Asymtek The part number for this manual is 78-0001-00, Revision B. The Cleanroom part number is 78-0001-00K, Revision B. To reorder this manual, please contact Asymtek, 1-760-431-1919.
Century Series Operations Manual P/N 76-0001-00, Revision A 3/00
NOTICE All information contained in or disclosed by this document is considered proprietary by Asymtek®. By accepting this material the recipient agrees that this material and the information contained therein are held in confidence and in trust and will not be used, reproduced in whole or in part, nor its contents revealed to others, except to meet the purpose for which it was delivered.
Manual Conventions Labels Buttons Menu Selections FILENAME.FM2 Dispensing system buttons, labels, switches or connections appear in this text style. Fluidmove for Windows (FMW) buttons and dialog boxes appear in this text style. All menu selections within FMW appear in this text style. style Filenames appear in THIS TEXT STYLE. Typed commands, names and values appear in this text style. Level 1 Safety Warning.
Table of Contents 1 GETTING STARTED...................................................................................1-1 Manuals Supplied ................................................................................................................. 1-1 2 INTRODUCTION.........................................................................................2-1 The Century Series C-720 ....................................................................................................
AV-2550 Specifications....................................................................................................... 9-14 10 HEIGHT SENSOR.....................................................................................10-1 Overview ............................................................................................................................. 10-1 Installation..........................................................................................................................
Table of Figures Figure 2-1 Front View....................................................................................................2-2 Figure 2-2 Dispensing Area ..........................................................................................2-3 Figure 2-3 Lower Cabinet..............................................................................................2-4 Figure 2-4 Rear View ....................................................................................................
Figure 11-4 Figure 11-5 Figure 11-6 Figure 11-7 Figure 11-8 Figure 11-9 Figure 12-1 Figure 12-2 Figure 13-1 Figure 13-2 Figure 13-3 Figure 16-1 Figure 16-2 Figure 16-3 Figure 16-4 Figure 16-5 Figure 17-1 HT-1000 Temperature Controller or HT-1200-RTD..................................11-4 HT-2000 Temperature Controller .............................................................11-4 4-Channel Encap Temperature Controller ...............................................
1 Getting Started Congratulations on your choice of an Asymtek Century® Series Automated Fluid Dispensing System! This section describes the materials that arrive with your system and helps you use the documentation. Manuals Supplied Your Century 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.
Which Manuals to Use Below is a guide for when to use each manual. For Installation or Upgrading To install, reinstall, or upgrade components of your system, see the Century Series Installation Manual. This manual may also be packaged in the Century Series Service Manual, if available.
2 Introduction The Century Series C-720 Century Series dispensing systems are designed for a wide range of industrial and electronic applications. The C-720 is a non-conveyorized fluid dispensing system for low to medium volume batch processing and augmented with features commonly associated with advanced systems. The operation of the C-720 is based on selected, installed options for your application. The platform allows for future operational flexibility.
Basic System Description Figure 2-1 through Figure 2-5 show several views and features of the dispensing systems. The callouts locate all major components, options, and switches seen from that view. Paragraphs following the views provide brief descriptions of the features.
Grounding Strap Connector Moritex Lights (Dual), Vision System (Option) Fluid Pressure Regulator 1 Valve Pressure Regulator 2 Fluid Pressure Regulator 2 Valve Pressure Regulator 1 Century S E R I E S F F O A NORDSON COMPANY Vacuum On/Off Button and Indicator Light Process Control Cover Heated Vacuum Tooling Plate Purge Station Tactile Needle Sensor Weigh Station, Digital Scale (option) Dispensing Head, dual-action shown (option) Figure 2-2 Dispensing Area Introduction 2-3
Mouse and Keyboard Tray (shown pushed in) PC, Computer System Temperature Controller HT-1000 (Option) HT-1000 NEEDLE HEATER HT-1000 NEEDLE HEATER COMPANY ENTER OMEGA CN76000 AUTOTUNE INDEX ENTER 8 OMEGA CN76000 AUTOTUNE INDEX 7 SPI AL SP2 OF OC DI-100 100 x 0.0001g Denver Instrument menu SPI AL SP2 OF OC ENTER OMEGA CN76000 AUTOTUNE INDEX SPI AL SP2 OF OC A NORDSON 9 0 help 4 5 6 .
Front View Features Below are short descriptions of the various parts and modules of the system (shown in Figure 2-1, Figure 2-2, and Figure 2-3) and their functions. Detailed operation instructions for some features are covered in other sections. Computer System (computer, monitor, keyboard, mouse) The Computer System is used to create and run dispensing programs with the Asymtek dispensing software Fluidmove® for Windows (FMW). The programs are stored on the hard drive.
Fluid Pump The fluid pump (also referred to as a “valve” or “jet”, depending on the type) dispenses the fluid onto the part. It is mounted on the dispensing head, and holds the syringe of dispensing fluid. For more information, see the appropriate fluid pump manual. Front Doors The front doors (shown but not called out) have an electrostatic, dissipative surface that does not hold an electrostatic charge. Door sensors connect the front doors to the Safety Interlock system.
Power ON and OFF The Start and Stop buttons are located on the Control Panel and control the power to the dispensing system. The Start and Stop buttons are momentary press down buttons. The Start button illuminates in green when pushed and remains illuminated until the Stop button or EMO is pressed. When the stop button is pressed, the dispensing activity shuts down. (The computer and monitor have their own power switches and are not affected.
Valve Pressure Gauges and Regulators The Valve Pressure Gauges indicate the air pressure supplied to the fluid pump. The C-720 comes standard with Dual-Action Plumbing. The Valve Pressure Regulators are located underneath the front hood of the system. See the appropriate fluid pump manual for the recommended setting for your pump. The maximum recommended setting is 6.3 kg/cm2 (90 psi). Vision System (option) The Vision System allows you to visually align fiducials as you program for dispensing.
Rear Views Service Shroud Cooling Fan (air exhaust) Air Intake Grill (passive air in) Hour Meter Air Filter / Water Trap See Figure 2-5 Main Power Circuit Breaker Service Panel Main Power Cable Receptacle Figure 2-4 Rear View Introduction 2-9
Air Filter and Water Trap Main Air Gauge and Regulator High Air Pressure Relief Figure 2-5 Rear View Close-Up 2-10 Introduction
Rear View Features Following are short descriptions of the various features of the dispensing system (shown in Figure 2-4 and Figure 2-5) and their functions. Detailed operation instructions for some features are covered in other sections. Air Filter and Water Trap The Air Filter and Water Trap remove particles and impurities in the facility air supply. Fan The Fan removes the hot air from the dispensing area.
Main Power Circuit Breaker The Main Power Circuit Breaker controls all electrical power to the entire system including the dispensing system, computer, monitor, and temperature controller. Service Panel The Service Panel located in the lower rear of the cabinet protects the system components inside the cabinet. The Service Panel should not be removed by the operator. Service Shroud The Service Shroud protects the rear connectors. Operators should not remove it.
3 Safety Your Century Series system is designed to be safe and reliable. This section describes the features and precautions needed to ensure safe operation of the Century Series system. Safety Precautions Please review the following list of safety precautions for the operator and dispensing system before operating your Century Series system. WARNING! CAUTION! Failure to comply with any of the safety recommendations below could cause serious bodily harm to the user.
System Protection Precautions 3-2 • Always wear a grounding strap and connect it to the grounding strap connector (see Figure 2-2) when operating the system. • Be especially careful when dispensing fluids that are caustic or conductive. Wear gloves, and immediately clean up and contain all spills. If fluid gets into internal portions of the dispensing systems, call Asymtek Technical Support immediately. • Maintain a clean and orderly work area. • Follow all recommended system maintenance.
Safety Warning Labels WARNING! CAUTION! Follow all safety warning labels. Failure to comply could cause serious bodily harm to the user and serious damage to the dispensing system. To ensure the safety of all personnel, always observe standard safety precautions and practices. Before using your dispensing system, take a moment to familiarize yourself with the system safety features and warning labels. Table 3-1 shows the four types of warning labels on the dispensing system.
Valve 2 Pressure Valve Pressure Fluid 2 Pressure Fluid Pressure Abort Pause 9 8 7 6 5 4 Program 3 2 1 Start 0 Z Axis Teach Conveyor Status Conveyor Pause Find Home Interlock Recovery Dispenser V1 Status Dispenser Reset Valve Status Interlock Reset Valve Reset V2 Century S E R I E S F F O A NORDSON COMPANY Figure 3-1 Safety Warning Labels, Front View 3-4 Safety
Figure 3-2 Safety Warning Labels, Rear View Safety 3-5
Integrated Safety Systems Your Century Series system offers the safety features described below. Safety Interlock System INTERLOCK is a key-activated safety device located on the Control Panel (see Figure 2-1 and Section 4 − Operation). It is designed to restrict access by the user to the inside of the dispensing system. The Safety Interlock has two modes—ON or OFF. Once an Interlock safety mode is selected, the key can be removed to prevent an inadvertent mode change.
