Dispense 2200 nordson

8/16/2019 Dispense 2200 nordson

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DispenseJet Series

DJ-2200

Owner’s Manual


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P/N 7210768, Revision C ©2010

NOTICE

This is an Nordson ASYMTEK publication, which is protected by copyright. Original copyright date 2006. No part of thisdocument may be photocopied, reproduced, or translated to another language without the prior written consent ofNordson 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 Nordson ASYMTEKmanuals can be downloaded from:

http://www.nordsonasymtek.com/support/tech_manuals.htm

Contact Us

Nordson ASYMTEK welcomes requests for information, comments, and inquiries about its products. Please contact ususing the information below:

Headquarters 2762 Loker Avenue WestCarlsbad, CA 92010-6603USA

Toll Free: 1-800-ASYMTEK (1-800-279-6835)

Tel: +1-760-431-1919

Fax: +1-760-431-2678

E-Mail: [email protected]

Website: www.nordsonasymtek.com

Technical Support

USA: 1-800-ASYMTEK (1-800-279-6835)

Other regions: www.nordsonasymtek.com TechSupport

Trademarks

Asymtek®, Century

®, Millennium

®, and Fluidmove

® and DispenseJet

® are registered trademarks of Nordson

ASYMTEK.

Axiom™ is a trademark of Nordson ASYMTEK.Microsoft

®, Windows

®, and Windows NT

® are registered trademarks of Microsoft Corporation.

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Table of Contents i

Table of Contents

1 Introduction .......................................................................................................................................... 1

Overview ................................................................................................................................................ 1 DispenseJet Description ........................................................................................................................ 1 Specifications ......................................................................................................................................... 2

2 Safety .................................................................................................................................................... 3 Overview ................................................................................................................................................ 3 Safety of Personnel ................................................................................................................................ 3 Preventing Equipment and Workpiece Damage .................................................................................... 4

3 Installation ............................................................................................................................................ 5

Overview ................................................................................................................................................ 5 Unpacking the DJ-2200 ......................................................................................................................... 5 Installing the DJ-2200 ............................................................................................................................ 5

4 Operation .............................................................................................................................................. 9

Overview ................................................................................................................................................ 9 Theory of Operation .............................................................................................................................10

Operating Instructions ..........................................................................................................................11 DispenseJet Setup Adjustments ..................................................................................................11 Changing Nozzles ........................................................................................................................13 Using the Standard Nozzle Nut ....................................................................................................13 Using the Air Assist Feature ........................................................................................................15 Setup and Valve Offset Routines .................................................................................................16 Changing the Syringe...................................................................................................................16 Draining the Fluid Lines ...............................................................................................................17 Changing Fluids ...........................................................................................................................18 Shutting Down DispenseJet Operations ......................................................................................18

Application and Process Development ................................................................................................18

5 Maintenance and Service ..................................................................................................................19

Overview ..............................................................................................................................................19 Maintenance Schedule ........................................................................................................................19

Cleaning the Nozzle .....................................................................................................................19 Purging the DispenseJet ..............................................................................................................21 Complete Cleaning .......................................................................................................................21 Complete Overhaul Service .........................................................................................................26 Settings and Adjustments ............................................................................................................38

6 Troubleshooting .................................................................................................................................41

7 Additional Information .......................................................................................................................43

Overview ..............................................................................................................................................43 Safety First ...........................................................................................................................................43

Ordering Parts ......................................................................................................................................43 Return Material Authorization ......................................................................................................43 Replaced Parts .............................................................................................................................43 Spare Parts ..................................................................................................................................44 Startup Kit ....................................................................................................................................47 Adjustment and Assembly Tools ..................................................................................................48 Cleaning Tools .............................................................................................................................49 Mounting Brackets .......................................................................................................................50

Exploded Views ...................................................................................................................................50


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Table of Figuresii

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 .................................................................................................. 8 Figure 4-1 Typical Jet DispenseJet Internal Workings ..............................................................................10 Figure 4-2 Preload and Micro-adjustment Settings ...................................................................................12 Figure 4-3 Changing Nozzles ....................................................................................................................14 Figure 4-4 Syringe with Receiver Head Attached .....................................................................................17 Figure 5-1 Disassembling the DJ-2200 .....................................................................................................24 Figure 5-2 Removal of Solenoid Valve and Disassembly of Micro-adjustment .........................................28 Figure 5-3 Disassembly of Upper and Lower Bodies. ...............................................................................29 Figure 5-4 Removing the Needle and Disassembling the Air Piston ........................................................30 Figure 5-5 Reassembly of the Upper and Lower Bodies and Solenoid Valve ..........................................33 Figure 5-6 Installing Heater and Seat Extension to Upper and Lower Bodies ..........................................34 Figure 5-7 Installing the Air Piston using the Air Piston Insertion Tool......................................................36 Figure 5-8 Installing the Micro-adjustment and Cap ..................................................................................37 Figure 5-9 Preload Screw Point of Reference ...........................................................................................38 Figure 5-10 Components of Micro-adjustment and the Preload Screw ....................................................40

Figure 7-1 DJ-2200 Series Spare Parts ....................................................................................................45 Figure 7-2 Co-axial Air Assist ....................................................................................................................46 Figure 7-3 Adjustment and Assembly Tools ..............................................................................................48 Figure 7-4 Cleaning Tools .........................................................................................................................49 Figure 7-5 DJ-2200 DispenseJet Exploded View (1 of 4) .........................................................................51 Figure 7-6 DJ-2200 DispenseJet Exploded View (2 of 4) .........................................................................52 Figure 7-7 DJ-2200 DispenseJet Exploded View (3 of 4) .........................................................................53 Figure 7-8 DJ-2200 DispenseJet Exploded View (4 of 4) .........................................................................55

Table of Tables

Table 1-1 DJ-2200 Series Specifications .................................................................................................... 2 Table 4-1 Minimum Recommended Parameters .......................................................................................18

Table 5-1 Routine Maintenance Schedule, Category A ............................................................................19 Table 5-2 Preventive Maintenance Schedule, Category B ........................................................................19 Table 6-1 Troubleshooting .........................................................................................................................41 Table 7-1 Recommended Spare Parts for the DispenseJet ......................................................................44 Table 7-2 Nozzle Spares for the DispenseJet ...........................................................................................44 Table 7-3 Recommended Co-Axial Air Assist Spares for the DispenseJet ...............................................46 Table 7-4 DJ-2200 Spares Kit ...................................................................................................................46 Table 7-5 DJ-2200 Startup Kit ...................................................................................................................47 Table 7-6 Adjustment and Assembly Tools ...............................................................................................48 Table 7-7 Cleaning Tools ...........................................................................................................................49 Table 7-8 Mounting Brackets .....................................................................................................................50


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Introduction 1

1 Introduction

Overview

This section provides you with an introductory description of the DispenseJet DJ-2200. More details areprovided 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 exceptionalvolumetric control for flux dot or line application. When equipped with the co-axial air assist feature, it iscapable of dispensing co-axial air-assisted lines or dots. Jetting allows coverage with less flux and residue tobe removed. Non-contact jet dispensing eliminates the need for Z-axis motion during the dispense cycle,which increases flux application speed and accuracy. Dispensing parameters can be changed usingcomputer-programmed patterns. The jetted flux can be immediately followed by a solenoid driven pulse of airto disperse the flux onto the substrate.

