10. Test lockout by hitting RUN button. 7
11. Block, chain or release stored energy sources. 12. Always unplug the machine and disconnect the main airline to the system before opening any panels for service. Once the machine has been disconnected from power and air, the electric cord and airline must remain in sight of the individual performing maintenance. This is to prevent accidental start-up of any energy sources. ii. OPERATOR HAZARD TRAINING Operators and technicians should know the closest location of the following safety related items in your facility: Emergency Exits Emergency Telephone Eye-Wash Station Fire Extinguisher First Aid Station MSDS Station
In the event of an emergency or malfunction, press the Emergency Machine Off (EMO) button. The EMO is the large red button located on the front panel of the dispensing system. Activating the EMO vents all pressure in the pneumatic system, de-energizes the servo power supply capacitors, and cuts power to all components. As a minimum, activate the EMO in the following situations: 1. 2. If anyone is in immediate danger of being injured by moving parts, hazardous materials, or electrical shock. If valuable dispensing system components or the work-pieces are in danger of being damaged. This can include: - Physical damage to the dispensing valve or work-piece by unexpected Dispensing Head movement. - Electrical damage to the dispensing system. If an injury occurs during operation or servicing of the System, it is recommended that the following steps be taken: 1. 2. 3. If the dispensing system is operating when the injury occurs, press the nearest EMO button to stop all system operations. Immediately report injury to supervisor in accordance with facility procedures. If it is an injury due to exposure to a hazardous material, refer to the treat recommendations on the material manufacturers Material Safety Data Sheet (MSDS). Seek medical help if necessary.

SPECIFICATIONS

Ultra 325TT Work Area Resolution (m) Repeatability (m) Max Speed (mm/sec) Acceleration Mechanical Configuration Control Method Drive System Foot Print (mm) Width x Depth x Height Weight (Kg) Tool Payload (Kg) Workpiece Payload (Kg) Programming Interface Program Capacity Point Capacity General Purpose I/O Discrete I/O 325 x 325 x 0.25g H-Bridge De-coupled Axes Closed Loop DC Servo Cable Drive 560 x 670 x Front Panel Buttons PDA Handheld 100 10,Inputs / 16 Outputs 1 Analog Input/Output 2 (Sink/Source) Inputs 2 (Sink/Source) Outputs 2 Solenoid Drivers 1 RS232 / 1 PDA Yes (Standard) Palm OS/ ACLWatts 100VAC~240VAC ( 10%) Integrated 1, 2 or 3 Lines, Circles, Arcs Continuous Paths Potting and Dots 10 Dot / 10 Line per Program Offsets, Jogging & Program Select

GETTING STARTED SYSTEM FEATURES
Z-head Electrical / Air Connections

Mounting Bracket

T-Slots Dispense Valves Universal Fixture
Pressure Gauges Pressure Regulators Power Button EMO Button Vacuum Control Interactive LCD Palm handheld

FRONT PANEL

LCD Menu Scroll Knob Interactive LCD X/Y, Z/T Jog Keys Power Button

Vacuum control

Emergency Machine Off (EMO)
P1 Gauge & Regulator 0 ~ 100PSI
P2 Gauge & Regulator 0 ~ 30 psi
Interactive LCD Soft Keys

Ground Strap Connector

RS232 PDA Connector
P1: 0-100 psi pneumatic channel. To adjust the pressure, first unlock the pressure knob by pulling outward, turn it to the right to increase pressure or left to reduce pressure. Push the knob inward to lock. P2: 0-30 psi pneumatic channel. To adjust the pressure, first unlock the pressure knob by pulling outward, turn it to the right to increase pressure or left to reduce pressure. Push the knob inward to lock Vacuum control: The vacuum is connected in parallel so both P1 & P2 channels can maintain a vacuum. To adjust the vacuum pressure, turn the control knob to the left to increase vacuum and turn it right to decrease vacuum. Interactive LCD: This is where you can view the current program selected, call up new programs, run tip offsets or purge routines, pause or resume a program. The LCD also outputs user-defined messages along with error messages. The arrow keys: X/Y, Z/T keys work in conjunction with the LCD that prompts the user to either teach current position or teach new position for tip location at origin. The keys are selectable between XY and ZT modes. E-Stop: The large red button with the yellow indicator shuts off power to all actuating devices such as servomotors and pneumatic circuits. To reset power, you must turn the red button clockwise to release then press the green button to restore power to the actuator. This button should only be used for real emergency stops. If you want to abort a program, press the soft key directly beneath the word abort on the LCD panel.

