (dry)
production run using the TS-01 Test Box as follows:
" NOTE If your system is equipped with substrate heaters, make sure the heaters have
reached the set point temperature (SP) before proceeding with this procedure.
a. Perform a service shutdown as specified in 2.11 Service Shutdown.
b. Attach the TS-01 upstream and downstream cable adapters to the TS-01 I/O Test Box.
c. Attach the TS-01 upstream and downstream cables to the appropriate SMEMA
connectors at the rear of the dispensing system.
d. Start the dispensing system as specified in 4.5 Powering on the Dispensing System.
e. Make sure that all of the I↔O/INDEP switches along the edge of the TS-01 I/O Test Box
are all set to INDEP.
f. Make sure that the DRIVERS/OPTO I/O switch in the corner of the TS-01 I/O Test Box is
set to OPTO I/O.
g. In the FmXP Main Window, click on Run a Program .
h. In the Production Window, click on Load .

i. Select a dispensing program from the list and click on Open. See Figure 4-27.

Figure 4-27 Program Open Window
! After the program has been loaded, the filename will appear in the Current Program
section of the Production Window.
j. In the Production Window, click on the Run button and then double click on Single
Dry Run in the area below the Run Production button.
! The Run Window will open.
Figure 4-28 Run Window

k. On the Run Status tab, verify the program filename is the one desired, the Dry radio
button is selected, and the Use Conveyor box is checked.
l. To start the program click on Go .

! A “Clear the conveyor” message appears. Make sure there are no boards or boats on
the conveyor belt.
! A “Waiting for a board” message appears.
m. Place a simulated production workpiece at the upstream end of the conveyor.
n. Press the Number 3 TS-01 button to move the workpiece to the dispense station.
! Dispensing is performed.
! When dispensing is complete, the red Number 4 LED on the TS-01 illuminates.
o. Press the Number 5 TS-01 button.
! The red Number 2 LED on the TS-01 illuminates.
! The workpiece will either stop at the post-dispense station if there is one, or exit the
system entirely if there is not.
CAUTION! Prevent workpieces from falling after exiting the dispensing system or they will be
damaged.
p. Place another simulated production workpiece at the upstream end of the conveyor.
q. Press the Number 3 button on the TS-01 to move the second workpiece to the
dispense station.
r. Repeat Steps (k) through (q) until you have completed several workpieces.
5. Verify the following:
a. All stop pins and lift tables function properly.
b. The workpiece loads, travels on the conveyor, and unloads smoothly without skewing
or binding.
c. All applicable conveyor stations are used.
d. When the hood is opened:
! The green beacon light goes OFF and the yellow beacon light comes ON.
! All dispensing system motion stops and all pneumatic devices remain in the same
position as they were before the hood was opened.
e. When the hood is closed, the yellow beacon light goes OFF, the green beacon light
comes ON, and all motion and pneumatic action resumes.
f. The camera image is clear and crosshairs go to the taught dispense locations.
g. The service station is used at the programmed times.
h. All taught fiducials are found.

5 Calibration and Adjustment
5.1 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 Height Sensor Probe

• Calibrating the Camera • Adjusting the Board Sensors
• Service Station Height Adjustment • Initializing the Digital Gauges
• Calibrating the Scale • Software Controlled Light Beacon
• Z-head Counterbalance Force Adjustment
Refer to Section 6 - 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! The procedures in this section should only be performed by a trained

service technician.
5.2 Safety First

for important safety information.
5.3 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.
5.4 Startup/Shutdown
Refer to Section 4 - Power Up and Testing for details on system and Fluidmove startup/shutdown
procedures.
Calibration and Adjustment 5-1

5.5 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 icon.
! 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. 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 5-1).
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 Upper screw 3 Screw (not shown)
2 Lower screw
Figure 5-1 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.
5-2 Calibration and Adjustment

5.6 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-to-
machine-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 icon.

! The conveyor will transport the substrate to the dispense station and the lift mechanism
will lift it off the conveyor belt.
2. In the FmXP Main Window, click on Configuration > Setup Vision.
! The Setup Vision Window opens (Figure 5-2).
Figure 5-2 FmXP Setup Vision

3. Click on Calibrate.
! The Calibration Window (Figure 5-3) opens.
Figure 5-3 FmXP Calibration Window
4. Position the camera over a fiducial and adjust the light level to obtain a good image contrast.
5. If the image is not in focus, focus the camera as described in 5.5 Focusing the Camera.
6. Click on Next.
7. Verify that the fiducial image is centered and click on Next.
! The Vision System will take a snap image of the fiducial.
8. If the fiducial is acceptable, select Next. If not, select Prev and define a new fiducial.
" NOTE The fiducial should fit inside the green square on the camera image.
9. 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.
10. 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.

5.7 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 5-4).
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
Item Description
1 Ceramic Tile
2 Mounting Screws
3 Leveling Feet (not shown)
Figure 5-4 Adjusting the Service Station Height

5.8 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 5-6).
Figure 5-5 Scale Cover Removal
Leveling Screws
Bubble
Figure 5-6 Leveling the Scale
4. When finished, replace the scale cover.

5. Start FmXP.
6. Select Configuration > Setup Scale from the Main Window.
! The Scale Setup Window (Figure 5-7) opens.

Figure 5-7 Setup Scale - Scale Operations Tab
7. Select “SART-WZ” from the Type pull-down menu.

8. Click on the Advanced tab (Figure 5-8).
Figure 5-8 Setup Scale - Advanced Tab

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 5-9):
Figure 5-9 FmXP Calibrating Scale Message
12. Upon completion, FmXP displays the following message:
Figure 5-10 FmXP Calibration Complete Message
13. Remove the weight from the scale and click OK.

5.9 Z-head Counterbalance Force Adjustment
The Z-head Counterbalance Force prevents the Z-head from crashing down upon disengagement of the
motor. There are three settings to accommodate various payloads.
To adjust the Z-head counterbalance (Figure 5-11):

1. Using a 3 mm hex key, loosen the screw on the lower Z-spring.
2. Move screw down to increase tension.
! If necessary, move screw up to decrease tension.
To test counterbalance tension:

1. Place valve on Z-head.
2. Move Z-head to middle of dispense area.
3. Open machine hood.
! Z-head should not drop more the 25.4 mm (1-inch).
4. Readjust tension if necessary.
Item Description
1 Z-spring screw
Figure 5-11 Z-head Counter Balance Force Adjustment

5.10 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 6.12 System Shutdown.
2. Manually move the dispensing head down.
3. Loosen the Height Sensor Probe locking screw at the back of the Z-axis plate.
See Figure 5-12.
4. Move the probe to the desired location (approximately 10 mm below the needle tip in the
gear down position).
5. Tighten the height sensor locking screw. Do not over-tighten.
1
4
Item Description
1 Z-Axis Plate (Front View)
2 Z-Axis Plate (Rear View)
3 Height Sensor Locking Screw
4 Height Sensor Probe
Figure 5-12 Adjusting the Height Sensor Probe
" NOTE For additional information on dispensing valve-to-height sensor offsets, see 6.6
Establishing Machine Offsets.

5.11 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 downward-
facing 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 5-13).
" NOTE Fiber ends are not designated as send or receive. Each ferrule can be used in
either amplifier position.
2. 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 5-13 Board Sensor - Side View
3. Move the SET-ADJ-RUN switch to the SET position (Figure 5-14). 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 4

1 TEACH Button 3 SET-ADJ-RUN Switch
2 MODE Button 4 MODE Switch
Figure 5-14 Board Sensor - Top View

4. Press the TEACH button until the Long Distance sensing function (F Ld ) is displayed.
See Figure 5-14.
5. Move the SET-ADJ-RUN switch to the RUN position to implement this setting.
5.11.1 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.
! The reference digital value should be less than 250 (approximate value).
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. 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.

5.12 Initializing the Digital Gauges
The S-920 Dispensing System is equipped with Cooling/Coaxial, Valve and Fluid Pressure Digital Gauges.
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 5-15).
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 PRESSURE MPa
SMC
2
35.4
OUT 1
3 SET 5

1 LED Display 4 Set Button
2 Switch Output Indicator 5 Down Button
3 Up Button
Figure 5-15 Initializing the Digital Gauge

5.13 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 5-16) opens.
Figure 5-16 Beacon Configuration Dialog Box
" NOTE Click on the desired tab to select one of the following categories: See Figure 5-17.
Error Conditions
Program States – 1
Program States – 2
FmXP States

Figure 5-17 Beacon Configuration Dialog Box
2. 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 5-18.
Figure 5-18 Dispenser I/O Dialog Box
" NOTE Refer to the Fluidmove User Guide or Online Help for detailed instructions.

6 Operation
6.1 Overview
At this point, we have installed the S-920, 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:
• Installing the Dispensing Valve • Creating a New Program

• Adjusting the Air Pressure • Installing Fluid on the Dispensing Valve
• Establishing Machine Offsets • Starting a Production Run
• Positioning the Conveyor and Dispensing Head • System Shutdown
• Camera Operation
" NOTE Refer to Section 5 - Calibration and Adjustment for the following procedures:
• Focusing the Camera • Z-head Counterbalance Force Adjustment

• Calibrating the Camera • Adjusting the Height Sensor Probe
• Adjusting the Service Station Height
WARNING! CAUTION!
DO NOT operate the Spectrum Series S-920 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.
6.2 Safety First

Operation of your S-920 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.
6.3 Startup
Refer to Section 4 - Power Up and Testing for details on system and Fluidmove startup/shutdown
procedures.
Operation 6-1
6.4 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.
6.4.1 Valve Pneumatic and Electrical Connections
Valve pneumatic and electrical connections are shown in Figure 6-1 and Figure 6-2. Refer to the manual
for your particular dispensing valve for additional information.
1 2

1 Fluid Air Pressure (Clear) 3 DV-Series Valve
2 Valve Electrical Connection
Figure 6-1 Valve Pneumatic and Electrical Connections (DV-8000 shown)
6-2 Operation
3
2 4
1

1 Cooling Air (Green) 4 Valve Electrical Connection
2 Valve Air Pressure (Black) 5 DJ-9000 Valve
3 Fluid Air Pressure (Clear)
Figure 6-2 Valve Pneumatic and Electrical Connections (DJ-9000 shown)
Operation 6-3
6.5 Adjusting the Air Pressure
6.5.1 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.
proceeding.
1
Item Description
1 Main Air Pressure Regulators
3 Main Air Pressure Gauges
Figure 6-3 Main Air Pressure Regulator and Gauge Sets
6-4 Operation
6.5.2 Adjusting the Cooling/Coaxial, Valve, and Fluid Air Pressure
1. Locate the Cooling/Coaxial, Valve, and Fluid Pressure Regulator adjustment knobs in the
front cabinet (Figure 6-4).
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.
" NOTE Pressure settings depend on the fluid being dispensed and dispensing valve being
used. Refer to the applicable dispensing valve manual for additional information.
4. 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.
proceeding.
3
4

1 Vacuum Control Regulator 3 Valve Air Regulator
2 Cooling/Coaxial Air Regulator 4 Fluid Air Regulator
Figure 6-4 Adjusting the Valve and Fluid Pressure Regulators
Operation 6-5
6.5.3 Adjusting the Vacuum Control
The Vacuum Control (Figure 6-4) 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:

1. Rotate the knob counterclockwise to increase vacuum pressure and decrease dripping.
2. Rotate the knob clockwise to decrease vacuum pressure.
6.5.4 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.
! The Low Air Pressure Detection Configuration Window (Figure 6-5) opens.
2. Adjust the dispensing system’s 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 6-5 Low Air Pressure Detection Window
6-6 Operation
6.6 Establishing Machine Offsets
Programming a dispensing sequence relies on using the camera. Dispensing is accomplished with a
needle or nozzle. The offsets between the camera and needle and camera and height sensor centerlines
need to be established prior to dispensing.
6.6.1 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. Refer to
5.6 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.
! The Setup Valve Offsets dialog box (Figure 6-6) opens.
Figure 6-6 Setup Valve Offsets Dialog Box
Operation 6-7
3. In the Setup Valve Offsets dialog box, make sure Valve 1 is selected.
4. Click on Run to End.

! A Teach Window opens.
5. Follow the on-screen prompts. Click on Help if you have questions.

! The Teach Window content and appearance can vary depending on your system
configuration.
! When the task has been completed, a check mark appears next to the task.
6. Repeat Steps 4 and 5 for the other tasks listed in the dialog box (as desired).
" NOTE Any tasks not applicable to your system configuration will be skipped.
7. When setup tasks are complete, click End in the Setup Valve Offsets dialog box.
" NOTE If you end the routine prematurely, you will receive an error message similar to
the one shown in Figure 6-7. Click on OK to exit the routine and save the
completed tasks or click on Cancel to continue.
Figure 6-7 FmXP Error Message 30694
6.6.2 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.
! The Production Window opens.
2. In the Production Window, click on the Setup button.
6-8 Operation
Figure 6-8 Production Window - Teaching Safe Z Height
3. Click on Teach Safe Z Height.

! The Teach Safe Z Height Window (Figure 6-9) opens.
Figure 6-9 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.
! The Safe Z-Height value will be recorded in the value textbox.
7. Click on Done.
WARNING! Safe Z-Height should never be taught lower than the tallest component on the
unit to be dispensed on.
Operation 6-9
6.7 Positioning the Conveyor and Dispensing Head
When necessary, an operator can use Fluidmove Position (Jog) Controls to adjust conveyor rail width,
reposition the workpiece X-axis location on the conveyor, and reposition the dispensing head in the X-,
Y-, and Z-axes. 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 These procedures assume that the dispensing system and computer have been turned on
as specified in 4.5 Powering on the Dispensing System.
6.7.1 Using the Touchpad
To operate position controls with the touchpad:

1. In the Fluidmove Main Window, click on Jog.
! The Position Controls dialog box opens. See Figure 6-10.
" NOTE The Position Controls 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.
2. Click on the Conveyor 1 radio button to activate the Conveyor 1 position controls or click on
the Dispenser radio button to activate the Dispensing Head position controls.
" NOTE See 6.7.3 Dual Conveyor Systems for systems equipped with dual conveyors.
Item Description
1 Y-axis Controls (rear rail forward and backward movement)
2 X-axis Controls (belt left and right movement)
3 Radio Buttons (Conveyor 1 selected)
Figure 6-10 Conveyor Position Controls
6-10 Operation
3. Conveyor position controls (Figure 6-10) 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 The single arrows and double arrows move the conveyor rail or belt different
distances per mouse click as specified in Table 6-1.
Table 6-1 Conveyor Position Controls: Jog Distance(1)
Movement Distance
Axis mm (inch)(2)
Y 0.0254 (0.001) 1.27 (0.0500)

X 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. Dispensing Head position controls (Figure 6-11) 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.
" NOTE Refer to Table 6-3 for a detailed explanation of position control commands for both the
dispensing head and conveyor.
Operation 6-11
1
5
3
Item Description
1 Target Box
2 Y-axis Controls (forward and back movement)
3 X-axis Controls (side to side movement)
4 Radio Button (Dispenser selected)
5 Z-axis Controls (up and down movement)
Figure 6-11 Dispensing Head Position Controls
" NOTE The single arrows and double arrows move the dispensing head different
distances and different velocities per mouse click. See Table 6-2.
Table 6-2 Dispensing Head Position Controls: Jog Distance and Velocity(1)
Distance Velocity
Movement mm (inch)(2) mm/sec (in/sec)
Axis
X-Y 0.0254 (0.001) 2.54 (0.100) 2.54 (0.100) 88.9 (3.500)

Z 0.0254 (0.001) 1.27 (0.050) 2.54 (0.100) 10.16 (0.400)
Notes: (1) Default distances and velocities. Refer to the Fluidmove User Guide or Online
Help to modify jog distances and velocities.
(2) Distance per mouse click on the arrow button.
6-12 Operation
Table 6-3 Position Control Commands
Name Dispensing Head Response Conveyor Response

Clicking in the Target Box moves the
Target Box Dispensing Head to the corresponding N/A
position in the dispensing area.
Moves the Dispensing Head as follows: Moves the rear Conveyor rail as follows:
Slow Backward (small increments) Slow Backward (small increments)
Y-axis Controls
Fast Backward (large increments) Fast Backward (large increments)
(move front/back)
Slow Forward (small increments) Slow Forward (small increments)
Fast Forward (large increments) Fast Forward (large increments)
Moves the Dispensing Head as follows: Moves the Conveyor Belt as follows:
Slow Right (small increments) Slow Right (small increments)
X-axis Controls
Fast Right (large increments) Fast Right (large increments)
(move left/right)
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
Fast Upward (large increments) N/A
(move up/down)
Slow Downward (small increments)
Fast Downward (large increments)
Click the Conveyor 1 radio button to
Click the Dispenser radio button to activate jog controls for the conveyor. On
Device
activate jog controls for the Dispensing dual conveyor systems, click Conveyor
Radio Buttons
Head. 2 to activate the jog controls for the
second conveyor.
Click to Video open a Video Display in Click to Video open a Video Display in
which you can see a close-up of the which you can see a close-up of the
Dispensing Area. Dispensing Area.
Click to open a dialog box where you can Click to open a dialog box where you can
configure Dispensing Head jog distance configure conveyor jog distance and
and speed. speed.
Click to access Fluidmove Online Help. Click to access Fluidmove Online Help.
Click to reinitialize the dispenser. Use Click to reinitialize the conveyor. Use this
this button if you are experiencing button if you are experiencing
communication problems with the communication problems with the
Dispensing Head. conveyor.
Clicking on Home sends the Dispensing
Head to its “Home” position. The home Clicking on Home sends the conveyor
position is the extreme left front corner of rear rail to its “Home” position. The home
the dispensing area, where the position is the extreme rear of the
Dispensing Head X, Y, Z-axis dispensing area.
coordinates are set to (0, 0, 0).
Operation 6-13
6.7.2 Using the Keyboard
To operate position controls using Keyboard commands:

1. Press [Ctrl + J] to open the Position Controls dialog box.
2. Using the mouse, click on the Conveyor 1 radio button to activate the conveyor position
controls or click on the Dispenser radio button to activate the dispensing head position
controls.
3. Press the appropriate keys shown in Table 6-4 to jog the selected device (conveyor or
dispensing head).
Table 6-4 Position Control Keyboard Commands

Speed of Dispensing Head Conveyor
Command(1)
Movement Response Response
Rear rail moves all the way
Moves to front left corner of
Ctrl + H to the back of dispensing
dispensing chamber
chamber
Slow(2) 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
(3)
Fast 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.
6.7.3 Dual Conveyor Systems

1. 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, or click on the
Dispenser radio button to activate the Dispensing Head position controls.
" NOTE(s) The selected jog device is indicated in the bottom right-hand corner of all major
windows.
Keyboard commands are the same for both single and dual conveyor systems.
6-14 Operation
1
Conveyor 1 4 Conveyor 2
Item Description
1 Conveyor 1 Y-axis Controls (rear rail forward and backward movement)
2 Conveyor 1 X-axis Controls (belt left and right movement)
5 Conveyor 2 X-axis Controls (belt left and right movement)
6 Conveyor 2 Y-axis Controls (rear rail forward and backward movement)
Figure 6-12 Conveyor Position Controls
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.
3. 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 The single arrows and double arrows

distances per mouse click.
move the conveyor rail or belt different
Operation 6-15
6.8 Camera Operation
The S-920 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.
6.8.1 Camera States
After the Genie software package installation, the GigE Server icon is visible in the desktop taskbar tray
area. The icons and descriptions are shown in Table 6-5.
Table 6-5 Genie Camera States
Icon State Description

The GigE server tray icon when the Genie device is found. It will
Device Available 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

Device IP Error
connected but there is some type of IP error.
Device Not A red X will remain over the GigE server tray icon when the Genie
Available device is not found. This indicates a major network issue.
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 6-13). LED Status indicators are described in
Table 6-6.
1 2
Table 6-6 Camera Status Indicators
LED Status 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
Item Description Slow Flashing Blue Waiting for an IP Address
1 Camera Status LED Fast Flashing Blue Ethernet Cable Disconnected
2 Network Status LED Steady Green Application Linked to the Camera
Slow Flashing Green Trigger Acquisition in Progress
Figure 6-13 Camera LED's (Rear View)
6-16 Operation
6.8.2 Lighting and Color Adjustment
The light intensity and color level can be adjusted to optimize the view of your workpiece. See Section 5 -
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 from the Main Menu.
• Select the Jog button in the Production Window.
• Press [Ctrl]+[J] on the keyboard.
3. At the bottom of the Jog Controls, click on Video and when the video display screen appears,
click on Reticles. See Figure 6-14.
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 6-14.
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 right side of the dialog box. Clicking on the light bulb icon toggles the light control
slide from a linked mode to an unlinked mode that permits up to 255 independent color
level/brightness levels.
" NOTE For more information concerning fiducials and video display contrast, refer to the
Operation 6-17
1
Item Description
1 Blue Light Adjustment Slide (in unlinked mode)
2 Red Light Adjustment Slide (in unlinked mode)
3 Color/Brightness Control Mode Button
4 Jog Controls
Figure 6-14 Camera Lighting Adjustment
6-18 Operation
6.9 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.
" NOTE The following procedures assume that the dispensing system is on and FmXP is running.
6.9.1 Loading a Part
1. In the FmXP Main Window, click on Teach a Program .

! The Programming Window opens.
2. Place the substrate on the conveyor.
3. Click on the Load 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.
4. Adjust the clamping mechanism as necessary to achieve a level dispensing plane.
! When using heated tooling with pedestals, the parts are NOT clamped but held in place
with vacuum and the tool itself must be leveled.
" NOTE 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.
6.9.2 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.
6.9.2.1 Heater Tooling
CAUTION! The operator can turn the heaters ON and OFF and monitor their function.
However, only authorized personnel should set heater parameters.
" NOTE Contact your applications engineer or Asymtek Technical Support for information about
setting heater parameters for your particular application.
Operation 6-19
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 6-15), click on Setup and in the list box select Setup
Heater 2.
! The Heater Control Window (Figure 6-16) will open.
Figure 6-15 Fluidmove Production Window
3. In the Heater Control Window (Figure 6-16), locate the loop (channel) for the desired heater.
6-20 Operation
3 4 5 6

1 Heater Loop - ON 4 Temperature Set Point Column
2 Heater Loop - OFF 5 Present Temperature Value Column
3 Channel (Loop) Name Column 6 Message Column
Figure 6-16 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 Section 8 - Troubleshooting or call a service technician.
6.9.2.2 Needle Heater
If your system is equipped with a needle heater, select Setup Heater 1 and follow the steps under 6.9.2.1
Heater Tooling to set up the needle heater.
" NOTE 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.
Operation 6-21
6.9.3 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-920 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 6-17).
Figure 6-17 FmXP Fluid Manager
" NOTE For additional information on the Fluid Manager, refer to the Fluidmove User Guide or
Online Help.
6-22 Operation
6.9.4 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 6-18.
! 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 6-18 Workpiece Alignment Options
Operation 6-23
2. Indicate the number of fiducials to be used in your program.
! 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).
3. Click OK.
6.9.5 Opening a New Program Window
To create a new program:
1. Select Teach a Program from the Main Menu.

! The last saved program opens when you start FmXP.
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 6-19).
! You will be prompted to define the number of fiducials and skip marks.
Figure 6-19 Create Workpiece
3. Enter the desired information and click OK.

! You will be prompted to teach the workpiece origin and fiducial locations, if applicable.
6-24 Operation
6.9.6 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.
6.9.7 Machine Setup
If Valve Offsets have not been defined, you will be prompted to do so now. Follow the instructions under
6.6 Establishing Machine Offsets.
1. In the FmXP Main Window, select Configuration > Machine Offsets > Valve Offsets or
Scripted Valve Offsets.
! The Machine Setup Window (Figure 6-20) opens.
2. Select Valve Offsets and click Run to End.
Figure 6-20 Machine Setup Window
Operation 6-25
Program Name Pattern Name
Fluid File
Pattern End
Instruction
Figure 6-21 Programming Window
To attach a fluid file:
" NOTE 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 6.9.3 Setting up the Fluid Manager.
1. In the Programming Window, Select File > Fluid Table > Load from the pull-down menu.
2. Select the new fluid file.
3. Click on Open.
6.9.8 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.
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 6.9.8.1 Dispensing Commands.
6-26 Operation
6.9.8.1 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 6-22). A Teach Window opens prompting you through the remainder of the process.
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 6-22 Program Commands Toolbar
Operation 6-27
6.9.8.1.1 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
Dispensing Elements from the Program Commands Toolbar, a Teach Window opens. The Teach
Window contains the Dispensing Elements toolbar (Figure 6-23). 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 Weight Control Fill

Line
Delta Z Line
Find Substrate Pattern

Height
Select Valve Multipass
Coat Dot Coat Line
Coat Grid Dot Grid
Figure 6-23 Dispensing Elements Toolbar
6.9.8.2 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.
" NOTE For detailed information about programming, refer to the Fluidmove User Guide or
Online Help.
6-28 Operation
To place a program command in a Conveyor Block:
1. In the Fluidmove Main Window, select Teach a Program.
2. Click on the Conveyor button on the Program Commands toolbar.

! The Conveyor drop-down menu (Figure 6-24) opens.
Figure 6-24 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 USE CONVEYOR 1:
2 END USE CONVEYOR:
4. Move the cursor to the beginning of the END USE CONVEYOR command.
5. Click on the Dispense Elements button on the Program Commands toolbar.

! A Teach Window opens.
6. Select the element you want to program from the Dispensing Elements toolbar and follow the
screen prompts.
7. Click on Done when you are finished.
! The dispensing command should be inserted between the Use Conveyor 1 and
End Use Conveyor commands.
8. Save the program.
! A sample program is shown in Figure 6-25.
Operation 6-29
Dual_Lane.fmw Workpiece
1 USE CONVEYOR 1:
2 LINE: 1, START: (15.139, 12.971), End: (1.139, 11.370)
3 END USE CONVEYOR:
4 USE CONVEYOR 2:
5 DOT: 1, (4.964, 24.501)
6 END USE CONVEYOR:
7 END:
Figure 6-25 Sample Dual Conveyor Program
To create additional patterns:
1. Click on the Pattern button on the Program Commands toolbar. See Figure 6-26.
Figure 6-26 Creating a Pattern
2. Select Create Pattern.

! The Create Pattern dialog box (Figure 6-27) opens.
6-30 Operation
Figure 6-27 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 in the Pattern textbox and select C1Line.

See Figure 6-28.
Figure 6-28 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 6-31
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 button on the Program Commands toolbar. See Figure 6-26.
3. Select Place Pattern.
! A Teach Window opens prompting you to select a pattern and teach the placement point.
4. Follow the screen prompts and click on Done when finished.
! Sample program screens are shown in Figure 6-29.
dual_lane.fmw Workpiece
1 USE CONVEYOR 1:
2 DO: C1Line AT (1.543, 3.567)
3 END USE CONVEYOR:
4 USE CONVEYOR 2:
5 DO: C2Dot at (0.382, 5.198)
6 END USE CONVEYOR:
7 END:
dual_lane.fmw C1Line
1 LINE: 1, START: (0.300, 0.300), End: (4.861, 2.118)

2 END:
dual_lane.fmw C2Dot
1 DOT: 1, START: (2.454, 2.110)

2 END:
Figure 6-29 Placing Patterns
" NOTE Conveyor Block Commands can only be placed in the Workpiece Pattern.
6.9.9 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.
6-32 Operation
6.9.10 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 6-30 Dry Run
6.10 Installing Fluid on the Dispensing Valve

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 6-33
6.11 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 6-30) 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 6.5 Adjusting the Air Pressure.
3. If applicable, turn on the heaters.
! Make sure the heaters have reached the desired set point temperature before running
production.
4. In the FmXP Main Window, click on Run a Program.
! The Production Window opens.
5. In the Production Window, click on the Setup button and then click on Setup Scripts and
then on Prompted Setup. See Figure 6-31.
Figure 6-31 Production Window – Setup Scripts
6. Follow the on-screen prompts and when finished, click on Exit to return to the
Production Window.
! If necessary, refer to the FmXP User Guide or Online Help for assistance.
" NOTE 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.
6-34 Operation
7. In the Production Window, click on Load .
! The Open Window (Figure 6-32) opens.
8. Select the program you wish to run and click on Open.
! The current program name will appear in the Production Window.
Figure 6-32 FmXP Open Window
9. In the Production Window, click on Run and then click on the Run Production button.
! The Run Window opens (Figure 6-33).
10. Load the workpiece.
11. Click on Go to start the dispensing process.
Figure 6-33 Run Window
Operation 6-35
6.12 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.
6.12.1 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.
! Cured epoxy is exceptionally difficult to clean!
6. 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 start menu, then shutdown.
8. Make sure Windows XP completely shuts down before turning off the computer.
9. Press the black OFF button on the S-920 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.
6-36 Operation
7 Maintenance
7.1 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! Maintenance procedures should be performed by trained personnel only.
7.2 Safety First

WARNING! CAUTION!
WARNING! CAUTION!
Make sure the dispensing system ventilation is ON during handling and cleanup
of all materials used with the dispensing system.
7.3 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 7-1
7.4 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-920 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 7-1.
Table 7-1 Routine Maintenance Procedures
Task Frequency Instructions
Remove spilled fluids with the manufacturer’s

recommended solvent and a soft cloth. Remove any
foreign objects from the dispensing area and tooling plate.
Clean Dispensing Area 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
Clean Purge Station
Daily recommended by the fluid manufacturer. Inspect the
Boot
rubber boot for damage. Replace if needed. See 7.5.2
Replacing the Purge Boot.
3. Replace Purge Station cover.
Replace Purge Station Daily

See 7.5 Replacing Consumables.
Cup
Replace Scale Cup Daily See 7.5 Replacing Consumables.
Clean Dispensing Clean all surfaces using a clean cloth and isopropyl
Weekly
System alcohol.
Check water level and empty if necessary. See 7.6

Drain Water Trap Weekly
Draining the Water Trap.
Check Air Cylinders Monthly Check for leakage.
Lubricate XYZ Axis Every three

See 7.8.2 Lubricating the X-Y Linear Guides.
Linear Guides months
Using lint-free cotton pads or swabs wetted with alcohol,

Clean Encoder Strips Every three wipe the encoder strips for their full length and inspect for
and Read Heads months damage. Similarly, clean the read heads to remove dirt,
dust, or foreign material.
7-2 Maintenance
Table 7-1 Routine Maintenance Procedures (Continued)
Task Frequency Instructions
Lubricate Mechanical Every three

See 7.8.1 Lubricating the Cables.
Drive Cables months
Every three
Clean Camera Lens Use the cleaning kit provided.
months
Tension Mechanical Every 6-12

See 7.9 Tensioning the Cables.
Drive Cables months
Tension Conveyor Belts As Needed See 7.10 Tensioning the Conveyor Belts.
Replace Conveyor Belts As Needed See 9.7 Replacing the Conveyor Belts.
7.5 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 7-1.
• Purge Boots
• Scale and Purge Cups
• Needle-nosed Pliers • Replacement Purge Boot (see Table 7-2)

• 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 7-2 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 7-3
7.5.1 Replacing Purge and Scale Cups
The cups in the purge and scale stations should be replaced at the intervals recommended in Table 7-1.
To replace the Purge and Scale cups:
WARNING! Follow all local regulations, the material manufacturer MSDS, and facility
practices concerning personal protective equipment and disposal of
hazardous materials.
" 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 7-1).
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! 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.
7-4 Maintenance
1
4
2
3
Item Description
1 Weigh Station
2 Weigh Station Cup
3 Purge Station Cup
4 Purge Station Lid
Figure 7-1 Replacing the Purge and Weigh Station Cups
Maintenance 7-5
7.5.2 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 7-2 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
1 Purge Boot
2 Purge Station Cover
Figure 7-2 Replacing the Purge Boot
7-6 Maintenance
7.6 Draining the Water Trap
Because the facility air supply may contain moisture that can damage the dispensing system, the S-920 is
equipped with a water trap that condenses 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.
1
1
Item Description
1 Water Trap
3 Drain Knobs
Figure 7-3 Draining the Water Traps
Maintenance 7-7
7.7 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. See Figure 7-4 to Figure 7-6.
To remove the X-axis covers:

1. Use a 5 mm hex key to loosen the M-6 screws in the back.
2. Lift off the covers and set aside.
Figure 7-4 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.
2. Slide out the covers and set aside.
Figure 7-5 Removing the Y-Axis Covers
7-8 Maintenance
To remove the rear cable covers:
1. Use a 5 mm hex key to loosen the M-4 screws.
2. Remove the covers and set aside.
Figure 7-6 Removing the Rear Cable Covers
7.8 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.
" NOTE To perform the following procedures, you will need Asymtek Grease Kit (P/N 7203262).
The kit contains a grease syringe. See Appendix A - Material Safety Information for the
Material Safety Data Sheet on the Asymtek Grease Kit.
7.8.1 Lubricating the Cables
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. Disconnect the electrical cables from the rear of the X and Y Servo Motors.
CAUTION! If the motor cables are not disconnected, rapid movement of the positioner during
this procedure will generate electrical current that may damage the X and Y
Servo Motor drive circuitry.
Maintenance 7-9
4. Open the dispensing system hood and move the dispensing head to the front middle of the
dispensing area.
WARNING! 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.
5. Wearing gloves, clean all accessible cables using a soft lint-free cloth and isopropyl alcohol.
WARNING! Fingers may be pinched if the dispensing head is moved while cleaning and
lubricating the cables.
6. 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.
7. Wearing rubber gloves, manually apply an adequate but not excessive amount of grease to
the exposed portion of all mechanical cables.
! From the rear of the system, apply grease to the portions of cable wrapped around the
motor pulley as well as the cable lengths leading to the rest of the positioner.
! From the front of the system, apply grease to the X and Y cables on the Motor Pulleys.
TIP Moving the dispensing head in the X and Y direction while applying the grease
to the motor pulley simplifies this step.
8. Manually move the dispensing head to the rear middle of the dispensing area and repeat
Steps 5-7.
9. When finished, replace the axis and cable covers.
7-10 Maintenance
7.8.2 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:

2. Manually move the dispensing head to the front of the dispensing area.
3. Remove the X- and Y-axis covers. See 7.7 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 7-7 and Figure 7-8).
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 7-11
Figure 7-7 Lubricating the X-Axis Linear Guides
Figure 7-8 Lubricating Y-Axis Linear Guides
7-12 Maintenance
7.9 Tensioning the Cables
To tension the cables:
2. Remove the X- and Y-axis covers. See 7.7 Removing the Axis Covers.
3. Loosen the X-Axis and two (2) Y-axis tensioner screws.
4. Move the Z-head in a circle around the dispensing area approximately 5 times.
5. Stop in the middle.
6. Retighten the tensioner screws.
1 2
Figure 7-9A Tensioning the X-Axis Cables Figure 7-9B Tensioning the Y-Axis Cables
Item Description
1 X-Axis Tensioner Screw
2 Y-Axis Tensioner Screw
Figure 7-9 Tensioning the Cables
Maintenance 7-13
7.10 Tensioning the Conveyor Belts
To tension the conveyor belts:
2. Loosen the belt tensioner screws (Figure 7-10).
3. Move the Motor Mount Tensioner up and down until the desired tension is obtained.
4. Tighten the tensioner screws.
5. Repeat Steps 1-3 for the other belt.
1 4

1 Motor Mount Tensioner - Rear Rail 4 Belt Tensioner Screws - Rear Rail (4)
2 Conveyor Belt 5 Motor Mount Tensioner - Front Rail
3 Belt Drive Pulley 6 Belt Tensioner Screws - Front Rail (4)
Figure 7-10 Tensioning the Conveyor Belts
" NOTE If the conveyor belts need to be replaced, refer to 9.7 Replacing the Conveyor Belts.
7-14 Maintenance
8 Troubleshooting
8.1 Overview
If you have difficulty operating your dispensing system, use this section to identify a possible solution to
the problem. If you have difficulties not listed in this section, or the suggested solution does not correct
the problem, contact Asymtek Technical Support. This section covers the following troubleshooting
procedures:
• System Power • Vision System

• System Accuracy • Scale
• Pneumatic • Needle Heater
• FmXP Startup • Tactile Sensor
• Dispense Head Controller Connections and Functions • Substrate Heaters
• Height Sensor • Conveyor
• Laser Height Sensor
" NOTE There are no user serviceable parts inside the electrical modules.
Refer to the FmXP User Guide or Online Help for assistance with FmXP.
8.2 Safety First

Operation of your S-920 Dispensing System involves air pressure, electrical power, mechanical devices,
and potentially the use of hazardous materials. The S-920 is an automated fluid dispensing system and the
type of fluids used vary widely. Customers should consult and adhere to their own internal safety
procedures with regard to material handling and the requirements outlined in their material safety data
sheets for the particular fluid being used. It is essential that every person servicing or operating the
WARNING! CAUTION!
Allow only qualified personnel to perform system troubleshooting. Observe and
follow the safety instructions in this document and all other related
documentation. Failure to do so may cause serious bodily injury to the user or
damage to the equipment.
8.3 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.
Troubleshooting 8-1
8.4 Basic System Troubleshooting
8.4.1 System Power
Table 8-1 System Power Troubleshooting
Symptom Possible Cause Recovery Procedures
The ON (l) button has not been Press ON (l) on the front panel. The green
pressed button will illuminate.
The S-920 incorporates circuit breakers with a
“push to reset” feature rather than fuses. For
detailed troubleshooting of power related
A circuit breaker has been tripped
issues, consult the power manager block
diagram 7207632BD or call Asymtek Technical
Support.
Check that the main power cable is connected
Main power cable is disconnected
to an AC source.
Turn ON (l) the main power switch at the rear
of the system. The S-920 sub-systems receive
electrical power entirely through the power
Main power circuit breaker is OFF manager, accessible from the rear of the
(0) machine. The main circuit breaker switch is the
No power to major
only mechanism for completely powering down
system components
the system, including power to the laptop
computer.
1. Turn the EMO button clockwise until it
pops out. The EMO buttons at the front
and rear of the system interrupt power to
EMO button has been activated all power connections except the laptop
computer.
2. Press ON (l) on the front panel.
Make sure the hood is closed. The interlock
places the servo control system in a low power
state that is just sufficient to hold the positioner
Interlock circuit is interrupted
in place for syringe changes. Opening the front
hood does not completely power down the S-
920, and does not power off the PC.
Ventilation Time Delay (Flux The dispensing system turns on after an
Applications) approximate 60-second vent air time delay.
Verify the power controls cables are properly
Power controls cable disconnected routed and connected from the Power
System fails to start Manager to the front panel switches.
Button failure Contact a service technician.
8-2 Troubleshooting
8.4.2 System Accuracy
Table 8-2 System Accuracy
Symptom Possible Cause Recovery Procedures
Refocus the camera. See 5.5 Focusing the
Loose camera lens
Camera.
Perform a Valve Offsets Routine. See 6.6
Bad offset routines
Establishing Machine Offsets.
Calibrate the camera. See 5.6 Calibrating the
Camera needs calibrated
Camera.
Inaccurate dispensing
Enable Cal Maps. Contact a service
Cal Maps disabled
technician.
Replace the needle. Refer to the applicable
Bent needle
valve manual.
Bad height sensor Contact Asymtek Technical Support.

Refocus the camera. See 5.5 Focusing the
Loose camera lens
Camera.
Fiducials not found
Re-teach the vision targets or entire program
Corrupted vision file
as necessary.
Troubleshooting 8-3
8.4.3 Pneumatic
Table 8-3 Pneumatic Troubleshooting
Symptom Possible Cause Recovery
With FmXP initialized, go to the tools menu,
then IO, then toggle the command button for the
Failed main air solenoid main air solenoid. The Valve and fluid air
buttons are also accessible from this tools IO
menu.
No air pressure System not connected to facility Check the main air inlet at the rear of the
air supply system.
Main air regulator closed Verify the main air regulator is set properly.
FmXP must be running to initialize the machine
FmXP not started
pneumatics.
Make sure the fluid pressure regulator is set to
Air pressure setting incorrect
the proper air pressure.
Contact Asymtek technical support for correct
bit mask values that control the pneumatic
Incorrect bit mask
No fluid pressure states for the particular fluid delivery system
being used.
Connect the syringe receiver head to the fluid
Syringe disconnected
(silver fitting) port on the dispensing head.
FmXP not started Start FmXP.
Make sure valve pressure regulator is set to the
Air pressure setting incorrect
proper air pressure.
Contact Asymtek technical support for correct
bit mask values that control the pneumatic
Incorrect bit mask
No valve pressure states for the particular fluid delivery system
being used.
Connect the syringe receiver head to the valve
Valve disconnected
(black fitting) port on the dispensing head.
FmXP not started Start FmXP.
" NOTE Refer to the system pneumatic diagram for details on pneumatics. See Appendix B
for details.
8-4 Troubleshooting
8.4.4 FmXP Startup
Table 8-4 FmXP Startup
Verify COM port settings and serial
Communications failure communications cables are attached. Restart
computer and retry.
The USB hub may have failed or lost power.
The laptop PC communicates to system
devices via the USB hub. Check the USB
USB communications failure
“The Dispenser ACLPlus connection and ensure the USB hub is
Device Failed to connected to its power source on outlet AC4
Respond” message from the power manager.
appears 1. Replace battery and reinitialize main PWA
memory.
Main PWA NVRAM failure 2. Run escape sequences and reload
machine specific personalities. Refer to the
system’s ACL Recovery Disk.
Check main PWA’s “Heartbeat” to see if board
Main PWA failure
is functioning. Cycle power and retry.
See System Power Recovery Procedures
No system power
(Table 8-1).
No dispensing head
Restore Interlock. See 2.10.1 Interlock
motion Interlock open
Recovery.
Home cable disconnected Connect cable.
Obstruction preventing machine
motion, and the servo system goes Remove obstruction.
Dispensing head fails to open loop
find home
Inspect and adjust home flag and retry. Replace
Home switch failure
home switch if broken.
Troubleshooting 8-5
8.4.5 Dispense Head Controller Connections and Functions
Table 8-5 Dispensing Head Troubleshooting
CAN terminator not present Verify presence of CAN terminator.
CAN firmware may need to be flashed to the
Corrupt firmware or incorrect revision correct or latest firmware. Contact Asymtek
Dispense Head Technical Support.
Controller fails to initialize
during FmXP startup Verify DHC power indicator LED’s for 3.3V, -
Failed Dispense Head Controller
12V, and 12V are illuminated.
Power Indicator lights on DHC will not be
200 Watt power supply has failed.
illuminated.
Height sensor has been adjusted or is Adjust height sensor and tighten locking screw.
loose See 5.10 Adjusting the Height Sensor Probe.
Dispenses at wrong
Z-axis position Perform a ”Valve Offsets” or “Calculate Master
Nozzle/needle has been changed Offsets” routine in FmXP. For assistance, refer
to the FmXP User Guide or Online Help.
Verify the valve type set in FmXP matches the
Valve setup incorrect dispensing valve, and that the valve is plugged
into the pump connector on the Dispense Head.
1. Ensure valve does not have cured material
inside of it.
No fluid dispensing 2. Exit FmXP, cycle power to the machine,
Valve Fatal Following Error (FFE) and retry.
3. PID parameters are not correct. Contact
Asymtek Technical support for correct PID
parameters for the particular pump being
used (applicable to the DV-7000, DV-8000,
and DP-2000 only).
8-6 Troubleshooting
8.4.6 Height Sensor
Table 8-6 Height Sensor Troubleshooting
Check for bent probe. Replace if necessary. See 9.9
Probe is damaged
Replacing the Height Sensor Probe.
No air pressure Verify main air pressure is ON (I).
Probe does not drop or Readjust the flow control located in the servo shelf by
retract Flow control improperly set
opening it to ¾ open. Refer to the system pneumatic
(closed to off) or there is a
diagram. Verify there is no kinked or pinched line from
pinched pneumatic line for the
the height sensor solenoid, through the cat track and to
height sensor.
the height sensor.
Main air pressure not set Readjust main air pressure regulator to system’s
Probe either drops too properly nominal pressure.
slowly or slams down with
too much force Readjust the flow control located in the servo shelf.
Flow control improperly set
Refer to the system pneumatic diagram.
Probe tip is lower than the
Adjust probe and perform “Valve Offsets” in FmXP.
needle tip when valve is in
See 5.10 Adjusting the Height Sensor Probe.
dispensing position.
Test the height sensor. FmXP provides a height sensor
test utility from the tools, diagnostics menu. The probe
The Height Sensor is not set up can be toggled up and down to verify probe
Needle hits substrate
properly. functionality. There is also a test procedure that
captures HS trigger values. FmXP can display a
statistical analysis of the captured values.
Reduce the HS velocity to 2 inches per second and re-
HS velocity is set too high run the valve offsets. Test the HS from the diagnostics
menu if necessary.
Safe Z-height too low Reteach Safe Z-height. See 6.6.2 Safe Z-height.
Probe hits substrate
before it is fully extended
Reteach the retract distance in the height sensor setup.
Retract distance too low
Refer to the FmXP User Guide or Online Help.
8.4.7 Laser Height Sensor

Table 8-7 Laser Height Sensor Troubleshooting
Check power connection and verify that Height Sensor
Height sensor is not plugged in
Height Sensor does not plugged in.
power up Bad resistor on the main board Use a multimeter to verify that the main board d-sub
d-sub connection. resistor is good.
Verify that dip switch number 6 on SW1 on the Main
Dip switches not set properly
Height Sensor does not Board is set to on. See Figure 8-2.
trigger Height sensor lens is dirty Check and clean the Height Sensor lens.
No communication with PC Verify I/O tools can toggle height sensor bits.
Intermittent function Loose or frayed cables Check cables for tight connection and wear.
Troubleshooting 8-7
8.4.8 Vision System
Table 8-8 Vision System Troubleshooting
No Image (FmXP Verify camera cable is securely connected to the
Camera not connected
display window is a connector on the top of the camera.
solid pink color) Faulty camera cable Replace camera cable.
Verify camera cable is securely connected to the
Camera not connected
Camera LED is OFF connector on the top of the camera.
Faulty camera cable Replace camera cable.
It may take several minutes for the camera to acquire
Camera LED
Camera not initialized a connection with the laptop. DO NOT attempt to run
Steady Red
FmXP or DALSA programs during this time.
1. Shutdown the computer and turn off power to the
Camera LED Slow machine.
Camera Initialization problem
Flashing Red 2. Restart the machine, and then the computer.
3. If necessary, contact a service technician.
Camera LED Fast
Camera overheated Contact a service technician.
Flashing Red
Camera LED Fast Verify Ethernet cable is securely connected to the
Ethernet cable disconnected
Flashing Blue camera and computer.
Increase light level in FmXP. See 6.8.2 Lighting and
Lighting intensity is too low
Color Adjustment.
Lighting module disconnected Restore lighting module connection.
No Image (FmXP 4. Remove and inspect the camera lens.
display window is
Lens is blocked by foreign matter 5. If necessary, replace lens.
dark or black)
See 9.8 Replacing the Camera Lens.
Lighting module is not functioning
Contact a service technician.
properly
Substrate is not within height
Adjust camera bracket. See 5.5 Focusing the
focus limits of the camera or the
Camera.
lens is loose
Unfocused image 1. Remove and inspect the camera lens.
Lens is damaged or there is 2. If lens is damaged or dirty, contact a service
foreign matter on the lens technician.
See 9.8 Replacing the Camera Lens.
Inaccurate 1. Recalibrate camera.
dispensing after Camera-to-needle offset is 2. Perform a “Valve Offsets” routine in FmXP. For
moving or replacing incorrect and vision system assistance, refer to the FmXP User Guide or
camera or lighting requires calibration Online Help.
module See 5.6 Calibrating the Camera.
Computer power switch OFF (0) Turn ON (I) computer power switch.
No monitor display
Monitor power or video cable is Verify that power and video cables are securely
not connected connected to the back of the monitor.
FmXP vision error Monitor power switch OFF Turn ON (I) monitor power switch.
encountered during Re-teach the vision targets or entire program as
Corrupted vision file
fiducial find necessary.
sequence. Loose camera lens Refocus the camera. See 5.5 Focusing the Camera.
8-8 Troubleshooting
8.4.9 Scale
Table 8-9 Scale Troubleshooting
Check power (+24V) and RS-232
No power
communications cables.
Verify that the RS-232 flex circuit connection is
Flex circuit connection
seated properly.
The flex circuit should be oriented so that the
No scale communication red dot [1] on the PCA matches the dot [2]
marked on the flex circuit. The flex circuit
Flex circuit orientation orientation can also be identified by the short
trace [3] that does not continue. See Figure 8-1.
Verify dip switch configuration as shown in
Figure 8-2.
Pedestal not installed. There is a
You will typically receive an FmXP error
Scale Error No. 54 minimum weight that must be
message when the pedestal is not installed on
(Figure 8-4) placed on the scale in order for it to
the scale.
read properly.
Verify that the scale lid is installed. Air
Lid not on scale
turbulence will cause scale instability issues.
Verify that the front hood of the machine is
Dispensing system hood open closed. Slight air turbulence can cause unstable
readings.
Unstable scale Verify that the machine is leveled properly by

Scale not level viewing the level bubble on the scale. See 3.8
Leveling the Scale.
In some rare cases, vibration through the floor
can cause scale instability issues. This is most
Floor vibration
common where the S-920 is not installed on a
concrete floor.
Figure 8-1 Scale Flex Circuit Orientation
Troubleshooting 8-9
Figure 8-2 Scale Dip Switch Configuration
" NOTE The scale can also be tested from the FmXP Terminal Mode. See instructions below.
To test the scale from the FmXP terminal mode:

1. From the FmXP Main Window, select Tools.
2. From the Tools menu, click on Terminal and then on Scale .

3. VERY CAREFULLY use the following commands to check the scale responses:
! ESC P (escape key and capital P) Outputs the current scale value to the terminal screen.
! ESC S (escape key and capital S) Restarts the scale, but gives no response.
! ESC T (escape key and capital T) Tares and Re-zeroes the scale.
4. If the scale responds to these commands then there may be a software configuration issue.
Verify the scale is configured from the configuration menu. The scale type selected should be
SART-WZ (Figure 8-3). For detailed instructions, refer to the Fluidmove User Guide or
Online Help.
8-10 Troubleshooting
Figure 8-3 FmXP Scale Setup Menu
Figure 8-4 Scale Error Message
Troubleshooting 8-11
8.4.10 Needle Heater
Table 8-10 Needle Heater Troubleshooting
Set Point (SP) value below Present
Change the SP value within the Heater Controls
Value (PV) or the heater is in an
Window. See 6.9.2 Setting the Heaters.
idle state
Verify the needle heater cable connections are
Disconnected heater
securely attached to the correct ports.
No needle heat Verify DHC indicator lights for 3.3V, -12V, and
Failed DHC power
12V are illuminated.
Verify the needle heater electrical parameters.
The resistance between pins 4 and 5 for the
Failed heater heating element should be 100 ohms +/- 5 ohms.
The resistance of the RTD sensor between pins
6 and 7 should be 108 ohms, +/- 5 ohms.
8.4.11 Tactile Sensor

Table 8-11 Tactile Sensor Troubleshooting
Visually inspect the sensor cap for fluid buildup.
If there is fluid, clean as specified in 8.4.11.1
Tactile Sensor Error. If there is no fluid, call a
service technician.
During setup routine,
error indicates that the Tactile sensor cap is stuck in the
tactile sensor is already down position The tactile sensor signal can be tested from the
engaged Fluidmove Tools > IO menu. Select IO and
inputs. Locate the tactile cap signal display and
monitor its state as the cap is depressed and
released. If the state does not change, the
precision switch may have failed.
1. Clean probe tip/tactile sensor cap. See
Fluid build-up on probe tip or tactile 8.4.11.1 Tactile Sensor Error.
Needle-to-height-sensor
sensor cap may have caused 2. Perform a “Valve Offsets” routine in FmXP.
offset is inaccurate
inaccurate height sensor calibration For assistance, refer to the Fluidmove User
Guide or Online Help.
8.4.11.1 Tactile Sensor Error
If you receive a tactile sensor error, the following procedure may remedy the error.
" NOTE If you continue to receive tactile sensor errors after performing the following procedure,
contact Asymtek Technical Support.
1. Gently lift the cap off of the tactile sensor as shown in Figure 8-5.
2. Use isopropyl alcohol and a soft cloth to remove any residual fluid from around the
circumference of the cap and around the tactile sensor opening. Carefully remove any
residual fluid from the sensor tip as well.
3. Replace the cap.
4. In the Main Window, click on Tools.
5. In the Tools Window, click on I/O Test.
6. Click on Dispenser.
7. Locate the I/O for the tactile sensor.
8. Gently press down on the tactile sensor and make sure that the bit toggles ON and OFF.
! If the bit does not toggle ON and OFF, the tactile sensor may need to be replaced. Contact
Item Description
1 Tactile Sensor Cap
2 Tactile Sensor
Figure 8-5 Tactile Sensor Exposed
8.4.12 Substrate Heaters
Table 8-12 Substrate Heater Troubleshooting
Missing vacuum hole screw(s) Replace screw(s).
Hissing air leak
Other pneumatic leaks Contact a service technician.
Erroneous temperature
Wrong display unit Change display unit to C.
display
Workpiece part not held Check for improper open or
Remove and install screws as applicable.
steady plugged vacuum holes
1. Verify air is connected to facility air supply.

Vacuum does not start or
System has low or no air pressure 2. Set main air regulator to approximately
fails to work properly
90 psi.
Set Point (SP) value below Present Change the SP value within the Heater Controls
Value (PV) Window. See 6.9.2 Setting the Heaters.
Verify the heater cable connections are securely
Disconnected heater
attached to the correct ports.
Hot plate does not heat
Hardware or software failure Contact a service technician.
Check the fuses by the heater power
Blown fuse on the Conveyor/Heater
connections on the conveyor controller and
Controller
replace if necessary. See 9.10 Replacing Fuses.
8.4.13 Conveyor
Table 8-13 Conveyor Troubleshooting
1. Turn the EMO button clockwise until it pops
EMO button has been activated back into position.
2. Press ON (l) on the operator’s console.
X or Y Motor cables are loose Call a trained service technician.
Rails or belt will not move
Check the fuses by the heater power
Fuse is blown in Conveyor/Heater
connections on the conveyor controller and
Controller Power Supply
replace if necessary. See 9.10 Replacing Fuses.
Conveyor/Heater Controller
Call a trained service technician.
malfunction
Adjust Tooling Air Pressure Regulator to supply
Tooling Air pressure is too low
275 kPa (40 psi).
Leaking component or line must be located and
There is an air leak in a pneumatic
repaired or replaced. Call a trained service
line or component
technician.
Stop pins, lift tables or
clamps are inoperative The pneumatic device has failed Call a trained service technician.
The Solenoid Valve must be replaced. Call a
Solenoid Valve is defective
trained service technician.
Conveyor may not be properly
Call a trained service technician.
configured in Fluidmove
Table 8-13 Conveyor Troubleshooting (Continued)
Workpiece or carrier is jammed Call a trained service technician.
Conveyor does not
SMEMA interface is not functioning
transfer parts from Call a trained service technician.
properly
upstream to downstream
machines Incorrect alignment of upstream or The machines must be realigned. Call a trained
downstream machine service technician.
Sensor is not active Call a trained service technician.
Board sensors not
sensing when board is Sensor is dirty Clean sensors with a soft cloth or with blown air.
present
Sensor is out of adjustment Call a trained service technician.
Stop Pin is not receiving air Call a trained service technician.
Clean sensor.
Board Sensor is dirty, not active or
Board will not index to If no improvement, call a trained service
out of adjustment
correct position technician.
Gap between conveyor rails is too Check conveyor width and readjust as
narrow necessary.
Conveyor/Heater Controller has Verify that the AC power cable is connected to
Conveyor does not move no power the module and to the facility power source.
at all (with Fluidmove
position controls) Fuse is blown in Conveyor/Heater
See 9.10 Replacing Fuses.
Controller
1. Stop the dispensing program.
2. Realign the workpiece on the conveyor belt.
Gap between conveyor rails is too
wide 3. Use the Fluidmove position controls to
Conveyor jams or does adjust the rail gap.
not move
4. Restart the dispensing program.
Stop the dispensing program and remove the
The carrier is bent
carrier.
Fails to find width Home The width “home” sensor has failed Call a trained service technician.
9 Parts Replacement
9.1 Overview
This section includes general information for ordering recommended spares and replacement parts for
your Spectrum S-920 Dispensing System. Replacement part numbers are listed in Appendix C. Part
number information is also available on Asymtek’s Find-A-Part web page:
http://webstore.asymtek.com/awweblive/apps/findapart_index.asp
This section contains the following procedures:
• Parts Ordering Information

• Cleaning and Inspection
• Unpacking and Inspecting Replacement Parts
• Gaining Access to Dispensing System Components
• Replacing the Conveyor Belts
• Replacing the Camera Lens
• Replacing the Height Sensor Probe
• Replacing Fuses
" NOTE This section does not include the removal and replacement of dispensing valve
components. Refer to the manual for your specific dispensing valve for instructions.
WARNING! CAUTION!
Operation of your S-920 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.
9.2 Record Keeping

The type of service performed should be recorded in the dispensing system maintenance records. Dates,
part numbers/serial numbers of replaced parts, names of technicians, and other pertinent data should be
recorded.
WARNING! Some part replacement procedures involve the use and disposal of hazardous
materials. Always follow the material manufacturer MSDS, facility requirements,
and local regulations for protection of personnel and disposal of materials.
Parts Replacement 9-1

9.3 Parts Ordering Information
9.3.1 Placing Your Order
Customers can order spare parts by contacting Asymtek Customer Service. Your Customer Service
Representative can take your order or assist you in setting up an account to purchase spare parts through
our Internet Web Store. When ordering parts, be prepared to provide the following information:
Your Company Name Billing Address

Shipping Address Part Number and Description
Purchase Order Number Quantity
Dispensing System Serial Shipping Instructions with Collect
Number (found on back panel) Account Number
" NOTE Find Customer Service contact information in the front of this manual or click on
Customer Service on Asymtek web page www.asymtek.com.
2
9.3.2 Shipping Instructions
When ordering parts, specify which carrier you prefer to use and provide your shipping account number.
If no instructions are received, Asymtek will determine the best shipping method and items will be
shipped prepaid with the shipping charge added to the invoice.
9.3.3 Warranty
Contact Asymtek Technical Support for any warranty issues pertaining to spare parts.
9.3.4 Credit and Exchanges
Contact Asymtek Customer Service for credit or exchanges of recommended spare parts or refurbished
components (components restored to original specifications but not sold as new).
9.3.5 Return Material Authorization
Contact Asymtek Technical Support to obtain a Return Material Authorization (RMA) before returning
any parts.
" NOTE Find your local Technical Support contact on the Asymtek web page,
www.asymtek.com/support.htm.
3H
9-2 Parts Replacement

9.4 Cleaning and Inspection
Always clean the area made visible after a failed part is removed from the dispensing system. Inspect the
area for signs of what may have caused the part to fail. This may help prevent future part damage.
While removing parts that will be reinstalled, visually inspect them for damage. If found undamaged,
retain them for reinstallation. Replace damaged parts and hardware as appropriate.
9.5 Unpacking and Inspecting Replacement Parts

Replacement parts are shipped to distributor or customer facilities in individual shipping cartons. Review
the packing slip to ensure that the correct parts were received. Contact Asymtek Technical Support if any
discrepancies are discovered.
Before unpacking your spare parts, visually inspect the carton for damage. If applicable, check the
ShockWatch and the Tip N’ Tell stickers for indications of improper shipping and handling. Inform the
freight carrier of any damage.
TIP Save shipping materials for returning failed parts.
WARNING! CAUTION!
Parts replacement should only be performed by a trained service technician.
Asymtek assumes no liability for personal injury or property damage that may
occur as a result of spare parts being replaced by a non-certified technician.

9.6 Gaining Access to Dispensing System Components
In order to gain access to some areas of the dispensing system, it will be necessary to remove covers,
doors, and access panels. Figure 9-1 shows the location of these features.
12H
WARNING! CAUTION!
Make sure that the dispensing system has been completely shut down before
attempting to remove any panel. Remove doors, covers, and panels carefully to
avoid damaging underlying components.
Figure 9-1 Gaining Access to Dispensing System Components

9.7 Replacing the Conveyor Belts
Checking the condition of the conveyor belts should be part of the routine maintenance schedule for the
dispensing system. Cracked, worn, or broken belts should be replaced immediately.
To maintain reliable system performance, it is recommended that the conveyor belts be changed every six
months. However, the belts may need to be changed more frequently or less frequently, depending upon
the volume of workpiece production.
• 4 mm Hex Key • Soft Cloth and Cotton Swabs

• 2.5 mm Hex Key • Two Conveyor Belts (P/N 7209910)
• Isopropyl Alcohol • Removable Thread Locker (P/N 40-0019)
• Phillips Head Screwdriver • Torque Wrench
To remove a conveyor belt:
CAUTION! This procedure should only be performed by a trained service technician.
" NOTES Only one belt should be removed at a time. Use the other belt as a reference for proper
orientation of the belt being replaced.
All components and fasteners removed during this procedure should be retained in an
orderly manner and in a safe location for reinstallation or shipment back to Asymtek.
1. Move the dispensing head to the home position.
2. Use the FmXP Jog Controls to move the rear conveyor rail to the extreme back of the
dispensing chamber.
4. Open the hood.
5. Remove any rail-mounted components that interfere with belt removal/replacement.
! If stop pins interfere, use a 2.5 mm hex key to remove the stop pins along the length of
the conveyor rails.
" NOTE For ease of reinstallation, you should note the locations and orientations of
rail-mounted components before removing them.
6. Slide the old belt off the pulley tires and discard.

4
3
2 6
1 8

1 Tensioner Screws 5 Motor Mount Tensioner
2 Pulley Tire 6 Rear Conveyor Rail
3 Conveyor Belt 7 Front Conveyor Rail
4 Belt Drive Pulley 8 Stop Pin
Figure 9-2 Conveyor Belt Removal/Installation

To install a conveyor belt:
CAUTION! This procedure should only be performed by a trained service technician.
1. Using isopropyl alcohol and a soft cloth or cotton swabs, clean all metal surfaces that make
contact with the belt, including pulleys and rails.
2. Compare the new belt to the one remaining on the other rail to determine its proper
orientation.
3. Loop the belt around the pulley tire at one end of the conveyor rail and extend it toward the
other end. See Figure 9-2.
13H
" NOTE If you are installing the belt by yourself, it may be helpful to hold the end of the
belt in place by attaching it to the conveyor rail with a tie wrap or rubber band.
4. Loop the conveyor belt around the two pulley tires and the belt drive pulley as shown in
Figure 9-2.
14H
5. Continue to extend the belt and loop it onto the pulley tire at the far end of the conveyor rail.
If you cannot get the belt onto the pulley tire, proceed as follows:
a. Loosen the four belt tensioner screws.
b. Move the Motor Mount Tensioner up until the belt is looped over the pulley.
c. Hold the pulley tire and belt securely in place while tightening the screws with a 4 mm
hex key. Torque the screws to 87 in-lbs (1.0 kg-m).
6. If used, remove the tie wrap or rubber band securing the conveyor belt to the end of the
conveyor rail.
7. Reinstall any removed stop pins to their former positions.
8. When both conveyor belts have been replaced, power on the dispensing system.
9. In the FmXP Jog Commands dialog box, click on both the slow and the fast X-axis
jog buttons to move the conveyor belts in both directions.
! The conveyor belts should move smoothly in both directions with no slipping on their
pulleys.
10. If necessary, tension the conveyor belts as described in 7.10 Tensioning the Conveyor Belts.

9.8 Replacing the Camera Lens
CAUTION! Except for lens replacement and lighting adjustments, all other configuration and
adjustments should only be performed by a trained service technician.
To remove and replace the camera lens:

1. Remove the lens by turning the lens tube counterclockwise (Figure 9-3).
15H
2. Screw on the replacement lens by turning the lens tube clockwise.
Item Description
1 Camera
2 Lens Tube
Figure 9-3 Camera Lens Replacement

9.9 Replacing the Height Sensor Probe
To replace the Height Sensor Probe:
1. Remove all valve clamps attached to the Z-head (Figure 9-4).
16H
2. Remove the Z-head top cover.

3. Remove the front valve panel.
4. Unhook the two springs from the upper spring bracket.
5. Remove the Z-plate.
6. Dismount the height sensor assembly from the Z-carriage.
4
6
5
2
Figure 9-4A Removing the Z-head Top Cover

17H Figure 9-4B Removing the Z-plate
18H
and Front Valve Panel

1 Z-head Cover and Front Valve Panel 4 Z-plate
2 Valve Clamps 5 Height Sensor Assembly
3 Upper Bracket Springs 6 Z-carriage
Figure 9-4 Removing the Z-Head Panels

7. Turn over the height sensor assembly to reveal the probe (Figure 9-5).
19H
8. Loosen the screw and remove the probe from the top.
9. Replace the probe and re-mount the height sensor assembly.
10. Re-attach the two springs to the upper bracket.
11. Reach under the Z-head cover and firmly pull out the two springs and hook on to the
lower bracket.
12. Re-attach the Z-plate, valve clamp, and all other covers.
Item Description
1 Height Sensor Probe
2 Lower Bracket Springs
3 Probe Adjustment Screw
Figure 9-5 Height Sensor Probe

9.10 Replacing Fuses
Use the following procedures to remove and replace a fuse.
CAUTION! Always replace fuses with fuses of identical rating and size. Failure to do so may
not protect components from damage.
• ESD Grounding Strap • Replacement Fuse (see Table 9-1)

• Small Flat Head Screwdriver* • Phillips Screwdriver*
*In the Spectrum Tools and Spares Kit (P/N 7204804) included with the dispensing system.
9.10.1 Fuse Mounting
This subsection describes the replacement of glass fuses mounted in the following manner:
• Board-Mounted Fuses
• Panel-Mounted Fuses
9.10.2 Replacement Fuses
There are approximately nine (9) replaceable fuses (see Table 9-1) on the standard Spectrum S-920 Series
Dispensing System. This number may vary depending on system configuration. All fuse locations are
clearly labeled.
Table 9-1 Replaceable Fuses
Part Mount
Qty. Location Rating Size
Number Type
7204226 1 PWA, SDHC 5A, 125V 280 mil Board
7204794 8 Heater Relay Module 6.3A, 250V, SLOW 5 x 20 mm Panel
9.10.3 Board-Mounted Fuses
This circuit board fuse is mounted in a holder on the Single Dispense Head Controller PWA (SDHC)
located in the back of the dispensing system. The fuse protects the SDHC from damage caused by
electrical overloads from +24V supplied circuits. See Figure 9-6.

To remove and replace the SDHC board-mounted fuse:
CAUTION! This procedure should be performed by a trained service technician only.

2. Open the rear dispensing system door and locate the SDHC. If necessary, refer to the
Electrical Diagram P/N 7207632BD in Appendix B.
CAUTION! The circuit board and its components are susceptible to damage by electrostatic
discharge. Observe all ESD protection protocols while performing this procedure.
3. Remove and properly dispose of the old fuse.

