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iv Table of Contents 2  Safety .................................................................................................................... 2-1  2.1  Overview ..................................................…

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Table of Contents iii
TABLE OF CONTENTS
1 Introduction .......................................................................................................... 1-1
1.1 Overview .................................................................................................................................. 1-1
1.2 System Description .................................................................................................................. 1-1
1.3 Safety First ............................................................................................................................... 1-1
1.4 Facility Requirements .............................................................................................................. 1-1
1.5 Manuals Supplied .................................................................................................................... 1-2
1.6 Training .................................................................................................................................... 1-2
1.6.1 Student Certification ................................................................................................... 1-2
1.6.2 Student Registration ................................................................................................... 1-2
1.7 Supported Coating Materials ................................................................................................... 1-2
1.8 Standard Equipment ................................................................................................................ 1-3
1.8.1 Computer System ....................................................................................................... 1-3
1.8.2 Easy Coat for Windows XP Software ......................................................................... 1-3
1.8.3 Chain Conveyor (SL-940E) ......................................................................................... 1-3
1.8.4 Light Beacon ............................................................................................................... 1-3
1.8.5 Safety Interlock ........................................................................................................... 1-3
1.8.6 Low Air Pressure Sensor ............................................................................................ 1-3
1.8.7 Solvent Cups ............................................................................................................... 1-3
1.8.8 Tooling Plate/Adjustable Tooling Rails (SL-941E) ...................................................... 1-4
1.8.9 Ventilation System ...................................................................................................... 1-4
1.9 Optional Equipment ................................................................................................................. 1-4
1.9.1 Bar Code/Data Matrix Reader .................................................................................... 1-4
1.9.2 Board Present Sensor ................................................................................................ 1-4
1.9.3 Brush Box ................................................................................................................... 1-4
1.9.4 Dual Simultaneous Applicator Capability .................................................................... 1-5
1.9.5 Dual Toggle Applicator Capability ............................................................................... 1-5
1.9.6 Flow Monitoring System ............................................................................................. 1-5
1.9.7 Laser Fan Width Control System ................................................................................ 1-6
1.9.8 Laser Pointer Programming Tool ................................................................................ 1-6
1.9.9 Low Fluid Sensor (for external reservoir).................................................................... 1-6
1.9.10 Low Fluid Scale ........................................................................................................... 1-6
1.9.11 Low Solvent Cup Sensor ............................................................................................ 1-6
1.9.12 Material Change Over System .................................................................................... 1-6
1.9.13 Pre-Queue Board Station ........................................................................................... 1-6
1.9.14 Upstream and Downstream SMEMA Sensors ........................................................... 1-6
1.9.15 UV Light ...................................................................................................................... 1-6
1.10 Vision System .......................................................................................................................... 1-7
1.11 Conformal Coating Applicators ................................................................................................ 1-8
1.11.1 SC-104HS/SC-105HS Circulating Film Coater ........................................................... 1-8
1.11.2 SC-104/105VCS Viscosity Control System ................................................................ 1-8
1.11.3 SC-204HS/SC-205HS Non-Circulating Film Coater ................................................... 1-8
1.11.4 SC-300 Swirl Coat Applicator ..................................................................................... 1-9
1.11.5 SC-400 PreciseCoat Conformal Coating Jet .............................................................. 1-9
1.12 System Features .................................................................................................................... 1-10
1.12.1 Front View Features ................................................................................................. 1-10
1.12.2 Rear View Features .................................................................................................. 1-16
iv Table of Contents
2 Safety .................................................................................................................... 2-1
2.1 Overview .................................................................................................................................. 2-1
2.2 Facility Requirements .............................................................................................................. 2-1
2.3 Intended Use ............................................................................................................................ 2-1
2.4 Basic Safety Precautions and Practices .................................................................................. 2-2
2.4.1 Safety of Personnel..................................................................................................... 2-2
2.4.2 Material Safety ............................................................................................................ 2-3
2.4.3 Preventing Coating System and Workpiece Damage ................................................ 2-3
2.4.4 High-Pressure Fluids .................................................................................................. 2-4
2.4.5 Halogenated Hydrocarbon Solvent Hazards .............................................................. 2-4
2.5 Disposal ................................................................................................................................... 2-4
2.6 Lifting and Transport Precautions ............................................................................................ 2-4
2.7 Laser Radiation ........................................................................................................................ 2-5
2.8 Earthquake Precautions .......................................................................................................... 2-5
2.9 Safety Warning Labels ............................................................................................................. 2-6
2.10 Emergency Shutdown ............................................................................................................ 2-11
2.10.1 Emergency Shutdown Situations .............................................................................. 2-12
2.10.2 Emergency Shutdown Recovery .............................................................................. 2-12
