Hybridc: User Manual Version 1.0

HybridC
HC-100/200
User Manual Version 1.0
This document contains proprietary information which is protected by copyright. All rights are
reserved. No parts of this document may be photocopied, reproduced, or translated into another
language without the prior written consent of DIMA SMT Systems NL. B.V..
The information contained in this document is subject to change without prior notice
(C) Copyright 2007 DIMA SMT Systems NL. B.V.
TB-0582
HYBRID Coater User Manual Ver1.0 Preface
Preface
The user documentation of the HYBRID Conformal Coating machine is meant for operators
and service technicians working with and on the HYBRID Conformal Coating machine
operated by HybridC application. It consists of two manuals: the user manual and the
machine reference manual.
• The User Manual describes the machine and explains normal production procedures and
maintenance procedures that can be performed by any user.
• The Machine Reference Manual describes user interface (the HybridC application) in
detail and it describes non-standard production procedures (like editing libraries or
creating a multiple-product file), and advanced machine features.
It is assumed that people operating and servicing the equipment and the software, are
familiar with the basics of Microsoft WINDOWS and that items like “folder” and “opening a
file” are known.
Throughout the user documentation, the term “HYBRID” will be used to indicate the HYBRID
Conformal Coating machine.
Following this preface, this User Manual starts with a summary of safety precautions. Next,
all menu items of the user interface are described. The following chapters describe the
machine functions and the way to perform procedures with these functions.
This User Manual is compiled with the greatest care. Due to new developments after the
release of this manual, it is however possible that this manual is not up to date with the latest
technology. The company DIMA SMT Systems NL. B.V. reserves the right to change
machine specification and other characteristics described in this manual, without prior notice.
The following trademarks are being acknowledged:
MS-Windows ™ is a trademark of the Microsoft Corporation.
CorrectPlace ™ is a trademark of ESI.

HYBRID Coater User Manual Ver1.0 Safety Summary
Safety Summary
Please take a moment to review these safety precautions. They are provided for your
protection and to prevent damage to the machine. This safety information applies to all
operators and service personnel:
Not complying with the safety recommendations can result in injury to

the user or damage to the machine.
General safety precautions:

• Read this manual before putting the machine into operation. The machine can involve
heat, pneumatic and electrical devices and the use of hazardous materials. The operators
must be aware of the possible risks and safety precautions when using the machine.
• Do not operate the machine when you are not familiar with the machine. Only trained
personal may perform operations at the machine.
• Only use a well grounded wall outlet for power supply.
• Prevent injury when working with fluid heaters by using thermal gloves.
• Never let the machine work without operator supervision.
• Periodically inspect all air and material hoses and electrical cables for damage.
• Disconnect the machine from power and air connections before performing any
maintenance or service to the machine.
Warnings:
Consult the Material Safety Data Sheet (MSDS) for all fluids used with
the Hybrid. The MSDS provides material usage instructions, safety
precautions, information about personal protective equipment, and
disposal instructions. Also check for compatible fluids when using more
than one fluid.
Fluids can be extremely dangerous when working with high pressure.

