MANUAL

TABLE OF CONTENTS
SAFETY
S.1 INTRODUCTION .................................................................................................. S-3
S.2 SAFETY PRECAUTIONS..................................................................................... S-3
S.3 MACHINE SAFETY LABELS ............................................................................... S-4
S.4 MACHINE SAFETY INTERLOCKS ...................................................................... S-5

S.4.1 EMERGENCY MACHINE OFF (EMO) SWITCHES..................................... S-5
S.4.2 LOCKING SAFETY DOORS SWITCHES.................................................... S-6
S.4.3 AIR PRESSURE SWITCH ........................................................................... S-6
S 4.4 CONVEYOR MOTION AND LIFT TABLE ..................................................... S-6
S.5 DEFINITIONS OF WARNINGS, CAUTIONS AND NOTES ................................. S-6
S.6 WARNINGS.......................................................................................................... S-7
S.7 MACHINE DISPENSING MATERIAL DISPOSAL .............................................. S-10
S.8 MATERIAL SAFETY DATA SHEETS ( MSDS )................................................. S-10

S.8.1 MATERIALS USED DURING DISPENSING.............................................. S-11
S.8.2 MATERIALS USED DURING MAINTENANCE.......................................... S-11
SECTION 1 INTRODUCTION
1.1 INTRODUCTION .................................................................................................. 1-3
1.2 TECHNICAL MANUAL INTRODUCTION ............................................................. 1-3
1.3 TECHNICAL MANUAL ORGANIZATION ............................................................. 1-3
1.4 APPENDIXES ....................................................................................................... 1-5
1.5 PARTS IDENTIFICATION .................................................................................... 1-6
1.6 PARTS REPLACEMENT ...................................................................................... 1-6
CAMALOT 5000 Table Of Contents i

1.7 CONSUMABLE MATERIALS ................................................................................1-6
1.8 OPTIONAL SUPPLEMENTS.................................................................................1-7
SECTION 2 DESCRIPTION
2.1 GENERAL DESCRIPTION....................................................................................2-3
2.2 FUNCTIONAL DESCRIPTION ..............................................................................2-3
2.3 INDIVIDUAL COMPONENTS................................................................................2-3

2.3.1 MACHINE......................................................................................................2-4
2.3.2 COMPUTER CONTROL SYSTEM ...............................................................2-4
2.3.2.1 MONITOR.............................................................................................2-4
2.3.2.2 TRACKBALL.........................................................................................2-4
2.3.2.3 KEYBOARD..........................................................................................2-4
2.3.2.4 SOFTWARE .........................................................................................2-5
2.3.3 CONVEYOR SYSTEM ..................................................................................2-5
2.4 TECHNICAL SPECIFICATIONS ...........................................................................2-5
2.5 SERIAL NUMBER TAG.........................................................................................2-7
SECTION 3 OPERATION
3.1 GENERAL INFORMATION ...................................................................................3-3
3.2 SAFETY PRECAUTIONS......................................................................................3-3
3.3 OPERATING CONTROLS ....................................................................................3-4

3.3.1 DESCRIPTIONS OF OPERATING CONTROLS ..........................................3-4
3.3.2 DESCRIPTION OF SAFETY RELAY CIRCUIT.............................................3-9
3.4 MACHINE SAFETY DOORS SYSTEM ...............................................................3-10
3.5 LIGHT TREE INDICATORS ................................................................................3-10
Page ii CAMALOT 5000 Table of Contents

3.6 DISPENSE PANELS .......................................................................................... 3-11
3.6.1 LEFT-HAND (LH) DISPENSE PANEL........................................................ 3-11
3.6.2 RIGHT-HAND (RH) DISPENSE PANEL..................................................... 3-13
3.7 REAR PANEL ..................................................................................................... 3-15
3.8 TRACKBALL....................................................................................................... 3-19
3.9 CAM/ALOT SYSTEM MAIN SCREEN................................................................ 3-22

3.9.1 FILE OPERATIONS SCREEN ................................................................... 3-41
3.9.2 DISPENSE PARAMETERS SCREEN........................................................ 3-43
3.9.3 DIAGNOSTICS SCREEN........................................................................... 3-45
3.10 PASSWORD..................................................................................................... 3-47

3.10.1 CREATING A PASSWORD ..................................................................... 3-48
3.10.2 ACTIVATING A PASSWORD .................................................................. 3-49
3.10.3 CHANGING A PASSWORD..................................................................... 3-49
3.10.4 REMOVING PASSWORD PROTECTION ............................................... 3-50
3.11 INITIAL SET UP................................................................................................ 3-50

3.11.1 DISPENSE SYSTEM................................................................................ 3-51
3.11.2 CONVEYOR SETUP ................................................................................ 3-52
3.11.2.1 DESCRIPTION OF SMEMA ............................................................ 3-52
3.11.2.2 INITIAL CONVEYOR SETUP .......................................................... 3-54
3.11.2.3 ADJUSTMENT OF INPUT BUFFER STOP PIN AND SENSOR...... 3-59
3.11.2.4 ADJUSTMENT OF OUTPUT BUFFER STOP PIN AND SENSOR.. 3-60
3.11.2.5 AUTOMATIC OPERATION.............................................................. 3-60
3.11.3 SETTING THE HEIGHT OF THE NEEDLE.............................................. 3-60
3.12 MACHINE START UP....................................................................................... 3-63
3.13 DISPENSING A PATTERN............................................................................... 3-64
SECTION 4 PROGRAMMING
4.1 SAFETY PRECAUTIONS ..................................................................................... 4-5
CAMALOT 5000 Table Of Contents iii

4.2.1 MOVING THROUGH A DIRECTORY ...........................................................4-6
4.2.2 LOADING A PATTERN.................................................................................4-6
4.2.3 MOVING THE CURSOR THROUGH A PATTERN.......................................4-7
4.2.3.1 SINGLE-STEPPING THROUGH A PATTERN .....................................4-8
4.2.3.2 SCROLLING THROUGH A PATTERN.................................................4-9
4.3 PROGRAMMING A DISPENSE PATTERN ........................................................4-10

4.3.1 CREATING A NEW PATTERN FILE ..........................................................4-10
4.3.1.1 SETTING DISPENSE PARAMETERS ...............................................4-11
4.3.1.2 PROGRAMMING A POINT.................................................................4-14
4.3.1.3 PROGRAMMING A SERIES OF DOTS .............................................4-14
4.3.1.4 PROGRAM A CIRCLE........................................................................4-15
4.3.1.5 SUBPATTERNS .................................................................................4-16
4.3.1.5.1 LOADING A SUBPATTERN .................................................4-16
4.3.1.5.2 REPLACING A SUBPATTERN.............................................4-16
4.3.1.6 CALL COMMAND ...............................................................................4-17
4.3.1.7 DATA SHEET .....................................................................................4-18
4.3.1.8 END THE PATTERN ..........................................................................4-19
4.3.1.9 SAVING A PATTERN .........................................................................4-19
4.3.1.10 RUNNING A PATTERN ....................................................................4-20
4.3.2 EDITING AN EXISTING PATTERN ............................................................4-20
4.3.2.1 SEARCHING FOR A STEP ................................................................4-20
4.3.2.2 INSERTING A STEP ..........................................................................4-21
4.3.2.3 DELETING A STEP ............................................................................4-21
4.3.2.4 CUT, COPY AND PASTE ...................................................................4-21
4.3.2.5 BLOCK EDITING ................................................................................4-22
4.4 APPLICATIONS ..................................................................................................4-22

4.4.1 PATTERN PARAMETERS..........................................................................4-22
4.4.1.1 CHANGING PARAMETERS IN MAIN SCREEN ................................4-22
4.4.1.2 MAINTAINING A SHOTSIZE ..............................................................4-23
4.4.1.3 CHANGING A PARAMETER..............................................................4-23
4.4.1.4 ADJUSTING A PARAMETER.............................................................4-24
Page iv CAMALOT 5000 Table of Contents

4.4.1.5 DISPENSING TIPS ............................................................................ 4-24
4.4.2 ADJUSTING THE PATTERN ..................................................................... 4-25
4.4.2.1. OPTIMIZE A PATTERN .................................................................... 4-25
4.4.2.2 OFFSET THE START POINT ............................................................ 4-26
4.4.2.3 SELECTIVE DISPENSING ................................................................ 4-27
4.4.2.4 DISPENSING ON MORE THAN ONE LEVEL ................................... 4-28
4.4.2.5 ADJUSTING BOTH TRAVELING AND DISPENSING HEIGHT ........ 4-28
4.4.2.6 ROTATE A PATTERN ....................................................................... 4-31
4.5 TRANSFERRING DATA VIA THE RS232 INTERFACE..................................... 4-31

4.5.1 EQUIPMENT .............................................................................................. 4-32
4.5.2 SETUP ....................................................................................................... 4-32
4.5.3 PROGRAM DATA FORMAT ...................................................................... 4-33
4.5.3.1 PARAMETER LINES ......................................................................... 4-33
4.5.3.2 INSTRUCTION LINES ....................................................................... 4-34
4.5.3.3 NAME LINES ..................................................................................... 4-35
4.5.3.4 CONTROL LINES .............................................................................. 4-35
4.5.3.5 COMMENT LINES AND OTHER COMMENTS ................................. 4-36
4.5.3.6 SAMPLE PATTERN........................................................................... 4-37
4.5.4 TRANSFERRING DATA............................................................................. 4-38
4.5.4.1 HOST-TO-CAM/ALOT TRANSFER ................................................... 4-38
4.5.4.2 CAM/ALOT-TO-HOST ....................................................................... 4-38
4.5.4.3 CAM/ALOT TO A PARALLEL INTERFACE PRINTER ...................... 4-39
4.5.4.4 CAM/ALOT TO A SERIAL INTERFACE PRINTER............................ 4-39
4.5.4.5 LOADING AND SAVING ASCII FILES ON THE CAM/ALOT............. 4-39
4.5.5 ERROR HANDLING ................................................................................... 4-40
4.5.5.1 PATTERN ERRORS .......................................................................... 4-40
4.5.5.2 INPUT / OUTPUT (I/O) ERRORS ...................................................... 4-40
4.6 GLOSSARY OF TERMS...................................................................................... 4-41
CAMALOT 5000 Table Of Contents v

SECTION 5 INSTALLATION
5.3 MACHINE INSTALLATION PRELIMINARY REQUIREMENTS ............................5-4

5.3.1 FLOOR SPACE REQUIREMENTS...............................................................5-4
5.3.2 AIR SUPPLY REQUIREMENTS ...................................................................5-4
5.3.3 ELECTRICAL POWER REQUIREMENTS ...................................................5-4
5.3.3.1 LINE VOLTAGE TRANSIENTS ............................................................5-5
5.3.3.2 LIGHTNING PROTECTION..................................................................5-5
5.3.3.3 CONDUCTOR SIZE..............................................................................5-5
5.3.3.4 MACHINE/SYSTEM GROUNDING ......................................................5-5
5.3.3.5 TESTING THE SYSTEM EARTH REFERENCE ..................................5-6
5.3.3.6 ADDITIONAL ELECTRICAL EQUIPMENT RECOMMENDATIONS.....5-6
5.4 MACHINE INSTALLATION ...................................................................................5-7

5.4.1 UNLOCK / LOCK MACHINE SAFETY DOORS ............................................5-7
5.4.1.1 UNLOCK / LOCK SAFETY DOORS USING SYSTEM SOFTWARE
(AFTER SHIPMENT)............................................................................5-7
5.4.1.2 UNLOCK SAFETY DOORS MANUALLY..............................................5-8
5.4.2 MACHINE SETUP.........................................................................................5-9
SECTION 6 MAINTENANCE
6.3 PREVENTIVE MAINTENANCE.............................................................................6-4
6.4 LUBRICATION ......................................................................................................6-5

6.4.1 BALL SCREW ...............................................................................................6-5
6.4.2 BEARINGS....................................................................................................6-5
Page vi CAMALOT 5000 Table of Contents

6.4.3 OPTIONAL LOADER AND UNLOADER LEAD SCREWS ........................... 6-6
6.5 REPLACEMENT OF OPTIONAL CONVEYOR RAIL INSERTS........................... 6-6
6.6 REVERSING CONVEYOR FLOW DIRECTION ................................................... 6-7

6.6.1 REVERSING MOTOR DIRECTION ............................................................. 6-7
6.6.2 RELOCATION OF CONVEYOR HARDWARE............................................. 6-8
6.6.2.1 RELOCATION OF CONVEYOR LIFT TABLE...................................... 6-8
6.6.2.2 RELOCATION OF STOP PIN AND DISPENSE SENSOR .................. 6-9
6.7 REPLACEMENT OF CONVEYOR BELTS ......................................................... 6-13
6.8 CALIBRATION OF CONVEYOR OFFSET ......................................................... 6-15
SECTION 7 TROUBLESHOOTING
7.1 GENERAL INFORMATION................................................................................... 7-3
7.3 CHECKING THE SYSTEM ................................................................................... 7-4

7.3.1 CHECK THE PULSE MOTORS .................................................................... 7-4
7.3.2 CHECKING X-, Y- AND Z-AXIS ENCODERS .............................................. 7-5
7.3.3 CHECKING THE HOME SWITCHES........................................................... 7-5
7.4 TROUBLESHOOTING.......................................................................................... 7-5

7.4.1 TROUBLESHOOTING MACHINE START UP AND OPERATION .............. 7-5
7.4.1.1 COMPUTER DOES NOT BOOT UP WHEN MACHINE ON BUTTON IS
PUSHED.............................................................................................. 7-6
7.4.1.2 HEADS DO NOT GO TO HOME POSITIONS WHEN TRACE OR
CAMERA ARE SELECTED ................................................................. 7-9
7.4.1.3 X-, Y-, OR Z-AXIS MOTOR DOES NOT MOVE................................. 7-12
7.4.1.4 SYSTEM WON'T DISPENSE - LIFT TABLE IS UP AND HEAD IS IN
PARK ................................................................................................. 7-14
7.4.1.5 LIFT TABLE NOT LIFTING ................................................................ 7-16
7.4.1.6 LIFT TABLE DOES NOT LOWER AFTER DISPENSING ................. 7-17
7.4.1.7 STOP PIN NOT FUNCTIONING ........................................................ 7-18
CAMALOT 5000 Table Of Contents vii

7.4.2 ELECTRICAL PANEL ASSEMBLY .............................................................7-18
7.4.2.1 ELECTRICAL FUSE BLOCK ..............................................................7-19
7.4.2.2 SAFETY DOORS DECODER CARD (DECODER).............................7-20
7.4.2.3 TURRET ROTARY PUMP CARD (TURRET CARD)..........................7-21
7.4.2.4 CONVEYOR CONTROL AND SYSTEM CONTROL BOARDS ..........7-21
7.4.2.5 SYSTEM TRANSFORMERS (T1 AND T2).........................................7-21
7.4.2.6 110 VOLT A/C OUTLETS...................................................................7-21
7.4.2.7 OPTIONAL NEEDLE CALIBRATOR AMPLIFIER UNIT .....................7-21
7.4.2.8 EMERGENCY MACHINE OFF (EMO) CIRCUIT SAFETY RELAY ....7-21
7.4.2.9 PROGRAMMABLE LOGIC CONTROLLER (PLC) .............................7-21
7.4.2.10 SOLID-STATE RELAY (SSR) FOR AN OPTIONAL HEATER UNIT 7-22
7.4.2.11 MAIN CONTACTOR (CR1)...............................................................7-22
7.4.2.12 ELECTRICAL CONNECTORS (J29, J30, AND J31) ........................7-22
7.4.2.13 ELECTRO-MAGNETIC INTERFERENCE (EMI) FILTER.................7-22
7.4.2.14 BRIDGE RECTIFIER ........................................................................7-22
7.4.2.15 AIR PRESSURE SWITCH (SP1)......................................................7-22
7.4.3 ERROR CODES .........................................................................................7-22
7.4.3.1 ERROR CODE 230.............................................................................7-22
7.4.3.2 ERROR CODE 231.............................................................................7-22
7.4.3.3 ERROR CODE 232.............................................................................7-22
Page viii CAMALOT 5000 Table of Contents

CAMALOT 5000 Table Of Contents ix
sSAFETY
S.1 INTRODUCTION .................................................................................................. S-3
S.2 SAFETY PRECAUTIONS..................................................................................... S-3
S.3 MACHINE SAFETY LABELS ............................................................................... S-4
S.4 MACHINE SAFETY INTERLOCKS ...................................................................... S-5

S.4.1 EMERGENCY MACHINE OFF (EMO) SWITCHES..................................... S-5
S.4.2 LOCKING SAFETY DOORS SWITCHES.................................................... S-6
S.4.3 AIR PRESSURE SWITCH ........................................................................... S-6
S 4.4 CONVEYOR MOTION AND LIFT TABLE ..................................................... S-6
S.5 DEFINITIONS OF WARNINGS, CAUTIONS AND NOTES ................................. S-6
S.6 WARNINGS.......................................................................................................... S-7
S.7 MACHINE DISPENSING MATERIAL DISPOSAL .............................................. S-10
S.8 MATERIAL SAFETY DATA SHEETS ( MSDS )................................................. S-10

S.8.1 MATERIALS USED DURING DISPENSING.............................................. S-11
S.8.2 MATERIALS USED DURING MAINTENANCE.......................................... S-11
CAMALOT 5000 Safety S-1

S-2 CAMALOT 5000 Safety
S.1 INTRODUCTION
This section provides safety information regarding the CAMALOT 5000 system. The
Operator should understand the purpose and correct operation of the system before
attempting any system activities.
S.2 SAFETY PRECAUTIONS
Safety must be considered and practiced at all times when operating or servicing the
CAMALOT 5000 system. This requires a continual effort on the part of the operator or
anyone else working on or near the CAMALOT 5000 system.
The following list of safety precautions must be considered and practiced at all times:
1. Before attempting to operate or service the CAMALOT 5000 system, all

personnel must read the instructions carefully. Failure to comply with the
instructions could result in personal injury or property damage.
2. Be sure that the CAMALOT 5000 system is operating properly. Always operate
the system with the safety doors closed.
3. Keep hands away from gantry, heads, needles, conveyor belts, lift table
mechanism, etc. during system operation and whenever electrical power and air
are ON.
4. Do not operate the machine with any covers removed.
5. Should any malfunction occur, press the MACHINE OFF push button located on
the main control panel to shut down the machine operation.
6. Never reach for parts in progress such as a fixture that has become loose from
the dispense area. Press the red EMERGENCY MACHINE OFF palm switch to
immediately shut off the machine.
7. Never put fingers or foreign objects into the openings of the machine.
8. Always wear eye protection.
9. Wear proper apparel. No loose clothing or jewelry.
10. Maintain a clean working environment.
11. Maintain the CAMALOT 5000 system in top working condition.

12. Test the safety features monthly.
13. Disconnect the air and electrical power when handling, moving or servicing.
S.3 MACHINE SAFETY LABELS
The CAMALOT system may display a number of DANGER, WARNING, and CAUTION
labels to identify hazardous conditions or hazardous materials that are used during the
dispense operation. Depending on optional equipment supplied, some or all of the
following labels may be used:
Area is hot. Contact with heated plates or components may

result in serious burns.
Before removing any panel to access the inside of the

Machine, electrical power and air must be disconnected.
Failure to do so may result in injury to personnel.

Personnel must keep hands clear of the Machine while it is
running. High-speed movement of the dispenser occurs
when the Machine is running.
Eye protection is required because of the material being

dispensed.
Machine may be started remotely. Operators must be

sure that there are no obstructions in the programmed
path of the dispenser.
S.4 MACHINE SAFETY INTERLOCKS
The machine Safety Interlocks are safety features that are utilized with the CAMALOT
5000 system.
S.4.1 EMERGENCY MACHINE OFF (EMO) SWITCHES
There is one red push/pull EMERGENCY MACHINE OFF (EMO) switch on the
machine. It is located on the front of the main control panel.
If the EMO switch is pressed, the switch must be pulled out and the RESET button on
the main control panel must be pressed to allow power to be reset. The EMO switch is
wired in series with the coil of CR1. If the EMO switch is pressed, CR1 will drop out.
This will electrically shut down the machine and dump the air pressure within the
machine.

S.4.2 LOCKING SAFETY DOORS SWITCHES
These switches prevent the machine safety doors from being opened while the
machine is automatically dispensing. The control system will automatically check the
status of the door closed and then the door locked signals. If the control system
detects that a door is opened or not locked and RUN is selected, the audible alarm will
sound and will remain on until the dispense cycle is complete.
The machine will also move the servo motors at a reduced speed. If RUN is selected
and the doors are closed, the doors will be automatically locked. After the doors are
locked, the status of the locks are checked. If the doors are locked, the machine will
run normally. Whenever either of the safety doors are open, the amber light will turn
on. While the door is open, if any of the menu selections are made that allow motion of
the axes, the audible alarm will sound. It will remain on until that selection is
deselected.
S.4.3 AIR PRESSURE SWITCH
The machine has an air pressure switch with a low setting of 40 PSI. If the pressure
drops below this setting, power to the machine control circuits and computer will be
turned off. The MACHINE ON push button will have to be pressed to re-energize the
machine.
S 4.4 CONVEYOR MOTION AND LIFT TABLE
A potential pinch hazard exists if the machine is “Paused” when in “RUN” mode. When
paused the conveyor remains active. If a board is presented to the machine, the
conveyor will transport the board to the dispense station and the lift table will lift the
board into dispense position. Therefore you must abort the current run process before
performing any adjustment or service other than dispense material replenishment, This
will place the machine in a safe mode that eliminates any conveyor movement without
an operator instruction.
S.5 DEFINITIONS OF WARNINGS, CAUTIONS AND NOTES
WARNINGS, CAUTIONS and NOTES will be found throughout this manual in various
procedures. It is important that the significance of each is thoroughly understood by the
operator or anyone else using this manual.
The following definitions apply:
WARNING Indicates a condition or procedure that could result in personal

injury or loss of life if not correctly observed.

CAUTION Indicates a practice or procedure that could result in damage or
destruction of equipment if not strictly observed.
NOTE Indicates addtional information.
S.6 WARNINGS
Specific WARNINGS that apply to the CAMALOT 5000 system covered by this manual
are listed below. These WARNINGS are repeated elsewhere in the manual following
paragraph headings and preceding the text to which they apply.
WARNING
KEEP HANDS AWAY FROM NEEDLE.
WARNING
TURN POWER OFF BEFORE LUBRICATING.
WARNING
ELECTRICAL SHOCK HAZARD
USE EXTREME CAUTION WHEN TROUBLESHOOTING

MACHINE WITH POWER APPLIED TO MACHINE. ONLY
QUALIFIED PERSONNEL SHOULD BE ALLOWED TO
PERFORM TROUBLESHOOTING ON MACHINE. SERIOUS
INJURY OR DEATH COULD RESULT.

WARNING
MOVING PARTS
LOADER/UNLOADER MAY MOVE UNEXPECTEDLY AT ANY

TIME THERE IS ELECTRICAL POWER AND AIR TO
LOADER/UNLOADER. DISCONNECT ELECTRICAL POWER
AND AIR AND THEN PERFORM APPLICABLE
LOCKOUT/TAGOUT PROCEDURES BEFORE ATTEMPTING
TO PERFORM MAINTENANCE ON LOADER/UNLOADER.
SERIOUS INJURY OR DEATH COULD RESULT.

WARNING
RUST PREVENTIVE
SHEATH PS8 (AEROSOL)
EXTREMELY FLAMMABLE. DO NOT USE NEAR OPEN

FLAMES, HOT SURFACES, OR OTHER SOURCES OF
IGNITION.
CONTENTS UNDER PRESSURE - DO NOT PUNCTURE,

INCINERATE, OR STORE WHERE TEMPERATURE MAY
EXCEED 120°°F (49°°C).
MAY BE HARMFUL OR FATAL IF SWALLOWED. IF

SWALLOWED, DO NOT INDUCE VOMITING. CALL A
PHYSICIAN IMMEDIATELY.
USE WITH ADEQUATE VENTILATION. AVOID

PROLONGED BREATHING OF VAPORS. INHALATION MAY
CAUSE THROAT IRRITATION, DIZZINESS AND NAUSEA.
GO TO FRESH AIR.
IF PROLONGED EXPOSURE IS EXPECTED, WEAR

PROTECTIVE GLOVES, RESPIRATOR, AND GOGGLES. IF
SPRAY GETS IN EYES, FLUSH THEM WITH WATER AND
SEEK MEDICAL ATTENTION.

WARNING
WHEN THE SYSTEM EARTH REFERENCE IS REMOVED

FROM THE PRIMARY OR DEDICATED SAFETY EARTH
GROUND BUS, HAZARDOUS VOLTAGES MAY EXIST
BETWEEN THE SYSTEM EARTH RETURN WIRE AND THE
SAFETY EARTH GROUND BUS. THIS WIRE SHOULD BE
HANDLED WITH EXTREME CARE.
THE VOLTAGE BETWEEN THE SYSTEM EARTH RETURN

WIRE AND THE SAFETY GROUND BUS MUST BE
MEASURED TO DETERMINE IF A HAZARDOUS CONDITION
EXISTS BEFORE ANY RESISTANCE MEASUREMENTS ARE
MADE THAT REQUIRE DISCONNECTION OF THE SYSTEM
EARTH RETURN WIRE.
S.7 MACHINE DISPENSING MATERIAL DISPOSAL
The CAMALOT 5000 system dispenses a variety of materials. Used ( empty ) syringes
and the optional needle purge cup contents will need to be disposed of properly. These
residual dispensing materials should be fully cured and disposed of according to
National and Local regulatory requirements. Also, Refer to the applicable Material
Safety Data Sheets ( MSDS ).
S.8 MATERIAL SAFETY DATA SHEETS ( MSDS )
The Material Safety Data Sheets ( MSDS ) are provided by companies that make and
distribute hazardous substances. There is no single mandatory MSDS form, therefore
many different types of MSDS forms may be observed. What is consistent though, is
the type of information included on each MSDS form.
Refer to to the applicable Material Safety Data Sheets ( MSDS ) and MSDS Booklet
located in the front of the manual.

