MH-900 Series Material Handling System Loader/Unloader Installation, Operations, and Maintenance Manual P/N 7223403 Rev A
NOTICE This is a Nordson ASYMTEK publication, which is protected by copyright. Original copyright date 2013. 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. Manuals on the Internet For the convenience of Nordson ASYMTEK customers and field service representatives, copies of this manual can be downloaded from: http://www.
Table of Contents 1 Introduction ...................................................................................................................................... 1-1 1.1 Overview ............................................................................................................................... 1-1 1.2 Safety First ............................................................................................................................ 1-1 1.3 Basic System Description ..............
3.7 Connecting to the Facility Air Supply .................................................................................... 3-5 3.8 Anchoring the MH-900 .......................................................................................................... 3-6 3.9 Configuration Menu ............................................................................................................... 3-9 3.9.1 3.9.2 3.9.3 3.9.4 3.9.5 3.9.6 3.9.7 4 Hardware Setup ........................................
6 7 Troubleshooting ............................................................................................................................... 6-1 6.1 Overview ............................................................................................................................... 6-1 6.2 Troubleshooting Guide .......................................................................................................... 6-1 6.3 Safety First ......................................................
Table of Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Loader/Same-Side Loader ................................................................................................. 1-2 MH-900 Loader (Front Right View and Back Left View)..................................................... 1-3 Loading Area ...................................................................................................................... 1-4 Shuttle Conveyor Gripper ..........
Figure 3-39 Figure 3-40 Figure 3-41 Figure 3-42 Figure 3-43 Figure 3-44 Figure 3-45 Figure 3-46 Figure 3-47 Jog Speed Configuration Window .................................................................................... 3-26 Loader Jog Screen ........................................................................................................... 3-27 System Setup Window ..................................................................................................... 3-28 Date and Time Setup ....
Figure 7-4 Figure 7-5 Figure 7-6 Figure 7-7 Figure 7-8 Figure 7-9 Figure 7-10 Figure 7-11 Figure 7-12 LCD Option Board DipSW4 ................................................................................................ 7-3 Removing the LCD Option Board ....................................................................................... 7-3 SW2 Dip Switch ..................................................................................................................
1 Introduction 1.1 Overview The MH-900 Series Loaders/Unloaders are optional part handling systems that provide flexible integration with upstream and downstream factory processes. They provide efficient part handling, minimizing operator intervention. This manual is intended primarily as a reference for production operators and service technicians. However, others unfamiliar with Nordson ASYMTEK products may also find this manual useful as a general introduction to the system.
1.4 System Configuration System 1.5 Description MH-912L Loader, Dual Lane MH-912U Unloader, Dual Lane MH-912S Same-Side Feed Loader/Unloader, Dual Lane System Features The figures in this section show views and features of the MH-900 Loaders/Unloaders. Callouts locate major components, options, and switches seen in each illustration. The numbers associated with the descriptions correspond to the callout numbers in the illustration.
1.5.1.1 Front Right and Back Left Views Functional descriptions of MH-900 components are shown in Figure 1-2. 1 4 2 3 5 6 MH-912L and MH-912S - Front Right View (Door Open) Item Name MH-912L and MH-912S - Back Left View Description 1 Light Beacon (option) The Light Beacon is a warning device for the operator. The beacon signals MH-900 status by displaying a colored light and/or issuing an audible tone. Refer to Section 2 - Safety for additional information.
1.5.1.2 Loading Area 1 2 5 3 3 4 Item Name Description Safety Doors Safety doors are located on the left and front of the machine and allow access to the loading area. Opening the safety doors during operation will stop the machine. Magazine Platform(s) The MH-900 is configured with a single magazine platform that can hold a maximum of twelve (12) magazines. The system may also be configured with an optional second platform.
1.5.1.
1.5.2 1.5.2.1 MH-912U Unloader Front Right and Back Left Views 1 2 4 3 5 6 MH-912U – Front Right View Item Name MH-912U – Back Left View Description 1 Light Beacon (option) The Light Beacon is a warning device for the operator. The beacon signals MH-900 status by displaying a colored light and/or issuing an audible tone. Refer to Section 2 - Safety for additional information. 2 Unloading Area The Unloading Area receives the processed magazines.
1.5.2.2 Unloading Area 1 5 2 4 3 Item Name Description The Conveyor transports the carrier to the production equipment via a conveyor belt. The default conveyor setup supports carrier lengths less than 216 mm. For longer lengths (more than 216 mm), the conveyor belt needs to be extended. This is achieved by manually transforming the extendable track and changing the belt. The Shuttle moves back and forth, shuttling the conveyor to accept carriers from a maximum of two (2) input positions.
1.5.2.3 Pusher 1 2 3 8 4 6 7 5 Item Name Description 1 Pusher The Pusher removes one carrier at a time from the conveyor by pushing it into an empty magazine slot. There are two (2) pneumatic actuators that control the Pusher: Pusher Extend/Retract and Pusher Up/Down. 2 Magazine Platform(s) The MH-900 is configured with a single magazine platform that can hold a maximum of 12 magazines. The system may also be configured with an optional second platform.
1.6 Control Panel The MH-900 Control Panel (Figure 1-8) contains the user interface and command buttons required for operating the MH-900. 1 2 6 3 Item Name 4 5 Description 1 Touch Screen Interface The MH-900 features Loadermove Touch software user interface. 2 Emergency Machine Off (EMO) Button In case of an emergency or malfunction, press the EMO button. Pressing the EMO button cuts the main power to the MH-900. 3 ON Button The ON (l) button controls power to the Power Manager.