They should be safely contained. Be sure the pressure is removed
before performing any adjustments or maintenance. A beam of high
pressure fluid can cut like a knife and can even result in death.
Never enter the machine when the motors are running, except when
prompted to do so by the user interface.
When you have to be inside the machine during production, hold the
production and disable the machine. Then you can enter the machine.
Do not overrule the hood locks and do not run the HYBRID with the
hoods open unless this is explicitly allowed.
Safety equipment:
Emergency switches:
On two places on the machine there are emergency switches installed. When an emergency
occurs, immediately push one of these switches. The machine immediately switches off. The
PC and the monitor stay on.
NOTE: the emergency switches do not result in a disconnect of the air supply. The air supply
can be removed by setting the air pressure to 0 Bar at the main pressure regulator of the
machine.
Hood locking:
When the motors are running, the hoods are automatically locked (except for some special
cases). This ensures that nobody can enter the machine without the authorisation of the
operator.
Exhauster guard:
The machine will guard the exhauster to ensure enough ventilation. When the exhauster is
not in operation or does not provide enough ventilation the machine will not start any
dispense or coating application.
Symbols:
These symbols are placed on the machine:
DIMA-054
This symbol is intended to alert you to the presence of “dangerous voltage”
230VAC (230 Volts) within the product’s enclosure that may be of sufficient
magnitude to constitute a risk of electrical shock to persons.
This symbol is intended to alert you not to enter the machine. Moving parts
may cause injury when you enter the machine when the motors are running.
DIMA-052
DIMA-059
Caution Hot. The motor behind the shield can be hot. Do not enter this zone.
This label is placed inside the process chamber at the shield protecting the
Y stepper motor.
DIMA-068
NOTE: To be performed by user!
This symbol is intended to alert you off possible use of irritating substances
inside the machine. If your system is setup to use these liquids this symbol
must be placed at four sides off the machine alongside the ‘Do not enter’
symbol as indicated at the picture below.
Next figure shows the positions on the HYBRID.
DIMA-054
230 VAC
DIMA-054
230VAC
2x 4x
Symbol: Hot
surface
Situated in left rear

of coating
compartment
If any symbol is not present on the machine or if you have any questions, do not use the
machine and please contact your suppliers. If the name or the address of your supplier is
unknown, please contact:
DIMA SMT Systems NL. B.V.

Beukelsdijk 2
5753 PA Deurne
The Netherlands
Int. Tel: +31-493-352752
Int. Fax: +31-493-352750
E-mail: sales@dimasmt.nl
HYBRID Coating User Manual Ver1.0 Table of Contents
Table of Contents
1. Product Information 1-1

1.1 Introduction 1-1
1.2 Field of Application and Intended Use 1-2
1.3 Technical Specifications 1-2
2. Installation 2-1
2.2 Transport 2-1
2.3 Placing 2-1
2.4 Connections 2-4
2.4.1 Power connection 2-4
2.4.2 Air Connection 2-5
2.4.3 SMEMA connection 2-6
2.4.4 Exhauster Connection 2-7
3. Hardware Description 3-1
3.1 Machine Exterior 3-1
3.2 Product Compartment HC-100 / HC-200 3-2
3.3 Coating Head HC-100 3-4
3.4 Coating Head HC-200 3-6
3.5 HC-100 Specific Options 3-8
3.5.1 Introduction 3-8
3.5.2 HC-100 Specific Option: HC-1021, -22, -23, and -24 Adapter 3-8
3.5.3 HC-100 Specific Option: HC-1030 / HC-1031 Valve Mount Assemblies 3-9
3.6 HC-200 Specific Options 3-12
3.6.1 Introduction 3-12
3.6.2 HC-200 Specific : HC-1000 and HC-1010 Additional Valve Mount Assemblies 3-12
3.7 Working with the HC-1000 / HC-1030 Z-slide Assembly 3-15
3.8 Working with the HC-1010 / HC-1031 Z-slide Assembly with Tilt 3-16
3.9 Common Machine Options 3-17
3.9.1 HC-1050 / HC-1051 Pressure reducing valves and Sensors 3-17
3.9.2 HC-1100 Static Work Holder 600x500mm with M5 inserts 3-18
3.9.3 HC-1101 Adjustable Clamping blocks (4x) with M5 screws 3-18
3.9.4 HC-1160 Transport Conveyor with Chain 3-19
3.9.5 HC-1170 Transport Conveyor with Belt and Clamping 3-20
3.9.6 HC-1200 Purge/Solvent bin holder (1 position) 3-23
3.9.7 HC-1201 Large Solvent Bin 3-24
3.9.8 HC-1210 (0,175 L) and HC-1215 (0,350 L) Cartridge Retainer with cap 3-24
3.9.9 HC-1230 10 L = 2,6 Gal Tank/ HC-1231 10 L= 2,6 Gal Tank Stainless Steel 3-25
3.9.10 HC-1300 Container Empty Detection by Weight Scale 0-30kg 3-27
3.9.11 HC-1305 Container Empty Detection by Weight Scale 1-60kg 3-27
3.9.12 HC-1320 Barrel/Syringe Empty Detection 3-28
3.9.13 HC-1570 ESI auto fiducial alignment software 3-29
3.10 Co-ordinate System 3-29
4. The User Interface 4-1
4.2 The Start-Up Dialog 4-1
page i
HYBRID Coating User Manual Ver1.0 Table of Contents
4.3 The Workspace 4-2

