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DJ-2200
Owners Manual
NOTICE
This is an Nordson ASYMTEK publication, which is protected by copyright. Original copyright date 2006. No part of this
document may be photocopied, reproduced, or translated to another language without the prior written consent of
Nordson ASYMTEK. The information contained in this publication is subject to change without notice.
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using the information below:
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Support
Technical Support
Trademarks
Asymtek , Century , Millennium , and Fluidmove and DispenseJet are registered trademarks of Nordson
ASYMTEK.
Axiom is a trademark of Nordson ASYMTEK.
Microsoft , Windows , and Windows NT
2010
Table of Contents
1
Introduction ..........................................................................................................................................1
Overview ................................................................................................................................................1
DispenseJet Description ........................................................................................................................1
Specifications .........................................................................................................................................2
Safety ....................................................................................................................................................3
Overview ................................................................................................................................................3
Safety of Personnel ................................................................................................................................3
Preventing Equipment and Workpiece Damage ....................................................................................4
Installation ............................................................................................................................................5
Overview ................................................................................................................................................5
Unpacking the DJ-2200 .........................................................................................................................5
Installing the DJ-2200 ............................................................................................................................5
Operation ..............................................................................................................................................9
Overview ................................................................................................................................................9
Theory of Operation .............................................................................................................................10
Operating Instructions ..........................................................................................................................11
DispenseJet Setup Adjustments ..................................................................................................11
Changing Nozzles ........................................................................................................................13
Using the Standard Nozzle Nut ....................................................................................................13
Using the Air Assist Feature ........................................................................................................15
Setup and Valve Offset Routines .................................................................................................16
Changing the Syringe...................................................................................................................16
Draining the Fluid Lines ...............................................................................................................17
Changing Fluids ...........................................................................................................................18
Shutting Down DispenseJet Operations ......................................................................................18
Application and Process Development ................................................................................................18
Troubleshooting .................................................................................................................................41
Table of Contents
Table of Figures
Figure 1-1 DJ-2200 Series DispenseJet and Air Assist Feature .................................................................1
Figure 3-1 Installing the DispenseJet to the C-730 Dispensing System .....................................................6
Figure 3-2 lnstalling the DispenseJet to the M-2000 Flux Dispensing System ...........................................7
Figure 3-3 Installing the Air Assist Feature..................................................................................................8
Figure 4-1 Typical Jet DispenseJet Internal Workings ..............................................................................10
Figure 4-2 Preload and Micro-adjustment Settings ...................................................................................12
Figure 4-3 Changing Nozzles ....................................................................................................................14
Figure 4-4 Syringe with Receiver Head Attached .....................................................................................17
Figure 5-1 Disassembling the DJ-2200 .....................................................................................................24
Figure 5-2 Removal of Solenoid Valve and Disassembly of Micro-adjustment.........................................28
Figure 5-3 Disassembly of Upper and Lower Bodies. ...............................................................................29
Figure 5-4 Removing the Needle and Disassembling the Air Piston ........................................................30
Figure 5-5 Reassembly of the Upper and Lower Bodies and Solenoid Valve ..........................................33
Figure 5-6 Installing Heater and Seat Extension to Upper and Lower Bodies ..........................................34
Figure 5-7 Installing the Air Piston using the Air Piston Insertion Tool......................................................36
Figure 5-8 Installing the Micro-adjustment and Cap ..................................................................................37
Figure 5-9 Preload Screw Point of Reference ...........................................................................................38
Figure 5-10 Components of Micro-adjustment and the Preload Screw ....................................................40
Figure 7-1 DJ-2200 Series Spare Parts ....................................................................................................45
Figure 7-2 Co-axial Air Assist ....................................................................................................................46
Figure 7-3 Adjustment and Assembly Tools ..............................................................................................48
Figure 7-4 Cleaning Tools .........................................................................................................................49
Figure 7-5 DJ-2200 DispenseJet Exploded View (1 of 4) .........................................................................51
Figure 7-6 DJ-2200 DispenseJet Exploded View (2 of 4) .........................................................................52
Figure 7-7 DJ-2200 DispenseJet Exploded View (3 of 4) .........................................................................53
Figure 7-8 DJ-2200 DispenseJet Exploded View (4 of 4) .........................................................................55
Table of Tables
Table 1-1
Table 4-1
Table 5-1
Table 5-2
Table 6-1
Table 7-1
Table 7-2
Table 7-3
Table 7-4
Table 7-5
Table 7-6
Table 7-7
Table 7-8
ii
Table of Figures
Introduction
Overview
This section provides you with an introductory description of the DispenseJet DJ-2200. More details are
provided in the sections that follow on how to properly install, operate and maintain the DJ-2200. This section
covers:
DispenseJet Description
Specifications
DispenseJet Description
The DispenseJet Series DJ-2200 is a non-contact dispenser providing high-speed delivery and exceptional
volumetric control for flux dot or line application. When equipped with the co-axial air assist feature, it is
capable of dispensing co-axial air-assisted lines or dots. Jetting allows coverage with less flux and residue to
be removed. Non-contact jet dispensing eliminates the need for Z-axis motion during the dispense cycle,
which increases flux application speed and accuracy. Dispensing parameters can be changed using
computer-programmed patterns. The jetted flux can be immediately followed by a solenoid driven pulse of air
to disperse the flux onto the substrate.
Introduction
Specifications
Table 1-1 contains the technical specifications for the DJ-2200 Series DispenseJet. If you have any
questions about facility requirements, refer to the applicable dispensing system manual or contact Asymtek
Technical Support.
