Axiom X-1000 Series Dispensing System Installation and Service Manual Models: X-1010 X-1020 P/N 392892, Revision C
NOTICE This is an Asymtek publication which is protected by copyright. Original copyright date 2002. 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 this manual can be downloaded from: http://www.asymtek.
Manual Conventions Bold Text Bold text indicates a software menu or button selection [Click on Go], switch position symbols [ON (I)], Internet address, or label on the dispensing system (Connect to the port labeled Valve 1). [Bracketed Text] [Bracketed Text] indicates a keyboard key to press or a keyboard sequence, such as [Enter] or [Alt+Tab]. Italics Italicized text is used for references to other sections/paragraphs in this manual and for documents outside this manual.
TABLE OF CONTENTS 1 INTRODUCTION.................................................................................................................. 1-1 Overview .............................................................................................................................. 1-1 Installation Sections ................................................................................................................... 1-1 Service and Maintenance Sections .............................................
4 COMPONENT INSTALLATION .......................................................................................... 4-1 Overview .............................................................................................................................. 4-1 Installing Dispensing Valves ................................................................................................ 4-1 Installing the Monitor ..................................................................................................
THEORY OF OPERATIONS ............................................................................................... 7-1 Overview .............................................................................................................................. 7-1 The Dispensing Process ...................................................................................................... 7-1 Description of System Components .....................................................................................
.1 Troubleshooting X and Y-axis Motion ......................................................................... 8-7 8.1.1X and Y Motion Fault Isolation Procedure ......................................................................... 8-8 8.1.2Main Power Fault Isolation Procedure............................................................................. 8-13 8.1.3System Power Fault Isolation Procedure ........................................................................ 8-20 8.1.
Safety First ......................................................................................................................... 10-2 Hazardous Materials ................................................................................................................ 10-2 Training .............................................................................................................................. 10-2 Unpacking and Inspecting Replacement Parts .................................................
APPENDIX D MATERIAL SAFETY INFORMATION ......................................................... D-1 Overview ............................................................................................................................. D-1 MSDS - MULTEMP PS NO 2-A 07-350 .............................................................................. D-1 MSDS Moly-Graph® Extreme Pressure Multi-Purpose Grease.......................................... D-4 APPENDIX E INSTALLATION CHECKLIST ......................
TABLE OF FIGURES Figure 1-1 Typical Dimensions for X-1000 Series Dispensing Systems .............................. 1-3 Figure 1-2 Axiom X-1000 Service Area Dimentions ............................................................ 1-4 Figure 2-1 Earthquake Protection, Side View ...................................................................... 2-5 Figure 2-2 Axiom X-1000 Center of Gravity .........................................................................
Figure 5-17 Leveling the Dispensing System ...................................................................... 5-34 Figure 5-18 Leveler Adjustment ........................................................................................... 5-35 Figure 5-19 Lift Table and Heater Tooling Level Check ...................................................... 5-37 Figure 5-20 Heater Control Window ....................................................................................
Figure 9-4 Cable Tensioner Locations ............................................................................... 9-10 Figure 9-5 Tensioning the Positioner Cables ..................................................................... 9-11 Figure 9-6 Linear Bearing Locations .................................................................................. 9-13 Figure 9-7 Accessing the Positioner Cables ......................................................................
TABLE OF TABLES Table 1-1 Facility Requirements ......................................................................................... 1-2 Table 2-1 Calculation of Overturning Force, X-direction..................................................... 2-6 Table 2-2 Calculation of Overturning Force, Y-direction..................................................... 2-6 Table 2-3 Safety Warning Symbols ..................................................................................
Table 8-18 Troubleshooting Summary – PMAC ................................................................. 8-49 Table 8-19 X-axis Rotary Signal Routing ........................................................................... 8-58 Table 8-20 Y-axis Rotary Signal Routing ........................................................................... 8-60 Table 8-21 Z-axis Rotary Signal Routing ............................................................................
1 Introduction Overview This manual is an instructional guide to be used by trained service technicians for the installation, service, and maintenance of the Axiom X-1000 Series Dispensing System.
Facility Requirements Before installing the Axiom X-1000 Series Dispensing System, you must take into account the facility requirements listed in Table 1-1. Meeting the requirements specified will ensure reliable operation and safety of the dispensing system. WARNING! CAUTION! Make sure that your facility meets the requirements below. Failure to meet these requirements could result in serious injury to personnel and damage to the dispensing system.
Side View Front View Top View Figure 1-1 Typical Dimensions for X-1000 Series Dispensing Systems Introduction 1-3
Figure 1-2 Axiom X-1000 Service Area Dimensions 1-4 Introduction
2 Safety Overview This section is intended to provide basic safety information necessary for installing, operating, maintaining, and servicing the Axiom X-1000 Series Dispensing System.
Basic Safety Precautions and Practices Compliance with the following recommended precautions and practices can prevent personal injury or damage to property during X-1000 Series Dispensing System operation and maintenance: Safety of Personnel 2-2 • Only trained personnel should be permitted to perform operation, maintenance, service, and troubleshooting procedures. • There should always be a second person present when performing maintenance on a system under power.
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 ESD precautions when working near ESD-sensitive components. Always wear a grounding strap and connect it to ground jacks before handling ESD-sensitive workpieces. • Immediately contain and clean up any caustic or conductive fluid spills as recommended in the material manufacturer’s MSDS.
Injury to Personnel If an injury occurs during operation or servicing of the dispensing system, it is recommended that the following steps be taken: 1. If the dispensing system is operating when the injury occurs, press the nearest EMO button to stop all system operations. 2. Immediately report injury to Supervisor in accordance with facility procedures. 3. If it is an injury due to exposure to a hazardous material, refer to the treatment recommendations on the material manufacturer’s MSDS. 4.
Earthquake Precautions Personnel To prevent injury during an earthquake, all personnel should follow facility earthquake safety guidelines. System Safe Mode Your X-1000 Dispensing System is designed to automatically go into a safe mode if electrical power is lost due to an earthquake. All hazardous electrical and pneumatic energy is bled out of the system.
Seismic Calculations Table 2-1 Calculation of Overturning Force, X-direction Symbol Unit Value Notes Wp lb 961 Total Wt. of Axiom X-1000 h mm 850 Height of CG L1 mm 800 Width of Machine L2 mm 362 Distance from front, RHS of machine to CG in X Symbol Value R (lb) -590.2 Equation Ra=Wp*(.85*L2-.94*h)/L1 Notes For overturning force, 85% of Wp can be used to resist overturning. This analysis is considering Fp HPM = .94Wp. Result: Tension Reaction at Feet, Machine Requires Anchors.
Figure 2-2 Axiom X-1000 Center of Gravity Safety 2-7
Figure 2-3 Axiom X-1000 Weight Distribution 2-8 Safety
Lifting and Transport Precautions WARNING! CAUTION! Failure to follow safe lifting procedures may cause serious injury to personnel or damage to the dispensing system. Considerations Before attempting to lift a load, personnel should take into consideration the following factors: 1. Does the load display a lift hazard warning label as shown below? If so, get assistance. 2. Is lifting and transporting equipment available that might make the task safer and easier? 3.
Safety Warning Labels WARNING! CAUTION! Comply with all safety warning labels or serious injury to personnel or damage to the dispensing system will occur. Worn or damaged labels should be replaced with new labels having the same part number. Warning labels on your Axiom X-1000 Series Dispensing System point out areas where personnel must use extreme caution to prevent serious injury and property damage. Table 2-3 shows the warning symbols that may be found on your dispensing system or optional equipment.
3 1 2 Item Description 1 Electrical Hazard Warning Label 2 Heavy Object Warning Label (on side of Computer) 3 Thermal Hazard Warning Label (X-1020 only) Figure 2-4 Typical Warning Label Locations, Front View Safety 2-11
2 4 1 3 2 Item Description 1 Heavy Object Warning Label (on side of Transformer) 2 Electrical Hazard Warning Label 3 Thermal Hazard Warning Label (X-1020 only) 4 Fire Hazard Warning Label Figure 2-5 Warning Label Locations, Rear View 2-12 Safety
Emergency Shutdown Your Axiom X-1000 Series Dispensing System features 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 being processed. Your dispensing system design includes two EMO buttons. One EMO button is located on the Operator’s Console, and the second is located on the rear panel of the dispensing system (see Figure 2-6).
Emergency Shutdown Situations WARNING! CAUTION! In an emergency, failure to completely shut down power to the dispensing system with the EMO can cause serious injury to the user and damage to the dispensing system. 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.
Service Shutdown Before performing any servicing or parts replacement, the dispensing system should be shut down as follows: 1. Wait for the dispensing program to complete. 2. Purge the Dispensing Valve as specified in the applicable Dispensing Valve Installation and Operation Manual. 3. Press the black OFF (0) button on the Operator’s Console and verify that all dispensing system motion stops. 4.
6. Switch the Main Circuit Breaker to the OFF (0) position. WARNING! The Needle Heater and Heater Tooling Plates retain heat for a time after the system has been shut down. Use extreme caution around these components to prevent burn injuries. 7. Open the Hatch and remove all workpieces from the dispensing chamber. 8. Remove the fluid syringe from the Dispensing Head and clean the Dispensing Valve as specified in the applicable Dispensing Valve Installation and Operation Manual. 9.
Lockout of Electrical and Pneumatic Energy Axiom X-1000 Series Dispensing System electrical and pneumatic components have been designed in accordance with industry-wide safety standards.
2 3 4 1 Item Description 1 Main Circuit Breaker 2 Circuit Breaker Locking Flange 3 Keyed Padlock (or other locking device) 4 Warning Tag Figure 2-8 Main Power Lock Out 2-18 Safety
Post-Service Start-up To start up the dispensing system: 1. Remove locks and tags on the Main Power Inlet and Main Air Inlet. 2. Reconnect the facility air hose and AC power cable to the dispensing system. 3. Reset the EMO Switches by turning the red EMO knobs counterclockwise until they pop out. 4. Switch the Main Circuit Breaker to the ON (I) position. ! The Light Beacon should display a solid yellow light. 5. Verify that the dispensing system Hatch is closed. 6.
Safety Interlock System The Safety Interlock System is a built-in safety feature that automatically reduces dispensing system servo power when the Hatch is opened. This system mainly prevents personnel from being injured by movement of the Dispensing Head and Conveyor.
Light Beacon Located at the top right corner of the system, the Light Beacon is a device that displays system status. See Figure 2-9. The Beacon has four different color lights which can be constantly ON or flashing and has an audible alarm. See Table 2-4 for an explanation of each color indication. " NOTE Software and hardware share control of the Beacon lights. Hardware-driven displays may override those caused by software conditions and vice versa.
Table 2-4 Beacon Color Indications Beacon Color System Status Recovery Procedure ALERT All motion, outputs, Dispensing Valve, and motion controls are disabled. One of the following conditions exist: A. Solid – System in an Emergency Stop condition. A. 1. Remedy problem causing the Emergency Stop. 2. Reset EMO button(s). 3. Restart the dispensing system. RED (Audible Alarm) B. Flashing – Software driven error message is displayed on the Computer Monitor. B. Respond to error message.
Decommissioning Procedures The Axiom System should provide you with years of safe and reliable service. When it becomes necessary to decommission the system, the components should be dispositioned as specified in Table 2-5. Table 2-5 Recommended Decommission Procedures Component Safety Disposition Consumer Fluid Discard in accordance with local safety/environmental regulations. Aluminum Parts Recycle aluminum conveyor base plate, conveyor rails, panels, doors, and hardware.
3 Uncrating and Placing Overview This section covers the following topics: • Removal of dispensing system from the shipping crate • Initial placement of the dispensing system • Unpacking the dispensing chamber • Unpacking of accessories from the shipping crate CAUTION! Check the “Tip & Tell” and “Shockwatch” devices, both on the outside of the crate and on the dispensing system, to make sure that the dispensing system has not been dropped or tipped.
Uncrating, Placing, and Unpacking the Dispensing System CAUTION! The following procedures should only be performed by a trained service technician. Tools and Materials Needed • 3-mm Hex Key • Hammer • 6-mm Hex Key • Flat bar • 6-mm (1/4-inch) Wrench • Work gloves • Two 9/16-inch Open End Wrenches • Safety glasses • 1 1/2-inch Open End Wrench • Forklift • Diagonal-cut Pliers • Pen • Small A-frame Ladder Uncrating the Dispensing System To uncrate the dispensing system: 1.
6. When the four Foot Restraint 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. 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. 7.
Placing the Dispensing System To place the dispensing system: 1. Move the dispensing system over the location where it will be installed. 2. Slowly lower the forklift until the dispensing system Conveyor rail is at the approximate height of the mating upstream and downstream equipment. 3. Raise or lower each Leveler (foot) as follows until they all touch the floor: a. Loosen the 1 1/2-inch Lock Nut on the Leveler. See Figure 3-2. b. Adjust the 1 1/2-inch Post Nut to raise or lower each Leveler as required.
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. After all perimeter packing material has been removed from the dispensing system, remove the keyboard and mouse from their boxes and place them in the keyboard tray. 2.
1 2 6 5 3 4 Item Description 1 Warning Label 2 Tie Wrap Securing the Dispensing Head 3 Keyboard and Mouse Boxes 4 Foam Block (between Conveyor Rails) 5 Tie Wraps (around Rails and Foam Block) 6 X-Axis Stopper Figure 3-3 Typical dispensing chamber Packaging 3-6 Uncrating and Placing
1 2 4 3 Item Description 1 Y-Axis Stopper 2 Y-Rail (right side) 3 X-Axis Stopper 4 X-Beam Figure 3-4 Dispensing Head Stopper Locations Uncrating and Placing 3-7
Unpacking the Accessories Crate CAUTION! This procedure should only be performed by a trained service technician. To unpack the accessories crate and take inventory: ? NOTE The accessories crate contains technical manuals necessary for the operation of your equipment, the Light Beacon, the Main Power Cable, and equipment storage cases. It also contains a tool kit and consumables kit tailored to the configuration of your dispensing system.
4 Component Installation Overview This section describes the installation and setup procedures for the following components: • Dispensing Valves (Valves, Pumps, and Jets) • Monitor • Light Beacon 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.
5. Locate the dark gray Power Cable coming from underneath the Monitor Swing Arm and securely connect it to the Monitor as shown in Figure 4-1. 6. Locate the power switch on the back of the Monitor and turn it ON (I). 7. Pivot the Monitor on the Monitor Swing Arm to verify that there is sufficient slack in the Cables. 8. Make sure the Monitor is in a position that will not interfere with the opening of the Hatch.
Installing the Light Beacon The Light Beacon is an integral part of the Safety Interlock System that warns and protects the equipment operator. CAUTION! This procedure should only be performed by a trained service technician.
1 5 4 2 3 Item 1 2 3 4 5 Description Alignment Pin (1 of 2) Hole for Alignment Pin (1 of 2) X-Y Servo Motor Cover Captive Thumbscrews Servo Shelf Cover Figure 4-2 Removing the Servo Shelf Cover 8. Position the rubber grommet on the Beacon Mast such that it seats properly with the cutout in the Right Side Cover. See Figure 4-3. 9. Carefully reinstall the Servo Shelf Cover.
1 6 2 5 4 3 Item 1 2 3 4 5 6 Description Mast Mount Bracket Power Cable 3-mm Mounting Screws Grommet Figure 4-3 Light Beacon Installation Component Installation 4-5
5 Power-up and Testing 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: • Connecting Power and Air Supplies • Pre-Power-up Checkout • Powering Up the Dispensing System • Component-Level Functional Tests • System-Level Functional Test Connecting Power and Air Supplies CAUTION! The following procedures should only be performed by a trained service technician.
To connect the system to facility power: 1. Locate the Main Power Cable. 2. Plug the female end of the Power Cable into the Main Power Inlet on the rear of the dispensing system. See Figure 5-1. 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.
To connect the system to the facility air supply: CAUTION! Make sure that facility air pressure is as specified in the Introduction section of this manual. Higher pressures will damage the dispensing system. 1. Locate the facility quick-disconnect air hose. 2. Make sure the dispensing system Main Air Regulator is closed. Verify facility air pressure is at 0 psi. 3. Connect the facility air supply hose to the Main Air Inlet connector on the back of the dispensing system. See Figure 5-2.
Pre-Power-up Checkout Before powering up the dispensing system, perform the following checks. Use the checklist in Appendix D to record completion of the procedures in this subsection. CAUTION! The following procedures should only be performed by a trained service technician. Tools and Materials Needed • 8 in-lb. Torque Wrench (P/N 48-8002) • Installation Checklist in Appendix D • Fully Installed Dispensing System The Torque Wrench is included in the dispensing system tool kit.
4. Place the torque wrench into the holes on top of the leftmost (Y-axis) Cable Tensioner and twist the wrench knob counterclockwise for two clicks. See Figure 5-4. CAUTION! Use only Asymtek torque wrench (P/N 48-8002) for adjusting mechanical cable tension. Use of any other tool can result in inaccurate dispensing performance or damage to the positioner cables. 5. Repeat the previous step for the Y-idle and then the X-axis Cable Tensioners. 6.
Preliminary Dispensing Head Clearance Check Perform the following procedure to make sure that there is sufficient clearance for the Dispensing Head to operate in the dispensing chamber. To check Dispensing Head clearance: 1. With the Hatch still open, manually move the Dispensing Head throughout the entire dispensing chamber making sure that it does not encounter any obstacles during its travel.
Powering Up the Dispensing System CAUTION! The following procedure should only be performed by a trained service technician. If any irregularity occurs during power-up, shut down the system and resolve the problem. If necessary, refer to the Troubleshooting section of this manual. To power up the dispensing system: ? NOTE If necessary, refer to the Introduction and Operation sections of the Axiom X-1000 Series Operations Manual for help identifying system components. 1.
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.
Pneumatic Regulators and Gauges Perform the following procedures to check the function of the Pneumatic Regulators and Gauges. To check function of Main Air Pressure Regulator and Gauge: 1. Locate the Main Air Pressure Regulator at the rear of the dispensing system. See Figure 5-5. 2. Unlock the Regulator Knob by pulling it upward and increase the air pressure to 80 psi (551 kPa) by turning the knob clockwise. 3. Monitor the Main Air Pressure Gauge to make sure that pressure builds at a steady rate.
4. After the Valve 1 Digital Gauge has been initialized, shut off air pressure by turning the Valve 1 Fluid Air Pressure Regulator Knob 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 Valve 1 Fluid Air Pressure Regulator Knob clockwise. 6. Monitor the Valve 1 Fluid Pressure Gauge display to make sure that the pressure builds at a steady rate. Listen for any air leaks as the pressure builds.
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. See Figure 5-5. 2. Open the Impingement Air Valve by turning the handle counterclockwise such that it is parallel with the airline. Listen for leaks.
2. Open the side door of the Computer and locate the green power LEDs in the upper left-hand corner of the Main Interface Board. See Figure 5-6. > All of the green power LEDs should be illuminated. 1 2 3 Item Description 1 Computer 2 Main Interface Board 3 Power LEDs Figure 5-6 Power LED Location on the Main Interface Board 3. If your system is equipped with a Scale, verify the green power LED on the Scale Interface Box behind the Computer is illuminated. 4.
5. Verify all green power LEDs on the XY Servo Interface Board are illuminated. See Figure 5-7. 6. Press the EMO button on the front of the dispensing system. 7. On the Main Interface Board, verify the +24V green power LED goes OFF and all other power LEDs stay ON. > Some of the power LEDs may take longer to deactivate than others. Give them a few seconds to completely go OFF. 8. On the XY Servo Interface Board, verify the +24V, +24V_A&B_ISO, and +SERVO power LEDs go OFF and all other LEDs stay ON. 9.