2 Safety 2.1 Overview This section is intended to provide basic safety information necessary for operating and servicing the MH-900. The MH-900 is attached to and electronically connected to production equipment systems. Therefore, safety precautions pertaining to the production system equipment must also be adhered to when operating or servicing the MH-900.
2.3 Basic Safety Precautions and Practices Compliance with the following recommended precautions and practices reduces the risk of personal injury or damage to property during operation and maintenance of the MH-900. 2.3.1 Safety of Personnel WARNING! CAUTION! Only trained personnel should be permitted to perform operation, maintenance, and troubleshooting procedures. 2-2 • Lock out and tag out power to the MH-900 before performing service or maintenance on the MH-900. See 2.
2.3.2 2.3.3 2.4 Material Safety • Follow Material Safety Data Sheet (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.
2.6 Safety Warning Labels Safety warning labels on the MH-900 point out potentially hazardous areas and remind personnel to take necessary safety precautions. Table 2-1 describes safety warning labels that may be on the MH-900. WARNING! CAUTION! Comply with all safety warning labels or serious injury to personnel or damage to the dispensing system may occur. Worn or damaged labels should be replaced with new labels having the same part number.
1 Item 1 Description Crush Hazard Label Figure 2-1 Safety Warning Label (Front Cabinet – Loader and Unloader) 1 1 2 2 Loader Item Unloader Description 1 Read Manual. Select LOAD MAGS before replacing magazines.
1 1 Loader Item 1 Unloader Description Crush Hazard Label Figure 2-3 Safety Warning Label (Side – Loader and Unloader) 1 Item 1 Description Hand Entanglement Hazard Label Figure 2-4 Safety Warning Label (Inside - Loader and Unloader) 2-6 Safety
2.7 Residual Safety Risks Safety Hazard Risk Area 1 A high risk crushing hazard is created by the movement of the conveyor. DO NOT reach into the conveyor while the system is operating. Keep hands away from this area unless the system power is off. A high risk crushing hazard is created by the movement of the elevator. DO NOT remove the access panels while the system is operating. DO NOT bypass the safety interlock. DO NOT operate the equipment with the access panels removed and /or doors open.
2.8 Emergency Shutdown In the event of an emergency or malfunction, press one of the EMO buttons (Figure 2-6). Pressing the EMO on the MH-900 turns OFF two relays in the Main Power System. NOTE The system may be configured to cut power to both the MH-900 and the dispensing system when the EMO button is pressed. The Nordson ASYMTEK Dispensing System also provides that capability.
2.9 Integrated Safety Systems The MH-900 has a built-in safety system that automatically protects personnel from being injured by machine motion. This system consists of the following: 2.9.1 • Safety Interlock System • Light Beacon Safety Interlock System Interlock Sensors detect the door status (open or closed). All motion stops when the door is open. 2.9.2 Light Beacon The Light Beacon is a device that displays system status and can warn the operator when fault conditions exist.
2.10 Service Shutdown Before performing service or parts replacement, the dispensing system should be shut down as follows: To perform a service shutdown: 2.11 1. Shutdown the MH-900 as described in 4.5.2 Shutdown. 2. Shutdown the dispensing system as described in the applicable dispensing system manual. 3. Perform a “Lockout/Tagout of Electrical and Pneumatic Energy” as described below.
2.12 Decommissioning Procedures The MH-900 System should provide you with years of safe and reliable service. When it becomes necessary to decommission the system, the components should be dispositioned as specified Table 2-3. Table 2-3 Recommended Decommissioning Procedures Component Disposition Consumer Fluid Discard in accordance with local safety/environmental regulations. Aluminum Parts Recycle any aluminum parts. Steel Parts Recycle any steel parts. Copper Wiring Recycle any copper wiring.
3 Installation and Setup 3.1 Overview This section describes installation procedures for the MH-900. See the manual for your particular dispensing system for dispensing system installation instructions.
3.4 Installing the Light Beacon NOTE The Light Beacon is an option. Tools and Materials Needed: Light Beacon 3 mm hex key (M4) To install the Light Beacon: 1. Remove the beacon cover cap on the top cover. 2. While holding the pole upright, slide the cable through the slotted opening on the bracket. 3. Position the pole in the pole bracket. 4. Using 3 mm hex key (M4), tighten the M4 button head cap screw for a secure installation. 5.
3.5 Aligning and Leveling the MH-900 to Connected Equipment Tools and Materials Needed: Pallet Jack Crescent Wrench 1-meter ruler Level To align the MH-900 to the connected equipment: 1. Verify that the dispensing system is level and the conveyor rail height is 37.25-inch. 2. Place a 1-meter ruler (or yardstick) on the dispensing system front conveyor rail. 3. Using a pallet jack, move the MH-900 to the side of the dispensing system so that the conveyor rails face each other.
3.6 Installing the Cables Tools and Materials Needed: • • • Main Power Cable(s) SMEMA Cable(s) Bypass Plug(s) WARNING! Use extreme caution when working around high voltage components. Make sure the Main Power Switch is turned OFF (0) before connecting any cables. To install the cables on Loader and/or Unloader: Attach SMEMA cables and bypass plug according to the diagrams and table below.
3.7 Connecting to the Facility Air Supply To connect the system to the facility air supply: CAUTION! Make sure that facility air pressure meets the requirements specified in Section 2 - Safety. Higher pressures may damage the equipment. 1. Locate the facility quick-disconnect air hose. 2. Make sure the dispensing system Main Air Regulator(s) is closed. Verify facility air pressure is at 0 psi. 3. Connect the facility air hose(s) to the quick-disconnect(s) on the Main Air Regulator(s). 4.
