DV-7000/DV-8000 Series ® Heli-Flow Pump Owner's Manual
NOTICE This is an Asymtek publication, which is protected by copyright. Original copyright date 2006. 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 Asymtek manuals can be downloaded from: http://www.asymtek.com/support/manuals.
Table of Contents Table of Contents ........................................................................................................................................1 1 Introduction ..........................................................................................................................................1 Overview ................................................................................................................................................1 DV-7000 ...................
Calibration and Adjustment..................................................................................................................32 Parts Ordering Information...................................................................................................................32 Preventive Maintenance ......................................................................................................................32 Cleaning the Pump ...............................................................
1 Introduction Overview The DV-7000 Series and DV-8000 Series Heli-Flow Pumps are rotary, positive displacement auger valves. Each valve has a closed-loop, servo-controlled motor with encoder feedback that can reverse to create a clean fluid cutoff. The DV-7000/DV-8000 pumps are designed and exclusively manufactured by Asymtek to meet high-volume production requirements. " NOTE The terms pump and valve are synonymous in this manual.
DV-7000 Features The DV-7000 (Figure 1-1) is designed with the following key features: • Footed cartridge with a fixed mechanical stand-off nozzle for extremely consistent dots and increased throughput • Luer-cartridge option allows use with a wide range of standard needles • Tool-free disassembly of wetted parts for quick and easy cleaning • Fast cartridge changeover • Cartridges are interchangeable with DV-8000 pumps • Closed-loop motor control with encoder feedback ensures high repeatability a
DV-8000 The DV-8000 Heli-Flow® pump (Figure 1-2) features interchangeable cartridges for use in high flow rate encapsulation and lid seal applications, allowing each pump to work with several different fluid types. The DV-8000 has a fixed head design for use with high-viscosity fluids and high flow rate for fast dam writing. Typical applications for the DV-8000 include thermal grease, silver epoxy, and lid seal and dam materials.
DV-8000 Series Features The DV-8000 is designed with the following key features: • Ideal for high-speed dams and lines of encapsulants, silver epoxy, lid seal, and thermal grease • Tool-free disassembly of wetted parts for quick and easy cleaning • Fast cartridge changeover • Cartridges are interchangeable with DV-7000 pumps • Closed-loop motor control with encoder feedback ensures high repeatability and precision dispense control • Long-life carbide cartridges • Powerful 11-watt motor and two
2 Safety Overview This section describes the precautions to be taken to promote safety of personnel and prevent unnecessary damage to your DV-7000 or DV-8000 Series Heli-Flow Pump and valuable workpieces. WARNING! CAUTION! Unsafe equipment conditions can result in personal injury or property damage. Failure to properly operate and maintain the system in accordance with this manual may jeopardize the built-in safety features. CAUTION! " NOTE The DV-7000 and DV-8000 pumps are precision instruments.
Safety of Personnel • Only trained personnel should be permitted to perform installation, operation, maintenance, and troubleshooting procedures on the DV-7000/DV-8000 Series pumps. • Before performing maintenance or service on the DV-7000/DV-8000 pumps, position it at the front of the dispensing chamber. This will provide easy access to components and limit exposure to hazardous areas. • Immediately push the red Emergency Machine Off (EMO) button on your dispensing system if personnel are in danger.
3 Installation Overview This section includes DV-7000/DV-8000 installation instructions for the Century, Millennium M-2000, Axiom, Spectrum, and DispenseMate Series Dispensing Systems. " NOTE For more information, refer to the manual for your particular dispensing system.
Installation on Century Series Systems " NOTE Illustrations in this section show the DV-7000, but installation instructions also apply to DV-8000 Series pumps. 1. Use the position controls to move the dispensing head to the front center of the dispensing area. 2. Perform a service shutdown and lock out/tag out power to the dispensing system as specified in the applicable dispensing system manual. 3. Slide the valve into the valve bracket (Figure 3-1). 4.
Height Sensor Bracket Valve Bracket Height Sensor Bracket Height Sensor Figure 3-2 Attaching the Height Sensor Bracket 7. Slide the pump (with Height Sensor, if installed) into the valve mounting plate (Figure 3-4). ! 8. Position the valve bracket on the mounting plate so that when the pump is installed it will not collide with components when moving around the dispensing area.
Installation on M-2000 Series or X-1000 Series Systems " NOTE Illustrations in this subsection show the DV-8000, but installation instructions also apply to DV-7000 Series Pumps. 1. Use the position controls to move the dispensing head to the front center of the dispensing area. 2. Perform a service shutdown and lock out/tag out power to the dispensing system as specified in the applicable dispensing system manual. 3.
