Asymtek Century Series User manual

Level 2
Maintenance
Training
P/N 73-0028-00
Revision A
Student
Guide
2
3 4
1
Century Series
C702, C708, C708-AICE,
SelectCoat

Level 2 Maintenance Training, Century Series P/N 73-0028-00 Revision A
Level 2 Training
Maintenance
Century Series, C700
Student Guide
P/N 73-0028-00
Revision A
Reserved by
Asymtek TSG Manuals
For further information
regarding additional
training, contact:
Asymtek Headquarters
Technical Support Group
2762 Loker Avenue West
Carlsbad, CA 92008
760.930.3337
Revised 05/19/2000

Level 2 Maintenance Training, Century Series iP/N 73-0028-00 Revision A
Level 2 Introduction
STUDENT GUIDE
1. Instructor’s Introduction
2. Today’s Time Schedule
3. Building Locations
4. Who should attend this workshop?
5. Prerequisite Skills Check
6. Course Objectives
7. Location of Lab Equipment
8. Equipment Used for The Course
9. Safety Review
10. Manual Reviews
Introduction

Level 2 Maintenance Training, Century Series ii P/N 73-0028-00 Revision A
Level 2 Introduction STUDENT GUIDE
1. Instructor’s Introduction
2. Today’s Time Schedule
•Start: 08:00am
•Breaks: 10:00am – 10:15am and 03:00pm - 03:15pm
•Lunch: 12:00pm – 01:00pm
•End: 05:00pm
3. Building Locations
•Restrooms.
•Lunchroom.
•Student Parking.
4. Who should attend this workshop?
This workshop is designed to satisfy your company’s requirement for Level 2 Training on
Asymtek Century Series systems. Level 2 Training covers preventative maintenance, trouble
shooting and basic repair. Although the workshop is designed specifically for preventative
maintenance and repair, all individuals associated with programming and maintenance of the
system are encouraged to attend.
5. Prerequisites Skills Check
Completion of Level 1 Operations Training is a prerequisite of this class.
The student should already be able to:
•Describe the high voltage safety guidelines.
•List the dangers of operating with compressed air.
•Describe the basic fundamentals of the safety interlock.
•Restore the Century Series systems to its original Run Production State.
•Describe normal and emergency power procedures.
•Load and unload boards from the conveyor using FMW.
•Clean valves.
•Demonstrate basic equipment operation.
•Demonstrate basic failure analysis.

Level 2 Maintenance Training, Century Series iii P/N 73-0028-00 Revision A
Level 2 Introduction
STUDENT GUIDE
6. Course Objectives
At the completion of this course, the student should be able to:
•Describe the facility requirements for a Century Series systems unit.
•Identify and describe the function of the system modules.
•Trace the electrical and pneumatic path of selected processes.
•Perform the preventive maintenance procedures for a Century Series systems.
•Identify selected faults and isolate the cause to a sub-assembly or module.
7. Safety Review
•Emergency Evacuation Routes
•Building Fire Alarms
•Emergency Reporting Procedures
8. Location of Lab Equipment
•Training
•Engineering Development
•Test Labs
9. Equipment Used for the Course
•Century Series systems
10. Manual Reviews
•Asymtek Maintenance Manual
•Level 2 Maintenance Training, Century Series
Instructor & Student Guides
CONVENTIONS REVIEW
•Labels •Warnings
•Buttons •Cautions
•Commands •Notes
•Glossary Terms •Tips
•Typed Commands •Help
•Filenames
LAYOUTS REVIEW:
•Manual Sections •Appendixes
•Manual Contents •Glossaries
•Table of Contents •Indexes

Level 2 Maintenance Training, Century Series iv P/N 73-0028-00 Revision A

Level 2 Maintenance Training, Century Series vP/N 73-0028-00 Revision A
Level 2 Course Outline
STUDENT GUIDE
MODULE 1 Equipment Safety
MODULE 2 Equipment Operation
MODULE 3 Preventative Maintenance
MODULE 4 Troubleshooting
Course
Outline