Table 1-1 DJ-2200 Series Specifications
Element
Parameters
Valve:
Weight (dry weight):
Syringe Size:
Reservoir Size:
Environmental/Facility:
Storage/Operating Temperature:
5 to 50 C (41 to 122 F)
Relative Humidity:
5 to 90 % (non-condensing)
Altitude Limitations:
Electrical:
24 VDC
Solenoid:
Heater:
8.5 Watts
2
Fluid Pressure:
Pneumatics:
Introduction
Safety
Overview
This section describes the precautions to be taken to promote personal safety and safe use of the DJ-2200
Series DispenseJet.
Dispensing system operation involves heat, air pressure, fluid pressure, mechanical and pneumatic devices,
electrical power, and the use of hazardous materials. Refer to the Safety section of the dispensing system
Operations Manual prior to installing and operating the DJ-2200 Series DispenseJet.
Safety is considered a joint responsibility between the original equipment manufacturer (Nordson ASYMTEK)
and the end-user (owner). All safety precautions and practices should be in accordance with local regulations
and facility practice.
WARNING!
Safety of Personnel
Safety
Only trained personnel should be permitted to perform installation, operation, maintenance, and
troubleshooting procedures on the DJ-2200.
Before performing maintenance or service on the DJ-2200, position it at the front of the
dispensing chamber. This will provide easy access to components and limit exposure to
hazardous areas.
Immediately push the red Emergency Machine Off (EMO) button on your dispensing system if
personnel are in danger.
Do not touch the moving parts while the dispensing system is operating.
Follow Material Safety Data Sheet (MSDS) recommendations for the proper handling of
hazardous materials.
Remove the DJ-2200 completely from the dispensing system and allow the heated parts to cool
before cleaning or performing maintenance.
Immediately push the EMO button on the dispensing system if the dispensing system, DJ-2200,
or a workpiece is in danger of being damaged.
Use standard Electrostatic Discharge (ESD) precautions when working near sensitive
components. Always wear a grounding strap and connect it to the ESD ground before handling
workpieces and equipment.
Immediately contain and clean up any caustic or conductive fluid spills as recommended in the
material manufacturers MSDS.
If fluid gets into internal portions of the DJ-2200, immediately contact Nordson ASYMTEK
Technical Support.
Use only replacement parts that are designed for use with the original equipment. See the
Additional Information section for an illustrated parts list.
CAUTION!
Safety
Installation
Overview
The DJ-2200 is designed for use on Nordson ASYMTEK Century C-730 and Millennium M-2000 Flux
Dispensing Systems. This section covers:
CAUTION!
Installation
Install the appropriate Z-head mounting plate (valve bracket) and bracket mount for the
dispensing system. Refer to Ordering Parts in the Additional Information section for part
numbers.
NOTE
These instructions assume that the co-axial air solenoid valve has not been installed
to the DispenseJet.
2.
Mount the jet to the Z-head mounting plate and tighten with a 3-mm hex wrench.
3.
Make the electrical connections according to the machine configuration shown in Figure 3-1 and
Figure 3-2.
4.
Connect the pneumatic air lines as shown in Figure 3-1 and Figure 3-2. You should hear a click
when the hose is inserted properly.
5.
For syringe installation and replacement, see Changing the Syringe in the Operation section.
1
4
5
7
8
9
Item
Description
10
Item
Description
Electrical Cable
Syringe Bracket
Z-mounting Plate
DispenseJet
10
Installation
Item
Description
Item
Description
Figure 3-2 lnstalling the DispenseJet to the M-2000 Flux Dispensing System
Installation
NOTE
These instructions assume that the air assist feature, consisting of the co-axial air solenoid
valve and the co-axial air nozzle nut and air tubing, has not been installed. Once installed,
the co-axial air solenoid valve remains installed when not being used.
Attach the co-axial air solenoid valve bracket to the bottom of the Z-head mounting plate using
two 2-mm hex screws with removable thread-locking adhesive ensuring a secure attachment.
2.
Using a flathead screwdriver, install the co-axial air solenoid valve to the installed bracket using
the two screws with removable thread-locking adhesive ensuring a secure attachment.
3.
Connect the co-axial air solenoid valve electrical connector to the co-axial air jack (typically near
the heater controller connectors on the dispensing system).
4.
Connect the blue (green or black) tubing from the dispensing system pneumatics to the co-axial
air solenoid valve.
6
5
Item
Description
2
Item
Description
Installation
Operation
Overview
This section covers the requirements and the necessary steps to properly operate the DJ-2200 DispenseJet.
The operations assume that an operational Dispensing System and DispenseJet are available. Before
operating the DispenseJet for the first time, you may want to get a better understanding of how the
DispenseJet works by reading the Theory of Operation in this section.
This section covers:
Theory of Operation
Operating Instructions
WARNING!
Follow proper power-up and shutdown procedures for the dispensing system when
making adjustments or changing fluids. Failure to adhere to safety warnings and
precautions could result in serious bodily harm to the user.
WARNING!
Operation
Theory of Operation
A typical cross-section of the internal workings of the DispenseJet is shown in Figure 4-1. During a
dispensing cycle, a solenoid-driven air pressure valve compresses a spring. The compressed spring retracts
a needle plunger and the fluid chamber space vacated by the needle plunger is filled with fluid. When air
exhausts from the solenoid valve, the spring expands and the needle plunger returns to its seat with an
impact force that ejects the fluid through the dispensing nozzle onto the substrate and then immediately
blocks the fluid from flowing through the nozzle. If desired, the dispensed fluid can be assisted by a short
burst of air from a co-axial air solenoid to assure consistent spreading of the fluid by disturbing the fluid
surface tension.
Fluid to be dispensed by the DispenseJet is contained in a syringe or an external reservoir and is fed to the
DispenseJet fluid chamber at 7 to 69 kPa (1 to 10 psi). To stabilize viscosity and improve flow characteristics
of the fluid, the fluid is fed through a heater that typically warms the fluid from the ambient room temperature
2
3
4
5
6
Item
Description
Item
Description
Micro-adjustment
Needle
Spring
Heater
Air Piston
Nozzle
10
Operation
Operating Instructions
Prior to using the DispenseJet for production runs, it is recommended that you conduct a brief test-run to
verify that adjustments and parameters are set for optimum performance.