Light Beacon Perform the following procedures to check function of the Light Beacon. To test the Light Beacon: 1. Close the dispensing system Hatch, make sure both EMOs are deactivated, and press the green ON (l) button on the Operator’s Console. > The green Beacon light should be ON. 2. Open the Hatch. > The yellow Beacon light should come ON and the green Beacon light should go OFF. 3. Close the dispensing system Hatch. > The green Beacon light should come ON and the yellow Beacon light should go OFF.
Figure 5-8 Dispenser I/O Test Dialog Box Power-up and Testing 5-15
Dispensing Head and Accessories Perform the following procedures check function of the Dispensing Head, its accessories, and the Safety Interlock. To check Dispensing Head clearance: 1. Open the Hatch, place a production sample workpiece in the dispense station of the Conveyor, and then close the Hatch. 2. In the FmNT Main Window, click on Configuration and then select Setup Conveyors. 3. In the Setup Conveyors dialog box, click on the Test I/O button. See Figure 5-9. 4.
7. Lower the probe and functionally test the Height Sensor as follows (see Figure 5-10): a. In the FmNT Main Window, click on the Configuration button and select Setup Height Sensor. b. In the Height Sensor Configuration dialog box, click on CAN-HS. c. In the dialog box, verify Tactile (RT) has been selected in the Type box. d. Click on Arm/Disarm until the “Current Arm State” reads ARMED and then click on OK twice to return to the Main Window. > The Height sensor probe should be in the down position.
10. 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. 11. Close the Jog Commands dialog box and then raise the Height Sensor Probe as follows: a. In the FmNT Main Window, click on the Configuration button and select Setup Height Sensor. b.
> 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. To test Dispensing Valves: Your dispensing system may have up to two Dispensing Valves (Valves, Pumps, or Jets). Perform post-installation checkouts in accordance with the Installation and Operations Manual for the Dispensing Valves(s) on your dispensing system.
Needle Sensor If your dispensing system has a Needle Sensor, perform the following procedures to make sure that it is functioning properly. 1. Verify your dispensing system has been configured for the type of Needle Sensor installed as follows: a. In the FmNT main Window, click on Configuration. b. Select Machine Offsets from the Configuration menu. c. In the dropdown menu, select Machine Offsets Parameters. d. In the Machine Offsets Parameters dialog box, verify the sensor type installed on your system.
6. Gently insert tip of a dispensing needle or the tip of a pin into the Y-axis Needle Sensor slot. > The NEEDLE_SENSE bit should toggle to 0 when the needle/pin passes in front of the beam and back to 1 when the needle/pin is removed. 7. If your dispensing system is equipped with a Tactile Needle Sensor, locate the bit labeled TACTILE_SENSE on the PIO 96 Channels 10-13 tab. 8. Lightly press on the Tactile Needle Sensor.
Dispensing Valve Pneumatics Perform the following procedure to check function of the Dispensing Valve pneumatic system. ? NOTE This procedure assumes that you are already in the FmNT Dispenser I/O Test dialog box. If not, refer to the first two steps in the Needle Sensor test procedure. 1. If a Dispensing Valve is currently installed on your dispensing system, disconnect all air hoses connected to the Dispensing Valve. 2.
11. Disconnect the syringe receiver heads from the blue and black fittings on the Valve 1 pneumatic Bulkhead. 12. If previously disconnected, reconnect all air hoses to the Dispensing Valve. 13. Repeat Steps 1 through 10 for the Valve 2 (V2_FLUID, V2_VALVE) pneumatic lines and the Dual Action pneumatic lines (DUAL_ACTION_AIR), if applicable to your configuration. > The Valve 2 pneumatic Bulkhead is located on the right-hand side of the Dispensing Head. 14.
7. In the Jog Commands dialog box, click on both the slow and the fast buttons to move the Conveyor Belt in both directions. See Figure 5-14. X-axis jog > The Conveyor Belt should move smoothly in both directions with no slipping on its pulleys. 8. 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. See Figure 5-14. > The Conveyor Rail should move smoothly in both directions. 9.
To check fixed-width Conveyor clearance, Safety Interlock, and X-axis movement: CAUTION! ? NOTE 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. This procedure assumes that you are already in the FmNT Tools Window. If not, refer to the first two steps in the Needle Sensor test procedure. 1.
4. Click on the ARM/DISARM button until the “Current Arm State” reads ARMED. > The Height Sensor Probe should be in the down position. 5. Click on OK twice to return to the Main Window. 6. In the Main Window, click on the Jog icon . 7. In the Jog Commands dialog box, click on Dispenser. 8. Using the target box or position controls, move the Height Sensor Probe over the left front Conveyor Rail. See Figure 5-15 for the approximate location.
1a 1b 2 1c 3 1f 4 1d 5 1e Item Description 1 Measurement Locations (order shown: a, b, c, etc.
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. b. Use the Y-axis fast jog buttons the sample workpiece. to adjust the rail width to the approximate width of c.
10. In the SMEMA Diagnostic dialog box, locate the upstream and downstream bits. Perform the actions specified in Table 5-2 and verify the results. If the results were not as specified, check all TS-01 connections and retest. Table 5-2 SMEMA Communication Test Matrix Action Result In dialog box, press Request Board from Upstream Tool output button. No. 2 LED on TS-01 comes ON. Press TS-01 button No. 3. Dialog box “Board Available from Upstream Tool” input changes to ON.
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 • FmNT is in the MPC555 I/O Diagnostic dialog box Perform this procedure as applicable to the configuration of your dispensing system. 1. Open the dispensing system Hatch. 2.
To check Lift Table /Clamp Bar operation: ? NOTES The pneumatic lines used in configurations with Lift Tables activate the Clamp Bars in other configurations. This procedure assumes that the dispensing system Hatch is open and FmNT is on the Station I/O Diagnostic tab of the MPC555 I/O Diagnostic dialog box. 1. Check under and around all Lift Tables, Clamp Bars, and Heater Tooling to make sure that no electrical or pneumatic lines are in danger of being pinched or snagged. 2.
To check vacuum for Contact Heaters (X-1020 only): WARNING! ? NOTES The Heaters may be hot. Use caution when working in the area of the Heaters or serious burns may result. 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 Hatch is open • Monitor displays Station I/O Diagnostic tab of MPC555 I/O Diagnostic dialog box 1.
6. In the Programming Window, click on the Unload a Board icon . 7. Make sure that the Stop Pins, Clamp Bars, and Lift Tables all function correctly during the unloading process. ? NOTE If the Stop Pins, Clamp Bars, or Lift Tables do not function correctly, refer to “Troubleshooting Conveyor” in the Troubleshooting section of this manual. 8. Click on the Return to Main Window icon .
8. 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 are, the dispensing system will rock back and forth. Adjust the Levelers so that they are all bearing the weight equally. 9. Re-level the dispensing system from side-to-side and from front-to-back, if necessary.
1 4 2 3 Item Description 1 Post Nut 2 Leveler (foot) 3 1 1/2-Inch Wrench 4 Lock Nut Figure 5-18 Leveler Adjustment 10. Once the dispensing system is level from front-to-back, side-to-side, and is stable with all four feet bearing the weight equally, tighten the 1 1/2-inch Lock Nuts. CAUTION! In the final leveled and aligned position, there should be no more than three inches of Leveler Post showing between the bottom of the dispensing system and the foot. 11.
Lift Table and Heater Tooling Leveling If your dispensing system is equipped with Lift Tables, perform the following procedure to make sure that they are level. ? NOTE This procedure assumes that each Lift Table is equipped with Heater Tooling and that the Height Sensor has been functionally tested. 1. In the FmNT Main Window, click on the Configuration button and select Setup Height Sensor. 2. In the Height Sensor Configuration dialog box, click on CAN-HS. See Figure 5-10. 3.
1 1 2 3 Item Description 1 Measurement Locations (approximate) 2 Heater Tooling (Contact Heater shown) 3 Front Conveyor Rail Figure 5-19 Lift Table and Heater Tooling Level Check 16. Raise the Dispensing Head with the Z-axis slow jog button goes OFF. 17. Lower the Dispensing Head with the Z-axis slow jog button illuminates (one click past the LED being OFF). until the green LED just until the green LED 18.
21. Calculate the variance in Heater Tooling height from end to end and front to back. > The height variance of the Heater from left to right should be within ±0.005 inch (±0.127 mm). > The height variance between front and back of the Heater should be within ±0.005 inch (±0.127 mm). > If the tooling is determined to be out of level, call Asymtek Technical Support. CAUTION! Only trained service technicians should attempt to adjust the level of the Lift Tables or Heater Tooling. 22.
> If the Heater Tooling does not meet the resistance requirements, it should be repaired or replaced before proceeding. 9. Reconnect the electrical cables, and close the Hatch. 10. Restore power to the dispensing system by turning the red EMO knob counterclockwise until it pops out and then pressing the green ON (l) button on the Operator’s Console.
To temperature test Heater Tooling and Needle Heaters: WARNING! ? NOTE The Heaters will be hot and can cause serious injury. Use extreme caution when measuring Heater temperature and checking connections. This procedure assumes that FmNT 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.
To test EMO effect on Heater Tooling and Needle Heaters: ? NOTE This procedure assumes that FmNT 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 Operator’s Console. 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.
1 5 4 3 2 Item Description 1 Video Display 2 Reticle Set-up Box 3 Target Box 4 Position controls 5 Lighting Controls Figure 5-21 Vision and Reticle Set-up Dialog Boxes 7. In the reticle set-up 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.
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 in accordance with the procedure in the Calibration and Adjustment section of this manual. 11. If your system has DOAL, 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.
Scale If your dispensing system is equipped with a Scale, perform the following procedure to make sure that it is ready for operation. 1. Open the Front Cabinet Door and verify the green power LED on the Scale Interface Box behind the Computer is illuminated. > If the LED is not illuminated, refer to “Troubleshooting Components” in the Troubleshooting section of this manual. 2. Close the Front Cabinet Door and open the dispensing system Hatch. 3. Remove the Weigh Station Cover, banjo wiper, and cup. 4.
Figure 5-23 Scale Setup Dialog Box Dispensing Calibration Module Perform the following steps to verify the Dispensing Calibration Module (DCM) is at the proper height and is level. ? NOTE This procedure assumes that the Vision System has been checked and calibrated and that the Scale is level. 1. Open the dispensing system Hatch, place a production sample workpiece in the dispense station of the Conveyor, and close the Hatch. 2.
6. View the image in the video display. > If the image is still focused, the height of the DCM does not need to be adjusted. > If the image is not focused, the height of the DCM must be adjusted to be in the same plane as the workpiece. Refer to “Dispensing Calibration Module Leveling and Height Adjustment” in the Calibration and Adjustment section of this manual. 7. Look at the Circular Level that is in the well on the top of the DCM. See Figure 5-13. > If the bubble is centered, the DCM is level.
System-Level Functional Test CAUTION! ? NOTE Provide a means to catch workpieces/carriers exiting the dispensing system or they will fall on the floor and be damaged. This procedure assumes that a production program has been created in accordance with the FmNT User Guide. 1. If applicable to your system, turn on the Heat Tooling as follows (see Figure 5-20): a. In the FmNT Main Window, click on Tools. b. In the Tools Window, click on Terminal. c. Click on Heaters. d.
3. Once you have completed the Valve Offsets or Scripted Valve Offsets routine, perform a simulated (dry) production run using the TS-01 Test Box as follows: ? NOTE If your system has Heat Tooling, make sure the Heaters have reached the set point (SP) before proceeding with this procedure. a. Perform a Service Shutdown as specified in the Safety section of this manual. b. Attach the TS-01 upstream and downstream cable adapters to the TS-01 I/O Test Box. See Figure 5-16. c.
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. See Figure 5-26. > The Run Window will open. 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.
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. 4. Verify the following: a. All Stop Pins, Lift Tables, and Clamp Bars should 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.
6 Calibration and Adjustment Overview Your Axiom X-1000 Series Dispensing System is calibrated and adjusted at the factory prior to shipping. However, if any components have been changed or moved, it may be necessary to recalibrate or readjust some components.
Camera Focus Adjustment and Calibration CAUTION! The following procedures should only be performed by a trained service technician. Tools and Materials Needed • 4-mm Hex Key • 5-mm Hex Key • Sample workpiece used during a production run To focus the Camera: ? NOTE The Camera can be focused using both a coarse adjustment and a fine adjustment depending on the extent of focusing necessary. Usually, only the fine adjustment is required. 1. To make a coarse focus adjustment, perform the following: a.
1 5 2 4 3 Item 1 2 3 4 5 Description Fine Focus Adjustment Screw Camera Lens Coarse Focus Adjustment Screws Vertical Camera Bracket Figure 6-1 Camera Focus Adjustment Calibration and Adjustment 6-3
To calibrate the Camera: ? NOTE The Camera should be leveled before calibration if it has been removed from the Dispensing Head and then reinstalled. 1. In FmNT Main Window, click on Configuration. 2. Select Setup Vision from the Configuration menu. > The Dialog Window for the Vision System opens. See Figure 6-2. 3. In the Dialog Window, click on the Calibrate button. > A video window is displayed that includes the video screen, light controls, and position controls.
Figure 6-2 Vision Setup Dialog Boxes Calibration and Adjustment 6-5
Scale Leveling and Calibration In order for the mass flow calibration to be accurate, the Scale must be level and calibrated. The Scale is located under the Dispensing Calibration Module (DCM). The Scale is leveled and calibrated at the Asymtek factory prior to shipping, but it may be necessary to re-level and calibrate it if the dispensing system has been moved, if you are experiencing mass flow calibration errors, or if any components have been changed or moved.
6. Locate and remove the three 1.5-mm mounting screws attaching the Circular Level inside the well on the top of the DCM. See Figure 6-6. 7. Place the Circular Level on top of the Pedestal and check the position of the bubble. > If the bubble is not centered, the Scale must be leveled. > If the bubble is centered, the Scale is level. Reinstall the Circular Level in the well on top of the DCM. Next, determine if the DCM needs leveling and height adjustment.
To level the Scale: 1. Remove the Dispensing Area Front Cover and place it in a safe place. See Figure 6-4. CAUTION! Lay the plate down on a flat surface. Do not stand it on edge or lean it against something as this may bend the plate. 2. Gently apply pressure to opposite corners of the Scale Base to determine its allaround stability. > The Scale Base should not be rigid. It should compress and move up and down, but it should not seem to be loose. 3.
To calibrate the Scale: NOTES Both the dispensing system and the Scale need to be leveled prior to performing the following procedure. Refer to “Leveling the Dispensing System” in the Power-up and Testing section in this manual for system leveling instructions. Scale leveling instructions immediately precede this procedure. Power must be applied to the Scale for a minimum of 45 minutes before performing this procedure. 1.
100 Figure 6-5 Scale Setup Dialog Box 6-10 Calibration and Adjustment
Dispensing Calibration Module Leveling and Height Adjustment Some X-1000 Series Dispensing Systems include a modular Dispensing Calibration Module (DCM) located in the front of the dispensing area. The DCM is leveled at the Asymtek factory prior to shipping. However, it may be necessary to re-level it if the dispensing system has been moved or if any components have been changed or moved. Table 6-1 describes the component parts of the DCM and their functions.
CAUTION! While moving the Camera, always make sure that dispensing head is high enough to clear all obstacles in the dispense area or damage may occur. 7. Move the Camera over a corner of the white ceramic tile near the Needle Sensor. The video image should be clear and focused. > If the image is focused, go to Step 9. > If the image is not focused, go to Step 8. 8. If the image is not focused, perform the following: a. Remove the Dispensing Area Front Cover. b.
1 5 1 4 2 3 Item 1 2 3 4 5 Description Recessed Fine Adjustment Screws (3 total) DCM Clamp Screws (Yaw) Ceramic Tile Circular Level DCM Clamp Screw (Pitch) Figure 6-6 Dispensing Calibration Module Calibration and Adjustment 6-13
Board Sensor Sensitivity Adjustment Upward-facing Board Sensors (X-1010 only) or downward-facing Board Sensors (X-1020 only) 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 are failing to sense the presence of a workpiece.
4. Close the Hatch and using FmNT Jog Controls, move the Dispensing Head to the back of the dispensing chamber. 5. If necessary, use FmNT Jog Controls to adjust Conveyor Rail width to fit the sample production board. 6. Open the Hatch and manually place a production sample board on the Conveyor Belts over the Board Sensor being adjusted. 7.
8. Manually move the board back and forth on the Conveyor Belt over the Board Sensor to verify the sensitivity adjustment. > The red LED should come ON (or the “Board Present” bit should say ON), when the sample board is moved over the Board Sensor. > The red LED should go OFF (or the “Board Present” bit should say OFF), when the sample board is not over the Board Sensor. 9. Repeat Steps 2 through 8 for each Board Sensor present on the Conveyor. 10. Remove the sample board and close the Hatch. 11.
Downward-facing Board Sensors (X-1020 only) Sensitivity adjustments for downward-facing Board Sensors are made on Fiber Optic Amplifiers mounted under the Dispensing Area Front Cover. Depending upon system configuration, there may be as many as three Board Sensors (pre-dispense, dispense, and post-dispense station). CAUTION! The following procedure should only be performed by a trained service technician.
11. Dial the thumbwheel one click towards the minus position. > GOOD should display for two seconds, indicating the ON-OFF threshold is identifiable. If HARD is displayed, then the sensor may not be able to tell the difference between ON and OFF. The Board Sensor lens will require realignment before proceeding.
12. Slide the mode selection switch to Run. > The Amplifier will display the incident light level. 13. Slide the switch to Mode. 14. Dial the thumbwheel until the flashing cursor is next to Output 2 and then push down on the thumbwheel. 15. Dial the thumbwheel until L (light on) is displayed and then push down on the thumbwheel to select. 16. Dial the thumbwheel until non is displayed and then push down on the thumbwheel to select. 17.
Lift Table/Clamp Bar Airflow Adjustment Flow Control Valves (FCVs) regulate the amount of air pressure supplied to the Lift Tables or Clamp Bars to control the speed of its up and down movement. For optimum operation, the Lift Tables or Clamp Bars should raise and lower at the same time and at the same rate. The location of the FCVs depends upon the device. The FCVs for Lift Tables are located on the pneumatic hoses inside of the dispensing area, behind the Lift Tables. See Figure 6-10.
To adjust the Lift Table/Clamp Bar airflow: 1. Open the dispensing system Hatch. WARNING! Do not reach into the dispensing chamber until yellow beacon light is displayed and all system motion has stopped. If the Heaters are hot, use extreme caution when performing this operation. 2. Locate the Flow Control Valves (FCVs) for the appropriate Lift Table or Clamp Bar. See Figure 6-9 and Figure 6-10.
3 1 4 5 2 Item 1 2 3 4 5 Description Pneumatic Supply Lines Flow Control Valves Heat Tooling Air and Electric Supply Bulkhead Rear Conveyor Rail Lift Table Figure 6-10 Lift Table Pneumatic Controls 6-22 Calibration and Adjustment
Impingement Heater Airflow Adjustment Adjustments to airflow Impingement Heaters at up to three processing stations (pre-dispense, dispense, and post-dispense) is made on flowmeters located in the lower front cabinet. The Impingement Air Shutoff Valve must be open to allow air to flow to the Impingement Air Flowmeters. When the Shutoff Valve is open, airflow to an Impingement Heater is adjusted by turning the knob on its flowmeter. Flow is read on the gauge directly above the flowmeter knob.
Linear Encoder Gap Adjustment It may be necessary to readjust the X and Y-axis Linear Encoder Scale-to-Scanner gap if the dispensing system is moved or if you experience accuracy problems during dispensing. CAUTION! The following procedure should only be performed by a trained service technician. Tools and Materials Needed • Removable Thread Locker (P/N 40-0019) • 0.9-mm Encoder Gapping Tool (P/N 194983) • 3-mm Hex Key To check the X and Y-axis Linear Encoder gap: 1.
