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Troubleshooting

8-1

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 Accuracy

•

•

•

•

•

•

Dispense Head Controller Connections and Functions

•

Substrate Heaters

•

•

•

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
dispensing system fully understands all hazards, risks, and safety precautions. Refer to

Section 2 - Safety

for important safety information.

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.

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Содержание Asymtek Spectrum S-920

Страница 1: ...Spectrum Series S 920 Dispensing System Installation Operations Maintenance Manual P N 7212417 Rev A...

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Страница 3: ...Spectrum Series S 920 Dispensing System Installation Operations and Maintenance Manual P N 7212417 Revision A...

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Страница 5: ...uals htm Contact Us Asymtek welcomes requests for information comments and inquiries about its products Please contact us using the information below Headquarters 2762 Loker Avenue West Carlsbad CA 92...

Страница 6: ...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 symbo...

Страница 7: ...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 Sys...

Страница 8: ...neumatic 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 3 Facility Requirements 3 1 3 4 Tools and Materials Needed 3 1 3 5 Uncrating and Placing the Disp...

Страница 9: ...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...

Страница 10: ...e 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...

Страница 11: ...ing 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 Cl...

Страница 12: ...raph 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 Heate...

Страница 13: ...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...

Страница 14: ...e 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 Configur...

Страница 15: ...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 Fig...

Страница 16: ...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...

Страница 17: ...uids 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...

Страница 18: ...r 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...

Страница 19: ...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...

Страница 20: ...hrough 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 u...

Страница 21: ...ard 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 t...

Страница 22: ...ers 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 cu...

Страница 23: ...00 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 wit...

Страница 24: ...f 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...

Страница 25: ...uns the Fluidmove for Windows XP FmXP dispensing software 3 Front Panel Digital Valve Fluid and Coax Cooling Pressure Gauges ON and OFF Buttons Emergency Stop and Grounding Strap Jacks are located on...

Страница 26: ...d jets 3 Conveyor The Conveyor transports the workpiece from an upstream system to the dispensing station and then to downstream systems All Conveyors are SMEMA compatible and have adjustable rear rai...

Страница 27: ...tion in the Z axis 3 Purge Station The Purge Station consists of a small reservoir that contains a disposable plastic cup and is attached to a vacuum generator Air flowing through the purge boot into...

Страница 28: ...ated on the front panel of the dispensing system Activating the EMO vents all pressure in the pneumatic system de energizes the servo power and cuts power to all system components except the computer...

Страница 29: ...the air pressure supplied to the fluid syringe 5 Conveyor Heater Modules Controls all conveyor functions motors sensors pneumatics etc It receives power from the Power Manager and supplies AC power t...

Страница 30: ...1 14 Introduction 1 10 5 Rear View Figure 1 7A Rear View 2 3 4 1 5...

Страница 31: ...ll system components except the computer 3 Main Circuit Breaker The Main Circuit Breaker is the main power switch for the dispensing system It protects the dispensing system from facility power surges...

Страница 32: ...licator Pneumatics 2 Lower E Pan The Lower E Pan houses the Mainboard X Y Axis Servo Amps Main Air Pneumatic Valves and Conveyor Pneumatic Valves 3 Rear Cabinet The Rear Cabinet houses the Power Manag...

Страница 33: ...MO button the green ON I button and the black OFF 0 button are directly connected to the Power Manager 2 Conveyor Heater Module Dual Conveyor Configuration shown The Conveyor Heater Module receives po...

Страница 34: ...der for programming purposes only 4 Loader Downstream Allows the dispensing system to communicate with a downstream unloader for programming purposes only 5 Network Allows the dispensing system to com...

Страница 35: ...res 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 acco...

Страница 36: ...r 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 co...

Страница 37: ...e 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 fac...

Страница 38: ...s 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...

Страница 39: ...ity 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...

Страница 40: ...rns that the labeled component is heavy and can cause muscle strain or back injury to personnel trying to lift it Moving Parts Present 70 0120 00 1 or 198883 2 This label warns of moving parts that ca...

