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DispenseJet Series

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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manuals can be downloaded from:
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using the information below:

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USA
Toll Free:
Tel:

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+1-760-431-1919

Fax:

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www.nordsonasymtek.com Tech
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

P/N 7210768, Revision C

are registered trademarks of Microsoft Corporation.

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

Maintenance and Service ..................................................................................................................19


Overview ..............................................................................................................................................19
Maintenance Schedule ........................................................................................................................19
Cleaning the Nozzle .....................................................................................................................19
Purging the DispenseJet ..............................................................................................................21
Complete Cleaning.......................................................................................................................21
Complete Overhaul Service .........................................................................................................26
Settings and Adjustments ............................................................................................................38

Troubleshooting .................................................................................................................................41

Additional Information .......................................................................................................................43


Overview ..............................................................................................................................................43
Safety First ...........................................................................................................................................43
Ordering Parts ......................................................................................................................................43
Return Material Authorization ......................................................................................................43
Replaced Parts .............................................................................................................................43
Spare Parts ..................................................................................................................................44
Startup Kit ....................................................................................................................................47
Adjustment and Assembly Tools ..................................................................................................48
Cleaning Tools .............................................................................................................................49
Mounting Brackets .......................................................................................................................50
Exploded Views ...................................................................................................................................50

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

DJ-2200 Series Specifications ....................................................................................................2


Minimum Recommended Parameters .......................................................................................18
Routine Maintenance Schedule, Category A ............................................................................19
Preventive Maintenance Schedule, Category B ........................................................................19
Troubleshooting .........................................................................................................................41
Recommended Spare Parts for the DispenseJet ......................................................................44
Nozzle Spares for the DispenseJet ...........................................................................................44
Recommended Co-Axial Air Assist Spares for the DispenseJet ...............................................46
DJ-2200 Spares Kit ...................................................................................................................46
DJ-2200 Startup Kit ...................................................................................................................47
Adjustment and Assembly Tools ...............................................................................................48
Cleaning Tools...........................................................................................................................49
Mounting Brackets .....................................................................................................................50

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.

Figure 1-1 DJ-2200 Series DispenseJet and Air Assist Feature

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):

380 g (without syringe)

Syringe Size:

5, 10, or 30 cc (0.17, 0.34, or 1.0 oz)

Reservoir Size:

177 or 591 cc, 3.9 liters (6 or 20 oz, 1 gal)

Environmental/Facility:
Storage/Operating Temperature:

5 to 50 C (41 to 122 F)

Relative Humidity:

5 to 90 % (non-condensing)

Altitude Limitations:

Approximately 1609 meters (5278 feet


maximum)

Electrical:

Valve, Operating Voltage:

24 VDC

Solenoid:

24 VDC, 12.7 watts

Heater:

8.5 Watts
2

Fluid Pressure:

0-2 Kg/cm (0-28 psi)

Pneumatics:

690 kPa (100 psi)

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!

Unsafe equipment conditions can result in personal injury or property damage.


Failure to adhere to safety warnings and precautions could result in serious bodily
harm to the user.

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.

Relieve pneumatic pressure before adjusting or servicing pressurized components.

Preventing Equipment and Workpiece Damage

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.

Perform all recommended DJ-2200 maintenance procedures at the suggested intervals.

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!

The DispenseJet Series DJ-2200 is a precision instrument of inherently safe design.


The use of any dispensing fluid and the related choice of solvent for cleaning, as
well as all associated safety precautions is the responsibility of the end-user.
Consult with your fluid supplier for recommendations on personal protective
equipment and safety practices.

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:

Unpacking the DJ-2200

Installing the DJ-2200

Unpacking the DJ-2200


Every care has been taken when packaging your DJ-2200. However, we recommend that you look for
obvious damage and verify contents against the packing slip.
Retain the case for storage of DJ-2200 and accessories. Retain shipping cartons for future use. If an item
needs to be returned to Nordson ASYMTEK, obtain a Return Material Authorization (RMA) from Nordson
ASYMTEK Customer Service before returning the parts.

Installing the DJ-2200


If the DJ-2200 was factory installed with the dispensing system, you can proceed directly to the Operation
section in this manual.
The following instructions are for the C-730 Dispensing System. Installations to other dispensing systems
may vary slightly.

Tools and Material Needed

Adjustment and Assembly Tools


Torque Wrench
Nozzles

CAUTION!

Installation

The DJ-2200 Series DispenseJet is a delicate precision instrument. Exercise care


when installing the DispenseJet. Failure to do so may cause damage to the
DispenseJet. Installation should be performed by trained personnel only.

To install the DispenseJet:


1.

