spectrum-s900 nordson

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Spectrum SeriesS-900 Dispensing

Systems

Quick OperationsManual

P/N 7217657 Rev B


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P/N 7217657, Revisi on B ©2008

NOTICEThis is an Asymtek publication, which is protected by copyright. Original copyright date 2007. No partof this document may be photocopied, reproduced, or translated to another language without the priorwritten consent of Asymtek. The information contained in this publication is subject to change withoutnotice.

Manuals on the Internet

For the convenience of Asymtek customers and field service representatives, copies of Asymtek manualscan be downloaded from:

http://www.asymtek.com/support/manuals.htm

Contact Us

Asymtek welcomes requests for information, comments, and inquiries about its products. Please contactus using the information below:

Headquarters 2762 Loker Avenue WestCarlsb ad, 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.asymtek.com

Technical Support

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

Other regions : www.asymtek.com/support.htm

Trademarks Asymtek ®, DispenseJet ®, Fluidmove ®, and Heli-flow ® are registered trademarks of Asymtek.Spectrum™, Calibrated Process Jetting (CpJ™), Rapid Response Heater™, and Controlled Process Heat (CpH™)are trademarks of Asymtek.Microsoft ®, Windows ®, and Windows ® XP are registered trademarks of Microsoft Corporation.

http://www.asymtek.com/support/manuals.htmhttp://www.asymtek.com/support.htmhttp://www.asymtek.com/support.htmhttp://www.asymtek.com/support.htmhttp://www.asymtek.com/support/manuals.htm


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Introduction 1

Table of Contents

1 Introduction .. ....................................................................................................................................... 5

1.1 Overview.. ................................................................................................................................... 5 1.2 System Description.. ................................................................................................................... 5 1.3 Safety First.. ................................................................................................................................ 5 1.4 Manuals .. .................................................................................................................................... 6 1.5 Training .. ..................................................................................................................................... 6

1.5.1 Student Certification .. .................................................................................................... 6

1.5.2 Student Registration .. .................................................................................................... 6 1.6 Supported Dispensing Fluids.. .................................................................................................... 6 1.7 S-900N Series Standard Configurations.. ................................................................................... 7 1.8 Standard Equipment .. ................................................................................................................. 8

1.8.1 Automatic Pattern Recognition (Vision) System.. .......................................................... 8

1.8.2 Calibrated Process Jetting (CpJ™) .. ............................................................................. 8 1.8.3 Computer System .. ........................................................................................................ 8

1.8.4 Conveyor.. ...................................................................................................................... 8

1.8.5 Fluidmove for Windows XP Software .. .......................................................................... 9

1.8.6 Integral Height Sensor .. ................................................................................................. 9

1.8.7 Light Beacon .. ................................................................................................................ 9

1.8.8 Low Air Pressure Alarm.. ............................................................................................... 9

1.8.9 Mass Flow Calibration .. ................................................................................................. 9

1.8.10 Precision Pneumatics .. .................................................................................................. 9

1.8.11 Programmable Fluid and Valve Pressure (S-92XN).. .................................................... 9

1.8.12 Emergency Machine Off (EMO).. ................................................................................... 9

1.8.13 Interlock .. ....................................................................................................................... 9

1.8.14 Service Station... .......................................................................................................... 10

1.8.15 System Light ... ............................................................................................................. 10

1.8.16 Ventilation Exhaust System... ...................................................................................... 10

1.9 Optional Equipment ... ............................................................................................................... 10 1.9.1 CAD Import ... ............................................................................................................... 10

1.9.2 Laser Height Sensor ... ................................................................................................. 10

1.9.3 Low Fluid Sensor ... ...................................................................................................... 10

1.9.4 Needle Heater... ........................................................................................................... 10

1.9.5 Pre-Queue/Post-Queue Stations... .............................................................................. 10


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2 Introduction

1.9.6 SECS/GEM Interface... ................................................................................................ 11

1.9.7 Substrate Heaters... ..................................................................................................... 11 1.10 Dispensing Valves ... ................................................................................................................. 11 1.11 System Features... .................................................................................................................... 12

1.11.1 Dispensing Area... ........................................................................................................ 14

1.11.2 Service Station... .......................................................................................................... 16 1.11.3 Front Panel ... ............................................................................................................... 17

1.11.4 Front Cabinet ... ............................................................................................................ 18

1.11.5 Rear View ... ................................................................................................................. 20

1.11.6 Rear View Open... ........................................................................................................ 22

1.11.7 Rear Cabinet... ............................................................................................................. 24

1.11.8 Rear Panel Connections... ........................................................................................... 25

2 Safety... ............................................................................................................................................... 27

2.1 Overview... ................................................................................................................................ 27 2.2 Facility Requirements ... ............................................................................................................ 27 2.3 Intended Use... .......................................................................................................................... 27 2.4 Basic Safety Precautions and Practices... ................................................................................ 28

2.4.1 Safety of Personnel... ................................................................................................... 28

2.4.2 Material Safety... .......................................................................................................... 29

2.4.3 Preventing Dispensing System and Workpiece Damage... ......................................... 30 2.5 Lifting and Transport Precautions... .......................................................................................... 30

2.5.1 Considerations... .......................................................................................................... 30 2.5.2 Precautions... ............................................................................................................... 31

2.6 Earthquake Precautions ... ........................................................................................................ 31 2.7 Safety Warning Labels... ........................................................................................................... 32 2.8 Laser Radiation... ...................................................................................................................... 37

2.8.1 Laser Height Sensor Specifications... .......................................................................... 37 2.9 Emergency Shutdown... ............................................................................................................ 38

2.9.1 Emergency Shutdown Situations... .............................................................................. 39

2.9.2 Emergency Shutdown Recovery ... .............................................................................. 39 2.10 Interlock ... ................................................................................................................................. 39

2.10.1 Interlock Recovery ... .................................................................................................... 39 2.11 Service Shutdown... .................................................................................................................. 40

2.11.1 Lockout/Tagout of Electrical and Pneumatic Energy... ................................................ 40 2.12 Light Beacon ... .......................................................................................................................... 42


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Introduction 3

3 Calibration and Adjustment ... .......................................................................................................... 43

3.1 Overview... ................................................................................................................................ 43 3.2 Safety First... ............................................................................................................................. 43 3.3 Record Keeping ... ..................................................................................................................... 43 3.4 Startup/Shutdown ... .................................................................................................................. 43 3.5 Focusing the Camera... ............................................................................................................. 44 3.6 Calibrating the Camera... .......................................................................................................... 45 3.7 Service Station Height Adjustment ... ........................................................................................ 47 3.8 Calibrating the Scale... .............................................................................................................. 48 3.9 Z-Head Counterbalance Force Adjustment ... ........................................................................... 51 3.10 Adjusting the Height Sensor Probe... ........................................................................................ 52 3.11 Adjusting the Board Sensors ... ................................................................................................. 53

3.11.1 Program Output for Look Down Configuration (ASPA,196581 Fiber Array) ... ............ 54 3.12 Initializing the Digital Gauges ... ................................................................................................ 55 3.13 Adjusting the Lift Table Speed... ............................................................................................... 56 3.14 Adjusting Manual Airflow for Impingement Heaters (S-92X) ... ................................................. 58 3.15 Controlled Process Heat... ........................................................................................................ 60

3.15.1 CpH Configuration ... .................................................................................................... 60

3.15.2 CpH Cool Down... ........................................................................................................ 62 3.16 Software Controlled Light Beacon ... ......................................................................................... 63

4 Operation ... ........................................................................................................................................ 65

4.1 Overview... ................................................................................................................................ 65 4.2 Safety First... ............................................................................................................................. 65

4.3

System Startup ... ...................................................................................................................... 66

4.3.1 Powering on the Dispensing System... ........................................................................ 66

4.3.2 Starting Fluidmove for Windows (FmXP) ... ................................................................. 66 4.4 Installing the Dispensing Valve... .............................................................................................. 68

4.4.1 Valve Pneumatic and Electrical Connections ... ........................................................... 68 4.5 Adjusting the Air Pressure ... ..................................................................................................... 70

4.5.1 Adjusting the Main Air Pressure ... ............................................................................... 70

