DP-3000 Series Linear Dispensing Pump Owner’s Manual P/N 78-0024-00, Revision D
NOTICE This is an Asymtek publication, which is protected by copyright. Original copyright date 2000. 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.
1 Introduction The DP-3000 Series Linear Dispensing Pumps are servo-controlled, piston-type pumps that can be used on Asymtek Millennium, Century, and Axiom fluid dispensing systems. The DP-3000 is a positive displacement pump capable of dispensing a specified amount of fluid at relatively high flow rates and accurate volume repeatability, regardless of fluid viscosity. Figure 1-1 shows a typical DP-3000 and identifies the hose and cable connections.
The DP-3000 introduces several key features, which enhance its performance over other commonly used pumps. 2 • Levers replace many separate tools for fast, clean disassembly and reassembly. • A “Quick Release” bracket makes removing the DP-3000 for cleaning quick and easy, with no tools required. • Very fast priming with minimal material waste. • Specially designed priming/pumping chambers for less fluid waste during priming; fewer trapped air bubbles mean fewer priming sequences.
Figure 1-2 shows the DP-3000 with the swinging bracket open for a better view of other major components.
Pump Configuration The DP-3000 Series Pumps have three key configurable components that determine performance. When you receive the pump for your system, it should be configured as requested for your application. The key components and how they affect pump performance are described in the table below. For more detailed information, see the Operation section. Table 1-1 Key Configuration Components Key Component Performance Stopcock Controls the flow direction of material for dispensing and refilling.
Encoded Motor Earlier models of the DP-3000 Series pumps were designed using motors which have specific speeds. See Table 1-3. The speed of the motor affects the flow rate accuracy of the volume of fluid dispensed. Newer models of the DP-3000 Series pumps are designed with an encoded motor. The encoder control assures consistency when installing the DP-3000 on different dispensing systems. The encoded motor also allows for a faster refill, permitting greater throughput.
Table 1-4 is a list of DP-3000 Series pump models and their applications. Use this table as a guide to help you determine the best configuration for your application. Table 1-4 DP-3000 Series Linear Dispensing Pump Applications Part Number 6 Application DP-3120 All speed, 1 cc capacity. Typically used for underfill applications. DP-3121 Very low flow rate, underfill applications. DP-3122 Underfill applications. DP-3124 Small capacity for cavity fill. DP-3140 All speed, 2 cc capacity.
2 Installation The DP-3000 Series Linear Dispensing Pump is designed for use on Asymtek Millennium, Century, and Axiom Series dispensing systems. Using the pump requires special electronics and cabling. If you have an earlier model that is not configured to accommodate a DP-3000, contact Asymtek to find out if an upgrade kit is available for your dispenser.
2. Use the Phillips-head screwdriver to loosen the screws on the Height Sensor bracket, and remove the Height Sensor from the old bracket. ! If the Height Sensor includes a bracket spacer, remove the bracket spacer. 3. Use the 5/64-inch hex key to loosen the five set screws on each side of the Z-head slot until the tops of the screws are flush with the inner surface of the slot. 4. Place the dovetail receiver assembly into the Z-head slot. See Figure 2-1. 5.
Power Cable Hei ctileRT Ta-Se ries ght Sen sor HS Height Sensor Bracket Height Sensor Figure 2-2 Installing the Height Sensor 9. Configure the DP-3000 with a dispensing chamber, stopcock, desired syringe size, proper Luer fittings, syringe clip, cartridge sleeve, if necessary, and needle as required for your application. Refer to “Using the DP-3000” in the Operation section for instructions. 10. Position the Quick Release mate onto the back of the DP-3000 as shown in Figure 2-3. 11.
13. 14. Flip the orange locking lever on the mate all the way up. ! This is the unlocked position. ! The lever is retained in the unlocked position by a detent; you will feel a click as it engages. Slide the mate (with the pump attached) all the way down the track into the dovetail receiver assembly. ! 15. The bottom surface of the mate should rest against the dovetail mating stop at the bottom of the dovetail assembly. See Figure 2-4.
20. Use the front panel controls or the Fluidmove position controls to slowly move the dispensing head around the dispensing area in the X, Y and Z axes, making sure that the pump can go low enough to dispense and high enough to avoid hitting any obstacles. ! 21. Adjust the height of the pump assembly within the Z-head slot, if necessary. Configure the Fluidmove software as described in “Software Configuration” later in this section.