S.8.1 MATERIALS USED DURING DISPENSING
Table S-1 has been provided ( Intentionally Blank ) for listing ( by hand ) any of the
Materials Used During Dispensing that may be required. Be sure to identify ( by an X )
whether or not ( YES or NO ) the applicable MSDS is available for reference. Place the
applicable Material Safety Data Sheets ( MSDS ) behind the table at the end of this
section.
S.8.2 MATERIALS USED DURING MAINTENANCE
Table S-2 lists the Materials Used During Maintenance and identifies ( by an X ) that the
Material Safety Data Sheets ( MSDS ) are available for reference. Refer to the
applicable Material Safety Data Sheets ( MSDS ) located at the end of this section.
Space has been provided in Table S-2 for listing ( by hand ) any additional Materials
Used During Maintenance that may be required in the future. Be sure to identify
whether or not ( YES or NO ) the applicable MSDS is available for reference. Place the
applicable Material Safety Data Sheets ( MSDS ) behind the table at the end of this
section.

TABLE S-1. MATERIALS USED DURING DISPENSING
MATERIALS MSDS AVAILABLE
YES NO

TABLE S-2. MATERIALS USED DURING MAINTENANCE
MATERIALS MSDS AVAILABLE
YES NO
Grease, Balkamp Lithium-Based X
Lubricant, NSK No. 1 (MULTEMP LRL, No. 3) X
Rust Preventive, Sheath PS8 (Aerosol) X

Section 1
INTRODUCTION
1.1 INTRODUCTION .................................................................................................. 1-3
1.2 TECHNICAL MANUAL INTRODUCTION ............................................................. 1-3
1.3 TECHNICAL MANUAL ORGANIZATION ............................................................. 1-3
1.4 APPENDIXES ....................................................................................................... 1-5
1.5 PARTS IDENTIFICATION .................................................................................... 1-6
1.6 PARTS REPLACEMENT ...................................................................................... 1-6
1.7 CONSUMABLE MATERIALS ............................................................................... 1-6
1.8 OPTIONAL SUPPLEMENTS ................................................................................ 1-7
CAMALOT 5000 Section 1: Introduction 1-1

1-2 Volume 1: Operation and Programming
1.1 INTRODUCTION
This section provides general information regarding the CAMALOT 5000 System. The
Operator should understand the purpose and correct operation of the System before
attempting any System activities.
1.2 TECHNICAL MANUAL INTRODUCTION
This technical manual contains the instructions to operate, functionally describe,

program, perform maintenance, troubleshoot and install the CAMALOT 5000 System.
Also included in this manual are the associated electrical and pneumatic schematics.
The Operator should refer to Volume 2, Section 8 (ENGINEERING DRAWINGS).
1.3 TECHNICAL MANUAL ORGANIZATION
This technical manual is divided into two volumes. Both Volume 1 and Volume 2 have
five individual sections. Table 1-1 identifies each section and provides a brief overview,
to the Operator of the CAMALOT 5000 System.
TABLE 1-1. TECHNICAL MANUAL ORGANIZATION
VOLUME SECTION TITLE SECTION OVERVIEW

NUMBER NUMBER
1 SAFETY No This Section provides safety

Number information regarding the
CAMALOT 5000 System. It is
identical to the SAFETY
Section in Volume 2.
1 INTRODUCTION 1 This section provides general

information regarding the
organization of this technical
manual, part identification, and
ordering replacement parts.
Also included is the
consumable materials list and
the location for optional
supplements are identified.

TABLE 1-1. TECHNICAL MANUAL ORGANIZATION (CONT)

NUMBER NUMBER
1 DESCRIPTION 2 This section provides general

and functional descriptions of
the System. Also Individual
components of the System are
functionally described and the
technical specifications are
identified.
1 OPERATION 3 This section provides

functional descriptions of the
System control panels and four
main operating screens. The
System files and directories
are explained.
Also included in this section

are detailed instructions
regarding the System initial set
up. Subsequent instructions
for the machine start up and
for dispensing a pattern are
identified.
1 PROGRAMMING 4 This section provides the

instructions to program a
variety of dispensing patterns
into the System. It also
discusses the CAMALOT files
and directories system.
2 SAFETY No This Section provides safety

Number information regarding the
CAMALOT 5000 System. It is
identical to the SAFETY
Section in Volume 1.

TABLE 1-1. TECHNICAL MANUAL ORGANIZATION (CONT)

NUMBER NUMBER
2 INSTALLATION 5 This section details the

location and installation of the
System. It includes an
illustration of the rear panel
which depicts the connections.
2 MAINTENANCE 6 This section discusses the

minimum maintenance
required by CAMALOT
Systems.
2 TROUBLESHOOTING 7 This section instructs the user

on checking the System and
troubleshooting a variety of
situations.
2 ENGINEERING 8 This section contains electrical

DRAWINGS and pneumatic schematics.
1.4 APPENDIXES
All three Appendixes ( A,B,C ) are located at the end of Volume 1.
Appendix A. This appendix is a glossary of terminology used within this manual.
Appendix B. This chart gives the details regarding the needle gauges and associated
information.
Appendix C. This appendix provides sample patterns for use in practicing writing a
program.

1.5 PARTS IDENTIFICATION
When a part is mentioned for the first time in a description or procedure, it will be
followed by a item number and the applicable figure reference number in parenthesis.
For Example: (9, Figure 4-1)
The item number serves to locate the part within the figure in which the part appears.
All the following item numbers associated with that figure will be in parenthesis. The
figure reference number remains in affect until a different figure reference number is
identified.
Unless otherwise specified, all dimensions within a figure are in inches.
1.6 PARTS REPLACEMENT
When ordering replacement parts, the Operator should refer to Volume 2, Section 8
( ENGINEERING DRAWINGS ) and the parts list in the applicable optional supplement.
However, to ensure the shipment of correct replacement parts, the actual part number
that is stamped or cast on the part being replaced should be used.
1.7 CONSUMABLE MATERIALS
Table 1-2 identifies the Consumable Materials used on the CAMALOT 5000 System.
The Consumable Materials are available from Camelot Systems Inc. However, the
manufacturer is identified for local purchase. Refer to the applicable Material Safety
Data Sheets (MSDS) located at the end of the SAFETY Section.
TABLE 1-2. CONSUMABLE MATERIALS
ITEM MANUFACTURER
Grease, Balkamp Lithium-Based Southwest Petro-Chem Division

6200 North 16th Street
Omaha, Nebraska 68110 USA

TABLE 1-2. CONSUMABLE MATERIALS (CONT)
ITEM MANUFACTURER
Lubricant, NSK No. 1 (MULTEMP Kyodo Yushi Co. ,Ltd.

LRL, No. 3) Dehtsu Kosah Dai-3-Bldg.
2-16-7 Ginza Chuo-Ku
Tokyo, Japan, 104
Rust Preventive, Sheath PS8 Birchwood Laboratories

(Aerosol) 7900 Fuller Road
Eden Prairie, Minnesota 55344 USA
Swabs, Cotton Local Purchase
Wiper, Lint-Free Local Purchase
1.8 OPTIONAL SUPPLEMENTS
Optional supplements are located at the end of Volume 2, if they are applicable to the
machine as purchased from Speedline Technologies, Inc.

SECTION 2
DESCRIPTION
2.1 GENERAL DESCRIPTION ................................................................................... 2-3
2.2 FUNCTIONAL DESCRIPTION ............................................................................. 2-3
2.3 INDIVIDUAL COMPONENTS ............................................................................... 2-3

2.3.1 MACHINE ..................................................................................................... 2-4
2.3.2 COMPUTER CONTROL SYSTEM............................................................... 2-4
2.3.2.1 MONITOR ............................................................................................ 2-4
2.3.2.2 TRACKBALL ........................................................................................ 2-4
2.3.2.3 KEYBOARD ......................................................................................... 2-4
2.3.2.4 SOFTWARE......................................................................................... 2-5
2.3.3 CONVEYOR SYSTEM ................................................................................. 2-5
2.4 TECHNICAL SPECIFICATIONS........................................................................... 2-5
2.5 SERIAL NUMBER TAG ........................................................................................ 2-7
CAMALOT 5000 Section 2: Description 2-1

2.1 GENERAL DESCRIPTION
The CAMALOT system is a computer-controlled system for dispensing a variety of

materials. The system is used to dispense solder paste, epoxies, adhesives, gels, etc.
for the electronics, automotive and medical industries. It can be used as a stand alone
machine or in-line with other SMEMA (Surface Mount Equipment Manufacturers
Association) compatible machines.
A variety of dispense valves and head configurations may be used to handle a full
range of dispense applications and materials.
The CAMALOT 5000 system is controlled by an IBM compatible computer, designated

PC486, that permits machine operation through an operator controlled trackball or
keyboard. An internal hard drive allows the operator to store dispense programs.
2.2 FUNCTIONAL DESCRIPTION
The CAMALOT system loads a fixture, dispenses a liquid material in a preprogrammed

pattern, and unloads the fixture.
• The operator programs the desired pattern into the computer system using the
trackball.
• The fixture is mounted onto the conveyor.
• The syringes are fitted with the needles, filled with the desired material, and
attached to the mounting plates.
• The air supply is turned on to the desired pressure.
• The preprogrammed dispensing pattern is loaded and both CONVEYOR ON and

RUN buttons are selected in the MAIN screen.
• The system then runs through the pattern, dispensing the material.
• The fixture is removed from the conveyor.
2.3 INDIVIDUAL COMPONENTS
The standard CAMALOT 5000 system consists of a CAMALOT 5000 machine,

computer control system, and conveyor system.

2.3.1 MACHINE
The standard CAMALOT 5000 machine has a gantry that moves along the Y-axis (front
to back). The X-axis, which moves left to right, is mounted on the gantry. A dispense
head is attached to the X-axis slides. The dispense head contains the Z-axis slides and
dispensing assembly which moves along the Z-axis (up and down). The gantry, X-axis,
and Z-axis dispense assemblies move on linear bearings which are driven by ballscrew
systems with anti-backlash nuts.
Power is provided by a closed-loop servo motor controller. The dispense assemblies

consist of syringe holders, standard 10 cc syringes and barrel adapters. Hollow
needles, which come in a variety of sizes, may be attached to the syringes. The
syringes are controlled by regulated air. Ultra-precision regulators and gauges control
the air pressure to an accuracy of 0.01 percent.
Safety equipment is built into the system. Wiring and pneumatic paths are bundled into
a hinged wire track to keep them away from critical operating surfaces.
2.3.2 COMPUTER CONTROL SYSTEM
The computer control system consists of an IBM compatible personal computer with
internal hard drive, monitor, trackball, keyboard, and machine operating and
programming software.
2.3.2.1 Monitor
The monitor is a color SVGA cathode ray tube (CRT) used to view the software when
programming and running the system.
2.3.2.2 Trackball
A trackball provides easy access to menu controls, software loading and PC operation.
It is used to program the system and to run patterns. The ball controls the cursor.
Three buttons are used to execute the commands.
If more convenient, the operator of the CAMALOT system can remove the trackball
from the holder and program the system while holding the trackball by hand.
2.3.2.3 Keyboard
A keyboard enables the operator to complete the programming.

2.3.2.4 Software
The built-in hard drive contains the software to program and run the system. It contains
four interconnected main menus, as well as pull-down and pop-up menus to help in
programming the dispensing pattern. Linear and circular subpattern routines for step-
and repeat applications and diagnostics are also available.
2.3.3 CONVEYOR SYSTEM
The conveyor system is a motor-driven belt type system which may be run in either
automatic or manual mode. The conveyor set up and manual control are done through
the use of screens on the computer monitor. The conveyor flow direction may be
reversed from the standard left-to-right flow to a right-to-left flow.
Upon receiving a start signal from the dispense program, the conveyor awaits a signal
from the board available sensor (on the upstream end of the conveyor) signaling that a
fixture has been loaded and is at the input station. When the signal is received, the
dispense stop pin is raised and the motor activates to run the fixture to the dispense
station. When the conveyor receives a signal from the in-position sensor, the input
buffer stop pin raises and a board is carried to the input buffer station. The motor
deactivates after a preset length of time and the lift table is raised to secure the fixture.
After the dispense program has been completed, the conveyor awaits a signal from
auto inspection option that the pattern is good and a signal from the downstream
sensor indicating that the previous fixture has been off loaded. When the conveyor
receives the signal from the downstream sensor that there is no fixture at that location,
the output stop pin is raised, the lift table, dispense stop pin, and input stop pin lower,
and the motor activates to run the processed fixture to the output station. If there is
another board at the input station, the cycle repeats. Otherwise, the conveyor
deactivates until it receives another start signal.
2.4 TECHNICAL SPECIFICATIONS
Table 2-1 identifies the technical specifications for the CAMALOT 5000 system.
TABLE 2-1. TECHNICAL SPECIFICATIONS
CATEGORY PARAMETER
Operating Parameters X Direction (left to right) 18.0 in.

(457.2mm)
Y Direction (front to back) 18.0 in.

(457.2mm)
Z Direction (up and down) 2.2 in.
(55.9mm)
Operating Speeds Slew speed and point-to-point is 16

in./sec. Eight increments of speed control
from 0.01 in./sec. to 4.5 in./sec. in the
dispense mode.
Dispense Head A 10cc disposable polypropylene syringe

with Luer Lock blunt end tips is standard.
Other dispensing options are available.
Method of Programming Teach mode trackball or RS232.
Method of Storage 3 1/2 - inch floppy disk or hard drive.
Monitor Color SVGA for operator prompting.
Electrical Requirements 230 VAC, 50 Hz, 10 amp. (International)

110 VAC, 60 Hz, 10 amp. (Domestic)
3
Pneumatic Requirements 5 SCFM ( 0.17 m /min), Clean dry air at
2
>80 PSI ( 7.0 kg/cm ), 5 micron filter
required.
Teach Accuracy + 0.002 inch (0.05 mm)
Repeatability + 0.001 inch (0.025 mm)
Acoustic Noise 70 dba.

2.5 SERIAL NUMBER TAG
CAUTION
REMOVAL OF THIS TAG VOIDS THE WARRANTY.
The serial number tag located on the machine rear panel contains information used for
tracking the machine and contains the identification marking CE when the system is
certified to CE requirements.
SERIAL#
MODEL#
VOLTS HZ 50/60 Ø
MAX
AMP
LARGEST SINGLE LOAD A
AIR PRESSURE PSI/BAR 80-100/5.5-6.9
DATE OF MFG (M0/YR)
145 WARD HILL AVE

HAVERHILL, MA, 01835, U.S.A.

Section 3
OPERATION
3.3 OPERATING CONTROLS.................................................................................... 3-4

3.3.1 DESCRIPTIONS OF OPERATING CONTROLS.......................................... 3-4
3.3.2 DESCRIPTION OF SAFETY RELAY CIRCUIT............................................ 3-9
3.4 MACHINE SAFETY DOORS SYSTEM............................................................... 3-10
3.5 LIGHT TREE INDICATORS................................................................................ 3-10
3.6 DISPENSE PANELS .......................................................................................... 3-11

3.6.1 LEFT-HAND (LH) DISPENSE PANEL........................................................ 3-11
3.6.2 RIGHT-HAND (RH) DISPENSE PANEL..................................................... 3-13
3.7 REAR PANEL ..................................................................................................... 3-15
3.8 TRACKBALL....................................................................................................... 3-19
3.9 CAM/ALOT SYSTEM MAIN SCREEN................................................................ 3-22

3.9.1 FILE OPERATIONS SCREEN ................................................................... 3-41
3.9.2 DISPENSE PARAMETERS SCREEN........................................................ 3-43
3.9.3 DIAGNOSTICS SCREEN........................................................................... 3-45
3.10 PASSWORD..................................................................................................... 3-47

3.10.1 CREATING A PASSWORD ..................................................................... 3-48
3.10.2 ACTIVATING A PASSWORD .................................................................. 3-49

3.10.3 CHANGING A PASSWORD .....................................................................3-49
3.10.4 REMOVING PASSWORD PROTECTION ................................................3-50
3.11 INITIAL SET UP ................................................................................................3-50

3.11.1 DISPENSE SYSTEM ................................................................................3-51
3.11.2 CONVEYOR SETUP.................................................................................3-52
3.11.2.1 DESCRIPTION OF SMEMA .............................................................3-52
3.11.2.2 INITIAL CONVEYOR SETUP ...........................................................3-54
3.11.2.3 ADJUSTMENT OF INPUT BUFFER STOP PIN AND SENSOR ......3-59
3.11.2.4 ADJUSTMENT OF OUTPUT BUFFER STOP PIN AND SENSOR ..3-60
3.11.2.5 AUTOMATIC OPERATION...............................................................3-60
3.11.3 SETTING THE HEIGHT OF THE NEEDLE ..............................................3-60
3.12 MACHINE START UP .......................................................................................3-63
3.13 DISPENSING A PATTERN ...............................................................................3-64

3.1 GENERAL INFORMATION
This section provides operation instructions for the CAM/ALOT system. Generally, this
section includes the following:
• Standard safety precautions.

• Descriptions of operating controls.
• Locations of controls.
• Descriptions of machine modes.
• Operating instructions.
• Operating system reference.
A description of the CAM/ALOT system technical specifications, machine control and

operation, size, weight, and options appears in Section 2 Description.
3.2 SAFETY PRECAUTIONS
As with operating and servicing every machine, safety must be considered and
practiced at all times. This requires a continual effort on the part of the operator,
service personnel, supervisors, or anyone else working on or near the CAM/ALOT liquid
dispense systems.
1. All personnel operating or maintaining this equipment must read the instructions
carefully before attempting to operate or service the CAM/ALOT dispensing
system. Failure to comply with instructions could result in personal injury or
property damage.
2. Always operate the unit with the safety doors closed and operating properly.
3. Keep hands and fingers away from gantry, heads, needles, etc. during machine
operation and whenever electrical power and air are on.
4. Do not operate the machine with the cover of any enclosure or covers over any
mechanism removed.
5. Push the MACHINE OFF button on the machine control panel to halt the
machine operation should any malfunction occur.
the dispense area. Push the emergency machine off (EMO) switch to shut the
machine off immediately.

11. Maintain the system in top working condition.
3.3 OPERATING CONTROLS
An operator control panel is used on the CAM/ALOT system to control air pressure to
the head or heads, safety interlock operation, emergency stop, and to turn the machine
on and off.
Control and set up of the conveyor is accomplished with the use of screens on the
CAM/ALOT computer monitor.
3.3.1 DESCRIPTIONS OF OPERATING CONTROLS
Figure 3-1 shows the locations of the operating controls. See Table 1-2 for descriptions
of the individual controls.

FIGURE 3-1. MAIN CONTROL PANEL
TABLE 3-2. MAIN CONTROL PANEL
CONTROL FUNCTION
AIR ADJUSTMENT The AIR ADJUSTMENT KNOB is used to adjust the air
KNOB (OPTIONAL pressure to the dispensing material for the applicable head
LEFT-HAND TOGGLE) or valve. The graphic symbol indicates more or less
(1) pressure.
AIR PRESSURE GAUGE The AIR PRESSURE GAUGE indicates the amount of air
(OPTIONAL LEFT-HAND pressure on the syringe containing the dispense material.
TOGGLE)
(2)
DISPENSE SELECTION The DISPENSE SELECTION SWITCH is a three-position

SWITCH (OPTIONAL switch.
LEFT-HAND TOGGLE)
(3) When SYRINGE is selected, air pressure from V1 port on
dispense panel will be on and the output at PDP1 (left-hand
pump) connector on dispense panel is activated for pump
use with a low-viscosity material.
When VALVE is selected, air pressure will be on

continuously at A1 port while the pump motor is running.
The dispensing speed of the pump connected to PDP1 can

be switched between low and high by software.
When 680 is selected, air pressure will be on continuously

at A1 port.

TABLE 3-2. MAIN CONTROL PANEL (Cont)
CONTROL FUNCTION
DISPENSE SELECTION The DISPENSE SELECTION SWITCH is a three-position

SWITCH (OPTIONAL switch.
RIGHT-HAND TOGGLE)
(4) When SYRINGE is selected, air pressure from V2 port on
dispense panel will be on and the output at PDP2 (right-
hand pump) connector on dispense panel is activated for
pump use with a low-viscosity material.
When VALVE is selected, air pressure will be on

continuously at A2 port while the pump motor is running.
The dispensing speed of the pump connected to PDP2 can
be switched between low and high by software.
When 680 is selected, air pressure will be on continuously

at A2 port.
EMERGENCY MACHINE The red push/pull EMO switch is the emergency machine
OFF (EMO) off (operation stop) switch. The entire machine is shutdown
(5) when the EMO switch is pressed.
To restart machine after the reason for the emergency stop

has been cleared, the EMO switch must be pulled out, the
MACHINE RESET button (9) pressed, and the MACHINE
ON button (6) pressed.
MACHINE ON The MACHINE ON push button is used to start the

(6) machine. The button has a green indicator light that is
illuminated when power is supplied to the machine.
INTERIOR LIGHT The LIGHT SWITCH is a two-position switch that is used to

SWITCH activate interior lights.
(7)

CONTROL FUNCTION
LIFT VACUUM SWITCH The LIFT VACUUM switch is a two-position switch used to
(8) activate (ON) or deactivate (OFF) the vacuum pump for the
optional vacuum board supports, optional vacuum sense,
etc.
MACHINE RESET The MACHINE RESET button is used to reset the safety
(9) relay circuit after the EMO (5) has been pressed, an EMO
circuit ground fault has occurred, or power has been lost.
The MACHINE RESET button does not have to be reset if
the machine was shut down using the MACHINE OFF
button (10).
MACHINE OFF Press the MACHINE OFF push button to turn the machine
(10) OFF at the end of operation. The button has a white
indicator light that is illuminated when power is supplied to
the machine. If the machine is shut down using the
MACHINE OFF push button, the safety relay does not need
to be reset before the machine is started again.
PURGE The PURGE button is a momentary button used to purge

(11) (manually expel) liquid from the needle of the valve
selected by the purge select switch (14). The purge
continues as long as the button is pressed.
AIR PRESSURE GAUGE The AIR PRESSURE GAUGE indicates the amount of air
(OPTIONAL RIGHT- pressure on the syringe containing the dispense material.
HAND TOGGLE)
(12)

CONTROL FUNCTION
AIR ADJUSTMENT The AIR ADJUSTMENT KNOB is used to adjust the air
KNOB (OPTIONAL pressure to the dispensing material for the applicable head
RIGHT-HAND TOGGLE) or valve. The graphic symbol indicates more or less
(13) pressure.
PURGE SELECT The PURGE SELECT switch is used to select the output
(14) A1 or A2 of the dispensing unit of the optional toggle head
or an individual cartridge of the optional 644-1 or 642-1
pumps.
3.3.2 DESCRIPTION OF SAFETY RELAY CIRCUIT
The safety relay circuit is designed to protect the operator/technician and system from
injury or damage by shutting down and locking out electrical and pneumatic power to
the machine in the event of a ground fault event in the EMO circuit, a power loss, or an
emergency machine off switch activated. The system is reset as follows:
NOTE
The safety relay circuit is identified as PNOZ2 on sheet 1 of the

electrical schematics.
Machine must have power supplied and Main Power Switch

must be turned to ON for machine startup.
• When main power is applied and rear main power switch is ON, the MACHINE
RESET button (9, Figure 3-1) must be pressed before the machine can be
started.
• If the EMO switch (5) is pressed when machine is ON, the MACHINE RESET
button must be pressed before the machine can be started.
• If the MACHINE OFF button (10) is pressed when machine is ON, the power will
turn off as normal, and the machine will be able to be started without resetting

the MACHINE RESET button. To start the machine, the MACHINE ON button
(6) must be pressed for approximately 10 seconds.
3.4 MACHINE SAFETY DOORS SYSTEM
The machine safety door system is a safety feature that is utilized with the CAM/ALOT
system.
The following information functionally describes the machine safety door system:
1. The safety doors can be locked or unlocked using system software. If

necessary, the safety doors can also be locked or unlocked manually.
2. When using the system software and the safety doors are locked, select the
SAFETY DOOR LOCKED / UNLOCKED button, located in the MAIN SCREEN
to unlock the safety doors. When manually performed, the safety doors need to
be addressed individually.
3. When the safety doors are open (unlocked), the operator can program and
perform setups. The machine will run at reduced speed when the doors are
open. A board dispensed at reduced speed should not be sent to the
downstream machine. The machine will not run in conveyor mode when the
doors are open.
4. When the safety doors are open (unlocked), the AMBER LIGHT on the light tree
will flash and a horn will sound anytime the machine is in motion.
5. When the safety doors are closed (locked), the AMBER LIGHT on the light tree
will stop flashing, the horn will stop sounding, and the machine will run at full
speed.
6. The CAM/ALOT system is shipped with the safety doors locked. After the
machine has been positioned in the desired location, the safety doors will need
to be unlocked using system software.
3.5 LIGHT TREE INDICATORS
The light tree features three different colored lights and an audible alarm which are
used as visual and audible indications of the machine status.
AUDIBLE ALARM The AUDIBLE ALARM will sound whenever any

function is selected that allows motion of the axes
and either of the safety doors are open. The alarm
continues to sound while there is any motion with the

safety doors open. The alarm will also sound
whenever there is a red screen type error displayed.
BLUE LIGHT The BLUE LIGHT flashes when operator attention is
needed (such as an optional Loader or Unloader
needs service or a syringe needs to be replaced).
This light can be on with the amber or green lights.
AMBER LIGHT The AMBER LIGHT flashes when the safety door is
open and whenever there is a red screen type error
displayed.
GREEN LIGHT The GREEN LIGHT flashes when the machine is
ready to run. This light will turn on to steady
illumination when the machine is running
automatically. This light will not turn on if the amber
light is on.
3.6 DISPENSE PANELS
The 5000 has two dispense panels. The dispense panels contain connections for
electrical and pneumatic connections and vacuum adjustment valve. All pumps,
syringes, camera, etc. are connected to the dispense panels. The LH and RH dispense
panels are shown in Figure 3-2 and Figure 3-3. Item descriptions are listed and
described in Table 3-3 and Figure 3-3.
3.6.1 LEFT-HAND (LH) DISPENSE PANEL
The Left-Hand (LH) Dispense Panel connection item numbers (in parenthesis) identified
in Table 3-3, in the CONNECTION column, coincide with Figure 3-2. The item number
(in parenthesis) serves to locate the connection in the illustration in which the
connection appears.
Table 3-3 identifies and functionally describes all the Left-hand (LH) Dispense Panel
connections, to the Operator of the CAM/ALOT 5000 System.