Figure 1-1 DJ-2200 Series DispenseJet and Air Assist Feature


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2 Introduction

Specifications

Table 1-1 contains the technical specifications for the DJ-2200 Series DispenseJet. If you have anyquestions about facility requirements, refer to the applicable dispensing system manual or contact AsymtekTechnical 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, 3.9 liters (6 or 20 oz, 1 gal)

Environmental/Facility:

Storage/Operating Temperature: 5 to 50 °C (41 to 122 °F)

Relative Humidity: 5 to 90 % (non-condensing)

Altitude Limitations: Approximately 1609 meters (5278 feetmaximum)

Electrical:

Valve, Operating Voltage: 24 VDC

Solenoid: 24 VDC, 12.7 watts

Heater: 8.5 Watts

Fluid Pressure: 0-2 Kg/cm2 (0-28 psi)

Pneumatics: 690 kPa (100 psi)


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4 Safety

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 sensitivecomponents. 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.

• Immediately contain and clean up any caustic or conductive fluid spills as recommended in thematerial manufacturer’s MSDS.

• If fluid gets into internal portions of the DJ-2200, immediately contact Nordson ASYMTEKTechnical Support.

• Use only replacement parts that are designed for use with the original equipment. See the Additional Information section for an illustrated parts list.

CAUTION! The DispenseJet Series DJ-2200 is a precision instrument of inherently safe design.The use of any dispensing fluid and the related choice of solvent for cleaning, aswell as all associated safety precautions is the responsibility of the end-user.Consult with your fluid supplier for recommendations on personal protectiveequipment and safety practices.


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Installation 5

3 Installation

Overview

The DJ-2200 is designed for use on Nordson ASYMTEK Century C-730 and Millennium M-2000 FluxDispensing 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 forobvious damage and verify contents against the packing slip.

Retain the case for storage of DJ-2200 and accessories. Retain shipping cartons for future use. If an itemneeds to be returned to Nordson ASYMTEK, obtain a Return Material Authorization (RMA) from Nordson ASYMTEK Customer Service before returning the parts.

Installing the DJ-2200

If the DJ-2200 was factory installed with the dispensing system, you can proceed directly to the Operation section in this manual.

The following instructions are for the C-730 Dispensing System. Installations to other dispensing systemsmay vary slightly.

Tools and Material Needed

• Adjustment and Assembly Tools

• Torque Wrench

• Nozzles

CAUTION! The DJ-2200 Series DispenseJet is a delicate precision instrument. Exercise carewhen installing the DispenseJet. Failure to do so may cause damage to theDispenseJet. Installation should be performed by trained personnel only.


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Installation 7

Item Description Item 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

51 62 3 4 7 8


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8 Installation

To Install the Air Assist Feature:

NOTE These instructions assume that the air assist feature, consisting of the co-axial air solenoidvalve 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. Attach the co-axial air solenoid valve bracket to the bottom of the Z-head mounting plate usingtwo 2-mm hex screws with removable thread-locking adhesive ensuring a secure attachment.

2. Using a flathead screwdriver, install the co-axial air solenoid valve to the installed bracket usingthe two screws with removable thread-locking adhesive ensuring a secure attachment.

3. Connect the co-axial air solenoid valve electrical connector to the co-axial air jack (typically nearthe heater controller connectors on the dispensing system).

4. Connect the blue (green or black) tubing from the dispensing system pneumatics to the co-axialair solenoid valve.


1 Co-axial Air Pneumatic Valve Tubing 6 Bracket Mounting Screw (two)

2 Co-axial Air Electrical Connector 7 Co-axial Air Nozzle and Air Tubing

3 Co-axial Air Solenoid Valve Screw (two) 8 Standard Nozzle Nut

4 Co-axial Air Solenoid Valve 9 Z-head Mounting Plate (Valve Bracket)

5 Co-axial Air Solenoid Bracket

Figure 3-3 Installing the Air Assist Feature

45

63

9

8

7

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1


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Operation 9

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. Beforeoperating the DispenseJet for the first time, you may want to get a better understanding of how theDispenseJet works by reading the “Theory of Operation” in this section.

This section covers:

• Theory of Operation

• Operating Instructions

• Application and Process Development

WARNING! Follow proper power-up and shutdown procedures for the dispensing system whenmaking adjustments or changing fluids. Failure to adhere to safety warnings andprecautions could result in serious bodily harm to the user.

WARNING! Flux applications and cleaning involve hazardous materials. Adhere to MSDSinstructions for the materials. Failure to adhere to safety warnings and precautionscould result in serious bodily harm to the user.


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10 Operation

Theory of Operation

A typical cross-section of the internal workings of the DispenseJet is shown in Figure 4-1. During adispensing cycle, a solenoid-driven air pressure valve compresses a spring. The compressed spring retractsa needle plunger and the fluid chamber space vacated by the needle plunger is filled with fluid. When airexhausts from the solenoid valve, the spring expands and the needle plunger returns to its seat with animpact force that ejects the fluid through the dispensing nozzle onto the substrate and then immediatelyblocks the fluid from flowing through the nozzle. If desired, the dispensed fluid can be assisted by a shortburst of air from a co-axial air solenoid to assure consistent spreading of the fluid by disturbing the fluidsurface tension.

Fluid to be dispensed by the DispenseJet is contained in a syringe or an external reservoir and is fed to theDispenseJet fluid chamber at 7 to 69 kPa (1 to 10 psi). To stabilize viscosity and improve flow characteristicsof the fluid, the fluid is fed through a heater that typically warms the fluid from the ambient room temperatureto an ideal and controlled temperature of 40

° C (104

° F).

In the jetting process, the DispenseJet moves in an X-Y plane to dispense a variety of pre-programmedpatterns in a confluence to create a uniform film of flux. (There is no movement required in the Z-axis duringor between the dispense cycles). The fluid, which was dispensed on the substrate, forms a dot or a linedepending on application.