4. Verify that you will be installing the correct replacement fuse and then trim the leads on the
replacement fuse and bend them in same orientation as the old fuse.
5. Insert the new fuse into the Fuse Holder (Figure 9-6).
25H
6. Power on the dispensing system as described in 4.5 Powering On the Dispensing System.
7. Verify that the LEDs on the SDHC are now lit.
9. Replace the covers.
5A Fuse*
Figure 9-6 Replacing the SDHC Board-mounted Fuse
*Replacement Fuse P/N 7204226 (included in P/N 7204804 Tools & Spares Kit).
See Appendix C for list of spare parts.

9.10.4 Panel-Mounted Fuses
These glass fuses are located on the front panel of the Conveyor/Heater module. The fuses protect the
module from damage caused by power surges from the heater tooling (Figure 9-7).
26H
Figure 9-7 Replacing a Panel-mounted Fuse
To remove and replace panel-mounted fuses:
CAUTION! This procedure should be performed by a trained service technician only.

2. With your fingers, gently push in and turn the fuse holder counterclockwise until the head of
the fuse holder pops out enough to allow you to grasp it (Figure 9-7).
27H
3. Pull the fuse holder out of its socket.

4. Remove and discard the damaged fuse.
5. Verify that you will be installing the correct replacement fuse and then insert the new fuse
into the fuse holder.
6. With your fingers, simultaneously push and twist the fuse holder clockwise into the socket
until it locks into place.

10 Specifications
10.1 Overview
Facility requirements and specifications are listed in Table 10-1 to Table 10-4. These specifications are
0H 1H
intended as a convenient reference for installation, system relocation, planning and operation. Meeting the
requirements will ensure reliable operation and safety of the dispensing system.
WARNING! CAUTION!
To ensure optimal performance and safety, it is necessary to install the
dispensing system in a facility that meets the necessary requirements listed in
Table 10-1. If you have any questions, please contact Asymtek Technical
2H
Support.

Table 10-1 Facility Requirements
Facility Requirements
Single Station: 600 mm x 1310 mm
System Footprint Two Station: 850 mm x 1310 mm
Three Station: 1100 mm x 1310mm
Single Station: 371kg [820 lbs]
Weight Two Station: 401kg [885 lbs]
Three Station: 431 kg [950 lbs]
689 kPa (6.8 atm, 100 psi), 3 CFM @ 100 psi (28 liters/hr = 3 SCFM) May
Air Supply
be higher depending upon application.
Main Power Supply 180 - 264 VAC, 47-63 Hz, Single Phase
Current Consumption 6A max (standard configuration)
Ambient Air Temperature 5-50 ℃
Relative Humidity < 90% non condensing
Altitude 1609 meters
Minimum Ventilation Rate 100 cfm
10.2.1 System Dimensions
Detailed system dimensions are shown in the diagram listed in Table 10-2. A laminated copy is included
3H
with the dispensing system.
Table 10-2 System Dimensions Diagram
Drawing Number Title

7210740 S-920 Facility Specification
Specifications 10-1
10.3 Specifications
Table 10-3 Specifications
Specifications
Single Dispense Head: 340 mm x 415 mm [13.4 in. x 16.3 in.]
Dispensing Area Z-Travel: 60 mm
Z-Axis Payload: 3 kg
Type: Brushless DC servo motors, closed-loop encoder feedback
X-Y Velocity: 1000 mm/s maximum
Z-Axis Velocity: 500 mm/s maximum
Motion System X-Y Repeatability: ±0.025 mm (0.001 in.)
Z-Axis Repeatability: ±0.025 mm (0.001 in.)
X-Y-Z Resolution: 0.005 mm (0.0002 in.)
Positional Accuracy: ±0.050 mm (0.002 in.)
Vision system with Automatic Pattern Recognition
Vision and Lighting Image size: 6.35 mm (0.25 in.) standard
Lighting: Programmable, red/blue LED, 256 steps
SMEMA Compliant
Single or Dual Lane Configuration
Flat Belt
Conveyor Motorized Rail Spacing
1 Dispensing Station standard, 3 Dispensing Stations available
Fiber-optic over-the-rail board sensors at all stations
Over-the-rail stop pins
Needle Vacuum Purge Cup
Service Station On-Board High Precision Scale
Needle Calibration Substrate
Heaters 120°C, ± 5°C for impingement heaters
Standard: Integral Mechanical Height Sensor
Height Sensor
Optional: Laser
Windows-based Laptop PC with DVD-RW drive
Computer User interface: Color LCD flat-panel display; ASCII keyboard & touchpad;
Ethernet network port, left and right USB ports
User Environment: Fluidmove for Windows XP
Software
Operating System: Windows XP
DispenseJet DJ-9000; DJ-2200, Heli-flow DV-7000 and DV-8000 pumps;
Fluid Delivery Method
DV-01, DV-02, DV-03, DV-05, DV-07, DV-09.
S-920 Idle: 550 W
S-920 Peak: 1000 W (Not including heaters)
Energy Consumption
S-922 Idle: 625 W
S-922 Peak: 1075 W (Not including heaters)
AIC Interrupt Capacity 10kA
Audible Noise Level 70 dBA, 76 db peak
Ionizing and Non-ionizing
N/A
Radiation
Contaminants N/A
Residual Risks of
Materials Used to None
Construct Equipment
10-2 Specifications
10.4 Stability Analysis
Table 10-4 Stability Analysis
Specifications
Single Station: 296.5 mm (11.67 in.)
Center of Gravity Two Station: 800.7 mm (31.52 in.)
Three Station: 587.4 mm (23.12 in.)
Weight Distribution (1)
Front Left 92.0 kg (202.9 lbs)
Front Right 93.9 kg (207.1 lbs)
Rear Right 94.2 kg (207.6 lbs)
Rear Left 91.8 kg (202.4 lbs)
Seismic Loading
Transverse Stability Anchors Required
Anchorage Force 208.6 kg (460 lbs)
Longitudinal Stability Anchors Required
Anchorage Force 64.4 kg (142 lbs)
Tilt Angle (1)
Transverse Stability-CCW 17.1
Transverse Stability-CC 16.8
Longitudinal Stability-CCW 30.8
Longitudinal Stability-CC 31.5
(1)
User facing front end of the unit.
Specifications 10-3
12 11 10 9 8 7 6 5 4 3 2 1
REV ECO DATE DESCRIPTION APPD
B.HEUY
1 9/8/2007 PRE PRODUCTION RELEASE. (raw)
NOTES:
1100.0
1. FACILITIES REQUIREMENTS: CONVEYOR WIDTH
H H
SYSTEM FOOTPRINT: SEE ILLUSTRATION
AIR SUPPLY: 621kPa(6.2 bAR, 90 Psi) 28 LITERS/MIN. = 1SCFM STANDARD. R481
MAIN AIR 1 @ UP TO 4.4 SCFM, DEPENDING ON APPLICATION. REAR DOOR
MAIN AIR 2 @ UP TO 15 SCFM FOR IMPINGEMENT AIR.
POWER REQUIREMENTS: 200-400 VAC, SINGLE PHASE, 50-60 Hz @ 30A 294
VENTILATION
SYSTEM WEIGHT: 357.4 TO 372.0 kg (788 TO 820lbs.) DEPENDING ON
CONFIGURATION 104
MAIN POWER
CRATE DIMENSIONS: 1930.0 X 1321.0 X 1981.0mm (76.0 X 52.0 X 78.0 in.)
CRATE WEIGHT: 544kg (1200lbs.
G VENTILATION REQUIREMENTS: UP TO 300 SCFM @ 1in. WATER. VARIES G
ACCORDING TO PLATFORM AND/ OR
APPLICATION.
2. STANDARDS COMPLIANCE: SEMI-S2; SEMI-S8; SMEMA; CE.
3. ALL DIMENSIONS TAKEN WITH BOARD TRANSFER HEIGHT OF 952mm. 999.7
4. ALLOW 300mm AT MACHINE FOR DISCONNECT OF MAIN POWER. 878
1061
STANDARD CORD LENGTH OF 2.5 METERS IS SUPPLIED FOR
FACILITY POWER. VENTILATION 936.2
PRODUCT
5. RECOMMENDED 1X 3.8in. (9.53mm) REDHEAD TRUEBOLT WEDGE ANCHOR FLOW
PER FOOT (REFERENCE ICBO REPORT #1372). MINIMUM OF 2000 PSI
REGULAR WEIGHT CONCRERE, EMBEDED 3 in.
F F
154
A 2X 12.7
63.5
433.0 DETAIL A
R472 SCALE 1 : 4
FRONT DOOR 543.0
250 250
E PRE-HEAT POST-HEAT E
1088 SEISMIC RESTRAINT DIAGRAM
D 0 1 2 3 4
D
GEOMETRIC DRAWING SYMBOLS:

STRAIGHTNESS PROFILE OF A LINE POSITION
FLATNESS PROF OF A SURFACE CONCENTRICITY
35 CYLINDRICITY ANGULARITY SYMMETRY
CIRCULARITY PERPENDICULARITY CIRC RUNOUT
XX BASIC DIM PARALLELISM TOTAL RUNOUT

M MAX MATERIAL CONDITION
P PROJECTED TOLERANCE ZONE
DIAMETER
COUNTER SINK THIRD ANGLE PROJECTION
COUNTER BORE
SQUARE
C DEPTH
C
80
2086 MAIN AIR #1 METRIC
1977
UNLESS OTHERWISE SPECIFIED
1526 DIMENSIONS ARE IN MILLIMETERS & PER ASME Y14.5M
TOLERANCE: X ± 0.5mm
TOLERANCE: 0.X ± 0.3mm
953
TOLERANCE: 0.XX ± .13mm
CONVEYOR
TOLERANCE ANGLES: ± 0° 30'
1069 HEIGHT 579 SURFACE FINISH: N7 MIN
1094 REAR EMO
FLAT PANEL REMOVE BURRS AND BREAK SHARP EDGES 0.25 MAX
948 829 DIMENSIONS DISPLAYED IN [ ] ARE INCHES
869
MAIN AIR #2
B 757 COMPUTER INSPECTION DIMENSIONS DISPLAYED: X.XX
B
HEIGHT THIS MATERIAL IS THE PROPERTY OF ASYMTEK.
NO RIGHTS ARE GRANTED TO USE SUCH MATERIAL
FOR ANY PURPOSE OTHER THAN FURNISHING OF
SERVICE AND SUPPLIES TO ASYMTEK.
106 B 2762 LOKER AVENUE WEST
CARLSBAD, CA 92008-6603
(760)431-1919 A NORDSON COMPANY
488.0 231.6 TITLE:
50.0
109.5 968.0 MAIN POWER 900 SERIES DATA SHEET, PRE
DISCONNECT
1187.0 & POST HEAT STATIONS
DRAWN: DATE:
1320.8 DRAFTER MM/DD/YY
CHECKED: DATE:
A ENGINEER:
ENGINEER
DATE:
MM/DD/YY A
APPROVAL: SCALE:
1:12
920 DATA SHEETS.SLDDRW
ELECTRONIC FILE: SHEET:
1 of 1
SIZE DRAWING NO. REV
QTY UNIT VENDOR PART OR NOMENCLATURE OR MATERIAL ITEM
QTY REQD
NO IDENTIFYING NO. DESCRIPTION
PARTS LIST
SPECIFICATION NO.
A1 920 DATA SHEETS 1
DOC-40 REV A 12 11 10 9 8 7 6 5 4 3 0 10 20 30 40 50 60 70 80 90 100
Appendix A Material Safety Information
A.1 Introduction
This section contains Material Safety Information for the following materials contained in the Asymtek
Grease Kit (P/N 7203262).
• MULTEMP PS NO 2-A 07-350

• Moly-Graph® Extreme Pressure Multi-Purpose Grease
WARNING! CAUTION!
A.2 MSDS - MULTEMP PS NO 2-A 07-350

Material Safety Data Sheet
SECTION I - Material Identity

Item Name
Part Number/Trade Name MULTEMP PS NO 2-A 07-350
National Stock Number 9150PS2A
CAGE Code KYODO
Part Number Indicator A
MSDS Number 193523
HAZ Code B
SECTION II - Manufacturer's Information
Manufacturer Name KYODO YUSHI CO LTD
Street DENTSU KOSAN DAI-8 BLDG
City GINZA, CHUO-KU
Country JA
Zip Code 2-16-7
Emergency Phone 03-3543-5813
MSDS Preparer's Information
Date MSDS Prepared/Revised 18SEP96
Active Indicator Y
Alternate Vendors
Appendix A - Material Safety Information A-1

MSDS - MULTEMP PS NO 2-A 07-350 (Continued)
1H
SECTION III - Physical/Chemical Characteristics

Appearance/Odor WHITE PASTE; SLIGHT ODOR
Boiling Point NA
Melting Point 190 C
Vapor Pressure NA
Specific Gravity 0.92
Solubility in Water NEGLIGIBLE
Container Type R
Container Pressure Code 1
Temperature Code 4
Product State Code S
SECTION IV - Fire and Explosion Hazard Data
Flash Point 215
Flash Point Method SCC
Lower Explosion Limit NA
Upper Explosion Limit NA
DRY CHEMICAL, WATER FOG, CO2, FOAM,
Extinguishing Media
SAND/EARTH
DENSE SMOKE. FIRE FIGHTER WEAR
Special Fire Fighting Procedures APPROVED SCBA. DO NOT USE WATER
EXCEPT FOG
SECTION V - Reactivity Data
Stability YES
Stability Conditions to Avoid AVOID OVER-HEATING
Materials to Avoid STRONG OXIDIZERS SUCH AS HYDROGEN
PEROXIDE, BROMINE, & CHROMIC ACID
Hazardous Decomposition Products CARBON MONOXIDE & DIOXIDE, OXIDE OF
NITROGEN
Hazardous Polymerization NO
Polymerization Conditions to Avoid WILL NOT OCCUR
SECTION VI - Health Hazard Data
Route of Entry: Skin U
Route of Entry: Ingestion U
Route of Entry: Inhalation U
Health Hazards - Acute and Chronic {EYES}
{EYES} IMMEDIATELY FLUSH W/ WATER
FOR AT LEAST 15 MIN. {SKIN} REMOVE
EXCESS W/ CLOTH OR PAPER & WASH
Emergency/First Aid Procedures THOROGHLY W/ SOAP & WATER. {INGEST}
CONSULT PHYSICIAN. DO NOT INDUCE
VOMITING {INHALE} KEEP VICTIM WARM &
QUIET. REMOVE TO FRESH AIR
A-2 Appendix A - Material Safety Information

MSDS - MULTEMP PS NO 2-A 07-350 (Continued)
2H
SECTION VII - Precautions for Safe Handling and Use

TRANSFER BULK OF MIXTURE INTO ANOTHER
CONTAINER. ABSORB RESIDUE W/ AN INERT
MATERIAL SUCH AS EARTH, SAND, &
Steps if Material Released/Spilled
VERMICULITE. SWEEP UP & DISPOSE SOLID
WASTE IN ACCORDANCE W/ LOCAL, STATE &
FED REGS
DISPOSE OF IN ACCORDANCE W/ STATE,
LOCAL & FED REGS. INCINIRATE IN ACCORD.
Waste Disposal Method
W/ APPLICABLE REGS. MATERIAL MAY BE
RECOVERED & RECYCLED
KEEP CONTAINER CLOSED UNTIL READY FOR
Handling and Storage Precautions USE. STORAGE AWAY FROM FIRE SOURCE OR
SUNLIGHT & IN COOL DRY AREA
DO NOT USE PRESSUE TO EMPTY
CONTAINER. WHEN EMPTY, CONTAINER MAY
Other Precautions HAVE VAPOR OR PRODUCT RESIDUE. DO NOT
CUT, PUNCTURE OR WELD ON OR NEAR THE
DRUM
SECTION VIII - Control Measures
Respiratory Protection GOOD VENTILATION SHOULD BE SUFFICIENT
Ventilation GOOD GENERAL VENT. SHOULD BE
SUFFICIENT
Protective Gloves RUBBER OR PLASTIC OIL RESISTANT
Eye Protection CHEMICAL SAFETY GOGGLES & IF HANDLED
HOT, FULL FACE SHIELD
Other Protective Equipment NONE
SECTION IX - Label Data
Protect Eye NO
Protect Skin NO
Protect Respiratory NO
Chronic Indicator UNKNOWN
Contact Code UNKNOWN
Fire Code UNKNOWN
Health Code UNKNOWN
React Code UNKNOWN
SECTION X - Transportation Data
SECTION XI - Site Specific/Reporting Information

Volatile Organic Compounds (P/G) 0
Volatile Organic Compounds (G/L) 0
SECTION XII - Ingredients/Identity Information
Ingredient # 01
Ingredient Name *REFINED MINERAL OIL
CAS Number 101316727
Percent 25

