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1、 Operation and Maintenance Manual Warnings, Cautions, and Notes Certain warning symbols are affixed to the machine and correspond to notations in this manual. Before operating the workcell, identify these warning labels and read the notices described below. Not all labels may be used on any specific
2、 system. Always wear-approved safety glasses when operating or working near the workcell. 6040 In situations where inattention could cause either personal injury or damage to equipment a warning notice is used. 6014 Do not smoke near the workcell. Always have a fire extinguisher available for emerge
3、ncy use. 6019 Before operating the system, read and understand the manuals provided with the unit. 6017 Before performing any repairs or maintenance to the system, turn off power and lock out the power disconnect switch. 6011 Never place hands or tools in areas designated by this symbol when the mac
4、hine is in operation. A dangerous condition may exist. 6008 Warning notices are used to emphasize that hazardous voltages, current, temperatures, or other conditions that could case personal injury exist in this equipment or may be associated with its use. Only qualified personnel should enter areas
5、 designated with this symbol. 6010 Before performing any repairs or maintenance to the system, read and understand the manuals provided with the unit. A qualified individual should only perform Service. 6018 Exercise caution when pressurized vessels are present. Identify and repair any leaks immedia
6、tely. Always wear appropriate safety equipment when working with pressurized vessels or vessels containing chemicals. 6054 Laser light source present. Do not stare directly into the beam. Do not use in the presence of highly reflective surfaces. 6003 Pinch hazard from moving parts. Avoid contact. 10
7、12 Shear hazard from moving parts. Avoid contact. 1099 Hot surface. Avoid contact. 6043 Do not remove protective guarding. 6060 This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purpo
8、rt to cover all details or variations in hardware or software, or to provide for every possible contingency in connection with installation, operation, or maintenance. Features may be described herein, which are not present in all hardware and software systems. Precision Valve lift the equipment eit
9、her from the back or the front. Place forks all the way in and making sure that blade reach from front to back. To place the dispense system 1. Move the dispense system to the location where it will be operated 2. Adjust the forklift height until the dispense equipment is approximately at the requir
10、ed height. If any foot touches the floor before the forklift reaches the required height. 3. Loosen the locking nuts, if necessary. Operation and Maintenance Manual Rev P 9/07 - 14 - 4. Once the workcell has reached the approximate required height; make sure that all four levelers (feet) are touchin
11、g the ground. If any feet are not touching the ground, use the crescent wrench to lower the feet by turning the feet clockwise. 5. Gentle lower the workcell and remove the forklift. NOTE: It is not necessary to tighten the locking nut at this time. Inspection 1. Open the front doors, and remove all
12、straps, tie wraps, and sponges around the dispense heads. 2. Thoroughly inspect the exterior of the machine for damage, loose fasteners, etc. Gently move the X FCA_DEV=5 would put the volume setting for monitor A at 0.5 cc and the allowable deviation at 5%. If the settings are programmed into the pa
13、th program, they are used instead of the settings from Flow Monitor setup. If no settings are programmed in the path, the machine defaults to the Flow Monitor setup settings. Auto Cycle Flow Error The Auto Cycle checks the material flow after every cycle if the error is turned ON in the Flow Control
14、 mode. If the volume was within parameters, no indication is given to the operator. In cases where the volume was outside acceptable parameters, the flow error screen appears. This screen is similar to the flow data screen shown above. The board should be removed before returning the machine to oper
15、ation. NOTE: Any changes made to settings in the material delivery system (material pressure, stroke adjustment, etc.) may affect the data from the flow monitor. If this happens, the operator may need to determine the correct material volume again. Flow Monitor Calibration Periodically, the flow mon
16、itor calibration should be checked. Start by connecting a PC to the Dispensing System, open a terminal screen and enter DEZ=0. This resets the flow monitor encoder to zero. Then dispense 10 cubic centimeters of material through any valve, by means of a manual purge. When finished, enter MG _DEZ on t
17、he terminal screen. This returns a value representing the number of encoder counts read by the flow monitor. Calculate the flow monitor calibration value: (Encoder Counts / 10) = FC_CAL. Change the value of the FC_CAL variable in the Machine-Specific Information section of the Main program to the re