BACK PANEL

Socket Adapter attached to RS232

Discrete I/O

Safety Interlock

Exhaust Fan

Main Power Circuit Breaker

Ethernet

General Purpose Outputs

General Purpose Inputs

Main Air Entry

Main Power Input

RS232: The RS232 port can be used to connect the Ultra TT System to a Computer or PDA. The Socket Bluetooth Adapter is connected here. Discrete I/O: There are four digital I/Os, one analog I/O, and two 24VDC solenoid drivers. The Discrete I/Os are used in conjunction with the control of any dispensing options or devices that require a position reference within a program. General Purpose Outputs: There are 16 General Purpose Outputs. They are either sinking or sourcing. The GP I/Os are used in conjunction with the control of any dispensing options or devices that require a timing reference within a program. General Purpose Inputs: There are 16 General Purpose Inputs. The General Purpose Inputs are 24VDC, sink to ground. They are used in conjunction with the control of any dispensing options or devices that require a timing reference within a program. Safety Interlock: If the Interlock signal is interrupted, the Interlock immediately stops all dispensing activity to protect the operator from injury. Main Air Entry: This connects to the facility air supply. The Ultra TT System requires 85 l/min (1SCFM) maximum of clean, dry air (no oilers) delivered no more than 100 psi. Main Power Input: The Main Power Input connects the dispensing system to the facility power supply. The Ultra TT System has an automatic sensing power supply integrated into the main power supply. It uses a main power supply between 100 Vac to 240 Vac (+/- 10%), 50-60 Hz. Main Power Circuit Breaker: The Main Circuit Breaker is the main power switch for the System. It protects the System from facility power surges and controls the flow of facility AC power supplied to the Power manager.

Main Air and Electrical

It is important that you have dry, clean filtered air that is aerosol free to prevent problems with the pneumatic system of your new Ultra TT system. Input air should not be more than 100 psi. If you have any doubts about your air supply, you should purchase one of the two filter regulator sets listed below.
2000F755TT Five-micron filter regulator Order this if you do not have dry clean filtered factory air supply
Plant air, 125 psi maximum to regulator. Output from regulator should be a minimum of 80 psi, maximum of 100 psi. Air input hose
2000F756TT Five-micron filter regulator with coalescing filter to remove aerosols from air supply
Main air input is located immediately to the left of the Fan Duct on the back panel of the machine and accepts 6mm diameter tubing. Simply push the 6mm tubing into the push-fit connector. Each unit is shipped with two power cords. Plug the appropriate power cord into the three-prong power cord slot located on the back of the machine next to the main power circuit breaker. The machine is equipped with a self-regulating power supply and will accept 100VAC ~ 240VAC +/- 10%, 50 ~ 60 Hz input voltage.
MOUNTING WORK-HOLDING FIXTURE
Use the four tapped (4) M4 holes on the Y-Carriage to mount your work-holding fixtures. It is important your work-holding fixture is mounted on the Y-carriage in a manner that it is parallel to the X-beam. Flatness of your fixture is important because it makes programming much easier. The Ultra TT system is 3D-capable and can be programmed to compensate for changes in Z-Height over the work envelope with the use of the built-in height sensor. However, invoking the built-in height sensor continuously through a dispensing program will significantly reduce throughput. EFD offers two versions of fixture plates that can be used with the Ultra TT system. When dispensing onto low profile parts, it may be necessary to raise the fixture plate up so that the part(s) is within reach of the dispense valve. Refer to Section 9 (Accessories) for more information.
CONNECTIONS ON THE Z-HEAD P1 quick-connect is connected to the 100 psi channel used for valve actuation and thicker fluids when using an EFD barrel reservoir. Line pressure is adjusted using the regulator marked P1 on the front panel. P1 pressure on the front panel should be set to 70 psi when using any EFD air-actuated valve. P2 quick-connect is connected into the 30 psi channel used for valve nozzle air on dual input valves and lower viscosity fluids when using an EFD barrel. Line pressure is adjusted by using the regulator marked P2 on the front panel. When using a single air input valve, the P2 channel can be used to adjust the fluid pressure reservoir if 30 psi is sufficient. If you require more than 30 psi of fluid pressure, in situations where higher viscosity materials are used, use the Aux Air connection instead. Aux Air quick-connect is usually used to supply fluid pressure. It is connected to the E-stop circuit. Fluid pressure will drop to 0 psi during emergency stop situations. Resetting the E-Stop switch and initializing the machine will return fluid pressure to normal. To regulate to the required pressure for a barrel-supplied valve for pressures in excess of 30 psi, use EFD barrel pressure regulator kit (P/N 1117HTT) that attaches to the Z head with special mounting hardware and connects to Aux Air.