3.8 Anchoring the MH-900 The MH-900 includes anchoring brackets to secure the machines to adjacent Nordson ASYMTEK dispensing equipment (Figure 3-5 and Figure 3-6). Figure 3-5 Loader with Single Station S-9XX Anchor Bracket NOTE Figure 3-6 Unloader with Single Station S-9XX Anchor Bracket Dispensers with multiple stations may require the extension bracket option. To anchor MH-900 to a single station dispenser: 1. Remove the dispenser-side mounting block from the MH-900 (Figure 3-7).
2. Remove the screw plate (Figure 3-8). Figure 3-8 Removing the Screw Plate 3. Install the dispenser-side mounting block onto the dispenser (Figure 3-9).
4. Align the dispenser and MH-900, mate the mounting blocks, and attach the mounting blocks with the original screw (Figure 3-10). A Pod Extension is used for attaching the MH-900 to dispensing systems equipped with pre-queue or post-queue stations (Figure 3-11).
3.9 Configuration Menu Prior to using your MH-900, it is necessary to perform a system configuration. Loadermove Touch software is required for this procedure. The Loadermove Touch Configuration Menu consists of the following items: Table 3-1 Configuration Menu Name Description System Setup Used to set the system date and time, screen contrast/brightness, and system passwords. See 3.9.5 System Setup. Hardware Setup Used to adjust magazine slots, conveyor rails, sensors, pusher and/or gripper. See 3.
3. The System Initialize screen (Figure 3-14) will briefly display. Figure 3-14 System Initialize Screen 4. Touch the Power-up Screen. 3-10 The Loadermove Touch Main Screen opens (Figure 3-15). Figure 3-15 Loadermove Touch Main Menu - Locked NOTE The padlocked sections are restricted areas. These sections are password protected.
To access the configuration menu: 1. Touch the Configuration button on the Loadermove Touch Main Menu (Figure 3-15). You will be prompted to enter a password (Figure 3-16). Figure 3-16 Password Keypad 2. Enter the factory default password: 7777777. 3. Press Enter to confirm password. After you have entered your password, the locks will be removed from the menu (Figure 3-17), providing you have appropriate access. See 3.9.5 System Setup. The Configuration Menu (Figure 3-18) will open.
3.9.1 Hardware Setup Hardware Setup is used to adjust the magazine guides, conveyor and gripper/kicker for customer specific magazines and parts. Tools and Materials Needed: Magazines Carriers Hex Keys : 3 mm , 2.5 mm, 2 mm Ruler Magazine Guides with Spring Clamps (included with MH-900, installed on table) MH Square Tool (included in the MH-900 accessories kit) To setup the hardware: 1. Click on 2. in the Configuration Menu (Figure 3-18).
6 4 3 2 1 Item 1 2 3 Description Slot 1 (with magazine) Slot 2 Slot 3 5 Item 4 5 6 Description Slot 4 Reference Guide Front Conveyor Rail Figure 3-20 Magazine Slots and Conveyor to access the jog screen and use the arrow keys to move the elevator and b. Click on shuttle as needed. Figure 3-21 Jog Screen c. Set up Magazine Slot 1. 1) Use the 3mm key to loosen the three (3) screws on the first magazine guide.
2 1 3 5 4 Item Description 1 MH Square Tool 2 Magazine in Slot 1 3 Reference Guide 4 Magazine Guides 5 Spring Clamps Figure 3-22 Magazine Slot Setup 4) Place a magazine guide with spring clamp beside the magazine. 5) Slide the MH Square Tool (or other 3.1 mm-thick spacer) between the magazine and the magazine guide. 6) Secure the magazine guide to the platform by tightening the three (3) screws. 7) Adjust the spring clamp position to cover the magazine length evenly. d.
2 1 3 Item Description 1 Magazine 2 3mm Hex Key 3 Movable Conveyor Rail Figure 3-23 MH-900 Conveyor Rail Setup, Side View f. Adjust the MH-900 conveyor rails leaving a gap of 1 mm (1/32-inch) on one side of the carrier. g. Using the 3 mm hex key, tighten the two bolts on the moveable MH-900 conveyor rail. h. Ensure the carrier can slide smoothly in and out of the magazine. 3. Align Conveyor Input and Output Lookup Sensors. a. Place a carrier into the magazine. b.
1 2 Item Description 1 Carrier In Sensor Bracket Screws 2 Carrier In Sensor Figure 3-24 Carrier In Conveyor Sensor Position - Loader f. Using your fingers, push the carrier out to the other end of the conveyor to verify the correct alignment. Readjust the alignment if necessary. g. Repeat Steps 3e to 3f for the Carrier Out sensor.
h. Repeat steps 3a to 3g for the unloader platform. i. Position the lookdown sensor to avoid interference with path of pusher/gripper (unloader and same-side-loader only). 1 2 Item Description 1 Look Down Sensor Bracket Screws 2 Look Down Sensor Figure 3-26 Look Down Sensor Position – Unloader and Same-Side Loader Adjust the Shuttle Forward Limit Figure 3-27 Adjust Shuttle Forward Limit 1. Jog the shuttle forward until the forward limit switch is reached and then back it up a few millimeters.
Gripper/Pusher Alignment (1 of 6) NOTE All references to the gripper apply to the MH-900 Loader and Same Side Feeder configurations only. All references to pusher apply to the MH-900 Unloader configuration only. Figure 3-28 Gripper Alignment #1 1. Clear part from the conveyor. 2. If necessary, adjust the gripper/pusher tower to align the gripper/pusher finger with part edge across width. 3. Adjust the gripper opening. a. Determine the opening gap.