1
S1
2
V1
12 VAC1
3
A1
11 PDP1
4
P1
10
P2 P3 P5 5
9
6
P6 P7 P8
FIGURE 3-2. LH DISPENSE PANEL
TABLE 3-3. LH DISPENSE PANEL
CONNECTION FUNCTION
S1 Provides electrical connections for optional touch probe.

(1)
VAC1 Provides a vacuum to suspend low-viscosity material at syringe tip in

(2) order to prevent material from dripping due to gravity. There is
usually no need to adjust VAC1. VAC1 is not to be used in
conjunction with a positive displacement pump (PDP).
PDP1 Electrical connection for optional dispensing pump (Positive

(3) Displacement Pump 1).
P3 Delivers compressed air to optional dual-height PDP.

(4)

TABLE 3-3. LH DISPENSE PANEL (CONT)
CONNECTION FUNCTION
P5 Used in conjunction with P4 connector for optional swing head.

(5)
P8 Delivers pulsed air to the gate valve B. Also used to deliver air to
(6) syringe No. 4 of the optional turret rotary pump.
P7 Delivers pulsed air to the gate valve A. Also used to deliver air to
(7) syringe No. 3 of the optional turret rotary pump.
P6 Pneumatic connection for optional touch probe.

(8)
P2 Delivers compressed air to toggle head option.

(9)
P1 Delivers compressed air to toggle head option.

(10)
A1 Constant pressure air supply for positive PDP (Positive

(11) Displacement Pump).
V1 Delivers regulated air or a vacuum to primary dispensing needle.

(12)
3.6.2 RIGHT-HAND (RH) DISPENSE PANEL
The Right-Hand (RH) Dispense Panel connection item numbers (in parenthesis)
identified in Table 3-4., in the CONNECTION column, coincide with Figure 3-3. The
item number (in parenthesis) serves to locate the connection in the illustration in which
the connection appears.
Table 3-4. identifies and functionally describes all the Right-Hand (RH) Dispense Panel
connections, to the Operator of the CAM/ALOT 5000 System.

1
H1
11
V2
VAC2 2
10 A2
PDP2 3
C1
C2
9 4
P10 P9 P4
8 5
TP1
T1 T2
7
6
T3 T4
FIGURE 3-3. RH DISPENSE PANEL
TABLE 3-4. RH DISPENSE PANEL
CONNECTION FUNCTION
H1 This receptacle is for the optional needle or syringe heater.

(1)
V2 This receptacle is used to deliver air or a vacuum to the secondary

(2) dispensing needle.
A2 This receptacle is a constant pressure air supply for the optional

(3) PDP 2 (Positive Displacement Pump 2).

TABLE 3-4. RH DISPENSE PANEL (CONT)
CONNECTION FUNCTION
C2 Provides power to optional Manual Fiducial Vision Camera or

(4) illuminator.
P4 Delivers compressed air to optional second dual-height PDP

(5) (Positive Displacement Pump). Also used in conjunction with P5 for
optional swing head.
Turret Pump This panel delivers power to the optional turret rotary pump through
Panel (Option) connector TP1 and air pressure to the individual cartridges through
(6) T1, T2, T3, and T4 connectors.
P9 This receptacle delivers pulsed air to the gate valve (A). Also used
(7) to deliver air to syringe No. 1 of the optional turret rotary pump.
P10 This receptacle delivers pulsed air to the gate valve (B). Also used to
(8) deliver air to syringe No. 2 of the optional turret rotary pump.
C1 Coaxial connector for optional vision system. Also supplies power to

(9) camera when optional Auto Correction Vision system is used.
PDP2 This receptacle is the connection for an optional dispensing pump

(10) (Positive Displacement Pump 2)
VAC2 This receptacle provides a vacuum to suspend low-viscosity material

(11) at syringe tip in order to prevent material from dripping due to gravity.
There is usually no need to adjust VAC2. VAC2 is not to be used in
conjunction with a positive displacement pump (PDP).
3.7 REAR PANEL
The rear panel contains external connections for in-line systems, computer
components, options, machine main power, etc. See Figure 3-4.

The rear panel connection item numbers (in parenthesis) identified in Table 3-5, in the
CONNECTION column, coincide with Figure 3-4. The item number (in parenthesis)
serves to locate the connection in the illustration in which the connection appears.
Table 3-5 identifies and functionally describes all the rear panel connections, to the
operator of the CAM/ALOT system.
FIGURE 3-4. REAR PANEL

TABLE 3-5. REAR PANEL
CONNECTION FUNCTION
RS232 Twenty-five pin connector for a cable interface to an external

CONNECTOR computer system.
(1)
SERIAL NUMBER Contains machine data such as serial number, model number,
TAG (2) electrical and pneumatic parameters, etc.
A-UPSTREAM SMEMA (Surface Mount Equipment Manufacturers Association)

CONNECTOR interface for in line systems. It connects the prior machine
(3) (machine A) to the CAM/ALOT system.
C-DOWNSTREAM SMEMA (Surface Mount Equipment Manufacturers Association)

CONNECTOR interface for in-line systems. It connects the following machine
(4) (machine C) to the CAM/ALOT system.
POWER Power receptacles for SVGA monitor and for manual fiducial
RECEPTACLES option.
(5)
HOUR METER Counts the hours of operation. It is used to determine

(6) maintenance schedules.
FAN FILTER Filter for cooling fan.

(7)
GROUNDING Used to ground operator accessories such as an anti-static pad.

STUD
(8)
MAIN POWER Main power switch for machine. Contains provisions for LOCK
SWITCH OUT / TAG OUT.
(9)
POWER CORD Machine main power cord.

(10)

TABLE 3-5. REAR PANEL (CONT)
CONNECTION FUNCTION
FILTER / Regulates compressed air input to the entire system.

REGULATOR
(11)
EXHAUST PORTS Exhaust pneumatic pressure.

(12)
CROSS HAIR Connector for power supply to optional manual fiducial system
GENERATOR cross hair generator.
CONNECTOR
(13)
VISION CABLE Connector for coaxial cable of optional manual fiducial system
CONNECTOR monitor.
(14)
MONITOR Fifteen-pin connector used to connect the operator VGA monitor.

CONNECTOR
(15)
TRACKBALL Connector for Trackball cord.

CONNECTOR
(16)
KEYBOARD Connector for computer keyboard.

CONNECTOR
(17)
PRINTER Twenty-five pin connector for a cable interface to an external

CONNECTOR printer.
(18)

3.8 TRACKBALL
The CAM/ALOT system uses a trackball pointing device to provide easy access to
menu controls, software loading and PC operation. It is used to program the system
and to run patterns. The ball controls the cursor. Three buttons are used to execute
the commands. See Figure 3-5.
If more convenient, the operator of the CAM/ALOT system can remove the trackball
from the holder and program the system while holding the trackball by hand.
The trackball component item numbers (in parenthesis) identified in Table 3-5, in the
COMPONENT column, coincide with Figure 3-5. The item number (in parenthesis)
serves to locate the component in the illustration in which the component appears.
Table 3-5 identifies and functionally describes all the trackball components (ball and all
the command buttons), to the operator of the CAM/ALOT system.
FIGURE 3-5. TRACKBALL

TABLE 3-5. TRACKBALL
COMPONENT FUNCTION
BALL The BALL is used to:

(1)
1. Move the cursor to the desired areas of the monitor screen.
2. Move the head on the X- and Y-axes when creating new patterns
or teaching.
3. Adjust the needle height on the Z-axis.
4. Increase or decrease selected parameters.
LEFT BUTTON The LEFT BUTTON is used to:

(2)
1. Enter the mode or command selected with the cursor.
2. Temporarily stop (PAUSE) the program in the RUN mode.
3. Restart the program when in PAUSE mode during a RUN.
4. Scroll through the library of files in the DIRECTORY window of

the MAIN screen, or subpattern menus, or scroll through the lines
of a dispensing pattern in the EDITING window of the MAIN
screen.
5. Perform operations when called for by the software.
SPEED The SPEED CHANGE BUTTON changes the cursor speed and
CHANGE head and syringe speed on X, Y, and Z-axes when ball is moved.
BUTTON Press button to increase cursor and X, Y, and Z-axes speeds. This
(3) allows for fine adjustment of coordinates. Press again and both
return to default speed.

TABLE 3-5. TRACKBALL (CONT)
COMPONENT FUNCTION
RIGHT The RIGHT BUTTON is used to:

BUTTON
(4) 1. Quit the program and send the dispensing head to the home
position when the program is in PAUSE mode during a run.
2. Lock out (temporarily disable) the X- and Y-axes to facilitate

programming. To do this:
• Enter the MAIN screen and go into TRACE mode.
• Enter a command, press the right button, and the axis
which has moved the least while programming the routine
will be locked out.
3. Confirm a selected function as a safety measure.
CENTER The CENTER BUTTON is used in conjunction with the camera

BUTTON option. The center button is used to:
(5)
1. Teach locations in the TRACE mode. To do this:
• Select the X and Y coordinates.
• Click the center button to move the needle up to its
maximum height.
• Click again to move the needle back down.
OPTION The OPTION SWITCHES are located on the bottom of the Trackball.
SWITCHES The switches are preset by Camelot and should not be changed.
(Not Shown)

3.9 CAM/ALOT SYSTEM MAIN SCREEN
The MAIN SCREEN is used to program new patterns and edit existing ones. See
Figure 3-6. The MAIN SCREEN contains the following windows:
• COMMAND WINDOW
• EDITING WINDOW
• OFFSETS WINDOW
• RUN WINDOW
Table 3-6 identifies and functionally describes all the MAIN screen windows to the
Additional screens are accessed by selecting buttons above the EDITING window .
See Table 3-6 for an explanation of the individual buttons. A brief description of the
function of a button is also displayed when the cursor is placed over a button.
COMMAND
WINDOW
OFFSETS
WINDOW
EDITING WINDOW RUN BUTTON
FIGURE 3-6. MAIN SCREEN

TABLE 3-6. MAIN SCREEN
WINDOW COMMAND SCREEN BUTTON FUNCTION

BUTTON NAME
NOTE
The list of commands identified in the COMMAND WINDOW may vary depending upon
installed options.
COMMAND The COMMAND

window displays a
command menu which
is used to program
dispensing routines
and patterns.
ZSENSE Used in conjunction

with optional touch
probe to sense Z
height of fixture at the
specified X- and Y-axis
coordinate. Touch
probe must be
enabled.
INSPECT Used in conjunction

with optional vision
inspection system.
Inspects specified dot
and supplies report at
end of run.
CHECK Used in conjunction

inspection system.
Same as INSPECT,
except CHECK will
stop run when bad dot
is found. Normally
used with dummy dots.

TABLE 3-6. MAIN SCREEN (CONT)

BUTTON NAME
REFPT Used in conjunction

alignment system.
Inserts a reference
point to be used for
determining an offset
to counter a misaligned
fixture.
POINT Dispenses a single dot.
MOVE Moves needle from

one place to another
between dispensing
commands. For
example to the
beginning coordinate
of a LINE, or CALL
command.
LINE Dispenses a
continuous line of
material after a MOVE
command.
NOTE
Subpatterns must be loaded via SUB OPERATIONS button before being called.
CALL To call up subpattern

name to insert after a
MOVE command. A
sub menu listing files in
subpattern library is
displayed.

WINDOW COMMAND SCREEN BUTTON NAME FUNCTION

BUTTON
CIRCLE Draws a circle after a

MOVE command. The
two points act as
tangents to the
diameter.
ARC Draws an arc between

two lines placed at an
angle. Replaces a
MOVE command
between two lines.
PAUSE Select command to

temporarily stop
machine motion during
a program run without
exiting a pattern.
WAIT Pauses program run

for a preset amount of
time before continuing.
Time is set in seconds
under Wait (Sec) in
DISPENSE PARA-
METERS.
CLEAN Used with needle

cleaner option. Moves
head at a programmed
speed and height
without dispensing
material.


BUTTON NAME
END Optional command to

signal end of a pattern.
Any instructions after
END command will be
ignored by system.
ROW OF DOTS Programs a series of

equally spaced dots. A
screen prompts for
Shotsize, Number of
Dots, and First and
Last Points.
DELETE To delete a line in

COMMAND AT program where cursor
is currently pointing.
FILLED Fills an area on board

RECTANGLE with material. A fill
type screen is
displayed, when the
filled rectangle is
selected.
The three types of fill

routines are Spiral In,
Spiral Out, and ZigZag.
Spiral In Dispenses material in a

box pattern then draws
a box inside of that and
so on until the box is
filled with material.


BUTTON NAME
Spiral Out Dispenses material

from the center of the
pattern to the outside.
ZigZag Draws a line, steps

over the offset and
draws a line in the
reverse direction.
(Serpentine.)
FILLED Dispenses material in a

CIRCLE circular pattern then
draws a circle inside of
that and so on until the
area is filled with
material.
A screen prompts for

Speed, Line Offset,
Start of Diameter, and
End of Diameter.

TABLE 3-6. MAKE/EDIT PATTERN SCREEN (CONT)

BUTTON NAME
NOTE
The EDITING window displays the dispense pattern that is currently in memory. A new
pattern is displayed as it is programmed. An existing pattern is displayed here for
editing. The caret defaults to above the first line of the pattern (home position). During
editing, it marks the current line.
EDITING The EDITING window

contains three parts:
1. Scroll pattern and

single-stepping
arrows.
2. Shaded bar.
3. Menu (commands).
Lower Right- Scrolls down pattern in

Hand Arrow EDITING window
without moving caret or
dispense head.
Upper Right- Scrolls up pattern in

Hand Arrow EDITING window
without moving caret or
dispense head.
Lower Left- Moves caret down one

Hand Arrow step (single-stepping)
in pattern.
Upper Left- Moves caret up one

Hand Arrow step (single-stepping)
in pattern.


BUTTON NAME
Shaded Bar Place cursor at

beginning, end or in
middle of shaded bar
to select that area of
pattern.
EDIT Edits a pattern.

(MODE:) Command and
program values can be
changed without
moving needle.
TRACE Allows dispense head

(MODE:) to execute moves as
pattern is being
programmed. Used for
teaching pattern to
system when there is
no vision system, and
dispensing a pattern.
If selected, while on a
line in a program, Z-
axis will move to
current Z setting.
CAMERA Used for teaching

(MODE:) pattern to system when
vision system is
installed. Allows
optional camera to
follow dispense
pattern. Viewed on
monitor.


BUTTON NAME
NOTE
Each line of the dispensing pattern will contain the information identified below.
# Number of line.
V Used with options with

more than one valve.
Displays number of
dispensing valve.
Defaults to number 1
valve.
S If used with POINT or

DOTS command, it
refers to shotsize. If
used with LINE
command, it refers to
speed that head
moves during
dispensing.
UP Height (along Z-axis) at

which needle travels
from dispense point to
above board.
DN Height (along Z-axis) at

which needle
dispenses material
above board.


BUTTON NAME
NOTE
X- and Y-axes zero positions (0,0) are normally located at the right rear corner of table.
X Distance needle is
from zero on X-axis.
Y Distance needle is
from zero on Y-axis
during execution.
Returns to zero after
execution.
HOME Moves dispense

needle to HOME
position when system
is in TRACE or
CAMERA mode. Caret
moves to its default
position in window.
HOME position for

needle is far right
corner of table and at
top of Z-axis (up). X, Y
and Z coordinates are
at their maximum.


BUTTON NAME
VALVE Displays cumulative

COUNTS number of dots
dispensed by each
valve since last syringe
change.
A partially filled syringe

appears to indicate a
syringe low condition.
An empty syringe
appears at top of
program when syringe
is empty. Head will
move to location
specified with syringe
button in OFFSETS
window and a screen
will appear to allow the
user to replace and
purge the syringe or to
continue.
OFFSETS The OFFSETS window

is used when a board
is not centered under
needle. Dispense
locations of pattern can
be shifted, or offset, to
compensate for
misalignment of a
board.
The window also

contains buttons used
for various operations.


BUTTON NAME
SYRINGE Select this button to

set X and Y
coordinates for the
head to move to when
changing a syringe.
PARK Select this button to

set X and Y
coordinates for the
head to move to while
next board is being
loaded.
SEARCH Select this button to

find a step in program
closest to input X and
Y coordinates.
OFFSET Select to offset datum

zeros for the X, Y, and
Z-axes .
NOTE
Y and X only display current offset from (0,0) if moved. If not selected, they will display
a (0,0) value.
X Displays X-axis offset

during program
execution. Defaults to
zero after program
execution.
Y Displays Y-axis offset

during program
execution. Defaults to
zero after program

execution.

BUTTON NAME
Z Displays current Z-axis

height in thous.
Defaults to 2200 (2.2
inches)(23.78mm).
Select to change Z-
axis height.
RUN The RUN button is

selected to dispense
material on board in
programmed pattern.
System must be in
TRACE mode.
When, in optional
CAMERA mode,
system runs through
pattern without
dispensing any
material. Each
programmed point is
displayed on vision
monitor.
A Pausing submenu is
displayed when any
button on the Trackball
is pressed during
dispense operation.
The Pausing submenu

displays the following
choices:

Continue Resumes execution of
the program RUN.

BUTTON NAME
Back One Moves to previous

Command commanded position.
Abort Disp Ends dispensing of the

board in the dispense
station. The board in
the dispense station
must be removed.
Abort All Aborts dispensing all

boards in the machine.
All boards in the
machine must be
removed.
OPERATIONS FILE Used to access FILE

BUTTONS OPERATIONS OPERATIONS screen.
SUB Used to access the

OPERATIONS SUB OPERATIONS
screen to load or
unload subpatterns.
DISPENSE Used to access

PARAMETERS DISPENSE
PARAMETERS screen
to change specific
dispensing parameters.
DATA SHEET Used to access DATA

SHEET screen.


BUTTON
BOARD Used to set board

COUNTERS counters for inspecting
boards, prechecking
dots, and cleaning
needles.
VALVE Used to set valve

COUNTERS counters for changing
syringes.
NEEDLE Select to calibrate

CALIBRATION needle offsets when
using an optional auto
needle calibrator.
CAMERA-TO- Select to create the

NEEDLE Camera-to-Needle
OFFSETS Offset.
VISION Used to access

ALIGNMENT VISION ALIGNMENT
screen to calibrate
camera, to specify
REFPTs, and to
change model size and
search area.
INSPECTION Used to access

CALIBRATION INSPECTION
CALIBRATION screen
to calibrate camera
and to change model
size and search area.


BUTTON
DIAGNOSTICS Used to access

DIAGNOSTICS
screen.
SETUP Used to access

CONVEYOR MANUAL CONVEYOR
CONTROLS screen for
setup of the conveyor.
PASSWORD Used to access

PASSWORD screen.
COMMUNICA- Used to access

TIONS COMMUNICATIONS
screen for RS232
transfers.
TO DOS Used quit the

CAM/ALOT system
and exit to DOS.
SAFETY Unlocks the machine

DOORS safety doors.
LOCKED /
UNLOCKED A locked doors will
display a closed
padlock and an
unlocked doors will
display an open
padlock. Both doors
must be closed before
the button will show
locked.


BUTTON NAME
CONVEYOR Enables conveyor

ON / OFF mode. Must be
selected before pattern
can be run.
PASS Used to pass a board

THROUGH ON through the machine
/ OFF without performing and
dispensing operations
on the board.
TOUCH Used to enable (ON) or

PROBE ON / disable (OFF) optional
OFF touch probe mode.
The touch probe must
be enabled to use
ZSENSE commands.
VISION Used to enable vision

ENABLE display in monitor.
OPTIMIZE Used to rearrange

sequence of dispense
routines to ensure
most efficient path for
X- and Y-axes to
travel.


BUTTON
ROTATE Used to rotate total

PATTERN dispense pattern to a
new X, Y angle of 90,
180, or 270 degrees
counterclockwise over
the board. Rotating a
pattern is cumulative.
Manually reset position
to zero before
executing.
INFORMATION Used to show software

version.
EDITING CUT Deletes one or more

BUTTONS highlighted commands.
Deleted commands are
cut to a clipboard and
allows commands to
be pasted somewhere
else.
Each time something is

cut, previously cut
material is overwritten
on clipboard.
COPY Copies a block of

highlighted commands.
PASTE Inserts a block of

commands copied or
cut from clipboard, into
the program.


BUTTON NAME
ENABLE / Allows the operator to

DISABLE mark commands to be
ignored (not executed)
during program run.
Marked commands are
converted to lower
case.
NEW FILE Used to obtain a blank

EDITING window in
the MAIN screen when
creating a new pattern
file.
BATCH BATCH REFPTS ON

REFPTS ON / instructs the system to
OFF perform all REFPT
operations at the
beginning of the
program. BATCH
REFPTS OFF instructs
the system to perform
each REFPT operation
as it is encountered.
BATCH BATCH ZSENSE ON

ZSENSE ON / instructs the system to
OFF perform all ZSENSE
operations at the
beginning of the
program. BATCH
ZSENSE OFF instructs
the system to perform
each ZSENSE
operation as it is
encountered.

3.9.1 FILE OPERATIONS SCREEN
The FILE OPERATIONS screen is used to load files from hard disk or floppy disk into
current memory, or to save files from memory to disk. See Figure 3-7. The FILE
OPERATIONS screen contains the following windows:
NOTE
The cursor defaults to the DIRECTORY window.
• DRIVE WINDOW
• FILE WINDOW
• DIRECTORY WINDOW
Table 3-7 identifies and functionally describes all the FILE OPERATIONS screen
windows, boxes, and buttons to the operator of the CAM/ALOT system.
DIRECTORY
WINDOW
DRIVE WINDOW FILE WINDOW
FIGURE 3-7. FILE OPERATIONS SCREEN

TABLE 3-7. FILE OPERATIONS SCREEN
WINDOW BOXES BUTTONS FUNCTION
DRIVE Lists available drive for file operations.
DIRECTORY The DIRECTORY window lists files in the

main directory and subdirectories.
FILE The FILE window displays all of the

available *.CAM or *.TXT files available in
the selected directory.
NOTE
A file name must be entered into the FILE NAME box before a command that requires a
file name can be executed.
File Displays selected file name from FILE

Name window or new name typed in with
keyboard.
Part Allows identifying comments to be attached

Number to file name.
Load Select to load file named in FILE NAME box

into memory. File name is displayed in
EDITING window of the MAIN screen.
Load Sub Select to load a new pattern into subpattern

library as a subpattern.
Save Select to save a pattern from memory to

disk.
Delete Use to delete a selected file (.CAM) from

disk.

TABLE 3-7. FILE OPERATIONS SCREEN (CONT)
WINDOW BOXES BUTTONS FUNCTION
Make Dir The Make Dir button is used to create a

new file directory.
Delete Dir Deletes a directory from the disk.
3.9.2 DISPENSE PARAMETERS SCREEN
The DISPENSE PARAMETERS screen is used to change parameters of patterns. The

system defaults to a preset value for each routine. Refer to Figure 3-8. Each parameter
can be modified to maximize results.
Table 3-7 identifies and functionally describes all the DISPENSE PARAMETERS
screen to the operator of the CAM/ALOT system.
FIGURE 3-8. DISPENSE PARAMETERS SCREEN

TABLE 3-8. DISPENSE PARAMETERS SCREEN
MENU FUNCTION
1 through 8 Number of value.
NOTE
There are eight values for the Speed, Shotsize and Height parameters. Choices are
listed by number in each step of the EDITING window in the MAIN screen.
Speed Lists eight values for head speed during dispensing of lines. Adjustable
(In/Sec) in increments of 0.01 inches/second.
Shotsize Lists eight values for dispensing time which determines size of dispensed
(mSec) dot. Measured in milliseconds. Minimum shotsize is 10 ms.
Height Lists eight values for needle height above board. Adjustable in
(Inches) increments of 0.001 inches. Default is 0.600 inch. Height may be set
from -0.020 inch to the maximum height allowed by the system and
options.
NOTE
All the parameters identified below can also be changed.
On Delay Delays motion of needle at start of a line to give a thicker material

(mSec) enough time to be dispensed. Measured in milliseconds.
Off Stops dispensing before end of a line. This gives material time to stop
Advance flowing from needle. Measured in inches.
(Inches)
Dwell Amount of time dispense head stays in down position after a dot is
(mSec) dispensed. This allows material time to finish flowing from needle.
Measured in milliseconds.