The micro-adjustment controls the needle travel distance. When turned clockwise, it decreases the pistontravel and fluid flow, and when turned counterclockwise it increases the piston travel and fluid flow.


1 Micro-adjustment 4 Needle

2 Spring 5 Heater

3 Air Piston 6 Nozzle

Figure 4-1 Typical Jet DispenseJet Internal Workings

1

2

3

4

5

6


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Operation 11

Operating Instructions

Prior to using the DispenseJet for production runs, it is recommended that you conduct a brief test-run toverify that adjustments and parameters are set for optimum performance.

NOTE Read the entire section before operating the DispenseJet. The sequence of events may varywith your particular application.

CAUTION! Operation of the DispenseJet should be performed only by Nordson ASYMTEK-trained operators or service technicians, or Nordson ASYMTEK field serviceengineers.


• Adjustment and assembly tools

• Nozzle kit

• Appropriate solvent and containers for the selected dispensing fluids

• Personal protective equipment

DispenseJet Setup Adjustments

There are two pre-requisite minor adjustments that must be performed on the DispenseJet (see Figure 4-2):

• Preload setting

• Micro-adjustment setting

NOTE For major adjustments, you need to remove and disassemble the DispenseJet. It is best tomake major adjustments before installing the DispenseJet to the dispensing system. See

“Settings and Adjustments” in the Maintenance and Service section in this manual.

Setting the Preload

To set the DispenseJet Preload:

1. Back off the micro-adjustment by turning it counterclockwise.

2. Count the number of times you completely turn the preload screw downward from its currentposition to regulate the desired space for the preload setting.

TIP It is best to determine the smallest dot or line to be dispensed before you set thepreload. Typically, too little tension or too much tension will result in poor

dispensing results.

3. Twist the preload lock nut all the way up on the preload screw so that it rests against the cap.

4. Using the kit-provided spanner wrench, turn the preload lock nut until it stops.


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12 Operation

5

5

0

0

2 0


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 onthe dispensing system, proceed as follows:

To set the Micro-adjustment:

1. Use the spanner wrench (included in kit) to loosen the preload lock nut (Figure 4-2).

2. Turn the outer micro-adjustment collar counterclockwise to the appropriate setting.

3. Use the spanner wrench to tighten the preload lock nut 1/8 turn.

Activating the Air Supply

To activate the Air Supply:

NOTE For flux applications, there is no need for valve speed settings.

1. Set the main air on the dispensing system between 586 to 620.5 kPa (85 to 90 psi).

2. Listen for air leaks.

If a hissing noise can be heard, refer to the Maintenance and Service section. If not,continue with the next step.

3. Set the valve pressure to 551.6 kPa (80 psi) and check for leaks.

If a leak is detected, refer to the Maintenance and Service section.

1

2

36

5

4


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14 Operation


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

1

2

3

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6


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Operation 15

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 theInstallation 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. Install the co-axial air nozzle nut and nozzle as follows:

a. Install the nozzle by carefully placing it in the standard nozzle nut so that the threadedportion of nozzle protrudes out of the standard nozzle nut.

CAUTION! Adhere to specified torque limits. The torque wrench clicks when the proper

torque is achieved. Forcefully over-tightening the nozzle nuts will causedamage. If damaged, replace the nozzle nuts.

b. Using the torque wrench, carefully install the standard nozzle nut by threading it on to thebottom of the DispenseJet.

c. Install the co-axial air nozzle nut onto the threaded portion of the nozzle using carefulalignment and light finger-tightening to allow room for final adjustment.

d. Using the torque wrench, loosen the standard nozzle nut to allow final installation of theco-axial air nozzle nut.

e. Position the co-axial air nozzle nut so that the protruding air inlet spout is conveniently facingin a direction that does not cause the air tubing to interfere with dispensing movement.

f. Using the torque wrench, carefully tighten the standard nozzle nut and the co-axial air nozzlenut.

3. Install one end of the co-axial air tubing by carefully pressing it onto the air-inlet spout on theco-axial air nozzle nut.

4. Install the other end of the co-axial air tubing to the air inlet of the co-axial solenoid valve.

TIP It may be easier to install the air tubing to the co-axial air nozzle nut first. This mayprevent the small nozzle from being dropped and lost. The tubing can be used tomanipulate the nozzle nut onto the nozzle.


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16 Operation

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.

NOTE The DJ-2200 DispenseJet setup process in Fluidmove must be performed prior to

programming the dispensing system and using the DJ-2200 DispenseJet. The setup is

identical for flux dot and flux line applications.

Changing the Syringe

To change the Syringe (Figure 4-4):

This procedure assumes you using the same fluid. If you are changing fluids, see “Changing Fluids” later inthis section.

1. If required, allow fluid to reach room temperature (refer to the MSDS for your fluid to determinerequirements).

2. Inspect the fluid in syringe for air bubbles.

NOTE Do not use any samples with visible air bubbles, as these will cause fluid voids anddispensing irregularities.

3. Remove the orange cap from the flat end of the syringe.

4. Check that the syringe has either an orange no-draft follower (preferred) or a yellow follower.

5. Remove the syringe tip cap.

6. Slide the receiver head onto the flat end of the syringe and tighten it.

7. Place the tip of the syringe securely into the elbow connector.

NOTE It is important to position the receiver head so that the long sides are parallel to theX-axis rods. If it is slanted or perpendicular to the X-axis, the receiver head will hit

the Z-head during dispensing.

8. Tighten the thumbscrew on the syringe bracket.

CAUTION! Do not over-tighten the syringe thumbscrew. Over-tightening may cause the

syringe to deform, forcing large amounts of fluid into the fluid chambers.

9. Connect the clear line from the receiver head to the clear (leftmost) line on the dispensing head.


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Operation 17

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 anddisposable towels and place the container at the purge station of the dispensing system.

2. Power up the dispensing system.

3. From the dispensing system control panel, manually move the DispenseJet so it is directly over

an open purge station (or select and click on PURGE from the Fluidmove software) to purge thesolvent from the fluid line.

4. Manually activate the solenoid valve by pressing the push-button underneath the solenoid valveto flush out all fluid in the fluid system, lines, syringe, or reservoir.

5. Lower fluid pressure to zero (0) and disconnect the air line and remove the syringe or reservoir.

1

2

3


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18 Operation

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 asapplicable to your application.

3. Purge (flush, or clean) the DispenseJet as appropriate (see “Purging the DispenseJet” in theMaintenance and Service section).

