Century® Series C-341 Dispensing System Installation, Operations, and Maintenance Manual
NOTICE This is an Asymtek publication, which is protected by copyright. Original copyright date 2004. 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.com/support/manuals.
Table of Contents 1 Introduction ...................................................................................................................................... 1-1 Overview ............................................................................................................................................ 1-1 Safety First ......................................................................................................................................... 1-1 Getting Started ..............
Table of Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 5-1 Figure 5-2 Figure 6-1 Figure B-1 Figure B-2 Figure B-3 Figure B-4 Figure B-5 Figure B-6 Figure B-7 Front View Features ............................................................................................................... 1-3 Control Panel ..........................................................
1 Introduction Congratulations on your choice of the Century C-341 Series Dispensing System! This document is intended primarily as a reference for production operators. However, others unfamiliar with Asymtek products may also find this document useful as a general introduction to the system.
Manuals Supplied Your Century C-341 Series Dispensing System arrives with manuals for installation and operation of major system components and software. For some system components, you may receive Original Equipment Manufacturer (OEM) manuals. Consult only Asymtek manuals unless directed to do otherwise by the manuals themselves or by the Asymtek Technical Service Group. Below is a sample list of manuals that may be shipped with your Century C-341 Series Dispensing System.
Front View Features Figure 1-1 to Figure 1-3 show front view features of the dispensing system. Detailed operating instructions for some of these features are treated in other sections of this manual. 1. Control Panel The Control Panel buttons and switches let you control certain programming and run functions. 2. Emergency Machine Off (EMO) Button The EMO button is a built-in safety feature located on the front panel of the dispensing system.
Control Panel The Control Panel (Figure 1-2) contains the controls necessary to operate your system. The Fluid Pressure Gauge, Emergency Stop Button, and the Operator’s ESD Grounding connection are also located on the Control Panel. The function of the Control Panel buttons and switches is described in Table 1-2.
Table 1-2 Control Panel Functions Button/Switch Function The Start and Stop buttons are located on the Control Panel and control power to major system components. I " NOTE During power-up, there is a 60 second delay to allow the dispensing system to vent properly. ABORT halts a production run. After you press the ABORT button, its red LED lights to indicate that the currently loaded program has been discontinued. ABORT After a program is aborted you must press RESET before you can restart the program.
Table 1-2 Control Panel Functions (Continued) Button/Switch Function When you press the Z-Axis button prior to pressing one of the motion control buttons, the Dispensing Head moves up and down as described below: Z-AXIS Moves the Dispensing Head up in small increments. Moves the Dispensing Head down in small increments. TEACH lets you set a desired point on the dispensing surface when prompted by the ECNT program. The software stores the location for future reference.
Dispensing Area The Dispensing Area (Figure 1-3) is where dispensing operations take place. 1. Dispensing Head (Robot) The Dispensing Head moves in the XYZ planes. It is controlled through the dispensing system software and the Control Panel. The Fluid Applicator is mounted on the Dispensing Head. 2. Fluid Applicator The Century Series C-341 Dispensing System can be configured with the Fluid Applicators listed in Table 1-1.
Rear View Features 1. Main Power Switch and Inlet The Main Power Switch controls electrical power to the entire dispensing system including the Computer and Computer monitor. The Main Power Inlet connects the Main Power Cord from the facility power source to the dispensing system. 2. Exhaust Vent Duct The Exhaust Vent Duct removes fumes from the dispensing area. A customer-supplied air duct must be connected from the dispensing system to the facility air ventilation system. 3.
2 Safety Overview This section is intended to provide basic safety information necessary for operating and servicing the Century C-341 Series Dispensing System.
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.
• Always wear appropriate personal protective equipment (PPE) as recommended by facility safety practices and the material manufacturer’s MSDS. • Know the MSDS recommendations for treatment of injury resulting from exposure to hazardous materials. • Make sure that the Main Power Cable and Main Air Supply Hose are securely connected before operating the dispensing system. • Before attempting to lift a load, take into consideration facility lifting and transport precautions.