TABLE 3-8. DISPENSE PARAMETERS SCREEN (CONT)
MENU FUNCTION
ShiftHtUp Distance for which head will run at slow speed when raising from a
(Inches) dispense operation. Used to eliminate tailing tendency of some
materials.
ShiftHtDn Distance for which head will run at slow speed when lowering to a
(Inches) dispense operation.
ToggleHt Distance from board that cartridge is raised during valve changes when
running a dispense program.
Wait (Sec) Amount of time dispense head remains stationary after a command is
executed before continuing through program. Measured in seconds from
1 to 500.
3.9.3 DIAGNOSTICS SCREEN.
The DIAGNOSTICS screen is used as a diagnostic tool to turn valves ON/OFF, or to

place system in diagnostics mode where functions of motors, encoders, limit switches
and trackball can be checked. See Figure 3-9.
Table 3-9 identifies and functionally describes the DIAGNOSTICS screen to the

FIGURE 3-9. DIAGNOSTICS SCREEN
TABLE 3-9. DIAGNOSTICS SCREEN
BOXES BUTTONS FUNCTION
CAUTION
Do NOT pulse motors in positive (+) direction from HOME
position. No extreme negative moves Should be made or
the head will strike into Mechanical stops.
PULSE MOTORS The PULSE MOTORS box displays buttons

offering choices of motor direction for all three
axes. These buttons are used during
troubleshooting.
SET OUTPUTS The SET OUTPUTS box displays buttons offering

a choice of six outputs, four valves, and ALL OFF.
The standard system defaults to valve 1. The
other valves are turned on when using optional
dispensing heads.
The Valve selections are used to purge the

cartridges of the dispensing head.
TABLE 3-9. DIAGNOSTICS SCREEN (CONT)

BOXES BUTTONS FUNCTION
ENCODERS The ENCODERS box displays the status of the X,

Y and Z-axes home positions and motor encoder
read-outs. This command is used for
troubleshooting purposes. In this mode, the
motors are disabled and the X-, Y- and Z-axes
can be moved by hand.
The X, Y and Z encoder read-out values reflect

the axis position and will change when moved. In
this mode, the motors are disabled and the axis
position can be moved by hand.
This command is used to troubleshoot or check

movement of the Trackball. X- and Y-axes will
move in relation to Trackball movement.
HOME The HOME button sends the head assembly to

the HOME position on all three axes. Clears
system after a GALIL ERROR has been
displayed.
TRACKBALL The TRACKBALL button is used during

troubleshooting to check movement of the
Trackball. Select the TRACKBALL button, and
the X- and Y-axes will move in relation to
movement of Trackball. Select the TRACKBALL
button again and the head assembly will return to
the HOME position.
3.10 PASSWORD
A password is used to restrict access to the system. When the password function is in
use, the only command that can be used is RUN, and the only file which can be
accessed is the current one. The following paragraphs specify how to create, activate,
change, and deactivate a password.

FIGURE 3-10. SET PASSWORD PROTECTION SCREEN
3.10.1 CREATING A PASSWORD
Create a password as follows:
1. Select PASSWORD button to access SET PASSWORD PROTECTION screen.
2. Using trackball, select level of password protection desired. See Figure 3-10.
3. Select NEW PASSWORD button. NEW PASSWORD screen will appear. See
Figure 3-11.
FIGURE 3-11. SET NEW PASSWORD SCREEN

4. Type existing password.
5. Select ACCEPT button or press ENTER key.
6. Type new password.
8. Password is entered into system. It will not function until it is activated.
3.10.2 ACTIVATING A PASSWORD
The following procedure is used to activate a password. When a password is activated,

there are three levels of password protection: offsets only, offsets and loading files, and
allow all changes except saving files. See Figure 3-10.
1. Load file into current memory.
2. Select PASSWORD button.
3. Select protection level.
4. Select ACCEPT button or ENTER key.
3.10.3 CHANGING A PASSWORD
The following procedure assumes that a file has been loaded and that there is an
existing password protection level selected.
1. Select PASSWORD button. SET PASSWORD PROTECTION screen (Figure

3-10) will appear.
2. Select NEW PASSWORD button. SET NEW PASSWORD screen (Figure 3-11)
will appear.
3. Type existing password.
5. Type new password.

NOTE
If password is activated and system is off, password will still be

active and system still locked out when restarted.
7. Activate new password.
3.10.4 REMOVING PASSWORD PROTECTION
A password must be removed to resume normal access to system. The following

procedure assumes that a file is loaded and that there is an active password.
1. Select PASSWORD button. REMOVE PASSWORD PROTECTION screen

(Figure 3-12) will appear.
2. Type password.
3. Select ACCEPT button. Password is deactivated.
FIGURE 3-12. REMOVE PASSWORD PROTECTION SCREEN
3.11 INITIAL SET UP
Before the CAM/ALOT system is used for the first time, the dispense system must be
installed and the dispense system and conveyor system must be set up.

The following paragraphs are used to install and set up the dispense system, and to set
up the conveyor system. The procedures assume that no options are installed.
To install standard dispense system, go to paragraph titled, Dispense System. To set

up conveyor, go to paragraph titled, Conveyor System.
To install an optional dispense system, go to applicable option supplement at back of

manual.
3.11.1 DISPENSE SYSTEM
The dispensing needle and syringe must be installed before material can be dispensed.
If needles or syringe other than those obtained from Camelot Systems, Inc. are used,
an adapter for the specific syringe manufacturer must be used. See Figure 3-13.
NOTE
The Z mounting plate has eight threaded holes which allow for
a variety of mounting positions. As a rule, the holder should be
flush with the bottom of the Z-axis mounting plate.
1. Attach the syringe holder to the Z-axis mounting plate with two screws.
1 2 3
FIGURE 3-13. SYRINGE ASSEMBLY
2. Attach desired dispensing needle (1) by twisting tightly into syringe finger.
3. Fill syringe (2) two-thirds full of material to be dispensed.

4. Connect syringe adapter (3) to end of syringe and turn into place.
5. Connect end of tube on syringe adapter to V1 connector (Figure 3-2) on

dispense panel.
NOTE
Too much tension may cause syringe plunger to stick and

interrupt proper material flow. If incorrect height setting is
chosen, syringe will slide back up through holder.
6. Slide syringe down into holder on Z-axis mounting plate. Turn thumb screw
knob until screw tip makes light contact with surface of syringe.
3.11.2 CONVEYOR SETUP
The conveyor can be adjusted to handle different board sizes. The following
paragraphs describe the initial set up for the conveyor system. The MANUAL
CONVEYOR CONTROLS screen (Figure 3-14) is accessed by selecting the SETUP
CONVEYOR button in the MAIN screen.
3.11.2.1 Description of SMEMA
The Surface Mount Equipment Manufacturer’s Association (SMEMA) interface of the

CAM/ALOT system was set up at Camelot Systems, Inc. To conform to SMEMA
interface standard 1.2. The definitions used are as follows:
Interface Signals
BUSY Continuity (contact closed or signal low) when

requesting a board.
No continuity (contact open or signal high) when not

requesting a board.
Signal state or level is planned so that when SMEMA

is disconnected, BUSY line is not requesting a board,
pallet, boat, etc.

The contact closed or signal low state of BUSY may
be referenced to as ready.
BOARD AVAILABLE Continuity (contact closed or signal low) when a board
is available.
No continuity (contact open or signal high) when a

board is not available
Signal state or level is planned so that when SMEMA

is disconnected, BOARD AVAILABLE line shows no
board available.
The contact open or signal high state of BOARD

AVAILABLE may be referenced to as BOARD NOT
AVAILABLE.
Location Designations
UPSTREAM Device (machine, conveyor, loader, etc.) that sends

product to next machine or device. Designated as A
in a lineup of two machines (A and B) with product
flowing from A to B.
DOWNSTREAM Device (machine, conveyor, loader, etc.) that receives
product from upstream machine or device.
Designated as B in a lineup of two machines (A and
B) with product flowing from A to B.
Signals Concerning UPSTREAM Devices
OUTPUT Sends BOARD AVAILABLE to downstream device.

INPUT Receives BUSY from downstream device
Signals Concerning DOWNSTREAM Devices
OUTPUT Sends BUSY to upstream device.

INPUT Receives BOARD AVAILABLE from upstream device.

Rules for UPSTREAM Devices
1. Board transfer can only occur when two conditions are met; device A has a
BOARD AVAILABLE and device B is ready (not BUSY).
2. The BOARD AVAILABLE signal from device A will remain valid (low or contact
closed) until the board has left device A.
Rules for DOWNSTREAM Devices
The READY signal must remain valid (low or contact closed) until the board has arrived
at device B.
Global Rule for UPSTREAM and DOWNSTREAM Devices
Board transfer cannot occur again until each signal opens for at least 50 milliseconds
(signals that were low or contact closed go high or contact opens).
Refer to SMEMA electrical schematics in Section 8, Engineering Drawings.
3.11.2.2 Initial Conveyor Setup
The following procedure is used to set motor time, adjust stop pin, test conveyor system
components, and to index a board to the dispense station to create a dispense
program.
These procedures assume that The CAM/ALOT machine is turned on and that the
MAIN screen is active on the computer monitor.
Table 3-10 identifies and functionally describes all the MANUAL CONVEYOR
CONTROLS SCREEN selections and indications, to the operator of the CAM/ALOT
system.

Manual Conveyor Controls
Input Stop Disp. Stop LiFt Table Output Stop
OFF OFF OFF OFF
Input Sensor Buffr Sensor Disp. Sensor End Sensor
Motor SloW Motor Jog Motor Time Motor Test

0.00
OFF
SmemA Quit
FIGURE 3-14. MANUAL CONVEYOR CONTROLS SCREEN
TABLE 3-10. MANUAL CONVEYOR CONTROLS SCREEN
SELECTION / FUNCTION
INDICATION
INPUT STOP Two-position switch to manually raise or lower stop pin at the
SWITCH input buffer. ON will raise stop pin and OFF will lower stop pin.
DISP. STOP Two-position switch to manually raise or lower stop pin at the
SWITCH dispense station. ON will raise stop pin and OFF will lower stop
pin.
LIFT TABLE Two position switch to manually raise or lower dispense station
SWITCH lift table. ON will raise table and OFF will lower table.
OUTPUT STOP Two-position switch to manually raise or lower stop pin at the
SWITCH output buffer. ON will raise stop pin and OFF will lower stop pin.

TABLE 3-10. MANUAL CONVEYOR CONTROLS SCREEN (CONT)
SELECTION / FUNCTION
INDICATION
INPUT SENSOR Indicates whether input sensor (input end of conveyor) is made
LIGHT (red) or unmade (black). Sensor may be tested by passing hand
over sensor.
BUFFR SENSOR Indicates whether sensor at input buffer station is made (red) or
unmade (black). Sensor may be tested by passing hand over
sensor.
DISPENSE Indicates whether sensor at dispense station is made (red) or

SENSOR LIGHT unmade (black). Sensor may be tested by passing hand over
sensor.
END SENSOR Indicates whether end sensor (output end of conveyor) is made
LIGHT (red) or unmade (black). Sensor may be tested by passing hand
over sensor.
MOTOR SLOW Two-position switch to select speed of conveyor motor when jog
SWITCH button is pressed. ON will cause conveyor motor to run at slow
speed and OFF will permit motor to run at high speed. Motor
slow switch is only used to test conveyor speeds.
MOTOR JOG Activates conveyor motor to run board to desired location.

BUTTON Conveyor will run until left button of trackball is released.
MOTOR TIME Used to set length of time conveyor continues to run after
BUTTON dispense sensor is made.
MOTOR TEST Used to determine if MOTOR TIME value is set correctly.

BUTTON
Set up conveyor as follows:
1. Select SETUP CONVEYOR button. MANUAL CONVEYOR CONTROLS screen

will appear.

NOTE
Upstream and downstream SMEMA connectors must be sent a

transition signal if there is no upstream or downstream machine
connected. If the signal is not in sent, the CAM/ALOT will wait
for input from the upstream and downstream machines and will
not run in AUTO mode.
2. If not already done, install a device to send a transition signal to the SMEMA
connector labeled UPSTREAM and the connector labeled DOWNSTREAM.
The connectors are located on the rear panel of the machine. See SMEMA
section of the electrical schematics in Section 8, Engineering Drawings.
3. Place a board on conveyor rail belts at input station so that sensor is covered.
Input sensor on computer monitor will turn red to indicate that input sensor is
made.
CAUTION
The conveyor width is not adjustable if an optional heated

chuck, vacuum chuck, or heated-vacuum chuck is installed
on the system. Damage to the conveyor system may result
if an attempt is made to adjust the width of the conveyor
rails without contacting Camelot Systems, Inc.
4. Place a 0.030 inch (0.76 mm) plastic shim between conveyor rear rail and
board.
5. If necessary, set gap using conveyor hand wheel.
6. Remove shim.
7. If necessary, select Disp. Stop button to raise stop pin at dispense station.
Button will change from OFF to ON.

NOTE
Motor time is the length of time in milliseconds that the

conveyor motor will run after the dispense sensor is made.
Motor time is set so that conveyor motor continues to run for a

minimal length of time after board contacts stop pin.
8. Select desired motor speed mode. When Motor SloW switch is ON, conveyor
will enter slow speed mode when dispense sensor is made. Otherwise,
conveyor will run at high speed until board contacts stop pin.
9. Select Motor Test button. Conveyor motor will activate and run board to stop
pin at dispense station. Disp. Sensor will turn red to indicate that a board is at
dispense station.
10. If motor stops before board contacts stop pin or if motor continues to run too
long after contacting stop pin, set motor time as follows:
NOTE
Time is set by typing number with keyboard. Time is in

milliseconds.
a. Select Motor Time button. Motor time screen will appear.
b. If motor deactivates before board contacts stop pin, increase time.
c. If motor runs too long after board contact stop pin, decrease time.
11. Repeat step 3 through step 10 until motor time is correct.

CAUTION
The conveyor width is not adjustable if an optional heated

chuck, vacuum chuck, or heated-vacuum chuck is installed
on the system. Damage to the conveyor system may result
if an attempt is made to adjust the width of the conveyor
rails without contacting Camelot Systems, Inc.
12. Using 0.030 inch (0.76 mm) plastic shim, check gap at dispense station. If
necessary, adjust gap.
13. Place board supports under board.
14. Select LiFt Table ON to raise dispense lift table.
15. Adjust stop plates and tooling pins to desired positions.
16. Program desired pattern as specified in Programming.
17. Select LiFt Table OFF to lower dispense lift table.
18. Select Disp. Stop OFF to lower stop pin at dispense station.
19. Select Output Stop ON to raise output buffer stop pin.
20. Click on Motor Jog button until board contacts stop pin. END SENSOR should
light to indicate board is at output station.
21. Remove board from conveyor.
3.11.2.3 Adjustment of Input Buffer Stop Pin and Sensor

1. If not already done, adjust motor time as specified in paragraph titled Initial
Conveyor Setup.
2. Select Input Stop ON to raise stop pin at input buffer station.
3. Place board on conveyor so that board leading edge is against input stop pin.
4. Adjust input stop pin so that board at input station is as close as possible to
board dispense station.
5. Remove boards.
6. Measure and record distance from center of dispense sensor to dispense stop
pin.

NOTE
In some cases, the input sensor may have to be moved past lift
table hanger. Nut plates are supplied in bottom of conveyor
fixed rail to secure sensor
7. Set center of input buffer sensor to same distance from input stop as dispense
sensor is to dispense stop.
3.11.2.4 Adjustment of Output Buffer Stop Pin and Sensor

1. If not already done, adjust motor time as specified in paragraph titled Initial
Conveyor Setup.
2. Select Output Stop ON to raise stop pin at output station.
3. Place a board on conveyor so that board leading edge is against output stop
pin.
4. Adjust output stop pin so that board is as close as possible to board at dispense
station.
5. Remove boards.
6. Measure distance from center of dispense sensor to dispense stop.
7. Set center of output buffer sensor to same distance from output stop as
dispense sensor is from the dispense stop.
3.11.2.5 Automatic Operation
The conveyor is automatically operated when a dispense program is loaded and

CONVEYOR ON / OFF button is ON and the RUN button is selected in the CAM/ALOT
system MAIN screen.
3.11.3 SETTING THE HEIGHT OF THE NEEDLE
The dispense height of the needle must be set before a pattern can be programmed or
run. The needle should be down near the board to accurately find the location for
dispensing the material. This procedure is only used when there is no touch probe
option installed or when the touch probe is not going to be used.
When the machine is turned on, the operating system boots and the camelot system
screen appears on the computer monitor. The next screen to appear is the MAIN
screen (Figure 3-7).

WARNING
KEEP HANDS AWAY FROM THE NEEDLE !
1. Select SETUP CONVEYOR button. MANUAL CONVEYOR CONTROLS screen

(Figure 3-14) will become active.
2. Select STOP PIN to raise stop pin and position board against stop pin.
3. Select LIFT TABLE to raise dispense station lift table and secure board.
4. Select QUIT button to return to MAIN screen.
NOTE
If the system is in EDIT mode, the head will not move. The
system must be in TRACE mode.
5. Select TRACE. Head will go to its home position on the X, Y and Z axes.
6. Select MOVE from the command window. The first step in the pattern is
displayed in the EDIT window. It contains the MOVE command and the default
parameters for the valve, speed/shotsize, up and down heights, and the X and
Y axis coordinates for HOME positions. The cursor highlights MOVE and the X
and Y coordinates.
NOTE
Any coordinates or values which are highlighted with shaded

bars on either side can be modified.
7. Using the trackball (1, Figure 3-5), position the dispense head over the desired
area of the board and click the left button. The X and Y coordinates change as
the dispense head moves along the axes indicating the position of the needle.

CAUTION
If a touch probe option is installed, touch probe must be

disabled or needle will be destroyed.
8. If necessary, disable touch probe by selecting TOUCH PROBE button above

editing window. Message will be displayed stating that touch probe has been
disabled.
9. Select the upper Z in the OFFSETS window. Click the left button (2). The Z-
axis coordinate in the OFFSETS window will be highlighted.
CAUTION
If the needle hits the board, it can be knocked out of

alignment or broken and the board can be damaged.
10. Slowly bring the needle tip down with the trackball until it almost touches the
surface. The highlighted Z-axis coordinate will change as the head moves. It
displays the height of the needle above the Z-axis zero.
11. Change the speed of the head movement to SLOW with the SPEED CHANGE
button (3) on the trackball.
12. Record the height of the needle.
NOTE
While different materials produce different results, the general

rule is the needle height should be set one-half the inside
diameter of the needle. This is the basic height from which all
other heights are measured. This height is referenced as
HEIGHT in the DISPENSE PARAMETERS screen. Height 1
default is 0.000 inch (0.000 mm) and height 2 through 8
defaults are 0.600 inch (15.24 mm).
13. Raise the needle approximately one-half the inside diameter of the needle.

For example: If the height of the needle on the Z-axis is 0.563 inch
(14.3 mm) (when it is just touching the board) and the
inside diameter of the needle is 0.030 inch (0.76 mm)
in diameter, raise the needle to 0.578 inch (14.6 mm).
The gap is 0.015 inch (0.38 mm).
14. Click the left button to set the needle dispensing height. The new height of the
needle on the Z-axis is displayed without the highlight.
15. After a test run, adjust the height if necessary.
3.12 MACHINE START UP
The following procedure is for normal daily start-up:
1. Check to be sure that air supply is at least 80 PSI (Pounds per Square Inch)(5.6
2
kg/cm ).
2. Remove any loose articles (tools, fixtures, etc.) from work area.
3. Ensure that safety light curtain is on and that interlock switch is turned to the ON
position.
NOTE
Upstream and downstream SMEMA connectors must be sent a

transition signal if there is no upstream or downstream machine
connected. If the signal is not in sent, the CAM/ALOT will wait
for input from the upstream and downstream machines and will
not run in AUTO mode.
4. If not already done, install a device to send a transition signal to the SMEMA
connector labeled UPSTREAM and the connector labeled DOWNSTREAM.
The connectors are located on the rear panel of the machine. See SMEMA
section of the electrical schematics in Section 8, Engineering Drawings.
The CAM/ALOT operating and programming system will automatically boot up when the
MACHINE ON button is pushed. The monitor will display the MAIN screen.

3.13 DISPENSING A PATTERN
Before a pattern can be dispensed, the initial set up must be performed. If the
dispensing system and conveyor have not been set up and the needle height set, set
up system as specified in paragraph titled, Initial Set Up.
In order or run a pattern, it must first be loaded into current memory and displayed in
the EDITING window of the MAIN screen.
Scroll down the list by selecting the lower right hand arrow. Click the left button on the
trackball and the list will continue to scroll as long as the button is pressed. Scroll up
the list by repeating this procedure using the upper right arrow. Go to the beginning,
end or anywhere in between in the list by placing the cursor at the beginning, end or in
the middle of the shaded strip.
Dispense pattern as follows:
1. Select FILE OPERATIONS button.
2. Select the desired pattern in the DIRECTORY window. That file name is now
displayed in the FILE window.
3. Select LOAD button. If a file is in current memory the system will display this
sub menu.
There is a pattern in memory
Hit right button to replace it
or left button to cancel load.
4. Press right button. The message Loading xxxx.CAM will appear. The file is
now loaded into current memory.
5. If necessary, select TOUCH PROBE button to enable optional touch probe for
ZSENSE.
6. Select CONVEYOR ON / OFF button to activate conveyor, and then select RUN
button. Machine will dispense pattern.

Section 4
PROGRAMMING

4.2.1 MOVING THROUGH A DIRECTORY .......................................................... 4-6
4.2.2 LOADING A PATTERN ................................................................................ 4-6
4.2.3 MOVING THE CURSOR THROUGH A PATTERN ...................................... 4-7
4.2.3.1 SINGLE-STEPPING THROUGH A PATTERN .................................... 4-8
4.2.3.2 SCROLLING THROUGH A PATTERN ................................................ 4-9
4.3 PROGRAMMING A DISPENSE PATTERN........................................................ 4-10

4.3.1 CREATING A NEW PATTERN FILE.......................................................... 4-10
4.3.1.1 SETTING DISPENSE PARAMETERS............................................... 4-11
4.3.1.2 PROGRAMMING A POINT ................................................................ 4-14
4.3.1.3 PROGRAMMING A SERIES OF DOTS............................................. 4-14
4.3.1.4 PROGRAM A CIRCLE ....................................................................... 4-15
4.3.1.5 SUBPATTERNS................................................................................. 4-16
4.3.1.5.1 LOADING A SUBPATTERN................................................. 4-16
4.3.1.5.2 REPLACING A SUBPATTERN ............................................ 4-16
4.3.1.6 CALL COMMAND .............................................................................. 4-17
4.3.1.7 DATA SHEET .................................................................................... 4-18

4.3.1.8 END THE PATTERN ..........................................................................4-19
4.3.1.9 SAVING A PATTERN .........................................................................4-19
4.3.1.10 RUNNING A PATTERN ....................................................................4-20
4.3.2 EDITING AN EXISTING PATTERN ............................................................4-20
4.3.2.1 SEARCHING FOR A STEP ................................................................4-20
4.3.2.2 INSERTING A STEP ..........................................................................4-21
4.3.2.3 DELETING A STEP ............................................................................4-21
4.3.2.4 CUT, COPY AND PASTE ...................................................................4-21
4.3.2.5 BLOCK EDITING ................................................................................4-22
4.4 APPLICATIONS ..................................................................................................4-22

4.4.1 PATTERN PARAMETERS..........................................................................4-22
4.4.1.1 CHANGING PARAMETERS IN MAIN SCREEN ................................4-22
4.4.1.2 MAINTAINING A SHOTSIZE ..............................................................4-23
4.4.1.3 CHANGING A PARAMETER..............................................................4-23
4.4.1.4 ADJUSTING A PARAMETER.............................................................4-24
4.4.1.5 DISPENSING TIPS.............................................................................4-24
4.4.2 ADJUSTING THE PATTERN......................................................................4-25
4.4.2.1. OPTIMIZE A PATTERN.....................................................................4-25
4.4.2.2 OFFSET THE START POINT.............................................................4-26
4.4.2.3 SELECTIVE DISPENSING .................................................................4-27
4.4.2.4 DISPENSING ON MORE THAN ONE LEVEL ....................................4-28
4.4.2.5 ADJUSTING BOTH TRAVELING AND DISPENSING HEIGHT .........4-28
4.4.2.6 ROTATE A PATTERN ........................................................................4-31
4.5 TRANSFERRING DATA VIA THE RS232 INTERFACE .....................................4-31

4.5.1 EQUIPMENT...............................................................................................4-32
4.5.2 SETUP ........................................................................................................4-32
4.5.3 PROGRAM DATA FORMAT .......................................................................4-33
4.5.3.1 PARAMETER LINES ..........................................................................4-33
4.5.3.2 INSTRUCTION LINES ........................................................................4-34
4.5.3.3 NAME LINES ......................................................................................4-35
4.5.3.4 CONTROL LINES ...............................................................................4-35
4.5.3.5 COMMENT LINES AND OTHER COMMENTS ..................................4-36

4.5.3.6 SAMPLE PATTERN........................................................................... 4-37
4.5.4 TRANSFERRING DATA............................................................................. 4-38
4.5.4.1 HOST-TO-CAM/ALOT TRANSFER ................................................... 4-38
4.5.4.2 CAM/ALOT-TO-HOST ....................................................................... 4-38
4.5.4.3 CAM/ALOT TO A PARALLEL INTERFACE PRINTER ...................... 4-39
4.5.4.4 CAM/ALOT TO A SERIAL INTERFACE PRINTER............................ 4-39
4.5.4.5 LOADING AND SAVING ASCII FILES ON THE CAM/ALOT............. 4-39
4.5.5 ERROR HANDLING ................................................................................... 4-40
4.5.5.1 PATTERN ERRORS .......................................................................... 4-40
4.5.5.2 INPUT / OUTPUT (I/O) ERRORS ...................................................... 4-40
4.6 GLOSSARY OF TERMS...................................................................................... 4-41

CAM/ALOT 5000 System. This requires a continual effort on the part of the operator or
anyone else working on or near the CAM/ALOT 5000 System.
The following list of Safety Precautions must be considered and practiced at all times:
1. Before attempting to operate or service the CAM/ALOT 5000 system, all

2. Be sure that the CAM/ALOT 5000 system is operating properly. Always operate
3. Keep hands away from gantry, heads, needles, etc. during system operation
and whenever electrical power and air are ON.
the dispense area. Press the red EMERGENCY MACHINE OFF (EMO) switch
to immediately shut off the machine.
11. Maintain the CAM/ALOT 5000 System in top working condition.
This section describes the software used to program the CAM/ALOT 5000 Machines.