Страница 41: ...m 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 In...

Страница 42: ...2 8 Safety 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 1 2...

Страница 43: ...tion 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 Warn...

Страница 44: ...2 10 Safety Item Description 1 Electrical Warning Label 2 General Warning Label Figure 2 6 Safety Warning Labels Power Manager 1 2...

Страница 45: ...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 NO...

Страница 46: ...wer 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...

Страница 47: ...cate 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 int...

Страница 48: ...emblies 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...

Страница 49: ...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 t...

Страница 50: ...eacon 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 Sol...

Страница 51: ...every person servicing or operating the dispensing system fully understands all hazards risks and safety precautions Refer to Section 2 Safety for additional information CAUTION Installation procedur...

Страница 52: ...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 t...

Страница 53: ...ont 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 mov...

Страница 54: ...king 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 t...

Страница 55: ...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...

Страница 56: ...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...

Страница 57: ...ove 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...

Страница 58: ...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...

Страница 59: ...entered 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...

Страница 60: ...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 Figure 3 11 Leveling the Scale 3 Replace the scale cover and...

Страница 61: ...oth 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 t...

Страница 62: ...nd 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...

Страница 63: ...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...

Страница 64: ...he 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 compu...

Страница 65: ...e 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 f...

Страница 66: ...stand 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 al...

Страница 67: ...stem Level Functional Test 4 2 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...

Страница 68: ...ccessories 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 posi...

Страница 69: ...sed 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 facil...

Страница 70: ...nd 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 minu...

Страница 71: ...he 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...

Страница 72: ...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...

Страница 73: ...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 Set...

Страница 74: ...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...

Страница 75: ...on 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 Wi...

Страница 76: ...pede 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...

Страница 77: ...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...

Страница 78: ...ce 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 Dig...

Страница 79: ...r 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 proce...

Страница 80: ...ing system hood 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 Th...

Страница 81: ...g 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...

Страница 82: ...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 syste...

Страница 83: ...urn to the Tools Window 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 sam...

Страница 84: ...gure 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 P...

Страница 85: ...Board Available from Upstream Tool input changes to ON In dialog box press Board Available to Downstream output button No 4 LED on TS 01 comes ON Press TS 01 button No 5 Dialog box Downstream Tool Re...

Страница 86: ...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 workpie...

Страница 87: ...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...

Страница 88: ...tact 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 sampl...

Страница 89: ...w 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...

Страница 90: ...e 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 Figur...

Страница 91: ...ve 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...

Страница 92: ...ure 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 th...

Страница 93: ...e 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...

Страница 94: ...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 c...

Страница 95: ...ng 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 ou...

Страница 96: ...r 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 ins...

Страница 97: ...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 Need...

Страница 98: ...e 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 an...

Страница 99: ...edestal 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 attem...

Страница 100: ...cale 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...

Страница 101: ...il 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 B...

Страница 102: ...Up and Testing 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...

Страница 103: ...is set to Auto If not the heater may respond inadequately Table 4 2 Heater Set Points Heater Type Set Point C Set Point F Impingement and Contact 80 176 Needle 40 104 4 When all loops have been confi...

Страница 104: ...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 t...

Страница 105: ...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 Off...

Страница 106: ...n 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 dispensin...

Страница 107: ...s 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 be...

Страница 108: ...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 wor...

Страница 109: ...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 techni...

Страница 110: ...k 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...

Страница 111: ...ixel 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 fie...

Страница 112: ...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 Af...

Страница 113: ...ion 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 o...

Страница 114: ...king 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...

Страница 115: ...Calibration and Adjustment 5 7 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...

Страница 116: ...0 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 Scal...

Страница 117: ...ounterbalance 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 tens...

Страница 118: ...en 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 T...

Страница 119: ...rea 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 Figu...

Страница 120: ...ng 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 ca...

Страница 121: ...e 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 Ver...