Light Beacon (option) Located at the top right corner of the system, the Light Beacon is a visual warning device that indicates different Interlock status conditions by turning on a different colored light for each condition. See Table 4-6 for an explanation of each color condition. The colors displayed on the Light Beacon match the colors displayed on the DISPENSER STATUS LED’s on the Control Panel of the Century Series System.
Emergency Shutdown WARNING! Failure to shut down total power to the Century Series system in an emergency with EMO and the Main Power Switch could cause serious bodily harm to the user and/or serious damage to the dispensing system. In case of an emergency or malfunction, push EMO (see Figure 2-1). EMO cuts power to system components. All system components are connected to the EMO outlet except the computer and monitor. Refer to the operator safety precautions for heated elements.
To shut down in an emergency: 1. Press EMO.
Electrical Power Electrical Power is supplied to the dispensing system through the Main Power Inlet. The Main Power Cable connects the facility AC power source to the Main Power Inlet located on the rear of the Century Series system (see Figure 3-4). All personnel working on or around the Century Series system must be aware of all electrical power supply sources. WARNING! When performing service or maintenance work on the system, be sure to lock out power (see “Locking Out Power” on page 3-11).
Locking Out Power WARNING! When performing service or maintenance work on the system, be sure to lockout the power by following the procedure below. Failure to do so could cause serious bodily harm to the user and/or serious damage to the dispensing system. To lockout the Century Series system: 1. Turn OFF (O) the Main Power Circuit Breaker. 2. Unplug the Main Power Cable from the facility source. 3. Lock Main Power cable in a locked box for safety.
Heated Vacuum Tooling Plate Safety WARNING! The Heated Vacuum Tooling Plate, parts and surrounding area could be hot. Even if the machine is turned off, the heated tooling plate can still be hot. Use extreme caution when working on or around these areas. Failure to do so could cause serious bodily harm to the user and/or serious damage to the dispensing system. The Heated Vacuum Tooling Plate generates heat while the machine is on and retains heat in the work area even after the machine is turned off.
Earthquake Precautions To protect the dispensing system from moving during an earthquake, the system must be anchored to the floor. The anchor joint (the point between each screw and the floor) must be able to withstand at least 100 kg (220 lbs.) of pullout force. Each leveler should be anchored to the floor with two screws.
Lifting Precautions WARNING! CAUTION! Failure to follow the Installation or Service Manual procedures for lifting the dispensing system could cause serious bodily harm to the user and/or serious damage to the dispensing system. If you need to move a Century Series system, call a service technician. Refer the service technician to the Century Series Installation Manual or the Century Series Service Manual for instructions on moving the system.
4 Operation ? NOTE Section 3 – Safety must be read along with this section before operating the system. Overview The C-720 is a batch process dispensing system that supports a variety of Advanced Semiconductor Package Assembly (ASPA) and Surface Mount Technology (SMT) applications. Typically, dispensing processes involve each of the critical operations listed below. The way in which each is accomplished may vary, depending upon system configuration.
Detailed Operation A typical C-720 dispensing process is described below. Setup and programming procedures are not included in the description. (For information on programming, see the Fluidmove for Windows User Guide). Figure 4-1 shows a typical operation flow chart. 1. A part is loaded into the system. The part is manually placed on the heated vacuum tooling plate. 2. The part is secured on the heated vacuum tooling plate.
PROGRAMMING MODE Start Fluidmove Load Part Secure Part Create New Program Load Old Program Align Fiducials Align Fiducials Teach Fiducials If no Height Sensor Edit Dispensing Pattern (As Needed) Set Dispense Height Routine Find Needle Save Program Dispensing Program Pattern Dispensing Pattern Parameters Save Program Figure 4-1 Operational Flow Chart Operation 4-3
PRODUCTION MODE Start Fluidmove Load Dispensing Program Set Dispense Height Routine Find Needle Part Manually Placed on Tooling Plate Run Dispensing Program Align Fiducials Program Runs UNLOAD *If not already loaded Figure 4-1 Operational Flow Chart (continued) 4-4 Operation
Dispenser Operation There are several operation controls and indicators for the dispensing system components. This section explains the general operational use of these controls. Computer System The computer is located inside the lower cabinet (see Figure 4-2). The CD-ROM drive, disk drive, power switch, and reset button are located on the front of the computer. Access to connections in rear of the computer should be limited to service technicians. The computer runs Fluidmove for Windows (FMW).
CD-ROM Drive HT-1000 NEEDLE HEATER HT-1000 NEEDLE HEATER Disk Drive COMPANY ENTER OMEGA CN76000 AUTOTUNE INDEX SPI AL SP2 OF OC ENTER OMEGA CN76000 AUTOTUNE INDEX Power Switch SPI AL SP2 OF OC A NORDSON ENTER OMEGA CN76000 AUTOTUNE INDEX SPI AL SP2 OF OC DI-100 100 x 0.0001g Denver Instrument Reset Button menu 7 8 9 0 help 4 5 6 .
CD-ROM Drive Press the button below and to the right of the disk tray to insert or eject a disk. Disk Drive The computer has at least one 3.5-inch, 1.4MB floppy disk drive. Insert disks through the drive door flap. Press the small button on the lower right to eject a disk. Hard Disk Drive Internal hard drive (see Section 8 − System Specifications). Hard Drive Activity Indicator This light blinks when the hard drive is active. Power Indicator The Power Indicator is green when power to the computer is ON.
Computer Operation The computer is usually left ON so that power comes on to the computer when the dispensing system Start button is turned ON. However, to clear major software and system failures, you may need to separately turn ON or OFF and reboot the computer. Follow the procedures below. To turn OFF or reboot the computer while the dispensing system is ON: 1. If possible, save any open files and close all programs. " If the computer is completely locked-up and unresponsive, skip to step 2.
Control Panel and Switches Figure 4-3 identifies the Control Panel functions, and Power Start and Stop controls. See Table 4-1 through Table 4-5 for detailed explanations of the functions.
EMO (Emergency Machine OFF) Table 4-1 EMO Button Button Function Located at the right end of the Control Panel, the large, red EMO (Emergency Machine OFF) button cuts electricity to the power manager and stops all system motion. EMO cuts power to all system components except the computer and the monitor. Switches WARNING! To cut power to the entire system, you must turn OFF (O O) the Main Power Circuit Breaker.
Control Panel The Control Panel is divided into three functional areas: • Download Program Controls • Motion Controls • Dispensing Status/Safety Interlock Controls The following tables describe each Control Panel function. Table 4-3 Download Program Control Functions Button/Indicator ABORT PAUSE Function ABORT halts a production run. After you press the ABORT button, the LED lights to indicate that the currently loaded program is discontinued.
Table 4-4 Motion Control Functions Button/Indicator Z AXIS TEACH Function Z-Axis Controls (up/down) • Click and release a single arrow to move dispensing head 1 mm (0.001 inches) • Click and hold single arrow to move dispensing head 25.4 mm per second (1 in/sec) • Click and hold double arrow to move dispensing head 50-75 mm per second (2-3 in/sec) TEACH lets you set a desired point on the dispensing surface with the Fluidmove program. The location of the fiducial is stored by the software.
Table 4-4 Motion Control Functions (Continued) Button/Indicator Function X/Y-Axis Controls (left/right, front/rear) and Conveyor Controls (conveyor belt, board clamp mechanism Press DISPENSER to control the X/Y motion of the dispensing head: CONVEYOR DISPENSER • The left and right arrows move the dispensing head to the left or right (X-Axis) • The up and down arrows move the dispensing head to the rear and front of the dispensing area (Y-Axis) • Click and release a single arrow to move dispense hea
Table 4-5 Dispensing Status Control Functions Button/Indicator Function CONVEYOR STATUS PAUSE These controls not applicable to the basic C-720 system configuration RESET INTERLOCK RECOVERY INTERLOCK DISPENSER STATUS INTERLOCK is a key-activated safety feature that prevents the conveyor and the dispensing head from moving while the access doors are open. During dispensing operations, this helps prevent personal injury or damage to the dispensing system.