MULTI AIR INPUT VALVE

EFD's multi-air input valves include 780S-SS.
Install the corresponding valve mounting fixture to the selected valve and then install the mounting fixture onto the Z-carriage. Refer to Section 8 (Accessories) for the entire list of EFD valve mounting fixtures.
The pulsed air for valve operation plugs into the P1 connector on the Z-head. Set the air pressure on P1 Gauge/Regulator to 70 psi. The pulsed nozzle air plugs into the P2 connector on the Z-head. Ensure the air pressure for P2 Gauge/Regulator is set to desired atomizing pressure. The fluid reservoir supply air quick-connect plugs into Aux Air channel located on top of the Zhead.
ELECTRIC AUGER VALVE Install the Auger valve onto its corresponding valve bracket (P/N 700806) before attaching onto the T-slots of the Z-carriage. The Auger valve uses a brushed DC motor and requires two electrical
connections into the 4-position terminal block located on top of the Z-Head. The positive (+) white wire goes to terminal 1 and the negative (-) brown wire goes into terminal 2. If the white and brown wires are connected inversely, the motor will run in reverse. The Auger valve will not dispense fluid while the motor is running backwards. If the valve is not dispensing but the motor is turning, check fluid pressure and ensure the wires are plugged into the proper terminal. The syringe barrel adapter quick-connects into the P2 connector on top of the Z-head. The fluid pressure can be set to pulse with the valve or remain constant. This setting is made in the valve setup (options window). The Ultra TT system also allows you to set parameters to turn off fluid pressure when the system is idle to prevent separation of solder paste. The valve speed is selected as a voltage ranging from 10.0 VDC to 24 VDC in 0.1 VDC increments. This setting is made in the valve setup (options window). Maximum 250 RPM with a 400 RPM option (for 792 valve) are provided with either an 8 or 16 pitch auger. Once the voltage has been selected, the Back EMF circuit will maintain a constant RPM.

MOUNTING LASER POINTER

Some customers may prefer to use a laser pointer to aid in positioning the X or Y dispense programming points. Note that the laser pointer should be used in conjunction with the height sensor. The height sensor, along with the dot/line parameter setting of the dispense gap will determine the z-height at the dispense point. EFD provides a laser pointer and bracket (#700820) that can be easily mounted onto the Ultra TT. To connect the optional laser pointer teaching device to the Ultra TT: 1. Secure the laser to the Z-head by sandwiching the laser bracket behind the syringe or valve bracket. Connect the laser pointers red wire to terminal pin #6 (+5VDC power supply) on the Z-head connecter and the blue wire to terminal #9. Next, check the functionality of the laser. a. b. c. Using the PDA, select Program from the Main screen. Tap the top left-hand corner of the Program screen and select Util from the menu bar. Select Toggle Laser. This will turn the laser pointer drive on. To turn the laser pointer off, select Toggle Laser again.

Speed control is determined by applied voltage to the motor. This speed is maintained through the use of a Back EMF circuit to ensure constant velocity. The range of operation is from 10 VDC to 24 VDC in 0.1 VDC increments.