2 1 3 Item 1 2 3 4 5 4 5 Description X-Axis Scale X-Axis Scanner Y-Axis Scale Y-Axis Scanner Gapping Tool Figure 6-12 X-Axis and Y-Axis Linear Encoder Locations Calibration and Adjustment 6-25
To adjust the Encoder Scanner to Encoder Scale gap: 1. If it is not already open, open the dispensing system Hatch. WARNING! Make sure the yellow beacon light is displayed and all system motion has stopped before reaching into the dispensing area. If the Heaters are still hot, use extreme caution when performing this operation. 2. Loosen the two 3-mm hex screws on the top of the Scanner. 3. Insert the 0.9-mm gapping tool into the space between the Scanner and the Scale. 4.
Heater Calibration To provide precise heating of the workpiece to the required temperature for the application of dispensing fluid, the Heater Tooling and Needle Heaters must be calibrated. The temperature differential (offset) between the programmed temperature value and the actual temperature being applied to the workpiece or fluid must be determined and entered into the software.
7. 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. 8. Wait for the temperature in the present value (PV) column to reach steady-state temperature at the set point (SP). 9. Measure and record the actual temperature of each Heater using a calibrated temperature probe as follows: a.
1 3 1 1 2 Item 1 2 3 Description Temperature Measurement Location Front Conveyor Rail Contact Heater Tooling Plate Figure 6-13 Heater Tooling Temperature Measurement Locations Calibration and Adjustment 6-29
Fluid Air Pressure Gauge Configuration The digital Fluid Air Pressure Gauge on your dispensing system precisely measures the pressure going to the syringe attached to the Dispensing Valve. The following procedure describes how to configure this gauge to ensure accurate fluid dispensing performance. ? NOTE Depending on your system configuration, you can have up to two Fluid Air Pressure Gauges. To initialize a Digital Pressure Gauge: 1.
9. Set the Valve 1 fluid pressure to the desired level for your application by turning the knob on the Valve 1 Fluid Pressure Regulator 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. 10. If applicable to your system configuration, repeat Steps 1 through 9 for the Valve 2 Fluid Air Pressure Gauge. MPa SMC 1 35.
Dispensing Head Counterbalance Adjustment Whenever you change the type or number of Dispensing Valves, or otherwise substantially change the weight on the Z-carriage of the Dispensing Head, you must adjust the Counterbalance Torsion Spring to ensure reliable dispensing operations. Tools and Materials Needed • 6-mm Hex Key • 5/8-in (16-mm) Open-end Wrench To adjust the counterbalance: CAUTION! The following procedure should only be performed by a trained service technician. 1.
4 1 2 3 Item 1 2 3 4 Description Z-carriage Dispensing Valve (DV-7000 shown) Counterbalance Tension Knob Locking Screw (recessed) Figure 6-15 Counterbalance Adjustment Calibration and Adjustment 6-33
7 Theory of Operations Overview All Axiom X-1000 Series Dispensing Systems work in accordance with the same basic theory of operation, demonstrating highly developed process control. In this section, typical Axiom X-1000 configurations are considered, but operational details may vary with the configuration of your system.
Part Loaded Part Arrives at Pre-Dispense Station • • • Stop Pin engages to stop part. Lift Table rises. Heater heats/maintains part temperature. Part Stops at Pre–dispense Station for Heating? Yes No Part Leaves Pre-Dispense Station • • Part Conveyed to Dispense Station Lift Table lowers. Stop Pin disengages. Part Arrives at Dispense Station • • • Stop Pin engages to stop part. Lift Table rises. Heater maintains part temperature. Dispensing Preparations Performed • • • • • Flow rate calibration.
Table 7-1 Dispensing System Operational Sequence Operational Step Details 1. A workpiece enters the Axiom X-1020 Dispensing System. a. The dispensing system communicates with the upstream machine via the SMEMA connection signaling that it is ready to accept a workpiece. b. The upstream machine receives the signal as an input. c. If the upstream machine is ready to send a workpiece, it responds with an output signal back to the dispensing system. d.
Table 7-1 Dispensing System Operational Sequence (continued) 5. Programmed dispensing preparations are performed. (Preparations performed may be different depending on your application.) a. The Dispensing Head moves to the Purge Station and a Dispensing Valve purge is performed. b. If required, fluid may be heated by a Needle Heater (DJ 2100, DP-3000, and DV-7000 Dispensing Valves). c. The Vision System locates master fiducials on the workpiece.
Description of System Components Conveyor Controller The heart of the Conveyor Controller is a microcontroller. The Controller receives commands from software through the Controller Area Network (CAN) bus for direct Conveyor I/O control and changes of system configuration. The CAN also provides the status of the Conveyor Controller operations to the FmNT software.
X and Y Servo Amplifiers The X and Y Servo Amplifiers are mounted on individual Interface PWAs located in the front of the Servo Shelf. Each Amplifier receives low-voltage direction and power commands from the PMAC, and receives motor direction signals from the Hall Sensors on the X and Y Servo Motors. The Amplifier reacts to the PMAC power commands and provides the high power level required to move the Servo Motor.
Positional Sensors XY Linear Encoders The X Linear Encoder is located on top of the X-beam and the Y Linear Encoder is located under the left Y-rail. These encoders supply Dispensing Head XY positional information on a constant basis to the PMAC. Rotary Encoder Each Servo Motor has its own Rotary Encoder. These encoders supply X, Y, and Z Servo Motor velocity and acceleration information to the PMAC. Hall Sensor Each Servo Motor has its own Hall Sensor.
Z Servo Amplifier The Z Servo Amplifier is mounted on an Interface PWA in the Dispensing Head. The Amplifier receives low-voltage direction and power commands from the PMAC, and receives motor direction signals from the Hall Sensor on the Z Servo Motor. The Amplifier reacts to the PMAC power commands and provides the high power level required to move the Servo Motor.
PIO96-J Card The PIO96-J Card provides Input/Output for signals controlled directly through FmNT. PMAC Card The Programmable Multi-Axis Controller (PMAC) issues commands that can simultaneously move the Dispensing Head in X-, Y-, and Z-axes. It uses a Digital Signal Processor (DSP) with an on-board Central Processing Unit (CPU) to handle the motion calculations. To maintain dynamic and static positional accuracy, the PMAC receives constant feedback from the Linear and Rotary Encoders.
Power Distribution The distribution of power to dispensing system components is as specified in Table 7-2. TIP Refer to the electrical diagrams in Appendixes A and B for further information.
Pneumatics Distribution Pneumatic distribution can vary depending upon system configuration. Figure 7-2 diagrams the pneumatic distribution on a typical Axiom X-1000 Series Dispensing System. ? NOTE Refer to Figure 5-5 in the Power-up and Testing section and the pneumatics block diagram in the Appendix A, if necessary.
Fluid Air Pressure Regulators/Gauges The two precision Fluid Air Pressure Regulators control the pressure to the fluid syringes. The pneumatic pressure lines are routed from the Valve 1 or Valve 2 Fluid Pressure Regulators, under the Conveyor, and to a cable conduit in the back of the dispensing system. The lines then go to the Servo Shelf and through the Cat Track to the Control Valves on the back of Dispensing Head.
Main Air Solenoid Located behind the Low Pressure Sensor on the Servo Shelf, the Main Air Solenoid turns ON the air pressure to the dispensing system when FmNT initializes and the green ON (l) button on the Operator’s Console is pressed. Stop Pin Solenoid Valve ? NOTE Your dispensing system may have up to three of these valves depending on system configuration. The electrically controlled Stop Pin Solenoid Valves are located in the valve manifold at the rear of the dispensing chamber.
Description of Electrical and Pneumatic Paths This subsection traces the electrical and pneumatic paths of commands for common actions of the dispensing system. The explanation for each commanded action is illustrated first in a flow diagram showing the major components involved, and then in a table identifying each component and its function in executing the command.
Dispensing Head Moves in X or Y-Axis Computer FmNT PMAC Card Main Interface PWA Servo Interconnect Cables Servo Shelf XY Servo Interface PWA X & Y Servo Amplifiers X&Y Hall Sensors X & Y Linear Encoders X & Y Servo Motors X & Y Rotary Encoders Dispensing Head Moves Figure 7-3 Flow Diagram - Dispensing Head X-axis or Y-axis Movement Theory of Operation 7-15
Table 7-3 Dispensing Head X-axis or Y-axis Movement Component Function FmNT Software Commands Dispensing Head X-axis, Y-axis movement. PMAC Card 1. Receives FmNT command to move Dispensing Head to a specific XY position. 2. Sends low-voltage direction and power level output signals to the X and Y Servo Amplifiers. 3. Receives feedback from: • X and Y Linear Encoders (position) • X and Y Rotary Encoders (velocity) 4. Calculates how much power should be delivered to Servo Motors.
Dispensing Head Moves in Z -Axis Computer FmNT PMAC Card Main Interface PWA Servo Shelf XY Servo Interface PWA Z Servo Interface PWA Z Servo Amplifier Z Hall Sensor Z Servo Motor Z Rotary Encoder Z Carriage Moves Dispensing Head Figure 7-4 Flow Diagram - Dispensing Head Z-Axis Movement Theory of Operation 7-17
Table 7-4 Dispensing Head Z-axis Movement Component Function FmNT Software Commands Dispensing Head Z-axis movement. PMAC Card 1. Receives FmNT command to move Dispensing Head to a specific Z-axis position. 2. Sends low-voltage direction and power level output signals to the Z Servo Amplifier. 3. Receives feedback from Z Motor Rotary Encoder (velocity). 4. Calculates how much power should be delivered to Z Servo Motor.
Dispensing Head Finds Home Computer FmNT PMAC Card Main Interface PWA Dispensing Head X Home Sensor Z Home Sensor Servo Interconnect Cables Z Servo Interface PWA XY Servo Interface PWA Z Servo Amplifier X & Y Servo Amplifiers Y Home Sensor Hall Sensor X&Y Hall Sensors Z Servo Motor X & Y Servo Motors Z Rotary Encoder X & Y Rotary Encoders Dispensing Head Homes X & Y Linear Encoders Figure 7-5 Flow Diagram - Dispensing Head Finds Home Theory of Operation 7-19
Table 7-5 Dispensing Head Finds Home Component Function FmNT Software Commands Dispensing Head to home. PMAC Card 1. Receives FmNT command to move Dispensing Head to a specific position. 2. Sends low-voltage direction and power level output signals to the X, Y, Z Servo Amplifiers. 3. Receives feedback from: • X and Y Linear Encoders (position) • X, Y, and Z Rotary Encoders (velocity) • Calculates how much power should be delivered to Servo Motors.
Table 7-5 Dispensing Head Finds Home (continued) OCCURS SIMULTANEOUSLY Component Z Servo Motor Function 1. Receives power from the Z Servo Amplifier. 2. Turns the drive gear (pinion) that moves the Dispensing Head in the Z-axis. Component X and Y Rotary Encoders Function Supply velocity and acceleration information to the PMAC. Z Rotary Encoder Supplies velocity and acceleration information to the PMAC.
Performing a Height Sense FmNT Height Sensor Probe Is Armed PIO96 Card PMAC Card Main Interface PWA Main Interface PWA XY Servo Interface PWA XY Servo Interface PWA Dispense Head Controller PWA Z Servo Interface PWA Z-axis Servo Motor Lowers Dispensing Head Z Servo Amplifier Height Sensor Probe Contacts Workpiece Position Capture Signal Sent to PMAC Z Servo Motor Dispense Head Controller PWA Main Interface PWA XY Servo Interface PWA XY Servo Interface PWA Main Interface PWA Z Servo Interfac
Table 7-6 Performing a Height Sense Component Function FmNT Software Commands a height sense. OCCURS SIMULTANEOUSLY Component Function Component Function PIO-96-J Card Sends signal for Height Sensor Probe to arm (lower). PMAC Card Commands Z Servo Motor to lower the Z Carriage. Main Interface PWA Relays Probe arming signal to XY Servo Interface PWA. Main Interface PWA Relays PMAC signals to the XY Servo Interface PWA.
Table 7-6 Performing a Height Sense (continued) Component PMAC Card Function 1. Receives height sense touch input. 2. Relays touch input information to FmNT. 3. Issues Z Motor stop command. Main Interface PWA Relays Z Servo Motor stop command to XY Servo Interface PWA. XY Servo Interface PWA Relays Z Servo Motor stop command Z Servo Interface PWA. Z Servo Interface PWA Relays Z Servo Motor stop command to Z Servo Amplifier. Z Servo Amplifier 1.
Conveyor Belt Moves FmNT Command Controller Area Network (CAN) Conveyor/Heater Controller Conveyor Interface PWA Board Sensors Conveyor Interconnect PWA Pneumatic Solenoids Motor Cables Conveyor Stepper Motors Figure 7-7 Flow Diagram - Conveyor Belt Movement Theory of Operation 7-25
Table 7-7 Conveyor Belt Movement Component Function Controller Area Network Communications network between Computer (FmNT) and Conveyor Controller Module. Conveyor Controller Receives execution commands and system setup parameters from FmNT. Sends Conveyor states and status to FmNT.
Stop Pins and Lift Tables/Clamp Bars Operate Sensor detects a board Conveyor Interconnect PWA Conveyor Controller Module (timing, commands to solenoids) Conveyor Interconnect PWA Pneumatic Solenoids activate/deactivate to operate Stop Pin or Clamp Bar/Lift Table Figure 7-8 Flow Diagram - Stop Pin and Lift Table/Clamp Bar Operation Table 7-8 Stop Pin and Lift Table/Clamp Bar Operation Component Function Board Sensor Detects presence of workpieces in pre dispense, dispense, and post dispense station
8 Troubleshooting Overview This section will help determine the origin of problems you may experience with your Axiom X-1000 Series Dispensing System and recommended corrective actions. ? NOTE This section assumes the operator has already performed basic troubleshooting specified in the “Troubleshooting” section of Axiom X-1000 Series Operations Manual.
Section Organization The Troubleshooting section is divided into five major subsections with individual divider tabs. The major subsections are based on the troubleshooting topics shown in Table 8-1. Table 8-1 Major Troubleshooting Subsections Topics Subsection Troubleshooting X and Y-axis Motion 8.1 Troubleshooting the Servo Controller (PMAC) 8.2 Troubleshooting Z-axis Motion 8.3 Troubleshooting Conveyor 8.4 Troubleshooting Components 8.
Tools and Materials Needed The following tools and materials are necessary to perform the troubleshooting procedures listed in this section: • Axiom X-1000 Series Operations Manual • Alignment Tools, Linear Encoder, P/N 194983 • Axiom X-1000 Series Electrical Schematics and Pneumatic Diagrams (see Appendixes) • Cable Tensioning Tool, P/N 48-8002 • Electrostatic Damage (ESD) Precautionary Material • FmNT User Guide • Multimeter (or other devices to measure Ohm, VAC, VDC) • Personal Protective
Troubleshooting Process The fault isolation process is presented in a descending order of functional verifications. Yes-or-no gate symbols are used to emphasize the elimination and isolation decision process. Typical examples are shown below. Example 1 4. Is the Cable malfunctioning? No Go to Step 5 Yes Cable has failed. See Parts Replacement section. No means the process has eliminated the Cable from being faulty and the fault isolation process is continued in Step 5.
On-Board System Status Indicators The dispensing system employs on-board Light Emitting Diodes (LEDs), a Light Beacon, and FmNT/firmware error messages to indicate system status. LEDs An illuminated or non-illuminated status LED has a specific significance. The function of the LEDs is to indicate the operational readiness of the system or its components. Observing the LEDs is key to the troubleshooting effort. Note that a few LEDs can change so frequently that they may not appear to change state.
Dispensing System Corrections Correcting failed system components, or functions to restore operation includes the following: • If the fault isolation points to a damaged part or component, the remedy consists of replacing the failed item. Parts replacement, exchanges, and warranty information can be found in the Parts Replacement section of this manual. • If the fault isolation points to a failed function of a component that is not damaged, the remedy consists of adjustment or calibration.
8.1 Troubleshooting X and Y-axis Motion If the Dispensing Head is not moving correctly in the X-axis and Y-axis, refer to Table 8-2 for a summary of the symptoms, probable causes, and fault isolation procedures. ? NOTE Problems resulting from environmental and application abnormalities, spills, obstructions, and workpiece irregularities that are not system related should be eliminated prior to advanced troubleshooting.
8.1.1 X and Y Motion Fault Isolation Procedure The X and Y Motion Fault Isolation Procedure consists of the following: • Main Power Verification • System/Servo Power Verification • Interlock Verification • Servo Controller (PMAC) Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
4. Verify the Computer’s power switch is in the ON (I) position. 5. Does the green Computer power LED illuminate? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Go to Step 6 6. Locate the power LEDs on the XY Servo Interface PWA. 7. Are the green 5V, A+15V, and A+5V LEDs illuminated? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Go to System/Servo Power Verification in this subsection. System/Servo Power Verification 1. Press the green ON (I) button on the Operator’s Console. 2.
7. Is the red Servo Motor AOK LED illuminated? No Go to Interlock Verification in this subsection. Yes Go to 8.1.5, XY Servo Amplifiers Fault Isolation Procedure Interlock Verification 1. If open, close the Front Hatch. 2. Does the green light on the Beacon illuminate when the Front Hatch is closed? No Go to Step 15 of “Main Power Verification” in 8.1.4, Interlock Fault Isolation Procedure Yes Go to Step 3 3. Locate the power LEDs on the XY Servo Interface PWA. 4.
4. Does the FmNT message “30753 The motor failed to close” appear when initializing FmNT? No Go to Step 5 Yes Go to 8.1.5, XY Servo Amplifiers Fault Isolation Procedure 5. Does the FmNT message “30796 The dispenser PMAC device initialization has failed” appear when initializing FmNT before any other message? No Go to Step 6 Yes Go to “PMAC Watchdog Error Verification” in 8.2.1, PMAC Initialization Fault Isolation Procedure 6. The FmNT message “30416 Dispenser motor reference not found.
13. Did the FmNT message “30735 The motors have gone open loop. Press OK to continue and reinitialize the motion controller” appear? No Yes Stop here. No XY motion fault. Verify fault. If fault reoccurs, contact Asymtek Technical Support. Go to Step 9 in “PMAC Fatal Following Error Verification” in 8.2.
8.1.2 Main Power Fault Isolation Procedure The Main Power Fault Isolation Procedure consists of the following: • Main Power Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual. WARNING! A dispensing system in need of troubleshooting may have High Voltage present in both designated and unsuspected places that can result in injury or death.
4. Is there 208 to 240 VAC at the facility power outlet? No Resolve facility power and then go back to Step 2. Yes Go to Step 5 5. Connect the System Power Cable to the facility power outlet. 6. Is there 208 to 240 VAC at the Cable Connector? No System Power Cable (P/N 06-4500-00 US, or P/N 06-4501-00) has failed. See Parts Replacement section. Yes Power Manager (P/N 62-1620-01) has failed. See Parts Replacement section. 7. Confirm the Computer Power Switch is in the ON (I) position. 8.
12. Locate the Computer Passive Backplane located on the right inside wall of the Computer. Locate four red LEDs labeled -5V, +5V, -12V, and +12V. 13. Are the LEDs illuminated? No Go to Step 14 Yes Go to Step 18 14. Switch the Main Circuit Breaker to the OFF (0) position. 15. Disconnect the Computer Power Cable (P/N 193949) from Power Manager AC outlet AC1. 16. Verify that 208 to 240 VAC is at the AC1 outlet. 17. Switch the Main Circuit Breaker to the ON (I) position. 18.
24. Are the green +5V, +12V, -12V, and A+5V LEDs illuminated? No Go to Step 53 Yes Go to Step 25 25. Switch the Main Circuit Breaker to the OFF (0) position. 26. Visually inspect the Cables listed in Table 8-3 for damage and correct connections. Table 8-3 Servo Cable Connections Cable Part Number XY Servo Interface Location Main Interface Location 06-4530-00 J18 J26 06-4525-00 J19 J29 27.
