DispenseMate Series ® DispenseMate 580 Dispensing System User Guide
NOTICE This is a Nordson 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 Nordson ASYMTEK. The information contained in this publication is subject to change without notice.
Table of Contents 1 Introduction ......................................................................................................................................... 1 1.1 Overview .................................................................................................................................. 1 1.2 Safety First ............................................................................................................................... 2 1.3 Getting Started ....................
3 Operation ........................................................................................................................................... 19 3.1 Overview ................................................................................................................................ 19 3.2 Theory of Operation ............................................................................................................... 19 3.3 Fluidmove for Windows XP (FmXP)................................
Troubleshooting ................................................................................................................................ 47 5.1 Overview ................................................................................................................................ 47 5.2 Safety First ............................................................................................................................. 47 5.3 Recordkeeping ...............................................
1 Introduction 1.1 Overview The DispenseMate 580 (D-580) Series Dispensing Systems bring new dispensing power to a compact package. Many of today’s advanced automated dispensing features are now available in a bench top format. The D-580 Series platform utilizes the same dispense control technology as some of Nordson ASYMTEK’s most advanced dispensing systems. This manual is intended primarily as a reference for production operators.
1.2 Safety First Operation of the D-580 Series Dispensing System involves air pressure, electrical power, mechanical devices, and the use of hazardous materials. It is essential that every person servicing or operating the dispensing system fully understands all hazards, risks, and safety precautions. Refer to Section 2 - Safety for additional information. WARNING! CAUTION! Consult the Material Safety Data Sheet (MSDS) for all fluids used with the dispensing system.
1.4 Standard Equipment 1.4.1 Computer System The Computer System consists of a laptop PC, mouse, and connecting cables. It runs Fluidmove for Windows XP (FmXP) software. 1.4.2 Fluidmove for Windows XP Software Fluidmove for Windows XP (FmXP) is Nordson ASYMTEK-proprietary software for use in a Windows XP environment, developed specifically for dispensing applications. 1.4.3 Tooling Plate The Tooling Plate is mounted to the Y-axis and secures the workpiece for batch system operations.
1.6 Dispensing Valves The D-580 Series Dispensing Systems support the following Nordson ASYMTEK jets, pumps, and valves. Refer to the DispenseMate 580 Series Installation Guide for additional information.
1.7 Front View 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. Front view features are shown in Figure 1-3. Z-Head Dispenser Connections All dispensing valves and dispensing options mounted to the Z-axis are connected through this area.
Z-Head Dispenser Connections: Cooling Air Connector (green) Valve air Connector (black) Fluid Air Connector (clear) Vacuum Purge Cup (optional) Valve Air Pressure Regulator/Gauge Precision Fluid Regulator/Gauge Tactile Sensor (optional) Vacuum Control EMO Button Start Button Off Button ESD Grounding Strap Connector Figure 1-3 Front View 6 Introduction
1.7.1 Dispensing Area The dispensing head, valve, camera, height sensor, and tooling plate are located in the Dispensing Area (Figure 1-4). Vision System The compact, high resolution, black and white camera and its vibration resistant lens are part of the Vision System. This advanced camera communicates with the computer through an integral 1000Mbps Giga-Ethernet connection. It is mounted on the dispensing head and is used to view work surfaces.
1.8 Rear View Features Rear View features of the D-580 Series Dispensing Systems are shown in Figure 1-5. 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. RS232 Port The RS232 Port connects the DispenseMate to the internal USB network which communicates with the laptop computer and FmXP.
RS232 Port Main Power Circuit Breaker DIP Configuration Switches Main Power Inlet Discrete I/O General Purpose Output Connector General Purpose Input Connector Main Air Inlet Interlock Figure 1-5 Rear View Features Figure 1-6 Computer Connections Introduction 9
2 Safety 2.1 Overview This section is intended to provide basic safety information necessary for operating and servicing the D-580 Series Dispensing Systems.