Страница 122: ...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 o...

Страница 123: ...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 NOT...

Страница 124: ......

Страница 125: ...veyor 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 Ca...

Страница 126: ...tion 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...

Страница 127: ...ription Item Description 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 D...

Страница 128: ...si 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 connecte...

Страница 129: ...e 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 fo...

Страница 130: ...ge 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 Figu...

Страница 131: ...et 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...

Страница 132: ...u 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...

Страница 133: ...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 re...

Страница 134: ...osition 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 th...

Страница 135: ...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 Dis...

Страница 136: ...pensing 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 mm inch 2 Velocity mm sec in se...

Страница 137: ...N A Device Radio Buttons Click the Dispenser radio button to activate jog controls for the Dispensing Head Click the Conveyor 1 radio button to activate jog controls for the conveyor On dual conveyor...

Страница 138: ...o front Rear rail moves to front Ctrl Z Moves downward N A Ctrl Z Moves upward N A Fast 3 Ctrl Shift Moves left Belts move left Ctrl Shift Moves backward Rear rail moves to back Ctrl Shift Moves right...

Страница 139: ...s 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...

Страница 140: ...GigE server tray icon shows a warning when a device is connected but there is some type of IP error Device Not Available A red X will remain over the GigE server tray icon when the Genie device is not...

Страница 141: ...trols 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 workpie...

Страница 142: ...n 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 Adjust...

Страница 143: ...he 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...

Страница 144: ...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...

Страница 145: ...owing 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 ope...

Страница 146: ...ight 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 Fl...

Страница 147: ...n 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 m...

Страница 148: ...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 Programming Window opens The last saved program opens when you start...

Страница 149: ...en 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 ava...

Страница 150: ...nd 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 eas...

Страница 151: ...uted 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...

Страница 152: ...mming 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 comman...

Страница 153: ...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 C...

Страница 154: ...2 5 DOT 1 4 964 24 501 6 END USE CONVEYOR 7 END 7 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...

Страница 155: ...o 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 patte...

Страница 156: ...DO C2Dot at 0 382 5 198 6 END USE CONVEYOR 7 END 7 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 7 Workp...

Страница 157: ...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 V...

Страница 158: ...justing 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 Pro...

Страница 159: ...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 Th...

Страница 160: ...spensing 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...

Страница 161: ...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...

Страница 162: ...e dispensing system Clean Purge Station Boot Daily 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 recommend...

Страница 163: ...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 Tools and Materials Needed Needle nosed Pliers Repla...

Страница 164: ...sing 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...

Страница 165: ...Maintenance 7 5 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 1 2 3 4...

Страница 166: ...s 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...

Страница 167: ...ste 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...

Страница 168: ...d 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 Axi...

Страница 169: ...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...

Страница 170: ...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 glove...

Страница 171: ...linear guides 1 Perform a service shutdown as specified in 2 11 Service Shutdown 2 Manually move the dispensing head to the front of the dispensing area 3 Remove the X and Y axis covers See 7 7 Remov...

Страница 172: ...7 12 Maintenance Figure 7 7 Lubricating the X Axis Linear Guides Figure 7 8 Lubricating Y Axis Linear Guides...

Страница 173: ...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...

Страница 174: ...desired tension is obtained 4 Tighten the tensioner screws 5 Repeat Steps 1 3 for the other belt Item Description Item Description 1 Motor Mount Tensioner Rear Rail 4 Belt Tensioner Screws Rear Rail 4...

Страница 175: ...d 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...

Страница 176: ...circuit breaker switch is the only mechanism for completely powering down the system including power to the laptop computer EMO button has been activated 1 Turn the EMO button clockwise until it pops...

Страница 177: ...Offsets Camera needs calibrated Calibrate the camera See 5 6 Calibrating the Camera Cal Maps disabled Enable Cal Maps Contact a service technician Bent needle Replace the needle Refer to the applicab...