Gripper/Pusher Alignment (2 of 6) Figure 3-30 Gripper Alignment #2 1. Place an empty magazine onto the elevator. 2. Insert one part into the magazine bottom position. 3. Jog the elevator/shuttle to align the part with the conveyor belts. If the part is not level with the conveyor, press elevator and shuttle. to go to the Jog Screen to adjust the Gripper/Pusher Alignment (3 of 6) Figure 3-31 Gripper Alignment #3 1. Pull the part onto the conveyor to align the edge with gripper/pusher finger.
a. Using the carrier edge as a reference, adjust the gripper assembly mounting height so that the bottom and top clearance gap is the same. b. The gripper/pusher assembly can be adjusted by loosening the four (4) screws holding the gripper assembly. c. 3. When loosening screws, support the assembly to prevent it from dropping too quickly. Tighten the four (4) screws. Close the gripper to test the alignment (loader only). a.
Gripper/Pusher Alignment (5 of 6) Figure 3-33 Gripper Alignment #5 1. Check that the gripper/pusher is extended into the magazine far enough to grip part. 2. If not, loosen the adjustment screws and slide the gripper/pusher assembly to align fingers with the part. 3. Test the gripper/pusher. a. Toggle ‘Close/Open Gripper’ to close the gripper. Check to make sure the grip is good. b. Toggle ‘Close/Open Gripper’ to open the gripper. Gripper/Pusher Alignment (6 of 6) Figure 3-34 Gripper Alignment #6 1.
3.9.2 Motion System Setup The Motion System Setup lets you set the shuttle and elevator speed during run mode, the elevator and shuttle travel limit, and elevator and shuttle travel distance. Figure 3-35 Motion System Setup 1. Enter the desired values. See Table 3-2. Table 3-2 Motion System Setup Options Name Run Mode: Description Shuttle Speed Shuttle speed for production run mode. Elevator Speed Elevator speed for production run mode.
2. The shuttle and elevator test routine can be activated after setting the travel distance value. Activate Test Routine to start the test 1. Press Play routine for shuttle and elevator moving sequence. 2. Press Stop routine. to stop the test Figure 3-36 Activating the Test Routine 3. Press Installation and Setup to return to the Configuration Menu.
3.9.3 Conveyor Setup Conveyor Setup sets delay, timeout, and hysteresis values for conveyor related sensing, transfer, and pushing/gripping functions. Figure 3-37 Conveyor Setup 1 1. Enter the desired values and press to move to next screen (Figure 3-38). See Table 3-3 for a description of Conveyor Setup options. Figure 3-38 Conveyor Setup 2 2. 3-24 Enter the desired values and press to return to the Configuration Menu.
Table 3-3 Conveyor Setup Options Name SMEMA Handshake Timeout Magazine Side Sensor Hysteresis Dispenser Side Sensor Hysteresis Look Down Sensor Hysteresis [appears on unloader and same-side loader only] Description Length of time MH-900 will wait for dispenser’s SMEMA handshake before entering into error state. Time delay applied to ON > OFF sensor state-change. Note: OFF > ON state-change is not delayed. Time delay applied to ON > OFF sensor state-change. Note: OFF > ON state-change is not delayed.
3.9.4 Jog Setup Jog Setup lets you set fast and slow jog speeds for the elevator and shuttle. You can also set elevator and shuttle travel distances through this menu. Figure 3-39 Jog Speed Configuration Window 1. Enter the desired jog configuration values. See Table 3-4 for a description of options. Table 3-4 Jog Screen Configuration Options Name 2.
Table 3-5 Jog Screen Options Item Shuttle Shuttle Elevator Elevator Description Moves the shuttle forward or backward at the Fast Jog Shuttle Speed set value. Moves the shuttle backward and forward at the Slow Jog Shuttle Speed set value. Moves the elevator up or down at the Fast Jog Shuttle Speed set value. Moves the elevator up or down at the Slow Jog Shuttle Speed set value. Figure 3-40 Loader Jog Screen Sends the shuttle to the home position. Opens the Test Gripper/Pusher Window.
3.9.5 System Setup System setup is used to set the system date and time, screen contrast/brightness, and system passwords. Figure 3-41 System Setup Window 1. Touch Date and Time in the System Setup Window (Figure 3-41). Figure 3-42 Date and Time Setup a. Touch the date or time display on the Date & time Setup screen to change the date and time. b. Use the number pad to set values. c. 2. 3-28 Press to return to the System Setup Window.
Figure 3-43 Adjust LCD a. Make adjustments as necessary, and click on when done. b. You will return to the System Setup screen. 3. Touch Password Setup You are allowed to change passwords for your security level and lower security levels only. Figure 3-44 Password Setup a. Select a level and enter a password. b. Only levels 0-2 are available. c. 4. Press Save & Quit when you have completed password setup. Press Installation and Setup to return to the Configuration Menu.
3.9.6 Preferences Preferences lets you set beacon and jog-mode preferences. Figure 3-45 Preferences 1. Select the desired preferences. See Table 3-6 for a description of options. 2. Press to return to the Configuration Menu. Table 3-6 Preferences Options Name 3-30 Description Pause State Beacon Lamp Color Selects the desired color of beacon when MH-900 is in Pause state. Yellow is the typical beacon color during Pause state.
3.9.7 Optional Conveyor Configuration for Long Carriers Carriers greater than 250 mm (9.84 in) in length will require the conveyor rails to be converted to their extended configuration. To extend conveyor rails: 1. Disassemble the rail as follows (Figure 3-46): a. Remove the two (2) rail brackets. b. Remove the two (2) black conveyor belts. c. Loosen the senor bracket and allow it to hang loosely.