Table 4-5 Dispensing Status Control Functions (Continued) Button/Indicator V1 VALVE STATUS V2 Function VALVE STATUS LED turns ON if there is a problem with the fluid pump motor. It usually indicates that the pump electronics (overcurrent protection circuitry) has detected a surge of power. When the LED is ON, the valve is disabled. V1 is Valve 1. V2 is Valve 2. To recover, press VALVE RESET. If the problem persists, the pump may need cleaning.
Light Beacon Light Beacon Valve Pressure Valve 2 Pressure Dispenser Status Valve Status Valve Reset Reset Century S E R I E S Figure 4-4 Light Beacon The Light Beacon, if installed, (see Figure 4-4) is ON whenever the dispensing system is ON. The Beacon indicates the dispenser’s status by displaying a red, yellow, green or blue light. The meaning of each color is described in Table 4-6.
Table 4-6 Panel / Beacon Colors, Dispensing Status and Recovery Procedures Panel / Beacon Color Dispensing Status ALERT All motion, outputs, valve and motion controls are disabled. One of the following conditions exists: A. Doors open or light curtain is obstructed when system is moving, INTERLOCK at I. RED B. System is in an abort state. C. INTERLOCK at I, Low pressure sensor has been activated. Recovery Procedures A or B: 1. Close doors or remove obstruction, or change INTERLOCK to O. 2.
Gauges and Regulators The C-720 has three types of gauges and regulators: • Main Air • Fluid • Valve WARNING! To reach inside the Century Series system front doors or through the light curtain (if installed), you must fully understand the related Safety Interlock and DISPENSER STATUS indicators. To reach the fluid and valve regulator controls, you must open the front doors and reach below and behind the Control Panel (see Figure 2-1, Front View or Figure 2-2, Dispensing Area).
Main Air Inlet Located next to the air filter, the Main Air Inlet provides regulated air pressure to the dispensing system from your facility air source. You can adjust the main air pressure with the metal T-bar regulator (see Figure 4-5 and procedure below). The recommended pressure from the facility air supply to the dispensing system is 586–620 kPa (85–90 psi). T-Bar Regulator Water Trap High Air Pressure Relief Figure 4-5 Main Air Gauges and Regulators To adjust the main air pressure: 1.
Fluid and Valve Fittings The pneumatic fittings for the fluid and valve pressure are located on the right side of the dispensing head. See Table 4-7 for color codes.
Fluid Pressure Regulators The fluid pressure regulator controls the air pressure of the clear pneumatic fitting located on the right side of the dispensing head. The Fluid 1 Pressure Regulator (see Figure 4-6) controls the pressure of the top clear air line located on the right side of the Dispense head (see Figure 4-8, Figure 4-9, and Figure 4-10). This fitting connects to the top of the syringe for a DJ-2000 and DP-3000. It is not used for DV-6000 or DV-7000 Dispense valves.
To adjust the fluid pressure: 1. Verify that the dispensing system is ON. The DISPENSER STATUS LED or Light Beacon (if installed) should be yellow or green. 2. Open the front doors. The green DISPENSER STATUS LED or Light Beacon (if installed) will turn yellow. 3. Reach underneath the left side of the front hood of the dispensing system and pull the fluid pressure regulator down to unlock it. 4. Rotate the regulator counter-clockwise to set the fluid pressure to 0 kg/cm2 (0 psi). 5.
Valve Pressure Regulators Depending on your application, valve pressure regulators (Figure 4-7) control the air pressure for the blue and black air lines that connect to the fluid pump (see Table 4-7). The Dispensing program toggles the pressure between the blue and the black air lines. The blue air line will be pressurized while valve is ON and the black air line is pressurized when the valve is OFF.
To adjust the valve pressure: 1. Verify that the dispensing system is ON. " The DISPENSER STATUS LED or Light Beacon should be yellow or green. 2. Open the front doors. The green DISPENSER STATUS LED or Light Beacon will turn yellow. 3. Reach underneath the right side of the front hood of the dispensing system and pull the valve pressure regulator down to unlock it. 4. Rotate the regulator counter-clockwise to set the valve pressure to 0 kg/cm2 (0 psi). 5. While watching the gauge, rotate the regulator.
Black Valve 1 Pressure Regulator Controls Blue Clear (Fluid 1 Regulator Controls) Valve 1 Valve 2 See Figure 4-11 for correct electrical power connections O F F Figure 4-8 Pneumatic and Electrical Connections Shown for Single Valve Configuration Using DP-3000) Operation 4-25
Black Valve 1 Pressure Regulator Controls Blue Clear (Fluid 1 Regulator Controls) Valve 1 Valve 2 r so en tS igh He ctileRT Ta-Series HS See Figure 4-11 for correct electrical power connections O F F Figure 4-9 Typical Dual-Valve Configuration Shown with DV-6000 as Valve 1 and DP-3000 as Valve 2 4-26 Operation
Black Blue Valve 1 Pressure Regulator Controls Clear (Fluid 1 Regulator Controls) Valve 1 Valve 2 He ctileRT Ta-Series HS t igh n Se so r See Figure 4-11 for correct electrical power connections Height Sensor Power Connectors in Back of Z-Head Figure 4-10 Pneumatic and Electrical Connections Shown for Single-Valve Configuration Using DV-6000 Operation 4-27
Power, Needle Heater 1 Power, Valve 1 Thermocouple 1 Power, Valve 2 VALVE 1 VALVE 2 HTR 1 HTR 2 Thermocouple 2 Power, Needle Heater 2 Figure 4-11 Electrical Connection Detail 4-28 Operation
Heated Vacuum Tooling Plate The Heated Vacuum Tooling Plate utilizes vacuum through the holes in the tooling plate to hold the workpiece against the Heated Vacuum Tooling Plate. The Heated Vacuum Tooling Plate is shown in Figure 4-12. Correct temperature of the workpiece improves the fluid flow and dispensing results of a specific fluid. The Temperature Controller brings the temperature of the tooling plate to a pre-set temperature and then maintains that constant temperature.
Phillips Head Screw Heated Vacuum Tooling Plate Vacuum ON/OFF Button Figure 4-12 Heated Vacuum Tooling Plate 4-30 Operation
OMEGA HT-1000 CN76000 SPI AL SP2 PV OF SV OC INDEX AL AUTOTUNE AL ENTER MADE IN USA Figure 4-13 HT-1000 Temperature Controller OMEGA HT-2000 OMEGA CN76000 SPI AL SP2 OF OC CN76000 SPI AL SP2 PV PV OF SV INDEX AL AL INDEX ENTER AL AUTOTUNE MADE IN USA AUTOTUNE OMEGA ENTER PV CN76000 SPI AL SP2 OF OC AL MADE IN USA CN76000 OMEGA SPI AL SP2 OF OC SV OC PV SV INDEX AL AUTOTUNE INDEX AL AUTOTUNE AL ENTER SV MADE IN USA AL ENTER MADE IN USA Figure 4-14
WATLOW ANAFAZE 4CLS UNITS PROCESS LOOP 01 FS SET POINT ALARM MAN AUTO CHG SP 45 C 45 AUTO 9 STATUS NO YES OUT% BACK RAMP SOAK ALARM ACK ENTER WATLOW ANAFAZE 4CLS 01 FS SET POINT ALARM MAN AUTO UNITS PROCESS LOOP CHG SP 45 C 45 AUTO 9 STATUS NO YES OUT% BACK RAMP SOAK ALARM ACK ENTER Figure 4-15 4-Channel Temperature Controller 4-32 Operation
Set Up Tooling Plate Vacuum Area: 1. Position the workpiece(s) on the Tooling Plate at a convenient location for the production run. ? NOTE Consider the following when determining the exact location of the workpiece: home position, type and number of workpieces, and fiducials. 2. Identify all screws that will be completely covered by the workpiece. Vacuum holes should be completely covered by the workpiece and holes not covered plugged by the screws. Ensure that the work area is kept clean.
Set Tooling Plate Temperature Control: The following procedures describe how to operate the HT-2000 Temperature Controller, how to set the temperature, and how to select the Celsius or Fahrenheit display. ? ? NOTE For the 4-Channel Temperature Controller and advanced operation, refer to Section 11 − Needle Heater. NOTE If you are running FMW and using the Needle Heater with a 4channel temperature controller, the Fluidmove software controls the Needle Heater. 1.
6. Press the INDEX on the HT-2000 Temperature Controller to record the value and return to the main display. ? NOTE The Set Value (SV) indicates the desired temperature. The Process Value (PV) indicates the actual temperature of the heating element underneath the Tooling Plate. 7. To turn the HT-2000 Temperature Controller to OFF, press the switch to OFF (00). WARNING! Operation The Vacuum Heated Tooling Plate can get very hot and remain hot for an hour after being turned to OFF.