Страница 178: ...per air pressure Incorrect bit mask Contact Asymtek technical support for correct bit mask values that control the pneumatic states for the particular fluid delivery system being used Syringe disconne...

Страница 179: ...and reinitialize main PWA memory 2 Run escape sequences and reload machine specific personalities Refer to the system s ACL Recovery Disk The Dispenser ACLPlus Device Failed to Respond message appears...

Страница 180: ...ensor has been adjusted or is loose Adjust height sensor and tighten locking screw See 5 10 Adjusting the Height Sensor Probe Dispenses at wrong Z axis position Nozzle needle has been changed Perform...

Страница 181: ...t utility from the tools diagnostics menu The probe can be toggled up and down to verify probe functionality There is also a test procedure that captures HS trigger values FmXP can display a statistic...

Страница 182: ...cted Restore lighting module connection Lens is blocked by foreign matter 4 Remove and inspect the camera lens 5 If necessary replace lens See 9 8 Replacing the Camera Lens No Image FmXP display windo...

Страница 183: ...tal not installed There is a minimum weight that must be placed on the scale in order for it to read properly You will typically receive an FmXP error message when the pedestal is not installed on the...

Страница 184: ...mands 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 e...

Страница 185: ...Troubleshooting 8 11 Figure 8 3 FmXP Scale Setup Menu Figure 8 4 Scale Error Message...

Страница 186: ...actile Sensor Troubleshooting Symptom Possible Cause Recovery During setup routine error indicates that the tactile sensor is already engaged Tactile sensor cap is stuck in the down position Visually...

Страница 187: ...luid 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 Tool...

Страница 188: ...ections on the conveyor controller and replace if necessary See 9 10 Replacing Fuses 8 4 13 Conveyor Table 8 13 Conveyor Troubleshooting Symptom Possible Cause Recovery EMO button has been activated 1...

Страница 189: ...nician Board Sensor is dirty not active or out of adjustment Clean sensor If no improvement call a trained service technician Board will not index to correct position Gap between conveyor rails is too...

Страница 190: ......

Страница 191: ...placement 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 el...

Страница 192: ...rvice on Asymtek web page 2www asymtek com 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 recei...

Страница 193: ...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 Befor...

Страница 194: ...ry to remove covers doors and access panels 12HFigure 9 1 shows the location of these features WARNING CAUTION Make sure that the dispensing system has been completely shut down before attempting to r...

Страница 195: ...rformed 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...

Страница 196: ...iption Item Description 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 Remo...

Страница 197: ...ue 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...

Страница 198: ...ion 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 15HFigure 9 3 2 Screw on...

Страница 199: ...two springs from the upper spring bracket 5 Remove the Z plate 6 Dismount the height sensor assembly from the Z carriage 17HFigure 9 4A Removing the Z head Top Cover and Front Valve Panel 18HFigure 9...

Страница 200: ...d 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 attac...

Страница 201: ...ent 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 locatio...

Страница 202: ...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...

Страница 203: ...formed by a trained service technician only 1 Perform a service shutdown as specified in 2 11 Service Shutdown 2 With your fingers gently push in and turn the fuse holder counterclockwise until the he...

Страница 204: ......

Страница 205: ...1 Facility Requirements Facility Requirements System Footprint Single Station 600 mm x 1310 mm Two Station 850 mm x 1310 mm Three Station 1100 mm x 1310mm Weight Single Station 371kg 820 lbs Two Stat...

Страница 206: ...Fiber optic over the rail board sensors at all stations Over the rail stop pins Service Station Needle Vacuum Purge Cup On Board High Precision Scale Needle Calibration Substrate Heaters 120 C 5 C fo...

Страница 207: ...Front Right Rear Right Rear Left 92 0 kg 202 9 lbs 93 9 kg 207 1 lbs 94 2 kg 207 6 lbs 91 8 kg 202 4 lbs Seismic Loading Transverse Stability Anchorage Force Longitudinal Stability Anchorage Force Anc...

Страница 208: ......