4.5.2 Adjusting the Cooling/Coaxial, Valve, and Fluid Air Pressure... .................................. 71

4.5.3 Adjusting the Vacuum Control ... .................................................................................. 74 4.5.4 Setting the Low Pressure Detection Threshold ... ........................................................ 74

4.6 Positioning the Conveyor and Dispensing Head ... ................................................................... 75

4.6.1 Using the Touchpad... .................................................................................................. 75

4.6.2 Using the Keyboard ... .................................................................................................. 81 4.7 Camera Operation ... ................................................................................................................. 82


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4 Introduction

4.7.1 Camera States... .......................................................................................................... 82

4.7.2 Lighting and Color Adjustment... .................................................................................. 83 4.8 Establishing Machine Offsets ... ................................................................................................ 85

4.8.1 Valve Offsets... ............................................................................................................. 85

4.8.2 Safe Z-Height... ............................................................................................................ 86

4.9 Creating a New Program ... ....................................................................................................... 88 4.9.1 Loading a Part... ........................................................................................................... 88

4.9.2 Setting the Heaters ... ................................................................................................... 88

4.9.3 Setting up the Fluid Manager... .................................................................................... 92

4.9.4 Workpiece Alignment... ................................................................................................ 93

4.9.5 Opening a New Program Window ... ............................................................................ 94

4.9.6 Teaching Fiducials... .................................................................................................... 95

4.9.7 Machine Setup... .......................................................................................................... 95

4.9.8 Attaching a Custom Fluid File... ................................................................................... 96

4.9.9 Entering Program Commands ... .................................................................................. 96

4.9.10 Saving the Program.... ............................................................................................... 102

4.9.11 Running the Program in Dry Mode .... ........................................................................ 103 4.10 Installing the Dispensing Fluid .... ............................................................................................ 103 4.11 Starting a Production Run.... ................................................................................................... 104 4.12 System Shutdown.... ............................................................................................................... 106

4.12.1 Post Production Shutdown .... .................................................................................... 106

5 Maintenance.... ................................................................................................................................. 107

5.1 Overview.... ............................................................................................................................. 107 5.2 Safety First.... .......................................................................................................................... 107 5.3 Record Keeping .... .................................................................................................................. 107 5.4 Routine Maintenance Procedures .... ...................................................................................... 108 5.5 Replacing Consumables.... ..................................................................................................... 109

5.5.1 Replacing Purge and Weigh Station Cups .... ............................................................ 110

5.5.2 Replacing the Purge Boot.... ...................................................................................... 112

5.6 Draining the Water Trap.... ...................................................................................................... 113 5.7 Removing the Axis Covers .... ................................................................................................. 114 5.8 Lubricating the Cables and Linear Guides .... ......................................................................... 115

5.8.1 Lubricating the Cables .... ........................................................................................... 115

5.8.2 Lubricating the X-Y Linear Guides.... ......................................................................... 117 5.9 Tensioning the Cables .... ........................................................................................................ 119 5.10 Tensioning the Conveyor Belts.... ........................................................................................... 120


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Introduction 5

1 Introduction1.1 OverviewThe Spectrum ™ 900N Series Systems are designed for inline production of semiconductor packagingprocesses, such as underfill, cavity fill, die attach, and encapsulation. This manual is intended primarily asa reference for production operators. However, process engineers and service technicians unfamiliar with

Asymtek products may also find this manual useful as a general introduction to the system. This sectionintroduces the Spectrum 900N Series (S-900N) Dispensing System and describes system configuration,lists the standard and optional features, il lustrates component location, and explains the function of thecomponents on the S-900N Dispensing Systems. This section covers the following topics:

• System Description • Standard• Manuals • Optional Equipment • Training • Dispensing Valves • Supported Dispensing Fluids • System Features • S-900N Series Standard Configurations

1.2 System DescriptionThe S-900N provides exceptional dispensing accuracy and repeatability, and is ideal for high-volumemanufacturing. The S-900N performs with a wide range of fluids, processes, and substrates used insemiconductor packaging and assembly. The S-900N easily integrates with jets and valves from

Asymtek, including the DispenseJet DJ-9000.

The system utilizes Asymtek’s Fluidmove ® software, the same industry-proven software package used onall Asymtek dispensing systems. Fluidmove and the S-900N’s flexible architecture makes it easy forcustomers to upgrade as needed, and provides the portability to develop programs offline that can betransferred to other sites or moved to inline systems.

Recommended applications include:

• Underfill • Lid Seal• BGA Solder Ball Reinforcement • Chip Encapsulation• Chip Scale Packaging • No Flow Underfill• Cavity Fill • Conductive Adhesive• Die Attach • Life Sciences

1.3 Safety FirstOperation of your S-900N Dispensing System involves heat, air pressure, electrical power, mechanicaldevices, and the use of hazardous materials. It is essential that every person servicing or operating thedispensing system fully understands all hazards, risks, and safety precautions. Refer to Section 2 - Safety for additional information.

WARNING! CAUTION! Consult the Material Safety Data Sheet (MSDS) for all fluids used with thedispensing system. The MSDS provides material usage instructions, disposalinstructions, and safety precautions.


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6 Introduction

1.4 ManualsYour Spectrum Series S-900N Dispensing System arrives with manuals for installation and operation ofmajor system components and software. For some system components, you may receive OriginalEquipment Manufacturer (OEM) manuals. Generally, these OEM manuals are only needed for referenceand advanced troubleshooting. Consult only Asymtek manuals unless directed to do otherwise by themanuals themselves or by Asymtek Technical Support

Below is a sample list of additional manuals that may be shipped with your Spectrum Series S-900NDispensing System, depending on system configuration.

• Fluidmove User Guide• Dispensing Valve Owner’s Manual (specific to your valve)• Original Equipment Manufacturer Manuals (as applicable)

1.5 Training Asymtek offers quality training for our dispensing platforms, valves, software, and applications both onand off-site. The labs at our Carlsbad, California, USA corporate location are dedicated to providing aspecialized course of instruction for our customer's specific needs. With the assortment of tools available

in our labs we are able to provide a better learning experience overall. Students will rebuild machinesubassemblies, troubleshoot real problems, and learn a variety of setup techniques. In addition, yourmachine's operability and production are not disturbed due to class usage.

1.5.1 Student Certi fication

Upon successful completion of the training course, the student is issued a Certificate of Completion.

1.5.2 Student Registration

Students can register for training at the Asymtek website www. asymtek.com/support/training or call1-800-ASYMTEK to request information or to register for training.

1.6 Supported Dispensing FluidsThe S-900N was designed for dispensing the following materials. Contact Asymtek for materials notlisted.

• Flip Chip & CSP Underfill materials• Dam and Fill Encapsulation materials• LED Encapsulation materials (silicon based)• Lid Seal materials• Reagent dispense materials

• Silicones NOTE It is the responsibility of the end-user to consult the Material Safety Data Sheet (MSDS)

for all fluids used with the dispensing system. The MSDS provides material usageinstructions, disposal instructions, and safety precautions.

http://www.asymtek.com/support/traininghttp://www.asymtek.com/support/training


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Introduction 7

1.7 S-900N Series Standard Configurations

System Features S-91XN S-92XN

ApplicationsEdge-Bond, Corner-Bonding,

SMA, Solder Paste, UVBonding, CMOS Imaging

Underfill, Encapsulation, WireCoating, Dam & Fill

Part ConveyanceStand alone\ In-Line Conveyor In-line In-line

Dual Lane Option Yes (S-912N) Yes (S-922N)

Number of Stations 1 or 2 (optional 3-6) 1 or 2 (optional 3-6)

Conveyor Belt ESD O-ring, ESD High Temp6-mm & 4-mm Flat BeltsESD O-ring, ESD High Temp

6-mm & 4-mm Flat Belts

Vision & Illumination

Vision Auto PR/Digital Camera Auto PR/Digital Camera

Part Illumination Red/Blue Red Blue

Dispense Tip Position & Maintain

Height Sensor Mechanical(Laser Option)Mechanical

(Laser Option)

Tactile Z sensor Yes Yes

Needle Finder No No

Mass Flow Calibration Option Yes

Purge Cup Yes Yes

Heater Options and Control

Heaters No

One- to three-station heat

control, vacuum orimpingement(up to 6 with S-922N)

Proc Dev Hot Plate No No

Controlled Process Heat (CpH) No Option

Miscellaneous

Low Fluid Alarm Option Option

Low Pressure Sensor Yes Yes

Programmable Fluid and ValvePressure Option Yes

Beacon Yes Yes

Clean Room Version / Option Class 1000 Class 1000

Power Manager (10A)Power Manager (30A)Power Manager (Japanese)

StandardOptionOption

OptionStandard

Option

Hatch (ESD Plastic)Hatch (Glass)

StandardOption

StandardOption


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8 Introduction

1.8 Standard Equipment

1.8.1 Automatic Pattern Recognit ion (Vision) System

The Vision System consists of a Dalsa-Coreco Genie M640 digital 640 x 480 pixel camera, light source,and laptop computer. The software consists of Fluidmove for Windows and its pattern recognition engine.The vision system serves three purposes:

• It allows the operator to teach dispensing locations on the substrate. The operator views alive image of the camera’s target and uses the graphical user interface to create thedispensing sequence.

