Asymtek C702 Page 68 Student Manual Download

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Level 2 Maintenance Training, Century Series

4-2

P/N 73-0028-00 Revision A

Level 2 Module 4

STUDENT GUIDE

LESSON 1

Describing Machine Faults

OBJECTIVE

: Upon completion of this lesson, the student should be able to

explain the correct technique for completely describing machine faults to other
service engineers.

Describing Machine Faults

Summarize the problem, and describe when it started.

Write down all of the details of the symptom, remembering how the correct
operation should be.

Tell what you believe is causing the problem, and how you isolated it to this
problem.

If it is isolated to a component, and you need to order the part, write down the
PN from the faulty component.

Have the SN of the dispenser available for the FSE.

Summary of Contents for C702

Page 1: ...Level 2 Maintenance Training P N 73 0028 00 Revision A Student Guide 2 3 4 1 Century Series C702 C708 C708 AICE SelectCoat ...

Page 2: ...ng Maintenance Century Series C700 Student Guide P N 73 0028 00 Revision A Reserved by Asymtek TSG Manuals For further information regarding additional training contact Asymtek Headquarters Technical Support Group 2762 Loker Avenue West Carlsbad CA 92008 760 930 3337 Revised 05 19 2000 ...

Page 3: ...roduction STUDENT GUIDE 1 Instructor s Introduction 2 Today s Time Schedule 3 Building Locations 4 Who should attend this workshop 5 Prerequisite Skills Check 6 Course Objectives 7 Location of Lab Equipment 8 Equipment Used for The Course 9 Safety Review 10 Manual Reviews Introduction ...

Page 4: ...repair Although the workshop is designed specifically for preventative maintenance and repair all individuals associated with programming and maintenance of the system are encouraged to attend 5 Prerequisites Skills Check Completion of Level 1 Operations Training is a prerequisite of this class The student should already be able to Describe the high voltage safety guidelines List the dangers of op...

Page 5: ...y Series systems Identify selected faults and isolate the cause to a sub assembly or module 7 Safety Review Emergency Evacuation Routes Building Fire Alarms Emergency Reporting Procedures 8 Location of Lab Equipment Training Engineering Development Test Labs 9 Equipment Used for the Course Century Series systems 10 Manual Reviews Asymtek Maintenance Manual Level 2 Maintenance Training Century Seri...

Page 6: ...Level 2 Maintenance Training Century Series iv P N 73 0028 00 Revision A ...

Page 7: ...e Training Century Series v P N 73 0028 00 Revision A Level 2 Course Outline STUDENT GUIDE MODULE 1 Equipment Safety MODULE 2 Equipment Operation MODULE 3 Preventative Maintenance MODULE 4 Troubleshooting Course Outline ...

Page 8: ...orrect method for powering Century Series systems up or down into FMW MODULE 2 EQUIPMENT OPERATION LESSON TOPIC L2M2 1 Describe the facility requirements for the Century Series system L2M2 2 Identify and briefly describe the benefits of available features for the Century Series L2M2 3 Describe the memory used in each module and how it is restored in case of loss L2M2 4 List and test the dispenser ...

Page 9: ...nsitivity of the PCB board sensors MODULE 4 TROUBLESHOOTING LESSON TOPIC L2M5 1 Explain the correct technique for completely describing machine faults to other service engineers L2M5 2 Describe the basic steps needed to succeed in troubleshooting L2M5 3 Describe the procedure for obtaining Asymtek qualified technical support L2M5 4 Describe how to order service parts from Asymtek referencing the s...

Page 10: ...Level 2 Maintenance Training Century Series iv P N 73 0028 00 Revision A ...

Page 11: ...Safety Guidelines LESSON 2 Safety Hazards LESSON 3 Compressed Air Vacuum Heat Dangers LESSON 4 Power AC Distribution LESSON 5 Components Under Pressure LESSON 6 Maintenance Modes LESSON 7 The Safety Interlock LESSON 8 The EMO Button LESSON 9 MSDS Information LESSON 10 Powering Up and Down Module 1 Equipment Safety ...

