DIMA HC-100 User manual

TB-1026

HybridC

HC-100/200

Service Manual Ver1.1

This document contains proprietary information which is protected by copyright. All rights are

reserved. No parts of this document may be photocopied, reproduced, or translated into

another language without the prior written consent of DIMA Group B.V. .

The information contained in this document is subject to change without prior notice.

HYBRID Coater Service Manual ver?1.1 Table of Contents

Table of Contents

1. Introduction 4

1.1 About this Manual 4

1.2 Model Overview 5

2. Safety 6

2.1 Warnings 6

2.2 Emergency Switches 6

3. Machine Overview 7

3.1 Introduction 7

3.2 Electrical Block Diagram 7

3.3 Block Diagram of Air 8

3.3.1 Routing of the Air Lines 9

3.3.2 Air Lines Routing of the Options 10

3.3.2.1 With Options HC-1050 or HC-1051 10

3.3.2.2 With Options HC-1000, HC-1010, or HC-1030 12

3.4 With Options HC-1160/1170 14

3.5 Electrical Compartment in Front 15

3.6 Electrical Compartment in Rear 17

3.7 Detection of Exhausted Air 19

3.8 X and Y Movement 19

3.9 Head with Connection PCB 20

3.10 Dispense Head PCB 21

3.11 Z Movement at HC-100 21

3.12 ZØ Movement at HC-200 22

3.13 Embedded Software 23

3.14 Additional Revision Information 23

3.14.1 General 23

3.14.2 HC-100 Specific 24

3.14.3 HC-200 Specific 24

3.14.4 HC-1160/ HC-1170 General 24

3.14.5 HC-1170 Specific 24

4. Machine Installation 25

4.1 Pre-installation Checks 25

4.2 Unpacking the Machine and Removing Transport Locks 25

4.3 Placing and Leveling the Machine 27

4.4 Connections and Pressure Setting 27

4.5 Completion of the Installation 28

4.6 Installing Special Options 28

4.6.1 Installing Options DD-52XX 28

4.6.2 Installing Option HC-1050/ HC-1051 28

4.6.3 Installing Option HC-1210/ HC-1215 31

4.6.4 Installing Option HC-1230/ HC-1231 31

4.6.5 Installing Options HC-1235 and HC-1236 32

4.6.6 Installing Option HC-1320 32

4.7 Installing Options HC-1380 and HC-1390 34

4.8 Installing Options HC-1160 and HC-1170 35

Table of Contents HYBRID Coater Service Manual ver1.1

4.8.1 Placing/Adjusting Stopper Pin/Product Detect Sensor of Conveyor 35

4.8.2 Adjusting the Conveyor Level and Height 37

4.9 Setting-up the weight scales 38

4.9.1 Settings 38

4.9.2 Setting-up the Com Parameters 38

5. Maintenance 41

5.1 Introduction 41

5.2 Service Diagnostics 41

5.3 Regular Maintenance 42

5.4 Checklist for the Maintenance of the HYBRID 46

6. Electrical Wiring 50

6.1 Electrical Wiring Diagrams 50

6.2 Overview of the Wiring Diagrams 50

7. Pneumatics 52

7.1 Overview 52

7.2 Pneumatics Diagram 52

8. Diagnostics for PCB’s 55

8.1 Introduction 55

8.2 Controller EL-04873 55

8.2.1 LED’s on Upper Left Side of the EL-04873 56

8.2.2 LED’s near Connectors P1 and P2 on the EL-04873 57

8.2.3 LED’s near Connector P3 and P4 on the EL-04873 58

8.2.4 LED’s on Upper Right Side of the EL-04873 59

8.2.5 LED’s on Bottom Left Side of the EL-04873 61

8.2.6 LED’s near Connectors P21 till P26 on the EL-04873 62

8.2.7 LED’s near Connectors P27 till P29 on the EL-04873 63

8.2.8 Explanation of DIP-switches on EL-04873 64

8.3 Advanced Power LED Controller EL-04872 66

8.4 Stepper Drivers EL-04874 67

8.5 Interconnection PCB EL-04875 68

9. Small Repairs and Adjustments 70

9.1 Pressure Settings 70

9.2 Focusing the Fiducial Camera 70

9.3 Replacing the Fiducial Camera at a HC-100 71

9.4 Replacing the Fiducial Camera at a HC-200 72

9.5 Replacing Stepper Motors 73

9.5.1 Replacing the Stepper Motors of the X and Y axis 73

9.5.2 Replacing the Stepper Motor of the Z axis on the HC-200 74

9.5.3 Replacing the Stepper Motor of the Ø axis 76

9.6 Replacing PCB’s of Stepper Motors 77

9.7 Replacing and Adjusting the Encoder 77

9.8 Exchanging the Flexible Cable Duct on the HC-200 80

9.9 Adjusting the X, Y, Z and Ø Limits 82

9.9.1 Adjusting the Limits for the X Axis 82

9.9.2 Adjusting the Limits for the Y Axis 82

9.9.3 Adjusting the Limits for the Z Axis with the HC-100 82

9.9.4 Adjusting the Limits for the Z Axis with the HC-200 83

9.9.5 Adjusting the Limits for the Ø Axis with the HC-200 84

HYBRID Coater Service Manual ver?1.1 Table of Contents