2. Remove the rails from the assembly, flip them over so that the long arm is upright, swap sides of the conveyor and reinstall as follows (Figure 3-47): a. Reinstall both rail brackets. b. Install the long green conveyor belt (P/N 7204765) on each rail. c. Secure the sensor bracket and readjust as necessary.
4 Operation 4.1 Overview Before operating your MH-900 Series Dispensing System, it may be helpful to familiarize yourself with the basics of how the system works. This section covers the following topics: • Loadermove Touch Software • Editing a Recipe • Theory of Operation • Deleting a Recipe • Startup/Shutdown • Loading a Recipe • Creating a New Recipe • Running Production 4.2 Safety First Operation of your MH-900 involves mechanical devices, air pressure, and electrical power.
4.4.2 Loader The operator installs one or more full magazines onto elevator table. The loader waits for a SMEMA “Load-Machine Ready” signal before activating the vertical elevator to move a magazine into the loading position*. The shuttle moves the magazine/frame sensor into position to identify the next available frame. When a frame is located, the shuttle aligns the conveyor section to the carrier.
START RUN Turn Off Load Board Available Signal Elevator & Shuttle Move to Magazine Detect Position Yes Sensor Detects Magazine? No More Carriers in Magazine? No Yes Elevator & Shuttle Move to Carrier or Next Carrier Detect Position Yes More Magazines in Loader? No Sensor Detects Carrier? No Continuous Continuous or Single Mode? Yes Single Elevator & Shuttle Move to Load Carrier Position, Gripper will pick the carrier into Shuttle Conveyor Position END Wait for Load Machine Ready Signal On
START RUN Wait for Load Machine Ready Signal On Turn Off Load Board Available Signal Load Machine Ready? No Yes Yes Elevator & Shuttle Move to Magazine Detect Position No Yes Sensor Detects Magazine? More Carriers in Magazine? More Magazines in Loader? No No Yes Continuous Elevator & Shuttle Move to Carrier or Next Carrier Detect Position Continuous or Single Mode? Single END Sensor Detects Carrier? No Yes Elevator & Shuttle Move to Load Carrier Position, Gripper will pick the carrier in
START RUN Waiting for “Unload Board Available” Signal “Unload Board Available” Signal ON More Magazines in Unloader? Yes No No Elevator & Shuttle Move to Carrier or Next Carrier Detect Position Yes Shuttle Moves to Pick Position Sensor Detect Open Carrier Slot? No Yes Turn On the “Unload Machine Ready” Signal Transfer the Carrier to Magazine Input Sensor On? No Yes Yes More Space in Magazine? Transfer the Carrier to Shuttle Conveyor Position No Input Sensor Off END No Yes Turn Off “U
4.5 Startup/Shutdown 4.5.1 Startup To power on the MH-900: 4.5.2 1. Turn the Main Power Circuit Breaker, located on the back of the MH-900 to the ON (l) position. 2. Ensure the bypass plug is connected to the ‘DISPENSER I/O’ connector on rear side of the machine. 3. If the EMO on the MH-900 has been activated, turn it to the right until it pops back into position. 4. Press the ON (I) button on the MH-900 Control Panel.
Shuttle Lane 1 Position Figure 4-6 Teach Shuttle Output 1 1. Place a part onto the shuttle conveyor. 2. Jog the shuttle to align with Lane 1. to open the Jog Screen (Figure 3-40). a. Press b. Use the shuttle arrows keys to move the shuttle to Output Lane 1. 3. Activate the conveyor belt to test alignment. 4. Press 5. Press Teach. 6. Operation The conveyor belt is activated from the Jog Screen. to close the Jog Screen and return to the Teaching Shuttle Output 1 window.
Shuttle Lane 2 Position 1. Repeat Steps 1-5 under Shuttle Lane 1 Position above. 2. If the system does not have dual lanes, touch to move to the next step. Figure 4-7 Teach Shuttle Output 2 Magazines Per Shelf Figure 4-8 Total Number of Magazines 1. 4-8 Enter the total number of magazines per shelf to be taught for this recipe.
Parts Per Magazine Figure 4-9 Carrier Setup 1. Enter the total number of parts per magazine. Bottom Shelf Magazine Positions . Figure 4-10 Teach First Carrier NOTE 1. Operation Aligning the bottom part to the conveyor is typically an iterative process. The steps below should be repeated as needed to achieve proper alignment. Jog the elevator and shuttle to the bottom part. Start with magazine Slot 1.
2. Slide the part between the magazine and shuttle. 3. The part should slide smoothly by hand between the magazine and shuttle before continuing to the next step. Verify by clicking Gripper/Pusher. to open the Jog Screen (Figure 3-21) and then click on Test The Test Gripper/Pusher window opens (Figure 4-11). To pull a part from the magazine to the conveyor, select Activate Gripper Sequence Out (not available on unloader).
Part Spacing 1. If the part spacing is known, it can be entered directly into the cell (Figure 4-12). 2. If not, teach the position of the top part of Magazine 1 by following the steps below: a. Jog the elevator and shuttle to the bottom part. b. Slide part between magazine and shuttle. c. 3. The part should slide smoothly by hand between the magazine and shuttle before continuing to the next step. Verify by clicking Gripper/Pusher.
Magazine Sensor Position The Magazine Sensor Position is defined by elevator and shuttle offsets relative to the pick position of the bottom part of Magazine 1. Figure 4-13 Magazine Sensor Position To define the magazine sensor position: 1. Jog the shuttle and elevator to align the sensor to the rear edge of Magazine 1, adjacent to the bottom part. 4-12 You may press GO to move to existing offset values. 2. The sensor indicator will turn green when activated. 3. Press Teach. 4.