33. Disconnect the Servo Interconnect A Cable (P/N 06-4525-00) from the Main Interface PWA. 34. Switch the Main Circuit Breaker to the ON (I) position. 35. Measure VDC at J29 (SERVO SIGNAL INTERCONNECT A) at Pin 36 and ground, then at Pin 33 and ground (connect ground to Pin 37). 36. Is the reading ≥4 VDC at Pin 36 and ≥14 VDC at Pin 33? No Main Interface PWA (P/N 60-1200-00) has failed. See Parts Replacement section. Yes Go to Step 37 37. Switch the Main Circuit Breaker to the OFF (0) position. 38.
50. Locate J18 on the XY Servo Interface PWA. 51. With the XY Servo DC Power Cable connected to the Main Interface PWA, measure VDC at Pin 1 (connect ground to Pin 4). 52. Is the reading ≥4 VDC? No XY Servo DC Power Cable (P/N 06-4530-00) has failed. See Parts Replacement section. Yes LED on the XY Servo Interface PWA (P/N 60-1211-00) has failed. See Parts Replacement section. 53. Switch the Main Circuit Breaker to the OFF (0) position. 54. Check continuity of the fuses on the Main Interface PWA. 55.
61. Are the readings in accordance with Table 8-4? No Go to Step 62 Yes Main Interface PWA (P/N 60-1200-00) has failed. See Parts Replacement section. 62. Measure VDC from the cable terminal on the Computer Interface Board (each wire clamp of the Cable Terminal is labeled with the VDC value). 63. Are the VDC readings the same as specified on the labels for the Cable Terminal wire clamps? No Yes The Computer (P/N 62-1632-00) has failed. See Parts Replacement section.
8.1.
System Power Verification 1. Press the green ON (I) button on the Operator’s Console. 2. Does the green ON (I) button stay illuminated? No Go to Step 7 Yes Go to Step 3 3. Locate the power LEDs on the XY Servo Interface PWA. 4. Are the green +24V_A&B_ISO and +24V LEDs illuminated? No Go to XY Servo Interface Power Verification in this subsection. Yes Go to Step 5 5. Locate the Dispense Head Controller status LEDs on the left side of the Dispensing Head. 6.
11. Press the green ON (I) button on the Operator’s Console. 12. Does the green ON (I) button on the Operator’s Console stay illuminated? No Go to Step 13 Yes Stop here. Dispensing system being in EMO state is root cause of power fault. 13. Verify the proper cables are connected to the Power Manager as specified in Table 8-5.
22. Check continuity between Pin 1 (black wire) and Pin 3 (red wire) at the green ON (I) button harness connector. 23. Is there continuity between Pin 1 (black wire) and Pin 3 (red wire)? No Go to Cable Verification in this subsection. Yes Go to Step 24 24. Press the green ON (I) button on the Operator’s Console and check the continuity of the green ON (I) button at the cable connector as specified in Table 8-6.
Power Cable Verification 1. Switch the Main Circuit Breaker to the OFF (0) position. 2. Disconnect Cable (P/N 06-4515-00) from the Power Control outlet of the Power Manager. 3. Verify the Cable is connected to front EMO Button, black OFF (0) button, and green ON (I) button. 4. Check continuity between the pins specified in Table 8-7.
Front EMO Button Verification 1. Reconnect the Cable (P/N 06-4515-00) to the Power Control outlet on the Power Manager. 2. Verify the Front EMO Cable is connected to Front EMO Button. 3. Verify the wiring to the Front EMO Button is as specified in Table 8-9. Table 8-9 Front EMO Cable Connections Front EMO Cable Connector Wire Color Front EMO Button Pin 1 Black Pin 11 Pin 2 White Pin 12 Pin 3 Red Pin 21 Pin 4 Green Pin 22 4.
10. Is there continuity between the pins specified in Table 8-10? No Front EMO Button (P/N 40-0016 and P/N 40-2521) has failed. See Parts Replacement section. Yes Power Controls Cable (P/N 06-4515-00) has failed. See Parts Replacement section. Rear EMO Button Verification 1. Reconnect the Cable (P/N 06-4515-00) to the Power Control outlet on the Power Manager. 2. Verify the Rear EMO Cable is connected to the Rear EMO Button. 3. Verify the wiring to the Rear EMO Button specified in Table 8-11.
9. Verify the continuity between the Rear EMO Button Cable pins specified in Table 8-12. Table 8-12 Rear EMO Button Cable Connections Rear EMO Cable Connector Wire Color Rear EMO Cable Connector Pin 1 Black to White Pin 2 Pin 3 Red to Green Pin 4 10. Is there continuity between the pins specified in Table 8-12? No Go to Step 11 Yes Reconnect the Rear EMO Cable (P/N 06-4511-00) and then go to Vent Switch Faker Verification in this subsection. 11.
Vent Switch Faker Verification 1. Switch the Main Circuit Breaker to the OFF (0) position. 2. Reconnect the Cable (P/N 06-4515-00) to the Power Control outlet on the Power Manager. 3. Verify the Vent Switch Faker (P/N 194034) is connected to J9. 4. Is the Vent Switch Faker connected? No Install Vent Switch Faker (P/N 19034) and then go to Step 5. Yes Go to Step 5 5. Verify the continuity of the Vent Switch Faker pins is as specified in Table 8-14.
4. Is there continuity between the pins specified in Table 8-15? No The OFF (0) button (P/N 40-2485) has failed. See Parts Replacement section. Yes Cable (P/N 06-4515-00) has failed. See Parts Replacement section. XY Servo Interface Power Verification 1. Locate the power LEDs on the Main Interface PWA. 2. Is the +24V LED illuminated? No Go to Step 3 Yes Go to Step 17 3. Press the black OFF (0) button on the Operator’s Console. 4. Switch the Main Circuit Breaker to the OFF (0) position. 5.
15. Measure VDC between Pin 1 and Pin 2 at the Power Manager +24V DC POWER OUT connector. 16. Is the reading greater than 23 VDC? No Power Manager (P/N 62-1620-01) has failed. See Parts Replacement section. Yes Cable (P/N 06-4510-00) has failed. See Parts Replacement section. 17. Press the black OFF (0) button on the Operator’s Console. 18. Switch the Main Circuit Breaker to the OFF (0) position. 19. Disconnect the DC Power Cable (P/N 06-4530-00) from the Main Interface Board XY SERVO DC POWER connector.
Dispense Head Controller Power Verification 1. Press the black OFF (0) button on the Operator’s Console. 2. Switch the Main Circuit Breaker to the OFF (0) position. 3. Disconnect the 555 Interconnect Cable (P/N 194154) from the left side of the Z-Head. 4. Switch the Main Circuit Breaker to the ON (I) position. 5. Press the green ON (I) button on the Operator’s Console. 6. Measure VDC between Pin 25 and Pin 10 on the 555 Interconnect Cable (P/N 194154). 7.
8.1.4 Interlock Fault Isolation Procedure The Interlock Fault Isolation Procedure consists of the following: • Interlock Power Verification • Interlock Switch Verification • Interlock Switch Cabling Verification • Hatch Open Signal Verification • Servo Low Power Signal Verification • Light Beacon Signal Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Interlock Power Verification 1. Verify the Main Circuit Breaker on the Power Manager is in the ON (I) position. 2. Is the Power Manager Fan functioning? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Go to Step 3 3. Is the green Computer power LED illuminated? No Go to Step 4 Yes Go to “System/Servo Power Verification” in 8.1.1, X and Y Motion Fault Isolation Procedure 4. Verify the Computer Power Switch is in the ON (I) position. 5. Does the green Computer power LED illuminate? No Go to 8.1.
10. Locate the power LEDs on the XY Servo Interface PWA. 11. Are the green +24V_A&B_ISO and +24V LEDs illuminated? No Go to 8.1.3, System Power Fault Isolation Procedure Yes Go to Step 12 12. Is the green +SERVO LED illuminated? No Go to 8.1.5, XY Servo Amplifiers Fault Isolation Procedure Yes Go to Step 13 13. Locate the Servo Motor LEDs on the XY Servo Interface PWA. 14. Is the red AOK LED illuminated? No Go to Interlock Switch Verification in this subsection. Yes Go to 8.1.
Interlock Switch Verification 1. Does the Front Hatch Interlock Key enter the Interlock Switch when the Front Hatch is closed? No Go to Step 2 Yes Go to Interlock Switch Cabling Verification in this subsection. 2. Realign the Interlock Key on the Front Hatch. 3. With the Interlock Key aligned and the Front Hatch closed, does the green light on the Beacon illuminate? No Go to Interlock Switch Cabling Verification in this subsection. Yes Go to Step 4 4.
Interlock Switch Cabling Verification 1. Press the black OFF (0) button on the Operator’s Console. 2. Switch the Main Circuit Breaker to the OFF (0) position. 3. Disconnect the Cable (P/N 06-4528-00) from the connector labeled Interlock on the Main Interface PWA on the left side of Computer. 4. Verify the Interlock Cable (P/N 06-4528-00) is connected to the Interlock Switch. 5. With the Front Hatch closed, check continuity between the pins specified in Table 8-16.
Hatch Open Signal Verification 1. Verify the Servo Interconnect A Cable (P/N 06-4525-00) is connected to XY Servo Interface PWA J19 and the Main Interface PWA J29. 2. Locate chips U15 and U14 on the Main Interface PWA on the Computer Door. 3. With the Front Hatch closed, measure the VDC at Pin 10 of chips U14 and U15 on the Main Interface PWA. Use TP2 labeled GND for ground. 4. Is the reading greater than 4 VDC? No Main Interface PWA (P/N 60-1200-00) has failed. See Parts Replacement section.
Servo Low Power Signal Verification 1. Verify the Signals Cable (P/N 06-0403-00) is connected to J9 on the XY Servo Interface PWA and J5 on Y Servo Amplifier PWA. 2. Verify the Signals Cable is connected to J7 on the XY Servo Interface PWA and J5 on the X Servo Amplifier PWA. 3. With the Front Hatch closed, measure the VDC at Pin 3, Jumper J1 on the X and Y Servo Amplifier PWAs. Use TP8 labeled GND on XY Servo Interface PWA for ground. 4. Is the reading greater than 4 VDC? No Go to Step 5 Yes Stop here.
Light Beacon Signal Verification 1. Locate U6 on the Main Interface PWA. 2. With Front Hatch closed, measure VDC between Pin 3 and Pin 4. 3. Is the reading greater than 23 VDC? No Go to Step 4 Yes Main Interface PWA (P/N 60-1200-00) has failed. See Parts Replacement section. 4. Press the black OFF (0) button on the Operator’s Console and switch the Main Circuit Breaker to the OFF (0) position. 5. Disconnect the Beacon Cable (P/N 06-4538-00) from J4 on the XY Servo Interface PWA. 6.
8.1.5 XY Servo Amplifiers Fault Isolation Procedure The XY Servo Amplifiers Fault Isolation Procedure consists of the following: • Main Power Verification • Servo Power Verification • Servo Amplifier Verification • External Disable Check • Power-up Reset Check Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Main Power Verification 1. Verify the Main Circuit Breaker on the Power Manager is in the ON (I) position. 2. Is the Power Manager Fan functioning? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Go to Step 3 3. Is the green Computer power LED illuminated? No Go to Step 4 Yes Go to Step 6 4. Verify the Computer Power Switch is in the ON (I) position. 5. Does the green Computer power LED illuminate? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Go to Step 6 6.
10. Locate the power LEDs on the XY Servo Interface PWA. 11. Are the green +24V_A&B_ISO and +24V LEDs illuminated? No Go to 8.1.3, System Power Fault Isolation Procedure Yes Go to Step 12 12. Is the green +SERVO LED illuminated? No Go to Servo Power Verification in this subsection. Yes Go to Servo Amplifier Verification in this subsection.
Servo Power Verification 1. On the XY Servo Interface PWA, locate the J3 connector. 2. Confirm there are two blue wires attached to the J3 connector labeled SERVO DC POWER ENTRY (the positions of these wires are labeled +SERVO). 3. Measure the VDC at the connector where each of the two blue wires come into J3 (Use TP1 labeled SERVO_RETURN on the XY Servo Interface PWA for ground). 4. Is the reading 67.5 ±2 VDC for each blue wire? No Go to Step 5 Yes XY Servo Interface PWA (P/N 60-1211-00) has failed.
13. Press the black OFF (0) button on the Operator’s Console and switch the Main Circuit Breaker to the OFF (0) position. 14. Disconnect the Servo AC Power Cord (P/N 56-0304-00) from Power Manager outlet AC3. 15. Switch the Main Circuit Breaker to the ON (I) position and press the green ON (I) button on the Operator’s Console. 16. Measure the VAC coming from the Power Manager outlet AC3. 17. Is the reading between 208 and 240 VAC? No Power Manager (P/N 62-1620-01) has failed. See Parts Replacement section.
Servo Amplifier Verification 1. Switch the Main Circuit Breaker to the ON (I) position and press the green ON (I) button on the Operator’s Console. 2. Locate the SERVO MOTOR LEDs on the XY Servo Interface PWA. 3. Observing the LEDs, determine status of Servo Amplifier using Table 8-17.
External Disable Check 1. Is FmNT open? No Go to Step 2 Yes Go to Step 5 2. Close the Front Hatch. 3. Open FmNT by double clicking on the FmNT icon. 4. Does FmNT initialize with no FmNT error messages (30735, 30416, and 30353) related to the Motion Controller? No Go to 8.2, Troubleshooting the Servo Controller Yes Go to Step 10 5. With the Front Hatch closed, go to FmNT Main Window and click on the Jog icon. 6. Click on Dispense and then on the Reinitialize button. 7.
10. Can the Dispensing Head be moved in X and Y axes with the Jog keys [Ctrl + Shift + Arrow keys] on the Keyboard? No Go to Step 11 Yes Stop here. Dispensing Head initialization is root cause of Servo Amplifier fault. 11. Does the green Beacon light illuminate when the Front Hatch is closed? No Go to “Light Beacon Signal Verification” in 8.1.4, Interlock Fault Isolation Procedure Yes Go to Step 12 12.
Power-up Reset Check 1. Locate the XY Servo Interface PWA power LEDs. 2. Is the green +SERVO LED illuminated? No Go to Servo Power Verification in this subsection. Yes Go to Step 3 3. Locate the J4 power connection at on the X and Y Servo Amplifier PWAs on the Servo Shelf. 4. Measure VDC between Pin 1 and Pin 2 of Power Cable (P/N 06-4534-00) connected to J4. 5. Is the reading at both Amplifiers 67.5 ±2 VDC? No Go to Step 6 Yes Servo Amplifier (P/N 60-1212-00) has failed. See Parts Replacement section.
8.2 Troubleshooting the Servo Controller (PMAC) To troubleshoot Programmable Multi-Axis Controller (PMAC) problems, refer to Table 8-18 for a summary of the symptoms, probable causes, and fault isolation procedures. FmNT error messages displayed on the Computer Monitor related to the PMAC are also discussed.
8.2.1 PMAC Initialization Fault Isolation Procedure The PMAC Initialization Fault Isolation Procedure consists of the following: • Main Power and Initialization Verification • PMAC Watchdog Error Verification • PMAC Fatal Following Error Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Main Power and Initialization Verification 1. Verify the Main Power Manager Circuit Breaker is in the ON (I) position. 2. Press the green ON (I) button on the Operator’s Console. 3. Exit FmNT. 4. Open the Front Hatch and move the Dispensing Head to the middle of the dispensing chamber. 5. Close Front Hatch. 6. Locate the power LEDs on the XY Servo Interface PCA. 7. Is the red SRVO_PWR LOW LED illuminated? No Go to Step 8 Yes Go to 8.1.4, Interlock Fault Isolation Procedure 8.
14. Does the Dispensing Head complete the homing process with no FmNT error messages? No Go to Step 15 Yes Go to Step 16 15. Did the Dispensing Head hit the mechanical hard stop in the X or Y-axis during the homing process? No Go to PMAC Fatal Following Error Verification in this subsection. Yes Go to 8.2.5, PMAC Home Sensor Fault Isolation Procedure 16. From the FmNT Main Menu, click on the Jog icon. 17.
PMAC Watchdog Error Verification 1. Open the Computer Door. 2. Locate and observe the yellow and green LED on the PMAC card slot. 3. Are the yellow and green LEDs illuminated? No Go to Step 14 Yes Go to Step 4 4. Is the red LED between the yellow and green LEDs illuminated? No Verify fault and return to 8.2, Troubleshooting the Servo Controller Yes Go to Step 5 CAUTION! Use proper Electrostatic Discharge precautions when handling the ESD sensitive PMAC Card.
14. Locate the Computer Passive Backplane on the right inside wall of the Computer. Locate four red LEDs labeled -5V, +5V, -12V, and +12V. 15. Are all the LEDs illuminated? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes PMAC Card (P/N 07-0735-01) has failed. See Parts Replacement section. PMAC Fatal Following Error Verification 1. Reinitialize the Dispenser. 2. FmNT message “30416 Dispenser motor reference not found. Select OK to home the dispenser” should appear. 3.
8. When using the [Crtl + Shift + Z + Up or Down Arrow keys], was there high vibration during the Z-axis movement? No Go to Step 9 Yes Go to “Z-Axis Rotary Encoder Verification” in 8.2.2, PMAC Rotary Encoder Fault Isolation Procedure 9. Press the black OFF (0) button on the Operator’s Console. 10. Open the Front Hatch and manually move the Dispensing Head around the dispensing chamber using only X or Y-axis movements and then in the Z-axis only. 11.
8.2.2 PMAC Rotary Encoders Fault Isolation Procedure The PMAC Rotary Encoder Fault Isolation Procedure consists of the following: • Rotary Encoder Power Down Verification • X-Axis Rotary Encoder Verification • Y-Axis Rotary Encoder Verification • Z-Axis Rotary Encoder Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
X-Axis Rotary Encoder Verification 1. In the Dispenser Terminal Window, type M101 and press [Enter] on the Keyboard. A numerical value should appear. Note the value returned. WARNING! CAUTION! Use caution when reaching your hand into the dispensing chamber while system is under power. Failure to take appropriate precautions could result in injury or property damage. 2. Manually move the Dispensing Head in the X-axis. 3. Again, type M101 and press [Enter]. Note the value returned. 4.
15. At the X-axis Servo Motor, the black wire on Rotary Encoder Cable should be orientated to Pin 1 labeled GND with the copper lead facing you. 16. Carefully remove the Servo Motor Connector (leads are fragile) and check for damage. 17. Are any of the Servo Motor Connector leads damaged? No Go to Step 18 Yes Servo Motor (P/N 62-1650-01) has failed. See Parts Replacement section. 18. Check continuity of Rotary Encoder Cable (P/N 06-4535-00). 19.
Y-Axis Rotary Encoder Verification 1. In FmNT Dispenser Terminal Window, type M301 and press [Enter] on the Keyboard. A numerical value should appear. Note the value returned. WARNING! CAUTION! Use caution when reaching your hand into the dispensing chamber while system is under power. Failure to take appropriate precautions could result in injury or property damage. 2. Manually move the Dispensing Head in the Y-axis. 3. Again, type M301 and press [Enter]. Note the value returned. 4.
15. At the Y-axis Servo Motor, the Rotary Encoder Cable, the black wire on Rotary Encoder Cable should be orientated to Pin 1 labeled GND with the copper lead facing you. 16. Carefully remove the Servo Motor Connector (leads are fragile) and check for damage. 17. Are any of the Servo Motor leads damaged? No Go to Step 18 Yes Servo Motor (P/N 62-1650-01) has failed. See Parts Replacement section. 18. Check continuity of Rotary Encoder Cable (P/N 06-4535-00). 19.