List of Consumables The following items represent operational support material required for the operation of the C-720 system. The items below are considered consumables and are to be discarded after use.
5 Startup/Shutdown This section describes how to start up and shut down the C-720 for production, programming, or service. These procedures are general recommendations. Your actual startup and shutdown procedures may vary. See your own documentation, if available. This assumes that an Asymtek technician has already installed your system and that all power cables are connected to the facility AC power source. Startup The following procedure describes how to start up your Century Series system.
Production Startup The following procedure describes how an operator runs a dispensing program with a clean fluid pump and/or a new syringe. The procedure assumes that the pump and syringe have been installed on the dispensing head, and that a dispensing program has been created (using either FMW or CADImport) and saved on the computer hard drive.
16. In the FMW Main Window… " Click on Teach a Program to create or edit a production program. See your Fluidmove manual for more details. (STOP HERE) " Click on Run a Program to run a production program. This brings up the Production Window. (CONTINUE BELOW) 17. In the Production Window, click on Load. Load 18. Select the program you wish to run. 19. Click on OK. OK This loads the production program into memory. 20. Click on Run. Run 21. Select Run Production. Production This brings up the Run Window.
Shutdown You can shut down your Century Series system in two ways: • Emergency Shutdown • Production or Service Shutdown (End of Shift) Emergency Shutdown WARNING! Failure to shut down total power to the Century Series system in an emergency with EMO and the Main Power Circuit Breaker could cause serious bodily harm to the user and/or serious damage to the dispensing system. During an emergency or malfunction, press EMO. EMO is the large red button on the Control Panel (see Figure 4-3 and Figure 3-3).
Production Shutdown (End of Shift) or Service Shutdown Depending on your company’s requirements, your Century system may be left ON or OFF at the end of a shift. However, we recommend 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. 2. Purge the fluid pump. " See your fluid pump manual for purging instructions. 3. Exit FMW. 4. Press OFF (O) Stop button on the Control Panel. 5.
6 Troubleshooting If you have difficulties operating your Century Series 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. ? NOTE Troubleshooting A “service technician” as mentioned in Table 6-1 refers to a service technician at your facility.
System Troubleshooting Table 6-1 System Troubleshooting Symptom Possible Cause Recovery A. Main Power Cable disconnected. Check that the Main Power Cable is connected to an AC source. B. Main Power Switch turned OFF. Turn ON the Main Power Switch at the rear of the system. 1. Turn EMO clockwise until it releases. 1. No power to major system components. C. EMO is depressed. 2. Close doors. 3. Press Start button on Control Panel. 4. Press FIND HOME. D.
Table 6-1 System Troubleshooting (continued) Symptom 3. Dispenses in the wrong Z location. Possible Cause Height Sensor has been adjusted. Recovery Perform Valve Offsets or Calculate Master Offsets (see 2B above). Press DISPENSER STATUS RESET. Wait three seconds. Press FIND HOME. A. System is in abort mode. 4. No response from Control Panel buttons. 5. Safety Interlock fails to reset. 6. Monitor or video image is missing. 7. Valve Status indicator light(s) is ON. B.
Table 6-1 System Troubleshooting (continued) Symptom 8. No Air Pressure. 9. Air is hissing at the rear of the system. Possible Cause A. System not connected to facility air supply. Check the Main Air Inlet at the rear of the system. B. Valve air pneumatic hose not connected Check valve air; secure connections if necessary Facility air pressure is too high (>100 psi). Disconnect Main Air supply and install a facility regulator. A. Needle Sensor not set up correctly. 10.
Heated Vacuum Tooling Plate Troubleshooting Table 6-2 Heated Vacuum Tooling Plate Troubleshooting Symptom Possible Cause Recovery A. Missing Vacuum Hole screw(s) Replace screw(s). B. Other pneumatic leaks Contact Asymtek Technical Support Group A. Wrong display unit Change display unit (F or C) B. Out of calibration Recalibrate. Call Asymtek Technical Support Group Check for improper open or plugged vacuum holes Remove and install screws as applicable 1. Hissing air leak 2.
7 Maintenance Routine maintenance of your Century Series system helps prevent part degradation and helps ensure high quality performance for every production run. The following simple procedures should be performed on a regular basis to maximize dispensing quality and system performance. It is essential that you follow all safety warnings and consider all safety warning labels when performing these procedures (see Section 3 −Safety). Perform the following procedures according to the schedule shown.
System Maintenance Table 7-1 System Maintenance Maintenance Procedure 1. Clean purge boot and purge lid Recommended Frequency Instructions a. Remove the purge station lid (see Figure 7-2). Daily b. Clean the boot and lid with a small bottle brush and the solvent recommended by the adhesive manufacturer (see MSDS). a. Remove the purge station lid. 2. Replace cup Daily b. Remove the plastic cup. c. Replace with clean cup. d. Put the lid back on. a.
Emptying the Water Trap Moisture from the outside air can condense in the pneumatic system. The water trap collects this condensed water, and you must empty it periodically or whenever it is full. WARNING! Do not remove the steel bowl guard protecting the water trap. The bowl is made of polycarbonate plastic, which could rupture if the inside or outside of the bowl is exposed to chemicals incompatible with polycarbonate. To empty the water trap: 1. Locate the water trap at the rear of the system. 2.
Replacing the Purge Boot To replace the purge boot: 1. Lift off the purge station lid (see Figure 7-2). If the system is running, the lid will be held down by a partial vacuum. 2. Using fingers or needle-nosed pliers, grip the top of the purge boot and pull it out from the top of the lid. Tearing the boot will not cause a problem, as it is being replaced. 3. Obtain a new boot. " If using a nozzle, use an olive-colored boot.
Purge Boot Purge Station Lid Figure 7-2 Purge Boot Close-Up Maintenance 7-5
Heated Vacuum Tooling Plate Maintenance The Vacuum Heated Tooling Plate operator-performed maintenance consists of cleaning. See Table 7-3 below. For other maintenance, contact Asymtek Technical Support Group. WARNING! CAUTION! ? NOTE The Vacuum Heated Tooling Plate can get very hot and remain hot for an hour after being turned to OFF. Never touch it while the system is ON or after it has been turned off before it has cooled off. Do not attempt to over-tighten the vacuum-hole screws.
List of Tools and Consumables The following items represent support material required for the operational maintenance of the Heated Vacuum Tooling Plate. Properly dispose of any consumable items. • Phillips-head screwdriver • Dry, soft, lint-free rag • Isopropyl alcohol (IPA) • Soft bristle brush • Tooling Plate Vacuum Hole screws ? NOTE All other items that may be required for the system operations are facility dictated and may vary with each production environment.
8 System Specifications Drive System X- and Y-Axis Speed 508 mm/sec (20 in/sec. X- and Y-Axis Control: Brushless DC stepper motor Z-Axis Speed: 203 mm/sec (8 in/sec) System Repeatability: +0.025 in. (+0.001 in.) System Resolution: +0.025 in. (+0.001 in.) Placement Accuracy +0.13 mm (0.005 in.) Computer Pentium-based PC Dispensing Area, Single 432 x 356 mm (17 x 14 in.) Dispensing Area, Dual 292 x 340 mm (11.5 x 13.4 in.
Facility Requirements 8-2 System Footprint: 1275 x 12399.5 (50.2 x 55.1 in.) Height: 1415 mm (55.7 in.) Power: 220/240 VAC, 30A, 50/60 Hz, 1000 Watts Air Pressure: 620 kPa (6.2 Bar) [4.21/s] (90 psi, 9 SCFM) Noise Level: <70 dB (70 dBA) Environmental: 5 to 55º C (41 to 131º F) Weight 363 kg (800 lbs.
Vision Area* (approximate) (434 x 343 mm) (17.1 x 13.5 in.) Working Envelope* (434 x 343 mm) (17.1 x 13.5 in.) Dispensing Area* (447 x 343 mm) (17.6 x 13.5 in.) Heated Vacuum Tooling Plate (457 x 361 mm) (18.0 x 14.2 in.) Y Camera Offset = 0 mm (0 in.) Purge Station X Camera Offset = 53 mm (2.1 in.) Weigh Station, Digital Scale (option) Tactile Needle Sensor * Dispensing and Vision Areas are the areas usable for dispensing and vision over the Heated Vacuum Tooling Plate.
Working Envelope* (284 x 315 mm) (11.2 x 13.7 in.) Vision Area* (approximate) (351 x 356 mm) (13.8 x 14.0 in.) 60 mm (2.38 in.) Dispensing Area 1* (406 x 348 mm) (16.0 x 13.7 in.) Heated Vacuum Tooling Plate (457 x 361 mm) (18.0 x 14.2 in.) Y Camera Offset = 51 mm (2.0 in.) Valve 1 & 2 Offset 0 mm (0 in.) Dispensing Area 2* (389 x 315 mm) (15.3 x 13.7 in.) X Camera Offset = 53 mm (2.1 in.) Distance Between Valves = 102 mm (4.0 in.