Page 12: ...posal of syringes and fluids Only qualified personnel should be permitted to perform maintenance and troubleshooting procedures Disconnect all power cords before servicing the machine ELECTROSTATIC DISCHARGE ESD Static Discharge The sudden transfer of electricity from one object to another Can cause severe undetectable damage to boards parts and assemblies Increased by the following 1 Low humidity...

Page 13: ...Level 2 Module 1 STUDENT GUIDE LESSON 1 Safety Guidelines CONTINUED WORK ENVELOPE SAFETY Do not wear loose clothing or jewelry If you have long hair make sure that it is tied back to prevent it from becoming entangled in moving parts Wear safety goggles Wear a grounding strap ...

Page 14: ...attention Keep hands away from moving parts Disconnect and lockout power before servicing HEAVY OBJECTS Can cause muscle strain or back injury if lifting improperly Require proper lifting Use lifting aids pallet jack or forklift and proper lifting techniques when moving the object ELECTRICAL Can cause severe injury or death Identify high voltage components Use extreme caution when working in or ar...

Page 15: ...V09 DV6000 Dual Action Dispensing Head VACUUM HEAT Controlled heating is supplied by the Vacuum Heated Tooling Plate option DANGERS If air tubes are pulled loose compressed air can be released making a loud noise and sending debris at your face If the DV 6000 syringe is pressurized it can push fluid out the bottom of the valve The Vacuum Heated Tooling Plate can get very hot and remain hot for som...

Page 16: ...ition returns power to the system MAIN POWER SWITCH Cuts all power supplied to the entire dispensing system Turning the Main Power OFF cuts power to all of the major components However power is still supplied to the machine through the Main Power Cord POWER ENTRY MODULE Provides power to the main mechanics of the system Contains a fuse to prevent damaging components in case of a power surge SAFETY...

Page 17: ...r to all components connected to the Power Manager is turned on or off using the Main Power Switch The Vision System heater controllers and computer system are not usually connected to the Power Manager EXERCISE 1 1 Checking connections 1 Turn ON I the Main Power Switch at the rear of the system 2 Turn ON I the Power Switch on the Control Panel 3 Press FIND HOME on the Control Panel 4 Start FluidM...

Page 18: ...URE Valve pressure controls the flow of air from the Main Air In through air lines that connect to the fluid pump or valve Air pressure pushes the fluid pump valve open or closed during dispensing Your dispensing program controls the pressure to operate the fluid pump or valve while dispensing fluid EXERCISE 1 2 Adjusting the air pressure for valve and fluid pressure 1 Open the front doors or reac...

Page 19: ...ds should be unplugged TEMPERATURE CONTROLLER Prior to maintenance to the temperature controller The Main Power Switch should be OFF O for at least one hour The Vacuum Heated Tooling Plate can get very hot and remain hot for some time after being turned OFF Never touch it while the system is ON or during the one hour cool down period All power cords should be unplugged The Main Circuit Breaker sho...

Page 20: ...revent an inadvertent mode change There are two Safety Interlock modes to choose from ON or OFF The Safety Interlock is used in conjunction with the door sensors or Light Curtain EXERCISE 1 3 Illustrating ON I features When the Safety Interlock is ON and a dispensing program is running opening the front door causes the immediate stoppage of all dispensing motion and also disables the heaters If th...

Page 21: ...ave been activated turn the red knob clockwise until the knob pops out to deactivate it EXERCISE 1 6 EMO Functionality Testing 1 Turn the Main Circuit Breaker ON I 2 Turn the Main Power Switch ON I 3 Check the EMO E stop buttons to see if they have been activated 4 The EMO E stop is used in case of emergency or malfunction 5 Pressing the EMO cuts power to all major system components 6 Some Millenn...