4.4 The Status Bar 4-3
4.5 User Management 4-5
5. Working with the HYBRID 5-1
5.2 A General Introduction to Dispensing 5-1
5.3 Dispensing Jobs 5-2
5.4 Valve overview 5-3
5.5 Files Overview 5-3
5.6 Turning on the Machine and Starting the Application 5-4
5.7 Opening a Product file 5-5
5.8 Preparing for Production 5-5
5.9 Adjusting the Conveyor Width 5-6
5.10 Producing a Product 5-7
5.11 Shutting Down the Application and Turning off the Machine 5-8
6. Troubleshooting 6-1
6.2 Frequently Asked Questions 6-1
6.3 Machine Start-up 6-2
6.4 General 6-2
6.5 Product Loading/Unloading 6-3
6.6 Production 6-4
7. Maintenance and Support 7-1
7.1 Maintenance 7-1
7.1.1 Daily Maintenance 7-1
7.1.2 Monthly Maintenance 7-1
7.1.3 Yearly Maintenance 7-2
7.2 Mapping the Motion System 7-2
7.3 Support 7-3
8. Spare Parts 8-1
A. Dispense Valve Selection Guide A-1
B. Ventilation Calculation B-1
page ii
HYBRID Coater User Manual Ver1.0 Chapter 1
1. Product Information
1.1 Introduction
The HYBRID Conformal Coating machine (HYBRID) offers you a flexible medium speed
machine for coating and dispensing not only PCB’s, but all kinds of items that need a full or
partial coating. Easy to operate mechanics and state of the art software enable the
production of a mixture of products with a minimum of change-over time.
The HYBRID has one head, equipped with up to four dispense units and a camera. The
product is clamped in the centre of the machine. Depending on the machine type, this can be
done manually (stand-alone machines) or by a built-in pin conveyor or transport belt (in-line
machines). The product width for the transport systems can easily be set manually thanks to
a snap-on system.
The head can reach the total working area of the machine. If the product is equipped with
fiducials, these can be automatically checked by the optional ESI CorrectPlace vision
system. The camera, which is always available, can also be used to easily teach areas on a
product that must be coated.
The head accommodates up to four dispense units, allowing the machine to use both
needles (for narrow lines) and spray valves (for wide lines and areas), and leaving possibility
to use more than one dispense fluid.
The machine is equipped with its own controller that controls the machine parts. Data to and
from the central computer are transferred through a serial connection.
To enable smooth operation in a production line, the machine meets the SMEMA standard
and the inline versions are equipped with SMEMA interface.
The HYBRID is operated through a MS-Windows oriented user interface.
At the moment there are two types available:

HC-100
The HC-100 robot is equipped with X, Y, and Z axes. The 3-axes robot can handle up to 4
different tools. Tools can be dispense valves, spray valves, grippers, etc. They are mounted
onto a Z slide, or on a Z slide combined with a fixed tilt mechanism as a fourth axis. This
combination is mounted onto an adapter for 1, 2, 3, or 4 valves. Tools and valves can be
configured outside of the machine and can be mounted onto the robot as one single unit. The
3-axes robot comes with a camera on the Z axis, computer with DIMASOFT user software, a
base for adapter plates, one electronic pressure transducer for the mains air supply, one
electronic pressure transducer for detection of exhausted air and illumination inside the
machine.
HC-200
The HC-200 robot is equipped with X, Y and Z and Φ axes. The 4-axes robot can handle up
to 4 different tools. Tools can be dispense valves, spray valves, grippers, etc. They are
mounted onto valve mount. Tools and valves can be configured outside of the machine and
can be mounted onto the robot as one single unit. The 4-axes robot comes with a camera on
the Z axis, computer with DIMASOFT user software, a base for up to 4 valve mounts, one
page 1-1
electronic pressure transducer for the mains air supply, one electronic pressure transducer
for detection of exhausted air and illumination inside the machine.
Both HYBRIDs can be configured as a batch or inline machine and can be reconfigured in
the field at any time.
Furthermore several stationary and product holders for transportation are available.
1.2 Field of Application and Intended Use