Shutting Down DispenseJet Operations

Follow the instructions in the applicable dispensing system manual for routine, service, and emergency shutdown of the dispensing system. When the dispensing system is not being used, an appropriate solvent maybe kept in the fluid lines to prevent residue buildup.

Application and Process Development

The Fluidmove software is used to program your flux applications. There are special dispensing patterns in

the Teach Window that apply to flux processes. The Fluidmove software will help you define the flux patternand film thickness. There are also variables for dot parameters and line parameters along with DJ-2200micro-adjust, preload, fluid pressure, and co-axial air pressure data.

NOTE For flux applications, there is no need for speed settings. For additional flux applications andprocess development, please contact Nordson ASYMTEK.

NOTE In the co-axial DOT mode, the air jets immediately after the fluid is dispensed onto thesubstrate. In the co-axial LINE mode, the air jets simultaneously with the fluid jet beingdispensed on the substrate.

It is recommended that you record, at a minimum, the following hardware and software settings during theprocess development (see Table 4-1).

TIP You may want to make a copy of this page for recording purposes.

Table 4-1 Minimum Recommended Parameters

Parameter Units of Measure Your Settings

Preload Number of Turns

Micro-adjustment * mm (inches)

Fluid Pressure kPa (psi)

Valve Pressure kPa (psi)

Co-axial Air Pressure kPa (psi)

Dispense Gap ** mm (inches)

* Each line on the collar = 0.05-mm; one (1) turn = 0.50-mm** In Dot or Line Parameters in Fluidmove


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Maintenance and Service 19

5 Maintenance and Service

Overview

Performing the recommended maintenance and service procedures increases the life of your DJ-2200 andensures 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. Thefrequencies are based on the average production environment. Your production operations and environmentmay differ.

Table 5-1 Routine Maintenance Schedule, Category A

Task Frequency Instructions

Look for evidence of jettingperformance fluctuations.

DailyCheck to ensure the desired originalsettings are maintained.

Listen for hard-to-detect air leaksand inspect for fluid leakage andother abnormalities.

WeeklyIf found, report leaks to productionsupervision.

Purge or flush fluid system lines. QuarterlySee “Draining the Fluid Lines” laterin this section.

Purge and prime fluid lines whenchanging dispensing fluid type.

As required betweendifferent fluid applications.

See “Purging the DispenseJet” laterin this section.

Table 5-2 Preventive Maintenance Schedule, Category B

Task Frequency Instructions

Change or clean the nozzle and

nozzle nut. Daily

See “Cleaning the Nozzle” later in

this section.

Complete Cleaning Service. Bi-Weekly or QuarterlyReview maintenance and servicerecords. See “Complete Cleaning” later in this section.

Complete Overhaul Service. AnnuallyReview maintenance and servicerecords. See “Complete OverhaulService” later in this section.

Cleaning the Nozzle

The nozzle should be cleaned after approximately 8- to 10-hours of normal use. This may vary depending onthe type of fluid.


• Torque Wrench

• Nozzle Brush

• Air Gun

• Solvent


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To remove the Nozzle:


2. If fluid is present in the reservoir or the syringe, obtain a suitable fluid collection container anddisposable 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. Manually activate the solenoid valve by pressing the push-button underneath the solenoid valveto flush out all fluid in the fluid system, lines, syringe, or reservoir.

5. Using the supplied torque wrench, carefully remove the standard nozzle nut with the co-axial airnozzle. If attached, press up on the orange-colored ring on the co-axial solenoid valve and gentlypull on the tubing until it is removed.

To clean the Nozzle:

1. Place the nozzle in the container with a small amount of solvent.

2. Carefully insert a cleaning-wire of correct size into the nozzle and gently agitate the interiorsurface.

3. Using a dry air gun, carefully blow air through the nozzle to clear fluid from the interior and into adisposable towel.

4. Submerge the nozzle in an ultrasonic cleaning system to remove any remaining residue.

5. Using a magnifier or microscope, inspect the nozzle interior for residue and scratches. If worn,replace it. If clean and undamaged, proceed with cleaning the nozzle from the bottom. Otherwiserepeat Steps 1 through 4.

To clean the Nozzle Nut:

1. Remove the standard nozzle nut and the co-axial air nozzle nut from the DispenseJet as a unit, ifattached.

2. Disconnect the co-axial air tubing.

3. Remove the co-axial air nozzle nut and the nozzle from the standard nozzle nut.

4. Remove and discard the Teflon gasket.

5. Using a nozzle brush, an appropriate solvent, and an ultra-sonic cleaning unit, clean and inspectthe removed parts. Repeat cleaning or replace the co-axial nozzle nut as appropriate.

To Reinstall the Nozzle:

Follow the “Changing Nozzles” instructions in the Operation section. Obtain a new Teflon gasket for thenozzle.

NOTE If you are not going to use the cleaned nozzles right away, store the nozzles in the protectivecase for the DispenseJet.


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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 Equipmentrecommendations.

2. Using the selected solvent instead of the flux fluid, follow the “Draining the Fluid Lines” instructions in the Operation section.

3. Select PURGE from the Fluidmove software to purge the solvent from the nozzle assembly.

Complete Cleaning

Typically, complete cleaning is performed on a bi-monthly or quarterly basis. However, the cleaning schedulemay vary depending on your application and production environment.

The following steps are necessary when performing a complete cleaning:

• Remove the DispenseJet from the dispensing system

• Disassemble the DispenseJet

• Inspect and clean

• Reassemble and reinstall the DispenseJet


The following tools and materials are needed:

• Adjustment and assembly tools

• Cleaning tools

• Air gun

• O-ring lubricant

• Conductive grease

Removing the DispenseJet from the Dispensing System

The instructions assume that the co-axial air solenoid valve and co-axial air nozzle are installed.

CAUTION! Do not subject the electrical cables to stress during the disassembly. Damagedcables cannot be replaced separately and can only be replaced with the next higherassembly.

To remove the DispenseJet:


2. Purge any remaining fluid from the reservoir.

a. Use the position controls to move the DispenseJet so it is directly over an open purge station(or click on PURGE from the Fluidmove software) to purge the fluid from the fluid lines. Ifnecessary, refer to the Fluidmove User Guide for instructions.

b. Manually activate the solenoid valve by pressing the push-button underneath the solenoidvalve to flush out all fluid in the fluid system, lines, syringe, or reservoir.


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3. Lower the fluid pressure to zero (0) and disconnect the clear pneumatic line (fluid pressure) andremove the syringe.

CAUTION! Follow Material Safety Data Sheet (MSDS) recommendations for the properhandling and disposal of fluids.