Page 22: ... STUDENT GUIDE LESSON 9 MSDS Information OBJECTIVE Upon completion of this lesson the student should be able to identify the MSDS hazards for encapsulation applications CHEMICAL FLAMMABLE CARCINOGENIC HYSOL FP 4323 No Yes 9001 No 9004 No 9006 No CV5186S Yes SE CURE 9101 No Yes SE CURE 9350 No ...

Page 23: ...Computer and Monitor Power Switch 4 Close all other programs 5 Double click the FMW icon in the FMW Program Group to start FMW 6 Click RUN A PROGRAM 7 Click SETUP 8 Select PROMPTED SETUP 9 Follow the on screen prompts 10 Click LOAD 11 Select the program you wish to run 12 Click OK EXERCISE 1 8 Service Start Up 1 Reconnect the Main Power Cord from the Main Power Inlet if it was disconnected for ser...

Page 24: ...e rear of the Century Series System OFF to complete power off the system EXERCISE 1 11 To shut down at the end of a shift 1 Wait for the dispensing program to complete 2 Press the Power Switch on the Control Panel OFF 3 Remove workpieces from the dispensing area 4 Remove the syringe from the dispense head 5 Clean or purge your fluid pump EXERCISE 1 12 To shut down for service 1 End your dispensing...

Page 25: ...Level 2 Maintenance Training Century Series 1 15 P N 73 0028 00 Revision A Level 2 Module 1 STUDENT GUIDE Notes ...

Page 26: ...Level 2 Maintenance Training Century Series 1 16 P N 73 0028 00 Revision A ...

Page 27: ...SSON 4 The Dispenser I O LESSON 5 The Vision System LESSON 6 Testing the Height Sensor LESSON 7 Basic Heating Elements Wiring LESSON 8 Pneumatics LESSON 9 The Dispense Valve LESSON 10 X Y Axis Dispenser Movement LESSON 11 Z Axis Dispenser Movement LESSON 12 Performing a Height Sense LESSON 13 Finding Home LESSON 14 Dispense Valve Purging LESSON 15 Temperature Controllers Module 2 Equipment Operati...

Page 28: ...WER 100 120 220 240V 50 60Hz 200W AIR PRESSURE 690kPa SHIPPING WEIGHT 202kg C708 FACILITY REQUIREMENTS FOOTPRINT 843x902mm HEIGHT 559mm SERVICE ACCESS CLEARANCE 203mm Rear POWER 100 120 220 240V 50 60Hz 200W AIR PRESSURE 690kPa SHIPPING WEIGHT 229kg C708 AICE FACILITY REQUIREMENTS FOOTPRINT 843x749mm HEIGHT 1460 5mm SERVICE ACCESS CLEARANCE 203mm Rear 597mm Front 540mm Left POWER 100 120 220 240V ...

Page 29: ...ir Pressure Relief Valve Protects production personnel from injury Improves production workplace environment INTEGRATED DV6000 CLOSED LOOP BACK EMF CONTROL Eliminates auxiliary equipment when using the DV6000 Provides more consistent dispensing using rotary positive displacement pump CHEMICAL RESISTANT MEMBRANE PANEL Easy to clean Better reliability in environments requiring handling of dispensing...

Page 30: ...ler and how it is restored in case of loss Personality Parameters Used to configure the motion of the AutoMove Include but are not limited to default motor speed alternate motor speed motor directions front panel direction keys Calibration Map A grid array of 24 by 24 points in an 18 in 2 or 12 in 2 workspace Contains correction factors which allow AutoMove to be consistent within 5 mils Atoms The...

Page 31: ...Action DA5 DA5 Purge Cup DA6 Recoverable Interlock DA6 Valve 1 Air DA7 Height Sensor DA7 Valve 2 Air DB0 Low Pressure Sensor DB0 Red Light Steady DB1 DB1 Yellow Light Steady DB2 Valve Fault DB2 Blue Light Steady DB3 DB3 Red Light Flashing DB4 DP2000 1 Busy DB4 Yellow Light Flashing DB5 DP2000 2 Busy DB5 Blue Light Flashing DB6 DP2000 1 Chamber Low DB6 Audible Alarm DB7 DP2000 2 Chamber Low DB7 Spa...