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

Fluid Air Pressure (Clear)

Mounting Screws (two)

Syringe and Clear Fluid Pressure Line

Electrical Cable

Syringe Bracket

Heater Power Connector

Z-mounting Plate

Temperature Controller Connector

DispenseJet

10

Solenoid Valve Electrical Connector

Figure 3-1 Installing the DispenseJet to the C-730 Dispensing System


6

Installation

Item

Description

Item

Description

Fluid Air Pressure (Clear)

Fluid Sensor Electrical Connector

Valve Air Pressure OFF (Black)

Temperature Control Connector

Co-axial Air Electrical Connector


(Optional)

Heater Power Connector

Solenoid Valve Electrical Connector

Co-axial Air (Optional)

Figure 3-2 lnstalling the DispenseJet to the M-2000 Flux Dispensing System

Installation

To Install the Air Assist Feature:

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.

Install the co-axial air solenoid valve as follows:


1.

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

Co-axial Air Pneumatic Valve Tubing

Bracket Mounting Screw (two)

Co-axial Air Electrical Connector

Co-axial Air Nozzle and Air Tubing

Co-axial Air Solenoid Valve Screw (two)

Standard Nozzle Nut

Co-axial Air Solenoid Valve

Z-head Mounting Plate (Valve Bracket)

Co-axial Air Solenoid Bracket


Figure 3-3 Installing the Air Assist Feature

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

Application and Process Development

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!

Flux applications and cleaning involve hazardous materials. Adhere to MSDS


instructions for the materials. Failure to adhere to safety warnings and precautions
could result in serious bodily harm to the user.

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

to an ideal and controlled temperature of 40 C (104 F).


In the jetting process, the DispenseJet moves in an X-Y plane to dispense a variety of pre-programmed
patterns in a confluence to create a uniform film of flux. (There is no movement required in the Z-axis during
or between the dispense cycles). The fluid, which was dispensed on the substrate, forms a dot or a line
depending on application.
The micro-adjustment controls the needle travel distance. When turned clockwise, it decreases the piston
travel and fluid flow, and when turned counterclockwise it increases the piston travel and fluid flow.

2
3

4
5

6
Item

Description

Item

Description

Micro-adjustment

Needle

Spring

Heater

Air Piston

Nozzle

Figure 4-1 Typical Jet DispenseJet Internal Workings

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.

Tools and Material Needed

Adjustment and assembly tools


Nozzle kit
Appropriate solvent and containers for the selected dispensing fluids
Personal protective equipment

DispenseJet Setup Adjustments


There are two pre-requisite minor adjustments that must be performed on the DispenseJet (see Figure 4-2):

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.

Setting the Preload


To set the DispenseJet Preload:
1.

Back off the micro-adjustment by turning it counterclockwise.

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 Lock Nut

DispenseJet Cap Markings

Preload Screw

Preload Window

Figure 4-2 Preload and Micro-adjustment Settings

Setting the Micro-adjustment


To make adjustments that may be necessary to regulate fluid volume while the DispenseJet is installed on
the dispensing system, proceed as follows:
To set the Micro-adjustment:
1.

Use the spanner wrench (included in kit) to loosen the preload lock nut (Figure 4-2).

2.

Turn the outer micro-adjustment collar counterclockwise to the appropriate setting.

3.

Use the spanner wrench to tighten the preload lock nut 1/8 turn.

Activating the Air Supply


To activate the Air Supply:

NOTE
1.

Set the main air on the dispensing system between 586 to 620.5 kPa (85 to 90 psi).

2.

Listen for air leaks.

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

For flux applications, there is no need for valve speed settings.

If a leak is detected, refer to the Maintenance and Service section.

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.

Using the Standard Nozzle Nut


This procedure assumes that the standard nozzle nut and nozzle are installed and that the co-axial air nozzle
nut is removed. Make sure to first drain the fluid system. See Draining the Fluid Lines in this section.
To use the Standard Nozzle Nut:
1.

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.

Set the fluid pressure to 34.5 kPa (5 psi).

4.

Turn the heater controller located inside the lower cabinet of the dispensing system to the ON (I)
position.

5.

Verify that the heater controller is preset to 35 Celsius (95 F).

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

Standard Nozzle Nut

Teflon Gasket (Optional)

Co-axial Air Nozzle Nut

Nozzle

Air Tubing (shown installed)

Figure 4-3 Changing Nozzles

14

Operation

Using the Air Assist Feature

NOTE

If installed, the co-axial air solenoid valve does not need to be removed when not in use.

To use the Co-axial Air Nozzle Nut (Figure 4-3):

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.