M-4 Screws M-4 Screws Z-Head Mounting Plate Dovetail Receiver Assembly Figure 2-6 Mounting Dovetail Assembly 4. 12 Place the flat washers onto the M4 screws. ! It is important to use washers with these screws to prevent damage to the aluminum on the dovetail receiver assembly. ! Use Loctite Removable Threadlocker #242 on the screws before replacing them. 5.
13. Place the Quick Release Mate (with the pump attached) into the dovetail receiver assembly. ! Make sure that the pump will not hit any obstacles as it moves around in the XY axis and that enough room has been allowed for the vision system. ! The pump should rest against the dovetail mating stop at the bottom of the bracket. (See Figure 2-4 to locate the dovetail mating stop.
Syringe Receiver Head (Clear) Valve Pressure (Blue) Stopcock Pressure (Black) Valve Power Cable Height Sensor Figure 2-8 Valve Cable and Hose Connections (Axiom X-1020 Series) To Install the DP-3000 with a Standard Bracket: This procedure can be used for installing a DP-3000 with a standard bracket on a Millennium, Century or M-2000 Series dispensing system. 1. Remove the currently installed fluid dispensing pump and bracket assembly. ! 2.
Software Configuration Once the DP-3000 is completely installed on your dispensing system, the Fluidmove software needs to be configured to accommodate the new pump. FmNT/FmXP: 1. Start the Fluidmove software. ! If Fluidmove is already running, save all currently loaded dispensing programs. This procedure requires the computer to be restarted. Any unsaved changes to the currently loaded dispensing program may be lost if not saved. 2. In the Main Window, click on Configuration>Setup Valves. 3.
Installation Verification Test After you have installed the DP-3000 on your dispensing system, it is recommended that you perform an Installation Verification test to ensure that the DP-3000 is accepting and properly responding to software commands by moving the piston appropriately. " NOTE 1. It is recommended that you perform this test without a fluid syringe installed to allow an unobstructed view of the piston movement. Turn the dispensing system ON.
3 Operation Before operating your DP-3000 Series Dispensing Pump, it may be helpful to familiarize yourself with the basics of how the pump works. In this section, typical configurations are considered. However, operational details may vary with the configuration of your system. Theory of Operation Operation of the DP-3000 is, for the most part, automatic. Once the pump is up and running, a minimal amount of operator attention is required.
Refill Valve Command Air from pneumatic line hits actuator, which rotates stopcock open to Refill position. Fluid flows from the reservoir through the stopcock. Motion action draws piston up to Refill position. Air pressure applied to the fluid reservoir through pneumatic line causes fluid to flow into the pumping chamber Sensors detect piston in Prime position. Air pressure to the actuator piston causes the stopcock to move to the dispense position. End of Refill process.
Operation Commands There are several software commands and hardware controls critical to pump operation. The following are brief descriptions of these commands and controls. Software Commands The Fluidmove software uses the following setup features and commands to operate the DP-3000 Series Dispensing Pump.
Purge or Purge Needle Infinite This command applies to all Asymtek pumps and is used to prepare the pump and the dispensing needle for dispensing. The dispenser moves to the Purge Station, the piston moves forward, pressing fluid from the pumping chamber and into the purge station cup. Purge can only be invoked when the pump is in Dispense-Ready condition. Forward/Reverse These commands allow the operator to turn on the motor and move the piston up or down for a specific duration.
Find Home 5 Valve Speed Controls Select Pause Reset Pause Go Set Origin Go To Origin Z Axes Teach DISPENSER Valve 1 Start Interlock Recovery Valve 2 AIR Reset ALARM INTERLOCK Reset Button Figure 3-3 Valve Speed Controls (M-600 Series) Valve Speed Controls Valve Pressure Fluid Pressure Abort Pause 9 8 7 6 5 4 Program 3 2 1 Start 0 Z Axis Teach Dispenser Conveyor Conveyor Status Interlock Recovery Dispenser Status Valve Status Interlock Pause Find Home V1 Reset Reset Val
LED Indicators There are four LEDs located on the front of the pump that indicate the operation status of the pump. All four lights are green; the indicators are defined by letter and position on the pump (definitions appear below). They may be used during troubleshooting to help identify a failure. Table 3-1 describes the LED indicator status. Table 3-2 describes common conditions based on LED status.
Using the DP-3000 The following procedure is an example of a typical DP-3000 dispensing process. It begins with a disassembled pump, then walks you through assembling the pump and getting it ready to dispense. It also explains how to use the operation commands to setup, refill, purge, and prime the pump. You should adapt this procedure to fit your specific application as necessary. Use of this procedure will ensure reliable dispensing performance.
