Spectrum Series S-900 Dispensing Systems Installation Operations Maintenance Manual P/N 7212417 Rev B
NOTICE This is an Asymtek publication, which is protected by copyright. Original copyright date 2007. 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.
Manual Conventions Bold Text Dispensing system labels, buttons and switches, and software menu selections and commands appear in this text style. [Bracketed Text] [Bracketed Text] indicates a single key or key combination to press on a computer keyboard, such as [Enter] or [Alt + Tab]. Text > Text Refers to a series of menu bar commands in Fluidmove for Windows XP (FmXP) software. WARNING! CAUTION! " Personnel Safety Warning.
Table of Contents 1 Introduction ...................................................................................................................................... 1-1 1.1 Overview .................................................................................................................................. 1-1 1.2 System Description .................................................................................................................. 1-1 1.3 Safety First............................
2 Safety ......................................................................................................................................... 2-1 2.1 Overview .................................................................................................................................. 2-1 2.2 Facility Requirements .............................................................................................................. 2-1 2.3 Intended Use................................................
4.5 Powering on the Dispensing System ....................................................................................... 4-4 4.6 Starting Fluidmove for Windows (FmXP)................................................................................. 4-4 4.7 FmXP Configuration................................................................................................................. 4-6 4.7.1 4.7.2 4.7.3 4.7.4 Conveyor Setup ......................................................................
6 Operation ......................................................................................................................................... 6-1 6.1 Overview .................................................................................................................................. 6-1 6.2 Safety First............................................................................................................................... 6-1 6.3 Startup ............................................
7.8 Lubricating the Cables and Linear Guides .............................................................................. 7-9 7.8.1 7.8.2 7.9 Lubricating the Cables ................................................................................................ 7-9 Lubricating the X-Y Linear Guides............................................................................7-10 Tensioning the Cables ........................................................................................................
.3 Specifications.........................................................................................................................10-2 10.4 Stability Analysis ....................................................................................................................10-3 Appendix A Material Safety Information.......................................................................................... A-1 A.1 Introduction .....................................................................
Table of Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 S-920N Front View ............................................................................................................. 1-9 Dispensing Area ...............................................................................................................1-11 Service Station..................................................................................................................
Figure 4-16 Figure 4-17 Figure 4-18 Figure 4-19 Figure 4-20 Figure 4-21 Figure 4-22 Figure 4-23 Figure 4-24 Figure 4-25 Figure 4-26 Figure 4-27 Figure 4-28 Figure 4-29 Figure 4-30 Conveyor I/O (Inputs 0-31) ...............................................................................................4-23 Setup Conveyors ..............................................................................................................4-26 Dispenser I/O (Outputs 0-31) ............................................
Figure 6-14 Figure 6-15 Figure 6-16 Figure 6-17 Figure 6-18 Figure 6-19 Figure 6-20 Figure 6-21 Figure 6-22 Figure 6-23 Figure 6-24 Figure 6-25 Figure 6-26 Figure 6-27 Figure 6-28 Figure 6-29 Figure 6-30 Figure 6-31 Figure 6-32 Figure 6-33 Figure 6-34 Figure 6-35 Figure 6-36 Machine Offsets................................................................................................................6-19 FmXP Error Message 30694 ..............................................................................
Figure C-8 Figure C-9 Figure C-10 Figure C-11 Figure C-12 Figure C-13 Figure C-14 xiv Illustrated Parts List (Conveyor Lift Table) ...................................................................... C-10 Illustrated Parts List (Scale and Service Station) ............................................................ C-11 Illustrated Parts List (X-Beam)......................................................................................... C-12 Illustrated Parts List (Y-Beam).............................
Table of Tables Table 2-1 Table 2-2 Table 2-3 Safety Warning Labels ....................................................................................................... 2-6 Laser Height Sensor Specifications..................................................................................2-11 Beacon Color Indications..................................................................................................2-16 Table 4-1 Table 4-2 SMEMA Communication Test Matrix..................................
1 Introduction 1.1 Overview The Spectrum™ 900N Series Systems are designed for inline production of semiconductor packaging processes, such as underfill, cavity fill, die attach, and encapsulation. This manual is intended primarily as a reference for production operators. However, process engineers and service technicians unfamiliar with Asymtek products may also find this manual useful as a general introduction to the system.
1.4 Manuals Your Spectrum Series S-900N 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. Generally, these OEM manuals are only needed for reference and advanced troubleshooting. Consult only Asymtek manuals unless directed to do otherwise by the manuals themselves or by Asymtek Technical Support.
1.
1.8 Standard Equipment 1.8.1 Automatic Pattern Recognition (Vision) System The Vision System consists of a Dalsa-Coreco Genie M640 digital 640 x 480 pixel camera, light source, and laptop computer. The software consists of Fluidmove for Windows and its pattern recognition engine. The vision system serves three purposes: • It allows the operator to teach dispensing locations on the substrate.
1.8.5 Fluidmove for Windows XP Software Fluidmove for Windows XP (FmXP) is Asymtek proprietary software for use in a Windows XP environment, developed specifically for dispensing applications. 1.8.6 Mechanical Height Sensor The Mechanical Height Sensor allows increased positional accuracy in fluid dispensing by automatically controlling the gap of the dispense tip to the surface of the workpiece. 1.8.7 Light Beacon The Light Beacon is an indicator device for the operator.
1.8.13 Interlock The Interlock is a built-in safety feature that automatically removes dispensing system servo motor power, stopping all dispensing activity, when the hood is opened. This prevents personnel from being injured by movement of the Dispensing Head and Conveyor. 1.8.14 Service Station The Service Station consists of a needle vacuum purge cup, on-board high precision scale, and a needle calibration substrate.
1.9.5 Pre-Queue/Post-Queue Stations Pre-and post-queue stations without heat can be added for higher throughput or as buffer stations. In addition, heat can be added to the S-92X Series pre-and post-queue stations. The S-92X Series can be configured with pre-dispense, dispense and post-dispense heat. The S-900N Series can be configured with single or dual-lane conveyors. A dual-lane configuration (S-922N) can accommodate up to six (6) heaters.
1.11 System Features The figures in this section show views and features of the dispensing system. Callouts locate major components, options, and switches seen in each illustration. Detailed operating instructions for some of these features are treated in other sections of this manual. System features are shown in Figure 1-1 to Figure 1-9.
6 7 Figure 1-1B S-920N with Optional Pre- and Post-Queue Stations Item Name Description 1 Light Beacon The Light Beacon is a device that displays system status and can warn the operator when fault conditions exist. 2 Dispensing Area The Dispensing Area is where all dispensing operations take place. See 1.11.1 Dispensing Area. 3 Front Panel Digital Valve, Fluid and Coax/Cooling Pressure Gauges, ON and OFF Buttons, Emergency Stop, and Grounding Strap Jacks are located on the Front Panel. See 1.11.
1.11.
1 4 2 3 Figure 1-2B Dispensing Area Close-Up (Dual Conveyors shown) Item Name Description Dispensing Valve The Dispensing Valve (DJ-9000 shown) controls or regulates the flow of material from a pressurized reservoir, such as a syringe. Devices include valves and jets. 2 Conveyor The Conveyor transports the workpiece from an upstream system to the dispensing station and then to downstream systems. All Conveyors are SMEMA compatible and have adjustable rear rail width.
1.11.2 Service Station 2 1 3 4 Item Name Description 1 Dispense Tile The Dispense Tile is a ceramic tile dispensed upon during system offset routines. 2 Tactile Needle Sensor The Tactile Needle Sensor measures needle/nozzle position in the Z-axis. Purge Station The Purge Station consists of a small reservoir that contains a disposable plastic cup and is attached to a vacuum generator. Air flowing through the purge boot into the cup removes excess fluid on the dispensing valve needle/nozzle.
1.11.3 Front Panel 2 1 3 7 Item Name 6 4 5 Description Grounding Strap Jack Grounding straps worn by the operator plug into this jack to prevent electrostatic discharge (ESD) damage to workpieces during dispensing operations. 2 ON/OFF Buttons The green ON (l) button illuminates and switches ON power to the dispensing system mechanics. The black OFF (0) button shuts down the dispensing activity and vents the air pressure. The laptop computer power remains ON.
1.11.
Figure 1-5B Front Cabinet (S-922N Dual Conveyor System - Dispense Heat Only) " NOTE Item The S-92X Series features programmable fluid and valve pressure. Air pressure is set through the FmXP software. This feature is an option on the S-91X Series Systems. Name Description 1 Vacuum Air Regulator Controls the vacuum level applied to fluid pressure air line when pressure is turned off. The vacuum helps prevent residual pressure buildup in the syringe that may cause fluid drip.
1.11.
Conveyor/Heater Pneumatics Fluid/Valve Pneumatics 7 Figure 1-6B Main Air Regulator and Gauge Sets (Close-up) Item Name Description Main Air Regulator and Gauge The system is equipped with two Main Air Regulators and Gauges. They control the air pressure supplied to all other system regulators. The regulators contain built-in air filter and water traps to ensure that only clean, dry air enters the system. Refer to 6.
1.11.
1 2 3 4 Figure 1-7B Rear View Open (S-920N with Pre-Queue and Post-Queue Stations) Item Name Description 1 Upper E-Pan The Upper E-Pan houses the Dispense Head Controller, Z-Axis Servo Amp, and Applicator Pneumatics. 2 Lower E-Pan The Lower E-Pan houses the Mainboard, X-Y Axis Servo Amps, Main Air Pneumatic Valves, and Conveyor Pneumatic Valves. 3 Rear Cabinet The Rear Cabinet houses the Power Manager and the Conveyor/Heater Module(s). See 1.11.7 Rear Cabinet.
1.11.7 Rear Cabinet 1 2 Item 1 2 Name Description Power Manager (30A shown) The Power Manager is located inside the rear cabinet. It houses the Main Circuit Breaker and the Main Power Inlet. It also contains the EMO circuitry. The EMO button, the green ON (I) button, and the black OFF (0) button are directly connected to the Power Manager. Conveyor/Heater Module The Conveyor/Heater Module receives power from the Power Manager and supplies AC power to the substrate heaters in the dispensing area.
1.11.8 Rear Panel Connections 1 2 3 4 5 6 7 Item Name Description Allows for SMEMA communication between Conveyor 2 and a downstream machine such as an unloader. Allows for SMEMA communication between Conveyor 2 and an upstream machine such as a loader. 1 CV2 Downstream 2 CV2 Upstream 3 Loader/Up Allows the dispensing system to communicate with an upstream loader for programming purposes only.
2 Safety 2.1 Overview This section is intended to provide basic safety information necessary for operating and servicing the Spectrum S-900N Series Dispensing System.
2.4 Basic Safety Precautions and Practices Compliance with the following recommended precautions and practices reduces the risk of personal injury or damage to property during S-900N Series Dispensing System operation and maintenance. WARNING! CAUTION! Failure to comply with any of the safety recommendations could cause serious injury to the user or damage to the dispensing system. 2.4.
2.4.2 Safety • Make sure the main power cable and main air supply hose are securely connected before operating the dispensing system. • If in a confined room, ensure adequate and uninterrupted air ventilation, and heating and cooling meet environmental stress limits of personnel and the dispensing system. • Where volatile organic compound (VOC) emissions can exceed safe limits, facility ventilation and filtration systems must be operational.
2.4.3 Preventing Dispensing System and Workpiece Damage • Immediately push the EMO button if dispensing system or a workpiece is in danger of being damaged. • Use standard Electrostatic Discharge (ESD) precautions when working near sensitive components. Always wear a grounding strap and connect it to the ESD ground before handling workpieces. • Immediately contain and clean up any caustic or conductive fluid spills as recommended in the material manufacturer’s MSDS.