Level 2 Maintenance Training, Century Series vi P/N 73-0028-00 Revision A
Level 2 Course Outline STUDENT GUIDE
MODULE 1 EQUIPMENT SAFETY
LESSON # TOPIC
L2M1.1 State the safety guidelines when working with a high voltage electric supply.
L2M1.2 Identify safety hazard features.
L2M1.3 State the possible dangers of working with heat and compressed air.
L2M1.4 Identify which modules have power when the main power switch is off.
L2M1.5 Identify components that are still under pressure when the main power switch is
off.
L2M1.6 Determine what state the Century Series system should be in for the different
types of maintenance work.
L2M1.7 Demonstrate the correct method of using the safety interlock and lockouts or
tag-outs on the equipment.
L2M1.8 Locate the safety features of and demonstrate how to use and reset an EMO
switch.
L2M1.9 Show where the MSDS info for C4 Epoxy is recorded in the manual and discuss
the potential hazards of this fluid.
L2M1.10 Demonstrate the correct method for powering Century Series systems up or
down into FMW.
MODULE 2 EQUIPMENT OPERATION
LESSON # TOPIC
L2M2.1 Describe the facility requirements for the Century Series system.
L2M2.2 Identify and briefly describe the benefits of available features for the Century
Series.
L2M2.3 Describe the memory used in each module and how it is restored in case of loss.
L2M2.4 List and test the dispenser I/O.
L2M2.5 Adjust and test the vision system.
L2M2.6 Show how the Height Sensor is tested using the Tools menu and the Terminal
Mode.
L2M2.7 Explain the wiring of the heating elements.
L2M2.8 Describe the pneumatic system of the Century Series system.
L2M2.9 Describe how the dispense valve dispenses fluid.
L2M2.10 Trace the electrical and pneumatic path of dispenser movement in the X/Y-axis.
L2M2.11 Trace the electrical and pneumatic path of dispenser movement in the Z-axis.
L2M2.12 Trace the electrical and pneumatic path of dispenser height sense.
L2M2.13 Trace the electrical and pneumatic path of dispenser finding home.
L2M2.14 Trace the electrical and pneumatic path of dispense valve purges.
L2M2.15 Describe what cable connections are used for temperature control.

Level 2 Maintenance Training, Century Series vii P/N 73-0028-00 Revision A
Level 2 Course Outline
STUDENT GUIDE
MODULE 3 PREVENTIVEMAINTENANCE
LESSON # TOPIC
L2M3.1 Clean, adjust, and verify the sensitivity of the needle sensor.
L2M3.2 Setup the height sensor and make probe adjustments.
L2M3.3 Disconnect, clean, and reconnect the dispensing valve.
L2M3.4 Clean the camera lens.
L2M3.5 Clean the fan and the vents.
L2M3.6 Clean, adjust, and verify the sensitivity of the PCB board sensors.
MODULE 4 TROUBLESHOOTING
LESSON # TOPIC
L2M5.1 Explain the correct technique for completely describing machine faults to other
service engineers.
L2M5.2 Describe the basic steps needed to succeed in troubleshooting.
L2M5.3 Describe the procedure for obtaining Asymtek qualified technical support.
L2M5.4 Describe how to order service parts from Asymtek referencing the spare parts
list.
L2M5.5 Isolate failure in the Z-axis.
L2M5.6 Isolate failure in the X/Y axis
L2M5.7 Isolate vision system errors.
L2M5.8 Correct a communication error between the computer and a module.
L2M5.9 Isolate dispense valve motor failures.