NOTE
Read the entire section before operating the DispenseJet. The sequence of events may vary
with your particular application.
CAUTION!
Operation of the DispenseJet should be performed only by Nordson ASYMTEKtrained operators or service technicians, or Nordson ASYMTEK field service
engineers.
Preload setting
Micro-adjustment setting
NOTE
For major adjustments, you need to remove and disassemble the DispenseJet. It is best to
make major adjustments before installing the DispenseJet to the dispensing system. See
Settings and Adjustments in the Maintenance and Service section in this manual.
2.
Count the number of times you completely turn the preload screw downward from its current
position to regulate the desired space for the preload setting.
TIP
It is best to determine the smallest dot or line to be dispensed before you set the
preload. Typically, too little tension or too much tension will result in poor
dispensing results.
3.
Twist the preload lock nut all the way up on the preload screw so that it rests against the cap.
4.
Using the kit-provided spanner wrench, turn the preload lock nut until it stops.
Operation
11
20
2
6
5
4
Item
Description
Item
Description
Micro-adjustment
Cap
Preload Screw
Preload Window
Use the spanner wrench (included in kit) to loosen the preload lock nut (Figure 4-2).
2.
3.
Use the spanner wrench to tighten the preload lock nut 1/8 turn.
NOTE
1.
Set the main air on the dispensing system between 586 to 620.5 kPa (85 to 90 psi).
2.
3.
If a hissing noise can be heard, refer to the Maintenance and Service section. If not,
continue with the next step.
Set the valve pressure to 551.6 kPa (80 psi) and check for leaks.
12
Operation
Changing Nozzles
The DispenseJet can be operated with the standard nozzle nut and nozzle only or with the co-axial nozzle
nut added to it (Figure 4-3).
NOTE
If installed, the co-axial air solenoid valve does not need to be removed when not in use.
When changing nozzles, select Using the Standard Nozzle Nut or Using the Air Assist Feature
instructions as appropriate.
Verify that the nozzle functions properly by activating the solenoid valve either manually using
the solenoid valve push button or automatically from the dispensing system software.
NOTE
Press the push-button on the bottom side of the solenoid valve to manually activate
the solenoid valve. A jet of air bursting out should be felt. Listen for the DispenseJet
needle to make contact with the micro-adjustment stop.
2.
Connect the fluid syringe, or the fluid reservoir line, to the elbow connector on the lower body of
the DispenseJet.
3.
4.
Turn the heater controller located inside the lower cabinet of the dispensing system to the ON (I)
position.
5.
6.
Allow 4 to 5 minutes for the temperature to reach its set point before starting the DispenseJet
operations.
7.
To prime the DispenseJet with fluid before beginning operations, proceed as follows:
a. Using the dispensing system controls, manually move the Z-head so that the DispenseJet
nozzle is directly centered over the DispenseJet purge station lid.
b. Activate the solenoid valve by pressing the push-button underneath the solenoid valve until
fluid begins to flow out of the nozzle in an even stream.
c.
Gently wipe the fluid from the end of the nozzle with a disposable towel.
8.
Set the fluid pressure to the recommended setting for the type of fluid used. Typical setting is
between 7 to 69 kPa (1 to 10 psi).
9.
You are now ready to perform the Setup and Valve Offset Routines described later in this
section.
Operation
13
2
3
5
6
Item
Description
Item
Description
Seat Extension
Nozzle
14
Operation
NOTE
If installed, the co-axial air solenoid valve does not need to be removed when not in use.
NOTE
Instructions assume that the co-axial air solenoid valve is installed. If not, refer to the
Installation section for instructions. Make sure to first properly drain the fluid lines (see
Draining the Fluid Lines in this section).
1.
If installed, use the provided torque wrench to remove the standard nozzle nut.
2.
CAUTION!
Adhere to specified torque limits. The torque wrench clicks when the proper
torque is achieved. Forcefully over-tightening the nozzle nuts will cause
damage. If damaged, replace the nozzle nuts.
b. Using the torque wrench, carefully install the standard nozzle nut by threading it on to the
bottom of the DispenseJet.
c.
Install the co-axial air nozzle nut onto the threaded portion of the nozzle using careful
alignment and light finger-tightening to allow room for final adjustment.
d. Using the torque wrench, loosen the standard nozzle nut to allow final installation of the
co-axial air nozzle nut.
e. Position the co-axial air nozzle nut so that the protruding air inlet spout is conveniently facing
in a direction that does not cause the air tubing to interfere with dispensing movement.
f.
Using the torque wrench, carefully tighten the standard nozzle nut and the co-axial air nozzle
nut.
3.
Install one end of the co-axial air tubing by carefully pressing it onto the air-inlet spout on the
co-axial air nozzle nut.
4.
Install the other end of the co-axial air tubing to the air inlet of the co-axial solenoid valve.
TIP
Operation
It may be easier to install the air tubing to the co-axial air nozzle nut first. This may
prevent the small nozzle from being dropped and lost. The tubing can be used to
manipulate the nozzle nut onto the nozzle.
15
NOTE
If required, allow fluid to reach room temperature (refer to the MSDS for your fluid to determine
requirements).
2.
NOTE
Do not use any samples with visible air bubbles, as these will cause fluid voids and
dispensing irregularities.
3.
Remove the orange cap from the flat end of the syringe.
4.
Check that the syringe has either an orange no-draft follower (preferred) or a yellow follower.
5.
6.
Slide the receiver head onto the flat end of the syringe and tighten it.
7.
Place the tip of the syringe securely into the elbow connector.
NOTE
8.
It is important to position the receiver head so that the long sides are parallel to the
X-axis rods. If it is slanted or perpendicular to the X-axis, the receiver head will hit
the Z-head during dispensing.