4. 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 forfuture reference.

Disassembling the DispenseJet

Cleaning and inspection require disassembly of major components and small and intricate parts of theDispenseJet. Refer to Figure 5-1, unless otherwise noted. This procedure assumes that the co-axial airsolenoid valve and nozzle are installed.

To disassemble the DispenseJet:

1. Using the provided torque wrench, remove the standard nozzle nut and co-axial air nozzle nut.

2. Remove the air tubing from the co-axial air nozzle nut.

3. Remove the co-axial air nozzle nut from the standard nozzle nut.

4. Loosen the micro-adjustment as follows:

a. Turn the micro-adjustment cap 4 to 6 turns counterclockwise.

b. Use the spanner wrench to loosen the lock nut.

c. Turn the preload screw to relieve compression on the compression spring.

5. Remove the seat extension and heater as follows:

a. Use the hex key to remove the two screws securing the heater and the seat extension to thelower body.

b. Separate the seat extension from the heater.

c. Remove the exposed large o-ring.

d. Set aside the disassembled parts for cleaning.

CAUTION! Handle o-rings and seals carefully. If o-rings or seals are damaged, leakage

or premature DispenseJet failure may occur.

NOTE The seat extension has special thermally-conductive grease applied to the non-threaded portion of the shaft. If the grease is accidentally removed, apply newconductive grease.


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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 sealintact.

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.Discard or replace the u-cup seal as appropriate.

b. Look for a broken needle tip or signs of wear marks such as polished streaks on the metalwhere it meets the u-cup seal.

8. Remove the elbow connector from the lower body by unscrewing it and set it aside for cleaning.

9. Leave the upper body, the solenoid air valve, and related parts in tact.

10. Further inspection and cleaning of the dissembled components and parts may be performed atthis time.


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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

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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, andconnector.

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 couldcause solenoid failure.

3. Further clean the seat extension, lower body, and elbow connector in a solvent bath ultra-soniccleaner.

4. Wipe the large needle clean with a solvent-soaked disposable towel.

5. Use an air gun to blow excess material from the DispenseJet fluid paths into a disposable towel.

6. Carefully inspect the interior of the cleaned components and parts to ensure they are free fromfluid residue and solvent. If parts are not clean, repeat steps 1 through 5 as necessary. Whenclean, proceed with step 7.

CAUTION! The needle and seat extension are a precision-fitted set. If one item is worn ordamaged, both items must be replaced. Do not mix parts from the old set with thenew set.

7. Clean the nozzles by following the instructions for "Cleaning the Nozzle" earlier in this section.

8. If desired, clean the solenoid valve by wiping it with a dry disposable towel while it is installed onthe Z-head mounting plate.

9. Carefully inspect the o-rings, u-cup seals, and Teflon gasket for wear or damage. Obtainreplacements as needed.

Reassembling and Reinstalling the DispenseJet

Once the components and parts are cleaned and replacements of worn or damaged parts are obtained, theDispenseJet can be reassembled and reinstalled to the Dispensing System.

To reassemble and reinstall the DispenseJet:

1. Gather the DispenseJet components, parts, and any replacement parts, on a flat surface.

2. Reassemble the lower body and the upper body as follows:

a. Carefully insert the small o-ring into the lower body.

b. Carefully install the lower body to the upper body and secure using the two hex headscrews.


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CAUTION! To prevent damage to the extension seat, verify that the micro-adjustment isopened 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 andprevent the formation of trapped-air pockets.

c. Carefully, install the large o-ring on the seat extension.

d. Align the dowel-pinhole on the seat extension to face toward the backside.

e. Install the seat extension/heater to the upper body using the two hex head screws and the7/64-inch hex key to tighten the screws.

4. Install the micro-adjustment.

5. Install the elbow connector into the lower body of the DispenseJet. The elbow connector shouldface upward.

6. If removed, install the co-axial air solenoid valve and the co-axial air nozzle nut. Refer to theinstructions in the Installation section.

7. Reinstall the DJ-2200 as described in “Installing the DJ-2200” in the Installation section.

Complete Overhaul Service

This procedure is intended to remedy problems identified in the “Troubleshooting ” section; such as the needto replace damaged or worn parts or to restore the functionality of the DispenseJet by a thorough cleaningafter continuous long production runs.

The following is covered in the Complete Overhaul Service:

• Disassembly of the DispenseJet

• Inspection and cleaning of disassembled parts

• Reassembly of the DispenseJet

• Settings and adjustments

NOTE For removal of DispenseJet from dispensing system and for initial disassembly of DispenseJetcomponents, follow instructions under “Purging the DispenseJet” earlier in this section. The

only steps described here are additional disassembly, inspection, cleaning, and re-assembly.


Use the same list of tools and material listed under “Purging the DispenseJet” earlier in this section.


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Disassembly of the DispenseJet

Inspect each part during the disassembly for wear and tear or damage. For parts replacement, remove anddisassemble 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 cannotbe 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. Remove the two hex head screws securing the solenoid valve from the upper body.

2. Remove the solenoid valve and set aside.

To disassemble the Micro-adjustment and associated parts (Figure 5-2):

1. Make a notation of the setting before disassembling the micro-adjustment.

CAUTION! Gently back-off the micro-adjustment to prevent damage to the needle and seatextension during disassembly.

2. Turn the micro-adjustment 4 to 6 turns counterclockwise to increase its setting.

3. Inspect the micro-adjustment for damage, wear and tear, or play in the moving mechanism. Ifdamaged, loosen the setscrews, remove the micro-adjustment and obtain a replacement.

4. Using the spanner wrench, loosen the preload lock nut.

5. Carefully remove the preload screw from the cap and the micro-adjustment while:

a. Observing the compression spring in the viewing window of the preload screw.

b. Counting the number of turns it takes to release contact on the compression spring.

6. Remove the compression spring from the cap.

7. Set aside the disassembled parts for cleaning and inspection.


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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.

CAUTION! To prevent damage to the tapered needle, do not use tools to grip the needlethreads.

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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 andcarefully remove the lower body from the needle and set it aside. Leave the needle intact in theupper 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.


1 Hex Head Screw (two) 4 Upper Body2 Fitting 5 Plug

3 Cap 6 Lower Body

Figure 5-3 Disassembly of Upper and Lower Bodies.

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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 module-adjusting wrench to loosen the spring retainer. Carefully remove the spring retainer and seal locknut.

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. Set aside removed parts for inspection and cleaning.

To remove the Co-axial Air Solenoid Valve:

1. Disconnect the co-axial air tubing from the co-axial air nozzle nut, the co-axial air valve electricalcable connector, and the blue air line from the dispensing system.