3. Gently slide the chamber retention slide out to the open position. See Figure 3-8. 4. Assemble the pumping chamber. ! Refer to either Figure 3-9 or Figure 3-10, depending on your pumping chamber configuration.
5. Insert the pumping chamber into the DP-3000 as shown in Figure 3-11. ! The prime port faces left, away from the chamber retention slide. The pumping chamber should fit over the piston and snugly up against the piston opening. 4 0 Pumping Chamber (Standard Chamber shown) Figure 3-11 Pumping Chamber Installation 6. Push the chamber retention slide in to lock the pumping chamber in place. 7. Place the stopcock into the Luer clamp block. See Figure 3-12.
8. Refer to Figure 3-13 and perform the following steps to close the DP-3000: a. Pull out on the blue detent lever to unlock the sliding bracket. b. Gently push up on the sliding bracket, making sure that the bottom of the pumping chamber fits into the top of the stopcock. c. Rotate the green chamber retention lever down 90° to lock the sliding bracket in place. d. Close the swinging bracket, making sure that the stopcock fits into the grooves on the stopcock actuator.
10. Flip the orange locking lever on the pump all the way up. See Figure 3-15. ! 11. Slide the pump all the way down the track of the dovetail receiver assembly on the dispensing head. ! 12. This is the unlocked position. The bottom surface of the pump should rest against the dovetail mating stop at the bottom of the dovetail assembly. See Figure 3-15. Flip the orange locking lever 190° (down) to lock the pump into place.
13. Connect the DP-3000 power cable and pneumatic hoses to the appropriate connections. Refer to Figure 3-16 for M-600 and Century Series Systems. Refer to Figure 3-18 for Axiom X-1020 Series Systems. Refer to Figure 3-18 for M-2000 Series Systems.
14. Install a priming port stopcock to the priming port. See Figure 3-19. ! Asymtek offers priming port adapters other than the type shown in Figure 3-19 which may better suit your specific needs. See “Priming Port Stopcock Options” later in this section for more information. Priming Port Luer Adapter Priming Port Stopcock (closed position) Figure 3-19 Installing Priming Port Stopcock 15. Use the 2.5-mm hex key to install the appropriate size syringe or cartridge clip.
16. Inspect the syringe for air bubbles in the fluid, and reject any samples that have visible voids. 17. Insert the syringe or cartridge into the clip. 18. Attach a receiver head to the syringe or cartridge. 19. Use the appropriate Luers and adapters to connect the fluid syringe to the DP-3000 stopcock. ! 20.
Receiver Head Hose Receiver Head Fluid Syringe Cartridge Sleeve (6-ounce shown) Plastic Luer Adapter Figure 3-22 Installing a Cartridge “L” Luer Extended “L” Luer Tube Luer Straight Luer Figure 3-23 Luer Adapter Options Operation 31
21. Connect a needle to the Luer lock hub on the bottom of the stopcock. ! 22. Set the fluid pressure between 40 and 80 psi, depending on your application. ! 23. Contact Asymtek if you need assistance in determining a valve pressure range. Perform either a Prompted Setup or a Valve Offsets routine depending on your system configuration. ! 25. Refer to the dispensing system Operations Manual for instructions on adjusting fluid pressure, if necessary.
i. " 26. Select Valve - Purge Needle from the Fluidmove Production Window drop-down menu. See Figure 2-10. ! The dispensing head moves to the purge station and purges the pump for a preset amount of time. ! If the pump seems to operate but no fluid flows from the needle, the purge duration may be too short. Either conduct multiple purges or extend the purge duration.
Automatic Refill This feature can greatly increase throughput by inserting a Refill command directly into the dispensing program. The DP-3000 will automatically refill at the point in the program where the Refill command appears. To insert a Refill command into the dispensing program: 1. Calculate the number of shots before you will need to refill by determining when the chamber will be running out of fluid.
Needle Sizes and Types Changing the size of the dispensing needle can change the width of the fluid line dispensed. A larger needle will create a larger line. However, using a smaller needle does not affect the flow rate. The DP 3000 Series pump accepts Luer lock dispensing tips. Use only the dispensing tips provided in the VK 6000 valve kit. " NOTE You should always use the largest diameter needle possible for your application to place the least amount of stress on the stopcock.