Height Sensor Bracket Valve Bracket Height Sensor Bracket Height Sensor Figure 3-8 8. " Attaching the Height Sensor Bracket (M-2000, X-1000 Systems) Location of the power connections depends on the dispensing system. Figure 3-10 and Figure 3-11 show typical connections on M-2000 and X-1000 dispensing systems. For systems with a Dual-Action Dispensing Head, refer to the applicable manual. Configure the Fluidmove software for the DV-7000/DV-8000 valve.
Installation on Spectrum Series Dispensing Systems 1. Use the Fluidmove software position controls to move the dispensing head to the front center of the dispensing area. 2. Perform a service shutdown and lock out/tag out power to the dispensing system as specified in the applicable dispensing system manual. 3. Slide the dovetail bracket (included with the dispensing valve) into the valve mounting bracket on the Z-axis face plate. 4.
Installation on DispenseMate 550 Series Dispensing Systems " 1. Use the Fluidmove software position controls to move the dispensing head to the front center of the dispensing area. 2. Perform a service shutdown and lock out/tag out power to the dispensing system as specified in the applicable dispensing system manual. 3. Loosen the six (6) screws on the Z-axis face plate (Figure 3-14A) and slide the face plate up so that it is flush with the Z-axis extrusion (Figure 3-14B).
Software Configuration Once you have installed the pump on your dispensing system, the dispensing software must be configured. WARNING! Only trained service technicians should perform this procedure. 1. Perform a system start-up as specified in the applicable dispensing system manual. 2. Start the Fluidmove software by double-clicking the Fluidmove icon desktop. 3. Select Configuration > Setup Valves from the Fluidmove Main Window. ! on the Windows The Setup Valves screen (Figure 3-16) opens.
a. In the Setup Valves dialog box, click on Edit (Figure 3-16). b. In the Settings dialog box, click on the Settings tab and click on the radio button next to Constant syringe pressure during dispensing (Figure 3-17). ! c. Activating this feature means that a constant supply of air pressure will be applied to the syringe as opposed to the air toggling ON and OFF as needed. A constant air supply can result in more a consistent dot size.
Installation Verification Test Once you have installed the pump on your dispensing system and configured the software, it is recommended that you perform this test to ensure that the pump accepts commands from your operating system and responds by moving the feedscrew in the correct direction. WARNING! Only trained service technicians should perform this procedure. 1. Start Fluidmove. 2. In the Main Window, click on Tools. 3. In the Tools Window, click on I/O Test and then click on Dispenser. 4.
6. Toggle the output OFF and make sure that the ball coupling stops turning. 7. In the Dispenser I/O Test dialog box, locate the Valve Reverse output. See Figure 3-18. ! The output name may be different on your system, but it should be similar enough to be easily identified. ! On systems with Dual-Action Dispensing Heads, you will have to select Valve 1 (V1) or Valve 2 (V2) for I/O testing, as applicable. 8. Toggle the output ON and check the direction of the ball coupling.
4 Operation Overview This section covers the following topics: • Theory of Operation • Installing/Changing a Fluid Syringe • Pump Adjustments • Priming the Pump • Assembling a Dispensing Cartridge • Valve Offsets • Loading a Dispensing Cartridge • DV-7000 Optional Configuration Theory of Operation The DV-7000 and DV-8000 pumps use the following mode of operation: 1.
Air Pressure Air pressure is used to move the material from the syringe to the feedscrew. The greater the pressure, the faster the material reaches the feedscrew. However, excessive air pressure can be detrimental to the dispensing process. Refer to the Specifications section for recommended air pressure settings. Software Parameters Refer to the Fluidmove User Guide or Online Help for detailed explanations of line and dot parameters.
Thrust Collar Feedscrew Cartridge Body Seal Guide Tool (P/N 196630) Lower Bearing Seal (spring side up) Cartridge Body Seal Insertion Tool (P/N 196629) Cartridge Fitting (Luer) Needle (Luer) Needle Retainer Figure 4-1 Installing a Cartridge Seal 20 Figure 4-2 Dispensing Cartridge Exploded Operation
Loading a Dispensing Cartridge DV-7000 CAUTION! " NOTE Only trained service technicians should perform this procedure. This procedure is for a pump already mounted on the dispensing head. 1. Use the position controls to move the dispensing head to the front center of the dispensing area. 2. Perform a production shutdown as specified in the applicable dispensing system manual. 3. Open the dispensing system door or hatch, and locate the pump on the dispensing head. 4.