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 dispensing system operation and maintenance. WARNING! 2.4.1 Safety 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 2.4.3 12 Material Safety • Follow MSDS recommendations for the proper handling, cleanup, and disposal of hazardous materials. • Know the MSDS recommendations for treatment of injury resulting from exposure to hazardous materials. • When working with multiple fluids, refer to the MSDS to ensure the materials are compatible. Preventing Dispensing System and Workpiece Damage • Immediately push the EMO button if the dispensing system or a workpiece is in danger of being damaged.
2.5 Electrostatic Discharge (ESD) Precautions CAUTION! Personnel operating, maintaining, or servicing the dispensing system must follow ESD precautions. Failure to do so could cause severe damage to dispensing system electronic components and/or workpieces. Electrostatic Discharge (ESD), also known as “static discharge”, is the sudden transfer of electricity from one object or person to another object or person.
2.6 Safety Warning Labels Safety warning labels affixed to the dispensing systems point out potential hazardous areas and remind personnel to take necessary safety precautions. Table 2-1 describes safety labels that may be affixed to the dispensing system. Locations of these warning labels are shown in Figure 2-1 and Figure 2-2.
Left Pinch Hazard Warning Label (other side) Right Pinch Hazard Warning Label Middle Pinch Hazard Warning Label Pinch Hazard Warning Label Figure 2-1 Safety Warning Labels, Front View Electrical (shock hazard) Warning Label Figure 2-2 Safety Warning Labels, Rear View Safety 15
2.7 Emergency Shutdown In the event of an emergency or malfunction, press the Emergency Machine Off (EMO) button. The EMO is the large red button located on the front panel of the dispensing system (Figure 2-3). Activating the EMO vents all pressure in the pneumatic system, de-energizes the servo power supply capacitors, and cuts power to all components except the computer and monitor.
2.7.2 Emergency Shutdown Recovery WARNING! Do not restart the dispensing operation until the condition that caused the emergency shutdown has been remedied. Failure to comply could cause serious injury to the user and/or serious damage to the dispensing system. NOTE If the main power circuit breaker has been tripped, you will need to restart the dispensing system as specified in 3.5 Startup. To recover after an emergency shutdown: 1. Locate and remedy the cause of the emergency shutdown.
To lock out/tag out pneumatic pressure: 1. Verify that all dispensing motion has stopped. 2. Lock out and tag out AC power as specified earlier in this section. 2.9 When the power is shut off, the main air solenoid valve shuts off and all air pressure inside the dispensing system is automatically released. 3. Locate the main air pressure regulator adjustment knob. 4.
3 Operation 3.1 Overview Before operating your D-580 Series Dispensing System, it may be helpful to familiarize yourself with the basics of how the system works. This section covers the following topics: 3.
3.5 Startup 3.5.1 System Startup If necessary, refer to the figures in Section 1 - Introduction to identify system components. To power on the dispensing system: 1. Verify that the main power cable 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 inlet. Refer to 3.10 Adjusting Air Pressure. 3. Turn the main power circuit breaker to the ON (I) position. 4.
CAUTION! Do not press any keys or the touchpad while FmXP is starting unless prompted to do so. If the FmXP Message 30416 - Dispenser Motor References Not Found appears, click OK to Home the dispenser (Figure 3-1). Figure 3-1 FmXP Message 30416 Figure 3-2 FmXP Main Window 2. The FmXP Main Window (Figure 3-2) will open. 3. Check to make sure the dispensing head is in the proper home position. NOTE 3.
Y-Axis Controls (tooling plate forward and backward movement) Z-Axis Controls (dispensing head up and down movement) X-Axis Controls (dispensing head side to side movement) Home Button Dispenser Radio Button Figure 3-3 Position Control Dialog Box NOTE The Position Control dialog box can be accessed from the FmXP Main Window, Production Window, Run Window, Programming Window, and Tools Window. For additional information on position controls, refer to the Fluidmove User Guide or Online Help.
3.6.2 Using the Keyboard To operate position controls using keyboard commands: 1. Press [Ctrl + J] to open the Position Control dialog box. 2. The Dispenser radio button will be selected, indicating that the dispensing head position controls are active. Press the appropriate key combinations shown in Table 3-2 to jog the dispensing head or tooling plate.