The type of needle used also has an effect on needle movement. Threaded needles provide the best support as they provide a full 360° of contact with the threads in the Luer lock ring. Square needles with flanges (square upper edge) offer less support and can move at the unsupported points on the flange (see Figure 3-25). Square needles offer support only at the corners, where the flange touches the Luer lock ring.
To Pump Chamber Note: A needle with Luer threads can be positioned in any direction Stopcock Taper O F F O F F To Fluid Syringe O O F F F F Luer lock ring O F O F F F O F F O F Insert the needle into the stopcock Luer lock ring F O O F F F F Insert the needle into the stopcock Luer lock ring O F O F F F Rotate needle slightly to get the threads started O F Position the needle so that the flat flange (with the gauge marking) is parallel to the stopcock crossbar F O F Note: Twisting t
O F Align the flat flange of the adapter lip parallel to the stopcock crossbar F Hold adapter stationary— do not twist it O F F Insert the HT-06 adapter straight into the stopcock Luer lock ring O F F Note: As you insert the HT-06 adapter straight into the stopcock, be sure to align the flat sides of the upper lip exactly with the crossbars of the stopcock HT-06 adapter inserted into stopcock Luer lock ring Hold the adapter still while twisting the Luer lock ring as shown to secure the adapter Figu
To install the stopcock/needle assembly into the pump: 1. Assemble the stopcock and needle assembly and insert it into the Luer clamp block as shown in Figure 3-29. 2. Flip the yellow Luer clamp block lever down in the direction shown in Figure 3-30. ! 3. The stopcock/needle assembly should now be held firmly in place. Pull the blue sliding bracket detent lever toward you, withdrawing the rod from the detent. ! This frees the sliding bracket. 4.
Priming Port Stopcock Options The threads on the standard priming port stopcock shown in Figure 3-19 can strip if overtightened. To prevent this, Asymtek offers a tube option that fits directly onto the priming port with no threads. A small cap is used to plug the tube when not in use. The tube can also be removed and the cap put directly onto the priming port. This option, shown in Figure 3-31, is used in conjunction with the metal luer priming port, shown in Figure 3-9.
4 Maintenance This section provides recommended maintenance procedures. Performing the recommended maintenance procedures at regular intervals is an essential factor in maintaining maximum performance from your DP-3000 Series dispensing pump. Recommended maintenance procedures are listed in Table 4-1. Table 4-1 DP-3000 Recommended Maintenance Procedures Maintenance Procedure Clean pumping chamber. Replace stopcock.
If necessary, refer to the figures in the Operation section for help locating parts when performing the following procedures To clean the DP-3000: " 1. Disconnect the DP-3000 black pneumatic hose from the dispenser. 2. Disconnect the DP-3000 blue pneumatic hose from the dispenser. 3. Disconnect the syringe receiver head hose from the dispenser. 4. Disconnect the DP-3000 power cable from the dispenser. 5. Remove the DP-3000 from the dispensing system.
Black O-Ring Plastic Prime Port Priming O-ring Scribe Urethane O-Ring Metal Luer Prime Port Priming Chamber Pumping Chamber Static O-ring Pumping Chamber Figure 4-2 18. 19. Pumping Chamber Seal Scribe Cleaning the Low-Pressure Chamber Assembly Priming Chamber Pumping Chamber Figure 4-3 Cleaning the High-Pressure Chamber Assembly Remove the prime port from the side of the priming chamber.
Greasing the Lead Screw You should grease the DP-3000 lead screw quarterly to reduce friction and wear on the pump. See Figure 4-4. Tools Needed: • Small flashlight • 10-cc syringe of synthetic PTFE fortified grease (included with the DP-3000 kit and available through Asymtek) To grease the Lead Screw: 1. Turn the upper knob to drive the piston to its lowest position. ! You can also lower the piston using the Fluidmove software. Follow the steps below. a. From the Main Window, click Tools. b.
5 Troubleshooting If you experience difficulties or poor performance when using DP-3000 Series pumps, use Table 5-1 for general troubleshooting, and Tables 5-2, and 5-3 for more specific troubleshooting to help correct the problem. If you cannot correct the problem, contact Asymtek Technical Support. Table 5-1 Troubleshooting Guide, General Symptom 1. Intermittent or no fluid dispensing. Possible Cause Recovery A. Pump poorly primed. A. Perform a priming sequence. B. Clogged dispensing tip. B.