4.1.1.1

Teaching Tip to Probe Offset
This is an optional function. You will need to teach the dispense tip to probe offset only if you intend to use height sensor commands within the program. It is recommended you use the height sensor if your application requires very small dots or fine lines. The tip to probe offset allows you to teach the height difference between the tip and the height sense probe (which is essentially also the surface of your part). To teach the offset: (1) Tap "Offset" under Valve #1 label in the Valve screen. (2) To jog the dispense tip to the surface of the part, tap "Jog" located at the top right of the screen. The Jog window appears. Now, jog the dispense tip to a point on the surface of your part. Refer to Appendix A on detailed jogging instructions. (3) When the desired location is reached, tap "OK". (4) Tap "Teach" corresponding to instruction 2. The machine will raise the Z-axis and advance the probe. (5) Tap "Jog" again and jog the height sensor probe to the same surface point. Tap "OK". (6) Tap "Teach" corresponding to instruction 4. Your machine now knows the XYZ offset for the current tip location.
WARNING! Do not toggle the height sensor probe when the Z-axis is lowered; this could cause damage to the machine and/or the part.
Tip: The minimum tip-to-probe offset is 6mm. This is an approximation of the distance the probe must move from surface contact to tripping the sensor (i.e. surface detection) without crashing the tip.
Toggle Valve If a Toggle bracket is selected, you will also need to teach an offset for the toggle valve. Follow the instructions in Section 4.1.1.1 to teach offset for the Toggle Valve. However, prior to teaching the offset, the toggle valve bit configuration must first be completed.

4.1.2.1

Configuring Toggle 1. At the Setup screen, tap "Setup" at the upper left-hand corner of the screen. 2. Select "Configuration" to configure the toggle bit (the internal I/O instruction to turn on the solenoid for the toggle bracket). 3. Enter the desired I/O bit to turn on the air solenoid i.e. will cause the toggle bracket to shift. Select Output Bit 7 for EXT_SOLENOID_B or Output Bit 6 for EXT_SOLENOID_A.
Note: The Ultra TT provides two external outputs to drive air solenoids. Each solenoid driver has a maximum power rating of 5 Watts. Select desired assertion level. To test the toggle bit you can press the down button to assert the toggle bit and press the up button to negate the toggle bit. The EXT_SOLENOID_A and EXT_SOLENOID_B connections are made on the Discrete I/O terminal block located on the rear panel. 24VDC+ is supplied on Pin 14 EXT_SOLENOID_A is supplied on Pin 13 EXT_SOLENOID_B is supplied on Pin 12 GND is supplied on Pin 11

PARK LOCATION

The park location is the position you want the dispense tip to move to after it has completed its taught program. This location is often a position closer to the work-piece than mechanical home in order to shorten the work cycle and also allows ample space for the part to be removed from the fixture plate. The default park location is set to mechanical home position which is X=0,Y=0, Z=0. This is indicated in the drop-down box as Home. To teach a new park location, first select New. Enter the new Park Location name. Next, teach the location by tapping Jog and moving the dispense tip to desired location. Tap OK to return to Park Location setup screen. Tap Teach to complete the new Park Location setup. To use the toggle bracket at park location, check the Use Toggle box. This will actuate the toggle bracket i.e. toggle down, at that park location, otherwise, the toggle bracket will toggle up at the part location. Teach the park location as above. Maximum number of locations is ten. Note locations include park, purge and purge toggle. 4.5 PURGE VALVE #1 To teach a new purge location: 1. Select New. Enter the new Purge Location name. 2. Teach the location by tapping Jog and moving the dispense tip to desired location. Tap OK to return to Purge Location setup screen. 3. Enter the desired purge time (in seconds). Note that the purge time is limited to a maximum of 65.535 seconds. 4. Tap Teach to complete the new Purge Location setup. 5. The selected purge routine is downloaded the next time a download from the PDA occurs. Once downloaded onto the machine, the purge routine can be accessed through the front panel LCD in program 99.

PURGE TOGGLE

This screen performs the same function as in Section 4.5, except it is for the Toggle Valve instead of Valve #1. This purge routine can be accessed through the front panel LCD in program 98. From time to time, you may want to run the purge routine from the PDA. This can be accomplished by selecting Util in the Program mode then select Purge Main or Purge Toggle from the drop-down menu
4.7 SAFE Z This feature allows a lower safe Z height (reference to Z=0) to be set so as to reduce the time it would otherwise take if the Z head has to return to the 0 position before each XY movement. It is especially useful if the part is very low i.e. daylight is large. The safe Z height is the height the Z head will move to before any XY non-dispense movements. Note that the height the Z head moves to between dispense locations within a program, is dictated by the retract distance specified for that line or dot type. The safe Z height should be a high enough position to clear any objects in the machines XY envelope. If the Safe Z is not configured, the machine will move the Z head up to the 0 position before any XY movements. To set a safe Z height: 1. Select Safe Z from the top right-hand drop-down box. 2. The probe will be actuated and drop down. If a toggle bracket is used, the toggle will also be actuated. 3. Using the probe and toggle, if applicable, as reference, move the Z head to a height where both the probe and toggle clears any object in the XY envelope. The probe should not be touching anything. 4. Tap Teach. 5. Your Safe Z height has been set