2. Remove the two co-axial air solenoid bracket mounting screws from the bottom of the Z-headmounting plate.

3. Set aside part for cleaning and inspection.


1 Air Piston (shown assembled) 5 Seal Lock Nut

2 Needle 6 O-ring

3 U-cup Seal 7 Air Piston

4 Spring Retainer 8 Upper Body

Figure 5-4 Removing the Needle and Disassembling the Air Piston

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Inspection and Cleaning of Disassembled Parts

CAUTION! Protect the Solenoid Valve, Heater, and Seat Extension from contact with coatingmaterial, and incompatible cleaning solutions or solvents. Contamination couldcause premature DispenseJet failure.

NOTE It is recommended that you replace o-rings and u-cup seals rather than clean them. New orclean o-rings must be treated with an o-ring lubricant.

To inspect and clean the disassembled components and parts:

1. Clean the needle, spring retainer and the seal lock nut thoroughly and inspect for cleanliness,damage, and wear and tear. Replace as needed.

NOTE Make sure to clean all threaded holes and body cavities thoroughly, and inspect forcleanliness, damage, wear and tear. If the needle has a worn tip or has polishedmetal streaks, replace it and the seat extension.

2. Clean the upper body and lower body exterior and interior cavities thoroughly and inspect forcleanliness, damage, and wear and tear. Replace as needed.

3. Clean the connector, plug, fitting, compression spring, cap, micro-adjustment, preload screw,preload lock nut, standard nozzle nut, and the co-axial air nozzle nut.

4. Clean the seat extension thoroughly and inspect for cleanliness, damage, and wear and tear.Replace as needed.

5. Clean the solenoid valve by wiping it with a dry disposable towel.

6. Clean the heater by wiping it with a dry disposable towel.

7. If electrical problems are indicated in the Troubleshooting section, use a multimeter to check thesolenoid valve, co-axial air solenoid valve, and the heater. Replace as needed.

Reassembly of the DispenseJet

The following instructions are for the preferred order of reassembly of parts disassembled during thecomplete service overhaul. Refer to “Purging the DispenseJet” earlier in this section when reassemblingother parts.

NOTE The DispenseJet should be assembled on a flat surface using appropriate tools andmaterials. Ensure all replacement parts are on hand before beginning.

CAUTION! Do not subject the electrical cables to stress during reassembly. Damaged cablescannot be replaced separately and can only be replaced with the next higherassembly.

CAUTION! Do not re-use a removed u–cup seal. Handle new o-rings and seals carefully. Ifo-rings or seals are damaged, leakage or premature DispenseJet failure may occur.


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NOTE The screws should be tightened to a torque of 1.36 N-m (12 in-lb), except where noted in theassembly 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. Using the ring and seal insertion tool, carefully seat the u-cup seal into the lower body.

c. Using the ring and seal insertion tool, carefully seat the o-rings to the u-cup seal into thelower body.

3. Set aside the assembled lower body.

To reassemble the Upper Body (Figure 5-5):

1. Install the u-cup seal to the upper body as follows:

a. Make sure the springy side of the u-cup seal is facing out.

b. Using the ring and seal insertion tool, carefully seat the u-cup seal into the upper body.

2. Using a flat-head screwdriver, install the fitting to the upper body in its correct place.

3. Using a flat-head screwdriver, install the plug to the upper body in its correct place.

4. Install the air hose to the air inlet of the upper body ensuring a secure fit

5. Set aside the assembled upper body.

To assemble the Lower Body, Upper Body, and Solenoid Valve (Figure 5-5):

1. Place the lower body and upper body on a flat surface and align the attachment holes.

2. Using the torque wrench, install the two screws through the lower body and the upper bodyensuring a secure attachment.

3. Place the solenoid valve on top of the upper body and align the attachment holes.

4. Using the torque wrench, install the two screws through the solenoid valve and the upper bodyensuring a secure attachment.

5. Set aside the assembled lower body, upper body, and solenoid valve.


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1 U-cup Seal 6 U-cup Seal

2 Upper Body 7 O-ring

3 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 threadedshaft.

2. Position the seat extension so that the dowel pinhole on the seat extension faces toward thebackside.

3. Rotate the seat extension into the heater to spread the conductive grease evenly and to avoidthe formation of air pockets.

4. Thoroughly wipe off any excess conductive grease from the seat extension threads.

To attach the Heater and Seat Extension to the Lower and Upper Bodies (Figure 5-6):

1. Position the heater and seat extension to the lower and upper bodies as shown in the illustration.

2. Align the attachment holes for the heater, seat extension, and the upper and lower bodies.

3. Using a torque wrench, install the two screws and tighten to a torque of 0.79 N-m (7 in-lb).

4. Set aside the assembled components.

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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. Using the o-ring lubricant, lubricate the seal area of the piston insertion tool and the inletarea of the upper body.

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d. Carefully install the air piston into the piston insertion tool so that the entire air piston iscompletely inside piston insertion tool.

e. Ensure that the air piston is installed without any gaps or folds and is evenly round.

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.

f. Turn the piston insertion tool upside down so that the air piston is facing down towards flatclean surface.

g. Using the o-ring lubricant, lubricate the o-ring and install the o-ring in the groove of thechamfered end of the seal lock nut.

h. Apply pressure to the seal lock nut while installing it in the top of the piston insertion tool andinto the air piston for a secure installation.

2. Using the o-ring lubricant, lubricate the threads of the needle.

3. Install the air piston to the needle as follows:

a. Place the piston insertion tool on the top of the needle.

b. Start turning the piston insertion tool clockwise a few turns to engage the needle threads.

c. Thread the seal lock nut onto the needle until the lip of the piston insertion tool seats in thechamber on top of the upper body.

d. Continue to turn the piston insertion tool until it disengages from the seal lock nut.

At this point, the top of the seal lock nut should be within 0.46-mm to 0.51-mm (0.018-inch to 0.020) above the top of the upper body.

e. Using the piston height gauge tool, place the notched edge across the seal lock nut so thatthe feet of the piston height gauge tool rest on the upper body surface.

No gap shall be visible under the notched feet or notch. If necessary, correct air pistoninstallation by repeating Step 3.

4. Gently pull up on the needle approximately 1/8–inch but do not pull the air piston out of the airpiston insertion tool.

NOTE Air piston adjustment is often necessary when you replace the upper body u-cupseal or the needle. In these cases, follow the disassembly and reassemblyinstructions in this section, but do not actually replace the air piston unless it isdamaged. Improper air piston adjustment may result in poor dot quality (dots notbreaking off from nozzle).