A.3 MSDS Moly-Graph® Extreme Pressure Multi-Purpose Grease
MATERIAL SAFETY DATA SHEET
Section 1: Product & Company Identification

Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Grease
Product Number (s): SL3330, 8SL3330
Manufactured By: CRC Industries, Inc. (215) 674-4300
885 Louis Drive, Warminster, PA 18974
4-Hour Emergency Information: CHEMTREC (800) 424-9300
Section 2: Composition/Information on Ingredients
CAS ACGIH OSHA OTHER
Component NUMBER TLV PEL LIMITS %
Petroleum Distillate 64742-52-5 10 mg/m3 5 mg/m3 NE 70-100
Molybdenum Disulfide 1317-33-5 10 mg/m3 10 mg/m3 NE 0-1
Natural Graphite 7782-42-5 2.5 mg/m3 2.5 mg/m3 NE 0-1
Section 3: Hazards Identification
Emergency Overview
Appearance & Odor: Moly gray/mild, bland petroleum odor
Potential Health Effects:
Inhalation Exposure to oil mists or fumes, which may be generated at high
temperatures, may irritate the nose, throat and upper respiratory tract.
Eyes: Irritation
Skin: Irritation
Ingestion: N/A
Carcinogenicity: OSHA: No IARC: No NTP: No
Chronic Overexposure NA
Medical Conditions Pre-existing skin and pre-respiratory conditions.
Aggravated by Exposure:
Section 4: First Aid Measures
Inhalation: Remove to fresh air. Give artificial respiration if necessary.
Eyes: Flush with large amounts of water for 15 minutes.
Skin: Remove contaminated clothing and wash area with soap and water.
Ingestion: Call a physician. Do not induce vomiting.
Section 5: Fire-Fighting Measures
Flashpoint: 450 °F Method: COC LEL: ND UEL: ND
Extinguishing Media: Carbon dioxide, dry chemical and foam
Hazardous Combustion CO2 and carbon monoxide
Products:
Fire-fighting Instructions: Remove containers from fire area if possible. Use self-contained
breathing apparatus for fire fighting.
NFPA: Health: 1 Flammability: 1 Reactivity: 0
HMIS: Health: 1 Flammability: 1 Reactivity: 0 PPE: B

MSDS Moly-Graph® Extreme Pressure Multi-Purpose Grease (Continued)
3H
Section 6: Accidental Release Measures

Spill/Leak Procedures: Area should be ventilated. Absorbent should be used to pick up excess
material. All used and unused product should be disposed of in accordance with federal, state and local
regulations.
Section 7: Handling and Storage
Handling Procedures: Store in a cool, dry area.
Section 8: Exposure Controls/Personal Protection
Engineering Controls: Adequate to prevent accumulation of vapors. Use mechanical means if
necessary to maintain levels below the exposure limits. If working in a
confined space, follow applicable OSHA regulations.
Respiratory: Use NIOSH/MSHA compliant respirators or self-contained breathing
apparatus above exposure limits. Follow OSHA regulations 29 CFR
1910.134.
Protective Wear chemically protective gloves and safety glasses. Use a splash
Clothing/Equipment: apron and boots if splashing occurs.
Section 9: Physical & Chemical Properties
Physical State: Semi-solid Appearance & Odor: Moly gray/mild, bland petroleum odor.
Specific Gravity: 0.90@60oF Boiling Point: ND
Freezing Point: ND Vapor Pressure: Neg.
Evaporation Rate: Neg. Vapor Density (air = 1) Neg.
pH: NA Solubility: Neg.
Volatile Organic Compounds
1.5 g/L: 14 lbs./gal: 0.12
%:
Section 10: Stability and Reactivity
Stability: Stable Hazardous Polymerization: No
Chemical Incompatibilities: Strong oxidizers
Materials to Avoid: Strong oxidizing agents
Hazardous Decomposition None
Products:
Section 11: Toxicological Information
Long-term toxicological studies have not been conducted for this product. See Section 3 of this MSDS
for acute symptoms of overexposure and carcinogenicity information.
Section 12: Ecological Information
Ecotoxicity: No data available.
Environmental Fate: No data available for biodegradation.
Section 13: Disposal Considerations
Disposal: This material if discarded may be hazardous waste under U.S. EPA
RCRA regulations. All disposal activities must comply with federal,
state and local regulations. Contact your local or state environmental
agency for specific rules. Do not dump into sewers, on the ground or
into any body of water.

MSDS Moly-Graph® Extreme Pressure Multi-Purpose Grease (Continued)
4H
Section 14: Transportation Information

Shipping Name Not Regulated
Hazard Class: NA UN Number: NA Packing Group: NA
Label: NA Placard: NA
Special Provisions: NA
Section 15: Regulatory Information
TSCA: All components are either listed under TSCA or are exempt.
SARA Title III: Section 311/312: NA Section 313*: None
CERCLA/Superfund (RQ): N/A
Extremely Hazardous No
Substances:
California Prop 65: No
* See section 2 for percentage
Section 16: Additional Information
Prepared By: Michelle Milburn Date: December 1, 2004
Technical Information: (800) 521-3168 CRC #: SL3330
This information is accurate to the best of CRC Industries' knowledge or obtained from sources
believed by CRC to be accurate. Before using any product, read all warnings and directions on the
label.
CAS: Chemical Abstract Service NA: Not Applicable
ppm: Parts per Million ND: Not Determined
TCC: Tag Closed Cup NE: Not Established
LEL: Lower Explosive Limit g/L: grams per Liter
UEL: Upper Explosive Limit lbs./gal: pounds per gallon
PPE: Personal Protection Equipment RQ: Reportable Quantity
COC: Cleveland Closed Cup TOC: Tag Open Cup

Appendix B Block Diagrams
Table B-1 describes available pneumatic and electrical block diagrams and dispensing system electronics
5H
that may help in understanding dispensing system operation and aid in troubleshooting.
B.1 Safety First

Use of engineering drawings to disassemble, service, and reassemble the dispensing system promotes
good safety practices only when used in conjunction with the precautions in the Section 2 - Safety and
other sections of this manual.
CAUTION! Only trained service technicians should perform troubleshooting, servicing, and
parts replacement.
B.2 List of Pneumatic and Electrical Diagrams

Laminated 11" x 17" versions of diagrams referenced in Table B-1 are included with the dispensing
6H
system.
Table B-1 Block Diagrams
Drawing Number Title

7207632PD Pneumatic Diagram, Spectrum Series S-920
7207632BD Electrical Diagram, Spectrum Series S-920
Appendix B - Block Diagrams B-1

B.3 Power Manager Connections
1
2
3
4
5
7
6
10
12
11
13
14

1 AC1 Unswitched Supplies AC power to the computer
2 AC3 EMO Switched Supplies AC power to the servo power supply
3 AC4 EMO Switched Supplies AC power to the USB power supply
4 AC5 EMO Switched (spare)
5 AC6 EMO Switched (spare)
AC7 EMO Switched
6 Supplies power to the conveyor module CV1
Conveyor Power
AC8 EMO Switched
7 Supplies power to the optional conveyor module CV2
Conveyor Power
8 Conveyor Power Reset Resets the circuit breaker to the AC outlet
9 Spare +24 VDC (spare)
10 Power Controls Connects to the Start, Stop, and EMO power controls
11 DC Power Status Provides machine power status to the main PWA electronics
12 +24 VDC Supplies DC power to the terminal block located on the lower e-pan
13 Rear EMO Connect to the rear EMO switch
14 Vent Air Switch Connects to the vent air switch (bypassed in default configuration)
Figure B-1 Power Manager Connections
B-2 Appendix B - Block Diagrams

B.4 Conveyor/Heater Module Connections
1 2
3 4 5 6 7 8 9 10 11 12

1 SMEMA Upstream Connects to the machine’s external upstream SMEMA port
2 SMEMA Dowstream Connects to the machine’s external downstream SMEMA port
3 Width Motor Controls the rail width stepper motor
4 Belt Rear Controls the rear belt stepper motor
5 Belt Front Controls the front belt stepper motor
6 CAN-1 CAN serial communications in to the module
7 CAN-2 CAN serial communications out of the module
8 Solenoids Controls solenoids related to conveyor functions (stop, lift, vacuum)
9 Sensors B (spare)
10 Sensors A Connects to board sensors mounted on the conveyor rails
11 Home Sensor Connects to the conveyor’s width home sensor
12 AC Power Connects AC power to the conveyor controller
Figure B-2 Conveyor/Heater Module Connections
Appendix B - Block Diagrams B-3

12 11 10 9 8 7 6 5 4 3 2 1
REV ECO DATE DESCRIPTION APPD
A 14352 09/11/07 PRODUCTION RELEASE DMEJIA
NOTES:
1. LINE TYPE KEY MECHANICAL
H HEIGHT H
MAIN AIR 1 Z HEAD SENSOR
MAIN AIR 2 COOL / COAX VALVE ON VALVE OFF FLUID

REGULATED AIR
VACUUM LINE
IMPINGEMENT HEATER 2
2. LAMINATE TO BE PROVIDED IN COLOR FOLLOWING
ASYMTEK DOCUMENT 196680, 'SPECIFICATION LAMINATING'
LOW PRESSURE
3. SEE 7207632BD FOR ELECTRICAL BLOCK DIAGRAM. SWITCH
ASSY, ELETRONICS PAN, UPPER A B
G 4. OPTION MAY NOT BE PRESENT 7209901 2 2 IMPINGEMENT HEATER 1 G
5. LOCATED ON FRONT PANEL
3
EX IN
1 3 1 3
6. MANUAL REGULATOR CONTROL CAN BE REPLACED LOW PRESSURE
V
SWITCH
WITH ELECTRONIC PRESSURE CONTROL, 7213421 J15, PWA SDHC J15, PWA SDHC J15, PWA SDHC
1
7. MANUAL FLOW CONTROL CAN BE REPLACED
WITH ELECTRONIC FLOW CONTROL, 7209621
AIR IN 6. ASSY, VALVE PNU. CTR 7. ASSY, IMPINGMNT & ASSY, PRE/POST
7209909 TOOL PNL 7210744 STATION
F F
DIGITAL DIGITAL DIGITAL
IN
FLOW
CONTROL
COOL / COAX VALVE FLUID

REGULATOR REGULATOR REGULATOR
(0 -100PSI) (0 - 100PSI) (0 - 60PSI)
MAIN REGULATOR 1 MAIN AIR 2
0 - 100 PSI
E TOOLING PRESSURE
E
AIR IN TOOLING REG
ASSY, LOWER ELECTRONICS PAN FLOW CONTROL

7209900
1 3
2
1 3
2
1 3
MAIN HEIGHT
MAIN AIR 1 S1, MAIN PWA SENSOR
AIR 2
MAIN REGULATOR 2
D 0 - 100 PSI J2, MAIN PWA
J2, MAIN PWA LOW PRESSURE J2, MAIN PWA
D
SENSOR 0 1 2 3 4
GEOMETRIC DRAWING SYMBOLS:

STRAIGHTNESS PROFILE OF A LINE POSITION
FLATNESS PROF OF A SURFACE CONCENTRICITY
CV2, PN. SOLENOIDS

CV1, PN. SOLENOIDS
CV2, PN. SOLENOIDS
CV1, PN. SOLENOIDS
CYLINDRICITY ANGULARITY SYMMETRY
CIRCULARITY PERPENDICULARITY CIRC RUNOUT
XX BASIC DIM PARALLELISM TOTAL RUNOUT

PURGE VAC 1 VAC 2 M MAX MATERIAL CONDITION
P PROJECTED TOLERANCE ZONE
DIAMETER
1 3
1 3
1 3
COUNTER SINK THIRD ANGLE PROJECTION
2
2
COUNTER BORE
A EX A EX A EX A EX
SQUARE
C C
B IN B IN B IN B IN
DEPTH
J2, MAIN PWA CV1, PN. SOLENOIDS CV2, PN. SOLENOIDS METRIC
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN MILLIMETERS & PER ASME Y14.5M
TOLERANCE: X ± 0.5mm
TOLERANCE: 0.X ± 0.3mm
PURGE CUP LIFT TABLE LIFT TABLE TOLERANCE: 0.XX ± .13mm
IN
IN
IN
VAC 1 VAC 2 TOLERANCE ANGLES: ± 0° 30'

SURFACE FINISH: N7 MIN
REMOVE BURRS AND BREAK SHARP EDGES 0.25 MAX
DIMENSIONS DISPLAYED IN [ ] ARE INCHES
B INSPECTION DIMENSIONS DISPLAYED: X.XX

B
THIS MATERIAL IS THE PROPERTY OF ASYMTEK.
NO RIGHTS ARE GRANTED TO USE SUCH MATERIAL
FOR ANY PURPOSE OTHER THAN FURNISHING OF
SERVICE AND SUPPLIES TO ASYMTEK.
2762 LOKER AVENUE WEST
CARLSBAD, CA 92008-6603
STOP PIN1 STOP PIN2 LIFT TABLE 1 LIFT TABLE 2 (760)431-1919 A NORDSON COMPANY
CONTACT HEATER 1 CONTACT HEATER 2
TITLE:
DIAGRAM, PNEUMATICS
S-920
DRAWN: DATE:
DMEJIA 01/24/07
CHECKED: DATE:
A ENGINEER:
DMEJIA
DATE:
01/24/07 A
APPROVAL: SCALE:
1:1
7207632PD.SLDDRW
ELECTRONIC FILE: SHEET:
1 of 1
SIZE DRAWING NO. REV
QTY UNIT VENDOR PART OR NOMENCLATURE OR MATERIAL ITEM
QTY REQD
NO IDENTIFYING NO. DESCRIPTION
PARTS LIST
SPECIFICATION NO.
A1 7207632PD A
DOC-40 REV A 12 11 10 9 8 7 6 5 4 3 0 10 20 30 40 50 60 70 80 90 100
Appendix C Parts List
C.1 Overview
This section includes general information for ordering recommended spares and replacement parts for the
S-920 Dispensing System. Table C-1 lists available spare parts kits and part numbers.
7H
Part number information is also available on Asymtek’s Find-A-Part web page:
http://webstore.asymtek.com/awweblive/apps/findapart_index.asp
0H
C.2 Safety First

Before attempting to replace any parts, please review the precautions in the Section 2 - Safety.
CAUTION! Only trained service technicians should perform troubleshooting, servicing, and
parts replacement.
C.3 Spare Parts List

Table C-1 contains a list of spare parts that will aid in ordering replacement parts for the Spectrum Series
8H
S-920 Dispensing System.
" NOTE Parts listed in Table C-1 are those in effect at the time of manual publication. Contact
9H
Asymtek for additional information.
Table C-1 Spare Parts List
Part Number Description

7210754 Assy, Ht sensor, removeable probe
7209626 Conveyor Board Sensors Assy
7210749 Encoder Set (read head only)
7213109 Stop Pin Assy
392141 Assy, needle heater
7209606-1 Camera Cable
198143 Beam Splitter, NER DOAL
7210737 Spring, Gas 30lb. 15.23 inches long
7214610 Encoder strip, 40u x 100mm
7214611 Encoder strip, 40u x 400 mm
7214612 Encoder strip, 40u x 600 mm
7207355 PWA, Home sensor
7209920 Applicator kit, encoder strip
Appendix C - Parts List C-1

Table C-1 Spare Parts List (Continued)
10H
Part Number Description

7200902-1 Mainboard
7209907 Camera Assy (w/NER)
7209904 Scale Assy
7209899 Laptop w/FMXP installed
7209628 Conveyor Module
7200890 PWA, SDHC with adv pnu control
7201079 Drive Motor, XY
7214000 PWA, Servo Power Control
7206865 Servo Amps
7209446 Motor, DC Servo (Z)
7209880 Assy, Servo Power Supply
7211920 PWA, Pneumatics Control
C-2 Appendix C - Parts List