• Routinely inspect all air hoses and electrical cables for damage. • Make sure that power cords and air supply hoses do not cross a walkway or aisle. • Make sure power and air connections to the dispensing system are securely attached. • Strictly follow facility clean room practices. • Dispose of hazardous materials and items contaminated with hazardous materials in accordance with applicable national and local statutes and regulations, facility practice, and the material manufacturer's MSDS.
Safety Warning Labels WARNING! Comply with all safety warning labels or serious injury to personnel or damage to the dispensing system may occur. Worn or damaged labels should be replaced with new labels having the same part number. Warning labels on your Century C-341 Series Dispensing System point out areas where personnel must use extreme caution to prevent serious injury and property damage. Table 2-1 shows the warning symbols that may be found on your dispensing system or optional equipment.
Emergency Shutdown Your Century C-341 Series Dispensing System features an Emergency Machine Off (EMO) button that the operator or service technician can use to immediately stop all dispensing operations in case of emergency. This feature helps prevent injury to personnel and damage to the dispensing system and workpieces being processed. The EMO button is located on the Control Panel on the front of the dispensing system (Figure 2-1).
Emergency Shutdown Recovery WARNING! Do not restart the dispensing operation until the condition that caused the emergency shutdown has been alleviated. Failure to comply could cause serious injury to the user and/or serious damage to the dispensing system. To recover after an emergency shutdown: 1. Locate and remedy the cause of the emergency shutdown. If necessary, refer to the Troubleshooting section. 2. Close the Dispensing Area doors. 3.
To lock out/tag out pneumatic pressure: 1. Press Stop on the Control Panel. 2. Lock out and tag out AC power as specified earlier in this section. ! 3. When the power is shut off, the Main Air Solenoid Valve shuts off and all air pressure inside the dispensing system is automatically released. Disconnect the facility air supply hose from the Main Air Inlet and place a warning tag on the Main Air Inlet.
ON Mode When the Interlock is ON (I) and a dispensing program is running, opening the front doors stops all dispensing motion and all position references are lost. For more information, see “Non-Recoverable Interlock Shutdown” later in this section. " NOTE If the Robot is parked over the Robot Safe Sensor, the doors may be opened. A Non-Recoverable Interlock Shutdown will not occur. See “Robot Safe Sensor” below. OFF Mode When the Interlock is OFF (0), it is in BYPASS mode.
Interlock Warning Tag This optional tag (see Figure 2-4) can be used to warn operators and service technicians that the Interlock safety feature has been bypassed. Please contact Asymtek for further information. DANGER SAFETYSHIELD INTERLOCK BYPA SSED Figure 2-4 Optional Interlock Warning Tag Non-Recoverable Interlock Shutdown When a non-recoverable interlock shutdown occurs, the motor power turns OFF, the system loses master references, and the red “ABORT” System Status Indicator LED illuminates.
3 Installation Overview This section describes installation procedures for the Century Series C-341 Dispensing System and covers the following topics: • Facility Requirements • Electrical Connections • Uncrating and Placing the Dispensing System • Exhaust Connection • Component Installation • Connecting Power and Air Supply • Pneumatic Connections • ECNT Configuration Safety First Before performing any of the system installation procedures in this section, please review the information presented i
Uncrating and Placing the Dispensing System CAUTION! This installation procedure should only be performed by a trained service technician. Tools and Materials Needed: • • Adjustable Wrench Appropriate Personal Protective Equipment • • Hammer Flat Bar To uncrate and place the dispensing system: 1. Locate and remove the envelope on the outside of the shipping crate. Open the envelope and locate the shipping list and uncrating instructions. 2.