5. Place the spring retainer on the needle.

6. Using the module-adjusting wrenches, hold the seal lock nut in place and tighten the springretainer for a secure tight installation.

CAUTION! To prevent damage to the needle, do not over-tighten the spring retainer.

7. To properly seat the needle, ensure that the top of the seal lock nut is flush to above the top ofthe upper body.


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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. Using the spanner wrench, install the preload lock nut on the preload screw.

4. Perform the next step if the micro-adjustment has been replaced or removed from thepreload screw.

a. Insert the micro-adjustment into the preload screw.

b. Use a hex key to tighten the preload set screws.

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5. With the micro-adjustment attached to the preload screw, place the preload screw on thecompression 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.


1 Cap Micro-adjustment 5 Seat Extension

2 Preload Set screw (two) 6 Compression Spring

3 Preload Screw 7 Hex Head Screw (two)

4 Preload Lock Nut 8 Upper Body

Figure 5-8 Installing the Micro-adjustment and Cap

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Settings and Adjustments

There are two adjustment settings that must be performed after disassembly and cleaning of theDispenseJet:

• 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 thefluid 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.

This procedure requires the DispenseJet to be disassembled.

1. Turn the micro-adjustment clockwise until the compression spring touches the top of thepreload screw. Look through the window of the preload screw to see the point of contact. SeeFigure 5-9. This is the preload screw point of reference and is equal to zero (0) turns.

Check that the preload lock nut is positioned at its highest position above the preload screwwindow while turning (if it is lower, it will restrict movement).

Figure 5-9 Preload Screw Point of Reference

2. From the preload screw point of reference, turn the preload screw the desired number of turnsdetermined for your application.

3. Use the spanner wrench to tighten the preload lock nut to the top of the cap.

4. Gently turn the micro-adjustment clockwise to seat the needle into the seat extension.

5. Open the micro-adjustment by turning it counterclockwise to the desired setting.

NOTE The preload and micro-adjustment settings will vary for different fluids. ContactNordson ASYMTEK Technical Support for particular fluid settings.


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To adjust the Micro-adjustment:

The micro-adjustment setting regulates the fluid volume for the dot or line. The higher up the setting, themore fluid is dispensed.

NOTE The preload screw must be adjusted before performing this procedure. Refer to the “Toadjust the Preload:” procedure earlier in this section.

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 0.05-inch hex key, tighten the preload set screws, locking the preload screw in place.

4. Using your fingers, loosen the micro-adjustment lock nut by turning it counterclockwise.

5. Turn the outer micro-adjustment collar down and clockwise until it stops.

CAUTION! Do not continue to turn the outer micro-adjustment collar once it stops, or you maydamage the DispenseJet.

6. Use a 1.5-mm hex key to loosen the micro-adjustment collar set screw.

7. Raise and turn the outer micro-adjustment collar clockwise so that the vertical zero (0) markingaligns with the vertical centerline on the inner micro-adjustment column.

NOTE The bottom of the outer micro-adjustment collar should align with the horizontal zero(0) marking on the inner micro-adjustment column.

8. Using the 1.5-mm hex key, tighten the micro-adjustment collar set screw.

9. Rotate the outer micro-adjustment collar counterclockwise to set the micro-adjustment to thedesired parameter.

NOTE Every ten marks on the outer micro-adjustment collar equal 0.10-mm. For example, amovement of five marks equals 0.05-mm relative to your starting position. Only the

increment marks on the outer micro-adjustment collar are relevant for adjustment.

10. Finger-tighten the micro-adjustment lock nut.


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Troubleshooting 41

6 TroubleshootingTo quickly identify problems, look for obvious signs such as burnt, missing, damaged, or loose parts, as wellas fluid obstructions and leakages. If a problem recurs, there may be other root causes. Table 6-1 facilitatestroubleshooting based on symptoms. Refer to the Additional Information section for part identification.

Table 6-1 Troubleshooting

Symptom Possible Cause Recovery

DispenseJet is notcycle jetting.

No signal to the solenoidvalve.

Check the solenoid connector between theDispenseJet and the Dispensing System.

Air pressure to the solenoidvalve is Off or insufficient.

Check the configuration to verify DispenseJet isselected as Valve 1.

Verify that the air pressure is 483 to 621 kPa (70 to90 psi).

Fluid leaks fromweep hole.

Worn seal or needle.Inspect the needle and seal for excessive wear.Replace parts if necessary.

Lower seal missing. Install a seal and secure it with the retaining ring.

Fluid dots or lines donot form correctly.

The nozzle is clogged.

Clean the nozzle with a compatible solvent andbottlebrush.

If the nozzle cannot be cleaned, replace it.

No fluid beingdispensed.

No fluid in syringe, air bubble

in the flow path, or micro-adjustment set too low or isclosed.

Use one of the following steps to purge the

DispenseJet:

1. Manually actuate the solenoid valve.

2. Open the micro-adjustment.

3. Send a signal to the solenoid valve to allowmaterial flow through the DispenseJet.

NOTE: You may have to remove the nozzle beforepurging the DispenseJet. Check the syringeconnections and pressure.

The nozzle fluid path isclogged.

DispenseJet is not jetting.Refer to above symptom “DispenseJet is not cycle

jetting”

DispenseJet componentmalfunctioning.

Disassemble the DispenseJet and inspect theinternal parts. Replace parts if necessary.


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42 Troubleshooting

Symptom Possible Cause Recovery

Too much fluid witheach shot.

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.

Co-axial air not functioningduring dispense.

Check function of co-axial air through input/output.

Check “Config.ini. file, Valve 1” and verify the“Assist bit mask” is set to “64” and that “Assist onstate” is set to “64”.

The M-600 DispensingSystem co-axial air notfunctioning during dispense.


DispenseJetperforms but hasproblems after theco-axial air isinstalled.

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.

Co-axial air not functioningduring dispense.

Check function of co-axial air through input/output.


The M-600 DispensingSystem co-axial air notfunctioning during dispense.

Check “Config.ini. file, Valve 1” and verify the Assist bit mask is set to “8” and that Assist on Stateis set to “8”.

Fluid leaks throughthe seat extension,or poor dot quality(dots not breakingoff from nozzle).

Air piston/lock nut ispositioned too low.

Use the piston height gauge tool to ensure correctposition. See the Maintenance and Service section.

Seat extension isfrequently damagedor poor dot quality

(dots not breakingoff from nozzle).

Air piston/lock nut ispositioned too high.

Use the piston height gauge tool to ensure correctposition. See the Maintenance and Service section.