9.10 Replacing the Differential Pressure Switch 84

9.11 Fitting a new stop pin in a conveyor 86

10. Spare Parts 87

A. Electrical Wiring Diagrams Revision 1.0 103

B. Electrical Wiring Diagrams Revision 1.1 110

C. Electrical Wiring Diagrams of Options 128

D. EL-04806 Dispense Head PCB Overview 139

E. EL-04873 Control PCB Overview 143

F. EL-04875 Connection PCB Overview 155

G. EL-04876 Dispense Head PCB Overview 161

H. EL-04879 Dispense Head PCB Overview 165

I. I/O Assignment 168

Chapter 1 HYBRID Coater Service Manual ver1.1

1. Introduction

1.1 About this Manual

This manual provides information to be used by the DIMA authorized service engineer to

maintain and repair the HYBRID Coating machine. It describes the HYBRID C, it’s cabling

and pneumatics, regular maintenance work, and the spare parts. The manual further

describes how to perform some small repairs, and modifications. The options for the HYBRID

C are also described in this Service Manual.

For general information about the HYBRID C, refer to the user documentation (User Manual

+ Machine Reference Manual).

Due to technical innovations and improvements, data in this manual may differ from the

machine at hand. DIMA however tries to keep this manual as up to date as possible.

Next table shows an overview of the previous and current versions of this manual.

Version Release date Changes

1.0 October 2007 Initial Release

1.1 July 2008 Set-up of Chapter 5 changed, also added

checklist. In Chapter 9 the Section about

stepper motors SS53 was extended . Also the

revision of the stop pin was added. Additional

SS-numbers were given in Chapter 10. Valve

heating added in several Chapters.

When you have any questions or remarks about the HYBRID Conformal Coating machine or

this Service Manual, please contact DIMA.

DIMA Group B.V.

Beukelsdijk 2

5753 PA Deurne

Tel : +31 493 352 752

Fax: +31 493 352 750

e-mail: [email protected]

HYBRID Coater Service Manual ver1.1 Chapter 1

1.2 Model Overview

The HYBRID C is available in two versions:

HC-100: The HC-100 robot is equipped with X, Y, and Z axis. The 3-axis robot can handle

up to 4 different tools. Tools can be dispense valves, spray valves, grippers, etc.

They are mounted onto a Z slide, or on a Z slide combined with a fixed tilt

mechanism as a fourth axis. This combination is mounted onto an adapter for 1, 2,

3, or 4 valves. Tools and valves can be configured outside of the machine and can

be mounted onto the robot as one single unit. The 3-axis robot comes with a

camera on the Z axis, computer with DIMASOFT User Software, a base for

adapter plates, one electronic pressure transducer for the main air supply, one

electronic pressure transducer for detection of exhausted air and illumination

inside the machine.

HC-200: The HC-200 robot is equipped with X, Y and Z and Φaxis. The 4-axis robot can

handle up to 4 different tools. Tools can be dispense valves, spray valves,

grippers, etc. They are mounted onto a valve mount. Tools and valves can be

configured outside of the machine and can be mounted onto the robot as one

single unit. The 4-axis robot comes with a camera on the Z axis, computer with

DIMASOFT User Software, a base for up to 4 valve mounts, one electronic

pressure transducer for the main air supply, one electronic pressure transducer for

detection of exhausted air and illumination inside the machine.

Both robots can be configured as a batch or inline machine and can be reconfigured in the

field at any time.

Chapter 2 HYBRID Coater Servicce Manual ver1.1

2. Safety

Refer to the User Manual for general Safety Information.

2.1 Warnings

Never enter the machine when the motors of the Coating

Head or of the Conveyor are running.

Do not overrule the hood locks and do not run the HYBRID

C in any way with the hoods open.

Do not overrule the push buttons place don the Safety

Panel.

When working with test fluids be aware of the following:

Consult the Material Safety Data Sheet (MSDS) for all fluids

used with the HYBRID C. The MSDS provides material

usage instructions, safety precautions, information about

personal protective equipment, and disposal instructions.