3.7 Safe Z-Height Safe Z-height is determined by choosing a height that ensures the needle, height sensor, or any part of the dispensing head does not collide with any obstacles while traveling around the dispensing area. 3.7.1 Setting Safe Z-Height Safe Z-height is the height below which the tip of dispensing head cannot go when moving from one set of coordinates to another during operation. To set the Safe Z-Height: 1. In the FmXP Main Window, click on Run a Program. 2.
Figure 3-5 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. 7. The safe Z-height value will be recorded in the Value textbox. Click on Done. WARNING! Safe Z-height should never be taught lower than the tallest component on the unit to be dispensed on.
3.8 Adjusting the Camera 3.8.1 Adjusting Light Level and Color CAUTION! NOTE Except for lighting adjustments and lens replacement, all other configuration and adjustments should only be performed by a trained service technician. If power to the camera has been interrupted, or if the PC has been rebooted, the camera system provided will need up to two minutes to establish a new connection to the Ethernet (Figure 3-6).
Reticles Button Video Button Blue Light Adjustment Slide (in unlinked mode) Red Light Adjustment Slide (in unlinked mode) Color/Brightness Control Mode Button Position (Jog) Controls Figure 3-8 Camera Lighting Adjustment Operation 27
3.8.2 Calibrating the Camera To calibrate the camera: 1. Place a workpiece on the tooling plate and turn on the vacuum switch. 2. In the FmXP Main Window, click on Configuration > Setup Vision. 3. Click on Calibrate. 4. If the image is not in focus, focus the camera as described below. 5. Click on Next. 6. Verify that the fiducial image is centered and click on Next. 7. The vision system will take a snap image of the fiducial. If the fiducial is acceptable, select Next.
3.8.3 Focusing the Camera NOTE This procedure assumes that the dispensing system has been powered on and FmXP is running. 3.8.3.1 Fixed Height Pattern Recognition System: To adjust the camera fixed height: 1. Hold the camera and use a 4 mm hex key to loosen the three side screws (upper, middle, and lower) on the bracket (Figure 3-9). 2. Position the camera over a fiducial. 3. Slowly move the camera bracket up and down. 4. When a sharp image is obtained, lock the upper screw. 5.
3.9 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. Ensure that there is air pressure to the system. 2. Within FmXP, click on Tools, I/O Test, (Dispenser Icon) and select the tab for Outputs 0-31. Click on the button that says “HS_PROBE_EXTEND” (this will extend the height sensor probe). 3.
3.10 Adjusting Air Pressure 3.10.1 Adjusting the Main Air Pressure To adjust the main air pressure: 1. Verify that the facility air is connected to the main air pressure regulator inlet (Figure 3-10). 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 pressure gauge registers 0 psi. 3.
3.10.2 Adjusting the Valve and Fluid Pressure To adjust the valve and fluid pressure: 1. Locate the fluid and valve air pressure regulator adjustment knobs on the front control panel (Figure 3-12). 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.
3.10.4 Setting the Low Pressure Detection Threshold This feature allows the user to set the air pressure level at which the software will issue an on-screen low air pressure error message. To set the low pressure threshold: 1. In the FmXP Main Window, select Configuration > Setup Runtime Preferences > Calibrate Low Air Pressure Detect. 2. The Low Air Pressure Detection Configuration Window (Figure 3-13) opens.
3.11 Setting the Heaters The only available Heater in the dispensing system is the needle heater. Heater temperature is set in the FmXP software. The heater controller monitors the Resistance Temperature Detector (RTD), compares it to the heat parameters set in Fluidmove, and regulates the voltage going to the heating element to maintain the set temperature. 3.11.1 Needle Heater CAUTION! NOTE The operator can turn the heaters ON and OFF and monitor their function.
Channel (Loop) Name Column Temperature Set Point Column Present Temperature Value Column Message Column Heater Loop ON Heater Loop OFF Figure 3-15 Heater Control Window 4. Activate the heater by double clicking the icon in the On/Off column until the heater loop turns yellow and red. icon NOTE 5. Operation To change heater temperature, double click on the heater loop name. The Heater Parameters dialog box will open.