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44 Additional Information

Spare Parts

The recommended spare parts for the DJ-2200 DispenseJet are listed in Table 7-1 and Table 7-2. The itemnumbers shown in the table correspond with numbered callouts in Figure 7-3.

Table 7-1 Recommended Spare Parts for the DispenseJet

ItemNumber

PartNumber Description

1 226289 Micrometer Assembly with Lock

2 226276 Preload Screw

3 982745 Preload Set Screw (Socket set, 4-40 x 0.125)

4 145461 Preload Lock Nut

5 234299 Compression Spring

6 226277 Spring Retainer

7 168833 Seal Lock Nut

8 973529 Barbed Elbow Fitting (0.25-inch Stainless Steel Tube)

9 234154 Plug (M5, Stainless Steel)10 249942 Solenoid Valve (3-way, 24 DC, 120 PSI)

11 338751 Dispenser Cap

12 340721 Slotted Fillister Screw (6-32 x 0.5-inch)

13/17 322399 Tapered Needle Seat and Seat Extension

14 338763 Elbow, Pos., ¼ Tube x 1/8, 150 Thread

15 338752 Lower Body


18 234167 RTD Sensor Heater (8.5W, 24V DC)

19 982747 Socket Head Screw (6-32 x 1.75-inch)

20 322429 Nozzle Nut

Spares for optional Nozzles available for the DJ-2200 DispenseJet are listed in Table 7-2. The item numbersshown in the table correspond with numbered callouts in Figure 7-3.

Table 7-2 Nozzle Spares for the DispenseJet

ItemNumber

PartNumber

Description

21 391777 20 Gauge Selective Flux Nozzle










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The recommended spare parts of the optional co-axial air assist feature available for the DJ-2200DispenseJet are listed in Table 7-3. The item numbers shown in the table correspond with numbered calloutsin Figure 7-2.

Table 7-3 Recommended Co-Axial Air Assist Spares for the DispenseJet

ItemNumber

PartNumber

Description

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., .3 feet

Figure 7-2 Co-axial Air Assist

Table 7-4 lists the parts contained in the DJ-2200 Spare Parts Kit.

Table 7-4 DJ-2200 Spares Kit

Part Number Description Quantity

01-0022-00 Vacuum Boot, 0.120 inner diameter 6

940139 O-ring, (White) 0.313 x 0.438 x 0.06-inch 6

168824 U-cup Seal 6

719082 O-ring, (Black) 9/16 x 11/16 x 1/16 6

940090 O-ring (Brown) 1

115055 Air Piston 1

245773 Conductive Grease 3

58-0030 Dixie Cup, 1-oz, (200/pkg.) 1

58-0036 Round-tip Cotton Swabs, 6-inch wood handle (100/pkg.) 2

2

1


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Adjustment and Assembly Tools

Table 7-6 lists the Adjustment and Assembly Tools parts. The item numbers shown in the table correspondwith numbered callouts in Figure 7-3.

Table 7-6 Adjustment and Assembly Tools

Item Number Part Number Description

1 901911 Module Adjusting Wrench

2 145468 Spanner Wrench

3 226274 Torque Wrench (19 in-lb)

4 392652 Piston Height Gauge Tool

5 226302 Seal Insertion Tool

6 115059 Ring and Seal Insertion Tool

7 274973 Air Piston Insertion Tool

8 272821 Ring Removal Tool

9 234150 0.05-inch Hex Key

10 234149 1.5-mm Hex Key

11 234151 7/64-inch Hex Key

12 129612 3/32-inch Hex Key

Figure 7-3 Adjustment and Assembly Tools

8

7

11

10

12

5

6

9

1

2

3

4


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Mounting Brackets

The mounting brackets required for installation of the DispenseJet to Nordson ASYMTEK DispensingSystems platforms are listed in Table 7-8.

Table 7-8 Mounting Brackets

Mounting Bracket P/N Dispensing System391765 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 behelpful when ordering replacement parts for the Pump.

NOTE Not all parts shown on the exploded views are available separately. Contact Nordson

ASYMTEK Customer Service or your local distributor for availabil ity.

WARNING! CAUTION! The exploded views are intended only as an aid for part identification for orderingpurposes. Only Nordson ASYMTEK-trained service technicians should performservicing and parts replacement. Nordson ASYMTEK assumes no liability forpersonal injury or property damage that may occur as a result of service/partsreplacement performed by other than Nordson ASYMTEK-trained technicians.


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Additional Information 51

Item Part No. Description

1 322359 Top Assembly, Valve DJ-2200

Figure 7-5 DJ-2200 DispenseJet Exploded View (1 of 4)


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1 322359 Valve, DJ-2200

2 391765 C-730 Flux Bracket Assembly (Ref.)

3 64-HS-RTA Height Sensor Adj. Base A (Ref.)



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See Figure 7-8, DJ-2200 DispenseJet Exploded View (4 of 4) for the listed items below.


1 226289 Micrometer Assembly

2 982745 Preload Set Screw (Socket Set 4-40 x 0.125-in)

3 145461 Preload Lock Nut

4 226276 Preload Screw

5 234299 Compression Spring

6 226277 Spring Retainer

7 168833 Seal Lock Nut

8 940090 Seal Lock Nut O-ring

9 115055 Air Piston

10 322399 Tapered Needle and Seat (Order with Item 12)

11 322399 Seat (Order with Item 11)

12 168824 Upper Body U-cup and Seal


14 338751 Dispenser Cap

15 973529 Barbed Elbow Fitting (0.25-inch Tube, M5)

16 329412 Solenoid Valve (3-way, 24 DC, 120 psi)

17 340720 Screw, Skt, (4-40x1.00), BL

18 338750 Upper Body

19 234154 Plug (M5, 5S)

20 338763 Elbow, Pos., ¼ Tube x 1/8 ISO THD

21 338752 Lower Body


23 168824 U-cup Seal

24 940139 White (Chemraz®) O-ring

25 719082 Black (Kalrez®) O-ring

26 234167 Heater with RTD Sensor (8.5W, 24V DC)

27 234119 Teflon Gasket





28 391781 24 Gauge Selective Flux Nozzle28 391782 26 Gauge Selective Flux Nozzle




29 322429 Nozzle Nut

30 982747 Socket Head Screw (6-32 x 1.75-inch)

31 234167 Heater Connector Cable (Order with Item 26)


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Additional Information 55


32 234167 Temp Contr. Connector (Order with Item 26)

33 234167 Solenoid Valve Elect. Connector (Order with Item 26)



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Dispense 2200 nordson

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