CAUTION!
9.
16
Connect the clear line from the receiver head to the clear (leftmost) line on the dispensing head.
Operation
Item
Description
Receiver Head
Syringe
Syringe Tip
Figure 4-4 Syringe with Receiver Head Attached
If fluid is present in the reservoir or the syringe, obtain a suitable fluid collection container and
disposable towels and place the container at the purge station of the dispensing system.
2.
3.
From the dispensing system control panel, manually move the DispenseJet so it is directly over
an open purge station (or select and click on PURGE from the Fluidmove software) to purge the
solvent from the fluid line.
4.
Manually activate the solenoid valve by pressing the push-button underneath the solenoid valve
to flush out all fluid in the fluid system, lines, syringe, or reservoir.
5.
Lower fluid pressure to zero (0) and disconnect the air line and remove the syringe or reservoir.
Operation
17
Changing Fluids
To change the Fluid to another Flux Application:
1.
Properly drain the fluid lines (see Draining the Fluid Lines earlier in this section).
2.
Remove the standard nozzle nut with the co-axial air nozzle nut as one unit, or separately as
applicable to your application.
3.
Purge (flush, or clean) the DispenseJet as appropriate (see Purging the DispenseJet in the
Maintenance and Service section).
NOTE
For flux applications, there is no need for speed settings. For additional flux applications and
process development, please contact Nordson ASYMTEK.
NOTE
In the co-axial DOT mode, the air jets immediately after the fluid is dispensed onto the
substrate. In the co-axial LINE mode, the air jets simultaneously with the fluid jet being
dispensed on the substrate.
It is recommended that you record, at a minimum, the following hardware and software settings during the
process development (see Table 4-1).
TIP You may want to make a copy of this page for recording purposes.
Table 4-1 Minimum Recommended Parameters
Parameter
Preload
Micro-adjustment *
Units of Measure
Number of Turns
mm (inches)
Fluid Pressure
kPa (psi)
Valve Pressure
kPa (psi)
kPa (psi)
Dispense Gap **
Your Settings
mm (inches)
18
Operation
Overview
Performing the recommended maintenance and service procedures increases the life of your DJ-2200 and
ensures high quality dispensing performance for every production run.
Maintenance Schedule
The recommended maintenance schedules for the DispenseJet are shown in Table 5-1 and Table 5-2. The
frequencies are based on the average production environment. Your production operations and environment
may differ.
Table 5-1 Routine Maintenance Schedule, Category A
Task
Frequency
Instructions
Daily
Weekly
Quarterly
As required between
different fluid applications.
Frequency
Instructions
Daily
Bi-Weekly or Quarterly
Annually
Torque Wrench
Nozzle Brush
Air Gun
Solvent
19
2.
If fluid is present in the reservoir or the syringe, obtain a suitable fluid collection container and
disposable towels for draining of fluid.
3.
Use the position controls to manually move the DispenseJet so it is directly over the purge
station (or click on PURGE from the Fluidmove software) to purge the solvent from the fluid lines.
4.
Manually activate the solenoid valve by pressing the push-button underneath the solenoid valve
to flush out all fluid in the fluid system, lines, syringe, or reservoir.
5.
Using the supplied torque wrench, carefully remove the standard nozzle nut with the co-axial air
nozzle. If attached, press up on the orange-colored ring on the co-axial solenoid valve and gently
pull on the tubing until it is removed.
2.
Carefully insert a cleaning-wire of correct size into the nozzle and gently agitate the interior
surface.
3.
Using a dry air gun, carefully blow air through the nozzle to clear fluid from the interior and into a
disposable towel.
4.
Submerge the nozzle in an ultrasonic cleaning system to remove any remaining residue.
5.
Using a magnifier or microscope, inspect the nozzle interior for residue and scratches. If worn,
replace it. If clean and undamaged, proceed with cleaning the nozzle from the bottom. Otherwise
repeat Steps 1 through 4.
Remove the standard nozzle nut and the co-axial air nozzle nut from the DispenseJet as a unit, if
attached.
2.
3.
Remove the co-axial air nozzle nut and the nozzle from the standard nozzle nut.
4.
5.
Using a nozzle brush, an appropriate solvent, and an ultra-sonic cleaning unit, clean and inspect
the removed parts. Repeat cleaning or replace the co-axial nozzle nut as appropriate.
20
NOTE
If you are not going to use the cleaned nozzles right away, store the nozzles in the protective
case for the DispenseJet.
Obtain a solvent (such as Isopropyl Alcohol) that is recommended for the fluid.
NOTE
If unsure, contact your material supplier for recommended solvents and always
review the MSDS for the solvent and fluid data and Protective Personal Equipment
recommendations.
2.
Using the selected solvent instead of the flux fluid, follow the Draining the Fluid Lines
instructions in the Operation section.
3.
Select PURGE from the Fluidmove software to purge the solvent from the nozzle assembly.
Complete Cleaning
Typically, complete cleaning is performed on a bi-monthly or quarterly basis. However, the cleaning schedule
may vary depending on your application and production environment.
The following steps are necessary when performing a complete cleaning:
CAUTION!
Do not subject the electrical cables to stress during the disassembly. Damaged
cables cannot be replaced separately and can only be replaced with the next higher
assembly.
2.
21
3.
Lower the fluid pressure to zero (0) and disconnect the clear pneumatic line (fluid pressure) and
remove the syringe.
CAUTION!
4.
Follow Material Safety Data Sheet (MSDS) recommendations for the proper
handling and disposal of fluids.
Refer to the manual applicable to your dispensing system when performing steps 3 and 4.
If the micro-adjustment assembly is set to a specific setting, make a note of this setting for
future reference.
Using the provided torque wrench, remove the standard nozzle nut and co-axial air nozzle nut.
2.
Remove the air tubing from the co-axial air nozzle nut.