Page 32: ...dispensing head does not encounter any obstacles such as parts or other components or is restricted by air hoses or cables as it moves around the dispensing area 4 Press FIND HOME and the fast button on the Dispenser Control Panel simultaneously 5 Press PAUSE on the Dispenser Control Panel 6 Press RESET on the Dispenser Control Panel 7 Perform a purge procedure 8 Turn the Air switch on the Auxilia...

Page 33: ...ick I O TEST in the Tools Window 29 Click DISPENSER 30 Toggle the bit labeled VALVE FORWARD on 31 Set the valve speed to 0 by turning the Valve Speed control knob counter clockwise 32 Return the valve speed to the desired setting 33 Toggle the VALVE FORWARD bit to OFF in the I O Test Window 34 Close the I O Test Window 35 Perform a simulated production run to verify weight control lines station ti...

Page 34: ...system with a choice of light sources to accommodate edge detection and fiducial detection THE AV2550 PATTERN RECOGNITION SYSTEM The parameters that control the search characteristics camera control and light levels are located in the vision system menus accessed through FMW Refer to On line help EXERCISE 2 3 Adjusting the focus of the AV700 1 Loosen the setscrew holding the camera in place using ...

Page 35: ...o display screen in the Programming Window 3 Check that the cross hairs are clear 4 Move the dispensing head over the Needle Sensor using the Position Controls on the Dispenser Control Panel 5 Check that the camera image in the video display screen is clear and focused 6 Close the video display screen by clicking on the camera icon 7 Click DISPENSING ELEMENTS on the Program Commands Toolbar 8 Adju...

Page 36: ...EXERCISE 2 6 Height Sensing Testing Procedure 1 Turn Main Power Switch ON 2 Press START on the Dispenser Control Panel if equipped 3 Press RESET on the Dispenser Control Panel 4 Turn system ON if the computer is not powered up by pressing power button 5 Start FMW by double clicking the FMW icon 6 Click TOOLS in Main Window 7 Click TERMINAL in Tools Window 8 Click DISPENSER 9 Check that the compute...

Page 37: ...LVE COMPATABILITY ILLUSTRATION HT 04 Asymtek DV 04 Valve Only HT 06 All Asymtek Valves except DV 04 HT 10N All Asymtek Valves using Metal Needles EXERCISE 2 7 Installing the Heating Element 1 Loosen the thumbscrew on the front of the Heating Element 2 Perform the following depending on your type of heating element HT04 Slide the heating element onto the needle and onto the valve tip HT06 Slide the...

Page 38: ...t until the Heating Element is at the desired temperature The heat transfer to the dispensing needle heats the needle The increased temperature decreases the stringing of epoxies and adhesives during dispensing processes This increases the accuracy of the dispensing Heating Element Wiring The Heating Element attaches to the needle or to the valve tip depending on the type of heating element used A...

Page 39: ...ly air to the fluid pump syringe and other mechanics EXERCISE 2 8 Completing power and pneumatic connections 1 Plug the black Main Power Cord into the Main Power Inlet located at the back of the system 2 Plug the other end of the Main Power Cord into a facility power outlet 3 Connect you facility air supply to the AIR IN connection at the left rear of the system 4 Locate a row of ports inside the ...

Page 40: ...which reverses the direction of the feedscrew and creates a suckback effect AUTOMATIC MODE The speed control monitors the back electromotive force EMF More power is supplied to keep the motor speed constant as fluid viscosity changes THE DJ2000 SERIES VALVE ON Air pressure is applied to the fluid syringe via the receiver head Fluid is forced down the channel to the rotating auger feed screw The DC...