Glossary
AC: Alternating Current. Contact Heaters: Heater tooling for applications in
which the part being dispensed upon may need to come
ASPA System: Advanced Semiconductor Package
into contact with the heating element or for applications
Assembly fluid dispensing system.
in which contact with the heating element is not an
Auer Boat: A carrier used to transport multiple issue.
workpieces through the dispensing system.
Controlled Process Heat (CpH): Controlled Process
Automove Control Language (ACL): Programming Heat (CpH) software increases functional control that
language used for Conveyor Atom files which control eliminates operator interaction altogether: software-
the Conveyor. managed heat levels (e.g., warm up, process ramp, cool
down, etc.) with programmable shut-off timers and
Axis: X, Y, or Z geometric dispensing coordinates. ‘step-down’ or ‘no-heat’ capability when a part is not
Board Sensors: Optic sensors located along the length present. CpH control improves both yield and ‘thermal
of the conveyor rails that detect the presence of a board footprint’ efficiency by requiring less power.
or part. Conveyor Atom: The Conveyor Atom is an Automove
Bulkhead: Bracket attached to the Dispensing Head Control Language (ACL) file that contains the software
that supports electrical and pneumatic connections for commands that control the conveyor. This file is
Dispensing Head accessories. downloaded to the Conveyor Controller Module, located
in the rear of the system, from the Fluidmove dispensing
Calibrated Process Jetting (CpJ): With this feature, software.
volumetric repeatability can be maintained during long
production runs to improve process capability (Cpk) Conveyor Belt: A large, motor-driven o-ring or flat
when dispensing fluids with one of Asymtek's belt that transports workpieces/carriers through the
DispenseJets. Dispense patterns are programmed with a dispensing chamber. There are two conveyor belts; one
specified weight. CpJ periodically samples the dispense for each conveyor rail.
weight per shot, then computes the number of shots for Conveyor/Heater Module: The Conveyor/Heater
each pattern. With this information, CpJ optimizes line Module controls all conveyor functions (motors,
speed based on maximum specified shot interval. sensors, pneumatics, etc.). It receives power from the
Camera Offset: The calibration of the XYZ location of Power Manager and supplies AC power to the substrate
the Camera with respect to the dispensing needle. heaters in the dispensing area.
CE: The abbreviation of the French phrase "Conformité Cooling/Coaxial Air Regulator: Controls the air
Européene" which literally means "European pressure supplied to either the valve cooling air port or
Conformity.” CE qualification indicates that a the DJ-2200 coaxial air assist, depending on machine
manufacturer's electric/electronic equipment product configuration.
complies with European Union health, safety, and Crosshairs: Two lines intersecting at a 90° angle in the
environmental protection Product Directives center of the video display on the computer monitor.
(standards). CE qualification means that the product can Used to teach dispensing points to the Fluidmove
be legally sold and freely transported within European software.
Union markets.
Current: The flow of electrons through an electrical
Chip: Also called a die. A small piece of circuit. Usually measured in amperes.
semiconducting material (usually silicon) that contains a
discrete component or an embedded integrated circuit. DC: Direct Current.
Circuit Breaker: A switch that automatically interrupts Die: See Chip.
the electrical supply to the system when the current
Dispense Station: The part of the dispensing chamber
exceeds the set level. Some circuit breakers can be
where dispensing is actually performed.
manually operated to turn power off and on for
servicing or maintenance purposes. Dispense Tile: The Dispense Tile is a ceramic tile
dispensed upon during system offset routines.
Circuit: A combination of electrical or electronic
components, interconnected to perform one or more Dispensing Area: The interior area of the dispensing
specific functions. system inside the hood where dispensing operations are
performed.
Cleaning Agent: A solvent or other cleaning liquid
recommended by the dispensing fluid manufacturer’s
Material Safety Data Sheet.
Glossary G-1
Dispensing Head: The robotic fluid applicator that Fluidmove Online Help: The help function in
moves during the dispensing operation. The Dispensing Fluidmove that is accessed by clicking on the Help
Valve, Height Sensor, Camera and Lighting, and button on most of the windows and dialog boxes on the
Dispense Head Controller are mounted on the Monitor screen.
Dispensing Head. Sometimes referred to as the Z-Head.
FmXP: See Fluidmove for Windows XP.
Dispensing Runs (Wet/Dry): A wet dispensing run is
Front Panel: The machine/operator interface that
when fluid is dispensed. A dry run is when the program
consists of system Start and Stop buttons and EMO
is executed but no fluid is dispensed.
button.
Dispensing Valve: A device used to control or regulate
FSL: Free-Standing Loader. A self-contained,
the flow of material from a pressurized reservoir, such
floor-mounted unit that transports a carrier or a
as a syringe. These devices include Valves, Pumps, and
workpiece into or out of a dispensing system. The
Jets.
Upstream FSL holds a full magazine of carriers, which
DOAL: Diffuse On-Axis Light. Camera lighting it feeds into the dispensing system. After the workpiece
module that has both red and blue LEDs that enhance has been processed, the Downstream FSL receives the
image quality of the workpiece. Promotes rapid and board or carrier into an empty magazine. FSL’s get their
accurate identification of fiducials and other points of instructions from programs created on the system
reference on the workpiece. Computer with LoaderMove software.
Electrostatic Discharge (ESD): Discharge of a static Fuse: A safety device that is designed to automatically
charge on a person’s body that travels through a cut off the flow of electricity when the flow of current
conductive path to ground. An electronic component through the fuse exceeds its rated capacity.
may suffer irreparable damage when it is exposed to the
Gauge: An analog or digital device used to measure
static charge.
internal pressure of fluid or air in a closed system.
Emergency Shutdown: The dispensing system is
Genie Camera: The Dalsa-Coreco Genie M640
intentionally stopped to prevent injury to personnel or
communicates bi-directionally to a host computer via
damage to equipment. Shutdown is accomplished by
Gigabit Ethernet. No frame grabber is required. The
pushing the EMO button or switching off the Main
camera is configured to run at 60 full frames per second
Circuit Breaker.
which is twice as fast as the analog PCVision cameras.
EMO: Emergency Off button on the front and back A frame can be transferred in 16.67 milliseconds.
panels of the dispensing system. Cuts power to the
Graphic Card: Computer card that outputs the video
dispensing system, but does not turn off power to the
signal to the monitor.
Power Manager, Computer, or Monitor. Heater power is
interrupted, but the heaters can remain hot for some Grounding Strap: A strap worn on the wrist of an
time. Part of the Safety Interlock System. Operator and plugged into front panel jacks to prevent
an electrostatic discharge (ESD) that may cause damage
ESD: See Electrostatic Discharge.
to the workpiece.
EU: European Union.
Heat Station Timers: Specify the time a part remains
Fiducial: A distinct shape or object on the workpiece. in the pre-heat or post-heat zones.
The Vision System uses fiducials for location reference.
Height Sensor: A device that measures substrate height
Flip Chip Underfill: Dispensing lines of fluid around and sends a signal to the system computer. The height
the perimeter of a flip-chip so that the fluid flows information is used to position the dispensing needle at
underneath the chip to seal and protect the connections. an exact distance above the workpiece surface.
Flip Chip: A die with solder bumps, placed with the High Pressure Relief Valve: Safety feature designed to
circuit side of the die facing downward on a PCB. prevent the dispensing system from being damaged if
the main air pressure is too high.
Flow Rate: Speed in milligrams per second that fluid
dispensed from the dispensing valve. Home: The dispense head location whose X, Y, Z
location is defined as the coordinates (0,0,0). The
Fluid Air Regulator and Gauge: The Fluid Air
default setting is where the dispensing head was located
Regulator and Gauge set supplies air to the Precision
when the system was first turned on. On Asymtek
Fluid Air Regulator and Gauge Set.
systems, the default home position is the front left hand
Fluidmove for Windows XP (FmXP): Asymtek corner of the dispensing chamber.
proprietary dispensing software based in a Windows XP
I/O: Input/Output. Communication between one
environment.
component or device and another.
G-2 Glossary
Icons: Small buttons on a computer screen with a Low Air Pressure Alarm: The Low Air Pressure
symbol representing the function that they perform. Alarm sounds when the system air pressure is too low.
Used to execute a menu shortcut.
Low Fluid Sensor: A device that triggers a Light
Impingement Flowmeters: The Impingement Beacon display or software error message when the
Flowmeters control the airflow through the fluid level is low.
Impingement Heaters in the dispensing chamber.
Low Pressure Detection Threshold: The air pressure
Impingement Heaters: Heaters tooling that does not level at which the FmXP software will issue an on-
come into contact with the part carrier, but blows hot air screen low air pressure error message.
up at the part.
Machine Offsets: Programming a dispensing sequence
Interlock: The Interlock is a built-in safety feature that relies on using the camera. Dispensing is accomplished
automatically removes dispensing system servo motor with the needle or nozzle. Camera-to-Needle and
power, stopping all dispensing activity, when the hood Camera-to-Height Sensor Offsets need to be established
is opened. This prevents personnel from being injured prior to dispensing.
by movement of the dispensing head and conveyor.
Main Circuit Breaker: The Main Circuit Breaker is the
Jet: A Fluidmove-controlled non-contact fluid dispenser main power switch for the dispensing system. It protects
that provides high-speed delivery and exceptional the dispensing system from facility power surges and
volumetric control for various fluids, including surface controls the flow of facility AC power supplied to the
mount adhesive, underfill, encapsulants, conformal Power Manager. A flange to the right of the Main
coating, UV adhesives, and silver epoxy. It is excellent Circuit Breaker allows it to be locked in the OFF
for substrates that may be compromised by contact position during servicing. Switching OFF the Main
dispensing. Circuit Breaker cuts power to all dispensing system
electrical components.
kPa: Kilo Pascals. Metric unit of pressure measurement.
Maintenance: Planned or unplanned activities intended
Laser Height Sensor: The non-contact Laser Height
to keep the dispensing system in good working order.
Sensor provides high-speed dispense height
measurement for delicate substrates, hybrids, and Mass Flow Calibration (MFC): Mass Flow Calibration
integrated circuits that may be compromised by tactile is a patented feature that enables the user to specify the
sensing. mass to be dispensed as a separate parameter within the
dispensing elements. This is made possible by using a
LCD: Liquid Crystal Display. This type of display is
high precision scale to take flow rate measurements.
used in the computer monitor.
Material Safety Data Sheet (MSDS): Information
Lead Frame: A type of workpiece carrier where
sheet for the safe usage of a specific material. It is
multiple workpieces are imbedded in a metal tape.
provided by the material manufacturer and is usually
LED: Light-Emitting-Diode. A semiconductor that included in the material packaging.
emits light. The materials used in the diode determine
Needle Heater: The Needle Heater is an RTD-
the color of light. Functions as a system status indicator
controlled heating element that provides needle heat on
and as an element in the Camera light source.
the DV-7000 and DV-8000 Dispensing Valves and
Levelers: Four adjustable pedestals (feet) on the bottom nozzle heat for the DJ-9000 Dispense Jet. The Needle
of the dispensing system. Heater heats the dispensing fluid to maintain a
consistent viscosity and flowrate.
Lift Height: The height that the workpiece is lifted by
the Lift Table at the dispense station of the Conveyor. Needle Sensor Substrate: A ceramic pad near the
Needle Sensor that is dispensed upon during needle
Lift Table: Lifts the workpiece a set height at the location definition routines.
dispense station of the Conveyor.
OEM: Original Equipment Manufacturer.
Light Beacon: A safety device with colored lights and
an audible alarm that is attached to the top of a Operation: Functions, such as setting and manipulating
dispensing system. It is part of the Safety Interlock dispensing system controls, by which the operator
System. causes the equipment to perform its intended purpose.
Linear Encoders: Device mounted on each axis that Operator: A non-technical level position. The
keeps track of the actual Dispensing Head position. production operator monitors and operates pre-
programmed dispensing systems during production runs
Lockout/Tagout (LOTO): The locking and tagging of and performs minor routine maintenance.
equipment during service and maintenance procedures
to help avoid injury or dispensing system damage due to Outputs: Electrical signals to control devices that must
unexpected energizing of equipment, start up, or the turn On and Off on command.
release of stored energy.
Glossary G-3
Pattern Recognition System: A vision system that Rapid Response Heaters: Rapid Response Heaters
finds workpiece fiducials to reliably locate dispensing with low-mass design rapidly ramp to temperature for
sites and compensates for minor workpiece uniform material flow and quick cool-down for fast tool
misalignment during dispensing. change out. An advanced hole pattern provides highly
uniform impingement heat across the entire part surface.
Personal Protective Equipment (PPE): Clothing and
Equipment worn to reduce the risk of personal injury Regulator: Device for controlling the amount of air
from hazards associated with operation, maintenance, pressure supplied to a pneumatic system.
and servicing of the dispensing system. This includes
Reticle: A group of lines, circles, angles, or other
the wearing of rubber gloves and safety glasses.
pattern used as a measuring reference, as a focusing
Pneumatic Devices: Air pressure actuated devices such target, or to define a camera field of view.
as Stop Pins, Clamp Bars, and Lift Tables.
RTD: Resistive Temperature Detector. A highly
Port: A hardware interface on a computer to which you accurate temperature sensor consisting of a coiled thin
can connect a device. An opening in a mechanical platinum wire covered in ceramic material and encased
device such as the vacuum port in a contact heater or the in a 1/8-inch stainless steel tube. Found in Needle
Conveyor port on the dispensing system. Heaters, Heater Tooling, and some Dispensing Valves.
Used in place of a thermocouple.
Post-Dispense Station: The part of the dispensing
chamber where a workpiece is held after it leaves the Safe Z-Height: Safe Z Height is the height below which
Dispense Station and before the workpiece leaves the the tip of dispensing head cannot go when moving from
system. The part may be heated in the Post-dispense one set of coordinates to another during operation.
Station, but no dispensing is performed.
SCFM: Standard Cubic Feet per Minute. A unit of flow
Power Manager: The Power Manager is located inside of a liquid or gas.
the rear cabinet and houses the Main Circuit Breaker
SECS/GEM: SEMI Equipment Communication
and the Main Power Inlet. It also contains the EMO
Standard (SECS), SEMI Generic Equipment Model for
circuitry. The EMO button, the green ON (I) button, and
Effective Factory Automation (GEM). SECS/GEM is
the black OFF (0) button are directly connected to the
the protocol used for linking several factory equipment
Power Manager.
units together via a host computer. The GEM standard
Precision Fluid Air Gauge and Regulator: The defines useful conventions for designing the
Precision Fluid Air Gauge and Regulator controls air communications interface on a unit of factory
supplied to the fluid syringe. equipment to improve operations with a host computer.
Pre-Dispense Station: The part of the dispensing SEMI: Semiconductor Equipment and Materials
chamber where a workpiece is held before entering the International. An organization that defines protocols for
Dispense Station. The workpiece may be heated in the the semiconductor industry.
Pre-dispense Station, but no dispensing is performed.
Service Shutdown: When all dispensing is stopped and
Production Shutdown: When all dispensing has been the dispensing system is made safe so that servicing can
stopped under non-emergency conditions such as the be performed.
end of a shift.
Service Station: The Service Station consists of a
Psi: Pounds per Square Inch (lbs/in2). English unit of needle vacuum purge cup, on-board high precision
pressure measurement. scale, and a needle calibration substrate.
Pump: See Dispensing Valve. Service Technician: Trained personnel responsible for
performing advanced system servicing procedures.
Purge Station: A location at the front of the dispensing
chamber where the outer diameter of the dispensing SMA: Surface Mount Adhesive. An adhesive used for
needle is cleaned and the Dispensing Valve is attaching chips to PWBs.
automatically purged at user-defined intervals. A
SMEMA: Surface Mount Equipment Manufacturers
disposable plastic cup inside of the Purge Station
Association. Established protocol for signal
catches the dispensed fluid.
communication between two or more different systems.
PWA: Printed Wiring Assembly. The completed PWB
Substrate Heaters: A contact or impingement heater
with electrical components installed. Also known as a
tooling plate located between the conveyor rails. These
printed circuit board assembly (PCBA).
heaters can be located in up to three conveyor stations
PWB: Printed Wiring Board. An insulating board (pre-dispense, dispense, and post-dispense). Used to
containing conductive tracks for electrical circuit heat workpieces to control the flow and cure time of
connections on which chips and other electronic dispensed fluid.
components are placed.
SVGA: Super Video Graphics Array. A video card that
produces high-quality color images at high resolution.
G-4 Glossary
Syringe: A reservoir containing the dispensing fluid Vision Card: Computer card that receives video signals
that is usually attached to the Dispensing Valve. from the Camera and performs fiducial image capture.
Tactile Sensor: A sensor located adjacent to the Needle Vision System: Includes the camera, light source,
Sensor that is used to calculate the Z-axis offset between computer hardware and software, and the monitor.
the Height Sensor probe and dispensing needle tip.
Water Trap: The facility air supply may contain
Tooling Air Regulator and Gauge: The Tooling Air moisture that can damage the dispensing system. The
Regulator and Gauge controls air pressure for Stop Pins water trap condenses this moisture before it enters the
and Lift Tables/Bar Clamps. dispenser pneumatic system.
Underfill: The process of flowing epoxy underneath a Workpiece: Any surface, part, or element (usually a
flip chip on a PWB to completely seal the solder bumps. PWB) that is being dispensed upon. Workpieces may be
installed in a carrier such as a lead frame or Auer boat.
V: Abbreviation for volt as in VAC (Volts Alternating
Current). See also AC, DC. X-Axis: Left to right movement of the Dispensing Head
in the dispensing chamber.
Valve Air Pressure Regulator and Gauge: The Valve
Air Pressure Regulator and Gauge set controls the air X-Beam: The apparatus that spans the width of the
pressure that actuates some Dispensing Valves dispensing chamber. The Dispensing Head is mounted
(DV-7000, DV-8000, and DP-3000) during dispensing. to the X-Beam and slides along it in the X-Axis.
Includes mechanical pulleys for the X-Axis cables.
Valve: See Dispensing Valve.
Y-Axis: Forward and backward movement of the
Viscosity: Viscosity is a measurement of the flow
Dispensing Head in the dispensing chamber.
properties of a fluid. High viscosity fluids have a high
resistance to flow and low viscosity fluids have a Z-Axis: Up and down movement of the Dispensing
low resistance. Head in the dispensing chamber.
Glossary G-5
Index
A Dispenser
position controls .................................................. 6-11
Access Panels ............................................................. 9-4 Dispensing Commands............................................. 6-27
Air Pressure Dispensing Fluids....................................................... 1-2
cooling, valve, and fluid pressure adjustment........ 6-5 Dispensing Head
main air pressure adjustment ................................. 6-4 clearance check.................................................... 4-10
programmable fluid and valve pressure ................. 1-5 clearance check - final ......................................... 4-23
Anchoring the Dispensing System ........................... 3-16 functional testing ................................................. 4-26
Applications Dispensing System
recommended......................................................... 1-1 anchoring ............................................................. 3-16
Axis description ............................................................. 1-1
removing axis covers ............................................. 7-8 dispensing area .................................................... 1-10
facility requirements ............................................ 10-1
B features .........................................................1-8–1-18
front cabinet......................................................... 1-13
Board Sensor front panel............................................................ 1-12
adjustment............................................................ 5-11 front view............................................................... 1-9
functional testing ................................................. 4-20 installation ............................................................. 3-1
interior access ........................................................ 9-4
C leveling .................................................................. 3-8
light........................................................................ 1-5
Cables light beacon ........................................................... 1-4
lubricating.............................................................. 7-9 maintenance ..................................... See Maintenance
tensioning ............................................................ 7-13 optional equipment .........................................1-5–1-6
CAD Import ............................................................... 1-5 rear cabinet .......................................................... 1-17
Calibrated Process Jetting (CpJ)................................. 1-3 rear panel connections ......................................... 1-18
Calibration rear view .............................................................. 1-14
camera.................................................................... 5-3 removing rear cable covers .................................... 7-9
scale ....................................................................... 5-6 removing X/Y-axis covers ..................................... 7-8
Camera safety ..................................................................... 2-1
calibration .............................................................. 5-3 service station ...............................................1-5, 1-11
connections .......................................................... 3-15 standard equipment................................................ 1-3
focusing ................................................................. 5-2 startup .................................................................... 4-4
Genie ..................................................................... 1-3 technical manuals .................................................. 1-2
lighting adjustment .............................................. 6-17 warranty................................................................. 9-2
lighting height adjustment ................................... 4-28 Dispensing Valve ....................................................... 1-7
operation .............................................................. 6-16 installation ............................................................. 6-2
software installation............................................. 3-15 installing fluid...................................................... 6-33
states .................................................................... 6-16 pneumatic and electrical connections .................... 6-2
Computer.................................................................... 1-3 pneumatics testing ............................................... 4-28
installation ..................................................3-12, 3-13 Dual Lane Conveyor ................................1-4, 4-15, 4-16
Contact Heaters ............................................ See Heaters position controls .................................................. 6-14
Controlled Process Heat (CpH) .................................. 1-6 programming ..............................................6-28–6-32
Conveyor .................................................................... 1-3
adjusting rail width .............................................. 4-17
belt replacement..................................................... 9-5
E
dual lane.............................. 1-4, 4-7, 4-15, 4-16, 6-14 Electrical
fixed width functional testing .............................. 4-16 connections ............................................................ 4-2
multi-move ............................................................ 1-3 Emergency Machine Off .................................. See EMO
position controls .................................................. 6-10 Emergency Shutdown .............................................. 2-12
SMEMA communication testing ......................... 4-18 recovery ............................................................... 2-13
CpJ ................................. See Calibrated Process Jetting situations.............................................................. 2-13
EMO..................................................................1-5, 2-12
D functional testing ................................................. 4-11
testing heaters ...................................................... 4-38
Digital Gauge Error Messages
initialization ......................................................... 5-13 dispenser motor references not found .................... 4-5
DispenseJet.................................... See Dispensing Valve
Index I-1
F substrate
setting temperature.......................................... 6-19
Facility Requirements .............................................. 10-1 temperature test.................................................... 4-37
Fiducials ................................................................... 6-24 Height Sensor ............................................................. 1-4
teaching................................................................ 6-25 laser ....................................................................... 1-5
Fluid safety ............................................................... 2-11
files ...................................................................... 6-26 specifications................................................... 2-11
manager ............................................................... 6-22 probe adjustment.................................................. 5-10
supported dispensing fluids ................................... 1-2 probe replacement.................................................. 9-9
Fluidmove .......................................................See FmXP
FmXP ......................................................................... 1-4
beacon configuration ........................................... 5-14
I
configuration.......................................................... 4-6 Impingement Flowmeters
conveyor setup....................................................... 4-6 functional testing ................................................. 4-13
creating a new program ....................................... 6-24 Impingement Heaters ................................... See Heaters
creating a program ............................................... 6-19 Installation
dispensing commands.......................................... 6-27 anchoring the dispensing system ......................... 3-16
dispensing elements ............................................. 6-28 component level functional tests.................4-10–4-42
dual conveyor programming.......................6-28–6-32 computer .....................................................3-12, 3-13
entering program commands ............................... 6-26 connecting the power and air supply ..................... 4-2
exiting .................................................................... 4-9 dispensing system .................................................. 3-1
fluid files.............................................................. 6-26 dispensing valve .................................................... 6-2
fluid manager....................................................... 6-22 leveler adjustment.................................................. 3-3
loading a part ....................................................... 6-19 light beacon ......................................................... 3-12
Program Commands Toolbar............................... 6-27 preliminary system check .................................... 4-10
running a program in dry mode ........................... 6-33 scale ....................................................................... 3-6
saving a program ................................................. 6-32 service station ...................................................... 3-11
scale setup.............................................................. 4-8 system level functional test.................................. 4-38
setting the heater temperature .............................. 6-19 uncrating and placing the dispensing system ......... 3-2
starting ................................................................... 4-4 unpacking dispensing chamber .............................. 3-4
teaching fiducials ................................................. 6-25 Interlock ............................................................1-5, 2-13
vision setup ............................................................ 4-9 recovery ............................................................... 2-13
workpiece alignment............................................ 6-23
Focusing the Camera.................................................. 5-2
Front Panel ............................................................... 1-12
J
fuse replacement Jet See Dispensing Valve
board-mounted..................................................... 9-11 Jog Controls ..................................See Position Controls
panel-mounted ..................................................... 9-13
replaceable fuse list.............................................. 9-11
L
G Laser Height Sensor ................................................... 1-5
safety ................................................................... 2-11
Gauges specifications ....................................................... 2-11
digital..................................................................... 1-4 Laser Radiation Safety ......................................2-2, 2-11
initialization .................................................... 5-13 Levelers
Grease Gun adjusting ................................................................ 3-3
loading ................................................................. 7-11 Leveling
dispensing system .................................................. 3-8
H scale ..................................................................... 3-10
Lift Table
Heaters functional testing ................................................. 4-21
contact.................................................................... 1-6 Light Beacon .....................................................1-4, 2-16
vacuum check.................................................. 4-22 color indications .................................................. 2-16
controlled process heat .......................................... 1-6 configuration........................................................ 5-14
EMO test.............................................................. 4-38 functional testing ................................................. 4-14
functional testing ................................................. 4-35 installation ........................................................... 3-12
impingement .......................................................... 1-6 Loading a Part .......................................................... 6-19
needle..................................................................... 1-4 Lockout/Tagout ........................................................ 2-14
setting the temperature .................................... 6-21 LOTO ...............................................See Lockout/Tagout
rapid response ........................................................ 1-6 Low Air Pressure Alarm ............................................ 1-4
Low Fluid Sensor ....................................................... 1-6
I-2 Index
Low Pressure Detection Threshold ............................ 6-6 keyboard commands ............................................ 6-14
Lubricating the Cables ............................................... 7-9 using the touchpad ............................................... 6-10
Lubricating the Linear Guides.................................. 7-11 Powering on the Dispensing System .......................... 4-4
Production Run
M dry mode .............................................................. 6-33
starting ................................................................. 6-34
Machine Offsets ................................................6-7, 6-25 Program Commands Toolbar ................................... 6-27
valve offsets........................................................... 6-7 dispensing elements ............................................. 6-28
Main Circuit Breaker................................................ 2-12 Purge Boot
Maintenance replacement............................................................ 7-6
draining the water trap ........................................... 7-7 Purge Station
loading the grease gun ......................................... 7-11 boot replacement.................................................... 7-6
lubricating the cables ............................................. 7-9 cup replacement..................................................... 7-4
lubricating the linear guides................................. 7-11 functional testing ................................................. 4-32
purge station ...................................................7-4, 7-6
record keeping ....................................................... 7-1 R
replacing consumables........................................... 7-3
routine procedures ................................................. 7-2 Rapid Response Heaters............................................. 1-6
scale ....................................................................... 7-4 Rear Panel Connections ........................................... 1-18
system access......................................................... 7-8 Record Keeping.......................................................... 9-1
tensioning the cables............................................ 7-13 Removing Axis Covers .............................................. 7-8
Manuals Removing Rear Cable Covers .................................... 7-9
technical................................................................. 1-2 Return Material Authorization ................................... 9-2
Mass Flow Calibration (MFC) ................................... 1-4 Running Production.................................................. 6-34
Material Safety ........................................................... 2-3
Material Safety Data Sheet..............................See MSDS S
MFC ..................................... See Mass Flow Calibration
MSDS..................................................................1-1, 2-3 Safe Z-height.............................................................. 6-8
Multi-Move Conveyor................................................ 1-3 Safety ......................................................................... 2-1
beacon color indicatons ....................................... 2-16
N earthquake precautions .......................................... 2-5
equipment lockout/tagout .................................... 2-14
Needle Heater............................................................. 1-4 hazardous materials ............................................... 9-2
EMO test.............................................................. 4-38 intended use ........................................................... 2-1
functional testing ................................................. 4-35 laser radiation ...............................................2-2, 2-11
setting the temperature......................................... 6-21 lifting and transport precautions ............................ 2-4
temperature test.................................................... 4-37 MSDS .............................................................1-1, 2-3
personnel safety ..................................................... 2-2
O service shutdown ................................................. 2-14
warning labels...............................................2-6–2-10
Optional Equipment ............................................1-5–1-6 Safety Interlock .......................................................... 1-5
Ordering Parts ............................................................ 9-2 Dispensing Head test ........................................... 4-26
Safety Warning Labels ......................................2-6–2-10
P Scale ........................................................................... 7-4
calibration .............................................................. 5-6
Pneumatics cup replacement..................................................... 7-4
adjusting the main air pressure .............................. 6-4 functional testing ................................................. 4-33
connections ............................................................ 4-2 installation ............................................................. 3-6
cooling, valve, and fluid pressure adjustment........ 6-5 leveling ................................................................ 3-10
digital gauges......................................................... 1-4 SECS/GEM ................................................................ 1-6
dispensing valve pneumatics test ......................... 4-28 Seismic Safety ............................................................ 2-5
programmable fluid and valve pressure ................. 1-5 Sensor
regulators and gauges board
functional testing............................................. 4-11 adjustment ....................................................... 5-11
setting the low pressure threshold.......................... 6-6 low fluid................................................................. 1-6
vacuum control Service Station ..................................................1-5, 1-11
adjustment ......................................................... 6-6 height adjustment................................................... 5-5
Position Controls setup..................................................................... 3-11
conveyor .............................................................. 6-10 Shutdown
dispenser .............................................................. 6-11 routine shutdown ................................................. 6-36
dual conveyor systems......................................... 6-14 service.................................................................. 2-14
Index I-3
SMEMA ................................................................... 4-18 needle heater ........................................................ 8-12
functional testing ................................................. 4-18 pneumatic .............................................................. 8-4
interface problems ............................................... 8-15 record keeping ....................................................... 8-1
Specifications scale ....................................................................... 8-9
dispensing system ................................................ 10-2 substrate heaters................................................... 8-14
facility requirements ............................................ 10-1 system accuracy..................................................... 8-3
stability analysis .........................................10-1, 10-3 system power ......................................................... 8-2
Standard Equipment ................................................... 1-3 tactile sensor ........................................................ 8-12
Startup ........................................................................ 4-4 vision system ......................................................... 8-8
Stop Pins TS-01 I/O Test Box .................................................. 4-40
functional testing ................................................. 4-21
U
T
Uncrating and Placing the Dispensing System........... 3-2
Tactile Sensor Unpacking
functional testing ................................................. 4-30 replacement parts ................................................... 9-3
Tensioning
cables ................................................................... 7-13 V
Testing
board sensors ....................................................... 4-20 Vacuum Control
contact heaters ..................................................... 4-22 adjustment.............................................................. 6-6
conveyor and conveyor pneumatics............4-15–4-19 Valve ............................................. See Dispensing Valve
dispensing head movement.................................. 4-26 Valve Offsets............................................................ 6-25
dispensing valve pneumatics ............................... 4-28 Ventilation Exhaust System ....................................... 1-5
EMO function ...................................................... 4-11 Vision System ............................................................ 1-3
impingement flowmeters ..................................... 4-13 camera lighting adjustment.................................. 4-28
lift tables .............................................................. 4-21 functional testing ................................................. 4-27
light beacon ......................................................... 4-14 lighting adjustment .............................................. 6-17
pneumatic regulators and gauges ......................... 4-11 reticles set-up....................................................... 4-28
purge station funtion ............................................ 4-32
scale ..................................................................... 4-33 W
stop pins............................................................... 4-21
substrate/needle heaters ....................................... 4-35 Warranty..................................................................... 9-2
system level functional test.................................. 4-38 Weigh Station................................................... See Scale
tactile sensor ........................................................ 4-30 Workpiece Alignment .............................................. 6-23
vision system ....................................................... 4-27
Training...................................................................... 1-2
registration ............................................................. 1-2
X
student certification ............................................... 1-2 X/Y Axes
Troubleshooting removing axis covers ............................................. 7-8
conveyor .............................................................. 8-14
dispensing head...................................................... 8-6
FmXP startup......................................................... 8-5
Z
height sensor .......................................................... 8-7 Z-head Counterbalance Force Adjustment ................. 5-9
laser height sensor ................................................. 8-7
I-4 Index