2.5.2 Precautions When lifting, transporting, and lowering heavy or large loads, personnel should observe the following precautions: 2.6 • Stand close to the load to be lifted and place your feet at shoulder width. • Firmly grip the load and bring the load close to your body. • Lift your head and shoulders first and with your back straight, use the strength of your legs to slowly and smoothly raise yourself up. • DO NOT twist your body. Change direction by first moving your feet.
2.7 Safety Warning Labels Safety warning labels on the S-900N Series Dispensing System point out potentially hazardous areas and remind personnel to take necessary safety precautions. Table 2-1 describes safety warning labels that may be on the dispensing system. WARNING! CAUTION! Comply with all safety warning labels or serious injury to personnel or damage to the dispensing system may occur. Worn or damaged labels should be replaced with new labels having the same part number.
1 Item 1 Description Read Manual Label Figure 2-1 Safety Warning Labels (Front Cover) 1 Item 1 Description Laser Radiation Warning Label (if Laser Height Sensor present) Figure 2-2 Safety Warning Labels (Front Inside Panel) Safety 2-7
1 2 Item Description 1 Laser Radiation Warning Label (if Laser Height Sensor present) 2 Hot Surface Label (if heaters present) Figure 2-3 Safety Warning Labels (Dispensing Area) 2-8 Safety
2 1 Item Description 1 Hot Surface Label (if heaters present) 2 Moving Parts Present Label Figure 2-4 Safety Warning Labels (Conveyor) 1 2 Item Description 1 Hand Entanglement Label 2 Hot Surface Label Figure 2-5 Safety Warning Labels (Rear)) Safety 2-9
1 Item 1 Description Electrical Warning Label Figure 2-6 Safety Warning Labels - Power Manager 2-10 Safety
2.8 Laser Radiation WARNING! The Height Sensor contains a Class 2 laser. DO NOT look directly at the laser beam. Looking directly at the laser beam may result in serious eye injury. If your S-900N Series Dispensing System is equipped with the optional laser height sensor, the following safety precautions should be observed in addition to the basic system safety precautions: " 2.8.1 • Operate the laser height sensor in accordance with the operator’s manual included with the equipment.
2.9 Emergency Shutdown In the event of an emergency or malfunction, press the EMO button. The S-900N Series has two EMO buttons. The EMO buttons are the large red buttons located on the front panel and the rear of the dispensing system (Figure 2-8). Activating the EMO vents all pressure in the pneumatic system and cuts power to all components except the laptop computer, the camera, the interior light, and the light beacon.
2.9.1 Emergency Shutdown Situations As a minimum, activate the EMO in the following situations: 2.9.2 • If anyone is in immediate danger of being injured by moving parts, hazardous materials, or electrical shock. • If valuable dispensing system components or the workpieces are in danger of being damaged. Emergency Shutdown Recovery WARNING! " NOTE Do not restart the dispensing operation until the condition that caused the emergency shutdown has been corrected.
2.11 Service Shutdown Before performing any service or parts replacement, the dispensing system should be shut down as follows: 1. Shutdown the dispensing system as described in 6.12 System Shutdown. 2. Perform a “Lockout/Tagout of Electrical and Pneumatic Energy” as described below. 2.11.
" NOTE Warning tags document the name of the technician taking the equipment out of operation, the date, and other facility-required information. It is a warning that the equipment cannot be put back into operation until the authorized technician has removed the tag. WARNING! If your dispensing system is equipped with a heater, allow sufficient time for the heater to cool prior to performing maintenance or service. Failure to do so may result in serious burn injury.
2.12 Light Beacon The Light Beacon is a device that displays system status and can warn the operator when fault conditions exist. The beacon has red, yellow, green, and blue lights that can be solid or flashing. The beacon also has an audible alarm. Table 2-3 provides possible reasons for each color indication. Software and hardware share control of the beacon lights. Sometimes, hardware-driven displays override those caused by software conditions and sometimes software-driven displays override.
3 Installation 3.1 Overview This section describes installation procedures for the Spectrum Series S-900N Series Dispensing System and covers the following topics: 3.
" NOTE If the dispensing system is being installed in a clean room, uncrate the system, remove all packaging material, including wrapping paper and tape from all parts and components, before moving into the clean room. 2. Locate and remove the envelope on the outside of the shipping crate. Open the envelope and locate the shipping list. ! As you unpack each item inside of the box, identify the item, locate it on the shipping list, and place a checkmark next to the item. 3.
5. Remove the two 1/2-inch hex head screws clamping the four shipping brackets to the levelers. 6. When the four shipping brackets have been removed, slide the forklift forks under the front of the dispensing system between the levelers (feet). Use the forklift to gently lift the dispensing system off of the crate. ! You may use the shipping crate for future shipping purposes or dispose of according to local regulations. ! Save the shipping brackets.
10. Remove bag and plastic wrap from the machine. " NOTE Location of packaging materials to be removed is indicated by the presence of red warning tags. 11. Remove all shrink-wrap and other packing material from the perimeter of the dispensing system. 12. Remove all perimeter packaging material from the dispensing area. " 3.6 NOTE Remove all shrink wrap and packing foam from the system prior to moving it to a clean room. Also, remove the protective plastic film from the front door.
1 Item Description 2 3 Item Description 1 Y-Axis Stopper 3 X-Axis Stopper 2 Y-Rail (right side) 4 X-Beam 4 Figure 3-3 Dispensing Head Stopper Locations 4. Remove the shipping bracket and warning tag attached to the Z-Head by loosening the screws. See Figure 3-4. ! Retain bracket and hardware for future shipping purposes.
5. Remove the tape covering the Service Station. Figure 3-5 Removing the Service Station Packing Tape 6. Remove the front cover by first removing the two screws from the ends of the cover. See Figure 3-6. 7. Lift the cover up and away from the machine. CAUTION! The scale stem is extremely sensitive. Hitting or applying pressure to the scale stem may damage the scale stem. See Figure 3-7.
8. If the system is equipped with a scale, loosen the strap covering the scale and remove the warning tag from the scale unit. " NOTE Do not remove the strap. The strap may be needed when moving or shipping machine. 9. Leave the scale uncovered until it has been leveled. See 3.8 Leveling the Scale.
3.7 Leveling the Dispensing System WARNING! CAUTION! This procedure should only be performed by a trained service technician. The system should be shutdown for service before performing this procedure. Refer to 2.11 Service Shutdown. To level the dispensing system: 1. Place the box level on the conveyor rail along the X-axis (Figure 3-8). 2. Observe the position of the bubble within the level’s window. ! The bubble should be centered, indicating the dispensing system is level from side-to-side.
4. Place the box level between the front and rear conveyor rails along the Y-axis (Figure 3-9). 5. Observe the position of the bubble within the level’s window. ! The bubble should be centered, indicating dispensing system is level from front-to-back. Figure 3-9 Leveling the Dispensing System – Y-Axis 6. If necessary, adjust the levelers (Figure 3-2) of the dispensing system as follows: a. Loosen the 1½-inch lock nut on the leveler. b.
3.8 Leveling the Scale If your dispensing system is equipped with a scale, you will need to verify that the scale is level prior to operation of your dispensing system. The scale is standard on S-92X dispensing systems and an option on the S-91X dispensing systems. To level the scale: 1. Check the scale level bubble. ! If the bubble is not centered, the scale must be leveled. If the bubble is centered, the scale is level. 2. Adjust the scale leveling screws until the scale is level (Figure 3-10).
3.9 Setting Up the Service Station The Service Station consists of both the weigh station and purge station. The scale is standard on S-92X dispensing systems and an option on the S-91X dispensing systems. To setup the Service Station: 1. Place the scale lid, cup, pedestal and breeze shield on the weigh station (Figure 3-12). Figure 3-12 Setting up the Weigh Station 2. Place the purge cup inside of the purge station (Figure 3-13). 3. Replace the purge station lid.
3.10 Installing the Light Beacon 1. Remove the Light Beacon from the storage area behind the front door panel. 2. Attach it to the top panel using the four (4) screws temporarily installed. 3. Make the beacon electrical connections. 1 3 2 Item Description 1 Light Beacon 2 Screws (4) 3 Beacon Electrical Connection Figure 3-14 Installing the Light Beacon 3.11 Installing the Laptop Computer 1. Remove the laptop computer from its packaging. 2.
Serial Number Label Figure 3-15 Dispensing System Serial Number Label 6. Power off the laptop computer. 7. Move the laptop tray arm bracket on the dispensing system so that the laptop tray is facing forward. 8. Attach the USB and Network cables and grounding wire attachment to their respective ports on the computer. 9. Attach the power cable to the rear of the computer. " NOTE The laptop is adhered to the tray with a hook and loop fastener. Align the laptop computer before placing it on the tray. 10.
3.12 Installing the Fluidmove Software The Fluidmove Software is installed at the factory prior to shipping. If your system is equipped with a Dalsa Genie Camera, the Dalsa software is automatically installed with the Fluidmove Software. For additional information, refer to the Fluidmove User Guide. 3.
4 Power-Up and Testing 4.1 Overview Once you have performed installation of the accessories, you are ready to power up and functionally test the dispensing system. This section covers the following topics: 4.
4.4 Connecting the Power and Air Supply CAUTION! The following procedures should only be performed by a trained service technician. Tools and Materials Needed • Main Power Cable • Facility Air Hose To connect the system to facility power: 1. Locate the main power cable, included in the accessories crate. 2. Plug the female end of the power cable into the main power inlet on the rear of the dispensing system (Figure 4-1).
To connect the system to the facility air supply: CAUTION! Make sure that facility air pressure meets the requirements specified in 10.2 Facility Requirements. Higher pressures will damage the dispensing system. 1. Locate the facility quick-disconnect air hose (Figure 4-2). 2. Make sure each dispensing system Main Air Regulator is closed. Verify facility air pressure is at 0 psi. 3. Connect the facility air hose(s) to the quick-disconnect(s) on the Main Air Regulator(s). 4.
4.5 " Powering on the Dispensing System NOTE If necessary, refer to the figures in Section 1 - Introduction to identify system components. 1. Verify that the main power cord is connected to the main power inlet and the facility power source. 2. Verify that the facility air is at the recommended pressure level and connected to the main air pressure regulator inlets. See 4.4 Connecting the Power and Air Supply. 3. Turn the main circuit breaker on the back of the system to the ON (I) position. 4.
2. If the FmXP Message 30416 - Dispenser Motor References Not Found appears, click OK to home the dispenser (Figure 4-3). Figure 4-3 FmXP Message 30416 ! The FmXP Main Window (Figure 4-4) will open. Figure 4-4 FmXP Main Window " 3. Check to make sure the dispensing head is in the proper home position. NOTE If you receive any error messages, refer to Section 8 - Troubleshooting or to the Fluidmove User Guide or Online Help.
4.7 FmXP Configuration The FmXP software is configured at the factory prior to shipping. The following section identifies FmXP configuration for standard components. Your configuration may vary depending on system configuration. 4.7.1 Conveyor Setup To set up the conveyor: 1. In the FmXP Main Window, select Configuration > Setup Conveyors. ! The Setup Conveyors Window opens (Figure 4-5). Figure 4-5 Setup Conveyor Window 2. Verify that Conveyor 1 Type is CCACLPlus.
Figure 4-6 FmXP - Setup Configuration - Conveyor 4. Click on OK to close the configuration dialog box. " NOTE If your dispensing system is equipped with a dual-lane conveyor, repeat steps 1-4 for Conveyor 2. The settings will be the same as Conveyor 1 described above. 5. In the Setup Conveyors dialog box, click on OK.
4.7.2 Heater Setup 1. In the Fluidmove Main Window, click on Configuration. 2. Select Setup Heaters. ! The Heater Setup Window (Figure 4-7) opens. Figure 4-7 Heater Setup Window 3. If the dispensing system is equipped with Controlled Process Heat, make sure that option is checked. 4. Select the desired heater runtime preferences. 5. 4-8 Click OK.