• It automatically aligns the user generated dispensing sequence to the actual position of thesubstrate during run operations. This is made possible by the advanced pattern recognitionsystem that compares expected and actual fiducial locations on the substrate. Corner finderand bitmap model finders are supported as well as a pattern skip feature.

• It is employed during the prompted setup routine to establish the vision-to-needle offsets andservice station locations.

The Dalsa-Coreco Genie M640 replaces the earlier analog cameras used with the ITI PCVision framegrabber. It communicates bi-directionally to a host computer via Gigabit Ethernet. No frame grabber is

required. The camera is currently configured to run at 60 full frames per second which is twice as fast asthe analog PCVision cameras. A frame can be transferred in 16.67 milliseconds.

Diffuse on-axis lighting (DOAL) provides for consistent substrate illumination with color temperature andintensity controlled through the software interface. Substrate images taught during programming (alongwith the lighting levels) are stored with the program, and are automatically retrieved when loading theprogram.

1.8.2 Calibrated Process Jetting (CpJ™)

With this feature, volumetric repeatability can be maintained during long production runs to improveprocess capability (Cpk) when dispensing fluids with one of Asymtek's DispenseJets. Dispense patternsare programmed with a specified weight. CpJ periodically samples the dispense weight per shot, and thencomputes the number of shots for each pattern. With this information, CpJ optimizes line speed based onmaximum specified shot interval.

1.8.3 Computer System

The Computer System consists of a laptop computer with an adjustable height bracket. It runs Fluidmovefor Windows XP (FmXP) software.

1.8.4 Conveyor

The Conveyor allows parts to be conveyed from upstream systems to the dispensing station, and then todownstream systems. All conveyors are SMEMA compatible and have adjustable rear rail width. Theconveyor system uses multi-move technology which allows parts to move concurrently. This aidsthroughput by minimizing conveyor time. The system is available with either a single lane or dual laneconveyor configuration.

The Dual Lane Conveyor allows parallel processing on two lanes for continuous dispensing, eliminatinglost time in non-dispensing activities. In some applications, a 60 to 80 percent increase in throughput canbe achieved with a dual lane versus a single lane conveyor. The conveyors are independently controlled,allowing different-sized parts to be processed in each lane for ultimate process flexibility.


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Introduction 9

1.8.5 Fluidmove for Windows XP Software

Fluidmove for Windows XP (FmXP) is Asymtek proprietary software for use in a Windows XPenvironment, developed specifically for dispensing applications.

1.8.6 Integral Height Sensor

The Integral Height Sensor allows increased positional accuracy in fluid dispensing by automatically

controlling the gap of the dispense tip to the surface of the workpiece.

1.8.7 Light Beacon

The Light Beacon is an indicator device for the operator. The beacon signals a dispensing statuscondition by displaying a colored light and/or issuing an audible alarm. See 2.12 Light Beacon .

1.8.8 Low Air Pressure Alarm

The Low Air Pressure Alarm sounds when the system air pressure is too low. The low air pressurethreshold value can be set through the Fluidmove software. Refer to the Fluidmove User Guide or OnlineHelp for additional information.

1.8.9 Mass Flow CalibrationMass Flow Calibration (MFC) is a patented feature that enables the user to specify the mass to bedispensed as a separate parameter within the dispensing elements. This is made possible by using ahigh precision scale to take flow rate measurements. The Fluidmove software features a fluid managerwhere the user specifies how the flow rate is to be taken. This helps to ensure a statistically meaningfulflow rate value is obtained. MFC has two major benefits. First, it ensures the right amount of material isdispensed for each part from the beginning to the end. Second, it reduces setup times on a daily basis byautomatically compensating for changes in viscosity or fluid delivery flow rate.

1.8.10 Precision Pneumatics

The S-900N features digital valve, fluid, and coax/cooling pressure gauges for high accuracy and easysetup. They regulate the air pressure required for the fluid reservoir. See 3.12 Initializing the DigitalGauges for additional information.

1.8.11 Programmable Fluid and Valve Pressure (S-92XN)

Electro pneumatic regulators control the valve pressure, fluid pressure and cooling/coaxial pressure.These regulators have been integrated into the platform such that all the pressure setpoint values are setthrough Fluidmove (as opposed to manual regulators). This reduces possibility of operator error whensetting the regulators manually. It also allows the user to import a recipe that includes all the pressure setpoints. Programmable Fluid and Valve Pressure is standard on the S-92XN and optional on the S-91XN.

1.8.12 Emergency Machine Off (EMO)

The S-900N Series Dispensing System features an EMO button that the operator or service techniciancan use to immediately stop all dispensing operations in case of emergency. This feature helps preventinjury to personnel and damage to the dispensing system and workpieces.

1.8.13 Interlock

The Interlock is a built-in safety feature that automatically removes dispensing system servo motor power,stopping all dispensing activity, when the hood is opened. This prevents personnel from being injured bymovement of the Dispensing Head and Conveyor.


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10 Introduction

1.8.14 Service Station

The Service Station consists of a needle vacuum purge cup, on-board high precision scale, and a needlecalibration substrate. The Vision Assisted Prompted Setup routine enables the user to teach the servicestation locations for fast and easy system setup. Refer to the Fluidmove User Guide or Online Help forinformation on Vision Assisted Prompted Setup.

1.8.15 System Light

The dispensing system features a light that illuminates the dispensing area when the system is on.

1.8.16 Venti lation Exhaust System

The Ventilation Exhaust System works in conjunction with the facility exhaust system to remove excessheat, fumes, or odors into an exhaust vent, not into the room. The system can be configured as eitherdown or updraft and can remove fumes – lighter and/or heavier than air. It baffles direct vapor and mist toa spill pan and is exhausted through a plenum.

1.9 Optional Equipment

1.9.1 CAD Import

CAD Import is an optional software utility used for surface mount adhesive or solder paste applications. Itenables the user to import ASCII CAD data for automated program generation. CAD Import comescomplete with a JEDEC component library.

1.9.2 Laser Height Sensor

The non-contact Laser Height Sensor provides high-speed dispense height measurement for delicatesubstrates, hybrids, and integrated circuits that may be compromised by tactile sensing. Refer to 2.8 Laser Radiation for important safety information regarding the Laser Height Sensor.

1.9.3 Low Fluid Sensor

Low fluid sensing can be accomplished by installing capacitive or magnetic sensors on the fluidreservoirs. In addition, low fluid sensing can be accomplished through the software, which features fluidusage tracking. By inputting the fluid mass contained in the reservoir, the software can keep track ofmaterial usage during dispensing. Both low and critically low values can be monitored. When a low fluidcondition is detected, the Light Beacon changes from green to blue. Additionally, the Fluidmove softwaredisplays yellow (caution), and then red (critical) user warnings for low fluid conditions in the Run Window.

1.9.4 Needle Heater

The Needle Heater is an RTD-controlled heating element that provides needle heat on the DV-7000 andDV-8000 Dispensing Valves and nozzle heat for the DJ-9000 Dispense Jet. The Needle Heater heats thedispensing fluid to maintain a consistent viscosity and flowrate. The Fluidmove software controls theheater temperature.

1.9.5 Pre-Queue/Post-Queue Stations

Pre-and post-queue stations without heat can be added for higher throughput or as buffer stations. Inaddition, heat can be added to the S-92XN Series pre-and post-queue stations. The S-92XN Series canbe configured with pre-dispense, dispense and post-dispense heat.