DV-8000 CAUTION! " NOTE Only trained service technicians should perform this procedure. This procedure is for a pump already mounted on the dispensing head. 1. Use the position controls to move the dispensing head to the front center of the dispensing area. 2. Perform a production shutdown as specified in the applicable dispensing system manual. 3. Open the dispensing system door or hatch and locate the pump on the dispensing head. 4.
9. Apply the proper bearing preload by pressing the red clutch lock release while lightly rotating the clutch cap two or three times to the left (clockwise) until the clutch engages the cartridge. See Figure 4-5. ! All that is needed to turn the clutch cap is a very light but even touch with your thumb and index finger. Do not apply radial pressure while turning the clutch cap or the friction on the threads will result in an improper preload setting.
Installing/Changing a Fluid Syringe Installing a Syringe of Conditioning Fluid (Solder Paste Applications Only) When using the DV-7000/DV-8000 valve to dispense solder paste, you should install a syringe of conditioning fluid and prime the pump in between cleanings. See "Solder Paste Applications" later in this section. You may leave the conditioning fluid installed, until you are ready to install the syringe of solder paste.
1 1 2 2 3 3 4 4 5 6 DV-8000 7 8 9 DV-7000 Item 10 11 Description 1 Syringe Air Hose (P/N 40-3510) 2 Receiver Head (P/N SA-603, SA-606, SA-610, or SA-635) 3 Syringe 4 Syringe Clip 5 Syringe Fitting (P/N 42-0229) 6 Syringe Bracket (P/N 02-0093-00, not used with rigid Feed Tube) 7 Flexible Feed Tube (42-0014) 8 Barbed Cartridge Fitting (P/N 42-0228) 9 Luer Elbow Assembly (P/N 63-0064-00) 10 Luer Adapter (P/N 42-0225) 11 Luer Cartridge Fitting (Luer – P/N 42-0028) Figure 4-
Installing/Changing a Syringe of Production Fluid WARNING! Refer to the Material Safety Data Sheet (MSDS) for information on safety, handling, and disposal for all fluids and materials before use. All fluids and materials must be disposed of according to local regulations. Wear personal protective equipment (PPE) when performing this procedure to prevent contact with caustic chemicals. CAUTION! Only trained service technicians should perform this procedure.
Priming the Pump The purpose of priming is to initiate fluid flow into the pump and to eliminate any air in the fluid path. Priming is necessary after any of the following has occurred: • Initial setup of the pump during installation • Disassembly/cleaning of the dispensing cartridge and/or fittings • Syringe Change This subsection contains priming procedures for both solder paste and non-solder paste applications.
8. In the Valve Forward dialog box click the radio button next to Forward and enter a duration of 120 seconds (2 minutes). ! The 120-second Valve Forward duration is an estimate of the time necessary for the production-run fluid to flow completely through the pump and be dispensed in a steady, unbroken stream. The preferred duration may vary. ! Pump motor speed should be at your production-run setting. Figure 4-7 FmNT Valve Forward Screens 9. Click on the Forward button to start the pump. 10.
Solder Paste Applications Solder Paste applications require a different priming procedure than non-solder paste applications because of the tendency of the paste to “cold weld” to the feedscrew. This cold welding increases feedscrew wear and affects dispensing performance.
10. If there is no drooling present, proceed to Step 11. If drooling persists, refer to the Troubleshooting section. 11. When drooling has stopped, open the dispensing system door/hatch, and perform the following: a. Remove the syringe of conditioning fluid and install a syringe of solder paste. b. Remove and set aside the needle from the dispensing cartridge. c. If the purge cup is full, remove it and replace with a clean purge cup. 12. Close the dispensing system door/hatch. 13.
DV-7000 Optional Configuration The optional configuration allows the DV-7000 to be used for dispensing lines and/or patterns. The optional configuration includes the following: • Luer-compatible Dispensing Cartridge • Stiffer Spring to stabilize the Floating Head • Rigid Feed Tube Assembly The special dispensing cartridge fits into the bottom of the pump in the exact same way as the standard dispensing cartridge.
5 Maintenance and Service Overview Maintenance of the DV-7000/DV-8000 Heli-Flow Pumps consists of cleaning and priming after dispensing operations, or between changes of dispensing fluids. Regular cleaning of the pump is essential to maintaining maximum dispensing performance.
Table 5-1 Recommended Maintenance Schedule Maintenance Procedure Recommended Frequency Instructions Clean the Dispensing Cartridge. Daily See “Cleaning the Pump” in this section. Prime the fluid pump. Daily See “Priming the Pump” in the Operation section. Inspect for fluid leakage and other abnormalities. Daily See the Troubleshooting section. Cleaning the Pump " NOTE The cleaning procedures assume that a syringe is presently connected to the pump.