5. 5.1

PROGRAMMING CREATING A NEW PROGRAM
Before you start this exercise, print out the form called Teaching Template in Appendix B of this guide. 1. Install the tooling plate7 on the Y-carriage and attach the printed template on it with cellophane tape. 2. Tap Program in the Main screen. This will take you to the program edit window. 3. From the Program drop-down menu, select New. This will open a dialog box to name your new program. 4. Type in new program name. Note that program names are casesensitive. If an attempt is made to create a new program with the same name as the program currently opened, an error message will be displayed.
5. Tap OK. This will open the Teach Program Origin window. The program origin is the point in the program from which all other movements relate to, or the (0,0) coordinate of the program. Refer to Appendix C for a detailed explanation of Program Origin.
6. Tap Jog to open the Jog window. Use the compass rose to move the dispense tip to the position marked Origin on the template. Refer to Appendix A for detailed jogging instructions. 7. Tap OK. Tap Teach and then OK. This will open the program edit window.
EFD can supply two tooling plates: 300 X 300mm (P/N 7007-300) or 500 X 500mm (P/N 7007-500). Alternative, user can design their own (reference System Drawings on Operation CD).
8. The Program window is where points are inserted, deleted and edited. This is the main programming window. Now you are ready to insert dispensing points into your program.
5.2 TEACHING DISPENSING POINTS To start dispensing, dispensing points must be located and taught. Dispensing points can be located in two ways: Using the nozzle tip; Using the laser pointer.
With the first method i.e. using the nozzle tip, you can elect to invoke the height sensor or not. However, the height sensor must be used in conjunction with the laser pointer in teaching dispensing points. To teach dispensing points with the laser pointer: 1. First, ensure that the tip to probe offset has been setup (Refer to Section 4.1.1.1). 2. Before programming, turn the laser pointer on: a. Using the PDA, select Program from the Main screen. b. Tap the top left-hand corner of the Program screen and select Util from the menu bar. i. Select Toggle Laser. This will turn the laser pointer drive on.

3. Establish the origin of the program using the laser pointer. 4. Insert a height sense instruction as close to the first dispense point as possible. You may choose to use the probe or the laser pointer to teach the height sense location. If you choose remember to check the Teach with Laser Pointer box.

the latter,

5. Teach the dispense points using the laser pointer as you would using a nozzle tip. Use the dispense gap for each dot/line type to determine the z-height of the dispense point/line. 6. When all dispense points have been taught, return to the program origin and re-teach the origin using the nozzle tip (instead of the laser pointer as you had done in Step 2 above).

TEACHING A DOT

Next, we will program four dots and set the desired dot parameters (Figure A on the template). 1. In the Program menu, tap Insert to start inserting program instructions. This will open the Select Instruction window. 2. In the Select Instruction menu, select Dot and tap OK. 3. You are now required to teach the first dot position. Tap Jog to open the Jog window. Position the dispense tip to the first point and tap OK. Select a number for Dot Type. Tap Edit to open the Dot Parameter window. 4. If the toggle bracket is selected in the Setup window, the toggle box will be visible to the Operator to select. Check the Use Toggle box if the dispense is to use the toggle valve/syringebarrel. Teach the dispense location (Refer to 3 above) using the toggle valve or syringe-barrel. Note that when the program is running, the toggle will actuate i.e. move down, before it begins to move to the taught dispensed location. 5. Enter the desired value for each Dot Parameter field. Refer to Appendix D for a detailed description of the different parameters that make up a Dot Type. When done, tap OK. 6. Tap Teach Dot to insert instruction. Each time Teach Dot button is pressed the line number will increment (circled in the left graphics). It allows the user to (1) verify that the Teach was taken and (2) confirm which instruction is being inserted / edited.
7. Jog to the next dot location. Select a dot type, if different from the earlier selection. There can be up to ten unique dot types per program. 8. Tap Done once all four Dot instructions have been taught. This will take you back to the main Program window.

ABC = Clockwise CBA = Counterclockwise
Next, teach the arc in Figure B on the template. Note: 1 = CP Start; 2 = CP Arc; and 5 = CP End. 1. 2. Select CP from the Select Instruction window. Tap OK. This will open the Continuous Path window. Tap Jog and jog the dispense tip to the lower left point of the arc (marked 1). Tap OK. 40

3. 4. 5. 6.