Install the co-axial air nozzle nut and nozzle as follows:


a. Install the nozzle by carefully placing it in the standard nozzle nut so that the threaded
portion of nozzle protrudes out of the standard nozzle nut.

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

Setup and Valve Offset Routines


The Fluidmove software uses prompts that can be followed to properly dispense, prime, purge, and refill
fluid. Parameters set in the Fluidmove dispensing software determine how long the valve remains open to
dispense each line or dot. Follow the instructions in the applicable dispensing system Operations Manual
and the Fluidmove User Guide.

NOTE

The DJ-2200 DispenseJet setup process in Fluidmove must be performed prior to


programming the dispensing system and using the DJ-2200 DispenseJet. The setup is
identical for flux dot and flux line applications.

Changing the Syringe


To change the Syringe (Figure 4-4):
This procedure assumes you using the same fluid. If you are changing fluids, see Changing Fluids later in
this section.
1.

If required, allow fluid to reach room temperature (refer to the MSDS for your fluid to determine
requirements).

2.

Inspect the fluid in syringe for air bubbles.

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.

Remove the syringe tip cap.

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.

Tighten the thumbscrew on the syringe bracket.

CAUTION!
9.

16

Do not over-tighten the syringe thumbscrew. Over-tightening may cause the


syringe to deform, forcing large amounts of fluid into the fluid chambers.

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

Draining the Fluid Lines


To drain the fluid lines:
1.

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.

Power up the dispensing system.

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).

Shutting Down DispenseJet Operations


Follow the instructions in the applicable dispensing system manual for routine, service, and emergency shut
down of the dispensing system. When the dispensing system is not being used, an appropriate solvent may
be kept in the fluid lines to prevent residue buildup.

Application and Process Development


The Fluidmove software is used to program your flux applications. There are special dispensing patterns in
the Teach Window that apply to flux processes. The Fluidmove software will help you define the flux pattern
and film thickness. There are also variables for dot parameters and line parameters along with DJ-2200
micro-adjust, preload, fluid pressure, and co-axial air pressure data.

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)

Co-axial Air Pressure

kPa (psi)

Dispense Gap **

Your Settings

mm (inches)

* Each line on the collar = 0.05-mm; one (1) turn = 0.50-mm


** In Dot or Line Parameters in Fluidmove

18

Operation

Maintenance and Service

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

Look for evidence of jetting


performance fluctuations.

Daily

Check to ensure the desired original


settings are maintained.

Listen for hard-to-detect air leaks


and inspect for fluid leakage and
other abnormalities.

Weekly

If found, report leaks to production


supervision.

Purge or flush fluid system lines.

Quarterly

See Draining the Fluid Lines later


in this section.

Purge and prime fluid lines when


changing dispensing fluid type.

As required between
different fluid applications.

See Purging the DispenseJet later


in this section.

Table 5-2 Preventive Maintenance Schedule, Category B


Task

Frequency

Instructions

Change or clean the nozzle and


nozzle nut.

Daily

See Cleaning the Nozzle later in


this section.

Complete Cleaning Service.

Bi-Weekly or Quarterly

Review maintenance and service


records. See Complete Cleaning
later in this section.

Complete Overhaul Service.

Annually

Review maintenance and service


records. See Complete Overhaul
Service later in this section.

Cleaning the Nozzle


The nozzle should be cleaned after approximately 8- to 10-hours of normal use. This may vary depending on
the type of fluid.
Tools and Material Needed

Torque Wrench
Nozzle Brush
Air Gun
Solvent

Maintenance and Service

19

To remove the Nozzle:


1.

Power up the dispensing system.

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.

Refer to the Fluidmove User Guide or Online Help for instructions

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.

To clean the Nozzle:


1.

Place the nozzle in the container with a small amount of solvent.

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.

To clean the Nozzle Nut:


1.

Remove the standard nozzle nut and the co-axial air nozzle nut from the DispenseJet as a unit, if
attached.

2.

Disconnect the co-axial air tubing.

3.

Remove the co-axial air nozzle nut and the nozzle from the standard nozzle nut.

4.

Remove and discard the Teflon gasket.

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.

To Reinstall the Nozzle:


Follow the Changing Nozzles instructions in the Operation section. Obtain a new Teflon gasket for the
nozzle.

20

NOTE

If you are not going to use the cleaned nozzles right away, store the nozzles in the protective
case for the DispenseJet.

Maintenance and Service

Purging the DispenseJet


To purge the Fluid Line:
1.

