DispenseJet Series DJ-2200 Owner’s Manual
NOTICE This is an Nordson ASYMTEK publication, which is protected by copyright. Original copyright date 2006. 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 Overview ................................................................................................................................................1 DispenseJet Description ........................................................................................................................1 Specifications ......................
Table of Figures Figure 1-1 DJ-2200 Series DispenseJet and Air Assist Feature .................................................................1 Figure 3-1 Installing the DispenseJet to the C-730 Dispensing System .....................................................6 Figure 3-2 lnstalling the DispenseJet to the M-2000 Flux Dispensing System ...........................................7 Figure 3-3 Installing the Air Assist Feature...............................................................................
1 Introduction Overview This section provides you with an introductory description of the DispenseJet DJ-2200. More details are provided in the sections that follow on how to properly install, operate and maintain the DJ-2200. This section covers: • DispenseJet Description • Specifications DispenseJet Description The DispenseJet Series DJ-2200 is a non-contact dispenser providing high-speed delivery and exceptional volumetric control for flux dot or line application.
Specifications Table 1-1 contains the technical specifications for the DJ-2200 Series DispenseJet. If you have any questions about facility requirements, refer to the applicable dispensing system manual or contact Asymtek Technical Support. Table 1-1 DJ-2200 Series Specifications Element Parameters Valve: Weight (dry weight): 380 g (without syringe) Syringe Size: 5, 10, or 30 cc (0.17, 0.34, or 1.0 oz) Reservoir Size: 177 or 591 cc, 3.
2 Safety Overview This section describes the precautions to be taken to promote personal safety and safe use of the DJ-2200 Series DispenseJet. Dispensing system operation involves heat, air pressure, fluid pressure, mechanical and pneumatic devices, electrical power, and the use of hazardous materials. Refer to the Safety section of the dispensing system Operations Manual prior to installing and operating the DJ-2200 Series DispenseJet.
Preventing Equipment and Workpiece Damage • Immediately push the EMO button on the dispensing system if the dispensing system, DJ-2200, or a workpiece is in danger of being damaged. • Use standard Electrostatic Discharge (ESD) precautions when working near sensitive components. Always wear a grounding strap and connect it to the ESD ground before handling workpieces and equipment. • Perform all recommended DJ-2200 maintenance procedures at the suggested intervals.
3 Installation Overview The DJ-2200 is designed for use on Nordson ASYMTEK Century C-730 and Millennium M-2000 Flux Dispensing Systems. This section covers: • Unpacking the DJ-2200 • Installing the DJ-2200 Unpacking the DJ-2200 Every care has been taken when packaging your DJ-2200. However, we recommend that you look for obvious damage and verify contents against the packing slip. Retain the case for storage of DJ-2200 and accessories. Retain shipping cartons for future use.
To install the DispenseJet: 1. Install the appropriate Z-head mounting plate (valve bracket) and bracket mount for the dispensing system. Refer to “Ordering Parts” in the Additional Information section for part numbers. NOTE These instructions assume that the co-axial air solenoid valve has not been installed to the DispenseJet. 2. Mount the jet to the Z-head mounting plate and tighten with a 3-mm hex wrench. 3.
1 Item 2 3 Description 4 5 Item 6 7 8 Description 1 Fluid Air Pressure (Clear) 5 Fluid Sensor Electrical Connector 2 Valve Air Pressure OFF (Black) 6 Temperature Control Connector 3 Co-axial Air Electrical Connector (Optional) 7 Heater Power Connector 4 Solenoid Valve Electrical Connector 8 Co-axial Air (Optional) Figure 3-2 lnstalling the DispenseJet to the M-2000 Flux Dispensing System Installation 7
To Install the Air Assist Feature: NOTE These instructions assume that the air assist feature, consisting of the co-axial air solenoid valve and the co-axial air nozzle nut and air tubing, has not been installed. Once installed, the co-axial air solenoid valve remains installed when not being used. Install the co-axial air solenoid valve as follows: 1.
4 Operation Overview This section covers the requirements and the necessary steps to properly operate the DJ-2200 DispenseJet. The operations assume that an operational Dispensing System and DispenseJet are available. Before operating the DispenseJet for the first time, you may want to get a better understanding of how the DispenseJet works by reading the “Theory of Operation” in this section.
Theory of Operation A typical cross-section of the internal workings of the DispenseJet is shown in Figure 4-1. During a dispensing cycle, a solenoid-driven air pressure valve compresses a spring. The compressed spring retracts a needle plunger and the fluid chamber space vacated by the needle plunger is filled with fluid.