4.7.3 Scale Setup If you system is equipped with a scale, perform the following procedure to ensure the scale is configured correctly in the Fluidmove software. The scale is standard on S-92X dispensing systems and an option on the S-91X dispensing systems. 1. In the FmXP Main Window, select Configuration > Setup Scale. ! The Scale Setup Window opens (Figure 4-8). 2. If your dispensing system is equipped with a scale, verify that Scale Type is SART-WZ.
4.7.4 Vision Setup 1. In the FmXP Main Window, select Configuration > Setup Vision. ! The Setup Vision Window opens (Figure 4-8). 2. Verify that the Vision System and Video Mixer are GENIE. If not, click on the GENIE from the drop-down list. and select 3. Click on OK to exit the Setup Vision Window. Figure 4-9 FmXP - Setup Vision 4.8 Exiting Fluidmove for Windows (FmXP) To exit FmXP, close all open FmXP windows and click Exit in the FmXP Main Window.
4.9 Preliminary System Check Before powering up the dispensing system, follow the steps below to make sure there is sufficient clearance for the dispensing head to operate in the dispensing chamber. CAUTION! The following procedures should only be performed by a trained service technician. To check Dispensing Head clearance: 1. With the hood still open, manually move the dispensing head throughout the entire dispensing chamber making sure that it does not encounter any obstacles during its travel. 2.
Tools and Materials Needed 4.10.1 • Production Sample Workpieces (3) • Metal Ruler • Multimeter • TS-01/TS-03 I/O Test Box • ¾-inch Wrench • Syringe Receiver Heads (2) • 1½ -inch Wrench • Small Box Level • 1.5 mm Hex Key • Calibrated Temperature Probe, Digital • Pen • Removable Thread Locker (P/N 40-0019) EMO To check EMO function: 1. Press the EMO button on the front of the dispensing system. 2.
To check the function of the Manual Valve Air Pressure Regulator and Digital Gauge (S-910): 1. Locate the Valve Air Pressure Regulator inside the front cabinet of the dispensing system (Figure 4-10). 2. Verify the LED display screen on the front panel is illuminated. ! If the LED is not working, check electrical connections. If still not working, contact Asymtek Technical Support. 3. Initialize the gauge as specified in 5.12 Initializing the Digital Gauges. 4.
2 3 1 4 5 8 7 6 Item Description 1 Vacuum Air Regulator 2 Cooling/Coaxial Air Regulator 3 Valve Air Regulator 4 Fluid Air Regulator 5 Impingement Air Valve (not used on S-910) 6 Tooling Air Gauge 7 Tooling Air Regulator 8 Impingement Flowmeters (not used on S-910) Figure 4-10 Air Regulator and Gauge Locations (S-912 shown) 4-14 Power-Up and Testing
To check the function of the Electronic Valve/Fluid Air Pressure Regulator (S-920): 1. In the FmXP Main Window, select Configuration>Setup Runtime Preferences>Electronic Pressure Ctrl Utility. ! The FmXP Air Pressure Window (Figure 4-11) opens. Figure 4-11 FmXP Air Pressure Window 2. Turn off the valve air pressure by clicking on the set point number and entering zero (0). 3. Increase the valve air pressure to 90 psi by clicking on the set point number and entering ninety (90). 4.
4.10.3 Impingement Air Flowmeters Perform the following procedure to check function of the Impingement Air Valve and Flowmeters. To check function of Impingement Air Valve and Flowmeters: " NOTE This procedure applies to S-920 Series systems equipped with impingement heat only. 1. Locate the Impingement Air Valve and Flowmeters in the front cabinet of the dispensing system. 2. Open the Impingement Air Valve by turning the handle counterclockwise so that it is parallel with the airline.
4.10.4 Light Beacon Perform the following procedures to check function of the Light Beacon. To test the Light Beacon: 1. Close the dispensing system hood, make sure the EMO is deactivated, and press the green ON (l) button on the front panel. ! The green beacon light should be ON. 2. Open the hood. ! The yellow beacon light should come ON and the green beacon light should go OFF. 3. Close the dispensing system hood. ! The green beacon light should come ON and the yellow beacon light should go OFF.
4.10.5 Conveyor and Conveyor Pneumatics Perform the following procedures, as applicable to your system configuration, to check the function of the conveyor and its associated components. To check adjustable-width conveyor clearance, Safety Interlock, and X- and Y-axis movement: CAUTION! Perform this procedure only if your dispensing system has been configured for an application that requires an adjustable conveyor width. DO NOT perform the procedure for fixed-width conveyor configurations. 1.
12. Close the Jog Window to return to the Tools Window. to return to the Main Window. 13. Click on Main 1 2 3 Item Description 1 Y-Axis Control 2 X-Axis Control 3 Home Button Figure 4-13 FmXP Jog Window (Conveyor 1 Selected) " NOTE For dual conveyor systems, the Conveyor 2 rails are manually adjustable to allow pitch variations between Conveyor 1 and Conveyor 2. Both of the rear rails move synchronously toward the back or front of the machine.
To check fixed-width Conveyor clearance, Safety Interlock, and X-axis movement: CAUTION! " NOTE Perform the following procedure only if your dispensing system has been configured for an application that requires a fixed conveyor width. DO NOT perform the procedure for adjustable-width conveyor configurations. This procedure assumes that you are already in the FmXP Tools Window. If not, refer to Steps 2 and 3 in 4.10.5 Conveyor and Conveyor Pneumatics. 1.
d. Close the hood and use the Y-axis slow jog button ! to finish adjusting the rail width. Rail width should allow the workpiece to rest on the belts as close to the rails as possible, allowing space for smooth, non-binding movement along the conveyor and for heat expansion of the workpiece. 3. If your system is equipped with dual conveyors, repeat Step 2 for Conveyor 2. Conveyor 2 Jog Commands are described in 6.6.1.2.1 Dual Conveyor Systems. 4. Close the Jog Window to return to the Tools Window. 5.
7. In the FmXP Main Window, click on Configuration and then select Setup Conveyors. 8. Click on I/O Test and then on the Outputs 0-31 tab (Figure 4-15). 9. Locate the upstream and downstream bits. Perform the actions specified in Table 4-1. Table 4-1 SMEMA Communication Test Matrix Action Result In dialog box, press Request Board from Upstream Tool output button. No. 2 LED on TS-01 comes ON. Press TS-01 button No. 3. Dialog box “Board Available from Upstream Tool” input changes to ON.
To check Board Sensor operation: " NOTE This procedure assumes the following: • Each conveyor station has a board sensor that is positioned to sense the workpiece. • The conveyor rail width has been adjusted to fit a production sample workpiece. Perform this procedure as applicable to the configuration of your dispensing system. 1. Open the dispensing system hood. 2. Place a production sample workpiece on the conveyor to the left of the dispense station board sensor. 3.
! If a bit does not toggle ON and OFF check the following: - Board Sensor connections. - Sensitivity of the Board Sensor. See 5.11 Adjusting the Board Sensors. ! If the bit still does not toggle, refer to Section 8 - Troubleshooting. 7. If your system is equipped with dual conveyors, repeat Steps 2-7 for Conveyor 2. To check Lift Table operation: " NOTE This procedure assumes that the dispensing system hood is open and the FmXP Conveyer I/O Test Dialog Box is open. 1.
To check vacuum for Contact Heaters: WARNING! " NOTES The heaters may be hot. Use caution when working in the area of the heaters or serious burns may result. This procedure assumes the following: • Sample workpieces are on the conveyor in the pre-dispense, dispense, and post-dispense stations as applicable to your system configuration. • The dispensing system hood is open. • The FmXP Conveyer I/O Test Dialog Box is open. 1. Raise all lift tables as described in the previous procedure. 2.
4.10.6 Dispensing Head and Accessories Perform the following procedures to check function of the dispensing head, its accessories, and the Safety Interlock. To check Dispensing Head clearance: " NOTE The following procedures assume the dispensing system is on and FmXP is running. 1. Open the hood, place a production sample workpiece in the dispense station of the conveyor, and then close the hood. 2. In the FmXP Main Window, click on Configuration and then select Setup Conveyors (Figure 4-17).
7. If your system is equipped with a retractable height sensor, follow the steps below: a. In the Tools Window, click on I/O Test. b. Click on Dispenser. ! The I/O Test Dialog screen opens. c. Locate the tab (Figure 4-18) with the height sensor probe output (HS_PROBE_EXTEND). d. Click the button next to HS_PROBE_EXTEND to toggle the bit ON (1). ! The height sensor probe should be in the down position.
8. In the Main Window, click on the Jog icon ! . The Jog Window (Figure 4-19) opens. 1 2 8 3 7 4 6 5 Item Description Item Description 1 XYZ Position Indicator 5 Locations Buttons 2 Target Box Position Indicator 6 Dispenser Radio Button 3 Z-Axis Controls 7 X-Axis Controls 4 Home Button 8 Y-Axis Controls Figure 4-19 FmXP Jog Window (Dispenser Selected) 9. Make sure the Dispenser Radio button is selected. If not, select it. 10.
13. To retract the height sensor, repeat Steps 7.a through 7.c above and then click the button next to HS_PROBE_EXTEND to toggle the bit OFF (0). ! The height sensor probe should be in the retracted position. To test the Safety Interlock effect on the Dispensing Head: 1. In the Main Window, click on the Jog icon . 2. In the Jog Window (Figure 4-19), verify the Dispenser radio button is selected and then click on the Home button. 3.
4.10.7 Vision System Perform the following checks to make sure that the Vision System is ready for operation. " NOTE The following procedure assumes the dispensing system is on and FmXP is running. 1. In the Programming Window, click on the Load a Board icon . 2. In the FmXP Main Window, click on Configuration and then select Setup Vision. 3. In the Setup Vision dialog box, click on the Setup Reticles button (Figure 4-20). 4.
6. In the Reticles Setup dialog box, enter the following sample settings: • Circle 1 (0.050) • Crosshair graduations (0.025) • Circle 2 (0.10) • Red reticle color • Rectangle (0.10 x 0.10) 7. Click on the Apply changes button and view the display. ! If any of the reticles are not visible on the screen, contact Asymtek Technical Support. 8. Turn off all of the reticle selections and click on the Apply changes button. 9. View the image in the video display. ! The reticles should not be visible.
10. Disconnect the syringe receiver head from the fluid pressure port and connect it to the blue fitting on the pneumatic bulkhead. Also connect a syringe receiver head to the black fitting on the bulkhead. ! Air should be coming out of the syringe receiver head connected to the black fitting. No air should be coming out of the syringe receiver head connected to the blue fitting. 11. Locate the bit labeled V1_VALVE_AIR and toggle the bit until it reads ON (1).
4.10.9 Tactile Sensor Perform the following procedures to make sure that the Tactile Sensor is functioning properly. " NOTE The following procedure assumes the dispensing system is on and FmXP is running. 1. Verify your dispensing system has been configured for the type of Needle Sensor installed as follows: a. In the FmXP Main Window, click on Configuration > Machine Offsets > Machine Offsets Parameters. b.
! The Dispenser I/O Test dialog box (Figure 4-22) opens. Figure 4-22 Dispenser I/O (Inputs 0-31) 4. Locate the bit labeled TACTILE_SENSOR. 5. Move the Z-head down to lightly touch the Tactile Needle Sensor. ! 4-34 The TACTILE_SENSOR bit should toggle to ON (1) when the Tactile Needle Sensor is pressed and return to OFF (0) when pressure is released.