Z-Axis Rotary Encoder Verification 1. From the FmNT Main Menu, click on the Tool icon. 2. In the Tool Menu, click on the Terminal icon. 3. Under the Terminal icon, click on the Dispenser icon. 4. Press the black OFF (0) button on the Operator’s Console. 5. Verify the Z-head Interconnect Cable (P/N 06-4550-00) is connected securely to J2 on the Z Servo Interface PWA and J31 on the XY Servo Interface PWA. 6. In the Dispenser Terminal Window, type M501 and press [Enter] on the Keyboard.
17. Is the difference of any set of values greater than 200 counts? No Z-axis Rotary Encoder is not root cause of the following error fault. Go to Step 9 in “PMAC Fatal Following Error Verification” in 8.2.1, PMAC Initialization Fault Isolation Procedure. Yes Stop here. Rotary Encoder is root cause of following error fault. Contact Asymtek Technical Support to verify fault. 18. Remove the Servo Shelf Cover. 19. Check continuity of Z-Head Interconnect Cable (P/N 06-4550-00.) Pinout is 1 to 1. 20.
8.2.3 PMAC Linear Encoder Fault Isolation Procedure The PMAC Linear Encoder Fault Isolation Procedure consists of the following: • Linear Encoder Mechanical Verification • X-Axis Linear Encoder Verification • Y- Axis Linear Encoder Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Linear Encoder Mechanical Verification 1. Visually inspect for damage the X-axis Linear Encoder Cable (P/N 194985, top) and Y-axis Linear Encoder Cable (P/N 194986, bottom) connected to the XY Servo Interface PWA at connection J23. 2. Are the Cables damaged? No Go to Step 3 Yes Cable(s) (P/N 194985, 194986) have failed. See Parts Replacement section. 3. Manually verify that the X and Y-axis Linear Encoder Cables are securely connected to the XY Servo Interface PWA at J23. 4.
X-Axis Linear Encoder Verification 1. From the FmNT Main Menu, click on the Tool icon. 2. In the Tool Menu, click on the Terminal icon. 3. Under the Terminal icon, click on the Dispenser icon. 4. Press the black OFF (0) button on the Operator’s Console. 5. In the Dispenser Terminal window, type M201 and press [Enter] on the Keyboard. A numerical value should appear. Note the value returned. WARNING! CAUTION! Use caution when reaching your hand into the dispensing chamber while system is under power.
16. Is the difference of any set of values greater than 200 counts? No Stop here. X-axis Linear Encoder is not root cause of the fault. Go to Y-axis Linear Encoder Verification in this subsection. Yes Stop here. Linear Encoder is root cause of following error fault. Contact Asymtek Technical Support to verify fault. 17. Remove the Servo Shelf Cover. 18. Verify that the Cable of the X-axis Linear Encoder (P/N 194985) is securely connected to the XY Servo Interface PWA (P/N 60-1211-00) at J23.
23. Check continuity of X-axis Linear Encoder signal routing from the XY Servo Interface PWA to the PMAC Controller as specified in Table 8-23.
Y- Axis Linear Encoder Verification 1. In the Dispenser Terminal Window, type M401 and press [Enter] on the Keyboard. A numerical value should appear. WARNING! CAUTION! Use caution when reaching your hand into the dispensing chamber while system is under power. Failure to take appropriate precautions could result in injury or property damage. 2. Manually, move the Dispensing Head in the X-axis. 3. Again, type M401 and press [Enter]. Note the value returned. 4.
13. Remove the Servo Shelf Cover. 14. Verify the Cable of the Y-axis Linear Encoder (P/N 194986) is connected to the XY Servo Interface PWA (P/N 60-1211-00) at J23. The Y-axis Linear Encoder Connector should be on the bottom. 15. Is the Cable properly connected? No Securely connect Cable to its proper location and go back to Step 5. Yes Go to Step 20 16. Disconnect Y-axis Linear Encoder Cable from J23 on XY Servo Interface PWA. 17.
19. Check continuity of Y-axis Linear Encoder signal routing from the XY Servo Interface PWA to the PMAC Controller as specified in Table 8-25.
8.2.4 PMAC Mechanical Fault Isolation Procedure The PMAC Mechanical Fault isolation Procedure consists of the following: • X and Y-axis Mechanical Verification • Servo Motor Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual. WARNING! A dispensing system in need of troubleshooting may have high voltage present in both designated and unsuspected places that can result in personal injury or death.
2. Is any mechanical correction required as a result of Step 1 inspections? No Go to 8.2.3, PMAC Linear Encoder Fault Isolation Procedure Yes Go to Step 3 3. Press the black OFF (0) button on the Operator’s Console. 4. Open the Front Hatch and manually move the Dispensing Head throughout the dispensing chamber in the X or Y, and Z-axis. 5. Are movements smooth and linear with no binding or unusual noise? No Go to Servo Motor Verification in this subsection. Yes Go to Step 6 6.
11. Did the FmNT message “30735 The motor have gone open loop? Press OK to continue and reinitialize the motion controller” appear? No Stop here. A mechanical issue is the root cause of the fatal following error. Yes Go to 8.2.1, PMAC Initialization Fault Isolation Procedure. If fault reoccurs, Contact Asymtek Technical Support. Servo Motor Verification 1.
8.2.5 PMAC Home Sensor Fault Isolation Procedure The PMAC Home Sensor Fault Isolation Procedure consists of the following: • X-Axis Home Sensor Verification • Y-Axis Home Sensor Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
X-Axis Home Sensor Verification 1. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, and switch the Main Circuit Breaker to the OFF (0) position. 2. Manually move the Dispensing Head to the middle of the dispensing chamber. 3. Remove the white Cover from the X-axis Home Sensor Cable (P/N 06-4540-00) connection. 4. Switch the Main Circuit Breaker to the ON (I) position.
13. Switch the Main Circuit Breaker to the OFF (0) position. 14. Disconnect the Z-Head Interconnect Cable (P/N 06-4550-00) from the rear of the Dispensing Head at the Z Servo Interface PWA connection J2 connector. 15. Switch the Main Circuit Breaker to the ON (I) position. WARNING! CAUTION! Use caution when reaching your hand into the dispensing chamber while system is under power. Failure to take appropriate precautions could result in serious injury or property damage. 16.
25. Measure VDC between Pin 1 and Pin 4 of the X-axis Home Sensor Cable (P/N 06-4550-00) at J3, connected to the X-axis Home Sensor PWA. 26. Is the reading less than 2 VDC? No Home/Limit Switch PWA (P/N 60-0785-00) has failed. See Parts Replacement section. Yes Go to Step 27 27. Manually move the Dispensing Head to the left side of the dispensing chamber until it contacts the X-axis Home Sensor. 28.
Y-Axis Home Sensor Verification 1. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, and switch the Main Circuit Breaker to the OFF (0) position. 2. Manually move the Dispensing Head to the middle of the dispensing chamber. 3. Remove the white Cover from the Y-axis Cable (P/N 06-4541-00) connection. 4. Switch the Main Circuit Breaker to the ON (I) position.
12. Place an opaque plastic card into the Y-axis Home Sensor slot. 13. Measure VDC between Pin 1 and Pin 4. 14. Is the reading less than 2 VDC? No Home/Limit Switch PWA (P/N 60-0785-00) has failed. See Parts Replacement section. Yes Go to Step 15 15. Switch the Main Circuit Breaker to the OFF (0) position. 16. Manually move the Dispensing Head to the front left corner of the dispensing chamber until it contacts the Y-axis Home Sensor. 17.
8.3 Troubleshooting Z-axis Motion If the Dispensing Head is not moving correctly in the Z-axis, refer to Table 8-26 for a summary of the symptoms, probable causes, and fault isolation. Table 8-26 Troubleshooting Summary – Z-Axis Motion of Dispensing Head Symptom Probable Cause Fault Isolation Procedure Subsection Recoverable Interlock State Interlock Fault Isolation 8.1.4 EMO State System Power Fault Isolation 8.1.3 Motors in Open-loop State Troubleshooting the Servo Controller (PMAC) 8.
8.3.1 No Z –axis Motion Fault Isolation Procedure The No Z Motion Fault Isolation Procedure consists of the following: • Main Power Verification • System/Servo Power Verification • Interlock Verification • Servo Controller (PMAC) Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Main Power Verification 1. Verify the Main Circuit Breaker located on the Power Manager is in the ON (I) position. 2. Is the Power Manager Fan functioning? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Go to Step 3 3. Is the green Computer power LED illuminated? No Go to Step 4 Yes Go to System/Servo Power Verification in this subsection. 4. Verify that the Computer Power Switch is in the ON (I) position. 5. Does the green Computer power LED illuminate? No Go to 8.1.
System/Servo Power Verification 1. Press the green ON (I) button on the Operator’s Console. 2. Does the green ON (I) button on the Operator’s Console stay illuminated? No Go to 8.1.3, System Power Fault Isolation Procedure Yes Go to Step 3 3. Locate the power LEDs on the XY Servo Interface PWA. 4. Are the green +24V_A&B_ISO and +24V LEDs illuminated? No Go to 8.1.3, System Power Fault Isolation Procedure Yes Go to Step 4 5. Is the green +SERVO LED illuminated? No Go to 8.3.
Interlock Verification 1. If open, close the Front Hatch. 2. Does the green Beacon light illuminate when the Front Hatch is closed? No Go to Step 14 of “Main Power Verification” in 8.1.4, Interlock Fault Isolation Procedure Yes Go to Step 3 3. Locate the power LEDs on the XY Servo Interface PWA. 4. Is the red SRVO_PWR LOW LED on the XY Servo Interface PWA illuminated when the Front Hatch is closed? No Go to Servo Controller (PMAC) Verification in this subsection. Yes Go to 8.1.
5. Does the FmNT message “30796 The dispenser PMAC device initialization has failed” appear on screen while initializing FmNT before any other messages? No Go to Step 6 Yes Go to “PMAC Watchdog Error Verification” in 8.2.1, PMAC Initialization Fault Isolation Procedure 6. The FmNT message “30416 Dispenser motor reference not found. Select OK to home the dispenser” should appear during initialization process. 7.
8.3.2 Z Servo Amplifier Fault Isolation Procedure The Z Servo Amplifier Fault Isolation Procedure consists of the following: • Main Power Verification • Servo Power Verification • Servo Amplifier Verification • External Disable Check • Power-up Reset Check Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
4. Verify that the Computer Power Switch is in the ON (I) position. 5. Does the green Computer power LED illuminate? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Go to Step 6 6. Locate the power LEDs on the XY Servo Interface PWA. 7. Are the green 5V, A+15V, and A+5V LEDs illuminated? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Go to Step 8 8. Press the green ON (I) button on the Operator’s Console. 9.
Servo Power Verification 1. On the XY Servo Interface PWA, locate the J3 connector. 2. Confirm there are two blue wires attached to the J3 connector labeled SERVO DC POWER (the positions of these wires are labeled +SERVO). 3. Measure VDC at the connector where the two blue wires come into J3. (Use TP1 labeled SERVO_RETURN on the XY Servo Interface PWA for ground.). 4. Is the reading 67.5 ±2 VDC for each blue wire? No Go to Step 5 Yes XY Servo Interface PWA (P/N 60-1211-00) has failed.
14. Disconnect the Power Cord from Power Manager outlet AC3. 15. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 16. Measure between 208 to 240 VAC coming from the Power Manager outlet AC3. 17. Is the reading between 208 to 240 VAC? No Power Manager (P/N 62-1620-01) has failed. See Parts Replacement section. Yes Go to Step 18 18.
Servo Amplifier Verification 1. Locate Servo Motor status LEDs AOK, SO1, SO2, SO3 on the XY Servo Interface PWA. 2. Compare the ON/OFF conditions of the LEDs with those in Table 8-27 and take the action specified. Table 8-27 Servo Amplifier Status Function AOK SO1 SO2 SO3 Action Amplifier OK Off Off Off Off Go to Interlock Fault Isolation, subsection 8.1.
6. Click on Dispense and then click on the Reinitialize button. 7. Does the Dispensing Head reinitialize? No Go to Step 8 Yes Go to Step 10 8. Is the red Servo Motor status AOK LED illuminated? No Go to Step 9 Yes Go to Power-up Reset Check in this subsection. 9. Is the Servo Amplifier status EXTERNAL DISABLE? No Go to Servo Amplifier Verification in this subsection. Yes Go to 8.2, Troubleshooting the Servo Controller 10.
13. Does a Door Open message appear in the bottom left corner of the FmNT window when the Front Hatch is closed? No Go to 8.2, Troubleshooting the Servo Controller Yes Go to 8.1.4, Interlock Fault Isolation Procedure Power-up Reset Check 1. Locate the XY Servo Interface PWA power LEDs. 2. Is the green +SERVO LED illuminated? No Go to Servo Power Verification in this subsection. Yes Go to Step 3 3. On the X and Y Servo Amplifiers PWA, locate the power connection at J26. 4.
8.4 Troubleshooting Conveyor If the Conveyor is not operating correctly, refer to Table 8-28 for a summary of the symptoms, probable causes, and fault isolation processes. Table 8-28 Conveyor Troubleshooting Summary Symptom Probable Cause Fault Isolation Procedure Subsection Board Sensors Board Sensor Fault Isolation 8.4.2 Pneumatic System Pneumatics Fault Isolation 8.4.1 Pneumatic System Pneumatics Fault Isolation 8.4.1 Conveyor Controller SMEMA Fault Isolation 8.4.
8.4.1 Pneumatics Fault Isolation Procedure The Pneumatics Fault Isolation Procedure consists of the following: • Mechanical Verification • Facility Power and Air Supply Verification • Pneumatics Verification • Purge Cup Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Mechanical Verification 1. Perform the following inspections: a. Listen for pneumatic leaks (a hissing sound). b. Look for cuts or disconnected pneumatic hoses. c. Look for pinched or obstructed pneumatic hoses. d. Look for obstructions that prevent Lift Tables and Stop Pins to raise or lower. e. Look for disconnected or poorly secured electrical cables. f. Look for damaged electrical cables. 2.
Pneumatics Verification 1. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 2. Are all pneumatic system devices inoperative and the yellow Beacon light flashing? No Go to Step 3 Yes Go to Step 7 3. From the FmNT Main Window: a. Select Tools. b. Select I/O Test. c. Select Conveyor. 4. Toggle the failed pneumatic device.
6. Can tooling pressure be adjusted to 40 psi? No Go to Step 7 Yes Solenoid Valve (P/N 197396 4-way or P/N 197397Dual 3-way) has failed. See Parts Replacement section. 7. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, switch Main Circuit Breaker to OFF (0) position, and disconnect Power Cable from the facility outlet. 8. Remove Main Air Solenoid Connector from J33 on XY Servo Interface PWA. 9.
18. Check continuity of Servo Interconnect B Cable (Pinout is 1 to 1). 19. Is there continuity? No Servo Interconnect B Cable (P/N 06-4525-00) has failed. See Parts Replacement section. Yes Go to Step 20 20. Exchange failed Solenoid Valve with one of the other Solenoid Valves (refer to Parts Replacement section for removal and installation of the Solenoid Valve). 21.
30. Measure VDC on Conveyor Controller J3 Pin 1 or Pin 2 and the corresponding pin as shown in Table 8-30. Table 8-30 Conveyor Controller J3 Pins Pin Conveyor Controller J3 Pin Conveyor Controller J3 1 +24 VDC 8 Stop Pin, right 2 +24 VDC 9 Vacuum on left 3 Lift up left 10 Vacuum on center 4 Left up center 11 Vacuum on right 5 Lift up right 12 Purge Cup air on 6 Stop Pin, left ~ 7 Stop Pin, center 25 31.
Purge Cup Verification 1. Measure VDC signal on the Main Interface PWA U19, Pin 1 and Pin 13. 2. Is the reading 24 VDC? No Go to Step 5 Yes Go to Step 3 3. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, switch Main Circuit Breaker to OFF (0) position, and disconnect Power Cable from the facility outlet. 4. Check continuity of Conveyor Interface Cable (Pinout is 1 to 1). 5. Is there continuity? No Conveyor Interface Cable (P/N 06-4600-00 has failed.
8.4.2 Board Sensor Fault Isolation Procedure The Board Sensor Fault Isolation Procedure consists of the following: • Mechanical Verification • Facility Power and Air Supply Verification • Board Sensor Verification • Conveyor Signals Cable Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Facility Power Supply Verification 1. Is facility power in accordance with the requirements in the Introduction section of this manual? No Resolve and go to Board Sensor Verification in this subsection. Yes Go to Board Sensor Verification in this subsection. Board Sensor Verification 1. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, switch Main Circuit Breaker to OFF (0) position, and disconnect Power Cable from the facility outlet.
8. Does the Board Sensor status indicator LED illuminate when a workpiece is passed beneath it? No Go to Step 9 Yes Go to Step 14 9. Inspect the Fiber-optic Cables for any damage that will interfere with light transmission. 10. Is the Fiber-optic Cable damaged? No Go to Step 11 Yes Fiber-optic Cable (P/N 56-0124) has failed. See Parts Replacement section. 11. Attach the Fiber-optic Cable from the failed Board Sensor to one of the other Board Sensors. 12.
17. Exchange the Board Sensor Connector with another Board Sensor Connector at the Conveyor Interconnect PWA. 18. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 19. Did the error follow the exchanged Board Sensor Connector? No Go to Step 20 Yes Board Sensor has failed. See Parts Replacement section. 20. Did the error move to the other Board Sensor? No Yes Stop here.
25. When the Board Sensor is unblocked, is the reading 24 VDC? No Conveyor Controller (P/N 62-1677-00 on X-1020 or P/N 62-1676 on X-1010) has failed. See Parts Replacement section. Yes Go to Step 26 26. When the Board Sensor is blocked, does the Conveyor Controller toggle from High (24 VDC) to Low (approximately 0 VDC)? (Note: Low is activated.) No Go to Conveyor Signals Cable Verification in this subsection. Yes Conveyor Controller (P/N 62-1677-00 for X-1020 or 62-1676-00 for X-1010) has failed.
8.4.3 Heater Fault Isolation Procedure The Heater Fault Isolation Procedure consists of the following: • Mechanical Verification • Heater Verification • Temperature Controller Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual. WARNING! A dispensing system in need of troubleshooting may have high voltage present in both designated and unsuspected places that can result in personal injury or death.
Heater Verification 1. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 2. Heater elements generating heat? No Go to Step 3 Yes Go to Temperature Controller Verification in this subsection. 3. Are the Heater Cables correctly and securely connected? No Correct, secure Heater Cable connections, and then go to Step 4. Yes Go to Step 4 4.
11. Remove side Cover on Conveyor Controller. 12. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 13. In the FmNT Heater terminal, turn Heater to ON. 14. Measure VDC between Terminal 3 and Terminal 4 of the Solid State Relay. 15. Does the reading oscillate between 0 and 5 VDC? No Go to Step 18 Yes Go to Step 16 16. Measure VAC between Terminal 1 and Terminal 2 of the Solid State Relay.
24. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 25. Measure VAC from Conveyor AC Power Cable. 26. Does the reading show 208 to 240 VAC (should be equal to specified facility supply voltage)? No Go to 8.1.2, Main Power Fault Isolation Procedure Yes Conveyor Controller (P/N 62-1677-00 on X-1020, and P/N 62-1676-00 on X-1010) has failed. See Parts Replacement section.
8.4.4 SMEMA Fault Isolation Procedure The SMEMA Fault Isolation Procedure consists of the following: • Mechanical Verification • Upstream Workpiece Transfer Verification • Downstream Workpiece Transfer Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Upstream Workpiece Transfer Verification 1. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, switch Main Circuit Breaker to OFF (0) position, and disconnect Power Cable from the facility outlet. 2. Connect the TS-03 Kit to the SMEMA upstream and downstream connectors. 3. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 4.