Operating Instructions Prior to using the DispenseJet for production runs, it is recommended that you conduct a brief test-run to verify that adjustments and parameters are set for optimum performance. NOTE Read the entire section before operating the DispenseJet. The sequence of events may vary with your particular application. CAUTION! Operation of the DispenseJet should be performed only by Nordson ASYMTEKtrained operators or service technicians, or Nordson ASYMTEK field service engineers.
5 0 0 5 20 1 2 6 3 5 4 Item Description Item Description 1 Micro-adjustment 4 Cap 2 Preload Lock Nut 5 DispenseJet Cap Markings 3 Preload Screw 6 Preload Window Figure 4-2 Preload and Micro-adjustment Settings Setting the Micro-adjustment To make adjustments that may be necessary to regulate fluid volume while the DispenseJet is installed on the dispensing system, proceed as follows: To set the Micro-adjustment: 1.
Changing Nozzles The DispenseJet can be operated with the standard nozzle nut and nozzle only or with the co-axial nozzle nut added to it (Figure 4-3). NOTE If installed, the co-axial air solenoid valve does not need to be removed when not in use. When changing nozzles, select “Using the Standard Nozzle Nut” or “Using the Air Assist Feature” instructions as appropriate.
1 2 3 4 5 6 Item Description Item Description 1 Seat Extension 4 Standard Nozzle Nut 2 Teflon Gasket (Optional) 5 Co-axial Air Nozzle Nut 3 Nozzle 6 Air Tubing (shown installed) Figure 4-3 Changing Nozzles 14 Operation
Using the Air Assist Feature NOTE If installed, the co-axial air solenoid valve does not need to be removed when not in use. To use the Co-axial Air Nozzle Nut (Figure 4-3): NOTE Instructions assume that the co-axial air solenoid valve is installed. If not, refer to the Installation section for instructions. Make sure to first properly drain the fluid lines (see “Draining the Fluid Lines” in this section). 1. If installed, use the provided torque wrench to remove the standard nozzle nut. 2.
Setup and Valve Offset Routines The Fluidmove software uses prompts that can be followed to properly dispense, prime, purge, and refill fluid. Parameters set in the Fluidmove dispensing software determine how long the valve remains open to dispense each line or dot. Follow the instructions in the applicable dispensing system Operations Manual and the Fluidmove User Guide.
1 2 3 Item Description 1 Receiver Head 2 Syringe 3 Syringe Tip Figure 4-4 Syringe with Receiver Head Attached Draining the Fluid Lines To drain the fluid lines: 1. If fluid is present in the reservoir or the syringe, obtain a suitable fluid collection container and disposable towels and place the container at the purge station of the dispensing system. 2. Power up the dispensing system. 3.
Changing Fluids To change the Fluid to another Flux Application: 1. Properly drain the fluid lines (see “Draining the Fluid Lines” earlier in this section). 2. Remove the standard nozzle nut with the co-axial air nozzle nut as one unit, or separately as applicable to your application. 3. Purge (flush, or clean) the DispenseJet as appropriate (see “Purging the DispenseJet” in the Maintenance and Service section).
5 Maintenance and Service Overview Performing the recommended maintenance and service procedures increases the life of your DJ-2200 and ensures high quality dispensing performance for every production run. Maintenance Schedule The recommended maintenance schedules for the DispenseJet are shown in Table 5-1 and Table 5-2. The frequencies are based on the average production environment. Your production operations and environment may differ.
To remove the Nozzle: 1. Power up the dispensing system. 2. If fluid is present in the reservoir or the syringe, obtain a suitable fluid collection container and disposable towels for draining of fluid. 3. Use the position controls to manually move the DispenseJet so it is directly over the purge station (or click on PURGE from the Fluidmove software) to purge the solvent from the fluid lines. Refer to the Fluidmove User Guide or Online Help for instructions 4.
Purging the DispenseJet To purge the Fluid Line: 1. Obtain a solvent (such as Isopropyl Alcohol) that is recommended for the fluid. NOTE If unsure, contact your material supplier for recommended solvents and always review the MSDS for the solvent and fluid data and Protective Personal Equipment recommendations. 2. Using the selected solvent instead of the flux fluid, follow the “Draining the Fluid Lines” instructions in the Operation section. 3.