3.12 Starting a Production Run To start a production run: 1. Verify that the main air, valve, and fluid pressures are set to the desired levels. 2. In the FmXP Main Window, click on Run a Program. 3. If not, adjust pressure as described in 3.10 Adjusting Air Pressure. The Production Window opens. In the Production Window, click on the Setup button and then click on Setup Scripts and then on Prompted Setup (Figure 3-16).
Current Program Load Select Program Open Figure 3-17 Production Window – Load Program 7. 8. 9. 10. In the Production Window, click on Run and then click on the Run Production button (Figure 3-18). The Run Window opens. Load the workpiece. If applicable, switch the heated vacuum tooling switch to the ON (l) position. Refer to Figure 1-4 for the location of the switch. Click on Go to start the dispensing process (Figure 3-18).
3.13 System Shutdown Routine shutdown may vary depending on your particular requirements. However, it is recommended that you incorporate the following procedures into your production shutdown routine. 3.13.1 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. If necessary, purge or remove and clean the dispensing valve as instructed in the applicable valve manual. 4.
4 Maintenance 4.1 Overview Following a routine maintenance schedule and maintenance procedures can prevent part degradation and ensure high quality performance for every production run. Table 4-1 lists recommended maintenance procedures and intervals that will help to ensure quality dispensing and optimize system performance. Basic maintenance procedures are described later in this section.
4.4 Basic Maintenance Procedures - Replacing Consumables Consumables are items that are discarded and replaced on a regular basis. The following items are common consumables and should be replaced at the intervals recommended in Table 4-1. Purge Cup • • Purge Boot Tools and Materials Needed • Needle-nosed Pliers • Replacement Purge Boot (Table 4-2) • Isopropyl Alcohol • Replacement 1 oz.
Purge Station Cover Purge Station Cup Figure 4-1 Replacing the Purge Station Cup 4.4.2 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 hood. 2. Remove the purge station cover (Figure 4-2). 3.
Purge Station Purge Boot Purge Station Cover Figure 4-2 Replacing the Purge Boot 4.5 Draining the Water Trap Because the facility air supply may contain moisture that can damage the dispensing system, the DispenseMate is equipped with a water trap that condenses 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 wastewater To drain the water trap: 1.
4.6 Removing the Axis Covers In order to perform the remainder of the maintenance procedures described in this section, it is necessary to remove the axis covers (Figure 4-4). To remove the axis covers: 1. Perform a system shutdown as described in 3.13 System Shutdown. 2. To remove the X-axis cover, loosen the two set screws and slide to the side. 3. DO NOT remove the spring pins. To remove the Y-axis Cover, remove the two screws at the back and pull it forward.
Tooling Plate Y-Axis Cables Z-Axis Cables (inside) X-Axis Cables (inside) Figure 4-5 Mechanical Drive Cables 4.7.2 Lubricating the X-, Y-, and Z-Axis Linear Guides NOTE To perform the following procedure, you will need Nordson ASYMTEK Grease Kit P/N 7203262. The kit contains a grease syringe. To lubricate the linear guides: 1. Remove the X- and Y-axis covers as described previously in this section. 2. Load the grease cartridge into the grease syringe. 3.
Dust Cap X-Bearing Housing Figure 4-6 Lubricating the X-, Y-, and Z-Axis Linear Guides 4.8 Tensioning the Cables To tension the cables: 1. Remove the X- and Y-axis covers as described previously in this section. 2. Tension the X-axis cables as follows: a. Loosen the two X-axis tensioner block screws (Figure 4-7). WARNING! When performing this procedure, loosen the tensioner block screws, DO NOT REMOVE THEM. Removing these screws will cause the springs to pop.
X-Axis Tensioner Block Screws Y-Axis Tensioner Block Screws Z-Axis Tensioner Block Screws Figure 4-7 Tensioning the Cables 46 Maintenance
5 Troubleshooting 5.1 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 Nordson ASYMTEK Technical Support. This section covers the following basic system troubleshooting procedures: 5.