13. Check continuity of SMEMA Upstream Cable, routed between Conveyor Controller and the Rear Bulkhead of the dispensing system. Pin connections are specified in Table 8-33. Table 8-33 Upstream Cable Pin Connections P1 Color P2 1 Black 9 2 White 3 3 Red 10 4 Green 4 5 Brown 1 6 Blue 2 7 Orange 11 8 Yellow 12 9 Purple N/C Shell Shield 8 14. Is there continuity? No SMEMA Upstream Cable (P/N 06-4645-00) has failed. See Parts Replacement section. Yes Go to Step 15 15.
19. Verify continuity of the P/N 06-4645-00 SMEMA Upstream Cable, routed between Conveyor Controller and the Rear Bulkhead of the dispensing system. Pin connections are specified in Table 8-34. Table 8-34 SMEMA Upstream Cable Pin Connections P1 Color P2 1 Black 9 2 White 3 3 Red 10 4 Green 4 5 Brown 1 6 Blue 2 7 Orange 11 8 Yellow 12 9 Purple N/C Shell Shield 8 20. Is there continuity? No Yes SMEMA Upstream Cable (P/N 06-4645-00) has failed. See Parts Replacement section.
Downstream Workpiece Transfer Verification 1. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, switch Main Circuit Breaker to OFF (0) position, and disconnect Power Cable from the facility outlet. 2. Connect the TS-03 Kit to the SMEMA upstream and downstream connectors. 3. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 4.
13. Verify continuity of the SMEMA Downstream Cable (P/N 06-4644-00), routed between Conveyor Controller and the Rear Bulkhead of the dispensing system. Pin connections are specified in Table 8-35. Table 8-35 SMEMA Downstream Cable Pin Connections P1 Color P2 1 Black N/C 2 White 1 3 Red 10 4 Green 2 5 Brown 12 6 Blue 4 7 Orange 11 8 Yellow 9 9 Purple 3 Shell Shield 8 14. Is there continuity? No SMEMA Downstream Cable (P/N 06-4644-00) has failed.
20. Verify continuity of the SMEMA Downstream Cable (P/N 06-4644-00), routed between Conveyor Controller and the Rear Bulkhead of the dispensing system. Pin connections are specified in Table 8-36. Table 8-36 SMEMA Downstream Cable Pin Connections P1 Color P2 1 Black N/C 2 White 1 3 Red 10 4 Green 2 5 Brown 12 6 Blue 4 7 Orange 11 8 Yellow 9 9 Purple 3 Shell Shield 8 21. Is there continuity? No Yes SMEMA Downstream Cable (P/N 06-4644-00) has failed.
8.4.5 Conveyor Motors Fault Isolation Procedure The Conveyor Motors Fault Isolation Procedure consists of the following: • Mechanical Verification • Rear/Front Belt Motor Verification • Width Motor and Cable Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Rear/Front Belt Motor Verification 1. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, switch Main Circuit Breaker to OFF (0) position, and disconnect Power Cable from the facility outlet. 2. Remove the Conveyor Controller Cover. 3. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 4.
11. Install the Rear Belt Motor connector in the Width Motor connector. 12. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 13. From any FmNT window, click on the Jog icon, or press [Ctrl + J] on the Keyboard. 14. Click on Conveyor and use the Jog Controls to change the Conveyor width. 15. Did the Rear Belt Motor turn? No Go to Step 25 Yes Go to Step 16 16.
25. Check continuity (Pinout is 1 to 1) of Belt Motor Cable (Interconnect PWA to Motors). 26. Is there continuity? No Belt Motor Cable (P/N 06-4622-00) has failed. See Parts Replacement section. Yes Belt Motor (P/N 07-0716-00) has failed. See Parts Replacement section. Width Motor and Cable Verification 1. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, switch Main Circuit Breaker to OFF (0) position, and disconnect Power Cable from the facility outlet. 2.
9. Disconnect the Rear Belt Motor connector from the Conveyor Interconnect PWA. 10. Install the Width Motor connector into the Rear Belt Motor receptacle. 11. Connect the Power Cable to the facility outlet, switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 12. From any FmNT Window, click on the Jog icon, or press [Ctrl + J] on the Keyboard. 13. Click on Conveyor and use the Jog Controls to move the Conveyor Belts. 14.
8.5 Troubleshooting Components If a component of the Systems is not functioning correctly, refer to Tables 8-39 for a summary of the symptoms, probable causes, and fault isolation processes for each component. Table 8-39 Troubleshooting Components Symptom Possible Cause Fault Isolation Subsection Scale malfunctioning Scale Control Module, or Calibration Module failures Scale Fault Isolation 8.5.
8.5.1 Height Sensor Fault Isolation Procedure The Height Sensor Fault Isolation Procedure consists of the following: • Height Sensor Power Verification • Height Sensor Probe Verification • Height Sensor Repeatability Verification • Height Sensor CAN Interface Verification • Height Sensor PIO 96 Signal Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Height Sensor Power Verification 1. Switch Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT . 2. Locate three top LEDs on the Dispense Head Controller and verify power to the unit. 3. Are the three top LEDs illuminated? No Go to 8.1.3, System Power Fault Isolation Procedure Yes Go to Step 4 4. Inspect the Height Sensor Cable (P/N 06-4590-00) for damage or secure connection. 5.
Height Sensor Probe Verification 1. Open FmNT and in the Main Window click on Configuration. 2. In the drop-down menu, select Setup Height Sensor. 3. In the Height Sensor Configuration Window, click on the CAN-HS button. 4. Click on CAN-HS button in the upper right-hand corner of the window until Main Menu appears. 5. Click on Arm /Disarm button and observe if the Height Sensor Probe moves up and down. 6.
14. Manually move the Height Sensor Probe upward and hold in position. 15. Does the HS_TOUCH/ [4A0] signal change from high (1) to low (0)? No Go to Height Sensor PIO Signal Verification in this subsection. Yes Go to Height Sensor Repeatability Verification in this subsection. Height Sensor Repeatability Verification 1. Have the Height Sensor Setup and the Camera-to-Probe Offset functions been performed? No Go to Step 2 Yes Go to Step 3 2.
9. Click on the Start button in the lower middle window. 10. Was the Height Sense test within the ranges shown in Table 8-40? No Go to Step 15 Yes Go to Step 11 11. In FmNT, increase the cycle number setting to 100. 12. Click on the Start button in the lower middle window. 13. When Height Sense test is complete, compare the results with the accuracy parameters specified in Table 8-40. 14. Was the result within the accuracy parameters specified in Table 8-40? No Go to Step 15 Yes Stop here.
Height Sensor CAN Interface Verification 1. Is the CAN terminator connector connected to the Bus-out port on the Dispense Head Controller? No Go to Step 2 Yes Go to Step 3 2. Connect the CAN terminator connector to the Bus-out port on the Dispense Head Controller. 3. Remove the Height Sensor Cover. 4. Measure VDC at locations 3 and 8 on the PCB where the cable is connected. 5. Is the reading 5 VDC in the Arm state and 0 VDC in the Disarm State? No Go to 6 Yes Height Sensor (P/N 195428) has failed.
14. Switch the Main Circuit Breaker to ON (I) position, press the green ON (I) button on the Operator’s Console, and enter FmNT. 15. Measure VDC at locations 7 and J18 on the Dispense Head Controller. 16. Is the reading 5 VDC for the Armed state and 0 VDC for the Disarmed state? No Go to Step 17 Yes Cable (P/N 195296) has failed. See Parts Replacement section. 17. Remove the Height Sensor Cover. 18.
Height Sensor PIO 96 Signal Verification 1. Locate U22 on the Main Interface PWA. 2. Measure the VDC at Pin 3 and test point TP 2 while the Height Sensor probe is Disarmed (up) and when it is Armed (down). 3. Is the reading 5 VDC for the Armed state and 0 VDC for the Disarmed state? No Contact Asymtek Technical Support Yes Go to Step 4 4. Locate Connector J5 on the Main Interface PWA. 5. Ensure that Ribbon Cable (P/N 19332) is securely connected to the PIO 96 Board. 6.
8.5.2 Tactile Sensor or Needle Sensor Fault Isolation Procedure The Tactile Sensor and Needle Sensor Fault Isolation Procedure consists of the following: • Dispensing Calibration Module Verification • Tactile Sensor Verification • Needle Sensor Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Tactile Sensor Verification 1. Inspect the Cable (P/N 06-4599-00) for damage and secure connection to the Dispensing Calibration Module and Main Interface PWA. 2. Is the cable damaged? No Ensure Cable is securely connected and then go to Step 3. Yes Cable (P/N 06-4599-00) has failed. See Parts Replacement section. 3. In the FmNT Main Window, click on Tools. 4. In the Tools Window, click on I/O Test and then click on the Dispenser button. 5.
12. Locate the backside of J24 on the Main Interface PWA labeled NEEDLE SENSOR. 13. Measure VDC between Pin 4 and Pin 5 on J24. 14. Is the reading 24 VDC? No Main Interface PWA (P/N 60-1200-00) has failed. See Parts Replacement section. Yes Go to Step 15 15. Locate backside of J24 on the Main Interface PWA labeled NEEDLE SENSORS. 16. Measure VDC between Pin 6 and Pin 5 on J24 while toggling the Tactile Sensor. 17.
Needle Sensor Verification 1. Inspect the Needle Sensor Cable (P/N 06-4599-00) for damage and secure connection to the Calibrated Service Station and the Main Interface PWA. 2. Is the Cable damaged? No Ensure Cable is securely connected and then go to Step 3. Yes Needle Sensor Cable (P/N 06-4599-00) has failed. See Parts Replacement section. 3. In the FmNT Main Window, click on Tools. 4. In the Tools Window, click on I/O Test and then click on the Dispenser button. 5.
12. Locate the backside of J24 on the Main Interface PWA labeled NEEDLE SENSORS. 13. Measure VDC between Pin 4 and Pin 5 on J24. 14. Is the reading 24 VDC? No Main Interface PWA (P/N 60-1200-00) has failed. See Parts Replacement section. Yes Go to Step 15 15. Locate backside of J24 on the Main Interface PWA labeled NEEDLE SENSORS. 16. Measure VDC between Pin 3 and Pin 2 on J24 while toggling the Needle Sensor. 17.
8.5.3 Scale Fault Isolation Procedure The Scale Fault Isolation Procedure consists of the following: • Mechanical Verification • Scale Operational Verification • Scale Power Verification • Scale Communications Verification Before troubleshooting a problem, please familiarize yourself with the important information provided in the Safety section of this manual.
Mechanical Verification 1. Inspect and confirm that the following conditions are present: a. System installation properly leveled and footpads firmly seated on floor. b. No noticeable vibrations in the dispensing system or adjacent machinery. c. No loose, damaged, or pinched cables. d. Scale Balance properly installed and leveled. e. Scale Cup Cover properly in place. f. Scale Pedestal not damaged and has no residual fluid build-up. g. Scale has a valid date on the calibration label. h.
6. In the FmNT Scale Setup Window, Scale Operations tab, observe the weight displayed next to Current Reading. 7. Remove the Scale Cup. 8. Did the weight displayed in the Scale Setup Window change? No Go to Step 13 Yes Go to Step 9 9. Click the Zero Scale button. 10. Did the reading change to and stabilize at 0.00? No Go to Step 11 Yes Stop here. Scale Operation is not root cause of the fault. 11. On the Setup Scale D104 tab, adjust the Filter and/or Stability settings.
16. Type [P] then press [Enter] and observe the digital readout. 17. Does the Scale return a numeric value? No Go to Scale Communications Verifications in this subsection. Yes Go to Step 18 18. Replace the Scale Cup and repeat Step 16. 19. Did the value change? No Scale (P/N 62-1614-00) has failed. See Parts Replacement section. (Balance and Control Modules must be a matched set by serial number.) Yes Contact Asymtek Technical Support 20.
Scale Power Verification 1. Open Lower Front Cabinet Door and open the Computer Door. 2. Locate LED D2 (+12 VDC) on the Main Interface PWA. 3. Is LED D2 illuminated? No Go to Step 4 Yes Go to Step 7 4. Exit FmNT, shut down Windows NT, press the black OFF (0) button on the Operator’s Console, switch Main Circuit Breaker to OFF (0) position, and disconnect Power Cable from the facility outlet. 5. Locate and inspect Fuse F2 on the Main Interface PWA. 6.
12. Check Scale Power Cable (P/N 06-4580-00) for continuity as specified in Table 8-42. Table 8-42 Scale Power Cable Pin Connections P1 Color P2 1 Red 1 2 Black 3 13. Does the Scale Power Cable have continuity? No Yes Scale Power Cable (P/N 06-4580-00) has failed. See Parts Replacement section. Main Interface PWA (P/N 60-1200-00) has failed. See Parts Replacement section.
Scale Communications Verification 1. Connect the Power Cable to facility outlet, switch Main Circuit Breaker to ON (I), and press the green ON (I) button on the Operator’s Console. (Do not enter FmNT). 2. In Windows NT, open HyperTerminal as follows: a. Click on Start > Programs > Accessories > HyperTerminal. b. Click on the HyperTerminal icon. c. In the Connection Description dialog box, enter a name. d. In the Connect To dialog box, select Using COM1. e.
10. Scroll down to [SCALE DI104] and confirm the following settings: • [SCALE DI104] • Name = DI104 • Port Type = Serial • Port Name = Com1 • Baud Rate = 9600 • Parity = None • Data Bits = 8 • Stop Bits = 1 • Event Char = None • Min Free Space = 0 • RTS-CTS = 0 • DTR = 0 11. Did the [SCALE DI104] file match the settings? No Go to Step 12 Yes Contact Asymtek Technical Support 12.
17. Click on the Settings tab and then select ASCII Setup. 18. Select the Echo typed characters locally checkbox. 19. Click OK and then OK again. 20. Type [P] then press [Enter] and observe if the Scale responds with a numeric value. 21. Did the Scale respond with a value? No Go to Step 22 Yes Computer (P/N 194751) has failed. See Parts Replacement section. 22. Close the HyperTerminal and exit Windows NT. 23.
9 Maintenance Overview Performing the recommended maintenance procedures at the intervals suggested in this section increases system life and ensures high quality dispensing performance for every production run.
Scheduled Maintenance WARNING! CAUTION! Any maintenance or servicing not included in this section must be performed by a trained service technician. Following a routine maintenance schedule can prevent part degradation and ensure high quality performance for every production run. There are several simple procedures you can perform on a regular basis to ensure quality dispensing and optimize system performance.
Table 9-1 Recommended Maintenance (continued) Maintenance Procedure Recommended Frequency Instructions Replace Purge Station boot. Every 2 weeks See “Replacing Consumables” in this section. Clean dispensing system chassis. Every 2 weeks Use isopropyl alcohol (IPA) and a clean, soft cloth to wipe down the top, sides and front of the dispensing system. Make sure that you remove all residual fluid and dirt. Clean Conveyor belts and rails. Every 2 weeks 1.
Record Keeping The type of maintenance performed (such as preventive and parts replacement) 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. This information can be used to coordinate PM activities with scheduled downtime.
5. If the cover is dirty with dispensed fluid, clean it with the MSDS recommended solvent and a soft cloth. 6. Obtain a new boot. See Table 9-2 for compatibility information. > If using a needle, the inside diameter of the purge boot should be compatible with the outside diameter of the needle. 7. Insert the new boot, narrow end first, into the top of the cover. 8. Push the boot downward through the hole in the cover until it starts to emerge from the bottom. 9.
To replace the Purge and Weigh Station cups: ? NOTE The Valve Offsets routine does not need to be performed after replacing the Purge Station and Weigh Station cups. 1. If a dispensing program is running, click on Pause in the FmNT Run Window. > The dispensing system will complete the current workpiece and then pause. 2. With no dispense program running, open the dispensing system Hatch. 3. Remove the Purge and Weigh Station covers. See Figure 9-2.
5 1 6 2 3 4 Item Description 1 Weigh Station Cover (P/N 194543) 2 Banjo Wiper (P/N 02-1570-03) 3 Weigh Station Cup (P/N 58-0030) 4 Scale Pedestal (P/N 194542) 5 Purge Station Cover (P/N 194701) 6 Purge Station Cup (P/N 58-0030) Figure 9-2 Replacing Purge and Weigh Station Cups Maintenance 9-7
Draining the Water Trap The facility air supply may contain moisture that can damage the dispensing system. The water trap condenses this moisture before it enters the dispenser pneumatic system. The operator or technician should drain the water trap weekly or whenever it is full. WARNING! Do not remove the bowl guard protecting the water trap.
1 4 2 3 Item Description 1 Regulator 2 Main Air Inlet 3 Drain Valve 4 Water Trap Bowl Guard (bowl inside) Figure 9-3 Emptying the Water Trap Maintenance 9-9
Tensioning the Positioner Cables Perform the following procedure at the interval specified in Table 9-1 to make sure that the Positioner Cables are at the proper tension. Tools and Materials Needed • Mechanical Cable Tensioning Tool (P/N 48-8002) To tension the Positioner Cables: CAUTION! Use only Asymtek tensioning tool (P/N 805478) for adjusting mechanical cable tension. Use of any other tool or a non-calibrated tool can result in inaccurate dispensing performance or damage to the dispensing system.
5. Repeat Step 4 for the X-axis and then the Y-idle Cable Tensioners. 6. From the mid-Y and mid-X position, manually move the Dispensing Head as follows for two complete cycles as follows: a. to the left rear corner of the dispensing area b. to the right rear corner c. to the right front corner d. to the left front corner 7. When the second cycle is complete, manually move the Dispensing Head to the mid-Y and mid-X position. 8. Repeat Steps 4 through 7. 9.
Lubricating the X-beam and Y-rail Linear Bearings Tools and Materials Needed • Soft, Lint-free Cloth • Grease Gun (P/N 09-2010-00) • Ammonia-based Cleaner • Linear Bearing Grease (NSK-PS2) (P/N 48-0024) • Safety Glasses • Rubber Gloves To lubricate the Linear Bearings: WARNING! Make sure that dispensing system is turned OFF before attempting this procedure or serious injury may occur. WARNING! Use Personal Protective Equipment when working with lubrication materials.
5. Locate the grease fitting on each of the four X-beam Linear Bearing Cars and four Y-rail Linear Bearing Cars. See Figure 9-6. 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. Perform a Post-Service Start-up as specified in the Safety section of this manual. 9. In FmNT, use the Position Controls to move the Dispensing Head back and forth in both the X-axis and the Y-axis. 10.
Lubricating the Positioner Cables Tools and Materials Needed • Safety Glasses • Grease, Lithium (Moly-Graph Grey) P/N 48-0006 • 4-mm Hex Key • Isopropyl Alcohol • Rubber Gloves • Soft, Lint-free Cloth To lubricate the cables: WARNING! ? NOTE TIP Verify that the Main Power Circuit Breaker is locked out and the facility air supply is disconnected from the Main Air Inlet before attempting this procedure or serious injury may occur.
7. 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. 8. Manually move the Dispensing Head to the rear middle of the dispensing area and repeat Steps 6 and 7. 9.
11. From the rear of the system, repeat Step 9 for 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. 12. Reinstall the Motor Access Panel and reconnect the electrical cables for the X and Y Servo Motors. 13. Reinstall the Motor Cover and two Rear Safety Covers. 14. Reinstall the dispensing system side panels.
10 Parts Replacement Overview This section includes general information for ordering recommended spares and replacement parts for Axiom X-1000 Series Dispensing Systems. Part numbers can be found on the exploded parts diagrams in Appendix C of this manual.
Shipping When ordering spare parts, specify which carrier you prefer to use. If no instructions are received, Asymtek will determine the best shipping method. Warranty Contact Asymtek Technical Support for any warranty issues pertaining to spare parts. 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).
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 ordered. 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.
