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Training Guide Course No. 196514

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

3 MODULE 3 ROUTINE MAINTENANCE

Lesson 3-1 Routine Maintenance Procedures

Lesson 3-2 Purge Boot and Weigh Station Maintenance

Lesson 3-3 Scale Leveling and Calibration

Lesson 3-4 Draining the Water Trap

Lesson 3-5 Lubricating the X-Beam and Y-Rail Linear Bearings

Lesson 3-6 Lubricating and Tensioning the Positioner Cables

Lesson 3-7 Cleaning and Replacing Conveyor Belts

Lesson 3-8 Dispense Pump/Valve Maintenance

Module 3

Routine

Maintenance

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

Brand	Nordson
Model	Asymtek X-1020
Category	Dispenser
Language	English

Nordson Asymtek X-1020 User Manual

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