10. Using your fingers, remove the lower bearing from inside of the cartridge body. 11. Using a cotton swab, carefully remove the seal from inside of the cartridge body. ! The seal is very fragile. If the seal is not damaged, it may be reused. 12. While holding the cartridge body in one hand and the needle retainer in the other, gently twist the retainer to the left to remove it from the end of the cartridge. 13. Remove the needle from inside the needle retainer.
16. Insert the appropriate size tungsten wire into the needle to open a path through the end of the needle. Do not force the wire through the needle. If there is a hard plug, proceed as follows: a. Use the drill bit supplied in the cleaning kit to remove the plug by gently rotating the bit by hand, being careful not to run the bit all the way through the needle. CAUTION! Do not run the drill bit all the way through the needle as this will increase the size of the needle opening. b.
6. Pull the dispensing cartridge out of the pump by gently pulling down on the nozzle. 7. Disconnect the 90-degree elbow fitting from the cartridge fitting. 8. Using a 1/4-inch wrench, unscrew the cartridge fitting from the cartridge. 9. Discard the cartridge fitting in accordance with MSDS recommendations. 10. While holding the cartridge body in one hand and the end of the feedscrew in the other, gently pull the feedscrew out of the body. ! 11.
15. Flush the large end of the needle with cleaning solvent. 16. Insert the appropriate size tungsten wire into the needle to open a path through the end of the needle. Do not force the wire through the needle. If there is a hard plug, proceed as follows: a. Use the supplied drill bit to remove the plug by gently rotating the bit by hand, being careful not to run the bit all the way through the needle.
1 3 2 4 DV-7000 3 1 4 2 DV-8000 Item Description 1 Fluid Syringe 2 Syringe Fitting 3 Pump Bracket 4 Locking Screw Figure 5-3 Removing the Pump for Service Pump Assembly and Disassembly Use the exploded diagrams and tools lists in the Parts Replacement section to help you disassemble and reassemble the pump. Contact Asymtek Technical Support if you have questions. CAUTION! 38 Only trained service technicians should perform pump assembly and disassembly.
6 Troubleshooting Overview This section will help you determine the origin of problems you may experience with your pump and suggest the recommended corrective actions. If you experience problems that are not listed in this section, or continue experiencing the problem after trying the suggested corrective actions, please contact Asymtek Technical Support for more advanced fault diagnostics.
Table 6-1 Troubleshooting Guide Symptom Recovery Pump poorly primed See “Priming the Pump” in the Operation section. Clogged needle Clean or replace the needle. Plugged pump Clean Pump. See “Cleaning the Pump” in the Maintenance and Service section. Speed Control set to 0 rpm See “Pump Adjustments” in the Operation section. No power to motor Make sure that pump power cord is connected to the power outlet on the dispensing head.
7 Specifications Overview The specifications below are intended as a convenient reference for personnel involved with installation, operation, and maintenance of the DV-7000 and DV-8000 Heli-Flow Pump. Safety First Familiarity with the performance specifications in this section can provide information leading to safe operation of the Pump. For additional safety information, refer to the Safety section. Specifications Table 7-1 contains the technical specifications for the DV-7000 and DV-8000 Pumps.
8 Parts Replacement Overview This section contains information that will aid in assembling, disassembling, and ordering replacement parts for the DV-7000/DV-8000 Heli-Flow Pump. " NOTE Part number information is also available on Asymtek’s Find-A-Part web page: http://webstore.asymtek.com/awweblive/apps/findapart_index.
Parts List/Exploded Views DV-7000 Tables A-1 through A-3 list spare parts and supplies kits for the DV-7000. Figures A-1 to A-3 show the DV7000 in exploded view. These illustrations can be helpful when ordering replacement parts for the pump. " NOTE Not all parts shown on the exploded views are available separately. Contact Asymtek Customer Service or your local distributor for availability.
1 2 3 4 10 5 6 12 13 Item 14 15 8 7 9 16 11 17 Part No. 18 Description 1 194571 Cap, Valve Body 2 194577 Pad, Thrust Spring (X2) 3 195360 Spring, Wave, 3/8 OD, 1/4 ID 4 194578 Guide, Spring 5 194572 Coupling, Drive, Hex 6 07-0017-00 QR Spring 7 02-0092-00 Retainer, QR Bearing 8 03-0641-00 Plate, Slide Adapter 9 40-0670 Guide, LM Bearing, 25.