Working Envelope* (284 x 315 mm) (11.2 x 12.4 in.) Vision Area* (approximate) (351 x 356 mm) (13.8 x 14.0 in.) 60 mm (2.38 in.) Dispensing Area 1* (406 x 348 mm) (16.0 x 13.7 in.) Heated Vacuum Tooling Plate (457 x 361 mm) (18.0 x 14.2 in.) Dispensing Area 2* (389 x 315 mm) (15.3 x 12.4 in.) Y Camera Offset = 53 mm (2.1 in.) Valve 1 & 2 Offset 33 mm (1.3 in.) X Camera Offset = 53 mm (2.1 in.) Purge Station Weigh Station, Digital Scale (option) Distance Between Valves = 102 mm (4.0 in.
9 Vision System Overview Asymtek offers a choice of two vision systems for many of its dispensing systems. The AV-700 Targeting Offset Camera is the basic vision system provided with the standard configuration. The AV-2550 Pattern Recognition System (PRS) is an advanced vision system with a choice of light sources to accommodate edge detection and fiducial detection. Both vision systems are compatible with the Asymtek dispensing software, Fluidmove for Windows® (FMW).
AV-700 Targeting Offset Camera The AV-700 displays a magnified video image of your workpiece on the computer monitor while you are running Fluidmove software. When you program using the AV-700, the camera video overlays a crosshairs on the image to let you locate XY coordinates for accurate dispensing pattern placement. The AV-700 operates in Download Mode or with FMW. The AV-700 vision system includes: • Pentium® computer with 356 mm (14 in.
Operation When the dispensing system is ON, the light ring illuminates and the camera turns ON. The camera magnifies the workpiece image and sends it to the system computer. The light ring card inside the computer supplies the camera with power. It also receives the camera signal and sends it to the video card. The video card displays an image on the computer monitor with a crosshair overlay. The crosshair is calibrated to the XY location using a Fluidmove setup routine.
Operation Controls To operate the AV-700 while programming in FMW: 1. In the FMW Main Window, click on Teach a Program. 2. The video display activates automatically when programming a dispensing command. " You can also activate the video display by clicking on the camera icon. 3. Follow the on-screen prompts and consult the On-Line Help, if necessary.
Adjustments for the AV-700 The built-in light ring and camera on the AV-700 may require adjustments to the brightness and focus. CAUTION! Any changes to focus of F-stop will cause problems with Auto Fiducial Finding programs. To adjust the brightness of the video display: 1. Locate the f-stop ring on the camera lens (see Figure 9-2). It has the numbers 1.6, 2, 4, 8 and 16 on it. These are different aperture sizes, which control brightness. 2. Twist the f-stop ring to the desired brightness.
To adjust the focus of the image: 1. To adjust focus, twist the Focus ring until focused. If focused, skip step 2. 2. If still not focused, perform as follows: a. Using a 5/64-inch hex key, loosen the setscrews holding the camera in place. b. Move the camera up or down until the displayed image is in focus. c. When satisfied, tighten the setscrews to secure the camera. d. Repeat step 1.
Minor Troubleshooting There are some troubleshooting procedures that an operator may perform. These are listed in Table 9-2. Some symptoms that appear to be problems with the vision system may actually have other causes. Refer unsolved problems to a service technician. Table 9-2 AV-700 Troubleshooting Symptom No image Check/Correction • Make sure that the lens cap has been removed from the camera. • Check the camera cable harness connection at the back of the dispensing head.
AV-700 Specifications Computer ® Desktop computer with Pentium processor and 356 mm (14 in.) SVGA monitor Field of View Size A-400 Series Benchtop 10.4 x 7.8 mm (0.41 x 0.31 in.) A-400 Series Gantry 11.0 x 8.4 mm (0.43 x 0.33 in.) A-600 Series 11.0 x 8.4 mm (0.43 x 0.33 in.) Century Series 11.0 x 8.4 mm (0.43 x 0.33 in.)* *Depends on dispensing area options.
Light Sources Dual Light, red LED visible light Light Ring NER Diffused On Axis Light Camera A-400 Series Benchtop 25-mm lens, adjustable f-stop A-400 Series Gantry 25-mm lens, adjustable f-stop A-600 Series 25-mm lens, adjustable f-stop Century Series 25-mm lens, adjustable f-stop Focal length 43 mm (1.7 in.) Focus Height Ranges See Table 9-3 and Figure 9-3 Table 9-3 Model Focus Height Range Max. Assembly + Component Height (A) Max. Component Height (B) Century Series 129 mm (5.1 in.
Camera Adjustable Camera Height Workpiece Light Ring Focal Length Maximum Component Height B A Maximum Component Assembly Height (including fixture) Figure 9-3 9-10 Tooling Fixture or Conveyor Rails Focus Height Ranges Vision System
AV-2550 Pattern Recognition System The AV-2550 Pattern Recognition System (PRS) magnifies the workpiece and displays it on the computer monitor. The AV-2550 can be used with FMW or FmNT. The AV-2550 has a Cognex® Vision Processor in addition to all of the same hardware as the AV-700 described above. This vision processor can recognize certain shapes, called fiducials, on the part or substrate and can be “taught” to recognize them on other parts for quick, accurate pattern placement.
Operation The sections below are an overview of the hardware operation of the AV-2550 system. See Figure 9-4 to locate parts. Theory of Operation The camera turns ON and the image is processed through the Cognex® Vision Processor and is displayed on the monitor. The camera generates a crosshair over the image. The crosshair is calibrated to the XY location using a Fluidmove setup routine. After calibration, the dispensing head, camera and light source are moved to a fiducial location on a workpiece.
Adjustments for the AV-2550 In FMW or FmNT, see On-Line Help for controlling these features. Minor Troubleshooting Operator-performed troubleshooting procedures are listed in Table 9-4. Some symptoms that appear to be problems with the vision system may actually have other causes. Refer unsolved problems to a service technician. Table 9-4 Symptom AV-2550 Troubleshooting Check/Correction Dispensing program freezes Reboot the computer and do not press [Esc] or [Enter] while in a ® Cognex menu.
AV-2550 Specifications Computer Pentiumâ computer with 356 mm (14 in.) SVGA monitor Field of View Size A-400 Series Benchtop 10.4 x 7.8 mm (0.41 x 0.31 in.) A-400 Series Gantry 11 x 8.4 mm (0.43 x 0.33 in.) A-600 Series 11 x 8.4 mm (0.43 x 0.33 in.) Century Series 11 x 8.4 mm (0.43 x 0.33 in.) Millennium Series 11 x 8.4 mm (0.43 x 0.33 in.) Working Envelope A-400/A-600 Series 12 x 12 in systems 254 x 305 mm (10 x 12 in.) 18 x 18 in systems 406 x 457 mm (16 x 18 in.
Environment 10–55°C (50–131°F) 10–85% RH (below 40°C (104°F)) Light Sources Light Ring, red LED visible light Dual Light (option) NER Diffused On Axis Light (option) Camera All systems 25-mm lens, adjustable f-stop Focal length 43 mm (1.7 in.
10 Height Sensor Overview The Retractable Adjustable Height Sensor is located on the dispensing head next to the needle or nozzle. It checks and gauges substrate height to help maintain consistent dispensing height on a non-level or warped substrate. Consistent dispensing height is essential to ensure consistent dispensing quality. If your system includes this option, it should have been installed at the Asymtek factory prior to shipping.
Installation See Figure 10-2 to locate parts. Tools and Materials Needed • Height Sensor • Philips head screwdriver CAUTION! Only a trained service technician should perform this procedure. To install the Height Sensor: 1. Determine the type of valve or fluid pump installed on your dispensing system. ? ? NOTE NOTE DV-6000 pumps, DP Series pumps, and the DJ-2000 DispenseJet® attach directly to the valve bracket (see Figure 10-2). Go to Step 3.
VALVE 1 VALVE 1 He le cti RT TaS-Series igh tS en so r H Fluid Pump (DV-6000 shown) Power Cord Height Sensor Valve Bracket Figure 10-2 Valve (DV-01 shown) Height Sensor Installation VALVE 1 VALVE 1 Power Cord r so en tS igh He tileRT c TaS-Series H Z-Head Bracket Spacer (For valves other than DV-6000/DV-06, DP or DJ Series) Height Sensor Figure 10-3 Height Sensor Height Sensor Installation with Bracket Spacer 10-3
Setup Before performing any dispensing programs with the Height Sensor, make sure that the Height Sensor is properly set up. To set up the Height Sensor, follow the instructions below. Hardware Setup Once you have installed your Height Sensor, perform the following hardware setup procedure to verify that the Height Sensor is in a neutral position before making any probe adjustments or performing the software setup procedure.