Table 5-1 Troubleshooting Guide, General (Continued) Symptom 4. Pump unable to complete reset routine. 5. Material drips or trails slightly from the needle. Recovery A. Pump air pressure too low. A. Set valve pressure to 40-80 psi. (For encoded models, set the fluid pressure to 40 psi instead of the valve pressure.) B. Speed Control too slow. B. Make sure Speed Control is greater than 1. C. Stopcock jammed with cured material. C. Replace the stopcock. D.
Table 5-2 Troubleshooting, Premature Stopcock Failure Symptom 12. Stopcock is cracked or leaking. Evidence of dispensing drooling or tailing (air in chamber). Possible Cause A. Pressure is too high in the pump chamber, or pressure exceeds recommended settings. Recovery A. Reduce dispensing pressure by one of the following methods: 1. Reduce dispense needle length; increase needle ID; or change to cone needle. (Needle size and type effects pressure). 2.
Table 5-2 Troubleshooting, Premature Stopcock Failure (Continued) Symptom Possible Cause Recovery 12. Stopcock is cracked or leaking. Evidence of dispensing drooling or tailing (air in chamber). C. Improper support of the 6-oz cartridge or improper stopcock installation. C. Correct the condition by performing one of the following steps: 1. Replace the metal feed elbow parts (P/Ns 030551-00 and 03-094-00) with Kit VK-DP31-6P parts (includes standoff ring 030797-00*. (Continued) 2.
Table 5-4 Piston Replacement Wear Limits Chamber Piston Size Diameter Wear Limit 1-cc 6.22mm (0.245-inch) 2-cc " NOTE 9.40mm (0.370-inch) Wear may be uneven. Measure piston diameter at several places, especially bottom tip. Table 5-5 Matched Cartridge Clip and Stopcock Syringe/Cartridge Clip P/N Matching Stopcock P/N 03-1280-00 42-0080 03-1280-01 42-0083 Table 5-6 Dispense Tip and Recommended Flow Rates.
Feed Screw Jam Recovery The piston has a working range between the Home position and the Purge position. If, for some reason, the piston travels beyond this range, it can become lodged in the extreme up or down position. When this happens, the motor stops and an error light comes on above the Valve 1/Valve 2 Speed Controls on the Auxiliary Control Panel. To recover from this error: 1. Reset the Dispensing System. a.
Manual Feed Screw Knob Figure 5-1 Inserting the Manual Feed Screw Knob (Cutaway View) DP-3000 Reaches Travel Limit Recovery If not programmed properly, a dispensing program can cause the DP-3000 to empty the entire pumping chamber before dispensing is completed. When this happens, Fluidmove will issue a warning that the DP-3000 has reached its travel limit. To recover from a travel limit error: 1. In the Fluidmove Main Window, click on Run a Program. 2.
Appendix A Illustrated Parts List The drawings included in this appendix are exploded view drawings illustrating all of the parts on the DP-3000. See Figures A-1 to A-4. Part numbers and descriptions are included in Table A-1. Use these drawing and part numbers when ordering spare parts for your DP-3000. Part numbers are subject to change without warning. Contact Asymtek for more information. Table A-1 Parts List ITEM NO. QTY. ITEM NO. QTY.
Table A-1 Parts List (Continued) ITEM NO. QTY. ITEM NO. QTY. 61 1 07-0013-00 SPRING,TORSION,NEEDLE HEATER 91 1 48-5005 WASHER, 1/4 BELLEVILLE SSSHR. 62 1 45-1007 BUSHING,FLANGED,1/8IDX3/16L 92 1 03-0079-00 NUT, ALUMINUM, BIMBA 63 1 03-0734-00 CLAMP,CABLE,HALLEFFECTS 93 1 03-2319-00 TRACK,LATCH,SWINGING BRACKET 64 2 49-3320 SCREW, M3X20, SOCK.HD.CAP,SS 94 1 02-0075-00 LATCH, SWINGING BRACKET 65 1 47-1456 SPRING, COMP, SS, .240 D, 1.
Figure A-1 Illustrated Parts List (1 of 4) 54 Appendix A - Illustrated Parts List
Figure A-2 Illustrated Parts List (2 of 4) Appendix A - Illustrated Parts List 55
Figure A-3 Illustrated Parts List (3 of 4) 56 Appendix A - Illustrated Parts List
Figure A-4 Illustrated Parts List (4 of 4) Appendix A - Illustrated Parts List 57
Asymtek Headquarters 2762 Loker Avenue West Carlsbad, CA 92010-6603 USA Tel: (760) 431-1919 1-800-ASYMTEK (1-800-279-6835) P/N 78-0024-00, Revision D © 2005