Component Installation Your Century C-341 dispensing system is assembled at the Asymtek factory. However, to protect components during shipment, some are packaged in the Accessories Crate to be installed after arrival. Installing the Fluid Applicator The Fluid Applicator should have already been installed on your dispensing system at the Asymtek factory. If it has not been installed, a trained service technician should install it in accordance with the appropriate Fluid Applicator manual.
Pneumatic Connections The C-341 Series Dispensing System requires 85 l/min (3 SCFM) of clean, dry air delivered through a 12.7 mm (0.5 in.) pipe or hose at 90 psi (620 kPa). Connect the air supply to the quick-disconnect fitting at the main air connection. See Figure 3-1. " NOTE WARNING! The maximum air supply pressure should not exceed 100 psi (689 kPa). All system pneumatic connections should be checked before the main air is connected.
Connecting Power and Air Supply CAUTION! This procedure should only be performed by a trained service technician. To connect the facilities power and air supply: 1. Unpack the Main Power cable and remove all packing material including plastic wrappers and tie wraps. 2. Plug the female end of the power cable into the Main Power Inlet on the back of the dispensing system. Plug the male end of the power cable into the facility power source. 3.
ECNT Configuration ECW.INI File When ECNT is installed, the ECW.INI file is created. This file contains settings for your system hardware. The first time ECNT is run, a setup procedure runs, asking you what hardware you have and how it is configured. Responses to each question are written into the ECW.INI file. All other settings are performed from the Configure menu on the Edit screen.
Figure 3-2 ECNT Operator Screen 3. Select Edit>Edit Mode from the ECNT Operator Screen menu bar to access the ECNT Edit Screen. See Figure 3-3.
4. Select Configure>Reconfigure from the ECNT Edit Screen. ! The Configure Dialog Box opens. See Figure 3-4. Figure 3-4 ECNT Configure Dialog Box 5. Select the item to be configured by clicking on it. " 6. To select more than one item, hold down the CTRL key while selecting additional items. When you are finished, click on OK. ! 7. NOTE The software must be restarted in order to perform the configuration.
4 Operation Overview Before operating your Century C-341 Series Dispensing System, it may be helpful to familiarize yourself with the basics of how the system works.
System Startup/Shutdown This subsection details basic start-up and shutdown procedures based on different levels of operation. Your actual start-up and shutdown procedures may vary. WARNING! Only authorized service technicians or process engineers should connect power cables to the power source. Operators should not attempt to make electrical connections. System Startup If necessary, refer to the figures in the Introduction section to identify system components. To power on the dispensing system: 1.
Production Shutdown Routine shutdown may vary depending on your particular requirements. However, it is recommended that you incorporate the following procedure into your production shutdown routine: To shut down at the end of a production shift: 1. Wait for the dispensing program to complete and verify that all motion has stopped. 2. Unload all workpieces. 3. Turn the Reservoir Air Pressure Switch on the right rear panel to the OFF (0) position. 4.
Basic ECNT Operation To Start ECNT: icon on the Windows desktop or click on the Windows Start 1. Double click the ECNT menu and select Programs>ECNT. ! The Robot will find Home in the Z-Axis, Y-Axis, and X-Axis, respectively. ! The ECNT Operator Screen will open. The screen will vary slightly depending upon system configuration. See Figure 4-1. Name Current Product Description Displays the name of the currently loaded program. Start Click to start production.
Loading and Running Programs To load a program: 1. If a program is currently running, click on the Stop ! 2. button. Production stops after the currently loaded product is coated. Click on the Change Product button or double-click the Current Product field. ! The product map opens. The product map is a tree structure of the folders and subfolders where the programs are stored.
System Status LEDS System Status LEDS shown in Figure 4-2 are color-coded for each System Status Condition. • The Applicator LED illuminates when the Applicator switch is ON. • The Heater LED illuminates when the Heater switch is ON. • The Interlock LED illuminates when: - the Interlock key is OFF. - the doors are opened and Robot is not parked over the Robot Safe Sensor. • The VENT AIR LED illuminates when vent air is insufficient.