4.10.10 Purge Station Perform the following procedure to check function of the purge station. " NOTE The following procedure assumes the dispensing system is on and FmXP is running. 1. Locate the bit labeled PURGE_CUP and toggle the bit until it reads ON (1) to turn the purge vacuum ON (Figure 4-23). Figure 4-23 Dispenser I/O (Outputs 32-63) 2. Place your finger on the purge boot opening and try to lift the purge cup cover. See Figure 4-24. 3.
2 3 4 1 Item Description Item Description 1 Ceramic Tile Substrate 3 Purge Station 2 Tactile Needle Sensor 4 Scale Figure 4-24 Service Station 4.10.11 Scale If your system is equipped with a scale, perform the following procedure to make sure that the scale is ready for operation. The scale is standard on S-92X dispensing systems and an option on the S-91X dispensing systems. 1. Open the dispensing system hood. 2. Remove the scale cover. 3.
5. In the FmXP Main Window, click on the Configuration button and select Setup Scale. 6. In the Scale Setup dialog box (Figure 4-25), click on the Scale Operations tab. 7. In the Scale Operations dialog box, click on the Zero Scale button and monitor the Current Reading portion of the dialog box. ! The current reading should be 0.000 mg. Figure 4-25 Scale Setup 8. Replace the cup and scale cover. ! The current reading should indicate an increase in weight. If not, refer to Section 8 -Troubleshooting.
4.10.12 Heater Tooling and Needle Heaters Perform the following electrical and temperature tests, as applicable to your system configuration, to make sure that the heaters are functioning properly. To electrically test Heater Tooling: WARNING! Make sure that the Heater Tooling is cool before performing this procedure or serious injury may occur. 1. In the FmXP Main Window, click on Tools 2. In the Tools Window, click on Terminal 3. Click on Heaters . . . 4.
4 3 2 5 1 Item Description 1 Heater On/Off Column 2 Channel (Loop) Name Column 3 Temperature Set Point Column 4 Present Temperature Value Column 5 Message Column Figure 4-26 Heater Control Window Power-Up and Testing 4-39
To temperature test Heater Tooling and Needle Heaters: WARNING! " NOTE The Heaters will be hot and can cause serious injury. Use extreme caution when measuring Heater temperature and checking connections. This procedure assumes that FmXP is in the Heater Control Window. If not, refer to Steps 1 through 3 of the previous procedure. 1. Check all air and electrical connections to the heaters. 2.
To test EMO effect on Heater Tooling and Needle Heaters: " NOTE This procedure assumes that FmXP is in the Heater Control Window and that the Heaters are at their set temperatures. 1. With the heater tooling and needle heaters at their set temperatures (SP), press the red EMO knob on the front panel. 2. Monitor the temperature values shown in the PV column of the Heater Control Window. ! The temperature values in the PV column should indicate that the heaters are cooling.
2. Perform a Valve Offsets routine as follows. See Figure 4-27. " NOTE See 6.8 Establishing Machine Offsets for a detailed description of machine offsets routines. a. In the FmXP Main Window, click on Configuration. b. Select Machine Offsets from the Configuration menu. c. In the dropdown menu, select Scripted Valve Offsets. Figure 4-27 Valve Offset Dialog Boxes ! 4-42 The Machine Setup dialog box opens (Figure 4-28).
Figure 4-28 Machine Setup Dialog Box 3. Click on Run to End to perform the offsets routine. 4. Once you have completed the Scripted Valve Offsets routine, perform a simulated (dry) production run using a TS-01 or TS-03 Test Box. The following steps assume that a TS-01 Test Box is being used. " NOTE If your system is equipped with substrate heaters, make sure the heaters have reached the set point temperature (SP) before performing this procedure. a. Perform a service shutdown as specified in 2.
Figure 4-29 Program Open Window ! After the program has been loaded, the filename will appear in the Current Program section of the Production Window. j. button and then double click on Single In the Production Window, click on the Run Dry Run in the area below the Run Production button. ! The Run Window will open.
k. On the Run Status tab, verify the program filename is the one desired, the Dry radio button is selected, and the Use Conveyor box is checked. l. To start the program click on Go . ! A “Clear the conveyor” message appears. Make sure there are no boards or boats on the conveyor belt. ! A “Waiting for a board” message appears. m. Place a simulated production workpiece at the upstream end of the conveyor. n. Press the Number 3 TS-01 button to move the workpiece to the dispense station.
5 Calibration and Adjustment 5.1 Overview After initial installation or if any hardware changes have been made, certain dispensing system components may need to be calibrated or adjusted.
5.5 " Focusing the Camera NOTE This procedure assumes that the dispensing system has been powered on and FmXP is running, and that a representative substrate is available to teach the focal plane. To focus the camera: 1. In the FmXP Programming Window, click the Load a Board ! icon. The conveyor will transport the substrate to the dispense station and the lift mechanism will lift it off the conveyor belt. This establishes the focal plane for dispensing as well as for the Service Station. 2.
5.6 Calibrating the Camera " NOTE " This procedure assumes that the dispensing system has been powered on, that FmXP is running, that a substrate is available, and that the camera has been focused. The camera is self-calibrating when using the calibrate button from the Setup Vision Window. The software makes a pixel count comparison to machine units by moving away from the taught image by a known value, finding the image again, and assigning a pixel-count-tomachine-unit value.
3. Click on Calibrate. ! The Calibration Window (Figure 5-3) opens. Figure 5-3 FmXP Calibration Window 4. Position the camera over a fiducial and adjust the light level to obtain a good image contrast. See 6.72 Lighting and Color Adjustment. 5. If the image is not in focus, focus the camera as described in 5.5 Focusing the Camera. 6. Click on Next. 7. Verify that the fiducial image is centered and click on Next. ! " The Vision System will take a snap image of the fiducial. 8.
5.7 Service Station Height Adjustment After the camera position has been adjusted for the part set height, the service station height must be adjusted to bring the ceramic square into focus. The service station can be adjusted upward 1-inch (25 mm) from the factory set position by performing both rough and fine height adjustments. Each adjustment will allow 1/2-inch (12.7 mm) of vertical adjustment. To adjust the service station height: 1.
5.8 Calibrating the Scale Tools and Materials Needed: • Calibration Weight Set (P/N 193758) • Latex gloves or tweezers • Screwdriver • Level To calibrate the scale: 1. Remove the scale cover. 2. Verify that the scale is level by checking the scale level bubble. a. If the bubble is not centered, the scale must be leveled. b. If the bubble is centered, the scale is level. 3. If necessary, adjust the scale leveling screws until the scale is level (Figure 5-6).
Figure 5-7 Setup Scale - Scale Operations Tab 7. Select “SART-WZ” from the Type pull-down menu. 8. Click on the Advanced tab (Figure 5-8).
9. Verify that the calibration weight is set to 50 and click on Calibrate. ! FmXP will prompt you to place the weight on the scale. 10. Using gloves or tweezers, place the 50 g calibration weight on the pedestal. 11. Replace the scale cover and click OK. ! FmXP will display the following message (Figure 5-9): Figure 5-9 FmXP Calibrating Scale Message 12. Upon completion, FmXP displays the following message: Figure 5-10 FmXP Calibration Complete Message 13.
5.9 Z-Head Counterbalance Force Adjustment The Z-head Counterbalance Force prevents the Z-head (dispensing head) from crashing down upon disengagement of the motor. There are three settings to accommodate various payloads. To adjust the Z-head counterbalance (Figure 5-11): 1. Loosen the Z-head counterbalance force adjustment screw (Figure 5-11). 2. Slide the screw assembly to the desired position. See Table 5-1.
5.10 Adjusting the Height Sensor Probe The Height Sensor Probe must be adjusted each time a different type of dispensing valve or a different length of needle is installed. To adjust the Height Sensor Probe: 1. Power down the system as described in 6.12 System Shutdown. 2. Manually move the dispensing head down. 3. Loosen the Height Sensor Probe locking screw (Figure 5-12). 4. Move the probe to the desired location (approximately 6 mm below the needle tip in the gear down position). 5.
5.11 Adjusting the Board Sensors Board Sensors are optical sensors located along the length of the front conveyor rail. The sensors detect the presence of the workpiece and report it to the Conveyor Controller. Board sensor sensitivity should be adjusted after initial installation and if the sensors fail to sense the presence of a workpiece.
4. Press the TEACH button until the Long Distance sensing function (F Ld ) is displayed. See Figure 5-14. 5. Move the SET-ADJ-RUN switch to the RUN position to implement this setting. 5.11.1 Program Output for Look Down Configuration (ASPA,196581 Fiber Array) 1. Ensure no part is under the sensor lens. The sensor leading edge should remain parallel to the rail insert. ! The reference digital value should be less than 250 (approximate value). 2. Move the MODE switch to L (Light On). 3.
5.12 Initializing the Digital Gauges The S-910N Series Dispensing System is equipped with Cooling/Coaxial, Valve and Fluid Pressure Digital Gauges. If the system is configured with the optional Electronic Pressure Control Utility, the digital gauges will not be present. To initialize the digital gauge: 1. Make sure the air pressure to the pressure gauge is OFF by turning the appropriate regulator knob counterclockwise until it stops. See Figure 1-5 and Figure 1-6. 2.
5.13 Adjusting the Lift Table Speed 1. From the FMXP Main Menu, select Configuration>Conveyor Setup>Test I/O. 2. Select the tab labeled Outputs 0-31 and locate the Lift output buttons for the station to be adjusted ( Left – Center- Right ). 3. Use these buttons to lift and lower the table to test the speed adjustment setting. Figure 5-16 Conveyor I/O Test Dialog 4. Open the dispensing system hood.
Figure 5-17 Pre-Dispense Lift Table Controls Figure 5-18 Post-Dispense Lift Table Controls Figure 5-19 Dispense Lift Table Controls Calibration and Adjustment 5-15
5.14 Adjusting Manual Airflow for Impingement Heaters (S-920) " NOTE This procedure applies to systems equipped with impingement heat and manual flow controls. Airflow to Impingement Heaters is adjusted by turning the applicable flowmeter adjustment knob located in the lower front cabinet door. Airflow is read on the gauge on the front of the flowmeter (Figure 5-20). Factors to be considered when determining the airflow include the following: • Maximum airflow is 4.0 SCFM.
1 3 2 Item Description 1 Flowmeter Adjustment Knob (Conveyor 1) 2 Flowmeter Adjustment Knob (Conveyor 2) 3 Impingement Air Valve Figure 5-20 Adjusting the Impingement Heater Airflow (S-922 Dual Conveyor) Calibration and Adjustment 5-17
5.15 Controlled Process Heat " NOTE This procedure applies to systems equipped with impingement heaters and Controlled Process Heat (CpH) only. 5.15.1 CpH Configuration If the dispensing system is equipped with (CpH), make sure that option is selected in the FmXP Heater Setup Window. See Figure 4-7. To configure CpH: " NOTE CpH can be added to any station and each station is configured independently. 1. In the FmXP Main Window, select Tools > Terminal. 2.
7. Enter the desired ramp temperature, airflow, and time. ! The ramp temperature is generally higher than the dispense station temperature and is used to quickly heat a part in the pre-dispense station. 8. Enter the desired standby temperature, airflow, and time. ! The standby temperature is generally lower than the dispense station temperature and is used to reduce energy when a board is not received for a specified amount of time. 9. Click on OK to close the Heater Control Window. 10.
5.15.2 CpH Cool Down The Cool Down feature will allow the operator to select which stations should be cooled down before working on or removing a heater module. The heater will be shut off and maximum air flow will be applied for a given amount of time specified by the operator. To cool down the heaters: 1. In the FmXP Main Window, click on Run a Program. ! The Production Window opens. 2. Click on Shutdown. ! The Cool Down button (Figure 5-24) appears. Figure 5-24 FmXP Main Window - Cool Down Button 3.