3.
Remove the co-axial air nozzle nut from the standard nozzle nut.
4.
5.
CAUTION!
22
NOTE
Handle o-rings and seals carefully. If o-rings or seals are damaged, leakage
or premature DispenseJet failure may occur.
The seat extension has special thermally-conductive grease applied to the nonthreaded portion of the shaft. If the grease is accidentally removed, apply new
conductive grease.
6.
Remove the exposed small o-ring that holds the u-cup seal in place. Leave the u-cup seal
intact.
Inspect the exposed needle and u-cup seal to determine need for replacement as follows:
a. Look for uneven roundness of the u-cup seal or signs of wear that prevents a good seal.
Discard or replace the u-cup seal as appropriate.
b. Look for a broken needle tip or signs of wear marks such as polished streaks on the metal
where it meets the u-cup seal.
8.
Remove the elbow connector from the lower body by unscrewing it and set it aside for cleaning.
9.
Leave the upper body, the solenoid air valve, and related parts in tact.
10.
Further inspection and cleaning of the dissembled components and parts may be performed at
this time.
23
1
2
4
5
11
12
13
14
9
10
Item
Description
Item
Description
Heater
Nozzle Nut
10
Elbow Connector
11
Needle
Lower Body
12
U-cup Seal
13
O-ring (small)
Seat Extension
14
O-ring (large)
24
Use a cotton-swab to remove excess material from the seat extension, lower body, and
connector.
2.
Use a cotton-swab and the recommended solvent to further clean the seat extension, lower
body, and elbow connector.
CAUTION!
Protect the solenoid valve from contact with material or solvent. Contamination could
cause solenoid failure.
3.
Further clean the seat extension, lower body, and elbow connector in a solvent bath ultra-sonic
cleaner.
4.
5.
Use an air gun to blow excess material from the DispenseJet fluid paths into a disposable towel.
6.
Carefully inspect the interior of the cleaned components and parts to ensure they are free from
fluid residue and solvent. If parts are not clean, repeat steps 1 through 5 as necessary. When
clean, proceed with step 7.
CAUTION!
The needle and seat extension are a precision-fitted set. If one item is worn or
damaged, both items must be replaced. Do not mix parts from the old set with the
new set.
7.
Clean the nozzles by following the instructions for "Cleaning the Nozzle" earlier in this section.
8.
If desired, clean the solenoid valve by wiping it with a dry disposable towel while it is installed on
the Z-head mounting plate.
9.
Carefully inspect the o-rings, u-cup seals, and Teflon gasket for wear or damage. Obtain
replacements as needed.
Gather the DispenseJet components, parts, and any replacement parts, on a flat surface.
2.
25
CAUTION! To prevent damage to the extension seat, verify that the micro-adjustment is
opened 4 to 6 turns counterclockwise.
3.
b. Rotate the seat extension into the heater to spread the conductive grease evenly and
prevent the formation of trapped-air pockets.
c.
d. Align the dowel-pinhole on the seat extension to face toward the backside.
e. Install the seat extension/heater to the upper body using the two hex head screws and the
7/64-inch hex key to tighten the screws.
4.
5.
Install the elbow connector into the lower body of the DispenseJet. The elbow connector should
face upward.
6.
If removed, install the co-axial air solenoid valve and the co-axial air nozzle nut. Refer to the
instructions in the Installation section.
7.
Reinstall the DJ-2200 as described in Installing the DJ-2200 in the Installation section.
NOTE
26
CAUTION! Do not subject the electrical cables to stress during removal. Damaged cables cannot
be replaced separately and can only be replaced with the next higher assembly.
To remove the Solenoid Valve from the Upper Body (Figure 5-2):
1.
Remove the two hex head screws securing the solenoid valve from the upper body.
2.
CAUTION! Gently back-off the micro-adjustment to prevent damage to the needle and seat
extension during disassembly.
2.
3.
Inspect the micro-adjustment for damage, wear and tear, or play in the moving mechanism. If
damaged, loosen the setscrews, remove the micro-adjustment and obtain a replacement.
4.
5.
Carefully remove the preload screw from the cap and the micro-adjustment while:
a. Observing the compression spring in the viewing window of the preload screw.
b. Counting the number of turns it takes to release contact on the compression spring.
6.
7.
27
3
4
Item
Description
Item
Description
Micro-adjustment
Upper Body
Preload Screw
Compression Spring
Solenoid Valve
Cap
Figure 5-2 Removal of Solenoid Valve and Disassembly of Micro-adjustment
CAUTION! To prevent damage to the tapered needle, do not use tools to grip the needle
threads.
28
Remove the two screws securing the cap to the upper body.
2.
If not already separated, remove the two screws securing the lower body to the upper body and
carefully remove the lower body from the needle and set it aside. Leave the needle intact in the
upper body for now.
3.
For future reference, note the fitting and plug locations on the upper body.
4.
Using a flat head screwdriver, remove the fitting and the plug from the upper body.
4
2
5
Item
Description
Item
Description
Upper Body
Fitting
Plug
Cap
Lower Body
29
Use the module-adjusting wrench to hold the top of the seal lock nut and another moduleadjusting wrench to loosen the spring retainer. Carefully remove the spring retainer and seal lock
nut.
2.
3.
Carefully remove the air piston, seal lock nut, and o-ring assembly from the needle.
4.
Carefully separate the air piston, seal lock nut, and o-ring.
5.
Disconnect the co-axial air tubing from the co-axial air nozzle nut, the co-axial air valve electrical
cable connector, and the blue air line from the dispensing system.
2.
Remove the two co-axial air solenoid bracket mounting screws from the bottom of the Z-head
mounting plate.
3.