Part Sensor Position The Part Sensor Position is defined by elevator and shuttle offsets relative to the pick position of the bottom part of Magazine 1. Figure 4-14 Carrier Sensor Position To define the part sensor position: 1. Jog the shuttle and elevator to align the sensor to the edge of the bottom part of Magazine 1. Operation You may press GO to move to existing offset values. 2. The sensor indicator will turn green when activated. 3. Press Teach. 4.
Save Recipe Figure 4-15 Save Recipe Window To save a recipe: 1. Touch an empty location on the Save Recipe screen. A keyboard will appear (Figure 4-16). Figure 4-16 Entering a Recipe Name 2. Enter the recipe name. 4-14 To overwrite the existing filename, select the filename and enter the new name. 3. Press ENT to save program. 4. Press to return to the previous page.
4.7 Editing a Recipe Recipes can be edited using either of following methods: • Edit values in the Teach a Program Recipe. • Edit values in the Edit Recipe screen (Figure 4-19). screen described in 4.6 Creating a New To edit values in Edit Recipe screen: 1. From the Loadermove Touch Main Menu, Select Tools . You will be prompted to enter a password. After you enter the password, all buttons will be enabled. The Tools Window opens (Figure 4-17. Figure 4-17 Tools Window 2.
4. Select Edit. The Edit Recipe window (Figure 4-19) opens. Parameters are described in Table 4-1. Recipe parameters may be edited by either entering values directly into cell or, when available, using the Teach button. TIP The Go button may be used to move the elevator and shuttle to the saved position. This can be useful when making small jog adjustments to saved positions.
Name Description Go to Mag1 top part Moves the shuttle and elevator to the top part of Magazine 1, based on saved pitch. See Figure 4-20. Note: The pitch value may be re-taught by selecting Teach after adjusting the jog position of the top part. Disable Pinchrollers Allows the user to select whether or not to disable pinch rollers during load and/or unload sequence. Number of magazines per shelf Number of magazines per shelf in selected recipe.
4.8 Deleting a Recipe To delete a recipe: NOTE All the parameters in the selected recipe will be deleted. 1. From the Loadermove Touch Main Menu, Select Tools 2. Select Recipe Maintenance. 3. Select the desired recipe in the Recipe Maintenance Window. . Figure 4-21 Deleting a Recipe 4-18 4. Press Delete. 5. Press to return to the Recipe Maintenance Window.
4.9 Loading a Recipe The Load Recipe window (Figure 4-22) can be accessed using either of following paths from the Main Menu: • Run > Load Recipe • Tools > Recipe Maintenance > Load NOTE Refer to 4.6 Creating a New Recipe for instructions on creating a recipe. Figure 4-22 Load Recipe Window Operation 1. Select the desired recipe in the Recipe Maintenance Window. 2. Press Load.
4.10 Running Production To start a production run: 1. Startup the MH-900 as described in 4.5.1 Startup. 2. Make sure that the connected dispensing system is on and that the dispensing system light beacon displays a green light. 3. From the Loadermove Touch Main Window (Figure 3-17), press Run . The Production Window (Figure 4-23) opens. Figure 4-23 Production Window 4. Select Run . The Run Window (Figure 4-24/Figure 4-25) opens.
Figure 4-25 Run Window – Unloader/Same-Side Table 4-2 Run Window Description Name Part Count Run Time Description Indicates the current part count. Indicates the start date, start time and end time. SMEMA Status - Loader BA = Board available at upstream machine (upstream machine signals to downstream machine). MR = Machine Ready downstream (downstream machine signals to upstream machine).
5. Verify that the correct recipe is selected. By default, the last selected recipe will be used. The current recipe name will be displayed at the top right of the Run Window. WARNING! An incorrect recipe may damage the carriers and/or equipment. 6. If the wrong recipe is selected, press to go back to the Production Window and load the correct recipe. See 4.9 Loading a Recipe. 7. to position the elevator in the upper-most position and the shuttle Select Load Mags in the front of the machine.
2 2 2 1 1 2 Zone 1 Item 1 2 Alternating 1 Description Full Magazine Empty Magazine Figure-4-28 Zone vs. Alternating NOTE The loader, unloader, and same side loaders will accommodate partially full magazines. When loading, empty carrier slots will be detected by the part sensor and skipped over. When unloading, full carrier slots will be detected by part sensor and skipped over. 9. 10. Press to start the production run. The conveyor will make a short move to check for part on conveyor.
4.10.1 Running a Single Board To run one board: 1. Select Run One Board from the Production Window (Figure 4-23). After system initialization is complete, the Run One Part Window (Figure 4-30) opens. Figure 4-30 Run One Part 2. Verify that the correct recipe is selected. By default, the last selected recipe will be used. The current recipe name will be displayed at the top right of the Run Window. WARNING! An incorrect recipe may damage the carriers and/or equipment. 3.
5 Maintenance and Service 5.1 Overview Performing the recommended maintenance procedures at the intervals suggested in this section increases system life and ensures smooth operation. Recommended maintenance procedures are listed in Table 5-1. NOTE These recommendations are for MH-900s operating in a 24/7-production environment. Except for the daily and weekly requirements, maintenance for single shift operations may be performed at less frequent intervals.
5.4 Recordkeeping The type of maintenance performed should be recorded in the MH-900 maintenance records. At minimum, dates, procedure type, technician name, part numbers/serial numbers of replaced parts, and post-procedure functional test results should be recorded. WARNING! CAUTION! Before performing the maintenance procedures in this section, perform a service shutdown as specified in 2.10 Service Shutdown. 5.