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:

Remove the DispenseJet from the dispensing system


Disassemble the DispenseJet
Inspect and clean
Reassemble and reinstall the DispenseJet

Tools and Material Needed


The following tools and materials are needed:

Adjustment and assembly tools


Cleaning tools
Air gun
O-ring lubricant
Conductive grease

Removing the DispenseJet from the Dispensing System


The instructions assume that the co-axial air solenoid valve and co-axial air nozzle are installed.

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.

To remove the DispenseJet:


1.

Power up the dispensing system.

2.

Purge any remaining fluid from the reservoir.


a. Use the position controls to move the DispenseJet so it is directly over an open purge station
(or click on PURGE from the Fluidmove software) to purge the fluid from the fluid lines. If
necessary, refer to the Fluidmove User Guide for instructions.
b. 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.

Maintenance and Service

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.

Shut down the dispensing system.

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.

Disassembling the DispenseJet


Cleaning and inspection require disassembly of major components and small and intricate parts of the
DispenseJet. Refer to Figure 5-1, unless otherwise noted. This procedure assumes that the co-axial air
solenoid valve and nozzle are installed.
To disassemble the DispenseJet:
1.

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.

Loosen the micro-adjustment as follows:


a. Turn the micro-adjustment cap 4 to 6 turns counterclockwise.
b. Use the spanner wrench to loosen the lock nut.
c.

5.

Turn the preload screw to relieve compression on the compression spring.

Remove the seat extension and heater as follows:


a. Use the hex key to remove the two screws securing the heater and the seat extension to the
lower body.
b. Separate the seat extension from the heater.
c.

Remove the exposed large o-ring.

d. Set aside the disassembled parts for cleaning.

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.

Maintenance and Service

6.

Remove the lower body as follows:


a. Use the 7/64-inch hex key to remove the two screws from the lower body.
b. Carefully pull the lower body off of the needle.
c.

Remove the exposed small o-ring that holds the u-cup seal in place. Leave the u-cup seal
intact.

d. Set aside the disassembled parts for cleaning.


7.

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.

Maintenance and Service

23

1
2

4
5
11
12

13
14

9
10

Item

Description

Item

Description

Micro-adjustment Lock Nut

Heater

Preload Lock Nut

Nozzle Nut

Upper Body and Solenoid Valve

10

Hex Head Screw (two)

Elbow Connector

11

Needle

Lower Body

12

U-cup Seal

Hex Head Screw (two)

13

O-ring (small)

Seat Extension

14

O-ring (large)

Figure 5-1 Disassembling the DJ-2200

24

Maintenance and Service

Inspecting and Cleaning


Inspect and clean the disassembled components and parts as follows:
1.

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.

Wipe the large needle clean with a solvent-soaked disposable towel.

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.

Reassembling and Reinstalling the DispenseJet


Once the components and parts are cleaned and replacements of worn or damaged parts are obtained, the
DispenseJet can be reassembled and reinstalled to the Dispensing System.
To reassemble and reinstall the DispenseJet:
1.

Gather the DispenseJet components, parts, and any replacement parts, on a flat surface.

2.

Reassemble the lower body and the upper body as follows:


a. Carefully insert the small o-ring into the lower body.
b. Carefully install the lower body to the upper body and secure using the two hex head
screws.

Maintenance and Service

25

CAUTION! To prevent damage to the extension seat, verify that the micro-adjustment is
opened 4 to 6 turns counterclockwise.

3.

Install the seat extension and heater as follows:


a. If needed, apply conductive grease on the seat extension shaft.

Make sure not to put grease on the threads.

b. Rotate the seat extension into the heater to spread the conductive grease evenly and
prevent the formation of trapped-air pockets.
c.

Carefully, install the large o-ring on the seat extension.

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.

Install the micro-adjustment.

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.

Complete Overhaul Service


This procedure is intended to remedy problems identified in the Troubleshooting section; such as the need
to replace damaged or worn parts or to restore the functionality of the DispenseJet by a thorough cleaning
after continuous long production runs.
The following is covered in the Complete Overhaul Service:

NOTE

Disassembly of the DispenseJet


Inspection and cleaning of disassembled parts
Reassembly of the DispenseJet
Settings and adjustments
For removal of DispenseJet from dispensing system and for initial disassembly of DispenseJet
components, follow instructions under Purging the DispenseJet earlier in this section. The
only steps described here are additional disassembly, inspection, cleaning, and re-assembly.

Tools and Material Needed


Use the same list of tools and material listed under Purging the DispenseJet earlier in this section.

26

Maintenance and Service

Disassembly of the DispenseJet


Inspect each part during the disassembly for wear and tear or damage. For parts replacement, remove and
disassemble the DispenseJet to the level necessary to gain access to the failed part.

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.

Remove the solenoid valve and set aside.