Select CP Start from the Point Type drop-down menu and tap Teach CP. The program will now advance to the next instruction line in the program. Tap Edit to set the line parameters accordingly for this arc application. Tap Jog again and move to the point at the top of the arc (marked 2). Tap OK and select Arc from the Point Type drop-down menu. Tap Teach CP to save this point. Tap Jog a third time and jog the dispense tip to the end point (marked 5). Tap OK and select End from the Point Type drop-down menu. Tap Teach CP to complete teaching the arc. Note that the direction of travel for the arc just taught will be clockwise.

CIRCLE

The circle command is strictly 2-dimensional i.e. Z values remain the same throughout every single element in the circle. The first Z-value entered is the value used in the (2-dimensional) circle. The next exercise is programming a circle (Figure C on the template). Note: 6 = Circle 1. From the Select Instruction window, select Circle then tap OK. This will open the Circle window and the operator is required to teach three points along the diameter of the circle. 2. Jog to the desired start point of your circle, then tap OK. Tap Teach to register the first point, then jog to a second point along the diameter of your circle, tap OK. Tap Teach to register the second point. Repeat this process for the third point. Once all three points are taught, the Operator needs to determine desired direction of travel for the circle pattern. Default is a counter-clockwise direction but can be changed by checking the box marked clockwise. 3. If the toggle bracket is selected in the Setup window, the toggle box will be visible to the Operator to select, if desired. The line parameters can be set or changed in the Line Parameters window. 4. If the three points taught do not define a circular shape, an error message will appear.
IRREGULAR CONTINUOUS PATH
Teaching irregular shapes requires the software to tie different elements together in a way that the taught path can be maneuvered in a smooth manner at a constant velocity. Short moves at sharp angles will limit the speed paths that can be run and should be avoided. Note: You can only incorporate lines and arcs elements in an irregular continuous path if it is strictly 2-dimensional. Otherwise, you will need to simulate the arc as a best-fit spline using several Mid-point commands.
Next, program Figure E on the template. The key at each point on Figure E indicates the Point Type required to achieve the desired path. Note: 1= CP Start; 2 = CP Arc; 3 = CP Mid; 5 = CP End

CHANGING PROGRAM ID NUMBER From time to time, you may need to reassign a program ID number. To do this, select Program ID in Edit drop-down menu. This will open the Change Program ID window. The Change Program ID window displays the current program ID number and the closest open available ID number. You can enter the desired ID number or use the default number provided.

CHANGING PROGRAM ORIGIN

You can change the program origin anytime: Tap the top left-hand corner of the Program screen. From the Edit drop-down menu, select Program Origin. Tap Go To to check the position of the current program origin Jog to the new program origin position Tap Teach to confirm
Note: Before confirming/changing program origin, the toggle valve will toggle up if it is in the down position.
WARNING! Do not tap Teach when Z is at zero position. Tapping Teach at zero position will erase all Z coordinates in the program and they cannot be recovered. You will then have to manually re-enter each line of the program.

EDITING FUNCTIONS

There are several editing functions available within the Program mode.
DELETING INSTRUCTION LINE(S) WITHIN A PROGRAM
1. Tap the top left-hand corner of the Program screen. 2. From the Edit drop-down menu, select Mark. 3. Select the program lines you want to delete. A -> sign will appear before the instruction to indicate which line has been selected. 4. From the Edit drop-down menu, select Cut. The selected instruction lines will be deleted from the program.
COPYING INSTRUCTION LINE(S) INTO ANOTHER PROGRAM Tap the top left-hand corner of the Program screen. From the Edit drop-down menu, select Mark for line-by-line selections or Select All to pick all the instruction lines. Tap the selected line again to deselect it. Select the program lines you want to copy. A -> sign will appear before the instruction to indicate which line has been selected. From the Edit drop-down menu, select Copy. Go to the program you want to paste these instruction lines onto. From the Edit drop-down menu, select Paste. The selected instruction lines will be copied into the new program.

POWER UP

Upon power up, the LCD will display a splash screen that indicates machines version of firmware (circled). The main board power-up test result will also be displayed here (either OK or FAIL). Note: As of the published date of this manual, the most current Firmware is Version 1.1

No air pressure

Unstable air pressure
Factory air supply fluctuates air compressor ON/OFF. There is no air pressure.