5.6 Mechanical Hardware Inspection The following mechanical components should be inspected on a quarterly basis: 5.
5.8 Removal and Replacement of Access Panels To remove the panels: NOTE Remove the panels in the following sequence. As you remove each panel, lift it up and away from the MH-900. 1. Detach the 2 retaining screws from the top of the front panel and remove the panel. 2. Detach the 2 retaining screws from the top of the lower left panel and remove the panel. 3. Detach the 2 retaining screws from the top of the upper rear panel and remove the panel. 4.
To replace the panels: 5.9 1. Place the front panel onto the MH-900 frame structure and align the attachment holes. Attach the two (2) screws to the bottom of the panel. 2. Place the lower left panel onto the MH-900 frame structure and align the attachment holes. Attach the two (2) screws through the panel. 3. Place the lower rear panel onto the MH-900 frame structure and align the attachment holes. Attach the two (2) screws to the top of the panel. 4.
5.10 Conveyor Belt Replacement NOTE Replacement requires access through the removal and installation of service panels. See 5.8 Removal and Replacement of Access Panels. Tools and Materials Needed: • Metric hex key set • Phillips-head screwdriver 5.10.1 Belt Removal 1. Remove and discard the damaged MH-900 conveyor belt from the pulley drives at the lefthand side of the conveyor assembly area. See Figure 5-2. 2.
6 Troubleshooting 6.1 Overview This section identifies symptoms and probable causes of operational difficulties with the MH-900 upstream and downstream systems. If you encounter difficulties not listed here, or if the suggested recoveries do not correct the problem, please contact Nordson ASYMTEK Technical Support. 6.2 Troubleshooting Guide Troubleshooting is divided into three tables. Table 6-1 lists operator-level procedures that may be performed by production operators.
Table 6-1 Operator Troubleshooting Symptom Carrier jams during load/unload Possible Cause Recovery MH-900 and dispensing system not aligned Level and align the MH-900 and dispensing system. See 3.5 Aligning and Leveling the MH-900 to Connected Equipment. Taught positions incorrect Verify taught positions. See 4.7 Editing a Recipe. Wrong program running Verify that the correct recipe is loaded. See 4.9 Loading a Recipe.
Table 6-3 Mechanical Troubleshooting Symptom Probable Cause Recovery Conveyor belt pulleys out of line Fasteners loose or missing Secure or replace fastener. MH-900 Conveyor Rail out of line Fasteners loose or missing Secure or replace fastener. MH-900 Cross Rail out of line Fasteners loose or missing Secure or replace fastener. Pinch rollers out of line Fasteners loose or missing Secure or replace fastener. Motor drive belt broken or missing Replace drive belt.
6.4 Error Messages If an error occurs during a production run, a window will open showing the error message and the recommended corrective action. Figure 6-1 shows examples of error messages. Figure 6-1 Error Messages Error messages and recommended corrective actions are listed in Table 6-4. Table 6-4 Error Messages Error Message Action There is a part on the conveyor. Remove part from conveyor. The part was mispicked. Push part back into magazine or remove part from system. A timeout has occurred.
6.5 I/O Test The I/O Test screens can be used to help diagnose problems by observing input bit states and/or toggling certain output bits. To access I/O Test screens: 1. From the Loadermove Touch Main Menu, Press Tools . You will be prompted to enter a password. Enter the password and all buttons will be enabled. The Tools Window (Figure 6-2) opens.
Figure 6-3 IO Test Input 3. Press IN2, OUT1-4 to access other input or output screens (Figure 6-4 to Figure 6-8).
Figure 6-6 IO Test Output 2 Figure 6-7 IO Test Output 3 Figure 6-8 IO Test Output 4 4. Press Troubleshooting to return to the Tools Menu.
6.6 Hidden System Configuration Screen Global configuration settings and parameters are located in the Hidden System Configuration Screen. This screen is only intended to be accessed by qualified service personnel. The Hidden System Screen can be accessed via either the Start Up screen or the Configuration Menu screen. To access Hidden System Screen: 1. From the Start Up screen or the Configuration Menu, press the area in middle of blue bar at top of screen. Press Here 2.
Figure 6-10 Hidden System Configuration Table 6-5 Hidden System Configuration Options Setting/Parameter Applicable Configurations Description Indicator Selected (green): Stepper Conveyor Motor Indicator not selected: DC Conveyor Motor All Acceleration value for elevator, shuttle All Deceleration value for elevator, shuttle All Coordinates of top shelf Dual Shelf Only Coordinates of bottom shelf All Loader, Same-Side Loader Only All Oven special only Same-side loader only Loader only Unloader only
7 Backup and Restoration 7.1 Backup of PLC Programs PLC programs can be transferred from the Omron PLC to an Omron Memory Cassette CP1W-ME05M by using the Omron LCD Option Board CP1W-DAM01. PLC programs can be transferred from a memory cassette to the PLC with or without the use of the LCD Option Board. This procedure does not require a computer or cables.
To remove the memory cassette: 1. Turn OFF the power supply to the PLC. 2. Grasp the end of the memory cassette between the thumbnail and index finger and slide it upward to remove it (Figure 7-2). Figure 7-2 Removing the Memory Cassette 7.1.2 Installing and Removing the LCD Option Board To install the LCD Option Board: CAUTION! Always turn OFF the power supply to the CPU Unit and wait until all operation indicators go out before installing or removing the LCD Option Board. 1.
3. Switch the DipSW4 of the CPU Unit to ON (Figure 7-4). DipSW4 is OFF at shipment. Figure 7-4 LCD Option Board DipSW4 To remove the LCD Option Board: 1. Press the up/down lock levers on both sides of the LCD Option Board at the same time to unlock the option board, and then pull it out (Figure 7-5).