2.11 Interlock ................................................................................................................................. 2-13
2.12 Service Shutdown .................................................................................................................. 2-13
2.13 Lockout of Electrical and Pneumatic Energy ......................................................................... 2-13
2.14 Light Beacon .......................................................................................................................... 2-15
3 Installation ............................................................................................................ 3-1
3.1 Overview .................................................................................................................................. 3-1
3.2 Safety First ............................................................................................................................... 3-1
3.3 Uncrating and Placing the Coating System ............................................................................. 3-1
3.4 Unpacking the Coating Area .................................................................................................... 3-4
3.5 Leveling the Coating System ................................................................................................... 3-6
3.6 Installing the Light Beacon ....................................................................................................... 3-8
3.7 Installing the Laptop Computer ................................................................................................ 3-9
3.8 Installing the Optional Genie Camera .................................................................................... 3-10
3.9 Anchoring the Coating System .............................................................................................. 3-10
4 Power-up and Testing ......................................................................................... 4-1
4.1 Overview .................................................................................................................................. 4-1
4.2 Safety First ............................................................................................................................... 4-1
4.3 Pneumatic Connections ........................................................................................................... 4-1
4.4 Electrical Connections ............................................................................................................. 4-2
4.5 Exhaust Connection ................................................................................................................. 4-2
4.6 Connecting Power and Air Supply ........................................................................................... 4-3
4.7 Powering On the System ......................................................................................................... 4-5
4.8 Camera States ......................................................................................................................... 4-6
Table of Contents v
4.9 Starting Easy Coat for Windows (ECXP) ................................................................................. 4-7
4.10 Testing the System .................................................................................................................. 4-8
4.11 Robot/Conveyor I/O ................................................................................................................. 4-8
4.12 Pneumatics ............................................................................................................................ 4-11
4.13 Robot (Dispensing Head) Function ........................................................................................ 4-15
4.13.2 Testing the EMO ....................................................................................................... 4-15
4.13.3 ECXP Robot Utilities ................................................................................................. 4-15
4.14 Conveyor Function ................................................................................................................. 4-17
4.14.1 ECXP Conveyor Utilities ........................................................................................... 4-18
4.14.2 Inverter ...................................................................................................................... 4-18
4.15 Coating System Options ........................................................................................................ 4-19
4.15.1 Laser Fan Width Control ........................................................................................... 4-19
4.15.2 Flow Meter ................................................................................................................ 4-20
4.15.3 Bar Code Scanner .................................................................................................... 4-20
5 Operation .............................................................................................................. 5-1
5.1 Overview .................................................................................................................................. 5-1
5.2 Safety First ............................................................................................................................... 5-1
5.3 Basic System Operation .......................................................................................................... 5-1
5.4 Conformal Coating ................................................................................................................... 5-1
5.5 Easy Coat for Windows XP (ECXP) ........................................................................................ 5-2
5.6 Dispensing Operations............................................................................................................. 5-2
5.6.1 Robot Concepts .......................................................................................................... 5-2
5.6.2 Tool ............................................................................................................................. 5-2
5.6.3 Fixture ......................................................................................................................... 5-2
5.7 Conveyor Operations ............................................................................................................... 5-3
5.7.1 Chain Conveyor .......................................................................................................... 5-3
5.8 Detailed Operation (SL-940E) ................................................................................................. 5-4
5.8.1 Coating Process .......................................................................................................... 5-4
5.9 Positioning the Robot ............................................................................................................... 5-6
5.10 Pneumatic Regulators and Gauges ......................................................................................... 5-7
5.10.1 Main Air Regulator and Gauge ................................................................................... 5-8
5.10.2 Reservoir Pressure Regulator and Gauge ................................................................. 5-9
5.10.3 Fluid Pressure Regulator and Gauge ....................................................................... 5-10
5.10.4 Conveyor Air Regulator and Gauge .......................................................................... 5-13
5.11 System Startup/Shutdown ..................................................................................................... 5-14
5.11.1 Startup ...................................................................................................................... 5-14
5.11.2 Shutdown .................................................................................................................. 5-15
5.12 Daily Routine Procedures ...................................................................................................... 5-17
5.13 Installing the Coating Applicator ............................................................................................ 5-18
5.14 Filling the Fluid Reservoir ...................................................................................................... 5-19
5.15 Changing Material/Flushing Fluid System ............................................................................. 5-20
5.16 Focusing the Camera............................................................................................................. 5-22