The S-900N Series can be configured with single or dual-lane conveyors. A dual-lane configuration(S-922N) can accommodate up to six (6) heaters. This configuration is ideal for applications with longpreheat cycles or long flow-out times.


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12 Introduction

1.11 System FeaturesThe figures in this section show views and features of the dispensing system. Callouts locate majorcomponents, options, and switches seen in each illustration. Detailed operating instructions for some ofthese features are treated in other sections of this manual. System features are shown in Figure 1-1 toFigure 1-9 .

Figure 1-1 A S-920N

1

3

4

2

5


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Introduction 13

Figure 1-1B S-920N with Optional Pre- and Post-Queue Stations

Item Name Descript ion

1 Light Beacon The Light Beacon is a device that displays system status and can warnthe operator when fault conditions exist.

2 Dispensing Area The Dispensing Area is where all dispensing operations take place.See 1.11.1 Dispensing Area .

3 Front PanelDigital Valve, Fluid and Coax/Cooling Pressure Gauges, ON and OFFButtons, Emergency Stop, and Grounding Strap Jacks are located onthe Front Panel. See 1.11.3 Front Panel .

4 Computer The Dispensing System features a laptop computer which runs theFluidmove for Windows XP (FmXP) dispensing software.

5 Exhaust Vent The Ventilation Exhaust System works in conjunction with the facilityexhaust system to remove excess heat, fumes, or odors.

6 Pre-Queue StationThe optional pre-queue station can be added for higher throughput oras a buffer station. In addition, the S-92XN Series can be configuredwith pre-dispense heat.

7 Post-Queue StationThe optional post-queue station can be added for higher throughput oras a buffer station. In addition, the S-92XN Series can be configuredwith post-dispense heat.

Figure 1-1 S-920N Front View

67


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14 Introduction

1.11.1 Dispensing Area

Figure 1-2A S-920N Front View (Open Dispensing Area)


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16 Introduction

1.11.2 Service Station


1 Dispense Tile The Dispense Tile is a ceramic tile dispensed upon during systemoffset routines.

2 Tactile Needle Sensor The Tactile Needle Sensor measures needle/nozzle position in theZ-axis.

3 Purge Station

The Purge Station consists of a small reservoir that contains adisposable plastic cup and is attached to a vacuum generator. Airflowing through the purge boot into the cup removes excess fluid onthe dispensing valve needle/nozzle.

4 Scale

The scale measures the weight of dispensed fluid and sends theinformation to the Fluidmove software for mass flow calibration. Thescale is standard on S-92X systems and an option on S-91Xsystems.

Figure 1-3 Service Station

1 2 3

4


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18 Introduction

1.11.4 Front Cabinet

Figure 1-5A Front Cabinet (S-912N Dual Conveyor System)

1 2 34

7

6

5


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Introduction 19

Figure 1-5B Front Cabinet (S-922N Dual Conveyor System - Dispense Heat Only)

NOTE The S-92XN Series features programmable fluid and valve pressure. Air pressure is setthrough the FmXP software. This feature is an option on the S-91XN Series Systems.


1Vacuum AirRegulator

Controls the vacuum level applied to fluid pressure air line when pressure

is turned off. The vacuum helps prevent residual pressure buildup in thesyringe that may cause fluid drip.

2 Cooling/Coaxial AirRegulatorControls the air pressure supplied to either the valve cooling air port orthe DJ-2200 coaxial air assist, depending on machine configuration.

3 Valve PressureRegulator Controls the air pressure supplied to the dispensing valve.

4 Fluid PressureRegulator Controls the air pressure supplied to the fluid syringe.

5 Conveyor/HeaterModules

Controls all conveyor functions (motors, sensors, pneumatics, etc.). Itreceives power from the Power Manager and supplies AC power to thesubstrate heaters in the dispensing area. If your system is equipped withdual conveyors, two Conveyor/Heater Modules are required.

6 ImpingementFlowmeters (S-92X)

Controls the airflow through the impingement heaters in the dispensingchamber. A manual shut-off valve controls the air going to the flowmeters.NOT USED ON THE S-91X.

7 Tooling AirRegulator

Controls the air pressure supplied to the stop pins and lift tables. Theregulator receives air from the main air regulator located on the back ofthe dispensing system.

Figure 1-5 Front Cabinet


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20 Introduction

1.11.5 Rear View

Figure 1-6A Rear View (30A Power Manager shown)

2

3

4

1

5


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Introduction 21

Figure 1-6BMain Air Regulator and Gauge Sets (Close-up)


1 Main Air Regulatorand Gauge

The system is equipped with two Main Air Regulators and Gauges. Theycontrol the air pressure supplied to all other system regulators. Theregulators contain built-in air filter and water traps to ensure that onlyclean, dry air enters the system. Refer to 4.5 Adjusting the Air Pressure for the recommended pressure settings and other important information.

2 Rear EMO

The Rear EMO is a built-in safety feature located on the rear panel of thedispensing system. Activating the EMO vents all pressure in thepneumatic system, de-energizes the servo power, and cuts power to allsystem components except the computer.

3 Main Circuit Breaker

The Main Circuit Breaker is the main power switch for the dispensingsystem. It protects the dispensing system from facility power surges andcontrols the flow of facility AC power supplied to the Power Manager. Aflange to the right of the Main Circuit Breaker allows it to be locked in theOFF position during servicing. Switching OFF the Main Circuit Breakercuts power to all dispensing system electrical components.

4 Main Power Cord The Main Power Cord connects the dispensing system to the facilitypower supply (30A power cord shown).

5 Rear PanelConnections See 1.11.8 Rear Panel Connections .

6 Water TrapThe facility air supply may contain moisture that can damage thedispensing system. The Water Trap condenses this moisture before itenters the dispenser pneumatic system.

Figure 1-6 Rear View

6

Conveyor/HeaterPneumatics

Fluid/ValvePneumatics


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22 Introduction

1.11.6 Rear View Open

Figure 1-7A Rear View Open (S-910N)

1

2

3

4


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Introduction 23

Figure 1-7 B Rear View Open (S-920N with Pre-Queue and Post-Queue Stations)


1 Upper E-PanThe Upper E-Pan houses the Dispense Head Controller, Z-Axis Servo

Amp, and Applicator Pneumatics.

2 Lower E-Pan The Lower E-Pan houses the Mainboard, X-Y Axis Servo Amps, Main AirPneumatic Valves, and Conveyor Pneumatic Valves.

3 Rear Cabinet The Rear Cabinet houses the Power Manager and the Conveyor/HeaterModule(s). See 1.11.7 Rear Cabinet .

4 Rear PanelConnections See 1.11.8 Rear Panel Connections .

Figure 1-7 Rear View Open

2

1

3

4


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24 Introduction

1.11.7 Rear Cabinet


1 Power Manager

(30A shown)

The Power Manager is located inside the rear cabinet. It houses theMain Circuit Breaker and the Main Power Inlet. It also contains the

EMO circuitry. The EMO button, the green ON (I) button, and the blackOFF (0) button are directly connected to the Power Manager.

2 Conveyor/HeaterModule

The Conveyor/Heater Module receives power from the Power Managerand supplies AC power to the substrate heaters in the dispensing area.It also controls all conveyor functions (motors, sensors, pneumatics,etc.). If your system is equipped with dual conveyors, there will be twoConveyor/Heater Modules.

Figure 1-8 Rear Cabinet (S-920N)

1

2


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Introduction 25

1.11.8 Rear Panel Connections


1 CV2 Downstream Allows for SMEMA communication between Conveyor 2 and adownstream machine such as an unloader.

2 CV2 Upstream Allows for SMEMA communication between Conveyor 2 and an upstreammachine such as a loader.

3 Loader/Up Allows the dispensing system to communicate with an upstream loaderfor programming purposes only.

4 Loader/Down Allows the dispensing system to communicate with a downstreamunloader for programming purposes only.

5 Network Allows the dispensing system to communicate with a host computer on alocal area network. Necessary for SECS/GEM functionality.

6 CV1 Downstream Allows for SMEMA communication between Conveyor 1 and adownstream machine such as an unloader.

7 CV1 Upstream Allows for SMEMA communication between Conveyor 1 and an upstreammachine such as a loader.

Figure 1-9 Rear Panel Connections

NOTE CV2 connectors are only present on S-912N and S-922N dual conveyordispensing systems.