To disassemble the Micro-adjustment and associated parts (Figure 5-2):


1.

Make a notation of the setting before disassembling the micro-adjustment.

CAUTION! Gently back-off the micro-adjustment to prevent damage to the needle and seat
extension during disassembly.

2.

Turn the micro-adjustment 4 to 6 turns counterclockwise to increase its setting.

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.

Using the spanner wrench, loosen the preload lock nut.

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.

Remove the compression spring from the cap.

7.

Set aside the disassembled parts for cleaning and inspection.

Maintenance and Service

27

3
4

Item

Description

Item

Description

Micro-adjustment

Upper Body

Preload Screw

Compression Spring

Preload Set screw (two)

Hex Head Screw (two)

Preload Lock Nut

Solenoid Valve

Cap
Figure 5-2 Removal of Solenoid Valve and Disassembly of Micro-adjustment

To disassemble the Lower Body (Figure 5-3):


To remove and disassemble the lower body follow the instructions under Purging the DispenseJet
earlier in this section.

CAUTION! To prevent damage to the tapered needle, do not use tools to grip the needle
threads.

28

Maintenance and Service

To remove and disassemble the Upper Body (Figure 5-3):


1.

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

Hex Head Screw (two)

Upper Body

Fitting

Plug

Cap

Lower Body

Figure 5-3 Disassembly of Upper and Lower Bodies.

Maintenance and Service

29

To remove the Needle and disassemble the Air Piston:


1.

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.

Carefully remove the needle by pushing it out of the upper body.

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.

Set aside removed parts for inspection and cleaning.

To remove the Co-axial Air Solenoid Valve:


1.

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.

Set aside part for cleaning and inspection.


1
4

5
6

3
8

Item

Description

Item

Description

Air Piston (shown assembled)

Seal Lock Nut

Needle

O-ring

U-cup Seal

Air Piston

Spring Retainer

Upper Body

Figure 5-4 Removing the Needle and Disassembling the Air Piston
30

Maintenance and Service

Inspection and Cleaning of Disassembled Parts

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.

To inspect and clean the disassembled components and parts:


1.

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.

Clean the solenoid valve by wiping it with a dry disposable towel.

6.

Clean the heater by wiping it with a dry disposable towel.

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.

Reassembly of the DispenseJet


The following instructions are for the preferred order of reassembly of parts disassembled during the
complete service overhaul. Refer to Purging the DispenseJet earlier in this section when reassembling
other parts.

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.

Maintenance and Service

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.

To reassemble the Lower Body (Figure 5-5):


1.

Install the elbow connector to the lower body ensuring that the fluid intake port is facing correctly.

2.

Install the u-cup seal to the lower body as follows:


a. Make sure the springy side of the u-cup seal is facing out.
b. Using the ring and seal insertion tool, carefully seat the u-cup seal into the lower body.
c.

3.

Using the ring and seal insertion tool, carefully seat the o-rings to the u-cup seal into the
lower body.

Set aside the assembled lower body.

To reassemble the Upper Body (Figure 5-5):


1.

Install the u-cup seal to the upper body as follows:


a. Make sure the springy side of the u-cup seal is facing out.
b. Using the ring and seal insertion tool, carefully seat the u-cup seal into the upper 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.

Set aside the assembled upper body.

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.

Maintenance and Service

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

Hex Head Screw (four)

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.

Set aside the assembled components.

Maintenance and Service

33

3
Item

Description

Item

Description

Seat Extension

Upper Body

Heater

Lower Body

Hex Head Screw (two)


Figure 5-6 Installing Heater and Seat Extension to Upper and Lower Bodies

To install the Air Piston and the Needle (Figure 5-7):


1.

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.

Maintenance and Service

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.

Using the o-ring lubricant, lubricate the threads of the needle.

3.

Install the air piston to the needle as follows:


a. Place the piston insertion tool on the top of the needle.
b. Start turning the piston insertion tool clockwise a few turns to engage the needle threads.
c.

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.

Place the spring retainer on the needle.

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 prevent damage to the needle, do not over-tighten the spring retainer.

To properly seat the needle, ensure that the top of the seal lock nut is flush to above the top of
the upper body.

Maintenance and Service

35

1
2
3
4
5

Item

Description

Item

Description

Spring Retainer

Air Piston

Seal Lock Nut

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.

Place the compression spring on the spring retainer.

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

Maintenance and Service

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.

Perform adjustments as described in Settings and Adjustments later in this section.