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Spectrum Series

P/N 7212417 Rev A

Installation, Operations, and

P/N 7212417, Revision A

Manuals on the Internet

Headquarters 2762 Loker Avenue West

Toll Free: 1-800-ASYMTEK (1-800-279-6835)

Txt. P/N 7212418, Revision A ©2007

TIP This symbol appears next to a timesaving or technique tip.

Table of Contents vii

viii Table of Contents

Figure 2-1 Safety Warning Labels (Front Cover) .................................................................................2-7

Figure 3-1 Removing the Shipping Brackets ....................................................................................... 3-2

Figure 5-1 Focusing the Camera ......................................................................................................... 5-2

xii Table of Contents

Figure 8-1 Scale Flex Circuit Orientation ............................................................................................. 8-9

Figure 9-1 Gaining Access to Dispensing System Components ......................................................... 9-4

Figure B-1 Power Manager Connections .............................................................................................B-2

Table of Contents xiii

Table 4-1 SMEMA Communication Test Matrix................................................................................4-19

Table 6-1 Conveyor Position Controls: Jog Distance(1) ....................................................................6-11

Table 7-1 Routine Maintenance Procedures ...................................................................................... 7-2

Table 8-1 System Power Troubleshooting.......................................................................................... 8-2

Table 9-1 Replaceable Fuses ...........................................................................................................9-11

Table 10-1 Facility Requirements .......................................................................................................10-1

Table B-1 Block Diagrams...................................................................................................................B-1

xiv Table of Contents

• System Description • Standard Equipment and Features

1.2 System Description

1.3 Safety First

1.5.1 Student Certification

1.5.2 Student Registration

1.6 Supported Dispensing Fluids

• Flip Chip & CSP Underfill materials

1.7.2 Calibrated Process Jetting (CpJ™)

1.7.3 Computer System

1.7.4.1 Single Lane

The Single Lane Conveyor provides continuous part processing.

1.7.5 Fluidmove for Windows XP Software

1.7.6 Integral Height Sensor

1.7.7 Light Beacon

1.7.8 Low Air Pressure Alarm

1.7.9 Mass Flow Calibration

1.7.10 Needle Heater

1.7.11 Precision Pneumatics

1.7.11.1 Digital Gauges

1.7.12 Safety Features

1.7.12.1 Emergency Machine Off (EMO)

1.7.13 Service Station

1.7.14 System Light

1.7.15 Ventilation Exhaust System

1.8 Optional Equipment

1.8.2 Laser Height Sensor

1.8.4 SECS/GEM Interface

1.8.5 Substrate Heaters

1.8.5.1 Rapid Response Heater™ System

1.8.5.2 Controlled Process Heat (CpH™)

Refer to the appropriate dispensing valve manual for additional information.

Figure 1-1 Front View

Figure 1-2 Front View (Open Dispensing Area - Dual Conveyors)

Item Name Description

Item Name Description

Figure 1-3 Dispensing Area

Item Name Description