5.16 Software Controlled Light Beacon Beacon Configuration allows you to easily configure beacon and audible alarm states for various FmXP/dispensing system operational conditions. To configure the desired beacon state and audible alarm: 1. In the Main Window, select Configuration > Setup Runtime Preferences > Beacon Control. ! The Beacon Configuration dialog box (Figure 5-26) opens.
Figure 5-27 Beacon Configuration Dialog Box 2. Click the Configure button next to the desired condition to display the Dispenser I/O dialog box where you can select the desired beacon state. See Figure 5-28. Figure 5-28 Dispenser I/O Dialog Box " 5-22 NOTE Refer to the Fluidmove User Guide or Online Help for detailed instructions.
6 Operation 6.1 Overview At this point, we have installed the S-900N Series, connected it to the necessary facilities, performed the sub-system checks, calibrated and adjusted the options, and are ready to begin final configuration for program generation. The sections that follow describe the general sequence of actions necessary to write and run a new dispensing program. References to FmXP are included as a guide. For detailed information on FmXP, please consult the Fluidmove User Guide.
6.4 Installing the Dispensing Valve To install the dispensing valve, slide the dovetail bracket (included with the dispensing valve) into the valve mounting bracket on the Z-axis face plate. Secure by turning the lever on the valve mounting bracket to the upward position. Refer to the applicable dispensing valve manual for additional information. 6.4.1 Valve Pneumatic and Electrical Connections Valve pneumatic and electrical connections are shown in Figure 6-1 and Figure 6-2.
2 3 4 1 5 Item Description Item Description 1 Cooling Air (Green) 4 Valve Electrical Connection 2 Valve Air Pressure (Black) 5 DJ-9000 Valve 3 Fluid Air Pressure (Clear) Figure 6-2 Valve Pneumatic and Electrical Connections (DJ-9000 shown) Operation 6-3
6.5 Adjusting the Air Pressure 6.5.1 Adjusting the Main Air Pressure 1. Verify that the facility air is connected to the Main Air Pressure Regulator Inlet. TIP For accurate pressure adjustment, lower the pressure below the desired level and then increase to the desired pressure. 2. Rotate the knob on the Main Air Pressure Regulator counterclockwise until the Main Air Gauge registers 0 psi. 3. Rotate the knob clockwise until the Main Air Pressure Gauge registers 90 to 100 psi (621 to 689 kPa). 4.
6.5.2 Adjusting the Cooling/Coaxial, Valve, and Fluid Air Pressure 6.5.2.1 S-91X Series Systems 1. Locate the Cooling/Coaxial, Valve, and Fluid Pressure Regulator adjustment knobs in the front cabinet (Figure 6-4). TIP For accurate pressure adjustment, lower the pressure below the desired level and then increase to the desired pressure. 2. Rotate the adjustment knob counterclockwise until the gauge registers 0 psi. 3.
6.5.2.2 S-92X Series Systems The S-92XN features programmable fluid and valve pressure. Electro pneumatic regulators control the valve pressure, fluid pressure and cooling/coaxial pressure. These regulators have been integrated into the platform. All the pressure setpoint values are set through Fluidmove (as opposed to manual regulators). This reduces possibility of operator error when setting the regulators manually. It also allows the user to import a recipe that includes all the pressure set points.
Using the Air Pressure Settings in the Fluid Manager: 1. In the FmXP Main Menu select Configuration>Setup Fluid Manager>Air Pressure Settings tab (Figure 6-6). 2. Click to select the appropriate setting and enter the desired value. 3. Click Save to save the settings in the fluid file. Figure 6-6 Fluid Manager - Air Pressure Settings To view the Current Air Pressure Settings: 1. You may press Ctrl + P in any FmXP Window to toggle the Current Pressure toolbar ON and OFF. See Figure 6-7.
6.5.3 Adjusting the Vacuum Control The Vacuum Control (Figure 6-4) allows low viscosity fluids to be consistently dispensed without dripping between cycles. The vacuum exerts a negative pressure (suckback) on the fluid, thereby decreasing dripping. To adjust the Vacuum Control: 1. Rotate the knob counterclockwise to increase vacuum pressure and decrease dripping. 2. Rotate the knob clockwise to decrease vacuum pressure. 6.5.
6.6 Positioning the Conveyor and Dispensing Head When necessary, an operator can use Fluidmove Position (Jog) Controls to reposition the dispensing head in the X-, Y-, and Z-axes, adjust conveyor rail width, and reposition the workpiece X-axis location on the conveyor. These position controls can be operated using the touchpad to click on-screen buttons, or by pressing key combinations on the keyboard. Both methods are described below. " NOTE 6.6.
6.6.1.1 Dispenser Position Controls 1. Click on the Dispenser Radio button to activate the dispensing head position controls. 2. Dispensing head position controls (Figure 6-10) operate as follows: " ! On the X-Y control panel, the arrows pointing to the Left move the dispensing head to the left and the arrows pointing to the Right move it to the right.
1 7 2 3 4 6 5 Item Description 1 Target Box 2 Y-axis Controls (forward and back movement) 3 X-axis Controls (side to side movement) 4 Radio Button (Dispenser selected) 5 Locations (moves the dispensing head to pre-defined locations, purge, scale, etc.
6.6.1.2 Conveyor Position Controls 1. Click on the Conveyor 1 radio button to activate the Conveyor 1 position controls. 1 2 3 Item " Description 1 Y-axis Controls (rear rail forward and backward movement) 2 X-axis Controls (belt left and right movement) 3 Radio Buttons (Conveyor 1 selected) Figure 6-11 Conveyor Position Controls NOTE See 6.6.1.2.1 Dual Conveyor Systems for systems equipped with dual conveyors. 2.
Table 6-2 Conveyor Position Controls: Jog Distance(1) Movement Axis Distance mm (inch)(2) Y 0.0254 (0.001) 1.27 (0.0500) X 0.0254 (0.001) 1.27 (0.0500) Notes: (1) Default distances. Refer to the Fluidmove User Guide or Fluidmove Online Help to modify jog distances. (2) Distance per mouse click on the arrow button. 6.6.1.2.1 Dual Conveyor Systems If the dispensing system is equipped with dual conveyors, the Conveyor 2 radio button will be active.
Table 6-3 Position Control Commands Name Target Box Y-axis Controls (move front/back) Dispensing Head Response Clicking in the Target Box moves the Dispensing Head to the corresponding position in the dispensing area.
6.6.2 Using the Keyboard To operate position controls using Keyboard commands: 1. Press [Ctrl + J] to open the FmXP Jog Window. 2. Using the mouse, click on the Dispenser radio button to activate the dispensing head position controls, the Conveyor 1 radio button to activate the Conveyor 1 position controls or the Conveyor 2 radio button to activate the Conveyor 2 position controls. 3. Press the appropriate keys shown in Table 6-4 to jog the selected device (conveyor or dispensing head).
6.7 Camera Operation The S-900N Series features a Dalsa-Coreco Genie M640 digital 640 x 480 pixel camera. It communicates bi-directionally to the laptop computer via Gigabit Ethernet. The camera is configured to run at 60 full frames per second, twice as fast as the analog PCVision cameras. A frame can be transferred in 16.67 milliseconds. 6.7.1 Camera States After the Dalsa-Genie software package has been installed, the GigE Server icon will be visible in the desktop taskbar tray area.
6.7.2 Lighting and Color Adjustment The light intensity and color level can be adjusted to optimize the view of your workpiece. See Section 5 Calibration and Adjustment for instructions on focusing and calibrating the camera. CAUTION! Except for lighting adjustments and lens replacement, all other configuration and adjustments should only be performed by a trained service technician. To adjust lighting intensity and color level: 1.
1 2 3 4 Item Description 1 Blue Light Adjustment Slide (in unlinked mode) 2 Red Light Adjustment Slide (in unlinked mode) 3 Color/Brightness Control Mode Button 4 Jog Controls Figure 6-13 Camera Lighting Adjustment 6-18 Operation
6.8 Establishing Machine Offsets Programming a dispensing sequence and running production involve the use of the camera. Dispensing is accomplished with a needle or nozzle. To ensure accurate dispensing and to avoid damage to the dispensing system or parts, offsets between the camera and needle and camera and height sensor must be defined prior to dispensing. 6.8.1 Valve Offsets FmXP provides a semi-automated routine called Valve Offsets to establish machine offset parameters.
3. Make sure Valve 1 is selected. 4. Click on Run to End. A Teach Window opens. ! " NOTE When using the Valve Offsets setup procedure, click on the Run button next to the desired task. You will need to repeat this step for each task in the dialog box (as desired). When setup tasks are complete, click End in the Setup Valve Offsets dialog box. 5. Follow the on-screen prompts. Click on Help if you have questions. ! The Teach Window content and appearance may vary depending on your system configuration.
Figure 6-16 Production Window - Teaching Safe Z Height Figure 6-17 Teaching Safe Z Height 4. Move the dispensing head over a workpiece fiducial. 5. Raise or lower the dispensing head until it reaches a Safe Z-Height. 6. Click on Teach. ! The Safe Z-Height value will be recorded in the value textbox. 7. Click on Done. WARNING! Operation Safe Z-Height should never be taught lower than the tallest component on the unit to be dispensed on.
6.9 Creating a New Program This section briefly covers the steps required to create a new dispensing program. For detailed instructions, refer to the Fluidmove User Guide or Online Help. " 6.9.1 NOTE The following procedures assume that the dispensing system is on and FmXP is running. Loading a Part 1. In the FmXP Main Window, click on Teach a Program ! . The Programming Window opens. 2. Place the substrate on the conveyor. 3.
6.9.2.1 Heater Setup 1. In the Fluidmove Main Window, click on Configuration. 2. Select Setup Heaters. ! The Heater Setup Window (Figure 6-18) opens. Figure 6-18 Heater Setup Window 3. Select desired settings and click on OK. 6.9.2.2 Heater Tooling CAUTION! " NOTE Operation The operator can turn the heaters ON and OFF and monitor their function. However, only authorized personnel should set heater parameters.
To setup the Heater Tooling in Fluidmove: WARNING! The heater may be hot. Avoid touching heater surfaces or burn injury may occur. 1. In the Fluidmove Main Window, click on Run a Program . 2. In the Production Window (Figure 6-19), click on Setup and in the list box select Setup Heater 2. ! The Heater Control Window (Figure 6-20) will open. Figure 6-19 Fluidmove Production Window 3. In the Heater Control Window (Figure 6-20), locate the loop (channel) for the desired heater. " 6-24 NOTE See 5.
4 3 5 6 1 2 Item Description Item Description 1 Heater Loop - ON 4 Temperature Set Point Column 2 Heater Loop - OFF 5 Present Temperature Value Column 3 Channel (Loop) Name Column 6 Message Column Figure 6-20 Heater Control Window 4. Activate the heater by double clicking the icon in the On/Off column until the heater loop icon turns yellow and red. " ! NOTE To change heater temperature, double click on the heater loop name. The heater parameters dialog box will open.
6.9.3 Setting up the Fluid Manager The Fluid Manager is a powerful tool that contains information about the dispensing fluid, such as line, dot, and mass parameters; purge duration; and pot life. It also contains flow rate setup parameters for the Mass Flow Calibration System. Mass Flow Calibration makes it possible to dispense the proper amount of fluid every time and helps to reduce setup time on a daily basis by eliminating trial-by-error guesswork for the various input parameters.
6.9.4 Workpiece Alignment Prior to creating your dispensing program, you should setup workpiece alignment and define the number of fiducials to be used in your program. Workpiece alignment refers to the position of the board or part in relation to the Dispensing Head X- and Y-axes. Even if the board is slightly askew, FmXP can use workpiece alignment to adjust the patterns and dispense correctly.
