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Asymtek X-1000 Series
Nordson Asymtek X-1000 Series User Manual
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Traini
ng Gu
ide
Course No. 196514
Level 2 Maintenance,
X-1000 Series Dispensing
Systems
2-73
P/N 196515 (Revision A)
Diagr
am Shee
t 2-8-2
Conve
yor R
ail L
evel
Measu
remen
t Loc
ation
s
Item Descript
ion
1
Approx
im
ate Measurem
ent Locat
ion (Or
der Shown:
A, B, C, etc.
)
2
Rear Co
nveyor Ra
il
3 Stop
Pin
4 Front
Conve
yor
Rail
5 Part
Sensor
5
3
2
1b
1a
1e
1d
1c
4
1f
130
132
Table of Contents
Table of Contents
5
Manual/Conventions Review
17
Course Terminal Objectives
18
Classroom Safety
19
Final Certification
21
Lesson 1-1 System Features
23
System Description
26
System Feature Summary
26
Basic Platform
28
Optional Equipment
28
Module 1 Equipment Safety
23
Lesson
29
Safety Warning Labels
29
Safety Warning Label Description
29
Lesson
33
Startup/Shutdown Procedures
33
Main Power Inlet/Circuit Breaker
34
Pneumatic Regulators and Gauges
34
Service Shutdown
35
Lock Out/Tag out AC Power and Pneumatic Pressure
36
Post-Service Startup
38
Lesson
39
Emergency Shutdown Procedure
39
Emergency Machine off (EMO) Buttons
39
EMO Operation
40
Emergency Shutdown Situations
40
Emergency Shutdown Recovery
40
EMO Circuit Diagram
42
Exercise
43
Testing the Functionality of the EMO Button
43
Lesson
45
Safety Interlock and Light Beacon
45
Light Beacon
46
Safety Interlock
46
Light Beacon Color Indications
47
Lesson
49
Facility Requirements
49
Facility Safety Precautions
50
Lesson
53
Safety Precautions
53
Operator Safety Precautions
54
Lifting Precautions
54
Material Safety Precautions
55
Electrostatic Discharge (ESD) Precautions
55
System Protection Precautions
55
Additional Precautions for Service Personnel
56
Lesson 2-1 Theory of Operation
57
System Mechanics
60
Dispense Head
60
Conveyor
61
Fmnt
61
Theory of Operation
62
Operations Flow Chart
63
Module 2 Equipment Operation
57
Lesson
65
Dispensing System Components
65
Power Manager
66
Conveyor Controller
66
Dispense Head Controller
68
Computer
69
Main Interface PWA
69
ITI Vision Card
69
ATI Graphics Card
70
PIO96-J Card
70
PMAC Card
70
Servo Shelf
73
Servo Power Transformer
73
XY Servo Interface PWA
73
Servo Amplifiers
73
Low Pressure Sensor
73
DC Cooling Fan
74
Main Air Solenoid
74
Dual Action Solenoid
74
Positional Sensors
76
Linear Encoders
76
Hall Sensors
76
Dispense Head
77
Dispense Head Mechanics
77
Z Servo Interface
77
Lesson
79
Power Distribution
79
Power Manager
79
Main Interface PWA
79
XY Servo Interface
79
Computer Power Supply
81
Conveyor Controller
81
Lesson
83
Pneumatic Distribution
83
Main Air Regulator and Gauge
83
Main Air Solenoid
83
Fluid Pressure Regulator and Gauge
83
Valve Pressure Regulator and Gauge
83
Tooling Air Pressure Regulator and Gauge
83
Dual Action Solenoid
85
Low Pressure Sensor
86
Stop Pin Valve
86
Clamp/Lifter Valve
86
Adjusting the Main Air Pressure Regulator
90
Exercises
90
Adjusting Impingement Flowmeters
93
Digital Pressure Gauge Configuration
95
Lesson
97
Electrical and Pneumatic Paths
97
Dispensing Head Moves in X or Y-Axis
98
Dispensing Head Moves in Z-Axis
99
Dispensing Head Finds Home
100
Dispensing Head Performs a Height Sense
101
Conveyor Belt Moves
102
Lesson
105
Vision System
105
Vision System Description
106
Theory of Operation
106
Focusing the Camera
108
Exercises
108
Calibrating the Camera
110
Lesson
113
Dispense Valves
113
Dp-3000
114
DV-7000
116
Dj-2000
118
Lesson
121
Conveyor Operations
121
Conveyor Configuration
121
Stop Pins/Clamp Bars
121
SMEMA Communication
121
Detailed Operation
121
Conveyor Configuration
126
Exercises:
126
Checking Adjustable Width Conveyor Clearance
128
Checking Fixed Width Conveyor Clearance
129
Leveling the Conveyor
130
Rough Adjusting the Conveyor Rail Width