The CAM/ALOT 5000 System uses a trackball pointing device to provide easy access
to menu controls, software loading and PC operation. It is used to program the system
and to run patterns.
If more convenient, the operator of the CAM/ALOT 5000 System can remove the
trackball from the holder and program the system while holding the trackball in the
hand.
The trackball and monitor are used together to program dispensing patterns into the
system.
4.2.1 MOVING THROUGH A DIRECTORY

1. Select FILE OPERATIONS button to activate FILE OPERATIONS screen
(Figure 4-1).
2. Select desired drive in DRIVE window.
3. Select desired directory in DIRECTORY window.
4. Scroll down list of files in FILE window as follows:
a. Place cursor on lower right-hand arrow.
b. Click left button on trackball. List will continue to scroll as long as button is
pressed.
c. Scroll up list by repeating this procedure using upper right arrow.
d. Go to beginning, end or anywhere in between list by placing cursor at

beginning, end or in middle of shaded strip.
4.2.2 LOADING A PATTERN
In order to edit or run a pattern, it must first be loaded into current memory and
displayed in EDIT window of the MAIN Screen.
1. Select FILE OPERATIONS button to activate FILE OPERATIONS screen

(Figure 4-1).
2. Select desired drive in DRIVE window.
3. Select desired directory in DIRECTORY window.
4. Select desired file in FILE window. Selected file will appear in FILE NAME box
above FILE window.

5. Select LOAD button from beside FILE window. If a pattern is already loaded,
the following message will be displayed:
There is a pattern in memory. Hit right button to replace it or

left button to cancel load.
Otherwise, Loading xxxx.CAM will be displayed on the monitor.
6. Close FILE OPERATIONS screen. Pattern will be displayed in EDIT window of

MAIN Screen.
DIRECTORY
WINDOW
DRIVE WINDOW FILE WINDOW
FIGURE 4-1. FILE OPERATIONS SCREEN
4.2.3 MOVING THE CURSOR THROUGH A PATTERN
NOTE
Head will follow steps in pattern when TRACE is selected.
Once a pattern has been created, move caret back and forth through pattern steps to
make changes. Step or scroll caret through in either TRACE or EDIT mode.

4.2.3.1 Single-Stepping Through A Pattern
1. Load pattern to be edited as specified in paragraph titled, Loading A Pattern.
2. Check dispense height to ensure needle has a clear path.
3. Select TRACE mode. See
COMMAND
WINDOW
OFFSETS
WINDOW
Figure 3-6. Main SCREEN
4. Select DOWN arrow on lower left-hand side of EDITING window. Dispensing

head moves to first step in pattern.
5. Click left button. Head moves to second position. Caret moves to next step
down in pattern corresponding to head position.
6. Continue clicking left button to step down in pattern. Head moves to position
indicated by caret.
7. Select UP arrow on upper left of EDITING window.

NOTE
When single-stepping through a pattern in EDIT mode, head

does not move.
8. Click left button to step up in pattern.
9. Select HOME button above EDITING window to send head HOME.
COMMAND
WINDOW
OFFSETS
WINDOW
FIGURE 4-2. MAIN SCREEN
4.2.3.2 Scrolling Through A Pattern

1. Load pattern to be edited as specified in paragraph titled, Loading A Pattern.
2. Select EDIT or TRACE mode.
3. Select center of shaded bar on right side of EDITING window. Middle of pattern
will be displayed on screen.

NOTE
Dispense head and caret will not move when scrolling through
pattern.
4. Select top or bottom of bar. Pattern moves to corresponding position.
5. Select UP or DOWN arrows on right side of EDITING window. Pattern will scroll
up or down in EDITING window.
4.3 PROGRAMMING A DISPENSE PATTERN
A new pattern can be created in two ways; a new file or editing an existing pattern and
renaming it. If pattern is going to be created from an existing pattern, go to paragraph
titled Editing an Existing Pattern. If pattern is going to be created from a new file, go to
paragraph titled Creating a New Pattern File.
The procedures assume that the user is familiar with the operation of the CAM/ALOT
machine and that the machine is on.
Either the dispense needle (TRACE) or cross hairs of the optional vision camera
(CAMERA) may be used to teach point coordinates. It is recommended that the
camera cross hairs be used to teach point coordinates.
4.3.1 CREATING A NEW PATTERN FILE
Before saving a new pattern in the directory, it must be given a name. A pattern may
be named after the coordinates have been programmed or before any coordinates have
been programmed. Pattern names may contain up to eight letters or numbers.
The main screen will be empty when the machine is first started.
1. If there is a pattern in memory, select the NEW FILE button. The following
message will be displayed:
Remove pattern XXXX.CAM from memory?

Hit right button to erase it or
left button to keep it.
2. Select left button if existing pattern has been changed and needs to be saved.
Otherwise, press right button.
3. Select FILE OPERATIONS button.

4. Using trackball, place cursor in FILE NAME box and press left button.
5. Using keyboard, type name of file. File name may be up to eight alphanumeric
characters. Additional descriptive text of up to 14 characters may be entered
into right half of FILE window. This will not be part of the file name.
6. If an error is made, press backspace key of keyboard.
7. To erase entire name from current file window, highlight name with trackball and
press delete key of keyboard.
8. When name is correct, select SAVE button to right of FILE window.
9. Close FILE OPERATIONS screen.
4.3.1.1 Setting Dispense Parameters

1. Select DISPENSE PARAMETERS button. PARAMETERS FOR DISPENSING
screen will appear. See Figure 4-3.
2. If necessary, change parameters as follows:
a. Using trackball, place cursor on parameter to be changed and press left

button of trackball.
b. Spin trackball to change value.
c. Press left button of trackball when desired value is shown. System will
accept the value.
3. When all parameters have been set, close PARAMETERS FOR DISPENSING
screen.

FIGURE 4-3. PARAMETERS FOR DISPENSING SCREEN
TABLE 4-1. PARAMETERS FOR DISPENSING SCREEN
PARAMETER FUNCTION
1 through 8 Number of value.
NOTE
There are eight values for the Speed, Shotsize and Height parameters. Choices are
listed by number in each step of the EDITING window in the MAIN screen.
Speed Lists eight values for head speed during dispensing of lines.
(In/Sec) Adjustable in increments of 0.01 inch/second.
Shotsize Lists eight values for dispensing time which determines size of
(mSec) dispensed dot. Measured in milliseconds. Minimum shotsize is 10
msec.

TABLE 4-1. PARAMETERS FOR DISPENSING SCREEN (CONT)
PARAMETER FUNCTION
Height Lists eight values for needle height above board. Adjustable in
(Inches) increments of 0.001 inch. Default is 0.600 inch. Height may be set
from -0.020 inch to the maximum height allowed by the system and
options.
NOTE
All the parameters identified below can also be changed.
On Delay Delays motion of needle at start of a line to give a thicker material

(mSec) enough time to be dispensed. Measured in milliseconds.
Off Advance Stops dispensing before end of a line. This gives material time to stop
(Inches) flowing from needle. Measured in inches.
Dwell (mSec) Amount of time dispense head stays in down position after a dot is
dispensed. This allows material time to finish flowing from needle.
Measured in milliseconds.
ShiftHtUp Distance for which head will run at slow speed when raising from a
(Inches) dispense operation. Used to eliminate tailing tendency of some
materials.
ShiftHtDn Distance for which head will run at slow speed when lowering to a
(Inches) dispense operation.
ToggleHt Distance from board that cartridge raised during valve changes when
running a dispense program.
Wait (Sec) Amount of time dispense head remains stationary after a command is
executed before continuing through program. Measured in seconds
from 1 to 500.

4.3.1.2 Programming A Point
The POINT command is the command that will be used the most during programming
of a pattern. The following procedure assumes that an optional vision system is
installed on the system. The cross hairs of the vision camera are used to teach the
point coordinates. If a vision system is not installed, the dispensing unit needle and
TRACE mode are used in place of the camera cross hairs and CAMERA mode.
1. If not already done, select the VIDEO ON button above EDITING window to
enable video display in center of EDITING window.
2. Select CAMERA mode.
3. Select POINT in command window.
4. Using trackball, move cross hairs to location of first dot and press left button.
5. Select POINT again.
6. Move cross hairs to next dot location and press left button.
4.3.1.3 Programming A Series of Dots

1. If optional vision is installed, select the VIDEO ON button above EDITING
window to enable video display in center of EDITING window.
2. If optional vision system is installed, select CAMERA mode. Otherwise, select

TRACE.
3. Select the ROW OF DOTS button under the COMMAND window. ROW OF
DOTS screen (Figure 4-4) will prompt for additional information.

FIGURE 4-4. DOTS COMMAND SCREEN
4. Select the 2 in NUMBER OF DOTS.
5. Using trackball, change to desired number of dots and press left button.
6. Select X, Y coordinates on FIRST POINT line.
7. Move needle to beginning of series of dots and press left button.
8. Select X and Y coordinates on LAST POINT line.
9. Move needle to end of series and press left button.
10. Select ACCEPT. Selected dot routine will be programmed in pattern as an

equivalent number POINT steps.
4.3.1.4 Program A Circle

1. Select MOVE command to signal system to move to a new point without
dispensing.
2. Align needle on one side of circle and execute.
3. Select CIRCLE command.
4. Align needle with a point on opposite side of circle (across diameter) and
execute. The system will draw a circle by entering these two points. The
needle will travel in a counter-clockwise direction.

4.3.1.5 Subpatterns
Any pattern saved in the directory may be recalled, stepped and repeated as a
subpattern. Use CALL command in COMMAND window to place a subpattern in a
pattern file.
4.3.1.5.1 Loading A Subpattern

1. Select FILE OPERATIONS button. FILE OPERATIONS screen (Figure 4-1) will
appear.
2. Select pattern file that is to be used as a subpattern.
3. Select LOAD button. Pattern is loaded into a separate subpattern library

reached by CALL command in COMMAND window of MAIN screen.
4.3.1.5.2 Replacing A Subpattern
Any subpattern can be chosen to replace another subpattern used in a main pattern.
This is extremely useful when small changes are made on the subpatterns.
1. Select FILE OPERATIONS button. FILE OPERATIONS screen (Figure 4-1) will
appear.
2. Select pattern which contains subpattern to be changed.
3. Load pattern.
4. Select SUB OPERATIONS button. SUB OPERATIONS screen (Figure 4-5) will
appear.
NOTE
If there are more than one subpattern in the directory, there will
be a dotted line appearing in the list of subpatterns. All of
those above dotted line have been called into main pattern and
are in current memory. All of those below the dotted line will be
available.
5. Select subpattern to be replaced from SUBPATTERNS CALLED BY MAIN

PATTERN.
6. Select REPLACE button. The following message appears:

Pick replacement for xxxx.CAM or
hit right button to cancel.
7. Go to SUBPATTERNS IN MEMORY window and select desired replacement.
FIGURE 4-5. SUB OPERATIONS SCREEN
4.3.1.6 Call Command
The CALL command is used to insert a subpattern in main pattern. The following
procedure assumes that the CALL command and subpatterns are being added to the
end of an existing pattern file.
1. If not already done, load file that is going to use the CALL command.
2. Select TRACE or CAMERA mode.
3. Go to line END command.
4. Select step above END statement. Caret will move to that step and needle will
travel to that location.
5. Select MOVE command.
6. Using trackball, move needle or cross hairs to starting point of the subpattern. X
and Y coordinates change to new position.
7. Select CALL in COMMAND window. A subpattern menu will appear on half

screen showing all patterns in current subpattern memory.

8. Select desired subpattern. A CALL appears in the EDITING window with
subpattern file name displayed.
9. Repeat Steps 5 through 8 to repeat pattern in another location.
NOTE
If subpattern exceeds limits of table, a window with a warning is

displayed.
Subpattern off (xxx edge, top, bottom).
Hit left button to continue.
10. Check dispense height before running pattern.
The program now consists of the main program with CALL commands for repeat
subpatterns. When the pattern file is run, it will first run main pattern, then execute
CALL commands.
4.3.1.7 Data Sheet
Data Sheet saves set-up information for the program. Select DATA SHEET button to
access data sheet.
Use keyboard to enter information. Data sheet is saved with the program. When that
program is reloaded, review data sheet to make sure machine is set up properly.

FIGURE 4-6. DATA SHEET
4.3.1.8 End the Pattern
Select END command. System automatically puts an END step on pattern when it is
saved or run. If an END step is put in middle of a pattern, and program is run, system
will stop dispensing at END step.
4.3.1.9 Saving A Pattern
After the pattern is named, save pattern to disk as follows:.
1. Select FILE OPERATIONS button in MAIN screen.
2. Select SAVE. The following submenu is displayed.
Saving pattern to xxxx.CAM

NOTE
When saving a new pattern, make sure the correct name

appears in the FILE NAME box.
The file named in FILE NAME box will be saved and its name will be listed in the FILE
WINDOW followed by .CAM. It is still in current memory and is displayed in the
EDITING WINDOW.
If a file with the same name already exists in the directory, the following sub menu is
displayed.
Overwrite existing file?
Hit left button to cancel
or right button to continue.
4.3.1.10 Running a Pattern
Check pattern by running system.
WARNING
KEEP HANDS AWAY FROM NEEDLE.
Select CONVEYOR ON / OFF button in MAIN screen, then select RUN. Window
scrolls and cursor follows program as it is executed. At end of program run, system will
automatically return dispense head to HOME position.
4.3.2 EDITING AN EXISTING PATTERN
It is sometimes necessary to edit or change and existing pattern. The following

paragraphs specify the methods of changing a pattern.
4.3.2.1 Searching For A Step
SEARCH function finds steps in a program which correspond to an area on board that
needs to be changed.
1. Load pattern to be edited.
2. Select TRACE mode.

3. Select SEARCH button in OFFSETS WINDOW. HOME position will be
displayed on X and Y coordinates below SEARCH. Head moves to HOME
position.
4. Using trackball, move needle as close as possible to X and Y location of area

which needs to be changed and press left button.
5. Click right-button to lower needle. Head will travel to nearest programmed

point. Caret will move next to line number of this point.
4.3.2.2 Inserting A Step

1. Load pattern to be edited.
3. Move caret to step that will precede new step.
4. Select desired command. New step appears below selected step. All
information following new step drops down one step.
4.3.2.3 Deleting A Step

1. Select step to be deleted. Caret moves to that step.
2. Select DELETE in COMMAND WINDOW.
3. Click left button.
4.3.2.4 Cut, Copy And Paste
Use CUT, COPY and PASTE commands to modify programs.
1. Put caret on first line to be edited. Press left button.
2. Put caret on last line in block of commands to be edited. Click right button.
Block will now be in inverse.
3. Select CUT button to delete highlighted block of commands or COPY button to

place a copy in buffer.
4. Insert a MOVE statement to place block of commands.
5. Select PASTE to insert commands.
6. Coordinates of first point will be same as coordinates of MOVE statement.

4.3.2.5 Block Editing
A block of commands can be edited just like a single line. Valve, shotsize, speed,
up/down heights can be changed as a group. A highlighted block of text can also be
moved using X. Y offset.
1. Highlight block of text.
2. Select shotsize number in any of lines.
3. Use trackball to change number.
4. Click left button to accept change (shotsize will be changed in block of text). To
apply X and Y offset, select X, Y after highlighting block of text. Use trackball to
enter offset. It will be applied to block of text.
4.4 APPLICATIONS
There are a number of ways to edit and dispense a pattern, including changing
parameters and modifying dispensing patterns.
4.4.1 PATTERN PARAMETERS
Parameters of a pattern can be changed. Dots can be made larger or smaller, closer or
farther apart. There are two ways to change parameters; from MAIN screen or
PARAMETERS FOR DISPENSING screen.
4.4.1.1 Changing Parameters in MAIN Screen
There are four parameters that can be changed in the MAIN screen. They are V
(valve), S (shotsize for points or speed for lines), UP (up height), and DN (down height).
Valve number is changed to deliver air to a specific syringe, shotsize is changed to
modify dot size, and up and down height is changed to vary .

NOTE
Material viscosity, needle diameter, dispense speed, shotsize,

height and air pressure are all interrelated. If one is changed,
the others must be adjusted to maintain the same dot size or
line width.
1. Change any values in EDIT window of MAIN screen by selecting value and
changing to a new number between 1 and 8. PARAMETERS FOR
DISPENSING screen (Figure 4-3) has eight different values for dispensing
speeds, shot sizes and heights. System defaults to numbers above their
respective columns in this menu.
2. Any of the eight values for speed, shotsize and height can be changed in the
PARAMETERS FOR DISPENSING screen. On Delay, Off Advance and Dwell
Time each have one value which can be changed.
4.4.1.2 Maintaining A Shotsize

1. If material viscosity is increased, increase shotsize or air pressure.
2. If viscosity is decreased, decrease shotsize or air pressure.
3. If needle diameter is increased, decrease shotsize or air pressure.
4. If shotsize is increased, decrease air pressure.
5. If air pressure is increased, decrease shotsize.
4.4.1.3 Changing A Parameter
To change shotsize, speed or height from EDIT window, all use the following
procedure:
1. Move caret to step with value to be changed (Step 9 in sample program).
2. Select parameter to be changed (4 under S).
3. Change number to 8 and press left button.
When sample program is run, this point will have a larger dot.

4.4.1.4 Adjusting A Parameter
To adjust a parameter in the PARAMETERS FOR DISPENSING screen, use the

following procedure:
1. Select value to be changed.
2. Increase or decrease value and press left button.
The maximum and minimum programmable values for each parameter are as follows:
NOTE
All eight values can be changed.
PARAMETER PROGRAMMABLE BETWEEN

Shotsize 10 to 4000 mSec.
Speeds 0.01 to 4.5 in/sec.
Height -0.020 to 2.000 inch
DWELL time 0 to 4000 mSec.
ON DELAY 0 to 990 mSec.
OFF ADVANCE 0.0 to 0.990 inches.
WAIT 1 to 500 seconds.
Run sample program to observe and verify changes.
• Increased speed reduces width of dispense line.

• Increase air pressure to match original line width.
• For a larger shotsize, dispense material will lay out flat from needle tip.
• If a dome or peak is required, increase height for that point.
4.4.1.5 Dispensing Tips
This section describes some basic guidelines for proper dispensing. Inconsistent
dispensing of material can be caused by several factors.
NEEDLE HEIGHT The closer needle is to board the smaller the amount
of material is dispensed. A good starting point is to
set gap to 1/2 of needle inside diameter. For
example, a twenty gauge needle has an I.D. of 0.023

inch. Set gap to 0.012 inch. Refer to Section 3
(OPERATION) for more details.
NEEDLE SIZE Needle inside diameter should be large enough to
allow proper flow. Some materials have particles that
can collect and block opening. Shorter needles
provide greater control when dispensing small dots
due to less material flow friction.. Refer to Appendix
B "Needle Size Chart" for more specific information.
DOT SIZE VARIATION If amount of dispensed material is inconsistent, use
following checklist to determine cause:
• Improper needle dispense height. If it is too
high, material will not stick to board.
• Insufficient air pressure.
• Low quality material.
STRINGING OR TAILS Some materials will always have a peak after
dispensing. To stop string from tailing over to next
dispensing area, try increasing Up height, or
increasing DWELL or OFF ADVANCE time. Tapered
needles may also help by reducing amount of surface
area which material can cling.
When dispensing lines, try adding a MOVE command
after LINE command. Needle will move back over
line just dispensed shearing off any tails or strings
which will fall back over previously dispensed
material.
4.4.2 ADJUSTING THE PATTERN
A pattern can be changed in several ways. It can be optimized or starting point can be
offset. Parts of pattern can be chosen to be dispensed alone, or a pattern can be
programmed to dispense material on more than one level.
4.4.2.1. Optimize A Pattern
The OPTIMIZE button in MAIN screen reviews path length of program in memory and
restructures to create the shortest, most efficient, path through the program. Programs
that are downloaded from a host computer will probably gain the most from optimization
since those patterns were not structured for CAM/ALOT system.
All MOVE statements inserted into a pattern for the purpose of dodging obstacles will
be deleted during optimization. It is not recommended a pattern created to avoid
different components and other obstacles be optimized. Because the path will be
changed, there is a risk that needle will crash into components. Up height can be

increased to help avoid this situation, then it is possible to optimize the program without
crashing the needle.
CAUTION
If an END statement is in the middle of a program, all

information following END statement will be lost. No
message will be displayed.
1. If necessary, load file into current memory.
2. Select OPTIMIZE button. The system displays sub menu.
Present pattern saved to disk?

Hit right button to continue,
or left button to cancel
3. If not already done, save pattern.
4. Click right button to optimize pattern. A window will display original path length
and new path length.
Original travel = xxxxxx
Reduced to xxxxxx
5. Hit left button to continue.
New pattern is in EDITING window. If pattern could not be improved, a message

stating OPTIMIZING FAILED is displayed. Original pattern is retained.
6. Click left button to continue. Optimized program is in current memory only.

Save optimized program in file directory.
4.4.2.2 Offset The Start Point
The position of a program can be shifted with OFFSET command. Use command if a
new needle is installed or if a new board is not positioned on fixture plate as previous
board.
2. Make note of Z-axis height.

3. Select Z in OFFSETS window. Z xxxx (dispense height) is highlighted.
4. Raise Z-axis dispense height to a safe level and press left button. Needle will
rise to new height.
5. Select step to be offset.
6. Click left button.
7. Select Z.
8. Lower Z-axis dispense height to proper level and press left button. Needle will
move to that level.
9. Using trackball, move needle to new starting point. X and Y coordinates in

OFFSETS window will change. The entire program will be shifted by amount
displayed in X and Y OFFSET.
10. Execute offset. X and Y-coordinates displayed in EDIT window are changed by
amount of offset.
4.4.2.3 Selective Dispensing
Selective dispensing allows a choice of which parts of a program to execute. Any step
or group of steps can be skipped during a run.
1. Load the program.
2. Select step to be skipped by placing caret before the line number and pressing
left button.
3. Press right button to highlight that command line.
4. Select SELECTIVE DISPENSE button. The command is now in lower case.
5. Select first step in a series of steps to be skipped.
6. Select last step in series to be skipped and press left button. All commands
from the first step to the last step are now in lower case.

NOTE
Selective dispensing will always toggle all conditions within

selective dispensing range.
If the pattern is run now, all the steps in upper case will be dispensed, all in lower case
will be ignored.
7. To reverse command, select the commands in lower case and press left button.
Commands will now be in upper case and will be included in RUN mode. If
program is large and only a few commands are to be used, use this short cut.
Example, a 100 step program.
a. Select first and last commands to disable all 100 steps of program.
b. Select first and last commands in series of run, such as steps 20 and 25.
These steps will now be in upper case and therefore only ones that will be
executed in RUN mode.
4.4.2.4 Dispensing On More Than One Level
The CAM/ALOT System can dispense liquids on more than one level. To do this, a
different dispense height must be established for each level. The traveling height can
also be changed for each level.
1. Set values for traveling and dispense heights for each level in PARAMETERS
FOR DISPENSING screen.
2. Program pattern as usual in MAIN screen, selecting desired dispense and

traveling height for each level.
3. Run pattern and adjust heights as needed.
4.4.2.5 Adjusting Both Traveling And Dispensing Height
The range of Z-axis needle movement has upper and lower height settings. The upper
setting is the needles distance above the board during operation. The lower setting is
the height at which the needle dispenses the liquid. Both are adjustable.
Each step in the pattern has an UP height and a DN (down) height. There are eight
possible height values in PARAMETERS FOR DISPENSING screen. Only 1 for the DN
height and 2 for UP height are used in a single level dispense pattern. All eight values
may be used in any combination in multilevel patterns.

UP height can be raised to a maximum of 2.000 inches. It defaults to 2 (0.250 inch) in
PARAMETERS FOR DISPENSING screen. DN height defaults to 1 (0.00 inch).
Values for these heights are set in PARAMETERS FOR DISPENSING screen and
selected for each level in MAIN screen.
Each of the eight height values can be selected to be used as an UP (traveling) value or
a DN (dispense) value.
1. Select MAIN screen.
3. Select DISPENSE PARAMETERS button.
4. Set heights three to eight to their maximum.
5. Close PARAMETERS FOR DISPENSING screen.
6. Select POINT.
7. Create a three-step pattern of points, one point for each Step (level).
NOTE
The head moves up and down as the numbers are changed.
8. Set dispense height for Step 1.
NOTE
DN value for Step 1 is the base height from which all other
heights are measured. Always set this height first.
9. Change UP value in Step 2 to 4.
10. Change DN value in Step 2 to 3.
11. Change UP value in Step 3 to 5.
12. Change DN value in Step 3 to 5.

NOTE
The UP and DN values for all steps except Step 1 can be set
with any number from three to eight. Numbers one and two are
assigned to Step 1. Note the assignment of each value.
13. Select X and Y coordinate of Step 2.
14. Move needle over next highest level.
16. Select third line under height.
18. Select fourth line under height.
19. Set UP or traveling height for Step 2.
20. Close PARAMETERS FOR DISPENSING screen.
21. Select X and Y coordinate of Step 3.
22. Move needle over next highest level and press left button.
24. Select fifth line.
26. Select sixth line.
NOTE
When a new needle is installed, the dispense height must be

adjusted. Dispense height offset will be applied to all UP and
DN heights.
27. Set UP height.

28. Close PARAMETERS FOR DISPENSING screen. Save this pattern for future
use.
4.4.2.6 Rotate A Pattern
NOTE
A pattern can be rotated 90, 180 or 270 degrees. It rotates

around its central axis counter-clockwise.
1. Select file to be rotated.
2. Select ROTATE PATTERN button.
3. The following sub menu is displayed.
Choose angle of rotation or hit right button to cancel 90

180 270
NOTE
If pattern contains subpatterns, file must be saved and

reloaded before it can be rotated.
4. Select desired angle. Pattern will be rotated to desired angle.
5. Save as a rotated pattern.
4.5 TRANSFERRING DATA VIA THE RS232 INTERFACE
This interface provides the facilities and equipment to transmit data between the
CAM/ALOT system and a host PC. Dispensing patterns may be transferred to a
computer or loaded from a computer for advance editing functions, off-line
programming, etc. Any text editor capable of creating an ASCII file can be used to
create patterns. All data is in the form of lines of ASCII characters terminated by CR
(carriage return ) or CRLF (carriage return, line feed).