No fluid pressure

1. Main Air Switch OFF. 2. Air pressure
No valve or syringe barrel pressure
3. Syringe Barrel Adapter is disconnected.
4. Incorrect setup in PDA software.

Leaky Regulator

Damaged Regulator.

Air Regulator is hissing

This is a normal function of the 30 psi bleed-type regulator (P2). P1 is a non-bleed regulator and should not hiss.
Table 11.3: Height Sensor Troubleshooting
Probe does not drop or retract
1. Probe malfunction. 2. No air pressure.
Check for bent probe. Verify Main Air Pressure is ON and set to 70 psi. Perform Tip-to-Valve-Offset. Refer to section 4.1.1.

Needle hits Substrate

Probe tip is lower than needle tip when valve is in dispensing position. 1. Height Sensor has been adjusted, loose or binding in the drive system. 2. Nozzle/needle has been changed without resetting Tip-to-Probe Offset 1. Height Sensor was tripped before Z-axis started the height sense move. Either the probe is still retracted, stuck in the up position or adjusted incorrectly. 2. Low air pressure. 3. Electrical wires are not plugged in properly at the Z-head. 1. Safe Z may be set too low.
Dispenses at wrong Z-axis position
Perform a Tip-to-Probe Offset. Refer to section 4.1.1.
Correct the Height Sensor alignment and rerun.
PDA indicates an error message (ERR 65 Height Sensor has detected surface before starting)
Verify Main Main Air Pressure is ON and set to 70 psi. Check the connection at the top of the Z-head. Raise Safe Z. Check to make sure that the probe is not too far below tip when extended (minimum distance below tip is 6 mm).
Probe hits Substrate when setting Tip-toProbe Offset
2. Probe is not hitting sensor.
To Replace Height Sensor Probe To remove the sensor you will need to remove the Z plate. To do this, pull it down by hand to access the Z balance spring or springs. Tie a wire to the spring then unhook it. Remove the four bolts from the Z head. You can now place it in top of the X beam to work on the probe. You should be able to straighten it without removing it. If you have to remove it, take the two Phillips screws out from the front of the Z plate. Remember where the little spring goes. When reassembling, be careful when you tighten the probe screw. Too tight and you can bend the probe. Reassemble in reverse order.

Multishot Delta This is the Z-height that the dispensing head will retract between each shot at the same X/Y location. It is used in conjunction with Number of Shots. Note that the Dwell Time parameter is applied between shots. The units are in inches or millimeters. In a potting application, the use of the Number of Shots and Multi-Shot Delta keep the dispense tip above the potting compound as part is being filled. Dwell Time Dwell Time measures how long the dispensing head stays at the final position after the end of dispensing before retracting multishot delta. This may be necessary to give the fluid a chance to detach from the tip and onto the substrate i.e. increasing the Dwell Time can reduce stringing of material. The units are in seconds. For most solder pastes and adhesives, 30 ms is sufficient. However, the Dwell Time can be set as long as 6 seconds for very elastic fluids. Reverse Time This parameter is only required when the 790 Auger valve has been selected in the Setup mode. At the end of dispensing a dot, the valve is reversed for the specified time period to remove any material from the tip of the needle. The Reverse Time value should be set according to fluid/paste viscosity. Generally, 10 ms (0.010 sec) is sufficient. Retract Speed This is the speed of the dispensing head while moving the Retract Distance (valve moving up). This parameter is useful in breaking off stringing material i.e. slowing retract speed. The units are either in inches/second or mm/second. Typically, 2 in/sec or 50.8mm/sec is sufficient. Retract Distance This is a vertical distance that the dispensing head moves after dispensing. The Retract Distance must be high enough to clear any obstacles on the work-piece during the movement to the next point. The Retract Distance can be reduced to increase throughput. The units are either in inches or millimeters. Typically, 10mm or 0.4 in is sufficient.
APPENDIX E Line Parameters Explained Line parameters control the different aspects of a line dispense command. They need to be set prior to teaching the end of a continuous path movement including the ARC and CIRCLE instructions. Although the program already has default settings, it is highly recommended that the User Operator review and set each Line Parameter to obtain the desired application results. Note that each program can be configured for up to 10 different line types, and each time-related line parameter is limited to a maximum of 65.535 seconds. Down Speed The Down Speed measures how fast the dispensing head lowers to dispense. The units are in inches/sec or mm/sec. Typically, 2 in/sec or 50.8mm/sec is sufficient. Dispense Gap The Dispense Gap is the distance between the needle tip and the substrate during dispensing operations. This distance is one of the more common adjustments made to optimize a dispensing program. Note: dispense gap is only used after a height sense is inserted in a program. Otherwise, the machine will move to taught Z-position. The units are in either inches or millimeters. Typically 15 - 20 mils (0.015 - 0.020 in) is sufficient. Pre-Move Delay Higher-viscosity fluids do not dispense as quickly as lower-viscosity fluids. The Pre-Move Delay parameter increases the time that the dispensing head is parked with the valve ON, prior to a programmed move. The delay at the beginning position insures that a full line is dispensed. The units are in seconds. Typically, 50 ms (0.050 sec) is sufficient for most fluids. Line Speed This refers to how fast the dispensing head moves during dispensing. This parameter controls the bead diameter within a given flow rate. The speed of the dispensing head affects the amount of fluid dispensed. The units are in inches/second or mm/second. Typical dispense speeds range from 1.0 4.0 inches/second (or 25.4 101.6 mm/second), depending upon fluid flow rates and path trajectory. Shutoff Distance This parameter controls the point where the valve stops dispensing before the end of the move. Post-extrusion often is affected by tip size, fluid pressure and material viscosity. Hence, if any changes are made to these factors mid-stream, it is likely that Shutoff Distance will need to be readjusted. Note: The shutoff distance cannot be longer than the last line segment e.g. CP Mid to CP End. 72