132
Checking Upstream/Downstream SMEMA Communication
133
Checking Overall Conveyor Component Operations
135
Lesson
137
Dispensing Calibration Module
137
Dispensing Calibration Module Components
138
Dispensing Service Area Leveling and Height Adjustment
138
Dispensing Calibration Module Leveling and Height Adjustment
139
Exercise:
139
Lesson 2-10 Linear Encoders
143
Linear Encoder Calibration
144
Linear Encoder Gap Adjustment
146
Adjusting the Encoder Scanner to Encoder Scale Gap
146
Exercises:
146
Lesson 2-11 Height Sensor
149
Theory of Operation
149
Height Sensor Setup
149
Probe Adjustments
151
Laser Height Sensor
151
Configuring the Height Sensor
152
Exercises:
152
Centering the Micrometer Locking Screw
154
Probe Removal and Replacement
156
Minor Probe Height Adjustments
158
Major Probe Height Adjustments
160
Probe Travel Adjustment
162
Lesson 2-12 Needle Sensor
165
Theory of Operation
165
Needle Sensor Setup
165
Needle Sensor Maintenance
166
Needle Sensor Configuration
168
Exercises:
168
Functional Testing of Needle Sensor
170
Lesson 2-13 Needle Heater
171
Needle Heater
172
Theory of Operation
172
Needle Heater Installation
172
Needle Heater Maintenance
172
Installing a Needle Heater
174
Exercises:
174
Adjusting Needle Heater Settings
176
Lesson 2-14 Part Heaters
179
Theory of Operation
179
Contact Heaters
180
Impingement Heaters
182
Heater Calibration
182
Electrically Testing Part Heaters and Needle Heaters
184
Exercises:
184
Temperature Testing Part Heaters and Needle Heaters
186
Checking Contact Heater Vacuums
187
Impingement Heater Airflow Adjustment
188
Checking the Function of Impingement Air Valve and Flowmeters
189
Heater Calibration
190
Lesson 2-15 Board Sensors
193
Upward Facing Sensors
193
Downward Facing Sensors
194
Sensitivity Adjustments
194
Board Sensors
194
Exercises:
195
Adjusting the Upward-Facing Board Sensors
196
Adjusting the Downward-Facing Board Sensors
201
Testing the Board Sensors
195
Lesson 2-16 Stop Pins/Lift Tables/Clamp Bars
203
Stop Pins
204
Lift Tables/Clamp Bars
204
Airflow Adjustment
204
Checking Stop Pin, Lift Table and Clamp Bar Operation
205
Exercises:
205
Leveling the Lift Tables
206
Lesson
211
Pmac
211
PMAC Initialization Files
212
PMAC Watchdog
213
Reinitializing the PMAC
213
PMAC Commands
214
Lesson 2-18 PMAC Plot
217
Gathering Data
219
Plotting Data
221
Analyzing Data
222
Saving and Printing Data
222
Module 3 Routine Maintenance
225
Lesson
227
Routine Maintenance Procedures
227
Routine Maintenance Procedure Schedule
228
Lesson
231
Purge Boot and Weigh Station Maintenance
231
Replacing Purge/Weigh Station Cups, Banjo Wipe and Cleaning the Purge Boot
232
Exercises:
232
Replacing the Purge Boot
234
Lesson
237
Scale Leveling and Calibration
237
Digital Scale
238
Scale Leveling and Calibration
238
Leveling the Scale
239
Exercises:
239
Calibrating the Scale
242
Lesson
245
Draining the Water Trap
245
Draining the Water Trap
246
Exercise:
246
Lesson
249
Lubricating the X-Beam and Y-Rail Linear Bearings
249
Lubricating the X-Beam and Y-Rail Linear Bearings
250
Exercise:
250
Lesson
253
Lubricating and Tensioning the Positioner Cables
253
Lubricating the Positioner Cables
254
Exercises:
254
Tensioning the Positioner Cables
256
Lesson
259
Cleaning and Replacing Conveyor Belts
259
Conveyor Belt Maintenance
260
Cleaning the Belts
260
Removing the Conveyor Belts
261
Exercises:
261
Installing a Conveyor Belt
262
Lesson
265
Dispense Pump/Valve Maintenance
265
Dp-3000
266
Dj-2000
267
Disconnecting the DP-3000
268
Exercises:
268
Cleaning the DP-3000
270
Reconnecting the DP-3000
272
Disconnecting the DV-7000
274
Cleaning the DV-7000
276
Reassembling and Reconnecting the DV-7000
278
Disconnecting the DJ-2000
280
Cleaning the DJ-2000
282
Reassembling the DJ-2000
285
Reconnecting the DJ-2000
286
Module 4 Troubleshooting