1

3
4

6
8

Item

Description

Item

Description

Cap Micro-adjustment

Seat Extension

Preload Set screw (two)

Compression Spring

Preload Screw

Hex Head Screw (two)

Preload Lock Nut

Upper Body

Figure 5-8 Installing the Micro-adjustment and Cap

Maintenance and Service

37

Settings and Adjustments


There are two adjustment settings that must be performed after disassembly and cleaning of the
DispenseJet:

Preload setting

Micro-adjustment setting

To adjust the Preload:

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).

Figure 5-9 Preload Screw Point of Reference


2.

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.

Open the micro-adjustment by turning it counterclockwise to the desired setting.

38

NOTE

The preload and micro-adjustment settings will vary for different fluids. Contact
Nordson ASYMTEK Technical Support for particular fluid settings.

Maintenance and Service

To adjust the Micro-adjustment:


The micro-adjustment setting regulates the fluid volume for the dot or line. The higher up the setting, the
more fluid is dispensed.

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.

Finger-tighten the micro-adjustment lock nut.

Maintenance and Service

39

5
5

20

Item

Description

Item

Description

Micro-adjustment Collar Set Screw

Micro-adjustment Lock Nut

Micro-adjustment

Preload Lock Nut

Micro-adjustment Collar

Preload Screw

Inner Micro-adjustment Column

Preload Set Screw

Figure 5-10 Components of Micro-adjustment and the Preload Screw


To install the Co-axial Air Solenoid Valve to the DispenseJet:
Refer to the Installation section for installation of the co-axial air solenoid valve to the DispenseJet.

40

Maintenance and Service

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.

Fluid leaks from


weep hole.

Air pressure to the solenoid


valve is Off or insufficient.

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).

Worn seal or needle.

Inspect the needle and seal for excessive wear.


Replace parts if necessary.

Lower seal missing.

Install a seal and secure it with the retaining ring.

Fluid dots or lines do


The nozzle is clogged.
not form correctly.

Clean the nozzle with a compatible solvent and


bottlebrush.
If the nozzle cannot be cleaned, replace it.

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

The nozzle fluid path is


clogged.

2.

Open the micro-adjustment.

3.

Send a signal to the solenoid valve to allow


material flow through the DispenseJet.

NOTE: You may have to remove the nozzle before


purging the DispenseJet. Check the syringe
connections and pressure.

DispenseJet is not jetting.

Refer to above symptom DispenseJet is not cycle


jetting

DispenseJet component
malfunctioning.

Disassemble the DispenseJet and inspect the


internal parts. Replace parts if necessary.

41

Symptom

Too much fluid with


each shot.

DispenseJet
performs but has
problems after the
co-axial air is
installed.

Possible Cause

Recovery

On-time set too long.

Reduce jet on time.

Micro-adjustment too high.

Reduce the micro-adjustment setting.

Fluid pressure too high.

Reduce fluid pressure.


Check function of co-axial air through input/output.

Co-axial air not functioning


during dispense.

Check Config.ini. file, Valve 1 and verify the


Assist bit mask is set to 64 and that Assist on
state is set to 64.

The M-600 Dispensing


System co-axial air not
functioning during dispense.

Check Config.ini. file, Valve 1 and verify the


Assist bit mask is set to 8 and that Assist on
state is set to 8.

On-time set too long.

Reduce jet on-time.

Micro-adjustment too high.

Reduce the micro-adjustment setting.

Fluid pressure too high.

Reduce fluid pressure.


Check function of co-axial air through input/output.

Co-axial air not functioning


during dispense.

Check Config.ini. file, Valve 1 and verify the


Assist bit mask is set to 64 and that Assist on
state is set to 64.

The M-600 Dispensing


System co-axial air not
functioning during dispense.

Check Config.ini. file, Valve 1 and verify the


Assist bit mask is set to 8 and that Assist on State
is set to 8.

Fluid leaks through


the seat extension,
or poor dot quality
(dots not breaking
off from nozzle).

Air piston/lock nut is


positioned too low.

Use the piston height gauge tool to ensure correct


position. See the Maintenance and Service section.

Seat extension is
frequently damaged
or poor dot quality
(dots not breaking
off from nozzle).

Air piston/lock nut is


positioned too high.

Use the piston height gauge tool to ensure correct


position. See the Maintenance and Service section.

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!

Parts replacement should be performed by Nordson ASYMTEK-trained technicians.


Nordson ASYMTEK assumes no liability for personal injury or damage that may occur
as a result of parts being replaced by anyone other than Nordson ASYMTEK
technicians.

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:

Your Company Name

Billing Address

Shipping Address

Serial Number of your dispensing system (found on the back panel of the system)

Part Number and Description of Part

Quantity

Purchase Order Number

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

Return Material Authorization


Obtain a Return Material Authorization (RMA) from Nordson ASYMTEK Customer Service before returning
parts.