4.5.1 EQUIPMENT
A chassis mounted DB25P connector labeled RS232 is supplied on all machines

except the 1414. The COM 2 port on the PC486 of the 1414 is used as the interface.
A floppy diskette (labeled RS232) that contains communications software is also
included.
4.5.2 SETUP
The CAM / ALOT machines (except the 1414) provide a DB25P connector (labeled
RS232) on the rear panel of the machine chassis. The host adapter and cabling must
have a minimum of pins 2, 3, and 7 connected and carried through to permit RS232
communications.
The RS232 software disk provided with the machine is for IBM or compatible hosts,
enabling the send and receive transmission of CAM/ALOT patterns through the COM 2
port of the machines.
A null-modem adapter or null-modem cable is required to cross over pin 2 to pin 3 and
pin 3 to pin 2 for proper communication. See Figure 4-7 for a sample wiring diagram.
2 2
3 3
7 7
FIGURE 4-7. SAMPLE WIRING DIAGRAM FOR A NULL-MODEM CABLE
Connect RS232 cable as follows:

NOTE
Not all hosts will have a DB25 connector. Some hosts have a
DB9 connector. The selection of an adapter by the user, with
the required type and gender, will keep the number or
connections to a minimum.
1. Connect null-modem cable or cable with a null-modem adapter to DB25P

(RS232) connector on rear of machine.
2. Connect other end of cable to COM port of host computer.
4.5.3 PROGRAM DATA FORMAT
Any text editor that can create an ASCII file can create patterns. All data is in lines of 7-
bit ASCII characters. Each line must end with a CR (carriage return) character. If an LF
(line feed) is present, it will be ignored. There are four types of lines that are used in
the CAD program. They are parameter line, instruction line, name line, control line, and
comment line.
Spaces may be used freely at the beginning or end of a line, or between individual
items (numbers, keywords or names) on a line. TAB characters are treated as spaces.
Spaces are not allowed within an item. Completely blank lines are a form of comment
line. They may be inserted. Specific separator characters may be placed between
items. The characters comma, semicolon, colon, slash, backslash and vertical bar , ; : /
\ | are also accepted as separators. Separators must be used in when skipping items in
the middle of a list.
Letters used to form keywords and names may be upper case (capitals), lower case or
mixed -they will always be converted to upper case. The entire keyword is used. The
keyword letters are indicated in bold face in the following paragraphs.
The RS232 disk includes a sample pattern. The sample will help explain the types of
data lines and the use of separators.
4.5.3.1 Parameter Lines
Parameter lines set the values shown on the PARAMETERS FOR DISPENSING
screen, and the X, Y and Z offsets shown on the MAIN screen. The parameter line
begins with a keyword identifying the type of parameter.
SPEED for speeds up to 8 values in inches per second
SHOT for shot sizes up to 8 values in milliseconds

HEIGHT for heights up to 8 values in decimal inches
ON for on delay a single value in milliseconds
OFF for off advance a single value in decimal inches
ORIGIN for origin up to 3 values (X, Y, Z offsets) in decimal inches
DWELL for dwell a single value in milliseconds
WAIT for wait time a single value in seconds
4.5.3.2 Instruction Lines
The CAM/ALOT will accept up to about 10,000 lines of instructions. Each line may
begin with an identifying number. A keyword then specifies the type of instruction (only
the first two letter are significant) and the specific data is then specified.
Example:
5; LINE; -2.0; 1.0; 1; 4; 2; 1

ARC for ARC followed by R; Phi; V; Speed; Up; Dn
CALL for CALL followed by a sub pattern name
CIRCLE for CIRCLE followed by X; Y; V; Speed; Up; Dn
CLEAN for CLEAN followed by X; Y; Z; Speed; Up; Dn
END for END (alone)
INSPECT for INSPECT followed by X; Y; Z; Speed; Up; Dn
MOVE for MOVE followed by X; Y; V; Speed; Up; Dn
LINE for LINE followed by X; Y; V; Speed; Up; Dn
PAUSE for PAUSE (alone)
POINT for POINT followed by X; Y; V; Speed; Up; Dn
REFPT for REFPT followed by X; Y; V; Speed; Up; Dn
WAIT for WAIT (alone)
ZSENSE for ZSENSE followed by X; Y; Z; Speed; Up; Dn
X and Y refer to coordinate values in decimal inches (unless modified by a previously

specified scale factor) and V, Sh, Sp, Up and Dn refer to single digits specifying the
valves, shot size, speed, up height and down height for the instruction. For arcs: R is
the radius, in the same units as X and Y; Phi is the angle in degrees counterclockwise

from the +x-axis to the starting radius; dPhi is the angular length of the arc in degrees
counterclockwise. dPhi must be between -360 and +360. When an arc instruction is
transmitted from the CAM/ALOT (or printed or written to a file) the X and Y of the end
point are included in parentheses as a comment.
4.5.3.3 Name Lines
The names must be made of up to eight letters and digits, in any order. the CAM/ALOT
system adds a .CAM extension to the name, replacing any extension (period and
following characters) already present.
Name lines specify the names of patterns and sub patterns.

MAIN for Main followed by a file name. May be used to name the
main pattern.
SUB for Sub followed by a name used in CALL instructions.
Must be used to mark the start of a sub pattern
definition.
Example:
Subpat; DIP7
4.5.3.4 Control Lines
Control lines change the treatment of subsequent input. If you transmit a pattern while
the display is set to show millimeters the output will start with metric; and all distances
will be transmitted in millimeters. If no EOF line is present, the CAM/ALOT has to wait
several seconds after transmission ends to be sure that the host PC has really finished.
An EOF tells the CAM/ALOT not to wait, but to stop immediately.
Example:
Scale 0.001 1 ' Use mils instead of inches

SCALE for scale Followed by two numbers (scale factors). The first
number affects distances. All speed, height, and off
advance parameters and all coordinate values after
this line will be multiplied by that factor. The
second number affects times. It will multiply all
shot sizes, on delays, dwells, and wait times
specified after this line.

METRIC for metric Alone. Specifies that all following lengths are in
millimeters. This is the same as "SCALE 0.03937
1".
EOF for End-Of-File marks end of input.
4.5.3.5 Comment Lines And Other Comments
Comments are notes that can be included in the file to make it more intelligible. The
CAM/ALOT ignores anything marked as a comment. Anything may be written at the
end of a line, using one of the characters ! " ' ? ` to mark it as a comment. Comments
can be located in the middle of a line, if they enclosed in a matched pair of parentheses
of any shape ( ) [ ] { } or < >. Comments may be located on their own lines, beginning
either with one of the comment markers (! " ' * ? `) or with a separator (, ; : / \ |). The
separator tells the CAM/ALOT to ignore the line (the line has no keyword). The optional
identifying line numbers that can go at the start of any line (not just instruction lines) are
a form of comment. They are useful for finding errors, since some error messages
show the text of the failing lines. The CAM/ALOT puts consecutive line numbers on all
instruction lines it transmits.

Example:
Line 17 is a parameter line with comments.
17 Height: 0.75 [inches] ; (skip height 2) ; +1.345 ! Set heights 1 and 3 only
4.5.3.6 Sample Pattern
The following sample pattern is included on the CAM/ALOT RS232 disk (an eight pin
DIP socket in a 2 x 3 inch rectangle), in the format transmitted by the CAM/ALOT.
SPEED; 0.40; 0.50; 0.75; 1.00; 1.50; 2.00; 2.50; 4.50

SHOT; 10; 200; 300; 400; 500; 600; 2000; 2550
HEIGHT; 0.000; 0.150; 0.300; 0.400; 0.500; 0.600; 1.500;1.250
ON; 90
OFF; 0.1
DWELL; 50
WAIT; 10
ORIGIN; 0; 0; 2.
Main ; SAMPLE.CAM
; X Y V S UP DN
1; MOVE ;
2.; 1.; 1; 4; 2; 1
2; LINE ; 5.; 1.; 1; 4; 2; 1
3; LINE ; 5.; 3.; 1; 4; 2; 1
4; LINE ; 2.; 3.; 1; 4; 2; 1
5; LINE ; 2.; 1.; 1; 4; 2; 1
6; MOVE ; 3.; 1.2; 1; 4; 2; 1
7; CALL ; DIP8.CAM
8; END
Sub pattern; DIP8.CAM
; X Y V S UP DN
1; POINT ; 0; 0; 1; 4; 2; 1
2; POINT ; 0; .1; 1; 4; 2; 1
3; POINT ; 0; .2; 1; 4; 2; 1
4; POINT ; 0; .3; 1; 4; 2; 1
5; POINT ; .3; .3; 1; 4; 2; 1
6; POINT ; .3; .2; 1; 4; 2; 1

7; POINT ; .3; .1; 1; 4; 2; 1
8; POINT ; .3; 0; 1; 4; 2; 1
9; END
EOF
4.5.4 TRANSFERRING DATA
The following paragraphs are used to transfer CAD data from a host computer to the
CAM/ALOT machine and from a CAM/ALOT machine to a host computer.
4.5.4.1 Host-To-CAM/ALOT Transfer

1. Insert RS232 diskette that came with the CAM/ALOT RS232 interface into the
host PC drive, type XFER and hit return (after the host PC is turned on and
running DOS).
2. Select OPTION 1: Transmit pattern to CAM/ALOT.
3. Enter the name of the pattern to be transmitted with the drive, pattern and
extension (if the disk is in drive A, for the sample pattern, type A:\SAMPLE.TXT
and hit return). The message Start receiving CAM/ALOT side then
hit any key to start transmission will be displayed.
4. Select the COMMUNICATIONS button on the MAIN screen of the CAM/ALOT

system.
5. Select the RX by RS232 button. When the message Awaiting transmission

appears, hit any key on the host computer. If the pattern is received correctly
the CAM/ALOT COMMUNICATIONS screen will disappear shortly after the last
bit of data is received. Otherwise, an error message will be displayed.
4.5.4.2 CAM/ALOT-To-Host
1. Make that sure the pattern to be transferred is in current memory on the
CAM/ALOT.
2. Insert the RS232 diskette into the host PC drive, type XFER, and hit return.
3. Select OPTION 2: Receive pattern from CAM/ALOT.
4. Enter the name of the PC file that will store the pattern with the drive, path and
extension.
5 When the message Awaiting transmission appears on the host PC, select the
COMMUNICATIONS button on the MAIN screen of the CAM/ALOT system and
select the TX by RS232 option.

6. The message Hit right button to transmit or left button to
cancel will appear. Press the right button. The MAIN menu will reappear on
the host computer soon after transmission is complete.
4.5.4.3 CAM/ALOT To A Parallel interface printer
The following procedure requires a PC compatible parallel interface printer and cable:
CAUTION
It is possible to connect a printer with a parallel interface

to the RS232 interface connector. This could result in
damage to the printer. A printer with a parallel interface
must never be connected to the RS232 interface connector.
1. Plug the printer cable into the connector labeled Printer. Never connect a
printer that has a parallel interface to the RS232 interface connector.
2. Make sure the pattern you want to print is in current memory on the CAM/ALOT.
3. Select the COMMUNICATIONS button on the MAIN screen and select the
PRINTOUT option.
4.5.4.4 CAM/ALOT To A Serial Interface Printer
The following requires a PC compatible serial printer and a cable:
1. Set the printer for 9600 baud 7 bit RS232 data, with one stop bit, no parity and
XON/XOFF handshaking. These settings must be available for the printer to be
suitable.
2. Connect the printer to the RS232 connector using the 25 pin host computer
cable.
3. Select the COMMUNICATIONS button on the MAIN screen and select the TX
by RS232 option to print the file in current memory.
4.5.4.5 LOADING AND SAVING ASCII FILES ON THE CAM/ALOT
All files on disk are listed in the files box of the FILE OPERATIONS screen. The files
with the extension .CAM are listed first, then the files with the extension .TXT. The
.CAM files are in binary format and the .TXT files are in ASCII format.

To load a .CAM file select the file in the FILES display and click the left button. The
filename will appear in the current file window. Select LOAD FILE button.
To load an ASCII file, select the filename in the FILES display. Select the LOAD .TXT
button. To save a file as an ASCII file select SAVE .TXT.
To delete an ASCII file select the file in the FILES display select the DELETE .TXT
button.
4.5.5 ERROR HANDLING
4.5.5.1 Pattern Errors
A pattern with syntax errors (invalid characters or an unrecognized keyword) will not be
accepted. An error message will show the first five lines having such errors.
Parameter values or valve, speed/shot size, up height or down height fields that are
above or below the legal range will be set to the maximum (resp. minimum) legal
values.
If the CAM/ALOT receives an instruction or a CALL with coordinates that do not fit, it
will change the X or Y origins as necessary to bring the pattern onto the table. A
warning message will be displayed if this is done, or if the pattern is too wide or too tall
to be fixed so easily.
All sub patterns Called must be present, either in the ASCII file or already loaded in the
library. You will be asked to approve the substitution of library sub patterns for missing
program subs.
4.5.5.2 Input / Output (I/O) Errors
I/O errors will cancel transmission or reception.
Serious errors (such as if the host computer is not turned on, or if a device that does
not conform to RS232 standard is connected) may interfere with the trackball. If
nothing happens when you hit left button, check connection to the RS232 port before
you restart the CAM/ALOT.

4.6 GLOSSARY OF TERMS
AIR: Used only in conjunction with the positive displacement

pump (PDP), the output jack is located adjacent to the PDP
output. Constant air pressure is regulated through the valve
1 gauge and regulator.
ARC: A command for the system to dispense a section of a circle.
Used to connect two lines positioned at an angle to each
other.
CALL: A command for the system to access a subpattern menu.
The subpatterns are then called up to be duplicated or
repeated.
CARET: The indicator denoting where the system will default. The
caret is symbolized as >.
CE The acronym CE indicates that a product conforms to a set
of European Community safety requirements. CE stands for
“Conformité Européenne” ( French translation of “European
Conformity” ).
CIRCLE: A command for the system to dispense in a counter-
clockwise direction to form a circle. Uses two points along
the diameter for the calculation. The CIRCLE command is
always preceded by a move command.
CLEAN: A command used to move the needle through the optional
needle cleaner.
COPY: An editing command to the system to copy a block of
statements for insertion into another part of the pattern.
CURSOR: The small rectangular image moved about the screen with
the trackball.
CUT: An editing command, used in conjunction with the PASTE
command, to move a block of statements to another location
in the current pattern.

DATA SHEET: A page that contains information about the setup (operator,
circuit number, etc.). It is stored with the program.
DEFAULTS: Preset numbers chosen by the CAMALOT system during
programming.
DELETE: An editing command to the system to erase a line of
information from the pattern.
DN (DOWN HEIGHT): The height at which the needle dispenses the material.
DOTS: A command for the system to dispense a string of points
along a path. A submenu prompts the operator to select a
shotsize, to align the first and last points and to enter the
number of dots in between. The computer will space the
dots equally between the first and last points.
DWELL: Instructs the system to wait a specified length of time at the
end of dispensing a point to allow material to flow out of the
needle. The time is programmable and set in milliseconds.
EDIT: The programming mode where the axes are disabled so that
coordinate placement and height values may be
manipulated without axis movement.
END: An editing command statement signaling the CAMALOT end
of program. In the RUN mode, the system returns to the
home position after it sees the END statement.
EXECUTE: Instructs the system to act. Initiated by clicking the left
button of the trackball.
FILL: Instructs the system to fill an area with material by drawing a
series of lines.
HEIGHT: The distance from the Z-axis or needle tip to the dispensing
surface. Eight programmable choices are available,
numbered 1 through 8. Each number has a value set in
inches. The height parameter is used for both up height
(UP) and down height (DN)
LINE: Instructs the system to dispense along a programmed path.
A MOVE command, followed by a LINE command, instructs
the system to dispense a line of material between the two
commands.
LED Light emitting diode.

MOVE: Instructs the system to travel to a location. This is a
nondispensing mode command unless followed by a LINE or
CIRCLE command. This command is ignored for points or
dots.

NOTE
Value for ON DELAY should not exceed the length of the
dispensed line.
ON DELAY: Instructs the system to wait prior to the start of dispensing a

line or circle. The time is programmable and set in
milliseconds. During the delay, air pressure is applied to the
dispenser head. This is designed to allow time for higher
viscosity materials to come out of the needle. This
command is ignored for points or dots.
NOTE
Value for OFF ADVANCE should not exceed the length of the
line being dispensed.
OFF ADVANCE: Instructs the system to turn off the air pressure to the
dispensing line or circle prior to the end of the line. The
value is programmable and set in inches. This is designed
to eliminate excess material at the end of the line when
dispensing low viscosity materials. This command is
ignored for points or dots.
PARAMETERS: The set of values under which the system will operate in the
RUN mode.
PASTE: An editing command, used in conjunction with the CUT
command, to move a block of statements in the current
program.
PAUSE: Instructs the system to temporarily stop dispensing in the
RUN mode and prompts the operator to Select, Continue or
Abort.
PDP: Positive displacement pump. An optional dispensing
accessory used in SMD applications.
POINT: A dispensing command for the system to dispense a specific

amount (shotsize) of material.
REFPT: Reference points. A command used exclusively with
CAMALOT camera options. Allows patterns to be realigned
prior to dispensing.
SHOTSIZE OR
SPEED (S): If the corresponding command is a POINT, then S
designates shotsize. For a LINE or a CIRCLE, it designates
speed.

SELECT: Changes any highlighted upper-case instructions to lower-
case letters, effectively commenting them out. When the
pattern is run, these instructions will be ignored.
SHOTSIZE: The programmable dispensing size of a dot. Eight choices
(numbered 1 through 8) are available per program. Each
number has a time value from 5 to 4000 milliseconds.
SLEW SPEED: The fixed speed at which the dispensing head travels in a
nondispensing mode (point to point).
SPEED: The programmable rate at which the dispense head travels
for a LINE or CIRCLE command. Eight choices (number 1
through 8) are available per program. Each number has a
value set in inches per second, varying from 0.01 to 4.5
inches/second.
TRACE: During programming, the TRACE mode enables real time
movement of the X, Y, & Z-axes in relation to trackball
movement. This mode must be selected prior to selecting
RUN.
V1: Valve number 1.
V2: Valve number 2.
VACUUM: Vacuum is factory set and should not be changed.
WAIT: A programmed time that the machine will pause execution.

Section 5
INSTALLATION
5.3 MACHINE INSTALLATION PRELIMINARY REQUIREMENTS............................ 5-4

5.3.1 FLOOR SPACE REQUIREMENTS .............................................................. 5-4
5.3.2 AIR SUPPLY REQUIREMENTS .................................................................. 5-4
5.3.3 ELECTRICAL POWER REQUIREMENTS................................................... 5-4
5.3.3.1 LINE VOLTAGE TRANSIENTS ........................................................... 5-5
5.3.3.2 LIGHTNING PROTECTION ................................................................. 5-5
5.3.3.3 CONDUCTOR SIZE............................................................................. 5-5
5.3.3.4 MACHINE/SYSTEM GROUNDING...................................................... 5-5
5.3.3.5 TESTING THE SYSTEM EARTH REFERENCE ................................. 5-6
5.3.3.6 ADDITIONAL ELECTRICAL EQUIPMENT RECOMMENDATIONS .... 5-6
5.4 MACHINE INSTALLATION................................................................................... 5-7

5.4.1 UNLOCK / LOCK MACHINE SAFETY DOORS ........................................... 5-7
5.4.1.1 UNLOCK / LOCK SAFETY DOORS USING SYSTEM SOFTWARE
(AFTER SHIPMENT) ........................................................................... 5-7
5.4.1.2 UNLOCK SAFETY DOORS MANUALLY............................................. 5-8
5.4.2 MACHINE SETUP ........................................................................................ 5-9
CAMALOT 5000 Section 5 Installation 5-1

5-2 Volume 2: Installation and Maintenance
This section describes the general procedures for installing the CAMALOT Liquid
Dispensing System 5000.
CAMALOT system. This requires a continual effort on the part of the operator or
anyone else working on or near the CAMALOTsystem.
1. Before attempting to operate or service the CAMALOT system, all personnel

must read the instructions carefully. Failure to comply with the instructions
could result in personal injury or property damage.
2. Be sure that the CAMALOT system is operating properly. Always operate the
system with the safety doors closed.
and whenever electrical power and air are ON.
the dispense area. Press the red EMERGENCY MACHINE OFF (EMO) switch
to immediately shut off the machine.
11. Maintain the CAMALOT system in top working condition.

5.3 MACHINE INSTALLATION PRELIMINARY REQUIREMENTS
5.3.1 FLOOR SPACE REQUIREMENTS
The CAMALOT system should be placed on a level floor away from excessive heat and
moisture. If equipped with a vision system, it should be placed away from outside,
unregulated, ambient lighting. The system requires the following minimum amount of
space:
• System - 57.0 inches (1448 mm) x 47 inches (1194 mm) x 75.0 inches (1905
mm).
5.3.2 AIR SUPPLY REQUIREMENTS
CAUTION
Damage due to improper air supply is not covered by the

warranty.
3
The system requires 6 CFM (Cubic Foot per Minute) ( 0.17 M /min) of clean, dry, 5
2
micron filtered air at a minimum of 80 PSI (Pounds per Square Inch) ( 5.6 kg/cm ). The
air must be oil and water free. The material to be dispensed may be contaminated if
the air is not clean and completely dry.
5.3.3 ELECTRICAL POWER REQUIREMENTS
The electrical power requirements conform to the customer's specification of 230 VAC
(Volts Alternating Current) nominal, steady state voltage of 0.9 to 1.1 of nominal
voltage, 49.5 to 50.5 Hz (Hertz), single phase. There is a maximum demand of 2.0 kVA
(Kilovolt Amperes) when operating at full duty cycle.
• System Machines require a 207-253 VAC, 15 amp, 50 Hz, 3 wire grounded

outlet. (International)
• System Machines require a 108-132 VAC, 15 amp, 60 HZ, 3 wire grounded

outlet. (Domestic)

5.3.3.1 Line Voltage Transients
The electrical power distribution system supplied with this equipment has been
designed to operate on standard power lines and will attenuate electrical transients on
the power line within certain limits.
Electric transients, which are rapid deviation from the ideal sine wave greater than the
magnitude of the power line, must be eliminated or reduced.
Voltage Impulses are not to exceed 1.5 ms (milliseconds) in duration with a rise / fall
time between 500 ns (nanoseconds) and 500 µs (microseconds) and peak value not
more than 200 % of the rated rms (root mean square) supply voltage.
Voltage dips are not to exceed 20 % of the peak voltage of the supply for more than
one cycle. There shall be more than 1 s (second) between successive dips.
5.3.3.2 Lightning Protection
The power lines should be equipped with lightning protection.
5.3.3.3 Conductor Size
The electrical conductor size shall be 14 AWG (American Wire Gauge) minimum for all
single conductors. Ground shall conform to IEC (International Electrotechnical
Commission), 204-1, Third Edition 1992-09, Section 5.
5.3.3.4 Machine/System Grounding
System grounding is provided in the machine with a ground terminal. At the time of
installation, PE (Potential Earth) grounding must be done in accordance with IEC 204-1,
Third Edition, 1992-09, Section 8. This is to keep electrical noise and electrical
differential potentials under control in large systems.
All of these ground connections are in addition to (not in place of) the ground leads
carried through various signal cables and the ground conductors contained in the power
cables. The ground wire in the power cable must also be connected to the ground,
usually through the conduit of the electrical distribution system. This is a noncurrent
carrying ground, not a neutral. The power cable conduit must not be used as the only
ground connection. Whenever possible, the power panel of the system should be
grounded.

5.3.3.5 Testing The System Earth Reference
A convenient means should be provided to verify that the entire system is indeed
referenced to earth at one and only one point (the system earth reference point). It is
necessary that this point be well defined and labeled with the mark PE (Potential
Earth).. It should additionally have a means of disconnection (single stud or lug) where
by this reference can be lifted and the system tested to determine if there is any point
other than this point at which the system is referenced to earth.
Two tests can be performed which will verify the proper isolation of the system
reference point. These tests should only be performed with the assistance of an
electrician.
The following test must be performed to verify the proper isolation of the system
reference point labeled with the mark PE (Potential Earth). This test must be performed
by a qualified electrician.
1. Apply current to the system.
2. Measure the current in the system earth return wire using a device which can
measure current without disconnection of the wire (a clamp-on ammeter). The
maximum current in the system earth return shall not exceed 10 mA
(miliamperes). Current in excess of this amount indicates improper primary
power/reference distribution, and should be investigated before operating the
system.
5.3.3.6 Additional Electrical Equipment Recommendations
The following additional equipment is recommended for preventive measures:
1. A static mat may be placed in front of the machine to prevent static problems. If
used, make sure that the mat is grounded as specified by the maufacturer’s
instructions. Both the mat and machine must be grounded at the same source.
A grounding lug (8, Figure 3-4) is located on the back rear panel of the machine.