Page 41: ...r is supplied to keep the motor speed constant as fluid viscosity changes DUAL ACTION DISPENSING HEADS DA600 Allows you to mount and independently operate almost any combination of two valves or fluid pumps for applications needing two different fluids The left dispensing head operates like standard Asymtek single dispensing heads The right dispensing head is a toggle head capable of rapid up and ...

Page 42: ...on completion of this lesson the student should be able to trace the electrical and pneumatic path of dispenser movement in the X or Y axis FMW COMMAND CONTROL PANEL COMMAND COM1 on SYSTEM COMPUTER 201D DISPENSER CONTROLLER MODULE X OR Y AXIS MOTOR DISPENSE HEAD MOVES TO THE COMMANDED LOCATION 201D FRONT PANEL CABLE X OR Y AXIS CABLE CB 01 CABLE ...

Page 43: ...ECTIVE Upon completion of this lesson the student should be able to trace the electrical and pneumatic path of dispenser movement in the Z axis FMW COMMAND CONTROL PANEL COMMAND COM1 on SYSTEM COMPUTER 201D DISPENSER CONTROLLER MODULE Z AXIS MOTOR DISPENSING HEAD MOVES TO COMMANDED HEIGHT 201D FRONT PANEL CABLE Z AXIS CABLE CB 01 CABLE ...

Page 44: ...ng OBJECTIVE Upon completion of this lesson the student should be able to trace the electrical and pneumatic path of a dispenser height sense FMW COMMAND COM1 on SYSTEM COMPUTER 201D DISPENSER CONTROLLER MODULE Z AXIS MOTOR DISPENSING HEAD MOVES TO COMMANDED HEIGHT CB 01 CABLE Z AXIS CABLE Z AXIS MOTOR HEIGHT SENSOR DROPS PROBE ...

Page 45: ...sson the student should be able to trace the electrical and pneumatic path of the dispenser finding home FMW COMMAND CONTROL PANEL COMMAND COM1 on SYSTEM COMPUTER 201D DISPENSER CONTROLLER MODULE X Y and Z AXIS MOTORS DISPENSING HEAD FINDS HOME IN THE Z AXIS FIRST THEN IN THE Y AXIS AND FINALLY IN THE X AXIS 201D FRONT PANEL CABLE X Y and Z AXIS CABLES CB 01 CABLE ...

Page 46: ...nge reservoir to the feedscrew FAILED DV06 INTERFACE See Exercise 2 9 Below FAILED DV06 DRIVERS The Automove Driver an open collector type circuit provides power to the DV01 interface If this circuit fails static methods of testing are ineffective See Exercise 2 10 Below EXERCISE 2 9 Tracing a failed DV06 Interface 1 Turn OFF the dispensing system power 2 Check the 38V fuse on the dispensing syste...

Page 47: ...9 Open the priming port stopcock 10 Close the priming port stopcock when you are confident that all the air has been removed from the chamber 11 Select DP2000 REFILL from the Setup Menu 12 Hold the plastic cup under the priming port again 13 Momentarily open the stopcock 14 Close the stopcock again 15 Select PURGE NEEDLE from the Setup Menu 16 Repeat the priming procedure if fluid drips from the n...

Page 48: ...ated tooling plate and a radiant heat element two DC devices such as two Needle Heating Elements or one AC and one DC device EXERCISE 2 13 Connecting HT1000 Cables 1 Plug the Temperature Controller Power Cable into the Temperature Controller Main Power Inlet 2 Plug the Controller 1 J type Thermocouple Cable into the J type Thermocouple 3 Plug the Controller1 Cable into HT XX EXERCISE 2 14 Connecti...

Page 49: ...17 Changing the display to Celsius or Fahrenheit 1 Press and ENTER simultaneously for five seconds 2 Press INDEX until UNIT displays 3 Toggle between Fahrenheit and Celsius using the buttons EXERCISE 2 18 Accessing the secure menu 1 Press and ENTER simultaneously for five seconds 2 Set the password to one that allows access to the secondary level using 3 Press ENTER to record the new password 4 Pr...

