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Asymtek M-2000
Nordson Asymtek M-2000 User Manual
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Trainee Guide
TR-L2-M2000
Level 2 Maintenance Trai
ning – M2000 Di
spensing Systems
P/N 73-0018-00 (Revi
sion B)
Asymtek, Carlsbad
A.
Site Map – Building 1
B.
Site Map – Building 2 – 1
st
Floor
C.
Site Map – Building 2 –
2
nd
Floor
D.
Site Map – Building 3
Appendices
342
344
Table of Contents
Introduction
3
Table of Contents
3
Change Record
5
Manual/Conventions Review
9
Course Terminal Objectives
10
Course Master Schedule
11
Classroom Safety
13
Table of Contents
21
Basic Platform and Optional Modular Components
23
System Description
23
Basic Platform
23
Optional Modular Components
23
Basic Platform for ASPA and PCBA Applications
23
Safety Warning Labels
35
Safety Warning Label Description
35
Power Supply and AC Distribution
37
Main Power Inlet/Circuit Breaker
38
Main Power Cord
38
Start Button
38
Safety Precautions
38
EMO Button
41
EMO Operation
42
Emergency Shutdown Situations
42
Exercise
43
Testing the Functionality of the EMO Button
43
Proper Powering on and off Procedures
45
Connecting to Facilities
46
Proper Powering on Procedure
46
Operator Startup
46
Powering down at the End of a Shift
47
Powering down for Service
47
Safety Interlock and Light Pole/Beacon
50
Safety Interlock
50
Light Pole/Beacon
52
Facility Requirements
53
Facility Safety Precautions
54
Safety Precautions
55
Operator Safety Precautions
56
Material Safety Precautions
56
Electrostatic Discharge (ESD) Precautions
56
System Protection Precautions
57
Additional Precautions for Service Personnel
57
Table of Contents
61
Power Distribution
65
Power Manager
65
24/48 DC Power Supply
66
Interconnect PCA
66
Computer
67
Computer Cards
67
Moritex Light Source
67
Hall Sensors
68
Linear Encoders
68
Rotary Encoders
68
Servo Motor
68
Stepper Motor
68
XYZ Home Limit Sensors
68
Conveyor Controller Module
71
Dispensing System Modules
71
Heater Relay Module
72
Temperature Controller Module
72
Timers Module
72
Pneumatic Distribution
75
Main Air Gauge and Regulator
76
Valve Pressure
76
Fluid Pressure
77
Tooling Pressure
77
Cooling Pressure
78
Tensioner Pressure
78
Conveyor
83
Dispense Head
83
Stop Pins/Clamp Bars/Lift Tables
83
Theory of Operation
83
Theory of Operation
84
Adjusting the AV-2550
91
Dispense Pumps/Valves
97
Pump/Valve Configuration
98
Pump/Valve Purging/Priming
105
Valve Setup
106
Height Sensor
109
Theory of Operation for HS-Series
110
Probe Adjustments for HS-Series
110
HS-Series Height Sensor Setup
110
Theory of Operation for LK-Series
111
LK-Series Height Sensor Setup
111
Setting up the HS-Series Height Sensor
112
Configuring the Height Sensor
114
Probe Height Adjustments for HS-Series
116
Adjusting Probe/Needle Distance and GU Stroke Length
118
Probe Removal and Replacement
120
Linear Encoders
121
Linear Encoder Calibration
121
Adjusting the X or y Axis Linear Encoder Height
124
Adjusting the Z-Axis Linear Encoder
126
Needle Sensor
129
Theory of Operation
129
Needle Sensor Setup
130
Cleaning the Needle Sensor
130
Needle Sensor Configuration
132
Tactile Sensor Error
134
Leveling the Needle Sensor
136
Pump/Valve Types
98
Needle Heater
139
Heating Element Compatibility
140
Temperature Controllers
140
Theory of Operation
140
Installing a Needle Heater
142
Operations, Controls and Adjustments
144
Heater Modules
145
Contact Heaters
145
Impingement Heaters
145
Removing and Replacing Heater Modules
150
Testing Heater Loops
151
Conveyor
153
Conveyor Configuration
153
Stop Pins/Clamp Bars/Lift Tables
153
Theory of Operation
153
Conveyor Configuration
158
Leveling the Conveyor
160
Board Sensors
161
Upward Facing Sensors
161
Downward Facing Sensors
161
Adjusting the Board Sensors
163
Tooling Flow Controls
167
Lift Tables/Clamp Bars
167
Stop Pins
168
Tooling Flow Controls
168
Adjusting the Tooling Flow Controls
169