3. Lower the fluid pressure to zero (0) and disconnect the clear pneumatic line (fluid pressure) and remove the syringe. CAUTION! 4. Follow Material Safety Data Sheet (MSDS) recommendations for the proper handling and disposal of fluids. Shut down the dispensing system. Refer to the manual applicable to your dispensing system when performing steps 3 and 4. If the micro-adjustment assembly is set to a specific setting, make a note of this setting for future reference.
6. Remove the lower body as follows: a. Use the 7/64-inch hex key to remove the two screws from the lower body. b. Carefully pull the lower body off of the needle. c. Remove the exposed small o-ring that holds the u-cup seal in place. Leave the u-cup seal intact. d. Set aside the disassembled parts for cleaning. 7. Inspect the exposed needle and u-cup seal to determine need for replacement as follows: a. Look for uneven roundness of the u-cup seal or signs of wear that prevents a good seal.
1 2 3 4 5 11 12 6 13 14 7 8 9 10 Item Description Item Description 1 Micro-adjustment Lock Nut 8 Heater 2 Preload Lock Nut 9 Nozzle Nut 3 Upper Body and Solenoid Valve 10 Hex Head Screw (two) 4 Elbow Connector 11 Needle 5 Lower Body 12 U-cup Seal 6 Hex Head Screw (two) 13 O-ring (small) 7 Seat Extension 14 O-ring (large) Figure 5-1 Disassembling the DJ-2200 24 Maintenance and Service
Inspecting and Cleaning Inspect and clean the disassembled components and parts as follows: 1. Use a cotton-swab to remove excess material from the seat extension, lower body, and connector. 2. Use a cotton-swab and the recommended solvent to further clean the seat extension, lower body, and elbow connector. CAUTION! Protect the solenoid valve from contact with material or solvent. Contamination could cause solenoid failure. 3.
CAUTION! To prevent damage to the extension seat, verify that the micro-adjustment is opened 4 to 6 turns counterclockwise. 3. Install the seat extension and heater as follows: a. If needed, apply conductive grease on the seat extension shaft. Make sure not to put grease on the threads. b. Rotate the seat extension into the heater to spread the conductive grease evenly and prevent the formation of trapped-air pockets. c. Carefully, install the large o-ring on the seat extension. d.
Disassembly of the DispenseJet Inspect each part during the disassembly for wear and tear or damage. For parts replacement, remove and disassemble the DispenseJet to the level necessary to gain access to the failed part. CAUTION! Do not subject the electrical cables to stress during removal. Damaged cables cannot be replaced separately and can only be replaced with the next higher assembly. To remove the Solenoid Valve from the Upper Body (Figure 5-2): 1.
1 2 3 4 7 5 8 6 9 Item Description Item Description 1 Micro-adjustment 6 Upper Body 2 Preload Screw 7 Compression Spring 3 Preload Set screw (two) 8 Hex Head Screw (two) 4 Preload Lock Nut 9 Solenoid Valve 5 Cap Figure 5-2 Removal of Solenoid Valve and Disassembly of Micro-adjustment To disassemble the Lower Body (Figure 5-3): To remove and disassemble the lower body follow the instructions under “Purging the DispenseJet” earlier in this section.
To remove and disassemble the Upper Body (Figure 5-3): 1. Remove the two screws securing the cap to the upper body. 2. If not already separated, remove the two screws securing the lower body to the upper body and carefully remove the lower body from the needle and set it aside. Leave the needle intact in the upper body for now. 3. For future reference, note the fitting and plug locations on the upper body. 4. Using a flat head screwdriver, remove the fitting and the plug from the upper body.
To remove the Needle and disassemble the Air Piston: 1. Use the module-adjusting wrench to hold the top of the seal lock nut and another moduleadjusting wrench to loosen the spring retainer. Carefully remove the spring retainer and seal lock nut. 2. Carefully remove the needle by pushing it out of the upper body. 3. Carefully remove the air piston, seal lock nut, and o-ring assembly from the needle. 4. Carefully separate the air piston, seal lock nut, and o-ring. 5.
Inspection and Cleaning of Disassembled Parts CAUTION! Protect the Solenoid Valve, Heater, and Seat Extension from contact with coating material, and incompatible cleaning solutions or solvents. Contamination could cause premature DispenseJet failure. NOTE It is recommended that you replace o-rings and u-cup seals rather than clean them. New or clean o-rings must be treated with an o-ring lubricant. To inspect and clean the disassembled components and parts: 1.