Page 50: ...Level 2 Maintenance Training Century Series 2 24 P N 73 0028 00 Revision A ...

Page 51: ...vel 2 Module 3 STUDENT GUIDE LESSON 1 Needle Sensor Adjustments LESSON 2 Height Sensor and Probe Adjustments LESSON 3 Cleaning the Dispensing Valves LESSON 4 Cleaning the Camera Lens LESSON 5 Cleaning the Fan Vents LESSON 6 Cleaning the Boards Module 3 Preventative Maintenance ...

Page 52: ...dle Also used to determine the XYZ location of the Height Sensor Probe in relation to the needle Allows you to change needles and continue production without reprogramming the dispensing system Can automatically compensate for XYZ changes in needle location due to a needle change or bent needle and between production runs thus minimizing operator error and eliminating wasted time spent manually ad...

Page 53: ...is clean 5 Clean with a cotton swab if necessary 6 Follow the on screen prompts EXERCISE 3 2 Find Needle XYZ 1 Select SETUP in the Programming Window 2 Select FIND NEEDLE XYZ 3 Follow the on screen prompts EXERCISE 3 3 Needle Parameters 1 Click CONFIGURATION from the Main Window 2 Select NEEDLE SETUP 3 Select SETUP PARAMETERS 4 Click the arrow next to the Sensor Type dialog box to view the availab...

Page 54: ... the Dispenser Control Panel 2 Push the Height Sensor Probe up making sure that the green LED on the Height Sensor turns ON when the probe is in the UP position 3 Click TOOLS in the Main Window 4 Click TERMINAL in Tools 5 Click DISPENSER 6 Type GU and GD 7 Check that the Height Sensor probe raises with the GU command and lowers with the GD command 8 Click EXIT on the menu bar 9 Click I O Test in T...

Page 55: ...Disconnect the CB 06N Interface Cable 4 Disconnect the blue air pressure line 5 Remove the syringe 6 Remove the valve from the bracket by using the 1 16 inch hex key to loosen the three setscrews on the left side of the bracket 7 Raise the valve and slide it out to the left 8 Remove and discard the needle 9 Loosen the two screws recessed on the underside of the valve body using the 3 32 inch hex k...

Page 56: ...leaner is running 5 Remove the valve body after two minutes 6 Remove any powdery residue remains on the body with pressurized air 7 Clean the feed screw carefully using a soft cloth and cleaning fluid EXERCISE 3 8 Reassembling the valve 1 Insert the feedscrew into the valve valve body through the Teflon lip seal 2 Insert and tighten the recessed screws on the underside of the valve body 3 Attach a...

Page 57: ...sconnect the blue air pressure line on the dispense head 3 Remove the syringe by loosening the nylon thumbscrew and turning the luer elbow counterclockwise 4 Remove the valve from the bracket by loosening the three setscrews on the left side of it 5 Raise the valve and slide it out to the left 6 Loosen the motor mount cleats on the top of the valve body using the 3 32 inch hex key 7 Pull the motor...

Page 58: ...eaner is running 5 Remove all components after two minutes 6 Remove any powdery residue remains in the valve with pressurized air 7 Clean the feed screw carefully using a bottlebrush EXERCISE 3 11 Reassembling the valve 1 Apply a small amount of conditioning fluid to the seal shoulder at the base of the motor feedscrew assembly on the valve 2 Apply a small amount of conditioning fluid to the feeds...

Page 59: ...ce a month Fluid Type Change Before using a new fluid Curable Materials Immediately after use Clogged Needle Tip Immediately Poor Dispensing Prime the pump Every 60 000 Cycles Replace the stopcock insert TOOLS AND MATERIALS NEEDED 3 21 inch hex key 5 64 inch hex key Bottle Brush 5 8 inch wrench Solvent compatible with your fluid Seal Removal tool Crescent Wrench Soft Cloth Mild solvent ...