APPENDIX F Technical Support Request Form
Also available at http://www.efd-inc.com/xyz/technical-form.html
Date: Requester: Location: Company: About the Unit Serial Number: Model Number: Firmware Version: Software Version: Type of PDA Used (indicate model): Palm PDA to TT interface: Cable / RS232 / Bluetooth Baud rate setting: Main Board Has the personality parameter of the machine been changed from factory setting? Yes / No Application Bracket Used: Single / Dual / Triple / Custom Valve Used: EFD Weight of bracket/valve on Z-axis: Weight of fixture/part on X-axis: Describe the application: / Other kg kg PDA Software / Sony
Problem Encountered Description of the problem
Error code on PDA: Error code on LCD panel: Describe what steps have been taken to resolve the problem:
Is a copy of the application program attached? Yes / No
APPENDIX G Electrical Block Diagram
A pdf copy of this drawing can also be downloaded from the TT User Guide CD. 77
APPENDIX H Pneumatic Block Diagram
A pdf copy of this drawing can also be downloaded from the TT User Guide CD. 78
GLOSSARY OF TERMS Fiducial A point of reference designed into a part or fixture that can be used to determine part or workpiece shift. This point is often used as the Origin point in a program. Jogging Refers to moving the Ultra TT series axes to teach either points or offsets. Jogging is accomplished by using the hard keys on the Palm handheld, the compass rose or blue field in the Jog window, and the front panel arrow buttons. Mechanical Home This is when all axes have returned to their travel origination points. This is determined by the location of the homing sensors. The Ultra TT is at mechanical home when the Z-axis is all the in the up position, X-axis is all the way to the left most position and the Y-axis is all the way to the back of the machine. Dispensing Tip Offsets This refers to the delta (change) in X/Y/Z of the dispensing tip when the tip has been removed and replaced with a new one. It is important that you teach the new tip position so the Ultra TT can accurately dispense your fluid. Soft Key Soft keys are software dependent and are designated by a highlighted function for the dome switch immediately below the command on the LCD Screen located on the front panel. Current Defined as flow from the positive terminal of the power supply to the negative terminal. Ground The negative terminal of the power supply Driver Controls the current in another electronic circuit (the load). A driver is considered to be ON when it allows current to flow in its load. A driver is considered to be OFF when it does not allow current to flow in its load. A driver may be a bipolar transistor or a Field Effect transistor. Opto-isolated devices are preferred. A driver may also be a mechanical switch or, preferably, an isolated relay contact. Load Any component or arrangement of several components that conducts current, when a driver is placed in an ON condition. The input circuitry of the Ultra TT is considered to be a load for external driver circuitry. The input circuits of external circuitry are considered to be loads for the output drivers of the Ultra TT. 79