The HYBRID can only be used to dispense all kinds of fluids, like coating materials, solder
paste, adhesive and other materials on PCB and other products. Always use the DIMA
equipment as described in the documentation supplied with the machine. Otherwise it can
result in injury to the user or damage to the machine.
When fitted with an optional drill, the HYBRID can be used to drill holes in, for example,
prototype PCBs.
Some examples of unintended use of the machine include:
• Removing or overruling the hood locks;
• making unauthorized changes to the machine or using damaged or incompatible devices;
• operating the machine outside the technical specifications;
• using explosive or corrosive materials.
NOTE: The responsibility for the above unintended use lies entirely with the user.
1.3 Technical Specifications

Dimensions : LxWxH 1100 x 1200 x 1800 mm + 500 mm signal light
Axes : HC-100 3 Axes + tilt, HC-400 4 axes + tilt
Work area : Stand alone : 600 x 600 mm without tilt,
Inline chain : 355 x 600 mm (optionally wider)
Inline belt : 375 x 600 mm (optionally wider)
Z-movement : 150 mm (50 mm with Z slide)
Clearance : Top 100 mm / bottom 100 mm
Rotation (HC-200) : 370 degrees
Motion : Stepper motor in combination with encoder, ball-screw and
linear bearings and spline-axis
Resolution : X and Y : 0.0125 mm
Z: 0.01 mm
Rotation : 0.036 deg
Revolver head (HC-200) : 4 dispenser positions with individual configuration
Mounting plate (HC-100) : Multiple valves
Vision : Teach / fiducial camera
ESI CorrectPlace fiducial recognition software (optional)
page 1-2
Controller : Processor-controller dedicated electronics

User interface : PC-controlled running on Windows XP ™, DIMASOFT©
compatible
Power : 220 – 240 VAC, 50-60 Hz, 1150 W
Required pressurised air : 6 Bar / 85 PSI / 100 l/min
Extraction of air : > 250 m³ / h
Temperature : Machine : 18-30 °C

For coating applications, only small variations are allowed
Noise : In operation < 70 dB(A)
Weight : 440 kg without tanks
page 1-3
2. Installation
2.1 Introduction
This chapter informs you about the equipment and floor space needed to transport and place
the machine. On delivery, the HYBRID is installed by DIMA authorised service personnel.
When you need to move the machine later on, this too should be done by DIMA authorised
service personnel.
2.2 Transport
The HYBRID weighs approximately 440 kg. Take care to
use means of transport suited for this weight. The figure
on the left shows where the machine can be picked up
with a pallet-truck or a fork-lift truck.
2.3 Placing
0.52 m
0.6 m
1.6 m
0.06 - 0.22 m
P+A
1.2m 1.0 m
Front View
page 2-1
12 100
440
105
ca. 615
Rear View Detail A
The HYBRID should be placed on a stable and level surface. Take care to leave enough
space in front and behind the machine so that these sides are accessible.
When directions related to sides of the machine are mentioned; this always refers
to the viewer standing in front of the machine. SO looking towards the front!
page 2-2
Inlet for air hose,

above left rear
bottom of machine
Outlet for power

cable, on right rear
bottom of machine
page 2-3
2.4 Connections
2.4.1 Power connection