Software Setup During the software setup process, you can assign values to control various Height Sensor parameters. In FMW and FmNT, you can control: • Up and Down Speed and Acceleration of the dispensing head during a height sense • Maximum Search Depth that the dispensing head will descend in search of the substrate • Retract Distance after a height sense FMW and FmNT have different procedures for setting up the Height Sensor.
Probe Adjustments To accommodate the dispensing pattern, the substrate material, and/or the needle size, you may need to adjust the probe height in relation to the needle height, or adjust the distance between the probe tip and the needle tip. These adjustments can improve throughput and dispensing quality. 10-6 CAUTION! Consult a service technician before performing any of these adjustments. CAUTION! Set up the hardware and software (earlier in this section) before making any probe adjustments.
Probe Height Adjustments An operator can make small-scale adjustments to probe height using the micrometer adjustment. Only a service technician should make large-scale adjustments to probe height. Service technicians can also adjust the Z-Axis velocity and acceleration. The Z-Axis velocity and acceleration values are applied to the dispense head during a height sense and can increase throughput. See the specifications on page 10-13 for more information.
To make large-scale adjustments to the probe tip height and position: CAUTION! Only a trained service technician should perform this procedure. 1. Raise the dispensing head so that neither the needle tip nor the probe tip is touching the work surface. 2. Make sure the probe is in the gear down (GD) position. 3. Using the 1/16-inch hex key, loosen the probe set screw accessed through the hole on the right side of the Height Sensor (see Figure 10-1). 4.
Probe Removal and Replacement Use the following procedure to remove and replace the Height Sensor probe. CAUTION! If your system is equipped with a DP-3000, you may need to upgrade the Height Sensor probe. A special probe is required for the DP-3000 dispensing valve. If you need to change that probe, contact Technical Support and ask for the DP-3000 probe replacement kit. Tools and Materials Needed • 1/16-inch hex key To remove and replace the Height Sensor probe: 1. Remove the Height Sensor. 2.
Z-Axis Velocity and Acceleration The Z-Axis velocity and acceleration control the speed and acceleration of the lowering and raising of the dispensing head during a height sense measurement. Adjusting the Z-Axis velocity and acceleration can improve throughput by decreasing the time for a height sense measurement. ? NOTE At the factory, Z-Axis velocity is set at 50.8 mm/sec (2.0 in/sec), and Z-Axis acceleration is set at 7620 mm/sec2 (300 in/sec2).
Operation Height Sensor operation is controlled by Setup selections in FMW or FmNT. You can also insert more height sense commands directly into dispensing programs. When not measuring height, the Height Sensor probe remains retracted, preventing it from interfering with the dispensing process. Theory of Operation The Height Sensor uses a stainless steel probe to contact the dispensing surface. The probe tip is machined to minimize surface contact. Approximately 5 grams (0.
Minor Troubleshooting Table 10-1 Symptom Height Sensor Troubleshooting Check Correction Check probe function: 1. Push the probe up with your finger. • Probe does not drop or retract If the green LED on the side of the probe fails to turn ON, the probe is not working. 2. Verify that the probe moves freely up and down. • Needle hits substrate 10-12 1. Call a service technician. 2. Clean probe with an appropriate solvent; if unsuccessful, call a service technician.
Specifications Height Compensation Accuracy Z-Axis Velocity 100 mm/sec (4 in./sec)* 50 mm/sec (2 in./sec)* 25 mm/sec Z-Axis Acceleration 7.5 m/sec 2 ± 0.051 mm 3 sigma 2 (300 in./sec )* 7.5 m/sec 2 (± 0.0020 in.) ± 0.038 mm 3 sigma 2 (300 in./sec )* 2.5 m/sec Repeatability 2 (± 0.0015 in.) ± 0.026 mm 3 sigma 2 (1 in./sec)* (100 in./sec )* Force 5 grams (0.18 oz) Probe Diameters 1.59 mm (0.0625 in.) 1.91 mm (0.0750 in.) Probe Retract Adjustable 5-10 mm (0.2-0.4 in.
11 Needle Heater Overview The Needle Heater consists of a temperature controller and a heating element that attaches to the dispensing needle. The heating element is selected for compatibility with your valve or fluid pump (see Table 11-1). On M-2000 and Millennium Series dispensing systems equipped with heaters, the temperature controller is an integrated feature. The heating element plugs into outlets on the dispensing head and the temperature is controlled through the Fluidmove software.
Table 11-1 Heating Element Compatibility Guide Heating Element Valve Compatibility HT-04 Asymtek DV-04 valve only HT-06 All Asymtek valves except DV-04 HT-10N All Asymtek valves using metal needles WARNING! CAUTION! The Needle Heater and all heating elements should be installed by a service technician. If the dispensing system needs to be moved, the Needle Heater should be disconnected.
Figure 11-2 Figure 11-3 Needle Heater HT-06 HT-10N 11-3
OMEGA HT-1000 PV SV OC INDEX AL AUTOTUNE Figure 11-4 CN76000 SPI AL SP2 OF AL ENTER MADE IN USA HT-1000 Temperature Controller or HT-1200-RTD OMEGA HT-2000 OMEGA CN76000 SPI AL SP2 OF OC SV INDEX AL AL OMEGA AUTOTUNE ENTER MADE IN USA PV PV SV INDEX AL AUTOTUNE AL AUTOTUNE 11-4 AL CN76000 CN76000 SPI AL SP2 OF OC INDEX Figure 11-5 SV AL OMEGA SPI AL SP2 OF OC PV INDEX ENTER MADE IN USA AUTOTUNE CN76000 SPI AL SP2 OF OC PV AL ENTER SV MADE IN USA AL
WATLOW ANAFAZE 4CLS UNITS PROCESS LOOP 01 FS SET POINT ALARM MAN AUTO CHG SP 45 C 45 AUTO 9 STATUS NO YES OUT% BACK RAMP SOAK ALARM ACK ENTER WATLOW ANAFAZE 4CLS 01 FS SET POINT ALARM MAN AUTO Figure 11-6 UNITS PROCESS LOOP CHG SP 45 C 45 AUTO 9 STATUS NO YES OUT% BACK RAMP SOAK ALARM ACK ENTER 4-Channel Encap Temperature Controller The HT-1000 and HT-1200-RTD Temperature Controllers control one DC device, such as the heating element.
To install the temperature controller (HT-1000, HT-1200-RTD and HT-2000): ? NOTE See the specifications at the end of this section for power requirements. 1. Place the temperature controller in the workstation into the appropriate slot or on top of the dispensing system so that the rear panel of the temperature controller faces towards the back of the dispensing system. 2. Route the heating element J-type thermocouple cable and power cable through the cat track and to the rear of the dispensing system.
To install the heating element: 1. Loosen the thumbscrew on the front of the heating element. 2. Do one of the following, depending on your type of heating element: " For the HT-04, slide the heating element onto the needle and onto the valve tip. " For the HT-06, slide the heating element onto the needle and onto the Luer lock fitting (call Asymtek and ask for the Luer Lock Adapter; see Figure 11-8). " For the HT-10N, insert the needle into the side slot of the heating element.
Luer Lock Fitting Figure 11-8 HT-06 on a DV-6000 Pump with Luer Lock Fitting Figure 11-9 11-8 HT-10N on a DV-6000 Pump Needle Heater
Operation Theory of Operation Depending on the type of heating element used, the heating element attaches to the needle or to the Luer Lock fitting. Needle heater temperature is set with the temperature controller. A thermocouple cable connects the heating element to the temperature controller, telling the controller the heating element’s temperature. The temperature controller adjusts voltage to the heating element to achieve the desired temperature.
Operation Controls and Adjustments If you are running FMW or FmNT and using the Needle Heater on a Millennium Series dispensing system or a C-720 with a 4-channel temperature controller, the Fluidmove software controls the Needle Heater. In most cases, the Needle Heater is configured for your application at the Asymtek factory. However, if you need to modify the setup, follow the instructions below. To setup the Needle Heater on a Millennium Series system equipped with heaters: 1. Start FMW or FmNT. 2.