FIGURE 5-1. REAR PANEL
3. A surge suppresser is recommended to prevent any damage to the computer

from electrical spikes.
5.4 MACHINE INSTALLATION
5.4.1 UNLOCK / LOCK MACHINE SAFETY DOORS
The CAMALOT 5000 machine is shipped with the machine safety doors locked. After
the machine has been positioned in the desired location and connected to the power
source, the safety doors need to be unlocked using system software.
The machine safety doors can be locked or unlocked using system software. If
necessary, the safety doors can also be locked or unlocked manually.
5.4.1.1 Unlock / Lock Safety Doors Using System Software (After Shipment)
1. unlock the machine safety doors for the first time (After Shipment) as follows:
a. Refer to paragraph titled, Machine Setup. Perform only the procedures

necessary to setup the machine so that the safety doors can be unlocked
using system software.

b. Apply power to system by switching main power switch (9, Figure 3-4) to ON
position
c. Press the MACHINE ON push button located on the main control panel. The
MAIN screen will appear on the computer monitor.
d. Select SAFETY DOORS LOCK / UNLOCK button on MAIN screen.
e. Both safety doors will become unlocked at the same time.
f. After opening both safety doors, press the MACHINE OFF push button
located on the main control panel to turn off the machine power. Do not
leave machine power on after opening doors.
g. Prior to removing shipping bracket from Z-axis, be sure that machine power
is off. Remove shipping bracket from Z-axis.
2. Lock the machine safety doors by closing door. Door will lock as soon as it is
closed.
5.4.1.2 Unlock Safety Doors Manually
If necessary, manually unlock the machine safety doors as follows:
NOTE
The safety doors will need to be unlocked individually.
1. unlock the right-hand (R/H) safety door as follows:
a. Insert the supplied Tamper-Resistant Torx Driver (P/N 18257, part of support
kit) through the small access hole in the lower support, just below the red
locking switch. Turn the screw counterclockwise and remove screw from the
switch.
b. While pulling slightly outward on safety door, insert the supplied 3/32 inch
(2.38 mm) Hex L-Key (P/N 18334, part of support kit) or equivalent into the
exposed hole until the door releases. Open the right-hand safety door.
c. Reinstall the screw through the small access hole in the lower support and
thread screw into the red locking switch. Turn screw clockwise until screw is
fully seated inside the locking switch. Hand-tighten only.
2. unlock the left-hand (L/H) safety door by repeating step 1.

5.4.2 MACHINE SETUP
1. Position the machine in desired location.
2. Remove and dispose of any transportation packing materials from the machine.
3. Remove cap screw that secures light tree mounting clamp to upper left-hand
corner on rear of machine.
4. Mount light tree to machine and secure with mounting clamp and cap screw.
5. Connect Molex connector of light tree.
6. Set height and level of machine as follows:
a. To check height, measure machine height from floor to top of conveyor fixed
rail. Height should be 37.00 + 1.00 inches (940 + 25.4 mm).
NOTE
The glass of a spirit level is crowned up. The edge of the level
with the glass must be placed against the under side of the
gantry mounting plate.
Machine must be leveled in the X and Y directions.
b. Place level against gantry mounting plate.
c. Secure each corner leveling foot to floor surface.
d. Make sure jam-nut against leveling screw shaft collar is backed off.
e. Using wrenching flats on bottom of foot shaft, adjust each corner until proper
height and level is obtained.
f. Tighten each shaft jam-nut against collar.
g. Check to ensure level has not changed. Readjust if necessary.

CAUTION
In geographical locations that are prone to seismic activity,

machine should be permanently fastened to floor. Damage
to machine could result.
7. If necessary, assemble permanent fastenings to floor using mounting holes

identified with the letter E in Figure 5-2.
FIGURE 5-2. MACHINE MOUNTING HOLES FOR PERMANENT FASTENING TO

FLOOR (LEFT SIDE)
8. Connect AC power cord to electrical source.
9. Connect air supply tube to air source.
10. Install applicable options. Option supplements are located at the end of Volume
2.
11. Connect monitor connector to VGA connector (15, Figure 3-4).

12. Connect monitor power connector to power receptacle (5).
13. Place computer monitor on top of machine.
14. Connect trackball to trackball connector (16).
15. Connect keyboard to keyboard connector (17).

FIGURE 5-3. FACILITIES LAYOUT DRAWING
CAMALOT 5000 Section 5: Installation 5-13
Section 6
MAINTENANCE
IMPORTANT NOTICE
The lubrication recommendations and procedures have
changed. Please refer to the new Lubrication Chart at the end
of this section for detailed information and procedures.
6.3 PREVENTIVE MAINTENANCE ............................................................................ 6-4
6.4 LUBRICATION...................................................................................................... 6-5

6.4.1 BALL SCREW .............................................................................................. 6-5
6.4.2 BEARINGS ................................................................................................... 6-5
6.4.3 OPTIONAL LOADER AND UNLOADER LEAD SCREWS ........................... 6-6
6.5 REPLACEMENT OF OPTIONAL CONVEYOR RAIL INSERTS........................... 6-6
6.6 REVERSING CONVEYOR FLOW DIRECTION ................................................... 6-7

6.6.1 REVERSING MOTOR DIRECTION ............................................................. 6-7
6.6.2 RELOCATION OF CONVEYOR HARDWARE............................................. 6-8
6.6.2.1 RELOCATION OF CONVEYOR LIFT TABLE...................................... 6-8
6.6.2.2 RELOCATION OF STOP PIN AND DISPENSE SENSOR .................. 6-9
6.7 REPLACEMENT OF CONVEYOR BELTS ......................................................... 6-13
6.8 CALIBRATION OF CONVEYOR OFFSET ......................................................... 6-15
CAMALOT 5000 Section 6: Maintenance 6-1

The CAMALOT 5000 system has been designed to be maintenance free. It requires
only periodic lubrication and cleaning. A grease gun and adapter are supplied to
maintain the X, Y, and Z-axis slide bearings. Lubricate and clean the slides once every
300 hours. Refer to the hour meter on the back of the machine for this information.
1. Before attempting to operate or service the CAMALOT system, all personnel

must read the instructions carefully. Failure to comply with the instructions
could result in personal injury or damage to the equipment.
2. Be sure that the CAMALOT system is operating properly. Always operate the
system with the safety doors closed.
and whenever electrical power and air are on.
the dispense area. Press the red EMERGENCY MACHINE OFF (EMO) palm
switch to immediately shut off the machine.
11. Maintain the CAMALOT system in top working condition.

6.3 PREVENTIVE MAINTENANCE
Clean X, Y, and Z-axis slide rails and conveyor splined shaft at least once per month as
follows:
WARNING
RUST PREVENTIVE
SHEATH PS8 (AEROSOL)
EXTREMELY FLAMMABLE. DO NOT USE NEAR OPEN

FLAMES, HOT SURFACES, OR OTHER SOURCES OF
IGNITION.
CONTENTS UNDER PRESSURE - DO NOT PUNCTURE,

INCINERATE, OR STORE WHERE TEMPERATURE MAY
EXCEED 120°°F (49°°C).
MAY BE HARMFUL OR FATAL IF SWALLOWED. IF

SWALLOWED, DO NOT INDUCE VOMITING. CALL A
PHYSICIAN IMMEDIATELY.
USE WITH ADEQUATE VENTILATION. AVOID

PROLONGED BREATHING OF VAPORS. INHALATION MAY
CAUSE THROAT IRRITATION, DIZZINESS AND NAUSEA.
GO TO FRESH AIR.
IF PROLONGED EXPOSURE IS EXPECTED, WEAR

PROTECTIVE GLOVES, RESPIRATOR, AND GOGGLES. IF
SPRAY GETS IN EYES, FLUSH THEM WITH WATER AND
SEEK MEDICAL ATTENTION.

CAUTION
Do not spray corrosion preventive compound directly onto

slide rails. compound may drip onto lead screw and
damage lead screw.
1. Spray lint-free wiper with Sheath PS8 corrosion preventive compound,

CAMALOT P/N 15440. Do not spray directly onto slide rail.
2. Wipe slide rails and conveyor splined shaft until clean.
6.4 LUBRICATION
WARNING
TURN POWER OFF BEFORE LUBRICATING.
6.4.1 BALL SCREW
The X, Y, and Z-axis balls screws are to be lubricated every 300 hours of operation,
using NSK No. 1 (MULTEMP LRL, No. 3) lubricant, CAMALOT P.N. 15954 (supplied).
Refer to the applicable Material Safety Data Sheet (MSDS) located at the end of the
SAFETY Section.
6.4.2 BEARINGS
The X, Y and Z-axis slides each contain cross-opposed bearings. These bearings
require periodic greasing with a lithium-based grease, CAMALOT P.N. 7074 (supplied).
Lubricate until the grease becomes visible. Always wipe off any excess grease.
1. X-axis: The X-axis grease fitting is located on the left side of the X-axis slide
bearing behind the Z-axis mounting plate. Push the head to the right until the X-
axis grease fitting is accessible.
2. Y-axis: There are four bearings on the Y-axis and each bearing has a grease
fitting. Two fittings are visible from the front of the machine and two are visible
from back of machine.
3. Z-axis: A grease fitting is located on top of Z-axis slide bearing.

6.4.3 OPTIONAL LOADER AND UNLOADER LEAD SCREWS
WARNING
MOVING PARTS
LOADER MAY MOVE UNEXPECTEDLY AT ANY TIME

THERE IS ELECTRICAL POWER AND AIR TO LOADER.
DISCONNECT ELECTRICAL POWER AND AIR BEFORE
ATTEMPTING TO PERFORM MAINTENANCE ON LOADER.
SERIOUS INJURY OR DEATH COULD RESULT.
1. Remove all electrical power and air to loader or unloader.
2. Using NSK No. 2 lubricant, CAMALOT P.N. 13197 (supplied), lubricate lead
screw every 300 hours of operation. Refer to applicable loader or unloader
instructions.
6.5 REPLACEMENT OF OPTIONAL CONVEYOR RAIL INSERTS
The following procedures are used to remove and install the optional replaceable
conveyor rail inserts. The inserts should be replaced whenever the black hard-coat of
the insert is worn through. Replace inserts as follows:
1. Remove cross-point flat head screws that secure insert to rail.
2. Remove insert.
CAUTION
Be sure that conveyor track belt is not pinched under

insert and that bevel of insert is at end of conveyor rail.
Damage to equipment could result.
3. Using screws removed from old insert, assemble new insert to rail so that bevel
of insert is at end of conveyor rail. Be sure that conveyor track belt is not
pinched by insert.

6.6 REVERSING CONVEYOR FLOW DIRECTION
The following procedures are used to change conveyor direction of travel from left-to-
right to right-to-left.
6.6.1 REVERSING MOTOR DIRECTION
The following procedure is used to reverse the direction of rotation of the conveyor track
motor.
1. Drive Z-axis head as far as possible to left.
2. Make pencil mark on front conveyor rail to indicate position of right-most needle
or camera cross hairs.
WARNING
USE EXTREME CAUTION WHEN PERFORMING

MAINTENANCE TO MACHINE. ONLY QUALIFIED
PERSONNEL SHOULD BE ALLOWED TO PERFORM
MAINTENANCE TO MACHINE. NEVER WORK ON A
MACHINE WHEN THERE IS ELECTRICAL POWER APPLIED
TO MACHINE. SERIOUS INJURY OR DEATH COULD
RESULT.
3. Turn off main power disconnect on rear electrical panel and secure using
approved company lockout/tagout procedures.
4. Remove connector of red wire from terminal on conveyor motor.
5. Remove connector of black wire from terminal on conveyor motor and connect
red wire to terminal in place of black wire.
6. Connect connector of black wire to terminal on conveyor where red wire had
originally been connected.

6.6.2 RELOCATION OF CONVEYOR HARDWARE
The change of conveyor direction requires that the lift table be relocated and that the
stop pin and dispense sensor be moved to the left end of the lift table. To relocate the
lift table, go to paragraph titled, Relocation Of Conveyor Lift Table. To move the stop
pin and sensor, go to paragraph titled, Relocation Of Stop Pin And Dispense Sensor.
The procedures assume that conveyor flow direction is to be changed from left-to-right
to right-to-left.
6.6.2.1 Relocation Of Conveyor Lift Table
The following procedure is used to align the lift plate with the board stop:
1. Loosen socket head cap screws (2 and 3, Figure 6-1) that secure lift plate to
conveyor rails and move lift plate assembly so that left edge of lift plate (1) is
aligned with pencil mark on front conveyor rail.
FIGURE 6-1. RELOCATION OF LIFT PLATE
2. Tighten cap screws to secure lift plate assembly

3. Assembly feed cover under lift plate assembly to cover exposed opening
created by moving the lift plate assembly as follows:
a. Remove two screws that secure horizontal cover on exposed end.
b. Locate feed cover and secure with screws that were removed.
6.6.2.2 Relocation Of Stop Pin And Dispense Sensor

The following procedure is used to move the stop pin, board stop, and dispense
sensor from the right end of the lift table to the left end of the lift table.
1. Remove tray cover from wire tray inside front of machine.
NOTE
Figure 6-2 depicts a setup for a right-to-left conveyor flow

direction.
2. Remove output buffer stop pin (7, Figure 6-2) and sensor (8) as follows:
a. Loosen two socket head cap screws that secure output stop pin (9) to front
conveyor rail.
b. Slide stop pin, screws, and nut plate out of rail as an assembly and set
aside. Do not disconnect pneumatic tubes from stop. Tubes should be long
enough to reach opposite end of conveyor.
c. Loosen two socket head cap screws that secure output sensor to front
conveyor rail.
d. Slide sensor, screws, and nut plate out of rail as an assembly and set aside.
Do not disconnect sensor wires from sensor. Wires should be long enough
to reach opposite end of conveyor.
3. Remove input buffer stop pin (5) and sensor (4) as follows:
a. Remove two socket head cap screws that secure input sensor to front
conveyor rail.
b. Remove sensor and bracket assembly and slide nut plate out of rail and set
aside. Do not disconnect sensor wires from sensor. Wires should be long

c. Loosen two socket head cap screws that secure input stop pin to front
conveyor rail.
d. Remove stop pin and bracket assembly and slide nut plate out of rail and set
aside. Do not disconnect pneumatic tubes from stop. Tubes should be long
4. Remove two socket head cap screws that secure dispense stop pin (7) to front
conveyor rail.
5. Remove nut plate by sliding out right end of conveyor and install nut plate into
groove in opposite end of rail by sliding in from left end of rail.
6. Remove two M6 X 10 socket head cap screws that secure board stop to stop
pin and remove board stop
7. Using M6 X 10 socket head cap screws, assemble board stop to stop pin
cylinder so that stop extends to the right.
8. Assemble stop pin cylinder assembly (7) to front conveyor rail so that right end
of board stop is aligned with pencil mark on front rail and hand-tighten cap
screws.
9. Remove two socket head cap screws that secure dispense sensor (6) to front
rail.
10. Move sensor so that center of sensor is approximately 5.75 in. (146mm) from
center of board stop. See Figure 6-2.
11. Assemble output stop pin (9) and sensor (8) as follows:
a. Remove screws that secure output sensor to nut plate.
NOTE
Sensor bracket will hit idler wheels if not assembled to right of

idler wheels.
b. Assemble nut plate into bottom groove in left end of conveyor rail. Slide
nutplate to right until it is inside conveyor belt idler wheels.
c. Using two socket head cap screws and nutplate, secure output sensor to
front conveyor rail.
d. Remove screws that secure nut plates to output stop pin.

NOTE
Stop pin will hit idler wheels if not assembled to right of idler
wheels.
e. Assemble nut plates into bottom groove in left end of conveyor rail. Slide
nutplate to right until they are to right of conveyor belt idler wheels.
f. Using two socket head cap screws and nutplate, secure output stop pin to
12. Assemble input stop pin (5) and sensor (4) as follows:
NOTE
Stop pin will hit frame of machine if it is not assembled to left of

machine wall
a. Assemble nut plate into bottom groove in right end of conveyor rail. Slide
nutplate to left until it is inside right wall of machine.
b. Using two socket head cap screws and nutplate, secure input stop pin to
c. Using two socket head cap screws assemble nutplate to input buffer sensor.
d. Assemble input buffer sensor to right end of front conveyor rail.
e. Using two socket head cap screws and nutplate, secure input sensor to front
conveyor rail.
f. Assemble wire tray cover to wire tray.
13. If machine is equipped with a vision option, go to step 14. If machine does not
have vision, align stop pin and lift table as follows:
a. If not already done, install dispensing needle onto head. If a toggle head is
used, install dispensing needle on right-hand toggle head.
b. Move head to left until head contacts left stop.
c. Move stop pin assembly until right edge of board stop is aligned with
dispense needle.

d. Tighten cap screws that secure stop pin assy. to front rail.
e. Go to step 21.
14. Turn on machine.
15. Move head to left until head contacts left stop.
16. Adjust head until cross hairs of camera are over board stop.
17. Move stop pin assembly until right edge of board stop is aligned with cross
hairs.
18. Tighten cap screws that secure stop pin assembly to front rail.
19. If necessary, adjust lift table so that left edge of lift plate is aligned with right
edge of board stop.
20. Turn off machine.
FIGURE 6-2. RELOCATION OF STOP PIN AND DISPENSE SENSOR
21. If necessary, adjust dispense sensor so that center of sensor is approximately

5.75 in. (146mm) from center of stop pin. See Figure 6-2.
22. Calibrate conveyor offset as specified in paragraph titled, Calibration of

Conveyor Offset.
23. Adjust input and output stops and sensors as specified in Volume 1, Section 3
OPERATION.

6.7 REPLACEMENT OF CONVEYOR BELTS
The following procedure is used to replace the conveyor rail belts. Both belts must be
replaced at the same time.
1. Unlock the machine safety doors.
2. After opening both safety doors, press the MACHINE OFF push button located
on the main control panel to turn off the machine power. Do not leave machine
power on after opening doors.
3. If not already done, close conveyor rails so they are about 3.0 inches apart.
4. Cut and remove existing belts.
5. Loosen four socket head cap screws (3, Figure 6-3).
6. Move idler wheels (1) as far as possible toward outside of hangers.
7. While using a wrench on wrench flats to prevent spline shaft from turning,
loosen transtorque of spline shaft until shaft can be pulled from drive pulley on
front rail hanger.

FIGURE 6-3. CONVEYOR BELT REPLACEMENT
CAUTION
Be sure that splice of belt is away from direction of

conveyor flow. Otherwise, splice may catch on board and
tear the belt.
8. Route new belt (2) around drive wheel on splined shaft and pulley wheels on
each end of front rail so that black side of belt is against rail and so that splice is
away from conveyor flow direction. See detail view in Figure 6-3
9. Route belt around drive wheel on splined shaft.
10. Route belt to inside of idler wheels (1) and around pulley wheels on each end of
front rail.

11. Align left outer edge of left-hand wheel with left edge of hanger and tighten cap
screw (3).
12. Align right outer edge of right-hand wheel with right edge of hanger and tighten
cap screw (3).
CAUTION
Be sure that splice of belt is away from direction of

conveyor flow. Otherwise, splice may catch on board and
tear the belt.
13. Route new belt around drive wheel on splined shaft and pulley wheels on each
end of rear rail so that black side of belt is against rail and so that splice is away
from conveyor flow direction. See detail view in Figure 6-3.
14. Route belt to inside of idler wheels.
15. Align left outer edge of left-hand wheel with left edge of hanger and tighten cap
screw (3).
16. Align right outer edge of right-hand wheel with right edge of hanger and tighten
cap screw (3).
17. Slide spline shaft into drive pulley and into front hanger.
18. While using a wrench on wrench flats to prevent spline shaft from turning,
torque transtorque nut of spline shaft to 150 lb in (17.0 NM).
6.8 CALIBRATION OF CONVEYOR OFFSET
The following procedure is used to calibrate the conveyor offset. The conveyor offset
allows a pattern that was programmed on one CAMALOT in-line system to be used on
another CAMALOT in-line system without having to program an offset for the pattern. A
pattern may only be moved to a system with the conveyor flow in the same direction. A
pattern that was created on a system with a left-to-right conveyor flow cannot be used
on a system with a right-to-left flow unless X Y offsets are programmed.
The conveyor offset is initially calibrated at the Speedline Technologies, Inc. factory.
Any time that the stop pin at the dispense station is moved, the conveyor offset must be
calibrated. Contact a Field Service Representative at Speedline Technologies, Inc. for
instructions on how to enable the conveyor button in the SET OFFSETS screen.

The following procedures assume that the system has the optional auto correction
vision system and that the conveyor button has been enabled in the SET OFFSETS
screen.
1. Raise dispense stop pin.
2. Place conveyor offset calibration board on conveyor rails so that the text on the
board can be read from the front rail. See Figure 6-5.
3. Position board so that leading edge is against board stop.
4. Position board clamps and raise lift table to secure board.
6. Select CAMERA-TO-NEEDLE OFFSETS button. SET OFFSETS screen will

appear. See Figure 6-4.
7. Select Conveyor button.
8. Click in the X Y coordinates box .
9. Using trackball, move head until cross hairs of camera are aligned with target on
conveyor calibration board P.N. 23290. See Figure 6-5.
10. Select CALIBRATE button.
FIGURE 6-4. CALIBRATING CONVEYOR OFFSET
11. Click ACCEPT button. Conveyor offset is now calculated and the Conveyor
button on the SET OFFSETS screen will disappear.

12. Contact a Field Service representative of Speedline Technologies, Inc. for
additional information necessary to change system files.
FIGURE 6-5. CONVEYOR OFFSET CALIBRATION BOARD

Lubrication Components and Recommendations
Notes Legend
r tant !
Impo
System Notes Component Fitting/Nozzle Strokes * The following notations apply as indicated in
the NOTES column of the chart at left.
606 X-Axis, Y-Axis, Z-Axis N 1/3
A
A Periodically apply a thin coating of Du-Lite
1414 X-Axis
Y-Axis (Left Hand) 2 Slides
N
H + 38683 Nozzle Extension
1/3
1/2
RG-55 Rust Preventive to the slide rails
with the oil wipe provided in the support kit. Revised
Machine
A-B-C
Y-Axis (Right Hand) 2 Slides H + 38683 Nozzle Extension 1/2
Z-Axis H 1/2 B To access standard system fittings, remove
1818
A-D
X-Axis
Y-Axis
H
N
2-1/2
1-1/3
the side cover.
Lubrication
Procedures
Z-Axis N 1/3 C To access “CE” system fittings, remove rear
3000 X-Axis H 1-2/3 cover and access port covers on sides.
Y-Axis N 1-1/3 ☛ Camalot systems utilize THK bearings
D For “CE” model, rear cover must be
for various motion components of the X,Y
A Z-Axis N 1/2
removed to access grease fittings.
and Z axes.
Measurement Assy.134 N 1/3
Measurement Chuck 153 N 1/3
X-Axis H 1-2/3 E Rear cover must be removed to access ☛ The procedures and lubricants described
grease fittings.
3600
Y-Axis N 1-1/3 in Section 6 of the Installation and Main-
tenance manual (Volume 2) have been re-
A-E Z-Axis N + 13731 Lube Nozzle 1/2
F Periodically apply a thin coating of THK “AFE”
vised.
Rail Installation Assy N 1/2
Slide Auto Actuator N 1/2 Vacuum Grease to slides. DO NOT use
Du-Lite RG-55 Rust Preventive Please follow the new recommendations and
procedures described herein.
3700 X-Axis H 1-2/3
A-E-H Y-Axis N 1-1/3
G Use only “AFE” Vacuum Grease
Z-Axis N 1/2
(Speedline P/N 38661). ☛ Consult the Components and Recom-
3800 X-Axis H 1-2/3 mendations chart inside for recommended
H Z-Axis must be in the down position to lubrication points.
A-E-H Y-Axis N 1-1/3
access grease fittings.

