IVEK DIGISPENSE 3009 User manual

DIGISPENSE 3009 CONTROLLER MODULE, STYLE B Page 3-1
29 October, 2019 IVEK Corp. P03R017E
Table of Contents
Section Description
Page #
3. DIGISPENSE 3009 CONTROLLER MODULE, STYLE B .......................................................................3-2
3.1 DESCRIPTION ....................................................................................................................................3-3
3.1.1 Front Panel Controls And Indicators................................................................................................3-3
3.1.2 Rear Panel Detail..............................................................................................................................3-4
3.1.3 Fluid Movement................................................................................................................................3-6
3.1.4 Dispense Rate..................................................................................................................................3-6
3.1.5 Direction............................................................................................................................................3-6
3.1.6 Acceleration......................................................................................................................................3-6
3.1.7 Drawback..........................................................................................................................................3-7
3.1.8 Torque .............................................................................................................................................. 3-7
3.1.9 Initial Rate.........................................................................................................................................3-7
3.2 ELECTRICAL.......................................................................................................................................3-7
3.3 STANDARD OPERATION...................................................................................................................3-7
3.3.1 Dispense Mode.................................................................................................................................3-8
3.3.2 Meter Mode.......................................................................................................................................3-8
3.3.3 Prime Mode ...................................................................................................................................... 3-8
3.3.4 Display..............................................................................................................................................3-8
3.3.5 Help ..................................................................................................................................................3-9
3.3.6 Permission Levels.............................................................................................................................3-9
3.3.7 Screens.............................................................................................................................................3-9
3.3.8 Setup ..............................................................................................................................................3-31
3.3.9 Start-up...........................................................................................................................................3-31
3.3.10 Faults.............................................................................................................................................3-33
3.4 ADVANCED OPERATION.................................................................................................................3-33
3.4.1 Production Mode.............................................................................................................................3-33
3.4.2 Fluidic Setup Mode.........................................................................................................................3-34
3.4.3 Display............................................................................................................................................3-35
3.4.4 Help ................................................................................................................................................3-36
3.4.5 Permission Levels...........................................................................................................................3-36
3.4.6 Recipes...........................................................................................................................................3-36
3.4.7 Screens...........................................................................................................................................3-36
3.4.8 Status.............................................................................................................................................3-86
3.4.9 Rear Panel Interfaces.....................................................................................................................3-86
3.4.10 Warnings........................................................................................................................................3-98
3.4.11 Faults.............................................................................................................................................3-99
3.4.12 Operating The System...................................................................................................................3-99
3.5 INSTALLATION...............................................................................................................................3-102
3.6 MAINTENANCE...............................................................................................................................3-102
3.6.1 Assembly/Disassembly Procedures .............................................................................................3-102
3.7 PROBLEM GUIDE...........................................................................................................................3-102
3.8 SPECIFICATIONS...........................................................................................................................3-103
3.9 MODEL NUMBER ...........................................................................................................................3-103
3.10 ILLUSTRATED PARTS BREAKDOWN...........................................................................................3-103

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List of Tables
Table Description
Page #
3.1 Screen Information…………………………………………………………………………….………..…..3-10
3.2 Standard Screen Information...........................................................................................................3-37
3.3 Advanced Use Screen Navigation ...................................................................................................3-38
3.4 Motor/Base Value Selection.............................................................................................................3-85
3.5 Input 1 - Input 4, Input CC 1 and Input CC 2 Signal Description.....................................................3-86
3.6 Output 4, AUX Out 1 and AUX Out 2 Signal Description.................................................................3-87
3.7 RS232 and RS485 Connections (DCE, 9 pin D-sub female)...........................................................3-89
3.8 Commands.......................................................................................................................................3-91
3.9 Common Operational Problems And Solutions .............................................................................3-104