Gaining Access to Dispensing System Components WARNING! Make sure that the dispensing system has been completely shut down before attempting to remove any panel, such as side panels, that can only be unfastened from inside the dispensing chamber. CAUTION! Remove doors, covers, and panels carefully to avoid damaging underlying components. In order to gain access to some areas of the dispensing system, it will be necessary to remove covers, doors, and access panels.
Replacing Fuses Use the following procedures to remove and replace a fuse if fault isolation procedures in the Troubleshooting section of this manual have confirmed that it must be replaced. CAUTION! Always replace fuses with fuses of identical rating and size. Failure to do so may not protect components from damage.
Board Mounted Fuses These glass fuses are mounted in holders on the Computer Main Interface PWA and on the Conveyor Controller Power Supply PWA. The fuses protect the components from damage caused by electrical overloads. See Figure 10-2. CAUTION! Always replace fuses with fuses of identical rating and size. Failure to do so may not protect components from damage. To remove and replace a board-mounted fuse: CAUTION! This procedure should only be performed by a trained service technician. 1.
1 5 2 3 4 Item Description 1 Conveyor/Heater Controller 2 Panel-Mounted Fuse 3 Fuse Cap 4 Glass Fuse 5 Board-Mounted Fuse (Conveyor Controller Power Supply shown) Figure 10-2 Board and Panel-Mounted Fuses Parts Replacement 10-7
Panel Mounted Fuses These glass fuses are located on the front panel of the Conveyor Controller. The fuses protect the Controller from damage caused by power surges from the Heater Tooling. See Figure 10-2. CAUTION! Always replace fuses with fuses of identical rating and size. Failure to do so may not protect components from damage. To remove and replace panel mounted fuses: CAUTION! This procedure should only be performed by a trained service technician. 1.
Box Mounted Fuses There is a glass box-mounted fuse in a drawer located on the Servo Shelf Transformer Power Inlet as shown in Figure 10-3. The fuse protects the Servo Supply Transformer and Servo Shelf electrical components from damage caused by power surges. A spare fuse is also in the drawer. CAUTION! Always replace fuses with fuses of identical rating and size. Failure to do so may not protect components from damage.
1 4 3 2 ` Item Description 1 Spare Fuse 2 Fuse Box 3 Active Fuse 4 Servo Supply Transformer Power Inlet Figure 10-3 Box-Mounted Fuse Replacement 10-10 Parts Replacement
Replacing Pneumatic Solenoid Valves The Pneumatic Valve Manifold controls airflow to pneumatic components in the Conveyor area such as the Stop Pins, Lift Tables/Clamp Bars, and Vacuum Generators. This manifold can consist of up to eight Pneumatic Solenoid Valves (PSVs) depending on your system’s configuration. Use the following procedures to remove and replace Solenoid Valve modules if fault isolation procedures in the Troubleshooting section of this manual have confirmed that they are faulty.
1 3 2 Item Description 1 Solenoid Valve Access Hatch 2 Hatch Cover Screws 3 Access Hatch Cover Figure 10-4 Removing/Installing the Solenoid Valve Access Hatch Cover To install a Pneumatic Solenoid Valve: CAUTION! ? NOTE This procedure should only be performed by a trained service technician. Apply removable thread locker to all threaded fasteners unless otherwise noted. 1. Locate the replacement PSV. 2. Verify that all sealing surfaces of the Valve Manifold are clean.
5. Tighten the clamp screw. > Do not use removable thread locker. 6. Reinstall the Access Hatch Cover on the back of the dispensing system. 7. Perform a Post-Service Start-up as specified in the Safety section of this manual.
Replacing 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 o-rings 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.
1 5 2 4 3 Item Description 1 O-ring Conveyor Belt (P/N 01-0306-00) 2 Rear Conveyor Rail 3 Belt Drive Pulley 4 Pulley Tire 5 Stop Pin Figure 10-6 Conveyor Belt Removal/Installation Parts Replacement 10-15
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 10-6.
Replacing the Scale If it is determined by the fault isolation procedures in the Troubleshooting section of this manual that the Scale must be replaced, this procedure will provide the steps necessary to remove the faulty unit and install a new one. CAUTION! This procedure should only be performed by a trained service technician. The Scale is a precision instrument with delicate components. Handle the Scale components with care or they may be damaged.
d. Carefully remove the Scale Control Module from the Rear Cabinet. ? NOTE Return the Scale Control Module to Asymtek even if it is not a failed unit. Refer to “Return Material Authorization” in this section for merchandise return instructions. 1 2 6 3 5 4 Item Description 1 Mounting Screws 2 Interconnect Cable 3 Communication Cable 4 Power Cable 5 Scale Control Module 6 Floor of Rear Cabinet Figure 10-7 Removing/Installing the Scale Control Module 5.
2 1 3 Item Description 1 Dispensing Area Front Cover 2 Quick-release Fastener (1 of 6) 3 Mounting Brackets Figure 10-8 Removing/Installing the Dispensing Area Front Cover 6. Turn each of the six Phillips head fasteners on the Dispensing Area Front Cover 1/4-turn to release the Cover from the mounting brackets (see Figure 10-8). Remove the Cover from the dispensing chamber. 7. Disassemble the Dispensing Calibration Module as follows (see Figure 10-9): a. Remove the Weigh Station Cover. b.
1 2 3 10 4 5 6 7 9 8 Item Description Item Description 1 Weigh Station Cover 6 Dispensing Calibration Module (DCM) 2 Plastic Cup 7 DCM Mounting Bracket 3 Scale Pedestal 8 Scale Base Plate 4 Breeze Shield 9 Balance Module 5 Purge Station Vacuum Fitting 10 Weigh Station Figure 10-9 Removing/Installing the Dispensing Calibration Module 10-20 Parts Replacement
8. Remove the Heater Tooling Plate as follows (see Figure 10-10): WARNING! Heater Tooling Plates present a thermal hazard until they cool. Use thermal protection or allow Heaters to cool before performing this procedure or serious burn injury may occur. a. Disconnect the Heater Power Cable. b. Disconnect the white (vacuum) or blue (impingement) Air Hose, as applicable. c. Lift the Heater Tooling Plate off of the Lift Table.
9. Remove the Lift Table from the Conveyor Base Plate as follows (see Figure 10-11): a. Disconnect the Pneumatics Air Hose. b. Lift the Lift Table straight up out of the Linear Bearing and off of the Lift Module Guide Rod.
10. Remove the Balance Module from the dispensing chamber as follows (see Figure 10-12): a. Remove four 4-mm socket head cap screws attaching the Balance Module to the Conveyor Base Plate. b. Disconnect the Balance Module Cable from the Scale Interconnect Cable. c. Carefully slide the Balance Module towards the back of the dispensing chamber, lift it around the front Conveyor Rail, and remove it from the dispensing chamber. ? NOTE The faulty Balance Module should be returned to Asymtek.
To install the Scale: ? NOTE Apply removable thread locker to all threaded fasteners unless otherwise noted. 1. Open the package containing the new Scale (P/N 392364) and verify that the serial numbers on the Scale Control Module and the Balance Module are identical. Enter the serial numbers in the maintenance/service records. ? NOTE Contact Asymtek Technical Support if serial numbers are not identical. 2. Install the Balance Module on the Conveyor Base Plate as follows: a.
c. Place the Breeze Shield into the Weigh Station hole in the DCM so it rests on the Top Plate of the Balance Module. d. Carefully install the Scale Pedestal by placing it straight down inside the Breeze Shield. CAUTION! Avoid putting pressure on the Scale Pedestal or damage to the sensitive weighing mechanism will occur. e. Install a clean plastic cup on the Scale Pedestal inside the Breeze Shield. f. Install the Weigh Station Cover. 7.
Replacing the Dispensing Head Use the following procedure to remove and replace the Dispensing Head Assembly if fault isolation procedures in the Troubleshooting section of this manual have confirmed that it is faulty. CAUTION! This procedure should only be performed by a trained service technician.
1 11 2 10 3 9 4 8 5 7 6 Item Description 1 Dispense Head Controller 2 Fluid Pressure Pneumatic Hose 3 Valve 1 Power Cable 4 Height Sensor Power Cable 5 Valve 1 Electrical/Pneumatic Bulkhead 6 Camera Horizontal Bracket Screws 7 Height Sensor 8 Dispensing Valve (DV-7000 shown) 9 Camera 10 Camera Coaxial Cable 11 Vertical Camera Bracket Screws Figure 10-13 Dispensing Head Front View Parts Replacement 10-27
4. If the dispensing system has a Dual-Action Dispensing Head, disconnect the following, if present, on the Valve 2 Electrical and Pneumatic Bulkheads (see Figure 10-14): a. Clear pneumatic hose from the FLUID PRESSURE #2 fitting. b. Black and blue pneumatic hoses from the pneumatic fittings labeled VALVE #2. c. Black and blue pneumatic hoses from the pneumatic fittings labeled TOGGLE. d. Power cable from the connector labeled VALVE #2. e. Power cable from the connector labeled LOW FLUID #2. 5.
9. Remove the two Phillips head screws attaching the Valve 2 Pneumatic Bulkhead to the Counterbalance Cover. See Figure 10-14. Allow the Bulkhead to hang by its attached pneumatic lines.
10. Remove the 3-mm socket head cap screws attaching the following components (as applicable) to the Z-Carriage Plate. See Figure 10-15. • Single Dispensing Valve Mounting Bracket (Valve 1 Bracket and attached Height Sensor Bracket) • Dual Valve Bracket (Valve 1 and Valve 2 Mounting Brackets, Height Sensor Bracket, and Toggle Bracket are mounted on this bracket) TIP To facilitate reinstallation of the components, make note of the location of the mounting holes used on the Z-Carriage Plate. 11.
12. Remove the two 4-mm socket head cap screws and washers attaching the back of the Dispensing Head to the X-Pulley Bracket. See Figure 10-16. 13. Push the Z-Carriage Plate downward and remove the two 4-mm socket head cap screws attaching the front of the Dispensing Head to the X-Pulley Bracket. See Figure 10-15.
To install the Dispensing Head Assembly: ? NOTE Apply removable thread locker to all threaded fasteners unless otherwise noted. 1. Carefully lift the new Dispensing Head assembly into position aligning the holes behind the Z-Carriage Plate with the holes in the X-Pulley Bracket. 2. While holding the Dispensing Head in position, install the two 4-mm socket head cap screws attaching the front of the Dispensing Head to the X-Pulley Bracket. See Figure 10-15. Torque the screws to 50 in-lbs (0.576 kg-m). 3.
11. Connect the following, if present, on the Valve 1 Electrical/Pneumatic Bulkhead (see Figure 10-13): a. Clear pneumatic hose to the pneumatic fitting labeled FLUID PRESSURE. b. Black and blue Valve 1 pneumatic hoses to the matching color pneumatic fittings labeled VALVE 1. c. Valve 1 power cable to the connector labeled VALVE NUMBER 1. d. Height Sensor power cable to the connector labeled HEIGHT SENSOR. e. Low Fluid Sensor power cable to the connector labeled LOW FLUID SENSOR. f.
15. Perform component functional tests as specified in Table 10-3. > If any component fails the functional test, check all connections and retest. If the component still fails, perform fault isolation in accordance with the Troubleshooting section of this manual. Table 10-3 Dispensing Head Functional Test Procedures Component Test Procedure Height Sensor Refer to Power-up and Testing section of this manual. Vision System Refer to Power-up and Testing section of this manual.
Computer Removal and Installation It may be necessary to remove the Computer from its location in the Lower Front Cabinet if fault isolation procedures in the Troubleshooting section of this manual have confirmed that there is a faulty card or other problem inside the Computer. CAUTION! This procedure should only be performed by a trained service technician.
To install the Computer: ? NOTE Apply removable thread locker to all threaded fasteners unless otherwise noted. 1. Lift the Computer, place it in the Lower Front Cabinet, and align the three holes in the Computer Mount with the corresponding holes in the floor of the Cabinet. WARNING! The Computer is heavy. Use caution while lifting the Computer out of the Lower Front Cabinet or back injury may occur. Refer to the Safety section of this manual for lifting precautions. 2.
1 2 3 4 Item Description 1 Captive Slotted Thumbscrews 2 Main Interface Panel 3 Computer Mount Screw (3 total) 4 Computer Mounting Bracket Figure 10-17 Computer Removal/Installation Parts Replacement 10-37
Replacing Computer Cards If fault isolation procedures in the Troubleshooting section of this manual have confirmed that there is a faulty Card in the Computer, replace it using one of the following procedures, as applicable: • PMAC Card • Image Capture Card or Video Card CAUTION! This procedure should only be performed by a trained service technician.
6. Disconnect the cables: a. From the rear of the PMAC Card. b. From J2 and J4 on the PMAC Daughter Card. c. From J2, J5, and J7 on the PMAC Card. 7. Remove the small Phillips head screw from the PMAC Card Hold-down Clip. 8. Gently pull up on the PMAC Card and remove it from the slot. ? NOTE The faulty PMAC Card should be returned to Asymtek. Refer to “Return Material Authorization” in this section for merchandise return instructions.
To install the PMAC Card: CAUTION! ? NOTE ESD precautions must be taken while handling the PMAC Card or severe damage from electrostatic discharge may occur. Apply removable thread locker to all threaded fasteners unless otherwise noted. 1. Remove the new Main Interface PWA from its ESD protective bag. 2. Visually verify the jumper settings for the new PMAC Card as shown in Figure 10-19.
3. Align the new PMAC Card with the connections in Slot Number See Figure 10-18. 4. Gently press down on the card until it is completely seated in the slot. > The shoulder on the bottom surface of the card will be flush with the top edge of the slot. 5. Connect the ribbon cables in the following order: a. To the rear of the PMAC Card. b. To J2 and J4 on the PMAC daughter card. c. To J2, J5, and J7 on the PMAC Card. 6.
Image Capture Card or Video Card Use the following procedure to remove and replace the Image Capture Card or the Video Card if fault isolation procedures in the Troubleshooting section of this manual have confirmed failure. To remove the Image Capture Card or the Video Card: CAUTION! ? NOTE ESD precautions must be taken while handling the PWAs or severe damage from electrostatic discharge may occur.
To install the Image Capture Card or the Video Card: CAUTION! ? NOTE 1. ESD precautions must be taken while handling the Card or severe damage from electrostatic discharge may occur. Apply removable thread locker to all threaded fasteners unless otherwise noted. Remove the new card from its ESD protective bag. 2. Align the new card to the connections in the appropriate slot. 3. Gently press down on the card until it is completely seated in the slot.
Replacing the Main Interface PWA Use the following procedure to remove and replace the Main Interface PWA if fault isolation procedures in the Troubleshooting section of this manual have confirmed that it has failed. CAUTION! ESD precautions must be taken while working on the Main Interface PWA or severe damage from electrostatic discharge may occur.
1 3 2 Item Description 1 Main Interface Panel 2 Hex Post (16 total as circled) 3 D-sub Connector (8 total) Figure 10-20 Hex Post Removal/Installation Parts Replacement 10-45
To install the Main Interface PWA: CAUTION! ? NOTE ESD precautions must be taken while handling the Main Interface PWA or severe damage from electrostatic discharge may occur. Apply removable thread locker to all threaded fasteners unless otherwise noted. 1. Remove the new Main Interface PWA from its ESD protective bag. 2. Align the screw holes of the new Main Interface PWA to the screw posts on the cover. 3.
1 4 2 3 Item Description 1 Computer Door 2 Hold-down Screw (3 total) 3 Main Interface PWA 4 Ribbon Cable Figure 10-21 Removing/Installing the Main Interface PWA Parts Replacement 10-47
Replacing the XY Servo Interface PWA CAUTION! This procedure should only be performed by a trained service technician. Tools and Materials Needed • 3-mm Hex Key • 1.
6. Remove the nine 3-mm socket head cap screws holding the XY Servo Interface PWA in place. TIP Note the orientation of the XY Servo Interface PWA to make reinstallation easier. 7. Remove the XY Servo Interface PWA from the Servo Shelf. ? NOTE The faulty XY Servo Interface PWA should be returned to Asymtek. Refer to “Return Material Authorization” in this section for merchandise return instructions.
8 7 9 1 2 6 3 5 4 Item Description Item Description 1 Grommet on Light Beacon Mast 6 XY Servo Interface PWA 2 Transformer 7 Capacitor 3 Amplifier Hold-down Screw 8 Interface PWA Hold-down Screw 4 X Servo Amplifier 9 Power Indicator LEDs 5 Y Servo Amplifier Figure 10-23 Removing/Installing Servo Shelf PWAs 10-50 Parts Replacement
To install the XY Servo Interface PWA: CAUTION! ? NOTE ESD precautions must be taken while handling the XY Servo Interface PWA or severe damage from electrostatic discharge may occur. Apply removable thread locker to all threaded fasteners unless otherwise noted. 1. Remove the new XY Servo Interface PWA from its ESD protective bag. 2. Use a 1.0 k-ohm bleeder resistor to discharge each Capacitor. Touch the positive and negative terminals on each Capacitor for at least 10 seconds.
Replacing Servo Amplifiers CAUTION! This procedure should only be performed by a trained service technician. Tools and Materials Needed • 3-mm Hex Key • Small A-frame Ladder • ESD Grounding Strap • Removable Thread Locker (P/N 40-0019) • Torque Wrench To remove a Servo Amplifier: ? NOTE 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.
8. Remove the Servo Amplifier. ? NOTE The faulty Servo Amplifier should be returned to Asymtek. Refer to “Return Material Authorization” in this section for merchandise return instructions. To install a Servo Amplifier: CAUTION! ? NOTE ESD precautions must be taken while handling the Servo Amplifier or severe damage from electrostatic discharge may occur. Apply removable thread locker to all threaded fasteners unless otherwise noted. 1. Remove the new Servo Amplifier from its ESD protective bag.
Appendix A Block Diagrams Overview This appendix contains electrical and pneumatic block diagrams that describe the major electrical and pneumatic systems. These diagrams may help in understanding dispensing system operation and aid in troubleshooting. The diagrams included in this appendix are described in Table A-1 and Table A-2.
BLOCK DIAGRAM, X-1010 PLATFORM
Z-HEAD
CONVEYOR
Appendix B Electrical Schematic Diagrams Overview This appendix contains electrical schematic diagrams that will aid in troubleshooting the dispensing system. The schematic diagrams included in this appendix are described in Table 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 instructions specified in the Safety section and other sections of this manual.
+24V EMO CIRCUIT, X-1000 FRONT EMO REAR EMO LATCHING, DP, NC (x2) VENT AIR SWITCHES SPST-NC (x2) 0 OFF BUTTON MOMENTARY, DP, NC +24V_STOP_A I ON BUTTON +24V_START_A MOMENTARY, DP, NO RETURN 2 4 6 SELF-LATCHING RELAYS 1 3 K3 5 1 3 5 K2 RTE44024S +24V_STOP_B 2 4 RTE44024S 6 +24V_START_B RETURN (AC FROM WALL) A1 A1 5L3 3L2 5L3 3L2 6T3 4T2 6T3 4T2 AC RELAYS A2 RETURN A2 RETURN (AC TO MACHINE) B–2 Appendix B
MACHINE INTERCONNECT
PMAC INTERCONNECT
CONVEYOR INTERCONNECT / DAC SIGNAL GENERATION
MAIN INDEX JUMPERS POWER CONSUMPTION TABLE POWER TABLE R6 TABLE OF CONTENTS R7 NET INDEX TABLE SPARES BOARD REVISION ID CIRCUIT
POWER MANAGEMENT POWER STATUS LEDS DC POWER IN
MPC 555 AND RELATED BUS ARCHITECTURE
FLASH MEMORY AND SRAM EXTERNAL MEMORY ISP CABLE AC CONVEYOR DRIVE CIRCUIT AC MOTORS
CAN BUS AND RS232 COMMUNICATION SUGGESTED NOTE: CAN BUS CAN-1 CAN-2 RS232 RS-232 PORT
SMEMA UPSTREAM MACHINE DOWNSTREAM MACHINE SMEMA UPSTREAM SMEMA DOWNSTREAM
CONVEYOR SIGNALS - INPUTS - SOLENOID VALVE OUTPUTS EXTERNAL I/O CONVEYOR INTERFACE CONVEYOR SIGNALS
STEPPER CONVEYOR DRIVE CIRCUIT NOTE: SILKSCREEN ON 194029 IS BACKWARDS FOR ALL 1N5822 FAN STEPPER MOTORS
RTD SIGNAL CONDITIONER, CH1, CH2 CHANNEL 1 TEMP. FEEDBACK CHANNEL 2 TEMP.