Level 2 Maintenance Training, Century Series iv P/N 73-0028-00 Revision A

Level 2 Maintenance Training, Century Series 1-1 P/N 73-0028-00 Revision A
Level 2 Module 1
STUDENT GUIDE
LESSON 1 Safety Guidelines
LESSON 2 Safety Hazards
LESSON 3 Compressed Air & Vacuum Heat Dangers
LESSON 4 Power & AC Distribution
LESSON 5 Components Under Pressure
LESSON 6 Maintenance Modes
LESSON 7 The Safety Interlock
LESSON 8 The EMO Button
LESSON 9 MSDS Information
LESSON 10 Powering Up and Down
Module 1
Equipment
Safety

Level 2 Maintenance Training, Century Series 1-2P/N 73-0028-00 Revision A
Level 2 Module 1 STUDENT GUIDE
LESSON 1 Safety Guidelines
OBJECTIVE: Upon completion of this lesson, the student should be able to
state the safety guidelines when working with a high voltage electric supply.
SAFETY PRECAUTIONS
•Locate and identify all safety warning labels on your system before initial use.
•Always operate the system with the safety interlock ON.
•In case of a system malfunction, immediately push the Emergency Stop
button.
•Be sure you read and understand the MSDS (Material Safety Data Sheet) for
the fluid being dispensed, and follow all recommendations for the proper
disposal of syringes and fluids.
•Only qualified personnel should be permitted to perform maintenance and
troubleshooting procedures.
•Disconnect all power cords before servicing the machine.
ELECTROSTATIC DISCHARGE (ESD)
•“Static Discharge” -The sudden transfer of electricity from one object to
another.
•Can cause severe, undetectable damage to boards, parts, and assemblies.
•Increased by the following:
1. Low humidity (dry air).
2. Movement across carpets.
3. Touching plastics, synthetics, and insulators.
•Precautions:
1. Wear an ESD wrist strap.
2. Touch a bare metal-grounded surface before touching the electrical
components.
3. Use a dissipative floor mat in your area.
4. Use only ESD approved equipment.
5. Ground all tools and equipment wherever possible.
6. Keep work area clean and clear of ESD causing items (i.e. packing foam).
7. Store electronic boards and assemblies in static safe bags.

Level 2 Maintenance Training, Century Series 1-3P/N 73-0028-00 Revision A
Level 2 Module 1
STUDENT GUIDE
LESSON 1 Safety Guidelines, CONTINUED
WORK ENVELOPE SAFETY
•Do not wear loose clothing or jewelry.
•If you have long hair, make sure that it is tied back to prevent it from
becoming entangled in moving parts.
•Wear safety goggles.
•Wear a grounding strap.

Level 2 Maintenance Training, Century Series 1-4P/N 73-0028-00 Revision A
Level 2 Module 1 STUDENT GUIDE
LESSON 2 Safety Hazards
OBJECTIVE: Upon completion of this lesson, the student should be able to
identify safety hazard features.
SYMBOL HAZARD DESCRIPTION
MECHANICAL Identify features that require special attention.
Moving parts, such as the Dispense Head, important
power supply components, such as the Main Power
Switch, or safety devices, such as the Interlock.
MECHANICAL
(PINCH)Can cause serious injury to hands or fingers.
Require special attention. Keep hands away from
moving parts. Disconnect and lockout power before
servicing.
HEAVY OBJECTS Can cause muscle strain or back injury if lifting
improperly.
Require proper lifting. Use lifting aids (pallet jack or
forklift) and proper lifting techniques when moving the
object.
ELECTRICAL Can cause severe injury or death.
Identify high voltage components. Use extreme caution
when working in or around these areas. Disconnect and
lockout power before servicing.
THERMAL Identify potentially hot components and surfaces.
Use extreme caution when working in or around these
areas.
FIRE Can cause fire or severe damage to the equipment.
Identify fuse requirements. Replace fuse with the same
type and current rating to protect against risk of fire.