To transfer programs to or from PLC to Memory Cassette using an Omron LCD Option Board: 1. Mount the memory cassette and LCD option board into PLC as shown in Figure 7-1 and Figure 7-3. Be sure to always turn OFF power supply to CPU unit before installation and removal. Verify Dip Switch 4 is set to the ON position. 2. Turn the CPU power ON. The LCD Option Board will initialize hardware, check EEPROM, and then check communication between the LCD Option Board and the CPU Unit.
8. In the [MC] menu we can transfer from the memory cassette to the PLC (>MC -> PLC) or from the PLC to the memory cassette (>PLC->MC). See additional notes below for Autboot PRG/RUN details shown after selecting MC->PLC. For the MH-900, Autboot RUN is recommended. Arrow up/down, then press OK to select your desired function. [MC] PRG >MC->PLC PLC->MC Compare * 9. Press the down button to select >OK, then press OK. Warning! This will overwrite the data in the destination device.
To transfer programs from Memory Cassette to PLC without an LCD Option Board: NOTE Use the following procedure to enable automatic transfer at startup. 1. Prepare a memory cassette with the required data. 2. Make sure the CPU power supply is OFF and remove the cover from the memory cassette slot and insert the memory cassette. 3. Open the cover on the CPU’s peripheral section and set the Dip Switch Pin SW2 to ON. Figure 7-6 SW2 Dip Switch 4. Turn ON the CPU power supply.
7.2 Backup of Touchscreen Code The touchscreen code can be transferred between the Omron touchscreen and a USB flash drive. This procedure does not require a computer or cables. NOTE The touchscreen code does not contain any recipe or global variables. Tools and Materials Needed: USB Drive (not included with MH-900) To transfer code from the touchscreen to the USB drive: 1. Power on the MH-900. 2. Insert a USB drive into USB slot behind touchscreen.
4. Select File (Figure 7-9). Figure 7-9 Transfer Menu 5. Select the lower icon showing transfer from touchscreen ‘IC’ memory to USB drive (Figure 7-10). Figure 7-10 Transfer from Touchscreen IC Memory to USB 6. Select YES when prompted to Download File (Figure 7-11). Information Info Download File? YES NO Update File Success OK Figure 7-11 Download File Prompts 7. Remove the USB drive. 7-8 NOTE The backup files (code) will be saved in a folder titled “HMI” on the USB drive.
To transfer code from the USB Drive to Touchscreen IC memory: 1. Repeat Steps 1-4 above. 2. Select the middle icon showing transfer from USB drive to touchscreen IC memory. Figure 7-12 Transfer from USB Drive to Touchscreen IC Memory 3. Select Yes to download file. 4. Restart the MH-900 after the code has been successfully downloaded.
8 Specifications 8.1 Overview To ensure optimal performance and safety, you must install the MH-900 in a facility that meets or exceeds the requirements listed in Table 8-1. All facility power sources must be safely grounded. 8.2 System Specifications WARNING! CAUTION! Make sure that your facility meets the requirements below. Failure to meet these requirements could cause serious bodily harm to the user and serious damage to the MH-900.
8.3 Carrier Dimensions Minimum and maximum carrier dimensions are listed in Table 8-2. Carriers must be flat and cannot be more that 25 mm (1.0-inch) shorter than the magazine. Special length accommodations are available upon request. Table 8-2 Accommodated Carrier Dimensions Type Size Magazine Width Min: 15 mm (0.59 inch), Max: 172 mm (6.77 inch) Magazine Length Min: 50.8 mm (2.0 inch), Max: 317.5 mm (12.5 inch) Magazine Height Min: 50.8 mm (2.0 inch) Max: 270 mm (10.
8.4 System Footprint 625 75** EMO Loader Footprint Unloader footprint is a mirror image. Dimensions are given in millimeters. **Carriers > 230 mm require a cover for the conveyor extension; footprint extends 75 mm. 600 Front Door 2170 1524 EMO 1465 1050 Main Air Main Power 955 Conveyor Height 106 55 1076.00 1186.
8.5 Stability Analysis Table 8-3 Stability Analysis Specifications Loader/Same Side Feed Unloader X: 283 mm (11.1 in) from left side of frame Y: 645 mm (25.4 in) from front of frame Z: 842 mm (33.1 in) from bottom of frame X: 283 mm (11.1 in) from left side of frame Y: 645 mm (25.4 in) from front of frame Z: 842 mm (33.1 in) from bottom of frame Weight Distribution (1) Front Left Front Right Rear Right Rear Left 61.1 kg (134.7 lbs) 62.4 kg (137.5 lbs) 54.0 kg (119.0 lbs) 52.5 kg (115.8 lbs) 61.
Nordson ASYMTEK Headquarters 2762 Loker Avenue West Carlsbad, CA 92010-6603 USA 1+760.431.1919 nordsonasymtek.com DECLARATION OF CONFORMITY The machine described below complies with the appropriate basic safety and health requirements of the listed directives based on its design and type, as delivered by Nordson ASYMTEK. In case of alteration of the machine, this declaration may lose its validity.
Index A Anchoring to Connected Equipment............................... 3-6 B Backup installing and removing the LCD option board........... 7-2 mounting and removing memory cassette ................ 7-1 PLC Programs ............................................................. 7-1 touchscreen code................................................ 7-7–7-9 transferring programs from PLC to Memory Cassette using Omron LCD Option Board ............................ 7-4 without LCD Option Board ..................
R Recipe creating a new recipe ........................................ 4-6–4-14 deleting .................................................................... 4-18 editing ............................................................. 4-15–4-17 loading ..................................................................... 4-19 saving ....................................................................... 4-14 Removal and Replacement of Access Panels .................. 5-4 Running Production ..................