RTD SIGNAL CONDITIONER CH3-4, CH5-8 DAUGHTER BOARD CONNECTION CHANNEL 3 TEMP. FEEDBACK TEMPERATURE SIGNAL CONDITIONER CARD . (IT MAY BE AN RTD PWA OR A TC PWA.) HEAT MONITOR DAUGHTER CARD CHANNEL 4 TEMP.
TC SIGNAL CONDITIONER CH1, HEATER RELAY OUTPUTS HEATER RELAY SIGNALS
TC SIGNAL CONDITIONER CH2-4
DIAGNOSTIC CONNECTORS, (MICTOR & BDM CONNECTORS) LA1 LA3 LA5 BDM PORT LA2 LA4 LA6
Appendix C Exploded View Drawings Overview This appendix contains exploded view drawings that will aid in ordering replacement parts for the Axiom X-1000 Series Dispensing System. The drawing included in this appendix is described in. 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 instructions specified in the Safety section and other sections of this manual.
7200243 FRU, AXIOM Z MOTOR/SLIDE, MCG 59 7200259 ASSY, CONV CONT ASPA, TC, RTD 49 7203899 FOOT, LEVELING, X1K 58 62-1665-01 ASSEMBLY, Z HEAD 48 7201081 SPARE KIT, X/Y SERVO MOTOR, X1K 57 210660 30A POWER MANAGER 47 7202537 SPARE, TACTILE SENSOR 56 62-1617-00 ASSY, NEEDLE SENSOR 46 7201540 REGULATOR, PREC, 0-60, 10-32 55 195545 ASSY, SCALE, X-1K, OEM-104P 45 194400 ASSY, REGULATOR & FLOW METERS 54 196652 ASSY, STOP PIN 44 7202660 CABLE, ADAPTER VIDEO/POWER 53 62-0181-00
2X 55 27 54 55 49 NOTE: LOWER DOOR NOT SHOWN. 7201540 194400 7200259 7201544 PART NO. REGULATOR, PREC,0-60,10-32 55 ASSY, REGULATOR/FLOW METERS 54 ASSY,CONV CONT,ASPA,TC,RTD 49 REGULATOR, PRESSURE SMC 27 DESCRIPTION ITEM 198435 REV.
5 12 10 NOTE: ITEM 12 SHOWN FROM BACK 1 13 NOTE: SHOWN EXPLODED ON THE NEXT PAGE. 194748 194712 194459 194035 193328 PART NO. KEYBOARD,DESK TOP,PS/2 CON 13 DISPLAY,FLT PAN,12.1" 12 MOUSE,MICROSOFT BASIC 10 ASSY BEACON 5 CABLE,MONITOR POWER 1 DESCRIPTION ITEM 198435 REV.
2 37 NOTE: COMPUTER SHOWN FROM BACK. 32 52 3 40 7201066 60-1200-00 7201722 59-0018 194013 193952 PART NO. ASSY, ROCKY MTHRBRD, 3702 R6 52 PWA,MAIN INTERFACE 40 PWA, PIO-96 LOW PROFILE 37 CARD,ITI PC VISION FRM. GRAB 32 ASSY,CNFGRD. PMAC & DPRAM 3 ADAPTER,PRINTER TO CAN,PS/2 2 DESCRIPTION ITEM 198435 REV.
31 3X 20 26 (31) 3X 7202538 LOW PROFILE BRD SENSOR, X1K 31 07-0716-00 STEP MOTOR,111IN-OZ,1.8 DEG 26 01-0306-00 BELT, CONVEYOR, LEAD FRAME 20 PART NO. DESCRIPTION ITEM 198435 REV.
50 51 3X 11 30 56 3X 44 19 39 46 26 7202537 SPARE, TACTILE SENSOR 56 194165 CABLE, T/C HEATER ADAPTER 51 03-1727-00 NEEDLE SENSOR PLUNGER 50 62-1617-00 ASSY,NEEDLE SENSOR 46 196652 ASSY, STOP PIN 44 60-0785-00 PCA, HOME/LIMIT SWITCH 39 42-1001 O-RING, 1 7/8 OD X 1/16 30 07-0716-00 STEP MOTOR, 111 IN-OZ, 1.8 DEG 26 392234 GENERATOR,VACUUM,PIAB M10 19 194701 COVER, PURGE CUP, CLEAR 11 PART NO. DESCRIPTION ITEM 198435 REV.
16 17 34 4 59-1250 197397 197396 194026 PART NO. 3X GENERATOR, VACUUM VALVE RPLC. 2X3 WAY VQ VALVE RPLC. 4WY, VQ MNFLD. ASSEMBLY,LIFT TABLE DESCRIPTION 34 17 16 4 ITEM 198435 REV.
42 45 195545 60-1265-00 PART NO. OMS, SCALE, X-1K, OEM-104P 45 PWA,CONVEYOR INTERCNNCT. 42 DESCRIPTION ITEM 198435 REV.
35 33 18 NOTE: HATCH & TOP REMOVED FOR CLARITY. 59-3001 #LIGHT, FLUORESCENT, 12VDC 59-1235 FLUORESCENT LIGHT BULB 392141 ASSY, NEEDLE HEATER PART NO. DESCRIPTION 35 33 18 ITEM 198435 REV.
22 14 15 21 NOTE: HATCH NOT SHOWN. 02-2303-00 02-2302-00 194986 194985 PART NO. FLAG, Y HOME, X-1000 FLAG, X HOME, X-1000 "Y" ENCODER "X" ENCODER DESCRIPTION 22 21 15 14 ITEM 198435 REV.
59 ( 48 ) 48 23 53 25 7 24 36 38 NOTE: SHOWN FROM THE BACK. 8 9 7200243 7202660 62-1665-01 198143 59-6030 06-4550-00 06-4547-00 7202659 194162 194154 194148 PART NO. FRU, AXIOM Z MTR/SLIDE, MCG CABLE, ADAPTER VID/PWR, CPC ASSEMBLY,Z HEAD BEAMSPLITTER, NER DOAL CAMERA,SENTECH STC-400 CABLE,Z SERVO SIGNALS CABLE,Z POSITIONER DC PWR. CABLE,CAMERA VID/PWR, CPC LIGHT,NER RED/BLUE,SINK DRIVE CABLE-R,555 INTERCONNECT CABLE,'CAN'EXTENDER,16' DESCRIPTION 59 53 48 38 36 25 24 23 9 8 7 ITEM 198435 REV.
57 29 47 4X 58 7203899 7201081 210660 40-2633 PART NO. FOOT, LEVELING, X1K 58 SPARE KIT,X/Y SERVO MOTOR,X1K 57 ASSY, 30A POWER MANAGER 47 FILTER REGULATOR, M-2000 29 DESCRIPTION ITEM 198435 REV.
28 43 6 NOTE: REAR COVER REMOVER FOR CLARITY. 2X 41 62-0181-00 ASSY,THREE WAY VALVE CONV.4 60-1212-00 PWA, SERVO AMPLIFIER 40-2508 SWITCH, LOW AIR 194036 ASSY, XY SERVO PWA PART NO. DESCRIPTION 43 41 28 6 ITEM 198435 REV.
Appendix D Material Safety Information Overview 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! 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.
MSDS - MULTEMP PS NO 2-A 07-350 (Continued) SECTION III - Physical/Chemical Characteristics Appearance/Odor Boiling Point Melting Point Vapor Pressure Specific Gravity Solubility in Water Container Type Container Pressure Code Temperature Code Product State Code WHITE PASTE; SLIGHT ODOR NA 190 C NA 0.
MSDS - MULTEMP PS NO 2-A 07-350 (Continued) SECTION VII - Precautions for Safe Handling and Use Steps if Material Released/Spilled Waste Disposal Method Handling and Storage Precautions Other Precautions TRANSFER BULK OF MIXTURE INTO ANOTHER CONTAINER. ABSORB RESIDUE W/ AN INERT MATERIAL SUCH AS EARTH, SAND, & 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. W/ APPLICABLE REGS.
MSDS Moly-Graph® Extreme Pressure Multi-Purpose Grease Section 1: Product & Company Identification Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number(s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Manufactured By: CRC Industries, Inc.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Section 3: Composition/Information on Ingredients COMPONENT CAS NUMBER % BY Wt. Hydrotreated heavy naphthenic distillates 64742-52-5 70 - 90 Lithium 12-hydroxystearate 7620-77-1 5 - 10 Zinc, dithiophosphate di-C1-14-alkyl esters 68649-42-3 0.5 - 1.5 Molybdenum sulfide 1317-33-5 0.2 - 1 Graphite 7782-42-5 0.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Section 6: Accidental Release Measures Personal Precautions: Use personal protection recommended in Section 8. Minimize skin contact. Environmental Precautions: Take precautions to prevent contamination of ground and surface waters. Do not flush into sewers or storm drains. Advise authorities if product has entered waterways.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Section 9: Physical and Chemical Properties Physical State: Color: Odor Specific Gravity: Initial Boiling Point: Freezing Point: Vapor Pressure: Vapor Density: Evaporation Rate: Solubility: pH: Volatile Organic Compounds: semi-solid grease grey mild petroleum 0.90 @ 60 F ND ND < 0.1 mmHG @ 68F >5 (air = 1) < 0.01 (butyl acetate = 1) Insoluble in water NA Wt %: 0.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Section 12: Ecological Information Ecological studies have not been conducted for this product. The following information is available for components of this product.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 State Regulations California Safe Drinking Water and Toxic Enforcement Act (Prop 65): This product may contain the following chemicals known to the state of California to cause cancer, birth defects or other reproductive harm: None State Right to Know: New Jersey: Pennsylvania: Massachusetts: Rhode Island: 1317-33-5 7782-42-5 1317-33-5, 7782-5 7782-42-5 Additional R
Appendix E Installation Checklist Overview This appendix contains the Installation Checklist used by service technicians while installing and functionally testing Axiom X-1000 Series Dispensing Systems. X-1000 Installation Checklist Instructions 1. The Installation Checklist should be completed in ink by a trained service technician. 2. The checkout must be completed in the order specified on the Checklist. The current checkout step must be completed before proceeding to the next step. 3.
X-1000 Installation Checklist Basic Information Customer: _________________________________________________________________________ System Model Number:_______________________________________________________________ System Serial Number: ______________________________________________________________ Software Version Installed: ___________________________________________________________ System Installed By: _________________________________________________________________ Dispensing Options: Low Fluid Sensor
X-1000 Installation Checklist Notes: ______________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ __________________
X-1000 Installation Checklist A. Initial Power-Up and EMO Step # Done (9) Test Performed Main Function(s) Tested 1. Test the Power Manager trip switch at the rear of the machine and reload the Circuit Breakers. Main Power Circuit Breakers 2. Test the machine ON/OFF switch. Machine power up/down circuitry. 3. Verify the proper LEDs are lit on the Main Interface PWA and Servo Interface PWA in the following conditions.
X-1000 Installation Checklist C. Step # Dispenser Set-Up and Mechanics Done (9) Test Performed When prompted by FMNT, select OK to send the dispenser to Home. 10. Check that the dispenser correctly finds home in X, Y, and Z-axes. Main Function(s) Tested PMAC, Servo interconnect X, Y, Z axis, Servo system 11. Ensure that the cables are set to the correct tensions. Cable tension 12.
X-1000 Installation Checklist Step # Done (9) Test Performed Main Function(s) Tested 20. Verify that the beacon can be controlled via the I/O screen and that the red, blue, yellow and green flash controls work. Beacon and beacon control 21. Verify that the beacon alarm sounds when toggled in I/O screen Beacon alarm functionality 22. Command the machine to find home and Interlock, beacon and beacon open the hood while the machine is in motion.
X-1000 Installation Checklist F. Step # Valve Operation Done (9) Test Performed Main Function(s) Tested 29. Ensure that no Valves are plugged into the system. Verify that the Valve control LEDS (A0-A3) on the side of the Z-head are all lit. Valve ID circuitry and 555 control 30. From the FMNT->TOOLS->IO TEST-> Bit operation and pneumatics routing Select V1_Valve Verify that the pressure switches from the black to the blue line on the Valve 1 ports.
X-1000 Installation Checklist Step # 35. Done (9) Test Performed Valve 1 DP-3000 Logic Test Verify that the DP-3000 resets, Refill, primes and refills properly from the Valve 1 position. The Valve state LEDs (no's A0-A3 on Z-head) LEDs should end up as below. Main Function(s) Tested Valve 1 control circuitry and 555 control DP-3000 operation, stopcock pneumatics After reset, refill - A3 m After prime - A1 m The Valve LEDs should end up as follows.
X-1000 Installation Checklist G. Step # Conveyor and Conveyor Pneumatics Done (9) Test Performed 38. Main Function(s) Tested Rail leveling Conveyor Mechanics Make sure that both Conveyor rails are leveled with each other within +/-5 mils. This can be done using the HS probe trigger point turning green, while verifying Z coordinate in FMNT. 39. LR= MR= RR= LF= MF= RF= Verify Conveyor rails are parallel to within ±4 mils. LR= RR= LF= RF= 40.
X-1000 Installation Checklist Step # 48. Done (9) Test Performed Conveyor Sensors Preheat station sensor toggles to “1” when a Customer board/boat is slid under the sensor. Main Function(s) Tested FMNT, CAN control, and the Sensor itself. Dispense station sensor toggles to “1” when a Customer board/boat is slid under the sensor. Post heat station sensor toggles to “1” when a Customer board/boat is slid under the sensor. 49. 50. Verify Board Sensors do not interfere with HS-RT probe during dispense.
X-1000 Installation Checklist Step # 56. Done (9) Test Performed Tooling Heaters Main Function(s) Tested FMNT-CAN Verify that the Conveyor heater terminal window comes up without any errors 57. Verify that the heaters ramp up to temperature (50 °C) within 5 minutes. Temp control, wiring Using an external heater probe: Verify that the heaters are heating to the set point temperature. Change set point to 140 °C and verify that they reach this temp within another 10 minutes.
X-1000 Installation Checklist H. Step # 60. Dispensing Options Done (9) Test Performed Needle heaters Verify proper operation of all needle heaters and both needle heater channels (needle heater 1 and 2) 61. Main Function(s) Tested DHC heat control, Needle heaters Scale installation, assembly Scale Ensure that the Scale is leveled by checking to see that the leveling bubble is within the circle 62.
X-1000 Installation Checklist I. Complete System Checks Step # Done (9) Test Performed Main Function(s) Tested 72. Perform Valve Offsets routine. All 73. Perform Camera assisted Valve Offsets. All 74. Perform a regular production run with the Conveyors using the TS-04 Box. All Repeat 20 times. 75. Verify that the carrier does not slam into the Stop Pins. Production mode Conveyor check 76. Check that the carrier reaches the Stop Pin. Production mode Conveyor check 77.
X-1000 Installation Checklist J.
Glossary AC: Alternating Current. Amperes Interrupting Capacity (AIC): Also known as “breaking capacity” or “short circuit rating”. It is the maximum current that an Overcurrent Protection Device can safely interrupt at rated voltage. Area-Fill: Dispensing lines of fluid within a geometric pattern to completely cover an area. ASPA System: Advanced Semiconductor Package Assembly fluid dispensing system. Auer Boat: A carrier used to transport multiple workpieces through the dispensing system.
Emergency Shutdown: The dispensing system is intentionally stopped to prevent injury to personnel or damage to equipment. Shutdown is accomplished by pushing the EMO button or switching off the Main Circuit Breaker. Gauge: An analog or digital device used to measure internal pressure of fluid or air in a closed system. End of Shift: When the Operator ends dispensing for the day and turns off the dispensing system.
Needle Heater: Heats dispensing needle to aid in fluid flow. Installed on some Dispensing Valves. Consists of a RTD sensor and a heater element attachment. Controlled by Dispense Head Controller. Needle Sensor: A sensor located on the Axiom X-1020 Dispensing Calibration Module that uses light beams to determine the XY location of the dispensing needle tip. Needle Sensor Substrate: A ceramic pad near the Needle Sensor that is dispensed upon during needle location definition routines.
SMEMA: Surface Mount Equipment Manufacturers Association. Established protocol for signal communication between two or more different systems. SMA: Surface Mount Adhesive. An adhesive used for attaching chips to PWBs. SVGA: Super Video Graphics Array. A video card that produces high-quality color images at high resolution. Syringe: A reservoir containing the dispensing fluid that is usually attached to the Dispensing Valve.
Index -Aaccess panel locations, 10-4 adjustment Dispensing Calibration Module height, 6-11 Dispensing Head counterbalance, 6-32 Impingement Heater airflow, 6-23 Lift Table/Clamp Bar airflow, 6-20–6-22 Linear Encoder gap, 6-24–6-26 -BBoard Sensor adjustment, 6-14–6-19 downward-facing, 6-17 functional testing, 5-30 troubleshooting, 8-103 upward-facing, 6-14 -CCamera calibration, 6-4 focusing, 6-2 lighting height adjustment, 5-43 Checklist, installation, 1 Clamp Bar airflow adjustment, 6-21 operational proce
-Ffacility requirements, 1-2 fuse replacement board-mounted, 10-6 box-mounted, 10-9 panel-mounted, 10-8 replaceable fuse list, 10-5 Linear Encoder description, 7-7 gap adjustment, 6-24–6-26 mechanical verification, 8-64 X-axis, troubleshooting, 8-65 Y-axis, troubleshooting, 8-68 Low Pressure Sensor, 7-6 lubrication Positioner Cables, 9-14 Positioner Linear Bearings, 9-12 -HHall Sensor, 7-7 Heater Tooling calibration, 6-26–6-29 EMO test, 5-41 impingement airflow adjustment, 6-23 troubleshooting, 8-108 vacu
Pneumatic Solenoid Valve Dual Action, 7-6, 7-12 Main Air, 7-6, 7-13 replacement, 10-11 Stop Pin, 7-13 Pneumatic System Conveyor device operational process, 7-27 description, 7-11 Dispensing Valve pneumatics test, 5-22 Positioner Cable lubrication, 9-14 Cable tension check, 5-4 Cable tensioning, 9-10 Linear Bearing lubrication, 9-12 Power Manager, 7-9 pre-power-up checkouts Cable tension, 5-4 Dispensing Head clearance, 5-6 purge boot sizes, 9-4 Purge Station boot replacement, 9-4 cup replacement, 9-6 functio
Lift Tables, 5-31 Light Beacon, 5-14 Needle Sensor, 5-20 pre-power-up, 5-4 Purge Station, 5-21 Regulators and Gauges, 5-9–5-10 Scale, 5-44 Stop Pins, 5-31 Vision System, 5-41 Transformer, Servo Power, 7-6 troubleshooting Board Sensors, 8-103 Conveyor, 8-95 Conveyor Motors, 8-119 Conveyor pneumatics, 8-96 EMO, 8-25–8-27 Heater Tooling, 8-108 Height Sensor, 8-126 Home Sensor, 8-74 Light Beacon signal, 8-39 Linear Encoders, 8-63 main power, 8-13 PMAC initialization, 8-50 PMAC mechanical fault, 8-71 Rotary Enco