5.4 Basic System Troubleshooting 5.4.1 System Power Symptom No Power to Major System Components 5.4.2 Pneumatic Symptom No Air Pressure No Fluid Pressure Table 5-1 System Power Troubleshooting Possible Cause The Start (l) button has not been pressed Press the Start (l) button on the control panel. Main power cable is disconnected Check that the main power cable is connected to an AC source. Main power circuit breaker is OFF Turn ON (I) the main power circuit breaker at the rear of the system.
5.4.3 Dispensing Head Table 5-3 Dispensing Head Troubleshooting Symptom Possible Cause No system power No X-, Y-, or Z-Axis dispensing head motion Recovery Refer to Table 5-1 - System Power Troubleshooting. Servo amps failed +48V power supply down Contact a service technician. Limits not cleared Dispense Head fails to find Home Dispense Head starts to move, stops, and goes open loop Jerky movement Dispenses at wrong Z-axis position 5.4.4 Home/Limit cable disconnected Connect cable.
5.4.5 Vision System Table 5-5 Vision System Troubleshooting Symptom Possible Cause Recovery Camera is not connected Verify camera cable is securely connected to the connector on top of the camera. Camera cable damaged Replace cable. Camera has not initialized Close FmXP. Restart FmXP after camera has initialized. See 3.8 Adjusting the Camera. Lighting intensity is too low Increase light level in FmXP. Lighting module is disconnected Restore lighting module connection.
6 Specifications 6.1 Overview The D-580 Series Dispensing System Specifications, facility requirements, and software requirements are presented in Table 6-1 through Table 6-4. These specifications are intended as a convenient reference for personnel planning, system relocation, installation, or operation, and others that may have an interest in system performance characteristics. 6.
6.4 Dispensing System Facility Requirements 6.4.1 DispenseMate 583 Table 6-2 DispenseMate 583 Facility Requirements DispenseMate 583 Facility Requirements System Footprint* 570 mm x 685 mm (22.4-inch x 26.9-inch) Height 630 mm (26.5-inch) Weight 45 kg (99.2 lbs.) Compressed Air Dry; 40° F Dew Point 620 kPa (90 psi, 5.5 Bar), up to 85 l/min (3 SCFM) maximum, depending on configuration Main Power Supply 100-240 VAC, 50/60 Hz, 10 A *without tooling 6.4.
Appendix A Block Diagrams This Appendix describes available pneumatic and electrical block diagrams and dispensing system electronics that may help in understanding dispensing system operation and aid in troubleshooting. The diagrams referred to in this appendix are listed in Table A-1 and are shipped with the dispensing system manuals and accessories. A.
Appendix B B.1 Parts List Overview This appendix contains a list of spare parts (Table B-1) and exploded view drawings (Table B-2) that will aid in ordering replacement parts for the dispensing system. B.2 Safety First Before attempting to replace any parts, please review the precautions in Section 2 - Safety. CAUTION! B.3 Only trained service technicians should perform troubleshooting, servicing, and parts replacement.
Part Number Description 7209539 7209541 7209129 58-0030 B.4 Cable, Ethernet, 2m Cable, USB A-B, 2m Hub, 7p, USB 2.
3 or 4 5 2x 6 2 1 4x 7 8 Item Number Part Number 1 2 3 4 5 6 7 8 7209164 7201204 7209530 7209533 7206865 7200901 55-5320 199280 Description Assembly, Electronics Pan Assembly, Z-Head Assembly, Drive, X, D-583 Assembly, Drive, X, D-585 Assembly, Servo AMP PWA, DM Main, Programmed Hex Post, D-SUB, 4-40x5/16 Interlock Connector Figure B-2 Parts List, Electronics Assembly 1 or 2 3 Item Number Part Number 1 2 3 199002 199003 7206865 Description Assembly, 325 Y Assembly, 525 Y Assembly, Servo AMP
1 2 Item Number Part Number 1 2 7205830 7206782 Description Height Sensor Assembly Probe, 1.
Nordson ASYMTEK Headquarters 2762 Loker Avenue West Carlsbad, CA 92010-6603 USA Tel: (760) 431-1919 1-800-ASYMTEK (1-800-279-6835) PN 7211971, Revision B ©2011