18、sult of the calculation. NOTE: For a more precise calibration, determine volume by weight. The specific gravity or density of the material must be known to do this. Flow Monitor Setup The settings for flow monitors are accessed through the Flow Monitor tab under Setup mode. If the machine has multip
19、le monitors installed, a tab for each one will be displayed on the right-hand side of the box. Operation and Maintenance Manual Rev P 9/07 - 27 - This option allows control over the flow monitor data that is used as a process check only during Auto Cycle. These settings are used to determine the mat
20、erial volume and whether or not it is excessive unless superseded by commands in a path program. The error selection turns the process verification check on and off. The error ON/OFF selection cannot be overridden by commands in a path program. Target Volume: Increase or decrease the material target
21、 level. Range is 0 to 99 cc. Deviation: Increase or decrease the allowable deviation. Range is 0 to 99%. Check Flow: Toggle the material flow error checking on or off. (Default is off) Calibration Procedures The workcell has one of three calibration methods: Standard, Operator Defined and Sensor Def
22、ined. If a Sensor Defined or Operator Defined method is installed on the workcell, the machine may or may not automatically enter its particular calibration mode following the homing sequence depending on the application the workcell was set up for. See page 31 for particulars on operating the workc
23、ell during a calibration sequence. Standard Needle Calibration The simplest calibration procedure requires the operator to visually inspect the position of a needle with respect to a calibration point (such as cross-hairs). If the needle is not directly above the point, the operator must physically
24、reposition the needle so it is above the calibration point. Operation and Maintenance Manual Rev P 9/07 - 28 - Operator Defined Needle Calibration This method is dependent upon the operator utilizing the trackball to redefine the coordinate system according to the positioning of a specific needle or
25、 dispense head. This process is optional. If the specific needle is located in the desired position this process can be skipped. The calibration routine automatically runs when the machine is powered on or if the controller is reset. The head moves to a calibration point (specified in the main progr
26、am). When at the calibration position the operator has control of the axes. Using the trackball, the position of the needle tip can be redefined in reference to a calibration point (such as cross-hairs). This process can also be run manually through the CAL function key if a needle needs to be repla
27、ced for any reason during operation. Sensor Defined Needle Calibration The NCU is referenced from the home position on the gantry. The start positions for each head to enter the NCU are referenced from the cross-hair mark on the top of the NCU. The coordinates are defined for each head using reflect
28、ive sensors in the NCU. Z is always calibrated first in a downward motion into the Z sensor. The X and Y coordinates are then calibrated from this position in reference to the positioning of the NCU in the work area. The needle moves into the next sensor (X or Y) finding the first coordinate, then m
29、oves to the opposite side of the sensor and finds a second coordinate. The calibration routine then calculates the average of the first and second coordinates and redefines the new position accordingly. This sequence is repeated for the remaining axis. Figure 3 - Needle Sensor Calibration Block Shut
30、down Procedure If the machine is in cycle, wait for the cycle to finish and then return to the Cycle Stop mode. If the machine is in any other mode, the operator should return to Cycle Stop. 1) Press the EMERGENCY STOP button. 2) Press Quit on the HMI program. The operator will be prompted for confi
31、rmation. A blue window will appear, indicating the machine is shutting down. 3) Shutdown the attached PC. The operator MUST ensure that the PC has been properly shut down BEFORE turning off power to the workcell! Operation and Maintenance Manual Rev P 9/07 - 29 - 4) Turn off power to the system. Rot
32、ate the main disconnect switch to the “0” position. 5) Clean any excess material from the tips of the needles. 6) Remove spray cap(s), wipe tip of needle/seat as well, clean cap thoroughly. 7) If the system will be down for an extended period of time, it is recommended to turn off the air to the mac
33、hine. The red lockout valve at the rear of the machine can be used for this. CAUTION! If maintenance is to be performed during the shutdown, be sure to lockout and tag the machine. Operation and Maintenance Manual Rev P 9/07 - 30 - Cycle Stop The Cycle Stop state is the default state for the workcel