Z-Axis N + 13731 Lube Nozzle 1/2
3900 X-Axis H 1-2/3 ☛ Illustrations and lubrication procedures

F-G Y-Axis N 1-1/3
Approved Lubricants are printed on the back of this foldout.
Conveyor Assembly N 1/2
! Slide Bearings - THK type “AFB”
5000, 5700 X-Axis H 1-1/2
NOTE: Failure to adhere to the cor-
A Bearing Grease or
rect procedures and service intervals
Y-Axis N 1-1/3
Z-Axis N 1/2
JIS Type 2 Lithium
X-Axis N 1.0 grease equivalent. could result in premature bearing fail-
ure and will void the machine warranty.
Gemini
A Y-Axis H 3.0
Part # 38660
Z-Axis N 1/2
! Slide Rails - Du-Lite RG-55
* Stroke Definitions Rust Preventive
One (1) Stroke = 3-3/8" movement of lever
One third (1/3) Stroke = 1-1/8" movement of the lever
Part # 38684
One half (1/2) stroke = 1-11/16" movement of the lever ! Slide Rails (3900) - THK type “AFE”
Vacuum Grease Document # 0LUB-03-00A
Part # 38661
General Lubrication Instructions Adapters Supplied In Support Kit
! Grease all system components at 6 month
intervals using the appropriate adapter/
nozzle as indicated in the Components and
Recommendations chart. Exclusive Nozzle
MG Type 70 Grease Gun P/N 38659
! Use the grease gun, cartridge and nozzles
provided in the System Support Kit.
! THK “AFB” type grease or any JIS Type 2
lubricant is recommended. Lube Nozzle P/N 13731
! Periodocally apply a thin coating of RG-55*
Rust Preventive to the slide rails with the oil
wipe provided in the kit
Instructions For Grease Gun Use Nozzle Ext. Assy. P/N 38683
! Make sure adapter is full of grease before
starting the greasing procedure. Grease
should appear at the tip of the adapter.
! Extend the grease gun handle fully - then
depress until free-travel is eliminated. Type H Nozzle
! One full stroke is equal to 3-3/8” movement
of the lever.
! One third (1/3) stroke is equal to 1-1/8” Type P Fitting
movement.
! One half (1/2) stroke is equal to 1-11/16”
movement.
Type N Fitting
* Use THK “AFE” type Vacuum Grease on
3900 models
Type L Fitting
90o Street Elbow P/N 38948

Section 7
TROUBLESHOOTING
7.3 CHECKING THE SYSTEM ................................................................................... 7-4

7.3.1 CHECK THE PULSE MOTORS .................................................................... 7-4
7.3.2 CHECKING X-, Y- AND Z-AXIS ENCODERS .............................................. 7-5
7.3.3 CHECKING THE HOME SWITCHES........................................................... 7-5
7.4 TROUBLESHOOTING.......................................................................................... 7-5

7.4.1 TROUBLESHOOTING MACHINE START UP AND OPERATION .............. 7-5
7.4.1.1 COMPUTER DOES NOT BOOT UP WHEN MACHINE ON BUTTON IS
PUSHED.............................................................................................. 7-6
7.4.1.2 HEADS DO NOT GO TO HOME POSITIONS WHEN TRACE OR
CAMERA ARE SELECTED ................................................................. 7-9
7.4.1.3 X-, Y-, OR Z-AXIS MOTOR DOES NOT MOVE................................. 7-12
7.4.1.4 SYSTEM WON'T DISPENSE - LIFT TABLE IS UP AND HEAD IS IN
PARK ................................................................................................. 7-14
7.4.1.5 LIFT TABLE NOT LIFTING ................................................................ 7-16
7.4.1.6 LIFT TABLE DOES NOT LOWER AFTER DISPENSING ................. 7-17
7.4.1.7 STOP PIN NOT FUNCTIONING ........................................................ 7-18
CAMALOT 5000 Section 7: Troubleshooting 7-1

7.4.2 ELECTRICAL PANEL ASSEMBLY .............................................................7-18
7.4.2.1 ELECTRICAL FUSE BLOCK ..............................................................7-19
7.4.2.2 SAFETY DOORS DECODER CARD (DECODER).............................7-20
7.4.2.3 TURRET ROTARY PUMP CARD (TURRET CARD)..........................7-21
7.4.2.4 CONVEYOR CONTROL AND SYSTEM CONTROL BOARDS ..........7-21
7.4.2.5 SYSTEM TRANSFORMERS (T1 AND T2).........................................7-21
7.4.2.6 110 VOLT A/C OUTLETS...................................................................7-21
7.4.2.7 OPTIONAL NEEDLE CALIBRATOR AMPLIFIER UNIT .....................7-21
7.4.2.8 EMERGENCY MACHINE OFF (EMO) CIRCUIT SAFETY RELAY ....7-21
7.4.2.9 PROGRAMMABLE LOGIC CONTROLLER (PLC) .............................7-21
7.4.2.10 SOLID-STATE RELAY (SSR) FOR AN OPTIONAL HEATER UNIT 7-22
7.4.2.11 MAIN CONTACTOR (CR1)...............................................................7-22
7.4.2.12 ELECTRICAL CONNECTORS (J29, J30, AND J31) ........................7-22
7.4.2.13 ELECTRO-MAGNETIC INTERFERENCE (EMI) FILTER.................7-22
7.4.2.14 BRIDGE RECTIFIER ........................................................................7-22
7.4.2.15 AIR PRESSURE SWITCH (SP1)......................................................7-22
7.4.3 ERROR CODES .........................................................................................7-22
7.4.3.1 ERROR CODE 230.............................................................................7-22
7.4.3.2 ERROR CODE 231.............................................................................7-22
7.4.3.3 ERROR CODE 232.............................................................................7-22

This section describes system checking and troubleshooting procedures.
1. Before attempting to operate or service the CAMALOT 5000 system, all

2. Be sure that the CAMALOT 5000 system is operating properly. Always operate
and whenever electrical power and air are on.
the dispense area. Press the red EMERGENCY MACHINE OFF(EMO) palm
switch to immediately shut off the machine.
11. Maintain the CAMALOT 5000 system in top working condition.

7.3 CHECKING THE SYSTEM
Several checks can be performed on the CAMALOT system from the DIAGNOSTICS
screen.
The following procedures assume that the DIAGNOSTICS screen is active on the
computer monitor.
7.3.1 CHECK THE PULSE MOTORS

1. Select motor to be tested in PULSE MOTORS window.
CAUTION
Make sure there are no obstructions in the path of the

needle. The machine moves rapidly when accessing this
mode.
2. Select the negative (-) direction to move the dispensing head away from HOME
position on the X-axis.
NOTE
Each click equals one full revolution of the motor.
3. Select the positive (+) direction to move it toward home on the X-axis.
CAUTION
DO NOT drive the motors beyond the home limit in the

positive (+) direction. The mechanical stop will go beyond
the home switch and bang against the home limit!
4. Repeat Steps 2 and 3 for the Y- and Z-axes.

7.3.2 CHECKING X-, Y- AND Z-AXIS ENCODERS
To check the X-, Y-, and Z-axis encoders, move the head assembly on the X-, Y-, or Z-
axis by hand. The encoder read out numbers should increase or decrease evenly.
Check all three axes. If they do not, consult Camelot Systems.
7.3.3 CHECKING THE HOME SWITCHES
To check the home switches, move the head to the home position for each axis. Make
sure the status displayed is on until the head reaches them. If not, then consult
Speedline Technologies, Inc.
Click the right button to exit the command. The head will move to the home position on
all three axes.
7.4 TROUBLESHOOTING
With proper maintenance, your CAMALOT system should be virtually trouble free. If
you do have a problem, consult the following tables for possible causes and solutions.
If applicable, refer to Safety Section, paragraph titled, Machine Safety Interlocks for
additional information when performing Troubleshooting procedures.
Troubleshooting tasks are identified by catagory type for safety reasons within the
tables as follows:
• Type 1- Machine is fully de-energized.

• Type 2- Machine is energized but live circuits are covered or insulated to prevent
accidental shock.
• Type 3- Machine is energized and live circuits of less than 30 Vrms, 240 VA, and
20 joules are exposed to accidental contact.
• Type 4- Machine is energized and live circuits of greater than 30 Vrms, 240 VA,
or 20 joules is exposed to accidental contact; or radio frequency (rf) is present.
• Type 5- Machine is energized and adjustments require physical entry into the
machine, or machine configuration will not allow the use of clamp-on probes.
If problems persist, call your local distributor or Speedline Technologies, Inc.
7.4.1 TROUBLESHOOTING MACHINE START UP AND OPERATION
The following procedures assume that the person performing the troubleshooting is
qualified. Therefore, the troubleshooting tables do not include ringing out wires for
open or short circuits and checking of light bulbs and mechanical switches. Refer to
Figure 7-1, Figure 7-2, and machine electrical schematics for reference.

7.4.1.1 Computer Does Not Boot Up When Machine On Button Is Pushed
WARNING

1. Before proceeding with the following troubleshooting steps, inspect all drive
motors for loose or broken drive belts.
2. Turn off main power switch and remove rear access panel. Turn on main power
switch and using extreme caution, perform troubleshooting as specified in Table
7-1. The troubleshooting task Types listed under the Action column ( in
parenthesis ) are explained in the paragraph titled, Troubleshooting.
TABLE 7-1. COMPUTER DOES NOT BOOT UP WHEN MACHINE ON BUTTON IS

PUSHED
VISUAL INDICATION CHECK ACTION
Machine ON push button 1. Computer monitor for If no green light, connect

is illuminated. power light. monitor to power source.
If still no green light,
continue.
Open floppy disk door on

front panel of machine and
look at lower-right corner
of PC for green power
light. If no green light,
continue.

PUSHED (CONT)
2. Turn off main power (Type 1) -Replace fuse.

switch. Using a suitable
meter, read voltage across
fuse F7. Reading should
be less than 1 ohm.
3. Turn off main power (Type 1) -Replace EMI

switch. Using a suitable filter.
meter, check continuity
from wire 211 to 212 and
from wire 103 to 213.
Readings should be less
than 1 ohm.
4. Turn off main power (Type 1) -Call Speedline

switch. Check that PC is Technologies, Inc. Field
plugged into EMI filter and Service.
that PC Power switch is
ON.
Machine ON push button 1. Machine is plugged in Continue.

is not illuminated. and power source is turned
ON.
2. Machine has air (Type 1) -Turn off main

pressure. power switch. Replace
machine ON push button
light and continue for light
ON indication above.
3. Machine has air (Type 1) -Turn off main

pressure while machine power switch. Replace
ON button is held down. Main Contactor CR1.

PUSHED (CONT)

4. Machine does not have Pull out dispenser, loader,

air pressure. and unloader E-stops.
Continue.
5. Turn off main power (Type 1) -Reset circuit

switch. Check 15A main breaker.
circuit breaker. See Figure
7-2. Continue
6. Turn off main power (Type 1) -If fuse is good,

switch. Using a suitable replace main circuit
meter, flip open fuse F1 breaker. If fuse F1 is
fuseholder and check blown, replace fuse and go
continuity across fuse. to step 8.
than 1 ohm. Continue.
7. Turn off main power (Type 1) -If fuse is blown,

switch. Using a suitable replace fuse. If fuse is
meter, flip open fuse F2 good, continue.
fuseholder and check
continuity across fuse.
than 1 ohm.
8. Turn off main power (Type 1) -If continuity,

disconnect switch. Check replace bridge rectifier. If
continuity between open, replace T1
terminals 106 and 107. transformer.

7.4.1.2 Heads Do Not Go To Home Positions When Trace or Camera Are Selected
WARNING

TABLE 7-2. HEADS DO NOT GO TO HOME POSITIONS WHEN TRACE OR

CAMERA ARE SELECTED
Light tree. 1. Check light tree for red If amber light is on, close
flashing light. safety doors. Green light
should flash
Select HOME button on

MAIN screen. If heads go
to home, keep safety
doors completely closed.
Continue.

CAMERA ARE SELECTED (CONT)
Open safety doors and try

to move gantry by hand. If
gantry moves, move all
axes out of home
switches.
Continue.
2. System board LEDs. (Type 3) -If no LEDs are

LED labeled ABT should illuminated, continue.
be illuminated. Otherwise, go to step 7.
3. Turn off main power (Type 1) -If fuse F6 is

switch. Check fuse F6. good, continue.
(Type 1) -Turn off main

power switch. Remove
jumper from W1.
Restart machine. Click on

TRACE on MAIN screen.
Continue.
4. Turn off main power (Type 1) -If either is open,

switch. Check continuity replace transformer T2.
between wires 203 and
103 and between wires
204 and 205.

5. Turn on main power Continue.

switch and attempt to
move axes by hand. If
axis does not move, motor
has power. If Z-axis motor
moves, Z-axis does not
have power.
6. Turn off main power (Type 1) -Remove

switch. connectors from Z-axis
motor. Make note of
connectors so they can be
connected to the same
locations.
Continue.
7. Connect ohmmeter (Type 1) - If each has

from armature red wire to continuity, replace system
ZM- on system board; then board.
armature black wire to
ZM+ on system board. Continue.
8. Check for loose or (Type 1) -Continue.

broken wires.
(Type 1) -Loosen red anti

backlash nut on Z-axis
lead screw 1/8 turn.
Connect wires to Z-axis
motor.

Restart machine. Select

HOME button. If Z-axis
does not go home, replace
Z-axis drive motor. If
necessary, tighten anti
backlash nut until knurled
barrel just contacts the o-
ring.
7.4.1.3 X-, Y-, or Z-Axis Motor Does Not Move
WARNING

The following procedure is the same for the X-, Y-, or Z-axis motors. Any problem that
causes a stoppage of X-, Y-, and Z-axis during a run is usually related to the Z-axis
motor or home switch. If all three axes are affected, troubleshoot for a problem with the
Z-axis motor first.

TABLE 7-3. X-, Y-, OR Z-AXIS MOTOR DOES NOT MOVE
X-axis does not move. 1. Check light tree for red If amber light is on, close
flashing light. safety doors. Green light
should flash.
Continue.
Go to MAIN screen and

select TRACE. Select
HOME button to send
head to HOME positions.
If head does not go to
home in X-axis, continue.
2. Turn off main power (Type 1) -Remove

switch. connectors from motor.
Make note of connectors
so they can be connected
to the same locations.
Continue.
3. Turn off main power (Type 1) -If continuity is

switch. Connect OK, replace system board.
ohmmeter from 321 to
Continue.
XM+, 322 to XM-, 323 to
YM+, 324 to YM-, 325 to
ZM+, and 326 to ZM- on
system board.
4. Turn off main power (Type 1) -Continue.

switch. Check for loose or
broken wires.

TABLE 7-3. X-, Y-, OR Z-AXIS MOTOR DOES NOT MOVE (Cont)

power switch. Loosen anti
backlash nut on Z-axis
lead screw 1/8 turn.
Connect wires to motor.
Restart machine. Click

HOME button. If axis does
not go home, replace drive
motor. If necessary,
tighten anti backlash nut.
7.4.1.4 System Won't Dispense - Lift Table Is Up And Head Is In Park
WARNING

Turn off main power switch and remove rear access panel. Turn on main power switch
and using extreme caution, perform troubleshooting as specified in Table 7-4. The
troubleshooting task Types listed under the Action column ( in parenthesis ) are
explained in the paragraph titled, Troubleshooting.

TABLE 7-4. SYSTEM WON'T DISPENSE
Lift table up, head in park 1. Optional Service optional

position. Light tree blue loader/unloader requires loader/unloader.
light flashing. servicing.
2. Fixture out of position Reposition fixture.

on optional vacuum
sensor.
Turn off main power

switch. Remove rear
access panel. Turn on
main power switch.
3. With fixture in position (Type 3) -LED is not

and vacuum on, check illuminated, remove rubber
conveyor board for IN4 boot from optional vacuum
LED illuminated. sensor and adjust sensor
until LED is illuminated.
Amber light flashing. 1. Safety doors are open. Close safety doors.

7.4.1.5 Lift Table Not Lifting
WARNING

TABLE 7-5. LIFT TABLE NOT LIFTING
No movement of lift table. 1. Air pressure. Adjust air pressure.
Continue.
2. Board in-position sensor LED is not illuminated,

replace sensor.
Continue.
Adjust flow control valves

on air cylinder.
Continue.

TABLE 7-5. LIFT TABLE NOT LIFTING (CONT)

power switch. Replace
conveyor board.
7.4.1.6 Lift Table Does Not Lower After Dispensing
WARNING

TABLE 7-6. LIFT TABLE DOES NOT LOWER AFTER DISPENSING
1. Board busy signal from (Type 1) -Turn off main

down stream sensor. power switch. Replace
downstream sensor.
2. Check conveyor board (Type 1) -Turn off main

for inputs. power switch. Replace
conveyor board.

7.4.1.7 Stop Pin Not Functioning
WARNING

TABLE 7-7. STOP PIN NOT FUNCTIONING
1. Check air pressure. Adjust air pressure.
Continue
2. Downstream sensor (Type 1) -Turn off main

busy signal. power switch. Replace
sensor.
7.4.2 ELECTRICAL PANEL ASSEMBLY
The Electrical Panel, located inside the lower rear of machine behind the rear access
panel, provides a central location for troubleshooting and maintenance for the following
items:
• Safety doors decoder and card for optional turret rotary pump

• Conveyor control board and system control board
• System transformers (T1 and T2) and 110 volt A/C outlets
• EMO circuit safety relay, program logic controller (PLC), optional needle calibrator
amplifier unit, and solid-state relays for optional heater circuits
• Main contactor (CR1), main circuit breaker, and fuse blocks
• Electrical connectors (J29, J30, and J31), electro-magnetic interference (EMI) filter,
bridge rectifier, and air pressure switch
7.4.2.1 Electrical Fuse Block
The fuse block, located on the DIN rail, incorporates system fuses used to protect the
components listed in Table 7-8. If a fault occurs the fuse is designed to blow (create an
open) before any system or component suffers any damage. Refer to Table 7-8 and
troubleshoot the component or system where a fault has occurred.
CAUTION
When replacing fuses on the main fuse block the original

type, voltage, and current size listed in Table 7-8 must be
used or damage to system components will occur.
When a fuse is replaced, the original type, voltage and current size must be used or
damage to system components will occur. Normally the information is marked on the
outside barrel ends of the fuse.
TABLE 7-8. MAIN ELECTRICAL FUSE BLOCK
FUSE NUMBER FUSE SIZE COMPONENT

(LOCATION)
F1 3.15 Ampere System transformer (T1)
F2 5 Ampere Main machine ON/OFF

circuit

TABLE 7-8. MAIN ELECTRICAL FUSE BLOCK (CONT)
FUSE NUMBER FUSE SIZE COMPONENT

(LOCATION)
F3 4 Ampere Conveyor
F4 4 Ampere Loader
(Optional)
F5 4 Ampere Unloader
(Optional)
F6 4 Ampere System transformer (T2)
F7 3 Ampere Electro-magnetic
interference (EMI) filter and
Cognex vision system
F8 4 Ampere Programmable logic

controller (PLC)
F9 1.6 Ampere Conveyor motor
F16 1.6 Ampere System fan
F17 3 Ampere Interior light
7.4.2.2 Safety Doors Decoder Card (Decoder)
The safety decoder card, located at the extreme right side, is used by the CAMALOT
system to monitor the status of the safety door locks and to lock or unlock the doors.
The inputs and outputs on the card and their functions are as follows:
• KEY - This input is unused at this time.
• LOCKED - This input is used to verify that the safety doors are closed and
locked.
• CLOSED - This input is used to verify that the safety doors are closed.

• SPARE - This output is used to turn on the amber light and is turned on when a
RED screen is displayed by the CAMALOT program.
• HORN - This output is used by the PLC to turn on the audible alarm.
• BRAKE - This output turns on the Z-axis brake when the CAMALOT program
disables the Z-axis motor.
• LOCK - This output unlocks the safety doors.
7.4.2.3 Turret Rotary Pump Card (Turret Card)
The turret rotary pump card, located at the extreme right side, selects one of the four
solenoids and clutches of the optional turret rotary pump.
7.4.2.4 Conveyor Control and System Control Boards
The conveyor control and system control boards, located on the top of the main control
panel receives and supplies logic to conveyor and machine system controls. The X, Y,
and Z-axis servo amplifiers are mounted on the system control boards.
7.4.2.5 System Transformers (T1 and T2)
The two system transformers (T1 and T2), are located to the left of the top and bottom
DIN rail. The top transformer (T1) supplies power to the bridge rectifier and to the
conveyor control board. The bottom transformer (T2) supplies power to the system
control board.
7.4.2.6 110 Volt A/C Outlets
Two 110 volt A/C outlets are supplied and located just below the T2 transformer. One
outlet is a receptacle for the PC486 computer and optional vacuum pump. The second
outlet is a receptacle for the interior lights and safety light curtain (when installed).
7.4.2.7 Optional Needle Calibrator Amplifier Unit
The optional needle calibrator amplifier unit, located just above the DIN rail, supplies a
means of adjusting and calibrating the needle on the Z-axis.
7.4.2.8 Emergency Machine Off (EMO) Circuit Safety Relay
This relay, located just above the DIN rail, is used by the EMO circuit to prevent the
machine from being restarted after a loss of power, an EMO switch being pushed then
reset, or a ground fault indication in the EMO circuit. The relay must be reset by
pressing the reset button on the control panel before the machine can be started.
7.4.2.9 Programmable Logic Controller (PLC)
The programmable logic controller (PLC), located above the DIN rail, provides logic for
operating one or two track conveyor mode, light tree, and audible alarm.

7.4.2.10 Solid-State Relay (SSR) for an Optional Heater Unit
This relay, located above the DIN rail, controls a heater unit for an optional heated
pump or a heated lift table or vacuum chuck.
7.4.2.11 Main Contactor (CR1)
The main contactor, located on the bottom DIN rail is used to switch power to the
machine ON and OFF. The contactor is controlled by the machine ON/OFF buttons.
7.4.2.12 Electrical Connectors (J29, J30, and J31)
The electrical connectors (J29, J30, and J31), located to the extreme left side provides
the connections for the majority of the components used throughout the machine.
7.4.2.13 Electro-Magnetic Interference (EMI) Filter
The electro-magnetic interference (EMI) filter, located to the extreme left side provides
an inline A/C filter for the PC486 computer.
7.4.2.14 Bridge Rectifier
The bridge rectifier, located to the extreme left side converts A/C power to D/C power.
7.4.2.15 Air Pressure Switch (SP1)
The air pressure switch, located to the extreme left side monitors incoming air pressure
to the machine. If incoming air pressure drops below a preset value of 40 PSI (276
kPa), power to the machine is turned OFF.
7.4.3 ERROR CODES
The following error code descriptions may be used to determine problems while
programming patterns.
7.4.3.1 Error Code 230

Possible Cause: The pattern is past the maximum X-axis travel point.

Possible Cause: The pattern is past the maximum Y-axis travel point.

Possible Cause: The pattern is past the maximum Z-axis travel point.

C11
C10
C8
C6
C9
VR1 VR2 VR3 VR4 VR5 VR6
J1
C7
AC
AC
24V
XHAIR
BRAKE
PDP0
PDP1
ILLUM
GND
BR1
R18
R17
R16
R15
R14
R13
R11
R10
R12
R8
R6
R4
R3
R2
ILLUM
R7
XHAIR
BRAKE
R9
R5
R1
XM+
PDP0 PDP1
XM-
YM+
YM-
C1
C2
C3
C4
C5
J2
ZM+
ZM-
5V
ZB+
P/N 12428B REV -

SYSTEMS
CAMELOT
ZB-
ZA+
ZA-
YB+
YB-
YA+
J3
YA-
XB+
Z
X
XB-
C14
XA+
XB- C15
R24
GND C16
FLS
C13
RLS
OHM
C12
KSW
R25
CWS
J4
A1
A2
A3
12V
ZHM C30
YHM C29
XHM C28
ABT C27
IN8 C26
J8
IN7 C25
R19
IN6 C24 R20
C31
IN5 C23
1HZ
U6
U9
C22
J5
IN4
RN5
C32
C21
POR
U8
IN3
U4
C20
IN2
C19 R21
J7
IN1
C33
C18
OUT7
C34
C17
U5
OUT6
RN4
U7
OUT5
U3
PDP0
PDP1
R22
OUT4
R22
OUT3
ABORT ALL
C35
OUT2
W1
RN3
J6
OUT1
U2
OUT0
GRN
YEL
RN2
RED
PDP1-
U1
PDP0-
PDP1+
PDP0+
RN1
24V
FIGURE 7-1. SYSTEM BOARD

FIGURE 7-2. COMPONENT LOCATIONS IN REAR ACCESS PANEL

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TABLE OF CONTENTS

S.1 INTRODUCTION .................................................................................................. S-3

S.2 SAFETY PRECAUTIONS..................................................................................... S-3

S.3 MACHINE SAFETY LABELS ............................................................................... S-4

S.4 MACHINE SAFETY INTERLOCKS ...................................................................... S-5

S.5 DEFINITIONS OF WARNINGS, CAUTIONS AND NOTES ................................. S-6

S.6 WARNINGS.......................................................................................................... S-7

S.7 MACHINE DISPENSING MATERIAL DISPOSAL .............................................. S-10

S.8 MATERIAL SAFETY DATA SHEETS ( MSDS )................................................. S-10

1.1 INTRODUCTION .................................................................................................. 1-3

1.2 TECHNICAL MANUAL INTRODUCTION ............................................................. 1-3

1.3 TECHNICAL MANUAL ORGANIZATION ............................................................. 1-3

1.4 APPENDIXES ....................................................................................................... 1-5

1.5 PARTS IDENTIFICATION .................................................................................... 1-6

1.6 PARTS REPLACEMENT ...................................................................................... 1-6

CAMALOT 5000 Table Of Contents i

1.8 OPTIONAL SUPPLEMENTS.................................................................................1-7

2.1 GENERAL DESCRIPTION....................................................................................2-3

2.2 FUNCTIONAL DESCRIPTION ..............................................................................2-3

2.3 INDIVIDUAL COMPONENTS................................................................................2-3

2.4 TECHNICAL SPECIFICATIONS ...........................................................................2-5

2.5 SERIAL NUMBER TAG.........................................................................................2-7

3.1 GENERAL INFORMATION ...................................................................................3-3

3.2 SAFETY PRECAUTIONS......................................................................................3-3

3.3 OPERATING CONTROLS ....................................................................................3-4

3.4 MACHINE SAFETY DOORS SYSTEM ...............................................................3-10

3.5 LIGHT TREE INDICATORS ................................................................................3-10

Page ii CAMALOT 5000 Table of Contents

3.7 REAR PANEL ..................................................................................................... 3-15

3.8 TRACKBALL....................................................................................................... 3-19

3.9 CAM/ALOT SYSTEM MAIN SCREEN................................................................ 3-22

3.10 PASSWORD..................................................................................................... 3-47

3.11 INITIAL SET UP................................................................................................ 3-50

3.12 MACHINE START UP....................................................................................... 3-63

3.13 DISPENSING A PATTERN............................................................................... 3-64

4.1 SAFETY PRECAUTIONS ..................................................................................... 4-5

CAMALOT 5000 Table Of Contents iii

4.3 PROGRAMMING A DISPENSE PATTERN ........................................................4-10

4.4 APPLICATIONS ..................................................................................................4-22

Page iv CAMALOT 5000 Table of Contents

4.5 TRANSFERRING DATA VIA THE RS232 INTERFACE..................................... 4-31

4.6 GLOSSARY OF TERMS...................................................................................... 4-41

CAMALOT 5000 Table Of Contents v

5.1 GENERAL INFORMATION ...................................................................................5-3

5.2 SAFETY PRECAUTIONS......................................................................................5-3

5.3 MACHINE INSTALLATION PRELIMINARY REQUIREMENTS ............................5-4

5.4 MACHINE INSTALLATION ...................................................................................5-7

6.1 GENERAL INFORMATION ...................................................................................6-3

6.2 SAFETY PRECAUTIONS......................................................................................6-3

6.3 PREVENTIVE MAINTENANCE.............................................................................6-4

6.4 LUBRICATION ......................................................................................................6-5

Page vi CAMALOT 5000 Table of Contents

6.5 REPLACEMENT OF OPTIONAL CONVEYOR RAIL INSERTS........................... 6-6

6.6 REVERSING CONVEYOR FLOW DIRECTION ................................................... 6-7

6.7 REPLACEMENT OF CONVEYOR BELTS ......................................................... 6-13