The HYBRID needs a well grounded 220-240 VAC single phase power supply. This has to
be fused by a 16 Amp slow fuse. There should be no other equipment connected to this fuse.
When the customer uses a 220-240 VAC single phase power supply (220 VAC), the HYBRID
can be connected by plugging the connector into the wall socket.
When the customer uses a 110-120 VAC power supply (110 VAC), the connector has to be
cut off from the cable and the cable has to be connected between two phases of the power
supply as indicated in the next figure. One phase and the neutral of the power supply are not
connected (N.C.).
220VAC Connection
L
V 220 VAC
N
110VAC Connection
L1
V 110 VAC V 220 VAC V 220 VAC 220 VAC
L2
V
V 110 VAC V 220 VAC

L3 N.C. N.C.
V 110 VAC
N Yellow/green Black Blue
Remove the power connection from the machine before performing maintenance or
service on the machine.
page 2-4
2.4.2 Air Connection

Pressure
regulator in front
bottom at the left
The HYBRID needs air with a pressure of at least 6.5-7 Bar or 94-102 PSI and a flow of at
least 100 l/min. The air supplied to the HYBRID should be cool dried and filtered with a 3 µm
filter. NOTE: The flow depends on the used valves on the machine.
Remove the air connection from the machine before performing maintenance or
service on the machine. It is also possible to set the pressure to 0 Bar by using the
knob on the pressure regulator.
page 2-5
2.4.3 SMEMA connection

The SMEMA connection is only available for a machine equipped with a HC-1160, or a HC-
1170 inline transport belt.
1. SMEMA
connector OUT
2. SMEMA
connector IN
3. Connector panel
for multiple
connections
The SMEMA connections are placed at the rear bottom in the PC compartment of the
HYBRID. To connect the HYBRID to other machines in a production line, cables can be
ordered. Refer to the spare parts list for the ordering numbers.
Appendix C of the machine reference manual shows the technical specifications of the
SMEMA signals.
page 2-6
2.4.4 Exhauster Connection

The Hybrid requires a 100 mm diameter exhaust duct capable of drawing a minimum of
250 m3, air at 400 Pa static pressure.
The above exhaust requirements are determined according the EN-IEC 60079-10: 2002
Annex B.5, based on the following facts:
• Processing with the Hybrid, 1 litre / hour of n-butyl acetate with a density of 0,88 kg/dm3.
• Safety factor of > 4.
• The ventilation should be well provided and absolutely guaranteed.
• Refer to appendix B for the detailed ventilation calculation.
For liquids which result in a higher ventilation requirement, contact your DIMA
representative for your particular system requirements.
Exhauster pipe at
rear of the
HYBRID
page 2-7
3. Hardware Description
This chapter gives an overview of the machine hardware.
3.1 Machine Exterior

Next figure shows the outside of the HYBRID. Both the HC-100 and the HC-200 look similar.
1. On-off switch
2. Emergency switch
3. Hood
4. Status light
5. Main switch
6. Monitor and
keyboard
7. Adjustable foot
(4X)
8. Safety Off switch
9. Optional pressure
regulators
10. PC compartment
page 3-1
The status light shows the status of the machine:
Green light on : The machine is coating a product.
Green light blinks : The machine is ready to start production.

Orange light on : The machine will not be able to finish a product, e.g. because
a fluid has run out.
Orange light blinks : The machine is initialising or has stopped because e.g. a fluid
has run out, or because the operator has stopped the
production.
Red light on : A machine error has occurred. Most of these errors can be
solved by the operator. An example is a motion error.
Red light blinks : A serious machine error has occurred. Most of these errors
need the attention of DIMA authorised service personnel.
3.2 Product Compartment HC-100 / HC-200

The figure below shows the mounting points for several options as the HC-1200 purge/
solvent bin as well as the HC-1210 cartridge retainers.
1. Cartridge
retainer
2. Possible
positions of a
cartridge
retainer at rear
panel
NOTE: these
positions are also
available on rear
of front panel
NOTE: Placing options at the product compartment can result in a smaller working area for
your coating head. Some options as the cartridge retainers should be mounted so that the
coating head can not damage this option. If the working area of the coating head is too large,
you can reduce this area by changing the position of for example the Y-limit as shown in the
figure below.
Pay attention that changing the position of the front Y-limit or the left X-limit
influences the calibration values.
page 3-2
1. Rear Y- limit
2. Retaining
screws of the
rear Y- limit
At the bottom centre of the PCB area the exhaust opening is made.
NOTE: do not place any objects on the opening. The machine will not start any dispense of
coating application when the openings are blocked.
1. PCB area
2. Exhauster
dome/opening
page 3-3
3.3 Coating Head HC-100