1

2

3

6

7

4

5


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Safety 27

2 Safety2.1 OverviewThis section is intended to provide basic safety information necessary for operating and servicing theSpectrum S-900N Series Dispensing System. This section covers the following topics:

• Intended Use • Laser Radiation • Basic Safety Precautions and Practices • Emergency Shutdown • Lifting and Transport Precautions • Interlock • Earthquake Precautions • Service Shutdown • Safety Warning Labels • Light Beacon

To further optimize safe dispensing system operation, precautions and recommended practices areincluded with the procedures throughout this manual.

WARNING! CAUTION! Unsafe equipment conditions can result in personal injury or property damage.Failure to properly operate and maintain the system in accordance with thismanual could cause the built-in safety features to be ineffective.

NOTE Safety is considered a joint responsibility between the original equipment manufacturer(Asymtek) and the end-user (owner). All safety precautions and practices should be inaccordance with local regulations and facility policy.

2.2 Facili ty RequirementsTo ensure optimal performance and safety, it is necessary to install the dispensing system in a facility thatmeets the necessary requirements. Refer to the S-900 Installation, Operations, and Maintenance Manual for details. If you have any questions, please contact Asymtek Technical Support.

2.3 Intended UseUse of Asymtek equipment in ways other than those described in the documentation supplied with theequipment may result in injury to persons or damage to property. Some examples of unintended use ofequipment include:

• Using incompatible materials• Making unauthorized modifications• Removing or bypassing safety guards or interlocks• Using incompatible or damaged parts• Using unapproved auxiliary equipment• Operating equipment in excess of maximum ratings


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28 Safety

2.4 Basic Safety Precautions and PracticesCompliance with the following recommended precautions and practices reduces the risk of personal injuryor damage to property during S-900N Series Dispensing System operation and maintenance.

WARNING! CAUTION! Failure to comply with any of the safety recommendations could cause seriousinjury to the user or damage to the dispensing system.

2.4.1 Safety of Personnel

• Only trained personnel should be permitted to perform operation, maintenance, andtroubleshooting procedures

• There should always be a second person present when performing maintenance on a systemunder power.

• Locate, identify, and obey all safety warning labels on your system before initial use. Refer to2.7 Safety Warning Labels for details.

• Immediately push the red Emergency Machine Off (EMO) button if personnel are in danger ofbeing injured.

• Lock out and tag out power and disconnect facility air to the dispensing system beforeperforming service or maintenance on the dispensing system. Refer to 2.11 ServiceShutdown for details.

• Lock out and tag out power to upstream and downstream machines before performingservice or maintenance on the dispensing system.

• When using conveyorized machines as stand alone equipment (not inline), make sure themachine is configured with the optional Conveyor Closeout Kit (P/N 7214478) to preventpersonal injury and equipment/workpiece damage.

• Do not wear loose clothing or jewelry while operating the system. Tie back long hair toprevent it from being caught in moving parts.

• Do not touch the dispensing head or other moving parts while the dispensing system isoperating.

• To prevent burn injury, wear thermal gloves when working around heater tooling and fluidheaters.

• If your system is equipped with a laser height sensor, use extreme care to avoid lookingdirectly at the laser beam or its reflection off of mirror-like surfaces. Refer to 2.8 LaserRadiation for details.

• Make sure the main power cable and main air supply hose are securely connected beforeoperating the dispensing system.

• If in a confined room, ensure adequate and uninterrupted air ventilation, and heating andcooling meet environmental stress limits of personnel and the dispensing system.


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Safety 29

• Where volatile organic compound (VOC) emissions can exceed safe limits, facility ventilationand filtration systems must be operational.

• Provide adequate space around the dispensing system to allow for movement ofmaintenance and service personnel. Allow space for access doors and service panels toopen fully.

• Make sure all facility power sources are safely grounded.

• Routinely inspect all air hoses and electrical cables for damage.

• Make sure power cords and air supply hoses do not cross a walkway or aisle.

• Before attempting to lift a load, take into consideration facility lifting and transportprecautions. See 2.5 Lifting and Transport Precautions .

• Maintain a clean and orderly work area.

2.4.2 Material Safety

• Follow Material Safety Data Sheet (MSDS) recommendations for the proper handling,cleanup, and disposal of all materials and fluids and their containers (i.e., syringes, cups,reservoirs, etc.) used with the dispensing system.

• Follow MSDS recommendations for the proper handling and disposal of all materials whencleaning dispensing equipment and spills.

• Make sure the dispensing system ventilation is ON during handling and cleanup of allmaterials used with the dispensing system.

• Know the MSDS recommendations for treatment of injury resulting from exposure tohazardous materials.

• Always wear appropriate personal protective equipment (PPE) as recommended by facilitysafety practices and the material manufacturer’s MSDS.

• When working with multiple fluids, refer to the MSDS to ensure the materials are compatible.

• If possible, save or recycle unused materials. Refer to the MSDS before saving or recyclingunused materials.


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Safety 31

2.5.2 Precautions

When lifting, transporting, and lowering heavy or large loads, personnel should observe the followingprecautions:

• Stand close to the load to be lifted and place your feet at shoulder width.• Firmly grip the load and bring the load close to your body.

• Lift your head and shoulders first and with your back straight, use the strength of your legs toslowly and smoothly raise yourself up.• DO NOT twist your body. Change direction by first moving your feet.• When transporting the load on a cart or a lifting device, reduce back strain by pushing rather

than pulling the load.

• When lowering the load, bend your knees, lower it slowly and smoothly, and keep yourfingers out from under the load.

2.6 Earthquake PrecautionsIn the event of an earthquake, your dispensing system must be secured to prevent movement that

could cause injury to personnel and damage to the dispensing system and facility. Each dispensingsystem leveler (foot) should be anchored to the floor. Refer to the S-900 Installation, Operations, andMaintenance Manual for details.

As a safety precaution, all hazardous electrical and pneumatic energy is automatically bled out of thesystem if electrical power is lost.

WARNING! All personnel should follow facility earthquake safety guidelines.


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32 Safety

2.7 Safety Warning LabelsSafety warning labels on the S-900N Series Dispensing System point out potentially hazardous areas andremind personnel to take necessary safety precautions. Table 2-1 describes safety warning labels thatmay be on the dispensing system.

WARNING! CAUTION! Comply with all safety warning labels or serious injury to personnel or damage tothe dispensing system may occur. Worn or damaged labels should be replacedwith new labels having the same part number.

Table 2-1 Safety Warning Labels

Warning Type Symbol PartNumber (1) Hazard

Electrical(Shock Hazard)

70-0116-00(1)

or

70-0050-00 (2)

This label warns of a high-voltage component that cancause shock, burn, or death. Use extreme cautionwhen working in or around these areas.Disconnect and lock out power before servicing.

GeneralWarning 70-0055-00

(2)This label identifies a component that requires specialattention. Can cause serious bodily harm to the user.Disconnect and lock out power before servicing.

Heavy Object(Lifting Hazard)

70-0118-00(1)

or

196666(2)

This label warns that the labeled component is heavyand can cause muscle strain or back injury topersonnel trying to lift it.

Moving PartsPresent

70-0120-00(1)

or

198883(2)

This label warns of moving parts that can causeserious injury to hands or fingers. Keep hands awayfrom moving parts.

Disconnect and lock out power before servicing.Hand

Entanglement/Moving Material

7214364(1)

This label warns of moving parts that can causeserious injury to hands and fingers.Disconnect and lock out power before servicing.

Hot Surface70-0121-00

(1)

or

70-2150-00(2)

Thermal warning labels identify potentially hotcomponents and surfaces. Use extreme caution whenworking on or around these areas.Can cause severe burns.

Laser 7206858(2)

Warns personnel of the possibility of hazardousradiation exposure if your system is equipped with aLaser Height Sensor or other laser device.

ConsultOperator’sManual

7206854 Warns personnel to read Operator’s Manual beforeoperating machine.

Notes: (1) Rectangular labels with symbols and text. These labels are placed on machines that are shipped anywhere but theEuropean community.

(2) Triangular labels with symbols only. These labels are placed on machines that are shipped to the Europeancommunity, referred to as “CE labeled” machines.