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3. DIGISPENSE 3009 CONTROLLER MODULE, STYLE B
3.1 DESCRIPTION
The Digispense 3009 Controller Module, Style B, hereafter referred to as the Controller Module, contains all the
control, monitoring, and interface components for the dispensing operations. The Controller Module measures 8 1/4"
(210mm) wide, 11 1/2" (292mm) deep, 5 3/4" (146mm) high (feet included) and weighs approximately 9.5 pounds (4.3
kilograms). The operator controls and interface connections are located on the front and rear panels.
3.1.1 Front Panel Controls And Indicators (Figure 3.1)
The front panel contains the operator interface for controlling the system. The following items are located on the front
panel.
1. Function Push-buttons
2. Display
3. Start Push-button
4. Active Indicator
5. Stop Push-button
6. Idle Indicator
7. Arrow Push-buttons
8. Enter Push-button
3.1.1.1 Function Push-buttons (Figure 3.1 Item 1)
These push-buttons change the value or initiate the operation for the item displayed directly above the push-button.
3.1.1.2 Display (Figure 3.1 Item 2)
This alphanumeric liquid crystal display is sixteen lines of forty characters each. The Controller Module status is
shown on upper right hand corner of the display.
345 6
2
7 (4)
1 (4)
8
Figure 3.1 Digispense 3009 Controller Module Front Panel

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3.1.1.3 Start Push-button (Figure 3.1 Item 3)
This push-button begins the pumping operation. The LED above the push-button illuminates when the pump is operating.
3.1.1.4 Active Indicator (Figure 3.1 Item 4)
The Active Indicator illuminates when the pump is operating and blinks when a fault occurs.
3.1.1.5 Stop Push-button (Figure 3.1 Item 5)
This push-button stops the pumping operation. The LED above the push-button illuminates when the pump is stopped.
3.1.1.6 Idle Indicator (Figure 3.1 Item 6)
The Idle Indicator illuminates when the pump is stopped.
3.1.1.7 Arrow Push-buttons (Figure 3.1 Item 7)
The Arrow Push-buttons move the cursor on the display and are used to change values.
3.1.1.8 Enter Push-button (Figure 3.1 Item 8)
The Enter Push-button has two functions; the first function selects a value to change that has been highlighted using
the arrow push-buttons, the second function stores the changed value in the Controller Module.
3.1.2 Rear Panel Detail (Figure 3.2)
The rear panel contains the interface connections for controlling the system. The following components are located on
the rear panel.
1. Power Entry Module
2. Fan
3. MOTOR Connector
4. AUX1 AUX2 Connector
5. CC TRIGGERS Connector
6. USB Connector
7. RS232 Connector
8. RS485 Connector
9. LOGIC I/O Connector
3.1.2.1 Power Entry Module (Figure 3.2 Item 1)
The power entry module contains a receptacle for a standard IEC power cord, an On (1) Off (0) switch, fuse holder
and fuses.
The design of the power entry module requires the line cord be disconnected before the fuse holder is removed. Refer
to the Title Page section of your manual for fuse information.
3.1.2.2 Fan (Figure 3.2 Item 2)
The fan keeps the devices in the Controller Module from getting too hot. Make sure the area around the fan is clear of
obstructions.

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3.1.2.3 MOTOR Connector (Figure 3.2 Item 3)
The Motor connector is used for making the electrical connections to the Motor
CAUTION
Never connect or disconnect the cable from this connector while power is on. Damage to the equipment
may result.
3.1.2.4 AUX1 AUX2 Connector (Figure 3.2 Item 4)
The AUX1 AUX2 Connector provides two outputs for triggering a variety of functions. Refer to section 3.3.9.2 for
additional information.
3.1.2.5 CC TRIGGERS Connector (Figure 3.2 Item 5)
The CC TRIGGERS (Contact Closure) connector provides two inputs (labeled 1 and 2) and a common for triggering a
variety of functions. Refer to section 3.3.9.1 for additional information.
3.1.2.6 USB Connector (Figure 3.2 Item 6)
The USB Connector provides an interface to control a variety of functions. The connector is a type-B device
connector. Refer to section 3.3.9.4 for additional information.
3.1.2.7 RS232 Connector (Figure 3.2 Item 7)
The RS232 interface provides control of all available functions and provides point-to-point communication. The
hardware is configured as Data Communications Equipment (DCE) standard. Refer to section 3.3.9.4 for additional
information.
1
2
3
4
5
6
7
8
9
Figure 3.2 Digispense 3009 Controller Module Rear Panel