The coating head HC-100 is the basic coating head which enables you to mount up to four
possible coating devices. All electric and pneumatic connections which are needed to apply
your coatings run through this head. This is the static head, which can move around in the
available working space but only in the X-, Y-, and Z-axis.
1. Air connector 01
2. Air connector 02
3. Air connector 03
4. Air connector 04
5. Connector 01
for dispense
pump DD-5100
6. Connector o2
for dispense
pump DD-5100
7. Stud bolt as
support for
cable bundle
8. Base of coating
head
9. Multiple
mounting holes
for adapter
plate
10. Multiple
mounting holes
for adapter
plates
11. Right hand

side of base of
coating head
page 3-4
12. Air through

connector 01
13. Air through

connector 02
14. Air through

connector 03
15. Air through

connector 04
16. Counterpart of
D25 connector
unit 4
17. Counterpart of
D25 connector
unit 3
18. Counterpart of
D25 connector
unit 2
19. Counterpart of
D25 connector
unit 1
20. Drive motor for

Z-axis of
coating head
21. Main switch for

air pressure to
coating head
page 3-5
3.4 Coating Head HC-200

General view of top side of square PCB without any equipment. Here it is shown in the same
position as indicated in the drawing on page 7. For convenience the number positions for the
Tool Units are marked on the transparent disc. When using only one or two tools
nevertheless start with Position 1.
Front view of base

coating head
General view of top side of square PCB with equipment. Here some possible Tool Units are
connected together with the respective electrical signal lines and air lines.
Side view of base coating head with tools HC-

1010 and HC-1000 attached
page 3-6
This figure shows the drive motor on top of the coating head. Here seen from the rear of the
HYBRID with the switch for the air pressure at the left of it.
1. Motor for motion in

Φ-axis of the
coating head
2. Main air switch for

options mounted
on coating head
HC-200
page 3-7
The next drawing shows the normal position of the PCB on the coating head with the FRONT
towards the operator. Here 01 means that Tool 01 is placed underneath here. The same applies
for Tool 2 to position 02 and so forth. It also means that the connections at the right of the
respective Tool are intended for the Tool at that position.
For example a HC-1010 at the position of Tool 01 will be connected to P11 and P21.
P5. Connector 01 for

dispense pump
DD-5100
P6. Connector 02 for

dispense pump
DD-5100
P11 till P14.

Connectors for
HC-1000
P21 till P24.

Connectors for
HC-1010 tilt
function
NOTE: The other connectors are intended for internal wiring of the machine.
3.5 HC-100 Specific Options
3.5.1 Introduction
Some options can only be used at the HC-100 due to its the mechanical, pneumatic, and
electrical construction. The next sections give a description of these HC-100 specific options.
3.5.2 HC-100 Specific Option: HC-1021, -22, -23, and -24 Adapter
Before any valve can be mounted at the Hybrid it is necessary to first mount an adapter
plate. This adapter plate is the interface between the Hybrid machine and the valve mount
assemblies as the HC-1030 and HC-1031.
For different types of adapter plates are available

• HC-1021 Adapter mount for 1 valves
The following figure shows a HC-1022 adapter plate, mounted at a HC-100 coating head.
page 3-8
Using M3 screws delivered with the valve mount assembly. Mounting holes in row 5, 6 or 7
for the HC-1030 and HC-1031 valve mount assemblies. When a wide tool is used, mount the
Z-slide on row 6, in order to not interfere with the tool mounted on row 5.
NOTE: Use a minimum of four mounting screws for the adapter plate to secure a tight fit!
1. Base coating head
2. Adapter plate HC-