5
6
3
8
Item
Description
Item
Description
Needle
O-ring
U-cup Seal
Air Piston
Spring Retainer
Upper Body
Figure 5-4 Removing the Needle and Disassembling the Air Piston
30
CAUTION! Protect the Solenoid Valve, Heater, and Seat Extension from contact with coating
material, and incompatible cleaning solutions or solvents. Contamination could
cause premature DispenseJet failure.
NOTE
It is recommended that you replace o-rings and u-cup seals rather than clean them. New or
clean o-rings must be treated with an o-ring lubricant.
Clean the needle, spring retainer and the seal lock nut thoroughly and inspect for cleanliness,
damage, and wear and tear. Replace as needed.
NOTE
Make sure to clean all threaded holes and body cavities thoroughly, and inspect for
cleanliness, damage, wear and tear. If the needle has a worn tip or has polished
metal streaks, replace it and the seat extension.
2.
Clean the upper body and lower body exterior and interior cavities thoroughly and inspect for
cleanliness, damage, and wear and tear. Replace as needed.
3.
Clean the connector, plug, fitting, compression spring, cap, micro-adjustment, preload screw,
preload lock nut, standard nozzle nut, and the co-axial air nozzle nut.
4.
Clean the seat extension thoroughly and inspect for cleanliness, damage, and wear and tear.
Replace as needed.
5.
6.
7.
If electrical problems are indicated in the Troubleshooting section, use a multimeter to check the
solenoid valve, co-axial air solenoid valve, and the heater. Replace as needed.
NOTE
The DispenseJet should be assembled on a flat surface using appropriate tools and
materials. Ensure all replacement parts are on hand before beginning.
CAUTION! Do not subject the electrical cables to stress during reassembly. Damaged cables
cannot be replaced separately and can only be replaced with the next higher
assembly.
CAUTION! Do not re-use a removed ucup seal. Handle new o-rings and seals carefully. If
o-rings or seals are damaged, leakage or premature DispenseJet failure may occur.
31
NOTE
The screws should be tightened to a torque of 1.36 N-m (12 in-lb), except where noted in the
assembly instructions. New o-rings must be treated with an o-ring type lubricant.
Install the elbow connector to the lower body ensuring that the fluid intake port is facing correctly.
2.
3.
Using the ring and seal insertion tool, carefully seat the o-rings to the u-cup seal into the
lower body.
2.
Using a flat-head screwdriver, install the fitting to the upper body in its correct place.
3.
Using a flat-head screwdriver, install the plug to the upper body in its correct place.
4.
Install the air hose to the air inlet of the upper body ensuring a secure fit
5.
To assemble the Lower Body, Upper Body, and Solenoid Valve (Figure 5-5):
32
1.
Place the lower body and upper body on a flat surface and align the attachment holes.
2.
Using the torque wrench, install the two screws through the lower body and the upper body
ensuring a secure attachment.
3.
Place the solenoid valve on top of the upper body and align the attachment holes.
4.
Using the torque wrench, install the two screws through the solenoid valve and the upper body
ensuring a secure attachment.
5.
Set aside the assembled lower body, upper body, and solenoid valve.
1
2
9
5
10
8
6
7
Item
Description
U-cup Seal
2
3
Item
Description
U-cup Seal
Upper Body
O-ring
Fitting
Elbow Connector
Solenoid Valve
Lower Body
10
Plug
Figure 5-5 Reassembly of the Upper and Lower Bodies and Solenoid Valve
To insert the Seat Extension into the Heater (Figure 5-6):
1.
Reapply the conductive grease on the seat extension without putting any grease on the threaded
shaft.
2.
Position the seat extension so that the dowel pinhole on the seat extension faces toward the
backside.
3.
Rotate the seat extension into the heater to spread the conductive grease evenly and to avoid
the formation of air pockets.
4.
Thoroughly wipe off any excess conductive grease from the seat extension threads.
To attach the Heater and Seat Extension to the Lower and Upper Bodies (Figure 5-6):
1.
Position the heater and seat extension to the lower and upper bodies as shown in the illustration.
2.
Align the attachment holes for the heater, seat extension, and the upper and lower bodies.
3.
Using a torque wrench, install the two screws and tighten to a torque of 0.79 N-m (7 in-lb).
4.
33
3
Item
Description
Item
Description
Seat Extension
Upper Body
Heater
Lower Body
Prepare the air piston for installation to the upper body as follows:
a. Place the u-cup seal on a clean flat surface.
b. Roll the lip of the u-cup seal so that a lip is formed to hang down toward the upper body.
c.
34
Using the o-ring lubricant, lubricate the seal area of the piston insertion tool and the inlet
area of the upper body.
d. Carefully install the air piston into the piston insertion tool so that the entire air piston is
completely inside piston insertion tool.
e. Ensure that the air piston is installed without any gaps or folds and is evenly round.
f.
NOTE
If the installation is unsuccessful and the air piston was damaged in the process,
replace air piston and repeat above steps. If not, continue with next step.
Turn the piston insertion tool upside down so that the air piston is facing down towards flat
clean surface.
g. Using the o-ring lubricant, lubricate the o-ring and install the o-ring in the groove of the
chamfered end of the seal lock nut.
h. Apply pressure to the seal lock nut while installing it in the top of the piston insertion tool and
into the air piston for a secure installation.
2.
3.
Thread the seal lock nut onto the needle until the lip of the piston insertion tool seats in the
chamber on top of the upper body.
d. Continue to turn the piston insertion tool until it disengages from the seal lock nut.
At this point, the top of the seal lock nut should be within 0.46-mm to 0.51-mm (0.018inch to 0.020) above the top of the upper body.
e. Using the piston height gauge tool, place the notched edge across the seal lock nut so that
the feet of the piston height gauge tool rest on the upper body surface.
4.
No gap shall be visible under the notched feet or notch. If necessary, correct air piston
installation by repeating Step 3.
Gently pull up on the needle approximately 1/8inch but do not pull the air piston out of the air
piston insertion tool.