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Safety 33

Item Description

1 Read Manual Label

Figure 2-1 Safety Warning Labels (Front Cover)

Item Description

1 Laser Radiation Warning Label (if Laser Height Sensor present)

Figure 2-2 Safety Warning Labels (Front Inside Panel)

1

1


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34 Safety

Item Description

1 Laser Radiation Warning Label (if Laser Height Sensor present)

2 Hot Surface Label (if heaters present)

Figure 2-3 Safety Warning Labels (Dispensing Area)

1

2


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36 Safety

Item Description

1 Electrical Warning Label

Figure 2-6 Safety Warning Labels - Power Manager

1


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Safety 37

2.8 Laser Radiation

WARNING! The Height Sensor contains a Class 2 laser. DO NOT look directly at the laserbeam. Looking directly at the laser beam may result in serious eye injury.

If your S-900N Series Dispensing System is equipped with the optional laser height sensor, the followingsafety precautions should be observed in addition to the basic system safety precautions:

• Operate the laser height sensor in accordancewith the operator’s manual included with theequipment. Failure to do so may result in injurydue to exposure to the laser beam.

• DO NOT disassemble the sensor head. Laseremission from the height sensor is notautomatically stopped if the sensor head isdisassembled.

• DO NOT look directly at the laser beam or itsreflection.

• Wear protective goggles when using the laserheight sensor.

• Check the laser beam path. DO NOT install theheight sensor in such a way that the laser beampasses at eye level.

• DO NOT open the hood while the laser is on.

NOTE The laser beam is not harmful to the skin sothere is no danger in exposing arms or handsto the beam. The only possible health hazardis in exposing the eyes to the laser beam,which could result in serious eye injury. Figure 2-7 Laser Height Sensor

2.8.1 Laser Height Sensor Specifications

Table 2-2 contains Laser Height Sensor specifications.

Table 2-2 Laser Height Sensor Specifications

Classification Class 2 Laser ProductLight Source Red semiconductor laser ( λ = 670 nm)

Maximum Output 1.0 mWEmitted Wavelength 670 nmSpot Diameter 110 μm at reference distanceReference Distance and Range 70 mm ± 15 mm (2.75 in. ± 0.6 in.)

Environmental Range 0 to 55 °C0 to 85% RH Ambient Light 4,000 lux max


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38 Safety

2.9 Emergency ShutdownIn the event of an emergency or malfunction, press the EMO button. The S-900N Series has two EMObuttons. The EMO buttons are the large red buttons located on the front panel and the rear of thedispensing system (Figure 2-8). Activating the EMO vents all pressure in the pneumatic system and cutspower to all components except the laptop computer, the camera, the interior light, and the light beacon.

TIP If the operator or technician is unable to reach the EMO button, the main circuitbreaker (Figure 2-8), which is located on the back of the system, can be used foremergency shutdown.

Front Panel Rear View

Item Description

1 Front EMO button

2 EMO Guard

3 Rear EMO button

4 Main Circuit Breaker

Figure 2-8 EMO/Main Circuit Breaker Locations

WARNING! In an emergency, failure to completely shut down power to the dispensingsystem with the EMO can cause serious injury to the user and/or damage to thedispensing system.

1 4

3

2


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Safety 39

2.9.1 Emergency Shutdown Situations

As a minimum, activate the EMO in the following situations:

• If anyone is in immediate danger of being injured by moving parts, hazardous materials, orelectrical shock.

• If valuable dispensing system components or the workpieces are in danger ofbeing damaged.

2.9.2 Emergency Shutdown Recovery

WARNING! Do not restart the dispensing operation until the condition that caused theemergency shutdown has been corrected. Failure to comply could cause seriousinjury to the user and/or serious damage to the dispensing system.

NOTE If the main circuit breaker has been tripped, you will need to restart the dispensingsystem. Refer to 4.3 System Startup for instructions.

To recover after an Emergency Shutdown :

1. Locate and remedy the cause of the emergency shutdown. If necessary, refer to the S-900Installation, Operations, and Maintenance Manual ..

2. If applicable, close the dispensing area doors.

3. Turn the EMO knob clockwise until it pops back into position.

4. Press the ON (I) button on the front panel.

5. Restart your dispensing program.

2.10 InterlockThe Interlock is an electronic connection that immediately cuts the power to any motion and pneumaticactuators. If the dispensing area hood is opened during dispensing, the interlock is activated and alldispensing activity immediately stops to protect the operator from injury.

2.10.1 Interlock Recovery

When the Interlock has been triggered, FmXP will display an Interlock Active message (Figure 2-9). Torecover from an interlock shutdown, close the dispensing area hood. When the FmXP Message 32691appears (Figure 2-10), click OK to continue dispensing or Cancel to abort.

Figure 2-9 Interlock Active Message Figure 2-10 Clear Interlock Message


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40 Safety

2.11 Service ShutdownBefore performing any service or parts replacement, the dispensing system should be shut downas follows:

1. Shutdown the dispensing system as described in 4.12 System Shutdown .

2. Perform a “Lockout/Tagout of Electrical and Pneumatic Energy” as described below.

2.11.1 Lockout/Tagout of Electrical and Pneumatic Energy

Companies may differ in their Lockout/Tagout (LOTO) procedures and requirements, and it is theresponsibility of the end user to determine compliance with local safety procedures. The purpose of anyLOTO effort is to help avoid injury or dispensing system damage due to unexpected energizing ofequipment, start up, or the release of stored energy during repair, maintenance, and operation ofequipment. Situations where LOTO practices may be employed on the S-900N Series include:

• Adjusting cables, belts, pulleys, or moving parts• Servicing bearings or motors• Troubleshooting, servicing, or replacing electronic components or assemblies

• Troubleshooting, servicing, or replacing pneumatic components or assembliesSituations where LOTO practices might not be required are when troubleshooting electrical, pneumatic, orhydraulic components or assemblies that make de-energizing the whole system impractical.Troubleshooting or servicing the S-900N Series while powered up and operating should only beaccomplished by fully trained and qualified personnel. There should always be a second person presentwhen performing maintenance on a system under power.

To lockout/tagout th e electrical and pneumatic energy:

1. Turn the main circuit breaker on the rear of the system to the OFF (0) position.

2. Unplug the main power cable from the back of the Power Manager.

3. Rotate the main air pressure knob counterclockwise until the gauge reads 0 psi and thendisconnect the main air supply by the quick release fitting.

4. Install an approved, keyed lock on the locking flange of the main circuit breaker so it cannotbe turned on; tag it with an approved tag.

Ensure that the owner, date, reason, and estimated time for repair are clearly marked onthe tag.

5. Install an approved lockout clamp and keyed lock onto the power connector so it cannot bereconnected to the power manager, and attach an approved tag.

Ensure the owner, date, reason, and estimated time to repair are clearly marked on thetag.

6. Install an approved lockout clamp and keyed lock onto the pneumatic fitting so it cannot bereconnected to the main air regulator, and attach an approved tag. Ensure the owner, date,reason, and estimated time to repair are clearly marked on the tag.


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Safety 41

NOTE Warning tags document the name of the technician taking the equipment out of operation,the date, and other facility-required information. It is a warning that the equipment cannot beput back into operation until the authorized technician has removed the tag.

WARNING! If your dispensing system is equipped with a heater, allow sufficient time for theheater to cool prior to performing maintenance or service. Failure to do so mayresult in serious burn injury.

Figure 2-11 Electrical/Pneumatical Lockout/Tagout


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42 Safety

2.12 Ligh t BeaconThe Light Beacon is a device that displays system status and can warn the operator when fault conditionsexist. The beacon has red, yellow, green, and blue lights that can be solid or flashing. The beacon alsohas an audible alarm. Table 2-3 provides possible reasons for each color indication.

Software and hardware share control of the beacon lights. Sometimes, hardware-driven displays overridethose caused by software conditions and sometimes software-driven displays override. Safety critical

conditions always have priority. Flashing light software commands have priority over solid lightcommands.

NOTE Light beacon action can be custom configured using the beacon control feature. See3.16 Software Controlled Light Beacon .

Refer to the S-900 Installation, Operations and Maintenance Manual for suggestedrecovery from common fault conditions.