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

Micrometer Assembly with Lock

226276

Preload Screw

982745

Preload Set Screw (Socket set, 4-40 x 0.125)

145461

Preload Lock Nut

234299

Compression Spring

226277

Spring Retainer

168833

Seal Lock Nut

973529

Barbed Elbow Fitting (0.25-inch Stainless Steel Tube)

234154

Plug (M5, Stainless Steel)

10

249942

Solenoid Valve (3-way, 24 DC, 120 PSI)

11

338751

Dispenser Cap

12

340721

Slotted Fillister Screw (6-32 x 0.5-inch)

13/17

322399

Tapered Needle Seat and Seat Extension

14

338763

Elbow, Pos., Tube x 1/8, 150 Thread

15

338752

Lower Body

16

282287

Slotted Fillister Screw (6-32 x 0.75-inch)

18

234167

RTD Sensor Heater (8.5W, 24V DC)

19

982747

Socket Head Screw (6-32 x 1.75-inch)

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

20 Gauge Selective Flux Nozzle

21

391778

21 Gauge Selective Flux Nozzle

21

391779

22 Gauge Selective Flux Nozzle

21

391780

23 Gauge Selective Flux Nozzle

21

391781

24 Gauge Selective Flux Nozzle

21

391782

26 Gauge Selective Flux Nozzle

21

391783

27 Gauge Selective Flux Nozzle

21

391784

28 Gauge Selective Flux Nozzle

21

391785

30 Gauge Selective Flux Nozzle

Description

Additional Information

14

15

13

16

4
17
5

12

18

11

7
8

21

19

10
9

20

Figure 7-1 DJ-2200 Series Spare Parts

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

Co-axial Air Nozzle Nut, M3

329410

Co-axial Air Nozzle Nut, N3

329411

Co-axial Air Nozzle Nut, W3

322445

Co-axial Air Nozzle Nut, M5

40-3501

Tubing, 1/8 O.D., .3 feet

Description

2
1

Figure 7-2 Co-axial Air Assist


Table 7-4 lists the parts contained in the DJ-2200 Spare Parts Kit.
Table 7-4 DJ-2200 Spares Kit
Part Number
01-0022-00

46

Description

Quantity

Vacuum Boot, 0.120 inner diameter

940139

O-ring, (White) 0.313 x 0.438 x 0.06-inch

168824

U-cup Seal

719082

O-ring, (Black) 9/16 x 11/16 x 1/16

940090

O-ring (Brown)

115055

Air Piston

245773

Conductive Grease

58-0030

Dixie Cup, 1-oz, (200/pkg.)

58-0036

Round-tip Cotton Swabs, 6-inch wood handle (100/pkg.)

Additional Information

Part Number

Description

Quantity

58-0037

Mini Round-tip Swabs, (25/pkg.)

58-0038

Mini Cotton-tip Swabs, wood handle (100/pkg.)

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

Wrench, Allen, Hex, 1.5-mm

234150

Wrench, Allen, Hex, 0.050-inch

234151

Wrench, Allen, Hex, 7/64-inch

129612

Wrench, Allen, Hex, 3/32-inch

901935

Wire, Cleaning, 0.003 diameter

901922

Wire, Cleaning, 0.007 diameter

901923

Wire, Cleaning, 0.011 diameter

901924

Wire, Cleaning, 0.014 diameter

901916

Pin, Vise

10

245773

Grease, Conductive

11

124520

Screwdriver

12

274973

Tool, Piston, Insertion

13

115059

Tool, Ring and Seal, Insertion

14

272821

Tool, Removal, Retaining Ring

15

145468

Wrench, Spanner

16

901911

Wrench, Module, Adjusting

17

901905

Nuzzle Brush

18

226302

Tool, Seal Insertion

19

226274

Wrench, Torque, 19 in-lb, -inch Hex

20

338757

Kit, Seal, DJ-2200

21

322431

Kit, Nozzle Gasket Replacement

22

340721

Screw, Socket Head Cap, #6-32 x 0.5, S.S.

23

340720

Screw, Socket Head Cap, #4-40 x 1.00, S.S.