NOTE
Air piston adjustment is often necessary when you replace the upper body u-cup
seal or the needle. In these cases, follow the disassembly and reassembly
instructions in this section, but do not actually replace the air piston unless it is
damaged. Improper air piston adjustment may result in poor dot quality (dots not
breaking off from nozzle).
5.
6.
Using the module-adjusting wrenches, hold the seal lock nut in place and tighten the spring
retainer for a secure tight installation.
CAUTION!
7.
To properly seat the needle, ensure that the top of the seal lock nut is flush to above the top of
the upper body.
35
1
2
3
4
5
Item
Description
Item
Description
Spring Retainer
Air Piston
Needle
O-ring
Upper Body
Figure 5-7 Installing the Air Piston using the Air Piston Insertion Tool
To attach the Micro-Adjustment and Cap to the DispenseJet (Figure 5-8):
1.
Attach the cap to the upper body using the two screws making sure the two notches are aligned.
2.
3.
Using the spanner wrench, install the preload lock nut on the preload screw.
4.
Perform the next step if the micro-adjustment has been replaced or removed from the
preload screw.
a. Insert the micro-adjustment into the preload screw.
b. Use a hex key to tighten the preload set screws.
36
5.
With the micro-adjustment attached to the preload screw, place the preload screw on the
compression spring and turn it clockwise to attach it to the upper body.
6.
3
4
6
8
Item
Description
Item
Description
Cap Micro-adjustment
Seat Extension
Compression Spring
Preload Screw
Upper Body
37
Preload setting
Micro-adjustment setting
NOTE
The preload setting affects the velocity of jet of fluid and regulates the cleanness of the
fluid break-off, which affects the shape of the dots or lines. The preload setting is
regulated through the number of times the preload screw is turned downward from its
current starting position.
This procedure requires the DispenseJet to be disassembled.
1.
Turn the micro-adjustment clockwise until the compression spring touches the top of the
preload screw. Look through the window of the preload screw to see the point of contact. See
Figure 5-9. This is the preload screw point of reference and is equal to zero (0) turns.
Check that the preload lock nut is positioned at its highest position above the preload screw
window while turning (if it is lower, it will restrict movement).
From the preload screw point of reference, turn the preload screw the desired number of turns
determined for your application.
3.
Use the spanner wrench to tighten the preload lock nut to the top of the cap.
4.
Gently turn the micro-adjustment clockwise to seat the needle into the seat extension.
5.
38
NOTE
The preload and micro-adjustment settings will vary for different fluids. Contact
Nordson ASYMTEK Technical Support for particular fluid settings.
The preload screw must be adjusted before performing this procedure. Refer to the To
adjust the Preload: procedure earlier in this section.
NOTE
1.
Using a 0.05-inch hex key, loosen the setscrews on the preload screw.
2.
Rotate the inner micro-adjustment column so the numbered markings face the solenoid valve.
3.
Using the 0.05-inch hex key, tighten the preload set screws, locking the preload screw in place.
4.
Using your fingers, loosen the micro-adjustment lock nut by turning it counterclockwise.
5.
Turn the outer micro-adjustment collar down and clockwise until it stops.
CAUTION!
Do not continue to turn the outer micro-adjustment collar once it stops, or you may
damage the DispenseJet.
6.
Use a 1.5-mm hex key to loosen the micro-adjustment collar set screw.
7.
Raise and turn the outer micro-adjustment collar clockwise so that the vertical zero (0) marking
aligns with the vertical centerline on the inner micro-adjustment column.
NOTE The bottom of the outer micro-adjustment collar should align with the horizontal zero
(0) marking on the inner micro-adjustment column.
8.
Using the 1.5-mm hex key, tighten the micro-adjustment collar set screw.
9.
Rotate the outer micro-adjustment collar counterclockwise to set the micro-adjustment to the
desired parameter.
NOTE Every ten marks on the outer micro-adjustment collar equal 0.10-mm. For example, a
10.
movement of five marks equals 0.05-mm relative to your starting position. Only the
increment marks on the outer micro-adjustment collar are relevant for adjustment.
39
5
5
20
Item
Description
Item
Description
Micro-adjustment
Micro-adjustment Collar
Preload Screw
40
Troubleshooting
To quickly identify problems, look for obvious signs such as burnt, missing, damaged, or loose parts, as well
as fluid obstructions and leakages. If a problem recurs, there may be other root causes. Table 6-1 facilitates
troubleshooting based on symptoms. Refer to the Additional Information section for part identification.
Table 6-1 Troubleshooting
Symptom
Possible Cause
No signal to the solenoid
valve.
DispenseJet is not
cycle jetting.
Recovery
Check the solenoid connector between the
DispenseJet and the Dispensing System.
Check the configuration to verify DispenseJet is
selected as Valve 1.
Verify that the air pressure is 483 to 621 kPa (70 to
90 psi).
No fluid in syringe, air bubble Use one of the following steps to purge the
in the flow path, or microDispenseJet:
adjustment set too low or is
closed.
1. Manually actuate the solenoid valve.
No fluid being
dispensed.
Troubleshooting
2.
3.
DispenseJet component
malfunctioning.
41
Symptom
DispenseJet
performs but has
problems after the
co-axial air is
installed.
Possible Cause
Recovery
Seat extension is
frequently damaged
or poor dot quality
(dots not breaking
off from nozzle).
42
Troubleshooting
Additional Information
Overview
This section includes information for ordering recommended spares, replacement parts, and available
optional parts for the DJ-2200 DispenseJet.
This appendix covers the following:
Ordering Parts
Exploded Views
Safety First
Review the Safety section of this manual before attempting to replace any parts.
CAUTION!
Ordering Parts
This section contains parts ordering information for the DJ-2200. Figure 7-1 through Figure 7-4 show
available replacement parts and their part numbers.
All customers can order spare parts by contacting Nordson ASYMTEK Customer Service.