To set the needle heater temperature: 1. Press INDEX on the temperature controller front panel until you see Set Point 1 (SP1). 2. Using I and J, adjust the temperature in the Set Value (SV) display to the desired value. 3. When you reach the desired value, press ENTER. 4. Press INDEX to record the value and return to the main display. To change the display to Celsius or Fahrenheit: 1. Press I and ENTER simultaneously for five seconds. The display will show SECr and a number from 1-4. 2.
Advanced Operation To further define the heating process for your specific applications, you may want to change the temperature controller’s Proportional Integral and Derivative (PID) values. Only an advanced operator, process engineer or service technician should perform this procedure. Also, please see the OEM temperature controller manual (if available) accompanying your system before changing any values.
Autotune The Autotune feature of the temperature controller can select new PID values for you. Follow the procedure listed below. Consult the OEM temperature controller manual (if available) for more detailed information. ? NOTE The Autotune process can take up to two hours. To use the Autotune feature: 1. Using the controls as described above, access the Secure Menu and set the following parameters to the values shown: S1St rE S2St dir S2t dE SP2 0 Pb2 12 2.
Minor Troubleshooting • Consult the OEM temperature controller manual for a complete list of diagnostic error messages and required actions. • Make sure that all connections are secure. • Call a service technician. Specifications for Temperature Controllers (by model) Parameter HT-1000 HT-1200-RTD HT-2000 4-Channel Encap Temperature Ambient to 100°C Ambient to 65°C Range (212°F) (149 °F) Ambient to 100°C (212°F) Ambient to 135°C (275°F) Temperature ± 1°C (1.8°F) Regulation Range ± 1°C (1.
12 Needle Sensor Overview The Needle Sensor can be installed at various locations around the dispensing area, depending on the model of dispensing system. There are two types of Needle Sensors currently available: the NS Series and the NSZ Series. Millennium Series and Century Series dispensing systems with FMW can use either type of Needle Sensor. The NSZ Series, which includes an accessory Tactile Sensor, is shown in Figure 12-1. The NS Series sensor is shown in Figure 12-2.
Markings for Height Sensor and Needle Calibration Needle Sensor LED (Green) Needle Slot or ns Se e dl ies ee er N -S S N Figure 12-2 NS Series Needle Sensor The NSZ Series Needle Sensor includes a Tactile Sensor, which is used to calculate the Zheight of the needle tip during the Valve Offsets routine in Fluidmove. Both types of Needle Sensors use a fiber optic LED and an infrared sensor to locate and record the XYZ location of the needle.
Setup Your Needle Sensor is installed on your system at the factory. In addition, Fluidmove is configured to work with the specific Needle Sensor. If you make significant changes to your system configuration, upgrade your Fluidmove software, or if you are having trouble with the Valve Offsets or Calculate Master Offsets, Find Needle XYZ or Find Needle routines, you will need to perform the setup procedures below.
Calculate Master Offsets Calculate Master Offsets is a user-prompted routine that records the location of the Purge Station, the Weigh Station and XYZ location of the needle using the Needle Sensor and Height Sensor probe. Refer to Fluidmove for Windows User Guide or see Fluidmove’s Online Help for more guidance. To perform Calculate Master Offsets: 1. In the Main window, click on Configuration. 2. Select Needle Setup 3. Select Master Offsets.
Find Needle XYZ Find the Needle XYZ is performed during programming or production runs. This routine checks the XYZ location of the needle and returns the information to the software, which automatically makes any needed adjustments to the dispensing program. You can run this routine at anytime, or program it at any point in a dispensing program. To perform a Find Needle XYZ: 1. In the Main window, click on either Teach a program or Run a program 2. In the programming window, select Setup from the menu bar.
Operation Both the NS Series Needle Sensor and the NSZ Series Needle Sensor work with FMW and FmNT. The software on the dispensing system is configured at the Asymtek factory to work with either type of Needle Sensor. Theory of Operation The dispensing head lowers the dispensing needle into the Sensor’s needle slot, then passes it in front of two light beams, one for the X-Axis and one for the Y-Axis. When the needle breaks a beam, a coordinate is recorded.
Minor Troubleshooting Table 12-1 Symptom LED does not come ON during routine. Needle Sensor Troubleshooting Possible Cause • Needle Sensor malfunction. • No power to Needle Sensor. Recovery Call a service technician. LED is constantly ON. Something blocking the sensor. Clean sensor slots with a soft cloth or by blowing air through them. Needle jams too far into the needle sensor slot. Needle height change beyond capability.
Specifications Model 12-8 NS Series NSZ Series Size 165 x 75 x 19 mm (6.5 x 3.0 x 0.75 in.) 159 x 100 x 21 mm (6.25 x 4 x 0.813 in.) Minimum needle length 1.4 mm (0.125 in.) 1.4 mm (0.125 in.) Minimum needle diameter 30 gauge 30 gauge Accuracy ± 0.1 mm (±0.005 in.) ± 0.1 mm (± 0.005 in.) Repeatability ± 0.051 mm (± 0.002 in.) ± 0.051 mm (± 0.002 in.
13 Dual-Action Dispensing Head Overview The Dual-Action Dispensing Head allows you to mount and independently operate almost any combination of two valves or fluid pumps for applications needing two different fluids. The left dispensing head operates like standard Asymtek single dispensing heads. The right dispensing head is a toggle head, capable of rapid up and down motion. Figure 13-1 and Figure 13-2 show two attached fluid pumps mounted on a dispensing system.
Valve 1 Air Fittings Fluid 1 Pressure Fluid 2 Pressure Start Abort Pause 9 8 7 6 5 Program 4 3 2 1 0 Z Axis X/Y Axis Interlock Recovery Teach Enable System Status Interlock Find Home Valve 1 Pressure System Reset Valve 2 Pressure V1 Valve Status Valve Reset V2 Century S He ctileRT Ta Series igh t Se ns DP-2000 DISPENSING R I E S Valve 1 Pressure Regulator or HS- E PUMP O Valve 2 Pressure Regulator F F Valve 2 Air Fittings Fluid Syringe Height Sensor Fluid 1 Pressure Regu
Valve 1 Air Fittings Fluid 1 Pressure Regulator Valve 2 Pressure Regulator MILLENNIUM Fluid Pressure S or ns t Se gh Hei ctileRT Ta-Series HS E R I E S Valve Pressure DP-2000 DISPENSING PUMP Valve 2 Air Fittings Light Curtain O F F Light Curtain EL EC TR TIC OP IC ON Fluid Syringe Height Sensor Figure 13-2 Dual-Action Dispensing Head Dual-Action Dispensing Head (Millennium) 13-3
Pump 1 r so en tS igh He ctileRT Ta-Series HS Mounting Bracket for Pump 2 Air Cylinder Airflow Toggle Speed Adjustments for Pump 2 Pump 2 Dispensing Head Slide Mount O F F Figure 13-3 13-4 DA-700 with Fluid Pumps Detached Dual-Action Dispensing Head
Setup The Dual-Action Dispensing Head is installed at the Asymtek factory or at your facility by an Asymtek Field Service Engineer. Fluidmove software guides you through a one-time set up, which establishes the offsets between the fluid pumps and Z-axis heights for the Height Sensor probe, if equipped. The Fluidmove for Windows (FMW) application has a specific procedure for setting up the Dual-Action Dispensing Head.
Setup Using FMW Tools Only an Asymtek Field Service Engineer or an FMW-experienced process programmer should attempt to perform the setup procedure. ? NOTE These instructions do not discuss all configurable options in FMW Tools. Contact Asymtek Technical Support for more complete information. To setup the system in FMW Tools: 1. Select FMW – Tools from the FMW Program Group. 2. Select Service Mode from the Log On Dialog Box. 3. Enter your password. 4. Choose OK. 5.
Operation Controls You can adjust the speed of each fluid pump during dispensing operations. The fluid pump pressure and fluid syringe pressure are controlled by dispensing system regulators. You can also adjust the toggle speed for Pump 2 and the spacing between the fluid pumps, but the spacing is set at the factory and should not need to be changed. Valve 1 and Valve 2 indicators are located near the Valve Speed Controls. (See the dispensing system operations manual.
Adjusting Fluid Air Pressure See the dispensing system operations manual for the location of the regulators and instructions on how to change the settings. See also the fluid pump installation and operation manual for correct pressures. Changing Fluid Pump Spacing To maximize your dispensing area, the space between Pump 1 and Pump 2 is set up for your application at the Asymtek factory. Depending on your fluid pumps and accessories, you can separate the pumps 100 mm (3.72 in) or 87 mm (3.