2. Indicate the number of fiducials to be used in your program. ! If No Fiducials is selected, you have the option of confirming the workpiece origin when opening an existing program. To activate this feature, make sure there is a checkmark in the textbox next to Confirm Origin location … • All dispensing locations on the workpiece are defined in reference to the workpiece origin. • The workpiece origin is defined as the point where the position counters are reset to (x0, y0) or (0, 0). 3. Click OK.
2. To create a new program, select File > New from the menu bar or click on the Program Wizard icon on the toolbar. ! This action clears the work area, loads the default fluid and heater files, and opens the Create Workpiece Window (Figure 6-24). ! You will be prompted to define the number of fiducials and skip marks. Figure 6-24 Create Workpiece 3. Enter the desired information and click OK. ! 6.9.6 You will be prompted to teach the workpiece origin and fiducial locations, if applicable.
6.9.8 " Attaching a Custom Fluid File NOTE The default fluid file is automatically attached to the program when you open the new program window. To attach a different fluid file, follow the instructions below. The fluid file is saved with the program. See 6.9.3 Setting up the Fluid Manager. 1. In the Programming Window, Select File > Fluid Table > Load from the pull-down menu. 2. If your systems is equipped with dual dispensing valves, you will be prompted to select Valve 1 or Valve 2. 3.
Dispensing Elements Inserts a Program Comment Disable/Enable Instruction Inserts a Send Command into your program Create a Pattern Inserts Process Commands into your program Inserts Procedures into your program Inserts Motion Commands into your program Inserts timer-related functions into your program Conveyor Step and Repeat Figure 6-25 Program Commands Toolbar Operation 6-31
6.9.9.1.1 Dispensing Elements There are several fundamental dispensing elements and patterns that form the foundation for all dispensing applications. These include lines, dots, circles, rectangles, area fill, etc. When you select Dispensing Elements from the Program Commands Toolbar, a Teach Window opens. The Teach Window contains the Dispensing Elements toolbar (Figure 6-26). Select the desired Dispensing Element by clicking on it.
To place a program command in a Conveyor Block: 1. In the Fluidmove Main Window, select Teach a Program. ! The Programming Window opens. 2. Click on the Conveyor ! button on the Program Commands toolbar. The Conveyor drop-down menu (Figure 6-27) opens. Figure 6-27 Programming Window - Conveyor Block Commands 3. Select Use Conveyor 1 Block or Use Conveyor 2 Block depending on where you want to dispense. ! A Conveyor Block command similar to the one below will be inserted into your program.
Dual_Lane.fmw 1 2 3 4 5 6 7 Workpiece USE CONVEYOR 1: LINE: 1, START: (15.139, 12.971), End: (1.139, 11.370) END USE CONVEYOR: USE CONVEYOR 2: DOT: 1, (4.964, 24.501) END USE CONVEYOR: END: Figure 6-28 Sample Dual Conveyor Program To create additional patterns: 1. Click on the Pattern button on the Program Commands toolbar. See Figure 6-29. Figure 6-29 Creating a Pattern 2. Select Create Pattern. ! 6-34 The Create Pattern dialog box (Figure 6-30) opens.
Figure 6-30 Create Pattern Dialog Box 3. For this example, enter C1Line as the name for the new pattern. 4. In the Fiducial section of the window, select None for no fiducials and click OK. 5. Repeat Steps 1 to 4 and create a pattern called C2Dot. To add program commands to your pattern: 1. Click on the arrow See Figure 6-31. in the Pattern textbox and select C1Line. Figure 6-31 Selecting a Pattern 2.
To place a pattern: 1. Make sure the Workpiece pattern is selected. Follow the steps above for instructions on selecting a pattern. 2. Click on the Pattern button on the Program Commands toolbar. See Figure 6-29. 3. Select Place Pattern. ! A Teach Window opens prompting you to select a pattern and teach the placement point. 4. Follow the screen prompts and click on Done when finished. ! Sample program screens are shown in Figure 6-32. dual_lane.
6.9.11 Running the Program in Dry Mode Once the sequence is written, it is helpful to run the camera through the program first (dry run) to visualize where the needle tip will go when dispensing. The Vision Window will open and show a live image of the dispensing path the system will make during a wet run. To run the program in dry mode: 1. Select Run > Dry Run from the Programming Window. ! Alternately, you may click on Dry Mode icon and then on Run . Figure 6-33 Dry Run 6.
6.11 Starting a Production Run You are now ready to run the program with fluid. Ensure that dry mode on the Run menu is not checked (Figure 6-33) and click the run button. The system will find the vision targets, height sense, and dispense in exactly the manner you have specified. All system functions from purging to measuring flow rates will be performed. To start a production run: 1. Verify that the main air, valve, and fluid pressures are set to the desired levels. 2.
7. In the Production Window, click on Load ! . The Open Window (Figure 6-35) opens. 8. Select the program you wish to run and click on Open. ! The current program name will appear in the Production Window. Figure 6-35 FmXP Open Window 9. In the Production Window, click on Run ! and then click on the Run Production button. The Run Window opens (Figure 6-36). 10. Load the workpiece. 11. Click on Go to start the dispensing process.
6.12 System Shutdown Routine shutdown may vary depending on your particular requirements. However, it is recommended that you incorporate the following procedures into your post production shutdown routine. 6.12.1 Post Production Shutdown To shut down at the end of a production shift: 1. Wait for the dispensing program to complete and verify that all motion has stopped. 2. Unload all workpieces. 3. Move the dispensing head to the front center of the system for easy access.
7 Maintenance 7.1 Overview Following a routine maintenance schedule and procedures can prevent part degradation and ensure high quality performance for every production run. This section covers the following topics: • Routine Maintenance Procedures • Lubricating the Cables and Linear Guides • Replacing Consumables • Tensioning the Cables • Draining the Water Trap • Tensioning the Conveyor Belts • Removing the Axis Covers WARNING! 7.
7.4 Routine Maintenance Procedures WARNING! CAUTION! Before performing any of the maintenance procedures in this section, perform a service shutdown described in 2.11 Service Shutdown. " NOTE The following maintenance procedures are for the S-900N Series Dispensing Systems only. Refer to the appropriate manual for recommended maintenance procedures for your specific fluid dispensing applicator. Routine maintenance procedures and required intervals are listed in Table 7-1.
Table 7-1 Routine Maintenance Procedures (Continued) Task Frequency Instructions Lubricate Mechanical Drive Cables Every three months See 7.8.1 Lubricating the Cables. Tension Mechanical Drive Cables Every 6-12 months See 7.9 Tensioning the Cables. Clean Camera Lens As Needed Use the cleaning kit provided. Tension Conveyor Belts As Needed See 7.10 Tensioning the Conveyor Belts. Replace Conveyor Belts As Needed See 9.7 Replacing the Conveyor Belts. 7.
7.5.1 Replacing Purge and Weigh Station Cups The cups in the purge and weigh stations should be replaced at the intervals recommended in Table 7-1. To replace the Purge and Scale cups: WARNING! " NOTE Follow all local regulations, the material manufacturer MSDS, and facility practices concerning personal protective equipment and disposal of hazardous materials. The Fluidmove Valve Offsets routine does not need to be performed after replacing the Purge Station and Weigh Station cups.. 1.
1 4 2 3 Item Description 1 Weigh Station 2 Weigh Station Cup 3 Purge Station Cup 4 Purge Station Lid Figure 7-1 Replacing the Purge and Weigh Station Cups Maintenance 7-5
7.5.2 Replacing the Purge Boot To replace the purge boot: WARNING! Follow all manufacturer MSDS, facility requirements, and local ordinances concerning personal protective equipment and disposal of hazardous materials. 1. When the dispensing system is idle, open the dispensing system hood. 2. Remove the Purge Station cover. 3. Using needle-nosed pliers, grip the top of the purge boot and pull it out from the top of the cover. Discard the used purge boot. 4.
7.6 Draining the Water Trap Because the facility air supply may contain moisture that can damage the dispensing system, the S-900N is equipped with two water traps that condense this moisture before it enters the pneumatic system. The operator or technician must drain the water trap weekly or whenever it is full. Tools and Materials Needed: • Container for waste water To drain the Water Trap: 1. Locate the Water Traps at the rear of the system. 2.
7.7 Removing the Axis Covers In order to lubricate the cables and linear guides and to tension the cables, it will be necessary to remove the axis and rear cable covers. To remove the X-axis covers: 1. Use a 5 mm hex key to loosen the four (4) M-6 screws (Figure 7-4). 2. Lift off the covers and set aside. Figure 7-4 Removing the X-Axis Covers To remove the Y-axis covers: 1. Use a 5 mm hex key to loosen the five (5) M-6 screws (Figure 7-5). 2. Slide out the covers and set aside.
To remove the rear cable covers: 1. Use a 5 mm hex key to loosen the eight (8) M-4 screws (Figure 7-6). 2. Remove the covers and set aside. Figure 7-6 Removing the Rear Cable Covers 7.8 Lubricating the Cables and Linear Guides The XYZ-Axes support the dispensing head and allow it to travel within the dispensing area. To ensure smooth dispensing head movement, the cables and linear guides must be lubricated approximately every three months. " 7.8.
4. Wearing gloves, clean all accessible cables using a soft lint-free cloth and isopropyl alcohol. WARNING! Fingers may be pinched if the dispensing head is moved while cleaning and lubricating the cables. 5. Visually inspect the cleaned cables for uneven and excessive wear. Run a lint-free cloth over cables while feeling for breaks in sheathing or swollen spots. " NOTE If the cables show signs of wear, skip this procedure and contact Asymtek.
4. Remove the blue cap from the grease cartridge and place it, open end down, into the grease gun cylinder. 5. Remove the seal from the bottom of the grease cartridge by pulling the tab. 6. Replace the top of the grease gun. 7. Screw the extension into the front side at the top of the grease gun. 8. Release the handle from the locked position. 9. Purge the air from the grease gun cartridge by dispensing grease into a waste receptacle until a solid stream flows from the gun.
Figure 7-7 Lubricating the X-Axis Linear Guides Figure 7-8 Lubricating Y-Axis Linear Guides 7-12 Maintenance
7.9 Tensioning the Cables To tension the cables: 1. Perform a service shutdown as specified in 2.11 Service Shutdown. 2. Loosen the X-Axis and two (2) Y-axis tensioner screws. 3. Move the Z-head in a circle around the entire length and width of the dispensing area approximately 5 times. 4. Stop in the center of the dispensing area. 5. Retighten the tensioner screws.
7.10 Tensioning the Conveyor Belts To tension the conveyor belts: 1. Perform a service shutdown as specified in 2.11 Service Shutdown. 2. Loosen the belt tensioner screw located on the back of the Motor Mount Tensioner (Figure 7-10). 3. Move the Motor Mount Tensioner right and left until the desired tension is obtained. 4. Tighten the tensioner screw. 5. Repeat Steps 1-3 for the other belt. 6. If the dispensing system is equipped with dual conveyors, perform steps 2-5 for the other conveyor.
8 Troubleshooting 8.1 Overview If you have difficulty operating your dispensing system, use this section to identify a possible solution to the problem. If you have difficulties not listed in this section, or the suggested solution does not correct the problem, contact Asymtek Technical Support. This section covers the following troubleshooting procedures: " 8.
8.4 Basic System Troubleshooting 8.4.1 System Power Table 8-1 System Power Troubleshooting Symptom No power to major system components Possible Cause The ON (l) button has not been pressed Press ON (l) on the front panel. The green button will illuminate. A circuit breaker has been tripped The S-900N incorporates circuit breakers with a “push to reset” feature rather than fuses.