Level 2 Maintenance Training, Century Series 1-5P/N 73-0028-00 Revision A
Level 2 Module 1
STUDENT GUIDE
LESSON 3 Compressed Air & Vacuum Heat Dangers
OBJECTIVE: Upon completion of this lesson, the student should be able to
state the possible dangers of working with compressed air or vacuum heat.
COMPRESSED AIR
The Asymtek Century Series uses compressed air at up to 85 psi of pressure for
the following components:
•Needle Heater
•Vacuum Heated Tooling Plate
•DV01-DV09
•DV6000
•Dual Action Dispensing Head
VACUUM HEAT
Controlled heating is supplied by the Vacuum Heated Tooling Plate option.
DANGERS
•If air tubes are pulled loose compressed air can be released making a loud
noise and sending debris at your face.
•If the DV-6000 syringe is pressurized it can push fluid out the bottom of the
valve.
•The Vacuum Heated Tooling Plate can get very hot and remain hot for some
time after being turned off.
PRECAUTIONS
•Do not apply pressure above 90psi under any circumstances.
If the fluid pump/valve or dispensing system is not working properly, refer to
troubleshooting the fluid pump/valve in the proper section of the Operations
Manual.

Level 2 Maintenance Training, Century Series 1-6P/N 73-0028-00 Revision A
Level 2 Module 1 STUDENT GUIDE
LESSON 4 Power & AC Distribution
OBJECTIVE: Upon completion of this lesson, the student should be able to
identify which modules have power when the main power switch is off.
MAIN POWER INLET/ CIRCUIT BREAKER
•The main source of power for the entire machine.
•Connects the machine to the facility power source.
•Generally supplies power to the rest of the system
Switching the Circuit Breaker to the OFF (O) position cuts power to the entire
system. The ON (I) position returns power to the system.
MAIN POWER SWITCH
•Cuts all power supplied to the entire dispensing system.
Turning the Main Power OFF cuts power to all of the
major components. However, power is still supplied to
the machine through the Main Power Cord.
POWER ENTRY MODULE
•Provides power to the main mechanics of the
system.
•Contains a fuse to prevent damaging components
in case of a power surge.
SAFETY INTERLOCK CABLE CONNECTOR
•The Interlock System connects to this port to
shut down power in an emergency.
VALVE CABLE CONNECTOR
•Power cables for the DV06, DV6000, or
DP2000 fluid pumps are connected to this port.
Z-AXIS CONNECTOR
•A port the Z-Axis power cable connects to.
Z-AXIS FUSE
•A fuse that provides a safeguard for the Z-Axis.
Interlock DV-06 Z-Axis Fuse

Level 2 Maintenance Training, Century Series 1-7P/N 73-0028-00 Revision A
Level 2 Module 1
STUDENT GUIDE
LESSON 4 Power & AC Distribution, CONTINUED
THE MAIN POWER CORD
•Connects the facility AC power course to the
Main Power Inlet.
AC Distribution
•Electrical power is supplied to the system through the Main Power Cord.
•The Main Power to all components connected to the Power Manager is turned
on or off using the Main Power Switch.
•The Vision System, heater controllers and computer system are not usually
connected to the Power Manager.
EXERCISE 1-1 Checking connections
1. Turn ON (I) the Main Power Switch at the rear of the system.
2. Turn ON (I) the PowerSwitch on the Control Panel.
3. Press FIND HOME on the Control Panel.
4. Start FluidMove.
5. Click TOOLS from the Main Window in FMW, or go to RUN in FMDOS.
6. Select DISPENSER in FMW, or TERMINAL MODE in FMDOS.
7. Type <OI>.