Specifications Pump 1 - Pump 2 spacing ∆ X = 95 mm (3.74 in) ∆ Y = ± 0.25 mm (0.001 in) ∆ Z = 11.9 mm (0.47 in) Work Space* * Depends on dispensing options. Century Series C-702 210 x 284 mm (8.27 x 11.21 in) Century Series C-708 362 x 438 mm (14.27 x 17.25 in) Century Series C-708 AICE 356 x 277 mm (14 x 10.9 in) Millennium Series 290 x 447 mm (11.4 x 17.6 in) Height of Carrier or Substrate* * Depends on dispensing options. Max 2.1 in (53.3 mm) for Millennium Systems.
14 Conveyors Conveyors are not available for the C-720 basic dispensing system. For other production floor dispensing solutions, contact Asymtek to locate the nearest Asymtek Center of Excellence.
15 Heaters Heaters are standard on the C-720 dispensing system. See Heated Vacuum Tooling Plate in Section 4 – Operation for information. For other production floor dispensing solutions, contact Asymtek to locate the nearest Asymtek Center of Excellence.
16 Appendix Century Series Options Asymtek offers a wide range of special options for fine-tuning your dispensing applications. This section introduces the options currently available for Century Series systems. For optional accessories available for this and other Asymtek platforms, see the sections on cross-platform options (9-15). Expanded Opto-I/O The Expanded Opto-I/O option for your Century Series system provides access to 24 I/Os.
Operation Opto-I/O is electrically isolated from the other components of the system. This is an important safety feature for preventing overloads. The three 26-pin connectors are Ports A, B and C. Port A is the default port during normal operation and does not need to be connected to any device if it is the only active port. Ports B and C can be activated as accessories are added. The cables are attached as needed.
Applicable ACL Commands I/O ports are controlled with the following commands. The ACL Reference Manual (P/N 76-CS02-01, Rev. 3.7 and later) details these capabilities.
Interconnects The following table of interconnects can be used for testing devices and I/Os. Normally, only trained service personnel use this table.
Low Air Pressure Sensor The Low Air Pressure Sensor alerts the operator to pressure drops that can occur in large facilities that operate numerous pneumatic devices. The Sensor attaches to the P18 pneumatic outlet on the Pneumatics Module (located under the rear cowling). If pressure drops below its assigned threshold, the Sensor triggers the Safety Interlock System, bringing dispenser movements to a halt. ELEC. 7 ELEC. 8 ELEC. 9 ELEC.
Operation Controls If you need to change the Main Air pressure, see “Adjusting Air Pressures” in Section 4 – Operation. To set the low-pressure valve to trigger the sensor, follow the instructions below. Tool Required • Flathead screwdriver To set the low pressure set point: 1. Set the system pressure with the Valve Pressure or Fluid Pressure regulators to the low kPa (psi) at which you want to trigger the alarm.
Hour Meter The Hour Meter measures the operation time of the dispensing system. Operation time is the total time, idle or operating, that the dispensing system is ON. The Hour Meter attaches to the rear of the system (see Figure 16-3). Hobbs QUARTZ 1 0012 6 10 8 HOURS Hour Meter Figure 16-3 Hour Meter Theory of Operation The Hour Meter connects to the dispensing system Power Manager. When the dispensing system is turned ON, power is supplied to the Hour Meter and it begins counting.
Digital Scale The C-720 can be equipped with an integral Digital Scale for accurate weight-sampling of dispensing fluids used for data collection in support of fluid dispensing quality analysis. The Digital Scale consists of the Digital Scale instrument and the Weigh Station (see Figure 16-4 and Figure 16-5). The Weigh Station consists of a cup recess for the disposable cup located in the dispensing area up.
Digital Scale Troubleshooting Table 16-3 below describes the symptoms that can be readily corrected by the operator. For other difficulties not listed, contact Asymtek technical Support Group. Refer to Section 7 – Maintenance, for additional information as applicable. Table 16-3 Digital Scale Troubleshooting Symptom Possible Cause Recovery A. Unit has not reached operating temperature Allow an average of 60 minutes of warm-up time for scale temperature to stabilize. B.
Digital Scale Maintenance The Digital scale operator-performed maintenance consists of tracking the hours of operational use, cleaning and periodically checking the Digital scale for accuracy. Refer to Table 16-4 below for preventive maintenance. Contact Asymtek Technical Support Group for calibration and service.
HT-1000 NEEDLE HEATER HT-1000 NEEDLE HEATER COMPANY ENTER OMEGA CN76000 AUTOTUNE INDEX ENTER 8 OMEGA CN76000 AUTOTUNE INDEX 7 SPI AL SP2 OF OC DI-100 100 x 0.0001g Denver Instrument menu SPI AL SP2 OF OC ENTER OMEGA CN76000 AUTOTUNE INDEX SPI AL SP2 OF OC A NORDSON 9 0 help 4 5 6 .
17 Glossary ABCD Box: Connects the computer to the upstream and downstream Free-Standing Loaders (FSL’s). It is used when programming the FSL’s. Circuit Breaker: An automatic switch that cuts the electrical supply to the system when the power exceeds the set level. ACL: Automove Control Language. Cognex Circuit Board: Used in the computer along with the Video Card to run the Vision System.
EMO: Emergency Machine OFF button, sometimes called E-Stop. A large red button that cuts power to the dispensing system only. Does not turn off power to the Power Manager. Heaters are usually turned off, but can remain hot for some time. Part of Safety Interlock System. After the EMO button is pressed, to reset it you must rotate the button clockwise until it pops out. European CE Standard: A set of standards adopted by the European Common Market for: safety, power, etc.
LRHC: Lower-Right-Hand-Corner PID: Proportional Integral and Derivative. Material Safety Data Sheet (MSDS): Information for the safe use of materials. Generally included in the fluid packaging. Pixels: The smallest unit of graphical data appearing on a computer monitor. A pixel usually consists of color and brightness information. Message Areas: In a Windows program, these are windows or boxes that contain information for the operator. PLC: Programmable Logic Controller.
Regulator: Device for controlling the amount of air pressure supplied to the system. SMEMA: Surface Mount Equipment Manufacturers Association. RTD: Resistance Temperature Detector. A wire coil or deposited film of pure metal, typically platinum. The element’s resistance increases with temperature in a known and repeatable manner. SSR: Solid State Relay. Safety Interlock System: A key activated device used to restrict access to the inside of the dispensing system.
Underfill: The process of flowing epoxy underneath a flip chip on a PCB to completely seal the solder bumps. URHC: Upper Right Hand Corner. Valve: A device used to control or regulate the flow of material from a pressurized reservoir, such as a syringe. Valves can be actuated by several methods, such as air pressure, augers, or solenoids. Valve Conditioning Fluid: A thick blue fluid used to condition the inside of dispensing valves.
18 Index A ABORT button, 4-11 ACL commands, 16-3 air cylinder, 13-4 air filter, 2-11 air pressure, 8-2; fluid, 4-22; main, 4-19; valve, 4-24 applications, 13-1 autotune, 11-13 AV-700 Targeting Offset Camera, 9-2 B beacon, light, 4-16 black pneumatic line, 4-20 blue pneumatic line, 4-20 brightness adjustments, 9-5 C calculate master offsets, 10-12, 12-4 camera calibrations, 9-13 CD-ROM drive, 4-6 circuit breaker: main power, 3-10 clear pneumatic line, 4-20 Cognex, 9-11 computer, 2-5, 4-6, 4-8; controls, 4-
I integrated safety systems, 3-6 interior light, 2-6 interlock, 3-6–3-7; key, 4-14 L levelers, 2-6 lifting precautions, 3-14 light beacon, 2-6, 3-7, 4-16; color code, 4-17 light ring, 9-5, 9-15 light ring card, 9-2 light source, 9-11 light, interior, 2-6 locking out power, 3-11 low air pressure sensor, 16-5, 2-11; adjusting set point, 16-6 lower cabinet, 2-4 M main air inlet, 2-11 main air pressure, 4-19; adjusting, 4-19; gauge and regulator, 2-11 main power cable, 2-11 main power circuit breaker, 2-9, 3-
testing: I/Os, 16-4 theory of operation, 4-1 toggle adjustment, 13-4 toggle control, 13-7 toggle head, 13-1; adjustments, 13-7 toggle speed, 13-8 tooling plate: temperature control setup, 4-34; vacuum area setup, 4-33 tools: maintenance, 7-7 troubleshooting, 6-1; AV-2550, 9-13; heated vacuum plate, 6-5; height sensor, 10-12; needle sensor, 12-7; system, 6-2 V VACUUM button, 4-29, 4-30 valve OFF, 4-20 Valve Offsets, 12-3 valve ON, 4-20 valve pressure, 4-23; adjusting, 4-24; gauge and regulator, 2-8 valve pr