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3.1.2.8 RS485 Connector (Figure 3.2 Item 8)
The RS485 Connector Provides control of all functions and allows for multi-drop communication. Refer to Section
3.3.9.4 for additional information.
3.1.2.9 LOGIC I/O Connector (Figure 3.2 Item 9)
The LOGIC I/O connector is used for making the electrical connection to the LOGIC I/O Interface Device. Refer to
section 3.3.9.3.
3.1.3 Fluid Movement
Fluid movement in the system is achieved by the displacement actions of the pump. A piston rotates in the pump
chamber moving fluid in and out of ports. The piston rotates to move a flat on the piston between the two ports to
achieve the desired fluid movement through the system. The movement of the piston is initiated by a Motor/Base
Module driven by a motor. The Controller Module provides the control and power to the motor to achieve the desired
fluid movement.
Fluid movement is controllable from two different contexts: Production Mode and Fluidic Setup Mode. Production
Mode is intended for normal controlled fluidic movement operations and Fluidic Setup Modes are intended for
preparing the entire fluidic system for those controlled operations.
3.1.4 Dispense Rate
The optimum value of the Dispense Rate needs to balance decreasing cycle times with an increasing risk of
cavitations of the fluid reducing repeatability. Also, since motor torque decreases with increasing speeds, the
probability of stalling the motor in the Motor/Base Module increases, especially when the viscosity of the fluid is high.
Advantages Disadvantages
Decreased Rates Lower probability of stalls& fluid cavitations Longer cycle time
Increase Rates Shorter cycle time Higher probability of stalls & fluid cavitations
3.1.5 Direction
The direction setting determines the direction of fluid movement through the Pump Module.
When the direction is forward, the piston rotates clockwise which causes fluid to move into one port and out of the
other.
When the direction is reverse, the piston rotates counter-clockwise which causes fluid to move through the ports in the
opposite direction relative to the forward setting.
3.1.6 Acceleration
The Acceleration setting determines how quickly the motor reaches the dispense rate from a stopped position. It is
also used to determine deceleration; how quickly the motor slows down when heading towards stop. Increasing the
acceleration may help increase the shearing of certain fluids from the tip improving repeatability. However, with higher
accelerations, high viscosity fluids may be more susceptible to causing the Motor/Base Module motor to stall.
Advantages Disadvantages
Decreased Acceleration Lower probability of stalls Less shear at tip
Lower probability of fluid cavitations Slightly longer cycle time
Increased Acceleration More shear at tip Higher probability of stalls
Slightly shorter cycle time Higher probability of fluid cavitations