Fluids can be extremely dangerous when working with high

pressure. They should be safely contained. Be sure the

pressure is removed before performing any adjustments or

maintenance. A beam of high pressure fluid can cut like a

sharp knife and can even result in death.

2.2 Emergency Switches

Emergency switches are installed on two places on the machine. Immediately push one of

these switches when an emergency occurs. The machine will immediately switch off. The pC

and the motor stay on.

When the situation is normal again, the Emergency Switch can be pulled out and the

machine can be restarted as described in the User Manual.

HYBRID Coater Service Manual ver1.1 Chapter 3

3. Machine Overview

3.1 Introduction

This Chapter gives an overview of the machine. Drawings of electrical wiring can be found in

Appendix A and B.

3.2 Electrical Block Diagram

Below figure shows the block diagram of the electrical parts of the machine.

Z-Limit

EL-04875

Connection

PCB

-Limit (HC-200 only)

-Encoder

(HC-200 only)

X-Limits

Y-Limits

Cable

Chain

Cable

Chain

EL-04874

Stepper Driver

EL-04874

Stepper Driver

EL-04874

Stepper Driver

EL-04874

Stepper Driver

EL-04874

Stepper Driver

EL-04874

Stepper Driver

EL-04548

Processor

Module

XYZ C1C2

Fuses Fuses

Power

Supply

24Vdc

Power

Supply

48Vdc

Control Circuit & Fuses

Fuses

Main Switch

On/Off Switch

Emergency Switch

Interiour Light

EL-04873

Control

PCB

PCMonitor

RS232/USB

Keyboard

Trackball

24Vdc

Differential

Pressure

Switch

Mounting

Bracket for up

to 8 Pressure

Sensors

EL-04872

Power

LED

Control

Cable

Chain

EL-04876

EL-04806

EL-04879

Valve Mount

Assembly

Valve Mount

Assembly

Valve Mount

Assembly

Valve Mount

Assembly

1234

Rotary Valve 1

Rotary Valve 2

EL-00578

Camera

EL-04870 or

EL-04807

Advanced Fid.

Camera

Illumination

Doorlock Front

Doorlock Back

Pushbutton

Control Panel

Exhauster

Detection

Chapter 3 HYBRID Coater Service Manual ver1.1

3.3 Block Diagram of Air

Below figure shows the block diagram of the air parts of the machine.

EL-04875

Connection

PCB

Cable

Duct

Cable

Duct

EL-04548

Processor

Module

EL-04873

Control

PCB

Mounting Bracket for up to

8 Pressure Sensors

(Pressure Sensors part of

Kit HC-1050 or HC-1051)

Cable Duct

Valve Mount

Assembly

Valve Mount

Assembly

Valve Mount

Assembly

Valve Mount

Assembly

1234

Air Filter

Pressure Regulation

Air Supply

Air

Distribution

Block

optional Pressure

Reducing Valves(Part of

Kit HC-1050 or HC-1051)

Output for

Medium

Pressure or

other optional

Functions

Valves for

Up/Down/Tilt/Normal

Valves for Atomising Air or

other functions

EL-04872

Power

LED

Control

Air Distributor Cross

(HC-200 only)

Main Air IN

optional

Solenoid

Valves

(Part of Kit

HC-1050 or

HC-1051)

This manual suits for next models

Table of contents

Other DIMA Dispenser manuals

DIMA

DIMA 943 User manual

Popular Dispenser manuals by other brands

Silver King

Silver King Majestic SK12MAJ Technical manual and replacement parts list

Franke

Franke F3Dn Twin Service manual

STIEBEL ELTRON

STIEBEL ELTRON UltraHot Plus Operation and installation instructions

DAN DRYER

DAN DRYER 282 installation guide

Essity

Essity Tork 473208 manual

CBS

CBS SD300BU-88 COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST

Sealey

Sealey MK77 manual

Fluid Management

Fluid Management Accutinter 1600 End user guide

Franke

Franke DVS SD99-010 Installation and operating instructions

Graco

Graco Dispensit 1053-10C operation & maintenance

ITALTINTO

ITALTINTO i50 user manual

Coca-Cola

Coca-Cola FREESTYLE 9000 user guide

Graco

Graco ProMix 2KE Operation

TECHCON SYSTEMS

TECHCON SYSTEMS TS1251 user manual

Wayne

Wayne GLOBAL VISTA CNG instruction manual

clarsen

clarsen H133 Instructions for use

PicoBrew

PicoBrew Zymatic user manual

BOWMAN

BOWMAN BP-007 manual