Table 2-3 Beacon Color Indications

Beacon Color System Status

ALERT All motion, outputs, dispensing valve, and motion controls are disabled untilthe fault is cleared.One of the following conditions may exist:

A. Solid – Emergency stop condition or heater error.

B. Flashing – General error or vision error. Software driven error message isdisplayed on the computer monitor.RED

C. Solid or Flashing - Software has been configured to display a solid orflashing red light.

CAUTIONSystem in a low power state or lacks sufficient air pressure.

One of the following conditions may exist: A. Solid – Hood is open (Interlock activated).

YELLOWB. Solid or Flashing - Software has been configured to display a solid or

flashing yellow light.

OPERATIONOne of the following conditions may exist:

A. Solid – The system is fully operational with the hood closed .

B. Solid or Flashing – Software has been configured to display a solid orflashing green light.

GREEN

USER DEFINED A. Solid – Software has been configured to display a solid blue light.

BLUE

B. Flashing – Software has been configured to display a flashing blue light.


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Calibration and Adjustm ent 43

3 Calibration and Adjustment3.1 Overview

After initial installation or if any hardware changes have been made, certain dispensing systemcomponents may need to be calibrated or adjusted. This section covers the following topics:

• Focusing the Camera • Adjusting the Board Sensors • Calibrating the Camera • Initializing the Digital Gauges • Service Station Height Adjustment • Adjusting the Lift Table Speed • Calibrating the Scale • Adjusting Manual Airflow for Impingement Heaters

(S-92X)

• Z-Head Counterbalance Force Adjustment • Controlled Process Heat• Adjusting the Height Sensor Probe • Software Controlled Light Beacon

Refer to Section 4 - Operation for the following routine setup and adjustment procedures:

• Installing the Dispensing Valve • Adjusting the Air Pressure • Setting the Heaters

NOTE Refer to the Fluidmove User Guide for information on Fluidmove programming andfluid setup.

CAUTION! The procedures in this section should only be performed by a trainedservice technician.

3.2 Safety FirstOperation of your S-900N Series Dispensing System involves heat, air pressure, electrical power,mechanical devices, and the use of hazardous materials. It is essential that every person servicing oroperating the dispensing system fully understands all hazards, risks, and safety precautions. Refer toSection 2 - Safety for important safety information.

3.3 Record KeepingThe type of calibration or adjustment performed should be recorded in maintenance records for thedispensing system along with names of technicians and other pertinent data.

3.4 Startup/ShutdownRefer to Section 4 - Operation for details on system and Fluidmove startup/shutdown procedures.


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44 Calibration and Adjustment

3.5 Focus ing the Camera

NOTE This procedure assumes that the dispensing system has been powered on and FmXP isrunning, and that a representative substrate is available to teach the focal plane.

To focus the camera:

1. In the FmXP Programming Window, click the Load a Board icon.

The conveyor will transport the substrate to the dispense station and the lift mechanismwill lift it off the conveyor belt. This establishes the focal plane for dispensing as well asfor the Service Station.

2. In the FmXP Main Window, click on Jog .

The Jog Window opens.

3. Click on Video .

The Video Window opens.

4. Position the camera over a fiducial or an easily recognized feature on the substrate.

5. Hold the camera and use a 7 mm hex key to loosen the upper and lower screws on the

bracket ( Figure 3-1).6. Use a 3 mm hex key to loosen the screw above the camera.

7. Slowly move the camera bracket up and down.

8. When a sharp image is obtained in the Video Window, lock the upper screw.

9. Tighten the lower screw on the camera bracket.

Item Description Item Description

1 Upper screw 3 Screw (not shown)2 Lower screw

Figure 3-1 Focusing the Camera NOTE A machine offsets routine must be performed after focusing the camera. For more

information, refer to the FmXP User Guide or Online Help.

1

2

3


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3.6 Calib rating the Camera

NOTE This procedure assumes that the dispensing system has been powered on, that FmXP isrunning, that a substrate is available, and that the camera has been focused. The camerais self-calibrating when using the calibrate button from the Setup Vision Window. Thesoftware makes a pixel count comparison to machine units by moving away from thetaught image by a known value, finding the image again, and assigning a pixel-count-to-

machine-unit value. With this value established, the vision system can accurately find thesubstrate and dispense at the correct location (provided the vision target image is withinthe field of view).

NOTE If the camera is ever refocused to accommodate a different part height, the calibrationroutine MUST be run again.

To calibrate the camera:

1. In the FmXP Programming Window, click the Load a Board icon.

The conveyor will transport the substrate to the dispense station and the lift mechanismwill lift it off the conveyor belt.

2. In the FmXP Main Window, click on Configuration > Setup Vision .

The Setup Vision Window opens (Figure 3-2).

Figure 3-2 FmXP Setup Vision


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3. Click on Calibrate .

The Calibration Window (Figure 3-3) opens.

Figure 3-3 FmXP Calibration Window

4. Position the camera over a fiducial and adjust the light level to obtain a good image contrast.See 4.7.2 Lighting and Color Adjustment .

5. If the image is not in focus, focus the camera as described in 3.5 Focusing the Camera .

6. Click on Next .

7. Verify that the fiducial image is centered and click on Next .

The Vision System will take a snap image of the fiducial.

8. If the fiducial is acceptable, select Next . If not, select Prev and define a new fiducial.

NOTE The fiducial should fit inside the green square on the camera image.

9. After the camera calibration sequence is complete, verify that the X and Y values arerelatively close to each other. If there is a large difference, repeat the calibration process anddefine a new fiducial.

10. If the results are satisfactory, select Done to save the calibration results.

NOTE Machine Offsets must be performed after calibrating the camera. For more information,refer to the FmXP User Guide or Online Help.


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3.7 Service Station Height Adjustment After the camera position has been adjusted for the part set height, the service station height must beadjusted to bring the ceramic square into focus. The service station can be adjusted upward 1-inch(25 mm) from the factory set position by performing both rough and fine height adjustments. Eachadjustment will allow 1/2-inch (12.7 mm) of vertical adjustment.

To adjust the service station height:

1. Loosen the three mounting screws holding the service station to the bracket (Figure 3-4).

2. Move the camera over the ceramic tile and adjust the three leveling feet to bring the ceramictile into focus.

3. Continue to adjust the leveling feet until all corners of the ceramic square are in focus.

4. Tighten the three mounting screws.

5. If the leveling feet do not provide enough vertical adjustment to bring the service stationinto focus:

a. Remove the 3 side mounting screws.

b. Slide the service station forward to gain access to the bracket mounting screws.c. Loosen these screws, adjust the bracket upwards, and retighten the screws.

d. Repeat steps 1-4 above.

Item Description1 Ceramic Tile

2 Mounting Screws

3 Leveling Feet (not shown)

Figure 3-4 Adjusting the Service Station Height

1

2

2


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3.8 Calibrating the ScaleTools and Materials Needed:

• Calibration Weight Set (P/N 193758) • Latex gloves or tweezers• Screwdriver • Level

To calibrate the scale:

1. Remove the scale cover.

2. Verify that the scale is level bychecking the scale level bubble.

a. If the bubble is not centered, thescale must be leveled.

b. If the bubble is centered, thescale is level.

3. If necessary, adjust the scaleleveling screws until the scale is level(Figure 3-6). Figure 3-5 Scale Cover Removal

Figure 3-6 Leveling the Scale

4. When finished, replace the scale cover.

5. Start FmXP.

6. Select Configuration > Setup Scale from the Main Window.

The Scale Setup Window (Figure 3-7) opens.

Leveling Screws

Bubble


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Figure 3-7 Setup Scale - Scale Operations Tab

7. Select “SART-WZ” from the Type pull-down menu.

8. Click on the Advanced tab (Figure 3-8).

Figure 3-8 Setup Scale - Advanced Tab


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9. Verify that the calibration weight is set to 50 and click on Calibrate .

FmXP will prompt you to place the weight on the scale.

10. Using gloves or tweezers, place the 50 g calibration weight on the pedestal.

11. Replace the scale cover and click OK .

FmXP will display the following message (Figure 3-9):

Figure 3-9 FmXP Calibrating Scale Message

12. Upon completion, FmXP displays the following message:

Figure 3-10 FmXP Calibration Complete Message

13. Remove the weight from the scale and click OK .


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3.9 Z-Head Counterbalance Force Adjus tmentThe Z-head Counterbalance Force prevents the Z-head (dispensing head) from crashing down upondisengagement of the motor. There are three settings to accommodate various payloads.