Page 60: ...UN A PROGRAM in the Main Window 5 Click SETUP 6 Double click DJ2000 PRIME from the SETUP menu 7 Loosen the securing bolt and open the swinging bracket using the 3 32 inch hex key 8 Loosen the stopcock clamp securing bolt and open the clamp using the 3 32 inch hex key 9 Loosen the two upper pumping chamber assembly screws using the 3 32 inch hex key 10 Slide the pumping chamber assembly with the st...

Page 61: ...nce a month Fluid Type Change Before using a new fluid Curable Materials Immediately after use Clogged Needle Tip Immediately Poor Dispensing Prime the pump Every 60 000 Cycles Replace the stopcock insert TOOLS AND MATERIALS NEEDED 3 21 inch hex key 5 64 inch hex key Bottle Brush 5 8 inch wrench Solvent compatible with your fluid Seal Removal tool Crescent Wrench Soft Cloth Mild solvent ...

Page 62: ...the Delrin spacer using the seal removal tool 9 Clean the seals and Delrin spacer using the small bottlebrush soft cloths and swabs 10 Clean the pumping chamber using the bottlebrush soft cloths and swabs 11 Place the pumping chamber Delrin spacer and all other re usable parts into an ultrasonic cleaner with the appropriate solvent 12 Inspect the interior of the pumping chamber to ensure that all ...

Page 63: ...uld be able to clean the camera lens THE CAMERA LENS Magnifies the workpiece image Sends the workpiece system to the system computer BENCHTOP 25mm lens Adjustable f stop Clearance 3 06 in GANTRY 600 SERIES 25mm lens Adjustable f stop Clearance 1 7 in RECOMMENDED FREQUENCY Quarterly PM EXERCISE 3 15 Cleaning the Camera Lens Use the Cleaning Kit There is a brush and solution for the lens ...

Page 64: ...ss to the fan 6 Remove the screws at the top and bottom of each module 7 Pull each module out of the cabinet and place them in a safe location 8 Unplug the fan from its power connector 9 Remove the plastic fan cover 10 Remove the screws in each corner of the fan using the Philips screwdriver 11 Remove the fan assembly 12 Clean the fan with a cloth or blown air 13 Clean out the dust tray underneath...

Page 65: ...ner of the dispensing area EXERCISE 3 17 To adjust the upward facing sensors 1 Locate the LED indicator on the backside of the pre dispense zone board sensor 2 Move the dispensing head over the sensor using the Position Controls 3 Turn the sensitivity adjustment screw counter clockwise until the LED or I O turns OFF 4 Move the dispensing head over the sensor and adjust the conveyor width to fit a ...

Page 66: ...Level 2 Maintenance Training Century Series 3 16 P N 73 0028 00 Revision A ...

Page 67: ...ON 2 The Basic Steps of Troubleshooting LESSON 3 Obtaining Asymtek Support LESSON 4 Ordering Service Parts LESSON 5 Isolating Failure in the Z Axis LESSON 6 Isolating Failure in the X or Y Axis LESSON 7 Isolating Communication Errors LESSON 8 Isolating Vision System Errors LESSON 9 Isolating Dispense Valve Motor Faults Module 4 Troubleshooting ...

Page 68: ...g machine faults to other service engineers Describing Machine Faults 1 Summarize the problem and describe when it started 2 Write down all of the details of the symptom remembering how the correct operation should be 3 Tell what you believe is causing the problem and how you isolated it to this problem 4 If it is isolated to a component and you need to order the part write down the PN from the fa...

Page 69: ...ue is routine and you ve already worked on it several times before run through the possible root causes in your head If you re working on a new problem jot down the root causes on a piece of paper 4 Create a Test Plan Come up with a test to eliminate each possible root cause Once you ve identified all the tests prioritize the order you ll do the tests by considering how long each test will take an...