24

282287

Screw, Socket Head Cap, #6-32 x 0.75

25

982747

Screw, Socket Head Cap, #6-32 x 1.75

26

982745

Screw, Socket Set, #4-40 x 0.125

27

Nozzles, not included

28

DJ-2200 DispenseJet, not included

Additional Information

Description

Quantity

47

Adjustment and Assembly Tools


Table 7-6 lists the Adjustment and Assembly Tools parts. The item numbers shown in the table correspond
with numbered callouts in Figure 7-3.
Table 7-6 Adjustment and Assembly Tools
Item Number

Part Number

Description

901911

Module Adjusting Wrench

145468

Spanner Wrench

226274

Torque Wrench (19 in-lb)

392652

Piston Height Gauge Tool

226302

Seal Insertion Tool

115059

Ring and Seal Insertion Tool

274973

Air Piston Insertion Tool

272821

Ring Removal Tool

234150

0.05-inch Hex Key

10

234149

1.5-mm Hex Key

11

234151

7/64-inch Hex Key

12

129612

3/32-inch Hex Key

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

Round/Round-tipped Swabs, (10 per package)

58-0038

Mini Cotton-tipped Swabs, wood handle, (100 per package)*

58-0037

Mini Round-tipped Swabs, (25 per package)*

58-0036

Round-tipped Cotton Swabs, 6-inch wood handle, (100 per package)*

901935

Tungsten Cleaning Wire, 0.003-inch diameter

901922

Tungsten Cleaning Wire, 0.007-inch diameter

901923

Tungsten Cleaning Wire, 0.011-inch diameter

901924

Tungsten Cleaning Wire, 0.014-inch diameter

901916

Pin, Vise

901905

Nozzle Brush

Description

* Available for purchase separately.

1
2

7
6

Figure 7-4 Cleaning Tools

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

Century Series, C-730 Dispensing System

391765

Millennium Series, M-600

N/A

Millennium 2000 Series

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

Figure 7-5 DJ-2200 DispenseJet Exploded View (1 of 4)

Additional Information

51

Item

Part No.

Description

322359

Valve, DJ-2200

391765

C-730 Flux Bracket Assembly (Ref.)

64-HS-RTA

Height Sensor Adj. Base A (Ref.)

Figure 7-6 DJ-2200 DispenseJet Exploded View (2 of 4)

52

Additional Information

Item

Part No.

Description

329412

Co-axial Solenoid Valve

391775

Co-axial Mounting Bracket

391765

C-730 Flux Bracket Assembly (Ref.)

64-HS-RTA

Height Sensor Adj. Base A (Ref.)

Figure 7-7 DJ-2200 DispenseJet Exploded View (3 of 4)

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

Preload Set Screw (Socket Set 4-40 x 0.125-in)

145461

Preload Lock Nut

226276

Preload Screw

234299

Compression Spring

226277

Spring Retainer

168833

Seal Lock Nut

940090

Seal Lock Nut O-ring

115055

Air Piston

10

322399

Tapered Needle and Seat (Order with Item 12)

11

322399

Seat (Order with Item 11)

12

168824

Upper Body U-cup and Seal

13

340721

Slotted Fillister Screw (6-32 x 0.5-inch)

14

338751

Dispenser Cap

15

973529

Barbed Elbow Fitting (0.25-inch Tube, M5)

16

329412

Solenoid Valve (3-way, 24 DC, 120 psi)

17

340720

Screw, Skt, (4-40x1.00), BL

18

338750

Upper Body

19

234154

Plug (M5, 5S)

20

338763

Elbow, Pos., Tube x 1/8 ISO THD

21

338752

Lower Body

22

282287

Slotted Fillister Screw (6-32 x 0.75-inch)

23

168824

U-cup Seal

24

940139

White (Chemraz) O-ring

25

719082

Black (Kalrez) O-ring

26

234167

Heater with RTD Sensor (8.5W, 24V DC)

27

234119

Teflon Gasket

28

391777

20 Gauge Selective Flux Nozzle

28

391778

21 Gauge Selective Flux Nozzle

28

391779

22 Gauge Selective Flux Nozzle

28

391780

23 Gauge Selective Flux Nozzle

28

391781

24 Gauge Selective Flux Nozzle

28

391782

26 Gauge Selective Flux Nozzle

28

391783

27 Gauge Selective Flux Nozzle

28

391784

28 Gauge Selective Flux Nozzle

28

391785

30 Gauge Selective Flux Nozzle

29

322429

Nozzle Nut

30

982747

Socket Head Screw (6-32 x 1.75-inch)

31

234167

Heater Connector Cable (Order with Item 26)


Additional Information

Item

Part No.

Description

32

234167

Temp Contr. Connector (Order with Item 26)

33

234167

Solenoid Valve Elect. Connector (Order with Item 26)

Figure 7-8 DJ-2200 DispenseJet Exploded View (4 of 4)

Additional Information

55

2762 Loker Avenue West


Carlsbad, CA 92010-6603 USA
Tel: (760) 431-1919
P/N 7210768, Rev. C

2010