8.4.2 System Accuracy Table 8-2 System Accuracy Symptom Possible Cause Loose camera lens Refocus the camera. See 5.5 Focusing the Camera. Bad offset routines Perform a Valve Offsets Routine. See 6.8 Establishing Machine Offsets. Camera needs calibrated Calibrate the camera. See 5.6 Calibrating the Camera. Cal Maps disabled Enable Cal Maps. Contact a service technician. Bent needle Replace the needle. Refer to the applicable valve manual. Bad height sensor Contact Asymtek Technical Support.
8.4.3 Pneumatic Table 8-3 Pneumatic Troubleshooting Symptom No air pressure No fluid pressure No valve pressure " 8-4 NOTE Possible Cause Recovery Failed main air solenoid With FmXP initialized, go to the tools menu, then IO, then toggle the command button for the main air solenoid. The Valve and fluid air buttons are also accessible from this tools IO menu. System not connected to facility air supply Check the main air inlet at the rear of the system.
8.4.4 FmXP Startup Table 8-4 FmXP Startup Symptom Possible Cause Communications failure Verify COM port settings and serial communications cables are attached. Restart computer and retry. USB communications failure The USB hub may have failed or lost power. The laptop PC communicates to system devices via the USB hub. Check the USB connection and ensure the USB hub is connected to its power source on outlet AC4 from the power manager.
8.4.5 Dispense Head Controller Connections and Functions Table 8-5 Dispensing Head Troubleshooting Symptom Dispense Head Controller fails to initialize during FmXP startup Dispenses at wrong Z-axis position Possible Cause CAN terminator not present Verify presence of CAN terminator. Corrupt firmware or incorrect revision CAN firmware may need to be flashed to the correct or latest firmware. Contact Asymtek Technical Support. Failed Dispense Head Controller Verify DHC power indicator LED’s for 3.
8.4.6 Height Sensor Table 8-6 Height Sensor Troubleshooting Symptom Probe does not drop or retract Probe either drops too slowly or slams down with too much force Needle hits substrate Possible Cause Probe is damaged Check for bent probe. Replace if necessary. See 9.9 Replacing the Height Sensor Probe. No air pressure Verify main air pressure is ON (I). Flow control improperly set (closed to off) or there is a pinched pneumatic line for the height sensor.
8.4.8 Vision System Table 8-8 Vision System Troubleshooting Symptom No Image (FmXP display window is a solid pink color) Camera LED is OFF Camera LED Steady Red Possible Cause Camera not connected Recovery Verify camera cable is securely connected to the connector on the top of the camera. Faulty camera cable Replace camera cable. Camera not connected Verify camera cable is securely connected to the connector on the top of the camera. Faulty camera cable Replace camera cable.
8.4.9 Scale Table 8-9 Scale Troubleshooting Symptom Possible Cause Recovery No power Check power (+24V) and RS-232 communications cables. Flex circuit connection Verify that the RS-232 flex circuit connection is seated properly. No scale communication Flex circuit orientation The flex circuit should be oriented so that the red dot [1] on the PCA matches the dot [2] marked on the flex circuit. The flex circuit orientation can also be identified by the short trace [3] that does not continue.
Figure 8-2 Scale Dip Switch Configuration " NOTE The scale can also be tested from the FmXP Terminal Mode. See instructions below. To test the scale from the FmXP terminal mode: 1. From the FmXP Main Window, select Tools. 2. From the Tools menu, click on Terminal and then on Scale . 3. VERY CAREFULLY use the following commands to check the scale responses: ! ESC P (escape key and capital P) Outputs the current scale value to the terminal screen.
Figure 8-3 FmXP Scale Setup Menu Figure 8-4 Scale Error Message Troubleshooting 8-11
8.4.10 Needle Heater Table 8-10 Needle Heater Troubleshooting Symptom No needle heat Possible Cause Recovery Set Point (SP) value below Present Value (PV) or the heater is in an idle state Change the SP value within the Heater Controls Window. See 6.9.2 Setting the Heaters. Disconnected heater Verify the needle heater cable connections are securely attached to the correct ports. Failed DHC power Verify DHC indicator lights for 3.3V, -12V, and 12V are illuminated.
8.4.11.1 Tactile Sensor Error If you receive a tactile sensor error, the following procedure may remedy the error. " NOTE If you continue to receive tactile sensor errors after performing the following procedure, contact Asymtek Technical Support. 1. Gently lift the cap off of the tactile sensor as shown in Figure 8-5. 2. Use isopropyl alcohol and a soft cloth to remove any residual fluid from around the circumference of the cap and around the tactile sensor opening.
8.4.12 Substrate Heaters Table 8-12 Substrate Heater Troubleshooting Symptom Possible Cause Recovery Missing vacuum hole screw(s) Replace screw(s). Other pneumatic leaks Contact a service technician. Erroneous temperature display Wrong display unit Change display unit to C. Workpiece part not held steady Check for improper open or plugged vacuum holes Remove and install screws as applicable. Vacuum does not start or fails to work properly System has low or no air pressure 1.
Table 8-13 Conveyor Troubleshooting (Continued) Symptom Conveyor does not transfer parts from upstream to downstream machines Board sensors not sensing when board is present Board will not index to correct position Conveyor does not move at all (with Fluidmove position controls) Conveyor jams or does not move Fails to find width Home Troubleshooting Possible Cause Recovery Workpiece or carrier is jammed Call a trained service technician.
9 Parts Replacement 9.1 Overview This section includes general information for ordering recommended spares and replacement parts for your Spectrum S-900N Dispensing System. Replacement part numbers are listed in Appendix C. Part number information is also available on Asymtek’s Find-A-Part web page: http://webstore.asymtek.com/awweblive/apps/findapart_index.
9.3 Parts Ordering Information 9.3.1 Placing Your Order Customers can order spare parts by contacting Asymtek Customer Service. Your Customer Service Representative can take your order or assist you in setting up an account to purchase spare parts through our Internet Web Store.
9.4 Cleaning and Inspection Always clean the area made visible after a failed part is removed from the dispensing system. Inspect the area for signs of what may have caused the part to fail. This may help prevent future part damage. While removing parts that will be reinstalled, visually inspect them for damage. If found undamaged, retain them for reinstallation. Replace damaged parts and hardware as appropriate. 9.
9.6 Gaining Access to Dispensing System Components In order to gain access to some areas of the dispensing system, it will be necessary to remove covers, doors, and access panels. Figure 9-1 shows the location of these features. 12H WARNING! CAUTION! Make sure that the dispensing system has been completely shut down before attempting to remove any panel. Remove doors, covers, and panels carefully to avoid damaging underlying components.
9.7 Replacing the Conveyor Belts Checking the condition of the conveyor belts should be part of the routine maintenance schedule for the dispensing system. Cracked, worn, or broken belts should be replaced immediately. To maintain reliable system performance, it is recommended that the conveyor belts be changed every six months. However, the belts may need to be changed more frequently or less frequently, depending upon the volume of workpiece production.
2 3 1 4 5 6 7 Item Description Item Description 1 Pulley Tire 5 Rear Conveyor Rail 2 Tensioner 6 Stop Pin 3 Tension Pulley Tire 7 Front Conveyor Rail 4 Conveyor Belt Figure 9-2 Conveyor Belt Removal/Installation 9-6 Parts Replacement
To install a conveyor belt: CAUTION! This procedure should only be performed by a trained service technician. 1. Using isopropyl alcohol and a soft cloth or cotton swabs, clean all metal surfaces that make contact with the belt, including pulleys and rails. 2. Compare the new belt to the one remaining on the other rail to determine its proper orientation. 3. Loop the belt around the pulley tire at one end of the conveyor rail and extend it toward the other end. See Figure 9-2. 13H 4.
9.8 Replacing the Camera Lens CAUTION! Except for lens replacement and lighting adjustments, all other configuration and adjustments should only be performed by a trained service technician. To remove and replace the camera lens: 1. Remove the lens by turning the lens tube counterclockwise (Figure 9-3). 14H 2. Screw on the replacement lens by turning the lens tube clockwise.
9.9 Replacing the Height Sensor Probe To replace the Height Sensor Probe: 1. Pull the Height Sensor Probe down. (Figure 9-4). 15H 2. Loosen the Height Sensor Locking Screw on the front of the height sensor assembly. 3. Remove the Height Sensor Probe. 4. Slide in the new probe and tighten the locking screw.
9.10 Replacing Fuses Use the following procedures to remove and replace a fuse. CAUTION! Always replace fuses with fuses of identical rating and size. Failure to do so may not protect components from damage. Tools and Materials Needed • ESD Grounding Strap • Replacement Fuse (see Table 9-1) • Small Flat Head Screwdriver* • Phillips Screwdriver* 16H *In the Spectrum Tools and Spares Kit (P/N 7204804) included with the dispensing system. 9.10.
To remove and replace the SDHC board-mounted fuse: CAUTION! This procedure should be performed by a trained service technician only. 1. Perform a service shutdown as specified in 2.11 Service Shutdown. 2. Open the rear dispensing system door and locate the SDHC. If necessary, refer to the Electrical Diagram P/N 7207632BD in Appendix B. CAUTION! The circuit board and its components are susceptible to damage by electrostatic discharge. Observe all ESD protection protocols while performing this procedure.
9.10.4 Panel-Mounted Fuses These glass fuses are located on the front panel of the Conveyor/Heater module. The fuses protect the module from damage caused by power surges from the heater tooling (Figure 9-6). 2H CAUTION! Always replace fuses with fuses of identical rating and size. Failure to do so may not protect components from damage. Figure 9-6 Replacing a Panel-Mounted Fuse To remove and replace panel-mounted fuses: CAUTION! This procedure should be performed by a trained service technician only.
10 Specifications 10.1 Overview Facility requirements and specifications are listed in Table 10-1 to Table 10-3. These specifications are intended as a convenient reference for installation, system relocation, planning and operation. Meeting the requirements will ensure reliable operation and safety of the dispensing system.
10.
10.4 Stability Analysis Table 10-3 Stability Analysis Specifications Center of Gravity Single Station: 296.5 mm (11.67 in.) Two Station: 800.7 mm (31.52 in.) Three Station: 587.4 mm (23.12 in.) Weight Distribution (1) Front Left Front Right Rear Right Rear Left 92.0 kg (202.9 lbs) 93.9 kg (207.1 lbs) 94.2 kg (207.6 lbs) 91.8 kg (202.4 lbs) Seismic Loading Transverse Stability Anchorage Force Longitudinal Stability Anchorage Force Anchors Required 208.6 kg (460 lbs) Anchors Required 64.
Appendix A Material Safety Information A.1 Introduction This section contains Material Safety Information for the following materials contained in the Asymtek Grease Kit (P/N 7203262). • MULTEMP PS NO 2-A 07-350 • Moly-Graph® Extreme Pressure Multi-Purpose Grease WARNING! CAUTION! Consult the Material Safety Data Sheet (MSDS) for all fluids used with the dispensing system. The MSDS provides material usage instructions, disposal instructions, and safety precautions. A.
MSDS - MULTEMP PS NO 2-A 07-350 (Continued) SECTION III - Physical/Chemical Characteristics Appearance/Odor Boiling Point Melting Point Vapor Pressure Specific Gravity Solubility in Water Container Type Container Pressure Code Temperature Code Product State Code WHITE PASTE; SLIGHT ODOR NA 190 C NA 0.
MSDS - MULTEMP PS NO 2-A 07-350 (Continued) SECTION VII - Precautions for Safe Handling and Use Steps if Material Released/Spilled Waste Disposal Method Handling and Storage Precautions Other Precautions TRANSFER BULK OF MIXTURE INTO ANOTHER CONTAINER. ABSORB RESIDUE W/ AN INERT MATERIAL SUCH AS EARTH, SAND, & VERMICULITE. SWEEP UP & DISPOSE SOLID WASTE IN ACCORDANCE W/ LOCAL, STATE & FED REGS DISPOSE OF IN ACCORDANCE W/ STATE, LOCAL & FED REGS. INCINIRATE IN ACCORD. W/ APPLICABLE REGS.