34、l. All other modes and capabilities can be accessed from this state through the function key buttons listed below. Manual: Manually operate the machine (see page 32). Also known as Jog or Teach mode. Auto: Run the machine in Auto Cycle (see page 34). Setup: View or change the setup functions of the
35、machine (see page 38). Linked: Displays the machine “heartbeat.” This indicator will blink while the PC is connected to the workcell, but NOT while the machine is in an error state. Operation and Maintenance Manual Rev P 9/07 - 31 - Program Selection The current active program can be changed at any
36、time by using the Program Selection drop-down menu (seen below). Path programs are downloaded to the controller using the included PathMaster software. NOTE: The selected program is not loaded into the controller memory until it is called from either auto cycle or the Run option in manual mode. Manu
37、al Mode Manual mode allows manual control of all devices on the workcell. There are tabs within Manual mode that are used to access different workcell functions. A trackball can be used to manipulate the axes, operate the valves, and teach positions to PathMaster. Operation and Maintenance Manual Re
38、v P 9/07 - 32 - Programming the workcell is accomplished in concert with a PC-compatible computer by using Precision Valve TE. 8) Command the X-axis to make a negative move. If the axis runs away debug and repeat the procedure. PRX=-2000 BGX 9) Display the current position and position error. TP; TE
39、. 10) Repeat step 6 through 9 for the Y, Z and W axes. Operation and Maintenance Manual Rev P 9/07 - 56 - Maintenance Schedule Table 5 Preventive Maintenance Schedule Type Of Service Service Area Every Shift Weekly Monthly Quarterly Dispensing Equipment Check all fluid pressures and dispense weights
40、. Check for material buildup on fixtures and locating surfaces. Check for any leaks around compression fittings. Retighten or replace if needed. Inspect the fluid delivery lines for excessive wear. Check the inline material filter for clogging. Electro- mechanical components Check motors for overhea
41、ting and smooth operation. Check for any chaffing of wires, pneumatic lines or material lines. Inspect enclosure air filter, clean with warm soapy water as needed. Air dry before reinstalling. (PVA250, PVA750 models only.) Grease the ball screw slides with Lithium Grease (JIS Type 2). Inspect all mo
42、ving cables for excessive wear. Conveyor System Clean conveyor belts. Check for material and dust buildup on the sensors. Check the conveyor belts for wear. Part-in-Place Sensors Clean with warm water, a mild solvent (like dish soap) and a soft cloth. DO NOT use moderate or harsh solvents, such as I
43、sopropyl Alcohol, Acetone, OS120, etc. Pneumatics Check for proper operation. Drain any accumulated water from the main Check the slides for wear and smooth operation. Operation and Maintenance Manual Rev P 9/07 - 57 - Operation and Maintenance Manual Rev P 9/07 - 58 - Type Of Service Service Area E
44、very Shift Weekly Monthly Quarterly Filter/Regulator. Dispensing / Spraying Equipment Lubricate packing as per the manufacturers recommendations. Clean Purge Cups Daily Clean Valve Tips Daily Procedures Ball Screw Slides The slides should be greased via the fitting on the carriage every 100KM or app
45、roximately once a month. Clean any buildup on the ball screw and seals. The manufacturer recommends using lithium-type soap base grease (JIS Type 2). Not all models have slide with grease fitting. If a slide does not have a grease fitting, simply apply a small amount of grease to the slide, and then
46、 work the slide back and forth. Inspection The cables in the flexible cable carrier should be checked for excessive wear. Any worn cables should be replaced. Check for loose screws in the top frame and end effecter. Conveyor Belt Replacement 1) Lockout the power and air supplies. 2) Remove the dust
47、cover plate. The dust cover plate is located near the conveyor motor on the inside of the conveyor. 3) Remove the old conveyor belt from the pulley wheels. 4) Clean the conveyor rails where the belt rides. 5) Install the new conveyor belt. Start by placing the belt on the pulley wheels farthest from
48、 the motor. NOTE: Make sure that there are no twists in the belt. 6) Place the belt around the large pulley wheel, then around the remaining wheels. 7) Rotate the pulley wheels several turns by hand. This ensures that the belt is correctly seated. 8) Replace the cover plate. Valves Refer to the Cut
49、Sheets section of the Operating Guide for information about the dispensing / spraying equipment. Servicing the Inline Material Filter Machines dispensing or spraying low viscosity materials (such as conformal coating) may have an inline stainless steel filter on the pressure vessel. If material flow appears restricted, the filter element could be clogged. All parts of the filter are stainless steel and can be cleaned several times before replacing. Follow these steps to clean or replace the filter: 1) Turn off air supply pressure to the pressure vessel. 2) Turn off