Level 2 Maintenance Training, Century Series 1-8P/N 73-0028-00 Revision A
Level 2 Module 1 STUDENT GUIDE
LESSON 5 Components Under Pressure
OBJECTIVE: Upon completion of this lesson, the student should be able to
identify components that are still under pressure when the main power switch is
off.
HIGH PRESSURE RELIEF VALVE
This safety valve opens when the incoming pressure
exceeds 100psi. If the incoming air pressure
reaches 120 psi the valve will open fully to bleed
off the excess air pressure.
FLUID PRESSURE
Fluid Pressure controls the flow of air from the
Main Air In through the clear fluid pressure air line.
This air line connects to the top of the syringe.
When you dispensing system is ON, air is
constantly applied to the syringe to maintain fluid
flow.
VALVE PRESSURE
Valve pressure controls the flow of air from the Main Air
In through air lines that connect to the fluid pump or valve.
Air pressure pushes the fluid pump/valve open or closed
during dispensing. Your dispensing program controls the
pressure to operate the fluid pump or valve while
dispensing
fluid.
EXERCISE 1-2 Adjusting the air pressure for valve and fluid pressure
1. Open the front doors or reach through the Light Curtain of the dispensing system.
2. Reach underneath the Control Panel on the right side to find the black control knob for the
Valve Pressure Regulator and on the left side for the black control knob for the Fluid Pressure
Regulator.
3. Pull down on the knob to unlock it for adjustments,
4. Turn each knob separately as follows, while watching the gauge.
5. Rotate the knob clockwise to increase pressure until the gauge reads the desired pressure.
6. Turn the knob counter-clockwise to decrease pressure to a setting that is below the desired
pressure setting.

Level 2 Maintenance Training, Century Series 1-9P/N 73-0028-00 Revision A
Level 2 Module 1
STUDENT GUIDE
LESSON 6 Maintenance Modes of Operation
OBJECTIVE: Upon completion of this lesson, the student should be able to
determine what state the Century Series should be in for the different types of
maintenance work.
MODULES MAINTENANCE
POWER ENTRY MODULE & DISPENSER CONTROLLER
Prior to maintenance to any of the above:
•The Main Power Switch should be OFF (O).
•The Main Power Circuit Breaker should be switched to OFF (O).
•All power cords should be unplugged.
TEMPERATURE CONTROLLER
Prior to maintenance to the temperature controller:
•The Main Power Switch should be OFF (O) for at least one hour.
The Vacuum Heated Tooling Plate can get very hot and remain hot for some
time after being turned OFF. Never touch it while the system is ON or during
the one hour cool down period..
•All power cords should be unplugged.
•The Main Circuit Breaker should be turned OFF (O).
FRONT PANEL MAINTENANCE
Prior to maintenance to any of the front panels:
•The Main Power Switch should be OFF (O).
•The Main Power Circuit Breaker should be switched to OFF (O).
•All power cords should be unplugged.
PURGE BOOT MAINTENANCE
Prior to maintenance to the Purge Boot:
•The purge station lid should be removed.

Level 2 Maintenance Training, Century Series 1-10 P/N 73-0028-00 Revision A
Level 2 Module 1 STUDENT GUIDE
LESSON 7 The Safety Interlock
OBJECTIVE: Upon completion of this lesson, the student should be able to
demonstrate correct use of the safety interlock system and excess air pressure on
the equipment.
THE SAFETY INTERLOCK
•A key restricted access device located on the Control
Panel.
•Used to restrict access to the inside of the dispensing
system based on different conditions.
•Once an interlock safety mode has been selected the
key can be removed to
prevent an inadvertent mode change.
•There are two Safety Interlock modes to choose from:
ON or OFF.
•The Safety Interlock is used in conjunction with the
door sensors or
Light Curtain.
EXERCISE 1-3 Illustrating ON (I) features
When the Safety Interlock is ON and a dispensing program is running opening the front door
causes the immediate stoppage of all dispensing motion and also disables the heaters. If the doors
are opened when the Safety Interlock is ON, all position references are lost. You must reset the
Century Series System and restart your dispensing program in order to continue.
EXERCISE 1-4 Illustrating OFF (O) features
This is the BYPASS mode. The light yellow pole/beacon light and yellow SYSTEM STATUS
lights are ON when the Safety Interlock in OFF.