NOTE The screws should be tightened to a torque of 1.36 N-m (12 in-lb), except where noted in the assembly instructions. New o-rings must be treated with an o-ring type lubricant. To reassemble the Lower Body (Figure 5-5): 1. Install the elbow connector to the lower body ensuring that the fluid intake port is facing correctly. 2. Install the u-cup seal to the lower body as follows: a. Make sure the springy side of the u-cup seal is facing out. b.
1 2 8 3 4 9 5 10 8 6 7 Item Description 1 U-cup Seal 2 3 Item Description 6 U-cup Seal Upper Body 7 O-ring Fitting 8 Hex Head Screw (four) 4 Elbow Connector 9 Solenoid Valve 5 Lower Body 10 Plug Figure 5-5 Reassembly of the Upper and Lower Bodies and Solenoid Valve To insert the Seat Extension into the Heater (Figure 5-6): 1. Reapply the conductive grease on the seat extension without putting any grease on the threaded shaft. 2.
4 5 1 2 3 Item Description Item Description 1 Seat Extension 4 Upper Body 2 Heater 5 Lower Body 3 Hex Head Screw (two) Figure 5-6 Installing Heater and Seat Extension to Upper and Lower Bodies To install the Air Piston and the Needle (Figure 5-7): 1. Prepare the air piston for installation to the upper body as follows: a. Place the u-cup seal on a clean flat surface. b. Roll the lip of the u-cup seal so that a lip is formed to hang down toward the upper body. c.
d. Carefully install the air piston into the piston insertion tool so that the entire air piston is completely inside piston insertion tool. e. Ensure that the air piston is installed without any gaps or folds and is evenly round. f. NOTE If the installation is unsuccessful and the air piston was damaged in the process, replace air piston and repeat above steps. If not, continue with next step.
1 2 3 4 5 6 Item Description Item Description 1 Spring Retainer 4 Air Piston 2 Seal Lock Nut 5 Needle 3 O-ring 6 Upper Body Figure 5-7 Installing the Air Piston using the Air Piston Insertion Tool To attach the Micro-Adjustment and Cap to the DispenseJet (Figure 5-8): 1. Attach the cap to the upper body using the two screws making sure the two notches are aligned. 2. Place the compression spring on the spring retainer. 3.
5. With the micro-adjustment attached to the preload screw, place the preload screw on the compression spring and turn it clockwise to attach it to the upper body. 6. Perform adjustments as described in “Settings and Adjustments” later in this section.
Settings and Adjustments There are two adjustment settings that must be performed after disassembly and cleaning of the DispenseJet: • Preload setting • Micro-adjustment setting To adjust the Preload: NOTE The preload setting affects the velocity of jet of fluid and regulates the cleanness of the fluid break-off, which affects the shape of the dots or lines. The preload setting is regulated through the number of times the preload screw is turned downward from its current starting position.
To adjust the Micro-adjustment: The micro-adjustment setting regulates the fluid volume for the dot or line. The higher up the setting, the more fluid is dispensed. The preload screw must be adjusted before performing this procedure. Refer to the “To adjust the Preload:” procedure earlier in this section. NOTE 1. Using a 0.05-inch hex key, loosen the setscrews on the preload screw. 2. Rotate the inner micro-adjustment column so the numbered markings face the solenoid valve. 3. Using the 0.
1 5 5 4 0 3 20 2 0 5 8 6 Item Description Item Description 1 Micro-adjustment Collar Set Screw 5 Micro-adjustment Lock Nut 2 Micro-adjustment 6 Preload Lock Nut 3 Micro-adjustment Collar 7 Preload Screw 4 Inner Micro-adjustment Column 8 Preload Set Screw Figure 5-10 Components of Micro-adjustment and the Preload Screw To install the Co-axial Air Solenoid Valve to the DispenseJet: Refer to the Installation section for installation of the co-axial air solenoid valve to the Dispe
6 Troubleshooting To quickly identify problems, look for obvious signs such as burnt, missing, damaged, or loose parts, as well as fluid obstructions and leakages. If a problem recurs, there may be other root causes. Table 6-1 facilitates troubleshooting based on symptoms. Refer to the Additional Information section for part identification. Table 6-1 Troubleshooting Symptom Possible Cause No signal to the solenoid valve. DispenseJet is not cycle jetting. Fluid leaks from weep hole.
Symptom Too much fluid with each shot. DispenseJet performs but has problems after the co-axial air is installed. Possible Cause Recovery On-time set too long. Reduce jet on time. Micro-adjustment too high. Reduce the micro-adjustment setting. Fluid pressure too high. Reduce fluid pressure. Check function of co-axial air through input/output. Co-axial air not functioning during dispense. Check “Config.ini.