Your Customer Service Representative can take your order or assist you in setting up an account to
purchase spare parts through the Nordson ASYMTEK Internet Web Store.
When ordering parts, be prepared to provide the following information:
Billing Address
Shipping Address
Serial Number of your dispensing system (found on the back panel of the system)
Quantity
Shipping Instructions
Part number information is also available on Nordson ASYMTEKs Find-A-Part web page:
http://webstore.asymtek.com/awweblive/apps/findapart_index.asp
Replaced Parts
Always clean and inspect the vacated area after a failed part is removed for indications of the root cause of
the failure. Correcting the root cause may help prevent future part damage.
Additional Information
43
Spare Parts
The recommended spare parts for the DJ-2200 DispenseJet are listed in Table 7-1 and Table 7-2. The item
numbers shown in the table correspond with numbered callouts in Figure 7-3.
Table 7-1 Recommended Spare Parts for the DispenseJet
Item
Number
Part
Number
226289
226276
Preload Screw
982745
145461
234299
Compression Spring
226277
Spring Retainer
168833
973529
234154
10
249942
11
338751
Dispenser Cap
12
340721
13/17
322399
14
338763
15
338752
Lower Body
16
282287
18
234167
19
982747
20
322429
Nozzle Nut
Description
Spares for optional Nozzles available for the DJ-2200 DispenseJet are listed in Table 7-2. The item numbers
shown in the table correspond with numbered callouts in Figure 7-3.
Table 7-2 Nozzle Spares for the DispenseJet
44
Item
Number
Part
Number
21
391777
21
391778
21
391779
21
391780
21
391781
21
391782
21
391783
21
391784
21
391785
Description
Additional Information
14
15
13
16
4
17
5
12
18
11
7
8
21
19
10
9
20
Additional Information
45
The recommended spare parts of the optional co-axial air assist feature available for the DJ-2200
DispenseJet are listed in Table 7-3. The item numbers shown in the table correspond with numbered callouts
in Figure 7-2.
Table 7-3 Recommended Co-Axial Air Assist Spares for the DispenseJet
Item
Number
Part
Number
329391
329410
329411
322445
40-3501
Description
2
1
46
Description
Quantity
940139
168824
U-cup Seal
719082
940090
O-ring (Brown)
115055
Air Piston
245773
Conductive Grease
58-0030
58-0036
Additional Information
Part Number
Description
Quantity
58-0037
58-0038
Startup Kit
Table 7-5 lists the parts contained in the DJ-2200 startup kit.
Table 7-5 DJ-2200 Startup Kit
Item Number
Part Number
234149
234150
234151
129612
901935
901922
901923
901924
901916
Pin, Vise
10
245773
Grease, Conductive
11
124520
Screwdriver
12
274973
13
115059
14
272821
15
145468
Wrench, Spanner
16
901911
17
901905
Nuzzle Brush
18
226302
19
226274
20
338757
21
322431
22
340721
23
340720
24
282287
25
982747
26
982745
27
28
Additional Information
Description
Quantity
47
Part Number
Description
901911
145468
Spanner Wrench
226274
392652
226302
115059
274973
272821
234150
10
234149
11
234151
12
129612
12
11
1
10
9
8
7
3
6
5
4
Figure 7-3 Adjustment and Assembly Tools
48
Additional Information
Cleaning Tools
Table 7-7 lists the Cleaning Tools parts. The Item Numbers shown in the Table correspond with numbered
callouts in Figure 7-4.
Table 7-7 Cleaning Tools
Item
Number
Part
Number
193840
58-0038
58-0037
58-0036
901935
901922
901923
901924
901916
Pin, Vise
901905
Nozzle Brush
Description
1
2
7
6
Additional Information
49
Mounting Brackets
The mounting brackets required for installation of the DispenseJet to Nordson ASYMTEK Dispensing
Systems platforms are listed in Table 7-8.
Table 7-8 Mounting Brackets
Mounting Bracket P/N
Dispensing System
391765
391765
N/A
Exploded Views
Figure 7-5 through Figure 7-8 shows the DJ-2200 DispenseJet in exploded view. These illustrations can be
helpful when ordering replacement parts for the Pump.
NOTE
Not all parts shown on the exploded views are available separately. Contact Nordson
ASYMTEK Customer Service or your local distributor for availability.
WARNING!
50
CAUTION!
The exploded views are intended only as an aid for part identification for ordering
purposes. Only Nordson ASYMTEK-trained service technicians should perform
servicing and parts replacement. Nordson ASYMTEK assumes no liability for
personal injury or property damage that may occur as a result of service/parts
replacement performed by other than Nordson ASYMTEK-trained technicians.
Additional Information
Item
1
Part No.
322359
Description
Top Assembly, Valve DJ-2200
Additional Information
51
Item
Part No.
Description
322359
Valve, DJ-2200
391765
64-HS-RTA
52
Additional Information
Item
Part No.
Description
329412
391775
391765
64-HS-RTA
Additional Information
53
See Figure 7-8, DJ-2200 DispenseJet Exploded View (4 of 4) for the listed items below.
Item
54
Part No.
Description
226289
Micrometer Assembly
982745
145461
226276
Preload Screw
234299
Compression Spring
226277
Spring Retainer
168833
940090
115055
Air Piston
10
322399
11
322399
12
168824
13
340721
14
338751
Dispenser Cap
15
973529
16
329412
17
340720
18
338750
Upper Body
19
234154
20
338763
21
338752
Lower Body
22
282287
23
168824
U-cup Seal
24
940139
25
719082
26
234167
27
234119
Teflon Gasket
28
391777
28
391778
28
391779
28
391780
28
391781
28
391782
28
391783
28
391784
28
391785
29
322429
Nozzle Nut
30
982747
31
234167
Item
Part No.
Description
32
234167
33
234167
Additional Information
55
2010