Страница 209: ...EV ECO DATE DESCRIPTION APPD 1 9 8 2007 PRE PRODUCTION RELEASE B HEUY raw NOTES CIRC RUNOUT PERPENDICULARITY A1 30 0 10 20 40 50 60 80 70 90 SIZE APPROVAL ELECTRONIC FILE DRAWN CHECKED ENGINEER TITLE...

Страница 210: ......

Страница 211: ...S provides material usage instructions disposal instructions and safety precautions A 2 MSDS MULTEMP PS NO 2 A 07 350 Material Safety Data Sheet SECTION I Material Identity Item Name Part Number Trade...

Страница 212: ...s DENSE SMOKE FIRE FIGHTER WEAR 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 S...

Страница 213: ...O EMPTY CONTAINER WHEN EMPTY CONTAINER MAY 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...

Страница 214: ...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 N...

Страница 215: ...n 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 Evaporat...

Страница 216: ...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 th...

Страница 217: ...ystem 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 perfor...

Страница 218: ...EMO Switched Conveyor Power Supplies power to the optional conveyor module CV2 8 Conveyor Power Reset Resets the circuit breaker to the AC outlet 9 Spare 24 VDC spare 10 Power Controls Connects to th...

Страница 219: ...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...

Страница 220: ......

Страница 221: ...EATER 1 CONTACT HEATER 2 ASSY IMPINGMNT SWITCH LOW PRESSURE SWITCH LINE TYPE KEY 1 2 LAMINATE TO BE PROVIDED IN COLOR FOLLOWING REV ECO DATE DESCRIPTION APPD A 14352 09 11 07 PRODUCTION RELEASE DMEJIA...

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Страница 227: ...g and parts replacement C 3 Spare Parts List 8HTable C 1 contains a list of spare parts that will aid in ordering replacement parts for the Spectrum Series S 920 Dispensing System NOTE Parts listed in...

Страница 228: ...oard 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 7...

Страница 229: ...ts interconnected to perform one or more specific functions Cleaning Agent A solvent or other cleaning liquid recommended by the dispensing fluid manufacturer s Material Safety Data Sheet Contact Heat...

Страница 230: ...y dispensing software based in a Windows XP environment Fluidmove Online Help The help function in Fluidmove that is accessed by clicking on the Help button on most of the windows and dialog boxes on...

Страница 231: ...expected energizing of equipment start up or the release of stored energy Low Air Pressure Alarm The Low Air Pressure Alarm sounds when the system air pressure is too low Low Fluid Sensor A device tha...

Страница 232: ...chips and other electronic components are placed Rapid Response Heaters Rapid Response Heaters with low mass design rapidly ramp to temperature for uniform material flow and quick cool down for fast...

Страница 233: ...uid High viscosity fluids have a high resistance to flow and low viscosity fluids have a low resistance Vision Card Computer card that receives video signals from the Camera and performs fiducial imag...

Страница 234: ......

Страница 235: ...ialization 5 13 DispenseJet See Dispensing Valve Dispenser position controls 6 11 Dispensing Commands 6 27 Dispensing Fluids 1 2 Dispensing Head clearance check 4 10 clearance check final 4 23 functio...

Страница 236: ...ting the temperature 6 21 rapid response 1 6 substrate setting temperature 6 19 temperature test 4 37 Height Sensor 1 4 laser 1 5 safety 2 11 specifications 2 11 probe adjustment 5 10 probe replacemen...

Страница 237: ...ressure threshold 6 6 vacuum control adjustment 6 6 Position Controls conveyor 6 10 dispenser 6 11 dual conveyor systems 6 14 keyboard commands 6 14 using the touchpad 6 10 Powering on the Dispensing...

Страница 238: ...functional test 4 38 tactile sensor 4 30 vision system 4 27 Training 1 2 registration 1 2 student certification 1 2 Troubleshooting conveyor 8 14 dispensing head 8 6 FmXP startup 8 5 height sensor 8 7...

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