7 Additional Information Overview This section includes information for ordering recommended spares, replacement parts, and available optional parts for the DJ-2200 DispenseJet. This appendix covers the following: • Ordering Parts • Exploded Views Safety First Review the Safety section of this manual before attempting to replace any parts. CAUTION! Parts replacement should be performed by Nordson ASYMTEK-trained technicians.
Spare Parts The recommended spare parts for the DJ-2200 DispenseJet are listed in Table 7-1 and Table 7-2. The item numbers shown in the table correspond with numbered callouts in Figure 7-3. Table 7-1 Recommended Spare Parts for the DispenseJet Item Number Part Number 1 226289 Micrometer Assembly with Lock 2 226276 Preload Screw 3 982745 Preload Set Screw (Socket set, 4-40 x 0.
14 1 15 3 13 2 16 4 17 5 12 6 18 11 7 8 21 19 10 9 20 Figure 7-1 DJ-2200 Series Spare Parts Additional Information 45
The recommended spare parts of the optional co-axial air assist feature available for the DJ-2200 DispenseJet are listed in Table 7-3. The item numbers shown in the table correspond with numbered callouts in Figure 7-2. Table 7-3 Recommended Co-Axial Air Assist Spares for the DispenseJet Item Number Part Number 1 329391 Co-axial Air Nozzle Nut, M3 1 329410 Co-axial Air Nozzle Nut, N3 1 329411 Co-axial Air Nozzle Nut, W3 1 322445 Co-axial Air Nozzle Nut, M5 2 40-3501 Tubing, 1/8” O.D., .
Part Number Description Quantity 58-0037 Mini Round-tip Swabs, (25/pkg.) 8 58-0038 Mini Cotton-tip Swabs, wood handle (100/pkg.) 2 Startup Kit Table 7-5 lists the parts contained in the DJ-2200 startup kit. Table 7-5 DJ-2200 Startup Kit Item Number Part Number 1 234149 Wrench, Allen, Hex, 1.5-mm 1 2 234150 Wrench, Allen, Hex, 0.050-inch 1 3 234151 Wrench, Allen, Hex, 7/64-inch 1 4 129612 Wrench, Allen, Hex, 3/32-inch 1 5 901935 Wire, Cleaning, 0.
Adjustment and Assembly Tools Table 7-6 lists the Adjustment and Assembly Tools parts. The item numbers shown in the table correspond with numbered callouts in Figure 7-3.
Cleaning Tools Table 7-7 lists the Cleaning Tools parts. The Item Numbers shown in the Table correspond with numbered callouts in Figure 7-4. Table 7-7 Cleaning Tools Item Number Part Number 1 193840 Round/Round-tipped Swabs, (10 per package) 2 58-0038 Mini Cotton-tipped Swabs, wood handle, (100 per package)* 3 58-0037 Mini Round-tipped Swabs, (25 per package)* 4 58-0036 Round-tipped Cotton Swabs, 6-inch wood handle, (100 per package)* 5 901935 Tungsten Cleaning Wire, 0.
Mounting Brackets The mounting brackets required for installation of the DispenseJet to Nordson ASYMTEK Dispensing Systems platforms are listed in Table 7-8. Table 7-8 Mounting Brackets Mounting Bracket P/N Dispensing System 391765 Century Series, C-730 Dispensing System 391765 Millennium Series, M-600 N/A Millennium 2000 Series Exploded Views Figure 7-5 through Figure 7-8 shows the DJ-2200 DispenseJet in exploded view. These illustrations can be helpful when ordering replacement parts for the Pump.
Item 1 Part No.
Item Part No. Description 1 322359 Valve, DJ-2200 2 391765 C-730 Flux Bracket Assembly (Ref.) 3 64-HS-RTA Height Sensor Adj. Base A (Ref.
Item Part No. Description 1 329412 Co-axial Solenoid Valve 2 391775 Co-axial Mounting Bracket 3 391765 C-730 Flux Bracket Assembly (Ref.) 4 64-HS-RTA Height Sensor Adj. Base A (Ref.
See Figure 7-8, DJ-2200 DispenseJet Exploded View (4 of 4) for the listed items below. Item 54 Part No. Description 1 226289 Micrometer Assembly 2 982745 Preload Set Screw (Socket Set 4-40 x 0.
Item Part No. Description 32 234167 Temp Contr. Connector (Order with Item 26) 33 234167 Solenoid Valve Elect.
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