To adjust t he Z-head coun terbalance (Figure 3-11):

1. Loosen the Z-head counterbalance force adjustment screw (Figure 3-11).

2. Slide the screw assembly to the desired position. See Table 3-1.

In order to slide the screw up and down, you may need reach behind the Z-slide and pullon the small bracket with your finger or an Allen wrench.

3. Tighten the Z-head counterbalance force adjustment screw.

To test counterbalance tension:

1. Place valve on Z-head and move it to middle of dispense area.

2. Open machine hood. The Z-head should not drop more the 25.4 mm (1-inch).

3. Readjust tension if necessary.

Item Description

1 Adjustment Screw

Figure 3-11 Z-Head Counter Balance Force Adjustment

Table 3-1 Counterbalance Spring Settings

Z-payload

(kg)

Counterbalance

Spring SettingTypical Applications

0 - 1.7 top Standard (i.e. single valve)Standard with laser height sensor

1.7 - 2.2 middle Dual actionDual action with laser height sensor

2.2 - 3 bottom Any custom tooling exceeding 2.2-kg

NOTE The settings in Table 3-1 are for reference purposes only. Certain applications mayrequire different settings.

1


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3.10 Adjusting the Height Sensor ProbeThe Height Sensor Probe must be adjusted each time a different type of dispensing valve or a differentlength of needle is installed.

To adjust the Height Sensor Probe:

1. Power down the system as described in 4.12 System Shutdown .

2. Manually move the dispensing head down.

3. Loosen the Height Sensor Probe locking screw (Figure 3-12).

4. Move the probe to the desired location (approximately 6 mm below the needle tip in the geardown position).

5. Tighten the height sensor locking screw. Do not over-tighten.

Figure 3-12A Height Sensor Probe (Front View) Figure 3-12B Probe-to-Needle Alignment

Item Description

1 Height Sensor Probe Locking Screw2 Height Sensor Probe

3 Needle

Figure 3-12 Adjusting the Height Sensor Probe

NOTE For additional information on dispensing valve-to-height sensor offsets, see 4.8 Establishing Machine Offsets .

6 mm

1 2

2

3


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3.11 Adjusting the Board SensorsBoard Sensors are optical sensors located along the length of the front conveyor rail. The sensors detectthe presence of the workpiece and report it to the Conveyor Controller. Board sensor sensitivity should beadjusted after initial installation and if the sensors fail to sense the presence of a workpiece. Dependingon whether the system has a single-lane or dual-lane conveyers, there may be as many as six downward-facing board sensors (pre-dispense, dispense, and post-dispense station for each conveyor). Sensitivityadjustments for downward-facing board sensors are made on Fiber Optic Amplifiers mounted under thedispensing area front cover.

To adjust dow nward-facing sensor sensitiv ity:

1. Unlock the fiber lock (UP position). Insert ferrule ends until the fibers cords are fully seated.Lock the fiber lock down into position (Figure 3-13).

NOTE Fiber ends are not designated as send or receive. Each ferrule can be used ineither amplifier position.

2. Verify that the digital value of the amplifier is less than 100 with the fiber array pointed awayfrom any objects (within 6-inches). This insures array “cross-talk” will not significantly degradethe signal.

Figure 3-13 Board Sensor - Side View

3. Move the SET-ADJ-RUN switch to the SET position (Figure 3-14). Press and hold the MODE button for 2 sec or until the Sensing Function menu is displayed.

The “Standard” sensing function ( F St ) is default.

Item Description Item Description

1 TEACH Button 3 SET-ADJ-RUN Switch

2 MODE Button 4 MODE Switch

Figure 3-14 Board Sensor - Top View

2

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1


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3.13 Adjusting the Lift Table Speed1. From the FMXP Main Menu, select Configuration>Conveyor Setup>Test I/O .

2. Select the tab labeled Outputs 0-31 and locate the Lift output buttons for the station to beadjusted ( Left – Center- Right ).

3. Use these buttons to lift and lower the table to test the speed adjustment setting.

Figure 3-16 Conveyor I/O Test Dialog

4. Open the dispensing system hood.

WARNING! Do not reach into the dispensing chamber until yellow beacon light is displayedand all system motion has stopped. If the Heaters are hot, use extreme cautionwhen performing this operation.

5. Locate the Flow Control Valves (FCVs) for the appropriate Lift Table.

NOTE Flow Control Valve locations are shown in Figure 3-17 to Figure 3-19 . If the system hasdispense heat only, the FCVs are located under the lift table. To gain access to theFCVs, it may be necessary to move the Dispensing Head to the rear of the machine.

6. Adjust the FCVs as follows:

a. For lift tables, adjust FCV with the black hose for upward speed, and FCV with the bluehose for downward speed.

b. After adjusting the FCVs test the lift/lower speed as follows:

7. Close the hood and use the output buttons to test. If more adjustment is required, repeatadjustment and test from Step 2.

8. Once you are satisfied with the operation of the Lift Tables, exit Conveyor setup and return tothe Main Window.


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Figure 3-17 Pre-Dispense Lift Table Controls Figure 3-18 Post-Dispense Lift Table Controls

Figure 3-19 Dispense Lift Table Controls


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3.14 Adjusting Manual Airflow for Impingement Heaters (S-92X)

NOTE This procedure applies to systems equipped with impingement heat and manual flowcontrols.

Airflow to Impingement Heaters is adjusted by turning the applicable flowmeter adjustment knob locatedin the lower front cabinet door. Airflow is read on the gauge on the front of the flowmeter ( Figure 3-20 ).Factors to be considered when determining the airflow include the following:

• Maximum airflow is 4.0 SCFM.

• Size, weight, and securing of the workpiece (high airflow can causemovement/misalignment).

• Effect of airflow on the time it takes to heat the workpiece to dispensing temperature.

• Effect of airflow on how fast the heat tooling reaches/maintains steady-state temperature.

• Ambient temperature of the dispensing area and its effect on dispensing fluid properties (potlife, viscosity, cure time).

To Adjust th e Flowmeters:

1. Locate the Impingement Air Valve and Flowmeters in the front cabinet of the dispensingsystem.

NOTE If the system is equipped with Pre-Queue and Post-Queue stations, there will beadditional flowmeters located on the Pre-Queue and Post-Queue stations tocontrol the heat for that station.

2. Open the Impingement Air Valve by turning the handle counterclockwise so that it is parallelwith the airline. Listen for leaks.

If there is an air leak, identify the source, shut off the air valve, and fix the leak beforeproceeding.

3. While monitoring the readouts on all Flowmeters, turn the Flowmeter Adjustment Knobscounterclockwise until maximum airflow is achieved.

The flow indicators should show an increase in airflow.

4. While monitoring the readouts on all Flowmeters, turn the Flowmeter Adjustment Knobsclockwise to lessen the flow.

The flow indicators should show a decrease in airflow.

5. Restore maximum airflow and open the dispensing system hood. Verify air is coming out of

the holes in Impingement Heater at each conveyor station.

6. If air is not flowing out of the heater, check the pneumatic connections.


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Item Description

1 Flowmeter Adjustment Knob (Conveyor 1)

2 Flowmeter Adjustment Knob (Conveyor 2)

3 Impingement Air Valve

Figure 3-20 Adjusting the Impingement Heater Airflow (S-922 Dual Conveyor)

12 3


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3.15 Controlled Process Heat

NOTE This procedure applies to systems equipped with impingement heaters and ControlledProcess Heat (CpH) only.

3.15.1 CpH Configuration

If the dispensing system is equipped with (CpH), make sure that option is selected in the FmXP HeaterSetup Window. See Figure 4-7.

To configu re CpH:

NOTE CpH can be added to any station and each station is configured independently.

1. In the FmXP Main Window, select Tools > Terminal.

2. Select Heater 2 (Conveyor 1) or Heater 3 (Conveyor 2).

The Heater Control Window opens. See Figure 4-28.

3. Double click on the station that you want to configure.

The Heater Control Loop Parameters Window opens. See Figure 3-21.

Figure 3-21 Heater Control Loop Parameters Window - Main Tab

4. Enter the desired setti

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