Tooling Rail Operation The Century C-341 features easily adjustable tooling rails to secure the workpiece in place. Adjusting the Tooling Rails To adjust the tooling rail width: 1. Loosen the front and rear L-handles. 2. Slide the rails to the desired position. The workpiece should fit securely between the rails. ! 3. Tighten the L-handles. To adjust the tooling rail length: 1. Loosen the stops on the inside edge. 2. Slide the stop to the desired position. The workpiece should fit securely. ! 3.
Adjusting the Fluid Pressure The fluid pressure range is from 0 to 60 psi. Your actual fluid pressure setting depends both on the fluid being dispensed and the Fluid Applicator used. WARNING! Failure to comply with any of the recommended pressure settings could cause serious injury to the user and/or damage to the dispensing system. To adjust the fluid pressure: 1. Verify the Reservoir Air Pressure Pneumatic Switch on the right rear panel is in the ON (l) position. 2.
5 Maintenance Overview Following the routine maintenance schedule and procedures 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 5-1 lists recommended maintenance procedures and intervals. Basic maintenance procedures are described later in this section.
Filling the Fluid Reservoir To fill the Fluid Reservoir: 1. Turn the Reservoir Air Pressure Pneumatic Switch to the OFF (0) position. 2. Relieve residual pressure in the Fluid System by opening the Fluid Pressure Relief Valve on the Fluid Reservoir. 3. Open the lid and check that the reservoir is clean and free from foreign materials. WARNING! Solvent vapors may be released when the lid is open. 4. Add fluid up to a maximum of 25 mm (1 in.) below the rim of the opening. 5.
Changing Material /Flushing Fluid System To change material and flush the Fluid System: 1. If applicable, turn OFF the heater and allow the fluid to cool for at least fifteen minutes. 2. Turn OFF air pressure to the Fluid Reservoir by turning the Reservoir Air Pressure Pneumatic Switch to the OFF position or by reducing pump fluid pressure to 0 psi. 3. Empty the remaining material from the reservoir. 4. Fill the reservoir with appropriate solvent. 5.
Emptying the Water Trap Moisture from the outside air can condense in the pneumatic system. The Water Trap collects this condensed moisture. You must empty it weekly or whenever it is full. To empty the Water Trap: 1. Disconnect the facility air supply from the Main Air Inlet. 2. Hold a container under the Water Trap to catch the water. 3. Using your finger, push the water drain knob at the bottom of the assembly. 4. Reconnect the facility air supply to the Main Air Inlet.
6 Troubleshooting Overview If you have difficulty operating your dispensing system, use this section to identify a possible solution to the problem. If you have difficulties not listed in this section, or the suggested solution does not correct the problem, contact Asymtek Technical Support. Basic System Troubleshooting Table 6-1 Basic System Troubleshooting Symptom System does not power-up when Start button is pressed Dispenses in the wrong location Troubleshooting Possible Cause Recovery A.
Table 6-1 Basic System Troubleshooting (continued) Symptom Possible Cause A. System is in abort mode. 1. Press RESET. Wait three seconds. 2. Press FIND HOME. - If motion occurs, restart the dispensing program. - If no motion occurs, call a service technician. B. Interlock activated (doors opened during dispensing). 1. Close both doors. 2. Press RESET. Wait three seconds. 3. Press FIND HOME. - If motion occurs, restart the dispensing program. - If no motion occurs, call a service technician.
Fuse Replacement The number of fuses may vary with the configuration of your system. All fuses are clearly identified. Replacement fuse locations for the Century C-341 Series Dispensing Systems are shown in Figure 6-1. 2 1 3 Item Description 1 Power Entry Fuse 2 Mechanics Fuse 3 Z-Head Fuse Figure 6-1 C-341 Fuse Locations CAUTION! Troubleshooting Always replace fuses with fuses of identical rating and size. Failure to do so will not protect components from damage and may cause fire.