A.3 MSDS Moly-Graph® Extreme Pressure Multi-Purpose Grease Section 1: Product & Company Identification Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number(s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 General Information Technical Assistance Customer Service 24-Hr Emergency (CHEMTREC) Manufactured By: CRC Industries, Inc.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Section 3: Composition/Information on Ingredients COMPONENT CAS NUMBER % BY Wt. Hydrotreated heavy naphthenic distillates 64742-52-5 70 - 90 Lithium 12-hydroxystearate 7620-77-1 5 - 10 Zinc, dithiophosphate di-C1-14-alkyl esters 68649-42-3 0.5 - 1.5 Molybdenum sulfide 1317-33-5 0.2 - 1 Graphite 7782-42-5 0.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Section 6: Accidental Release Measures Personal Precautions: Use personal protection recommended in Section 8. Minimize skin contact. Environmental Precautions: Take precautions to prevent contamination of ground and surface waters. Do not flush into sewers or storm drains. Advise authorities if product has entered waterways.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Section 9: Physical and Chemical Properties Physical State: Color: Odor Specific Gravity: Initial Boiling Point: Freezing Point: Vapor Pressure: Vapor Density: Evaporation Rate: Solubility: pH: Volatile Organic Compounds: semi-solid grease grey mild petroleum 0.90 @ 60 F ND ND < 0.1 mmHG @ 68F >5 (air = 1) < 0.01 (butyl acetate = 1) Insoluble in water NA Wt %: 0.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 Section 12: Ecological Information Ecological studies have not been conducted for this product. The following information is available for components of this product.
Product Name: Moly-Graph® Extreme Pressure Multi-Purpose Lithium Grease Product Number (s): SL3141, SL3144, SL3145, SL3146, SL3330, 8SL3141 State Regulations California Safe Drinking Water and Toxic Enforcement Act (Prop 65): This product may contain the following chemicals known to the state of California to cause cancer, birth defects or other reproductive harm: None State Right to Know: New Jersey: Pennsylvania: Massachusetts: Rhode Island: 1317-33-5 7782-42-5 1317-33-5, 7782-5 7782-42-5 Additional R
Appendix B Block Diagrams This section describes dispensing system electronic connections that may help in understanding dispensing system operation and aid in troubleshooting. Table B-1 lists available pneumatic and electrical block diagrams. B.1 Safety First Use of engineering drawings to disassemble, service, and reassemble the dispensing system promotes good safety practices only when used in conjunction with the precautions in the Section 2 - Safety and other sections of this manual. CAUTION! B.
B.
Item Name Description 1 AC1 Unswitched Supplies AC power to the computer 2 AC1-AC2 Breaker Reset Resets the AC1-AC2 circuit breakers 3 AC2 Unswitched Spare unswitched DC outlet 4 AC3 EMO Switched Supplies AC power to the servo power supply 5 AC4 EMO Switched Supplies AC power to the USB power supply 6 AC5 EMO Switched (spare) 7 AC6 EMO Switched (spare) 8 AC7 EMO Switched Supplies power to the conveyor module CV1 9 AC7 Breaker Reset Resets the AC7 circuit breaker 10 AC8 EMO Swit
B.
11 12 1. 2. MAIN AIR 1 NOTES: MAIN AIR 2 REGULATED AIR 3. 4. VACUUM LINE H 9 10 LINE TYPE KEY 7 8 LAMINATE TO BE PROVIDED IN COLOR FOLLOWING ASYMTEK DOCUMENT 196680, 'SPECIFICATION LAMINATING' 5. 4 5 6. PRESENT WHEN PRE/POST STATIONS INSTALLED BASE MACHINE ASSY, PRE QUEUE STATION 1 2 3 MANUAL FLOW CONTROL CAN BE REPLACED WITH ELECTRONIC FLOW CONTROL, 7209621 SEE 7207632BD FOR ELECTRICAL BLOCK DIAGRAM.
Appendix C Parts List C.1 Overview This section includes general information for ordering recommended spares and replacement parts for the S-900N Dispensing System. Table C-1 to Table C-3 lists available spare parts kits and part numbers. Part number information is also available on Asymtek’s Find-A-Part web page: http://webstore.asymtek.com/awweblive/apps/findapart_index.asp C.2 Safety First Before attempting to replace any parts, please review the precautions in the Section 2 - Safety. CAUTION! C.
Table C-2 S-920 Spare Parts Kit (Level 2) Part Number 7217653 Description KIT, SPARES, 920, LEVEL 2 7200902-1 PWA, 920 MAIN, PROGRAMMED 7201079 DRIVE MOTORS, X/Y, X1K 7206865 PWA, CM SERVO AMP 7209628 ASSY, CM CONV/HEAT CNTRLR W/CPH 7209880 ASSY, CM SERVO POWER SUPPLY 7209887 ASSY, 920 Z-HEAD 7209904 ASSY, S-9XX SCALE 7209907 ASSY, CAMERA, S-920 7211920 PWA, PNEUMATICS CONTROL 7213111 CONTROLLER, MASS FLOW 7214000 PWA, SERVO POWER CONTROL 7216265 PWA, SDHC, PNEUM & HI AMP LED Table
C.4.1 Safety Controls Item No. Part No.
C.4.2 Computer Components Item No. Part No. Description 1 392175 BUMPER,RECESSED 2 7209899 ASSY,920 COMPUTER 3 7209623-1 CABLE,CAN INTERFACE 4 7205214 ADAPTER,USB TO CAN 5 7209129 HUB,USB 2.
C.4.3 Hatch Components Item No. Part No. Description 1 7206882 ASSY,12V LED LIGHT 2 7210737 SPRING,GAS 30LB,15.
C.4.4 Front Cabinet Item No. Part No. Description 1 7210751 ASSY, CONV PN.PANEL, MANUAL FLOW 2 7209909 ASSY, VALVE PNUEMATIC CTLR. Figure C-4 Illustrated Parts List (Front Cabinet) " C-6 NOTE If the dispensing system has Controlled Process Heat (CpH), the part number for Item No. 1 would be 7210744. Item No. 2 would not be present.
C.4.5 Upper Rear Cabinet Item No. Part No.
C.4.6 Lower Rear Cabinet Item No. Part No.
C.4.7 Conveyor Components Item No. Part No. Description 1 196581 FIBER ARRAY DIFFUSED, 90 DEG 2 7207355 PWA, HOME SENSOR 3 7216530 AMP, FIBER, TERM.
C.4.8 Conveyor Lift Table Item No. 1 Part No.
C.4.9 Scale and Service Station Item No. Part No. Description 1 7209905 ASSY, SERVICE STATION, ASPA 2 7209904 ASSY, S-9XX SCALE 3 7213397 REGULATOR, E/P, 0-130PSI, 0-5V 7212975 KIT,S-9XXN MANUAL REGULATORS (NOT SHOWN) Figure C-9 Illustrated Parts List (Scale and Service Station) " NOTE E/P Regulators are standard on the S-92X Series Dispensing Systems. Manual regulators are standard on S-91X Series Dispensing Systems.
C.4.10 XYZ Mechanics C.4.10.1 X-Beam Item No. Part No.
C.4.10.2 Y-Beam Item No. Part No.
C.4.10.3 Z-Head (Camera, Height Sensor) Item No. Part No.
C.4.10.4 Z-Head (Camera Parts, Cables) Item No. Part No.
C.4.
Item No. Part No. Description 1 7206865 PWA, CM SERVO AMP 2 7216265 PWA, SDHC W/ADV. PNEUM. CTRL 3 7214000 PWA, SERVO POWER CONTROL 4 7200902-1 PWA, PNEUMATICS CONTROL 5 40-2100 VALVE, 3 WAY, 24V 6 43-1222-80 FITTING, ELBOW, 1/8NPT-1/4TUBE 7 40-2200 VALVE, 4 WAY AIR, 24V 8 40-2840 MUFFLER, 1/8 MPT 9 43-2021-80 ELBOW, 10-32 X 1/4 HOSE, SWIVEL 10 392803 FITTING, 1/8NPT X DUAL-Y 1/4OD 11 43-2135-80 FIT'G, BRANCH TEE1/4TUBEX1/8MPT 12 43-1121-80 ELBOW, 90 SWIV.
Glossary AC: Alternating Current. ASPA System: Advanced Semiconductor Package Assembly fluid dispensing system. Auer Boat: A carrier used to transport multiple workpieces through the dispensing system. Automove Control Language (ACL): Programming language used for Conveyor Atom files which control the Conveyor. Axis: X, Y, or Z geometric dispensing coordinates. Board Sensors: Optic sensors located along the length of the conveyor rails that detect the presence of a board or part.
Dispensing Head: The robotic fluid applicator that moves during the dispensing operation. The Dispensing Valve, Height Sensor, Camera and Lighting, and Dispense Head Controller are mounted on the Dispensing Head. Sometimes referred to as the Z-Head. Dispensing Runs (Wet/Dry): A wet dispensing run is when fluid is dispensed. A dry run is when the program is executed but no fluid is dispensed.
Icons: Small buttons on a computer screen with a symbol representing the function that they perform. Used to execute a menu shortcut. Impingement Flowmeters: The Impingement Flowmeters control the airflow through the Impingement Heaters in the dispensing chamber. Impingement Heaters: Heaters tooling that does not come into contact with the part carrier, but blows hot air up at the part.
Pattern Recognition System: A vision system that finds workpiece fiducials to reliably locate dispensing sites and compensates for minor workpiece misalignment during dispensing. Personal Protective Equipment (PPE): Clothing and Equipment worn to reduce the risk of personal injury from hazards associated with operation, maintenance, and servicing of the dispensing system. This includes the wearing of rubber gloves and safety glasses.
Syringe: A reservoir containing the dispensing fluid that is usually attached to the Dispensing Valve. Vision Card: Computer card that receives video signals from the Camera and performs fiducial image capture. Tactile Sensor: A sensor located adjacent to the Needle Sensor that is used to calculate the Z-axis offset between the Height Sensor probe and dispensing needle tip. Vision System: Includes the camera, light source, computer hardware and software, and the monitor.
Index A Access Panels ............................................................. 9-4 Air Pressure cooling, valve, fluid pressure adjustment (S-91X) .. 6-5 cooling, valve, fluid pressure adjustment (S-92X) .. 6-6 main air pressure adjustment ................................. 6-4 programmable fluid and valve pressure ................. 1-5 Anchoring the Dispensing System ........................... 3-14 Applications recommended.........................................................
E G Electrical connections ............................................................ 4-2 Electronic Pressure Control Utility ............................ 6-6 Emergency Machine Off .................................. See EMO Emergency Shutdown .............................................. 2-12 recovery ............................................................... 2-13 situations.............................................................. 2-13 EMO......................................................
L Laser Height Sensor ................................................... 1-6 safety ................................................................... 2-11 specifications ....................................................... 2-11 troubleshooting ...................................................... 8-7 Laser Radiation Safety ......................................2-2, 2-11 Levelers adjusting ................................................................ 3-3 Leveling dispensing system .................
Removing Rear Cable Covers .................................... 7-9 Return Material Authorization ................................... 9-2 Running Production.................................................. 6-38 S Safe Z-height............................................................ 6-20 Safety ......................................................................... 2-1 beacon color indicatons ....................................... 2-16 earthquake precautions .........................................
Vision System ...................................... See also Camera description ............................................................. 1-4 FmXP setup ......................................................... 4-10 functional testing ................................................. 4-30 lighting adjustment .............................................. 6-17 reticles set-up....................................................... 4-31 troubleshooting .....................................................