1 6 2 7 3 8 4 5 Item 9 Part No. Description 1 62-0434-00 Motor Assy w/ Encoder, 19:1 2 49-3206 Screw, M3 X 0.5 PH, Flat (6X) 3 02-0093-00 Bracket, Syringe 4 03-868-00 Cover, Base 5 40-2667 Coupling, Mini Joint, 7/32 X 0.158 6 03-0687-00 Bracket, Motor 7 49-9212 Screw, M2.5 X 12 mm Flat Head (3X) 8 49-4212 Screw, M4 X 0.7 PH, Flat X 12 mm 9 49-3210 Screw, M3 X 0.
1 6 7 2 3 4 5 Item Part No. Description 1 06-0025-01 Cable Assy, DV-7000 2 49-3206 Screw, M3 X 0.5 PH, Flat (6X) 3 03-0638-00 Clip, Syringe, 10CC 4 49-3306 Screw, M3 X 0.5 X 6mm, Socket Cap 5 02-0094-00 Cover 6 02-0239-00 Cover, Back 7 49-3206 Screw, M3 X 0.
DV-8000 Table 8-4 through Table 8-6 list spare parts and supplies kits for the DV-8000. Figure 8-4 through Figure 8-13 show the DV-8000 in exploded view. These illustrations can be helpful when ordering replacement parts for the pump. " NOTE Not all parts shown on the exploded views are available separately. Contact Asymtek Customer Service or your local distributor for availability. Table 8-4 Recommended Spare Parts (DV-8000) Part Number Title 40-2667 7/32 X 0.
1 2 3 Item Part No. Description 1 195853 Cover, Lower Valve 2 195838 Back Plane, Valve 3 49-3308 Screw, M3 X 0.5 X 8 mm, Socket Cap (X2) Figure 8-4 DV-8000 Exploded View (1 of 10) 3 2 1 Item Part No. Description 1 49-9212 Screw, M2.5 X 12 mm Flat Head (3X) 2 03-0687-00 Bracket, Motor 3 197558 Motor Assy, 11 Watt w/ Encoder, 19:1 3 197559 Motor Assy, 11 Watt w/ Encoder, 4.
1 Item 1 Part No. 49-4308 Description Screw, M4 X 0.7 X 8 mm, Socket Cap Figure 8-6 DV-8000 Exploded View (3 of 10) 2 1 Item 1 2 Part No. 40-2667 -- Description Coupling, Mini Joint, 7/32 X 0.
1 2 3 4 Item Part No. Description 1 197556 Assy, Clutch, Cap 2 195851 Bearing, Thrust, Ball, 6 ID X 12 OD 3 195844 Hex Coupler 4 197560 Assy, Body, Valve Figure 8-8 DV-8000 Exploded View (5 of 10) 3 2 1 Item Part No. Description 1 195846 Lock, Cap, Valve 2 195847 Lock Release, Valve 3 198436 Cap, Vinyl, 0.
2 1 Item Part No. Description 1 49-3308 Screw, M3 X 0.5 X 8 mm, Socket Cap (X2) 2 195850 Spring, Comp, 0.18 OD, 0.14W, 0.
3 1 4 2 Item Part No. Description 1 198439 Label, Serial Number, DV-8000 2 49-3206 Screw, M3 X 0.
Note: Applies to 19:1 Configuration Only 1 2 3 4 Item Part No. Description 1 49-3206 Screw, M3 X 0.5 PH, Flat (6X) 2 03-0639-00 Clip, Syringe, 30 cc 3 49-3308 Screw, M3 X 0.
Note: Applies to 4.4:1 Configuration Only 2 3 1 4 5 6 7 Item Part No. Description 1 198440 Assy, Heat Sink, DV-8000-04 2 02-0094-00 Cover 3 49-3204 Screw, M3 X 0.5 X 4 mm, PH, Flat M/S, S/S (X2) 4 49-3206 Screw, M3 X 0.5 PH, Flat (6X) 5 193227 Clip, 6 oz, Upper 6 49-3308 Screw, M3 X 0.5 X 8 mm, Socket Cap (2X) 7 193226 Clip, 6 oz/2.
Cartridges Table C-1 lists the Dispensing Cartridge assemblies available. Contact Asymtek Customer Service or your local distributor for the latest information.
Asymtek Headquarters 2762 Loker Avenue West Carlsbad, CA 92010-6603 USA Tel: (760) 431-1919 1-800-ASYMTEK (1-800-279-6835) P/N 7212372, Revision A © 2006