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3.1.7 Drawback
Drawback is provided in Dispense and Meter modes to allow the fluid to move in the opposite direction after a
dispense to better separate the fluid at the tip. Often, high viscosity or “stringy” fluids are susceptible to poor
separation at the end of a dispense. Drawback provides a snapping motion in the fluid to attempt to shear it off at the
tip. There are three parameters available for configuration of Drawback: Drawback Volume, Drawback Rate, and
Drawback Dwell.
The Drawback Volume determines the amount of fluid to move backwards after a dispense. Typically, this is
configured for a small fraction of the dispense volume.
The Drawback Rate determines the rate of fluid movement during the backwards drawback.
The Drawback Dwell determines the amount of time the fluid movement pauses between the end of the cycle and the
beginning of the next cycle. Typically, this is left at the default value, but may be increased if it benefits the application.
3.1.8 Torque
The torque setting determines the peak current available to the motor. Increasing the torque decreases the
probability of stalling with high viscosity fluids. Decreasing the torque increases efficiency by decreasing steady state
heat loss in the motor when using low viscosity fluids.
Advantages Disadvantages
Decreased Torque Reduced heat loss in the motor Higher probability of stalls
Increased Torque Lower probability of stalls Increased heat loss in the motor
3.1.9 Initial Rate
The initial rate determines the speed at which acceleration starts. Increasing the initial rate may decrease the overall
dispense cycle time. Decreasing the initial rate may help overcome stalling with larger motors. Typically, this is left at
the default value.
3.2 ELECTRICAL
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this
device may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation. Industry Canada Compliance to CAN ICES-3 (A)/NMB-3(A).
3.3 STANDARD OPERATION
The Controller Module provides the controls for producing liquid flow via a positive displacement pumping mechanism.
The systems utilize solid-state electronics, stepping motor drives, and precision machined ceramic pump heads.
These components combine to provide exceptional accuracy and precision (0.1% or less is achievable), high
reliability, and low maintenance.
Volume commands for the Controller Module use number of full strokes. Rate commands are in revolutions per minute.
Pumping is started using the Start push-button based on the screen being viewed (Prime, Dispense, Meter). Push
the Stop push-button to stop Meter operation or to stop Prime and Dispense operation before their respective
volume setting is reached.

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3.3.1 Dispense Mode
Dispense Mode is the typical operating mode to use when dispensing fixed amounts of fluids. The amount of fluid to
dispense is determined by the calibration of the pump and the configured Dispense Volume. Each stroke of the pump
dispenses the calibrated pump volume. The repeatability of the dispense volume is dependent on many factors
including: tubing setup, selected tip, fluid characteristics, and pump characteristics, and fluidic movement profile.
Parameters such as Dispense Rate, Drawback, Drawback Rate, Drawback Dwell, and Acceleration provide
configuration of the fluidic movement profile to provide the flexibility to meet the needs of various applications. The
minimum volume of fluid that may be dispensed is 1 calibrated chamber volume, and the maximum volume of fluid
that may be dispensed is 10,000 calibrated chamber volumes.
3.3.2 Meter Mode
Meter Mode allows for variable fluid movement. The beginning and ending of the fluid movement may be initiated by
either the front panel start-stop buttons, RS232/RS485/USB commands or LOGIC I/O signals. However, the most
precise control of the start and stop of metering is via the LOGIC I/O signals.
Once initiated, fluid will Meter until stopped. If Drawback is enabled, it will be performed upon the stopping of the
Dispense. There are two stop modes available in Meter Mode: Stop Position and Stop Meter.
Stop Position is the most typical mode and ensures that upon a stop command, the pump continues to the
configured Stop Position. This implies that a Meter operation will always dispense an integer multiple of calibrated
chamber volumes.
Stop Immediate, on the other hand, will cause the pump to stop immediately upon receiving the stop command
(plus a little movement required for de-acceleration). This is typically used in conjunction with a dual-ended
motor/base to simulate continuous metering. This implies that the dispense volume will not be a multiple of the
calibrated chamber volume.
3.3.3 Prime Mode
Prime Mode is the most typically used Fluidic Setup Mode and is used to prime the fluidic tubing and components
from the reservoir through to the tip before Production Mode operation. Having Prime as a separate mode from
Dispense and Meter Mode permits selection of optimum values for priming, which may be different than optimum
values for Dispense and Meter. It is also often used in the Reverse Direction to remove the fluid from the fluidic
system after Production Mode operations are completed.
The minimum volume of fluid that may be moved during a prime operation is 1 calibrated chamber volume and
the maximum volume that may be moved is 60,000 calibrated chamber volumes. Once initiated, the Prime
operation will move the desired amount of fluid through the system unless stopped early.
NOTE
It is recommended to perform a Dispense in the desired Production Mode after a Prime operation in order to
properly setup the fluid for repeatable dispenses.
3.3.4 Display
The display provides an operator interface to all operating parameters in the Controller Module. New values can be entered
and current values displayed for all the functions of the system. The current operating mode and system status are shown
on the display. The display contains multiple interface screens each providing information to the operator.
The display shows system status, settings and general information. The display is divided into six fields as shown.
Following is a description of what will be displayed in each field.

