Nordson Asymtek X-1020

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Training Guide Course No. 196514

Level 2 Maintenance, X-1000 Series Dispensing Systems 2-151 P/N 196515 (Revision A)

Diagram Sheet 2-16-2

Pneumatic Controls

Rear Conveyor

Rail

Heat Tooling Air and

Electric Supply Bulkhead

Pneumatic Suppl

Lines

Pneumatic Control

Clamp Bar

(Rear Rail)

Front

Conveyor

Rail

Clamp Bar

Pneumatic

Cylinder

Flow Contro

Valve

(Front Rail)

Lift Table

Main Page

Table of Contents5
Manual/Conventions Review17
Course Terminal Objectives18
Classroom Safety19
Final Certification21
Lesson 1-1 System Features23
- System Description26
- System Feature Summary26
- Basic Platform28
- Optional Equipment28
Module 1 Equipment Safety23
Lesson29
- Safety Warning Labels29
  - Safety Warning Label Description29
Lesson33
- Startup/Shutdown Procedures33
Lesson39
- Emergency Shutdown Procedure39
Lesson45
- Safety Interlock and Light Beacon45
Lesson49
- Facility Requirements49
  - Facility Safety Precautions50
Lesson53
- Safety Precautions53
Lesson 2-1 Theory of Operation57
- System Mechanics60
- Dispense Head60
- Conveyor61
- Fmnt61
- Theory of Operation62
- Operations Flow Chart63
Module 2 Equipment Operation57
Lesson65
- Dispensing System Components65
Lesson79
- Power Distribution79
Lesson83
- Pneumatic Distribution83
Lesson97
- Electrical and Pneumatic Paths97
Lesson105
- Vision System105
Lesson113
- Dispense Valves113
Lesson121
- Conveyor Operations121
Lesson137
- Dispensing Calibration Module137
Lesson 2-10 Linear Encoders143
- Linear Encoder Calibration144
Lesson 2-11 Height Sensor149
- Theory of Operation149
- Height Sensor Setup149
- Probe Adjustments151
- Laser Height Sensor151
  - Configuring the Height Sensor152
  - Exercises:152
Lesson 2-12 Needle Sensor165
- Theory of Operation165
- Needle Sensor Setup165
- Needle Sensor Maintenance166
  - Needle Sensor Configuration168
  - Exercises:168
    - Functional Testing of Needle Sensor170
Lesson 2-13 Needle Heater171
- Needle Heater172
- Theory of Operation172
- Needle Heater Installation172
- Needle Heater Maintenance172
  - Installing a Needle Heater174
  - Exercises:174
    - Adjusting Needle Heater Settings176
Lesson 2-14 Part Heaters179
- Theory of Operation179
- Contact Heaters180
- Impingement Heaters182
- Heater Calibration182
  - Electrically Testing Part Heaters and Needle Heaters184
  - Exercises:184
Lesson 2-15 Board Sensors193
- Upward Facing Sensors193
- Downward Facing Sensors194
- Sensitivity Adjustments194
Lesson 2-16 Stop Pins/Lift Tables/Clamp Bars203
- Stop Pins204
- Lift Tables/Clamp Bars204
- Airflow Adjustment204
  - Checking Stop Pin, Lift Table and Clamp Bar Operation205
  - Exercises:205
    - Leveling the Lift Tables206
Lesson211
- Pmac211
Lesson 2-18 PMAC Plot217
- Gathering Data219
- Plotting Data221
- Analyzing Data222
- Saving and Printing Data222
Module 3 Routine Maintenance225
Lesson227
- Routine Maintenance Procedures227
  - Routine Maintenance Procedure Schedule228
Lesson231
- Purge Boot and Weigh Station Maintenance231
  - Replacing Purge/Weigh Station Cups, Banjo Wipe and Cleaning the Purge Boot232
  - Exercises:232
    - Replacing the Purge Boot234
Lesson237
- Scale Leveling and Calibration237
Lesson245
- Draining the Water Trap245
  - Draining the Water Trap246
  - Exercise:246
Lesson249
- Lubricating the X-Beam and Y-Rail Linear Bearings249
  - Lubricating the X-Beam and Y-Rail Linear Bearings250
  - Exercise:250
Lesson253
- Lubricating and Tensioning the Positioner Cables253
  - Lubricating the Positioner Cables254
  - Exercises:254
    - Tensioning the Positioner Cables256
Lesson259
- Cleaning and Replacing Conveyor Belts259
Lesson265
- Dispense Pump/Valve Maintenance265
Module 4 Troubleshooting287
Lesson289
- Obtaining Asymtek Technical Support289
Lesson293
- Power Failure293
Lesson317
- Testing the I/O Functions of the Dispenser and Conveyor317
Lesson327
- Troubleshooting XY-Axis Motion327
Lesson341
- Troubleshooting Z-Axis Motion341
Lesson355
- Troubleshooting the Servo Controller (PMAC)355
Lesson377
- Troubleshooting Pneumatics377
Lesson385
- Troubleshooting the Conveyor385
Lesson407
- Troubleshooting the Scale407
Lesson 4-10 Troubleshooting the Height Sensor415
- Height Sensor Fault Isolation Procedure416
- Height Sensor Troubleshooting Summary416
- Troubleshooting Guidelines417
Lesson 4-11 Troubleshooting the Tactile and Needle Sensors423
- Needle Sensor/Tactile Sensor Fault Isolation Procedure424
- Needle Sensor/Tactile Sensor Troubleshooting Summary424
- Troubleshooting Guidelines424
Lesson 4-12 Troubleshooting the Vision System431
- Vision System Troubleshooting Summary432
Lesson 4-13 Troubleshooting Dispense Valves433
- DP-3000 Troubleshooting433
- DJ-2000 Troubleshooting433
Module 5 Parts Replacement445
Lesson447
- Removing and Replacing Fuses447
Lesson451
- Removing and Replacing Conveyor Belts451
  - Removing a Conveyor Belt451
  - Installing a Conveyor Belt454
Lesson455
- Removing and Replacing Pneumatic Solenoid Valves455
  - Removing a Pneumatic Solenoid Valve456
  - Exercises:456
Lesson461
- Removing and Replacing the Scale461
  - Removing the Scale461
  - Installing the Scale469
Lesson471
- Removing and Replacing the Dispensing Head471
  - Removing the Dispensing Head Assembly472
  - Exercises:472
    - Installing the Dispensing Head Assembly476
Lesson479
- Removing and Installing the Computer and Computer Cards479
  - Removing and Installing the Computer480
  - Exercises:480
Lesson487
- Removing and Replacing the Main Interface PWA487
Lesson497
- Removing a Servo Amplifier497
- Installing a Servo Amplifier499

Nordson Asymtek X-1020

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