Replacement Fuses Replaceable fuses for the Century C-341 Series Dispensing Systems are identified in Table 6-2 and Table 6-3. Table 6-2 Fuse Description and Ratings for 100-120V Supply 100-120V SUPPLY Fuse Location Rating Part Number 3.15A 197119 Fuse, 3.
7 Specifications Overview Century C-341 Dispensing System specifications are presented in Table 7-1 and Table 7-2. These specifications are intended as a convenient reference for personnel planning system relocation, installation, or operation, and others that may have an interest in system performance characteristics.
System Specifications Table 7-2 System Specifications Century C-341 System Specifications Dispensing Area* 458 x 458 mm (18 x 18 in.) Motion System: Type: Brushless DC stepper motor Z-Axis Velocity: 508 mm/s (20 in./s) maximum 381 mm/s (15 in./s) default 203 mm/s (8 in./s) X-Y Repeatability Z-Axis Repeatability ±0.025 mm (0.001 in.), 3 sigma ±0.025 mm (0.001 in.), 3 sigma X-Y Resolution Z-Axis Resolution ±0.025 mm (0.001 in.), 3 sigma ±0.025 mm (0.001 in.), 3 sigma Positional Accuracy: ±0.
Appendix A Additional Information Overview This section describes available pneumatic and electrical block diagrams and dispensing system electronics that may help in understanding dispensing system operation and aid in troubleshooting. The diagrams referred to in this appendix are listed in Table A-1 and are shipped with the dispensing system manuals and accessories. Dispensing system I/O is detailed in Table A-2.
Dispensing System Electronics Table A-2 Dispensing System Electronics In# Function Note Out# Function DA 0 DA 0 Rotate DA 1 DA 1 Fluid DA 2 DA 2 Tilt DA 3 Fluid High Pressure DA 4 DA 4 Toggle/Tilt Back DA 5 DA 5 DV-XX On/Off DA 3 Low Fluid Sensor A B DA 6 Recoverable Interlock DA 6 Air Assist DA 7 Rotate Home DA 7 Air High Pressure NOTE: A-2 Note B A) Unlike other input bits, it is normally active and goes off to indicate fluid is low.
Appendix B Illustrated Parts List Overview This section contains photographs, part numbers and descriptions that will aid in ordering replacement parts for the Century C-341 Series Dispensing System. Safety First Before attempting to replace any parts, please review the precautions in the Safety section. CAUTION! Only Asymtek-trained service technicians should perform troubleshooting, servicing, and parts replacement. 1 2 3 4 Item No. 1 2 3 4 5 Part No.
1 2 3 6 7 5 4 Item No. 1 2 3 4 5 6 7 Part No. 40-1202 121335 40-2470 40-2480 40-2502 40-2490 62-0383-00 Description Regulator, Watts, 0-125 psi Gauge, Pressure Switch, Start Switch, Stop Interlock Key Switch Rocker, Switch, Narrow EMO Assembly Figure B-2 Parts List - Control Panel 1 2 3 Item No. 1 2 3 Part No.
2 1 Item Part No. Description 1 40-2504 Switch, Low Diff. Press. 2 62-0210-00 Assembly, Air Filter Figure B-4 Parts List - C-341 Rear View 1 2 Item Part No.
1 2 3 Item Part No. Description 1 42-0002 1/10 Gal. Reservoir 2 40-1970 Cartridge, 10.3 oz (inside) 3 42-0702 Plunger, Cartridge, 10 oz.
2 1 3 4 Item Part No. Description 1 200116 PWA, INTERFACE BTC 2 60-0200-02 8-BIT I/O BOARD 3 7216992 POWER SUPPLY, 24V, 45W, 1.
Asymtek Headquarters 2762 Loker Avenue West Carlsbad, CA 92010-6603 USA Tel: (760) 431-1919 1-800-ASYMTEK (1-800-279-6835) P/N 7201828, Revision C © 2008