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3
4
5
1
2
6
(FPB1) (FPB2) (FPB3) (FPB4)
NOTE
References to push-buttons for fields 3 through 6 refer to the push-button located below a word on the
display. For example, the push-button located under 'REFERENCE' will be called the Reference push-button.
These are referred to as Function Push-Buttons 1 through 4 (FPB1 - FPB4).
Field 1 - This field displays screen name and status information.
Field 2 - This field displays all the operating parameters.
Fields 3 thru 6 - These fields provide function legends for
the four function push-buttons directly below the screen.
NOTE
A legend does not appear if the function is not per-
mitted due to permission levels (section 3.2.6),
Configurable Input 2 (section 3.3.9.3) or the value of the
Serial Interface "k1" command (Table 3.8).
Field 5 is the FPB3 key described in the Reset Parameter
Warning screen (section 3.3.7.23).
3.3.5 Help
Help is available when selecting or entering new values by pressing the FPB1 push-button. Information pertaining to
the selected value will be displayed. Press the FPB1 key again to clear the help information from the screen.
3.3.6 Permission Levels
There are four levels of permission; Operator, I/O Test, Supervisor and Keylock. Each level allows access to selected
items on the display.
The permission level can be changed in the Change Permission screen (Section 3.2.7.8).
The highest level is Keylock. This level allows access to all items on all screens including the Front Panel Lock. The
most typical level is Supervisor, which allows access to all items on all screens other than the Front Panel Lock.
The I/O Test level allows access to the same items as the Operator except it also allows access to the I/O Test
screen. The Operator level does not allow changing system parameters. Recipes can be selected and loaded, but
not changed.
3.3.7 Screens
There are twenty screens used to setup, operate and exit the system. The most commonly used screens are shown in
Figure 3.3. Each screen contains information relating to operating the system. Table 3.1 lists each screen
alphabetically and provides a brief overview of its function. Figure 3.3 shows the basic screens and provides a map of
how to get to each screen. Transition between screens is limited by permission level, operating mode and interface
signals.

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Screen Description
Change Permission Allows changing the Permission level.
Dispense Displays total strokes, cycles, and allows changing volume, recipe, direction, rate and
drawback settings.
Drawback Allows changing drawback volume, drawback rate and drawback dwell.
Enter New Value Used for entering a numerical value.
Fault Displays the current fault if present.
Meter Displays total strokes, cycles, and allows changing recipe, direction, rate and draw-
back settings.
Power up Displays the controller type.
Prime Allows changing recipe, direction, rate and duration.
Recipe Used for saving a new recipe or retrieving an existing recipe.
Select New Value Used for selecting a new value from a list.
Setup A Displays recipe #, Permission level and allows changing Mode, Auto Retrigger and
Production Dwells settings.
Warning Recipe Exists Appears when you try to save a recipe using a previously used number.
Table 3.1 Standard Screen Information
POWER UP SCREEN
PRIME SCREEN
DISPENSE or
DRAWBACK SCREEN
METER SCREEN
These screens open
when a recipe button is
pressed.
RECIPE SCREEN
WARNING RECIPE
EXISTS SCREEN
SETUP A SCREEN
CHANGE PERMISSION
SCREEN
This screen opens when
This screen opens when
you press Enter to select
you press Enter to change
a value from a list.
a numerical value.
SELECT NEW VALUE
ENTER NEW VALUE
SCREEN
SCREEN
This screen opens
when a fault occurs.
Returns to Setup A
screen.
FAULT SCREEN
Figure 3.3 Standard Use Screen Navigation