SMEMA Transfer
171
SMEMA Handshaking with Upstream Machine
171
SMEMA Handshaking with Downstream Machine
171
Table of Contents
177
Routine Maintenance Procedures
179
Routine Maintenance Schedule
179
Purge Boot and Weigh Station
181
Disposables
182
Tools and Materials Needed
182
Replacing the Purge and Weigh Station Cups and Banjo Wipe
183
Replacing the Purge Boot
184
Scale Leveling and Calibration
185
Digital Scale
186
Scale Leveling and Calibration
186
Leveling the Scale
188
Calibrating the Scale
190
Configuring the Scale
191
Setting up the Scale
192
Draining the Air Regulator Water Trap
193
XYZ Rails
195
Routine Maintenance
196
Tools and Materials Needed
196
Lubricating the X-Axis
197
Dispense Pumps/Valves
199
Disconnecting the DP-3000
202
Cleaning the DP-3000
204
Reconnecting the DP-3000
206
Disconnecting the DV-6000
208
Cleaning the DV-6000
210
Reassembling and Reconnecting the DV-6000
212
Disconnecting the DV-7000
214
Cleaning the DV-7000
216
Reassembling and Reconnecting the DV-7000
218
Disconnecting the DJ-2000
220
Cleaning the DJ-2000
222
Reassembling the DJ-2000
225
Reconnecting the DJ-2000
226
Cleaning and Replacing Fans and Vents
227
Cleaning the Fans and Vents
227
Conveyor Belts
229
Cleaning the Belts
230
Removing and Replacing Conveyor Belts
231
Conveyor Belt Maintenance
230
Auto Tension Procedure
235
Tensioning the Cables
235
File Select
236
Setup
236
Run
237
Tensioning the Cables
237
Table of Contents
241
Default Chapter
243
Obtaining Asymek Technical Support
243
Ordering Replacement Parts
244
Request for Technical Support (RTS) Form
244
XYZ Axis Failure
247
Symptoms and Causes of XYZ Axis Failure
249
Pneumatic Failure
251
Symptoms and Causes of Pneumatic Failure
252
Conveyor Failure
253
Symptoms and Causes of Conveyor Failure
254
Heater Failure
255
Symptoms and Causes of Heater Failure
256
Testing Heater Loops
257
Resetting Heater Thermostat
258
Checking Zone Sensor
259
Scale Failure
261
Symptoms and Causes of Scale Failure
261
Symptoms and Causes of Vision System Failure
263
Vision System Failure
263
Dispense Valve Failure
265
DJ-2000 Troubleshooting
265
DP-3000 Troubleshooting
265
DV-6000 Troubleshooting
265
DV-7000 Troubleshooting
265
Height Sensor Failure
279
Symptoms and Causes of Height Sensor Failure
279
Height Sensor Troubleshooting
280
Needle Sensor Failure
281
Symptoms and Causes of Needle Sensor Failure
281
Needle Sensor Troubleshooting
282
Removing and Replacing Fuses
283
Board Mounted Fuse
284
Panel Mounted Fuse
284
Removing and Replacing Main Line Fuses
285
Removing and Replacing Panel Mounted Fuses
287
Communications Error
289
No Computer Interface
289
Module
290
Testing the I/O Functions of the Dispenser and Conveyor
291
Testing I/O Functions
291
Conveyor I/O Test
291
Dispenser I/O Test
291
Conveyor I/O Testing
294
Using the TS-03 Test Kit to Test the Conveyor Controller Module
296
Dispenser I/O Testing
298
Reinitializing Conveyor Controller Memory
301
Conveyor Atom
301
Reinitializing Conveyor Controller Memory
303
Reinitializing the PMAC
305
PMAC Initialization Files
306
PMAC Watchdog
307
PMAC Commands
308
PMAC Plot
311
Gathering Data
313
Plotting Data
315
Saving and Printing Data
316
Removing and Replacing the Power Manager Module
323
Removing and Replacing the Power Manager Module
324
Removing and Replacing the Conveyor Controller Module
327
Removing and Replacing the Temperature Controller Module
331
Removing and Replacing the Heater Relay Module
335
Removing and Replacing the Heater Relay Module
336
Removing and Replacing Pca's
339
Removing and Replacing the Main Interface Board
339
Removing and Replacing Circuit Boards
339
Removing and Replacing the Servo Boards
342
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Nordson Asymtek M-2000 Specifications
General
Brand
Nordson
Model
Asymtek M-2000
Category
Dispenser
Language
English
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