Page 70: ... if it will save time and then isolate further if you succeed at correcting the problem with those two or three changes For example if the vision fails and you suspect it is a vision card you can swap the entire computer instead of just one card at a time Use common sense and remember the recent history of the equipment Was there a software upgrade just performed Was there a PM performed on the ne...

Page 71: ...4 5 P N 73 0028 00 Revision A Level 2 Module 4 STUDENT GUIDE LESSON 3 The Request for Technical Support Form OBJECTIVE Upon completion of this lesson the student should be able to complete an Order Request Form to obtain Asymtek Technical Support ...

Page 72: ...who can receive the part This should be an MTE or line supervisor that knows he will be a contact No Fill out a Order Request Form Email the form to the RMA Process Coordinator The RTS should include the following information The type of machine the SN of the machine an accurate description of the failure and how the replacement part should be shipped Call Asymtek Technical Support during business...

Page 73: ... Z Axis Cable Dispenser Controller Module Fuse Personality Parameters Main PCA Z Axis Home PCA Mechanical Alignment Z Axis Cable Z AXIS STUTTERS VIBRATES OR SLIPS Program Z Parameters Check if valve is tightened down correctly along with every luer needle Check if MZCB is tightened down firmly Try to rock it up and down from the fixed end to see if there is undesired play Check if bearings success...

Page 74: ...oner System in Interlock State NO X Y AXIS DISPENSING HEAD MOTION Interconnect Cables Dispenser Controller Module Fuse Personality Parameters Main PCA Interconnect Cables Home PCA DISPENSING HEAD FAILS TO FIND HOME Shutter Alignment Dispenser Controller Module Personality Parameters Main PCA Interconnect Cables X Y AXIS STUTTERS VIBRATES OR SLIPS X Y Positioner Settings Memory personalities calibr...

Page 75: ...e tie wrapped harness connecting the computer to the camera and the light ring Adjust the focus Check to make certain that the substrate is within the height focus limits of the system UNFOCUSED IMAGE The camera lens may have been dropped damages from harsh chemicals of the environment or has hit objects during operation A service technician will need to be called AV2550 ERRORS SYMPTOM CHECKS PROG...

Page 76: ...eumatics Module STOP PINS CLAMPS INOPERATIVE Interconnect Cables NO FUNCTIONALITY Conveyor Controller Module Fuse Conveyor Controller Module Interface Module NO UPSTREAM DOWNSTREAM INTERFACE Upstream Downstream System Although there are many configurable settings for baud rate Comport settings in Windows the typical communication problems are the result of one of these two things a POWER FAILURE t...

Page 77: ... below spec and when the valve purges hardly any fluid comes out Understand the Problem Ask the operator when the problem started and if anything has been done to the machine recently Repeat the problem and observe exactly what is happening Use Available References Look in your reference material for any applicable RFCs or trouble shooting instructions Brainstorm Root Causes Write all the possible...

Page 78: ...Level 2 Maintenance Training Century Series 4 12 P N 73 0028 00 Revision A ...

Page 79: ...Level 2 Maintenance Training Century Series APPENDIX P N 73 0028 00 Revision A Level 2 Summary Final Certifications STUDENT GUIDE Summary Final Certifications ...

Page 80: ...Level 2 Maintenance Training Century Series APPENDIX P N 73 0028 00 Revision A ...

Page 81: ...eight Sensor is tested using the Tools menu and the Terminal Mode L2M2 7 Explain the wiring of the heating elements L2M2 8 Describe the pneumatic system of the Century Series system L2M2 9 Describe how the dispense valve dispenses fluid L2M2 10 Trace the electrical and pneumatic path of dispenser movement in the X Y axis L2M2 11 Trace the electrical and pneumatic path of dispenser movement in the ...

Page 82: ...Level 2 Maintenance Training Century Series APPENDIX P N 73 0028 00 Revision A ...

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