287
Lesson
289
Obtaining Asymtek Technical Support
289
Describing Machine Faults
290
Request for Technical Support Form
290
Ordering Replacement Parts
290
Lesson
293
Power Failure
293
Machine Power Fault Isolation Procedure
293
System Power Fault Isolation Procedure
294
Interlock Fault Isolation Procedure
294
Power Troubleshooting Summary
295
Troubleshooting Guidelines
295
Lesson
317
Testing the I/O Functions of the Dispenser and Conveyor
317
Testing I/O Functions
318
Conveyor I/O Test
318
Dispenser I/O Test
319
Conveyor I/O Testing
320
Exercises:
320
Using the TS-03 Test Kit to Test the Conveyor Controller
322
Dispenser I/O Testing
324
Lesson
327
Troubleshooting XY-Axis Motion
327
XY-Axis Motion Fault Isolation Procedure
328
XY Servo Amplifier Fault Isolation Procedure
328
XY-Axis Motion Troubleshooting Summary
328
Troubleshooting Guidelines
329
Lesson
341
Troubleshooting Z-Axis Motion
341
No Z-Axis Motion Fault Isolation Procedure
342
Z Servo Amplifier Fault Isolation Procedure
342
Z-Axis Motion Troubleshooting Summary
342
Troubleshooting Guidelines
343
Lesson
355
Troubleshooting the Servo Controller (PMAC)
355
PMAC Fault Isolation Procedure
355
PMAC Troubleshooting Summary
356
Troubleshooting Guidelines
357
Lesson
377
Troubleshooting Pneumatics
377
Pneumatics Fault Isolation Procedure
378
Pneumaticstroubleshooting Summary
378
Troubleshooting Guidelines
378
Lesson
385
Troubleshooting the Conveyor
385
Conveyor Fault Isolation Procedure
386
Conveyor Troubleshooting Summary
386
Troubleshooting Guidelines
387
Lesson
407
Troubleshooting the Scale
407
Scale Fault Isolation Procedure
408
Scale Troubleshooting Summary
408
Troubleshooting Guidelines
408
Lesson 4-10 Troubleshooting the Height Sensor
415
Height Sensor Fault Isolation Procedure
416
Height Sensor Troubleshooting Summary
416
Troubleshooting Guidelines
417
Lesson 4-11 Troubleshooting the Tactile and Needle Sensors
423
Needle Sensor/Tactile Sensor Fault Isolation Procedure
424
Needle Sensor/Tactile Sensor Troubleshooting Summary
424
Troubleshooting Guidelines
424
Lesson 4-12 Troubleshooting the Vision System
431
Vision System Troubleshooting Summary
432
Lesson 4-13 Troubleshooting Dispense Valves
433
DP-3000 Troubleshooting
433
DJ-2000 Troubleshooting
433
Module 5 Parts Replacement
445
Lesson
447
Removing and Replacing Fuses
447
Replaceable Fuses
448
Board Mounted Fuses
448
Panel Mounted Fuses
448
Box Mounted Fuses
448
Fuse Replacement Precautions
448
Replacing Board and Panel-Mounted Fuses
449
Exercises:
449
Replacing Box Mounted Fuses
450
Lesson
451
Removing and Replacing Conveyor Belts
451
Removing a Conveyor Belt
451
Installing a Conveyor Belt
454
Lesson
455
Removing and Replacing Pneumatic Solenoid Valves
455
Removing a Pneumatic Solenoid Valve
456
Exercises:
456
Lesson
461
Removing and Replacing the Scale
461
Removing the Scale
461
Installing the Scale
469
Lesson
471
Removing and Replacing the Dispensing Head
471
Removing the Dispensing Head Assembly
472
Exercises:
472
Installing the Dispensing Head Assembly
476
Lesson
479
Removing and Installing the Computer and Computer Cards
479
Removing and Installing the Computer
480
Exercises:
480
Removing the PMAC Card
482
Installing the PMAC Card
484
Removing and Replacing the Image Capture or Video Card
486
Lesson
487
Removing and Replacing the Main Interface PWA
487
Removing/Installing the Main Interface PWA
488
Exercises:
488
Removing the XY Servo Interface PWA
491
Installing the XY Servo Interface PWA
491
Exercises:
492
Lesson
497
Removing a Servo Amplifier
497
Installing a Servo Amplifier
499
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Nordson Asymtek X-1000 Series Specifications
General
Brand
Nordson
Model
Asymtek X-1000 Series
Category
Dispenser
Language
English
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