1022
3. Mounting screws;
minimum of four!
4. Mounting holes of
adapter plate for
three possible
positions
5. Mounting holes for

one Z-slide

Z-slide for wide
tool

Z-one slide
3.5.3 HC-100 Specific Option: HC-1030 / HC-1031 Valve Mount

Assemblies
At an adapter plate a HC-1030 or HC-1031 is furthermore required before valves can be
placed. The HC-1030 is a valve mount adapter with only a Z-Slide, the HC-1031 has also
the possibility to rotate to allow coating at a specific angle. Throughout this document this is
called tilt.
page 3-9
1. Air lines from

rear to Z-slide
2. Wires from rear

to Z-slide
3. Mounting screws
of the Z-slide to
the adapter plate
4. Z-slides HC-
1030
5. Base plates of
HC-1020
To mount a valve mount assembly in combination with a HC-1020 to the Hybrid:

Turn off the machine and disconnect the air from the head using the air switch at the head.
Refer to section 3.3 Coating Head HC-100 for more information.
1. Ensure an adapter plate is mounted as indicated in section 3.5.2 HC-100 Specific Option:
HC-1021, -22, -23, and -24 Adapter.
2. Mount the first Z-Slide to the adapter plate using the delivered 2x M3x16 screws. For the
first tool use the left holes (front view) and for the second tool the right hand holes. For a
wide tool e.g. with tilt function, you must use the most left holes or the right hand holes.
These tilt tools are wider at the right hand side.
6. Adapter plate
HC-1022
7. Mounting screws
for HC-1020
8. First cartridge
retainer
9. Right series of
vertical holes
10. Clamp guide of

HC-1020
11. Clamping
screws
3. Mount the base plate # 5 of the HC-1020 on the Z-slide. Use the provided screws # 7 and
mount them on the most right series of vertical holes in the Z-slide. Now you can mount
page 3-10
any optional cartridge tool to the clamp piece #10 of by using the clamping screws #11.
The screws allow you to mount the cartridge as low or as high as you need.
NOTE: Take care that during upward and downward movement of the tools along with the
cartridges they don’t interfere!
12. Wires from D25

connectors to
solenoid valve
13. Valves for air

supply to unit 1
on front of
coating head
14. Valves for air

supply to unit 2
on front of
coating head
4. Connect the D25 connector at the back side of the head at the first free place (# 1) at the
PCB. Connect the red and black wires which run from the D25 connector with its
connector to the top of the solenoid valves, see next NOTE for its respective purposes.
5. Connect the air supply to the first block on the left (rear view) in the following order.
NOTE: The first tool is the tool on the left (front view) for this purpose you use the first
solenoid valve block on the left (rear view). There are three solenoid valves in one block; # 1
is to be used for working the Z-slide, #2 is to be used for working the dispense needle and #
3 is free and can be used e.g. for working the tilt action. Accordingly the solenoid valve block
on the right (rear view) is intended for the right tool on the front.
6. On the right side of the coating head there is free space for mounting two more tools and
these also can be connected at the rear of the coating head. Free space for the D25
connectors is on positions # 3 and # 4.
page 3-11
15. intended for D25

connector # 4

connector # 3

connector # 2

connector # 1
3.6 HC-200 Specific Options
3.6.1 Introduction
Some options can only be used at the HC-200 due to the mechanical, pneumatic, and
electrical construction of the machine. In the next sections a description of these HC-200
specific options is given.
3.6.2 HC-200 Specific : HC-1000 and HC-1010 Additional Valve

Mount Assemblies
At an adapter plate a HC-1000 or HC-1010 is required to place valves. The HC-1010 is a
valve mount adapter with only a Z-Slide, the HC-1010 has also the possibility to rotate to
allow coating at a specific angle. Throughout this document this is called tilt.
To mount a valve mount assembly to the Hybrid:

1. Turn off the machine and disconnect the air from the head using the air switch at the
head. Refer to section 3.4 Coating Head HC-200 for more information.
page 3-12
1. Motor for the Φ-

action of the
coating head.
2. Air switch on
top of coating
head
2. Remove the placed sealing plate with the two M5x12 screws.
NOTE: At the back side of this plate a small sealing ring is placed. Carefully remove the
plate and store this plate including the sealing ring for possible later usage.
1. Sealing plate
2. Mounting screws
M5x12
3. Sealing ring
3. Mount the complete HC-1000 or HC-1010 unit using the two delivered M5x12 screws.
NOTE: At the back side of the unit a small sealing ring. Take care that this ring is kept at it’s
place.
page 3-13
1. Valve assembly
as sold; here the
sealing ring is
covered by
protection tape
2. New valve
assembly HC-
1000
4. Connect the two electrical connectors (numbers 3 and 4) to the sockets (numbers 7 and
8) as indicated at the below and on next page.
5. Connect the air as shown in the next figure and the connections at # 6 are for connecting
possible air lines to the needle of the syringe.
3. Connector
4. Connector
5. Air lines for

actuating the Z-
slide
6. Possible
connections for air
lines for actuating
the needle of the
syringe
page 3-14
7. Socket for
connector # 4
8. Socket for
connector # 3
3.7 Working with the HC-1000 / HC-1030 Z-slide Assembly

At the HC-1010 you can mount several different valves. For this purpose two M4x25 screws
are delivered with this option. The speed of the Z-slide is set to make smooth movements, if
your application requires other movement speeds, you can use the speed regulators at air
supply for the Z-slide.
NOTE: the required time for a slide movement up or down should not exceed two seconds
due to software implementation.
page 3-15
3.8 Working with the HC-1010 / HC-1031 Z-slide Assembly with

Tilt
Refer to the previous section for information about the Z-slide functionality. For the tilt you
can set the coating angle at both 30 and 45 degrees by changing the mounting position of
the limitation plate.
1. Hole for limitation arm of tilt plate; this results in an 30° angle
2. Hole for limitation arm of tilt plate; this results in an 45° angle
3. Mounting plate for the coating assembly
4. Mounting screws for the coating assembly
5. Air operated tilt cylinder
6. Lower (left hand) sensor for adjusting control lamp to

accommodate possible change of tilt angle. Should light up
red when tilt function is completed (out). When tilt plate is
vertical (in) the high sensor should light up red.
7. Adjusting screw/clamp of down sensor
NOTE: When the mounting position of the limitation arm is

changed from 30° to 45° or reverse it is required to change the
position of the lower sensor of the pneumatic tilt sensors. Use
the Options, Test machine parts, Head functions to set the tilt
position. When the angle is set to 45°, the lower sensor should
be moved up. When the angle is set to 30°, the lower sensor
should be moved down. Use the tilt button (on the screen) to
perform the tilt movement and check that the left arrow
indication is green. After tilt action is performed the right hand
arrow should be green. When both arrows are blinking red
there is a technical failure. Pay attention that the upper (right
hand) sensor does not need to be adjusted.
page 3-16
3.9 Common Machine Options

The following options can be used on either the HC-100 as well as the HC-200.
3.9.1 HC-1050 / HC-1051 Pressure reducing valves and Sensors

The HC-1050/51 set is used to control a pressure output that can be used for purposes as
atomising air for spray valves, and pressure for fluid tanks and cartridges.
Two different versions are available:

• HC-1050 Set for generating a pressure output of 0-7 Bar
• HC-1051 Set for generating a pressure output of 0-2,5 Bar
A set consists of a pressure regulator in combination with a pressure sensor connected at

the main electronic controller PCB. There is no difference in appearance to the operator for a
HC-1050 or a HC-1051, so it is important that a clear label is placed during installation of
this option. Also the configuration of this option must be performed by the DIMA authorized
service engineer, refer to the section about the machine configuration at the Machine
Reference Manual.
Don’t forget to place a clear label above each pressure regulator. This option may
only be installed by a DIMA authorized service engineer.
page 3-17
3.9.2 HC-1100 Static Work Holder 600x500mm with M5 inserts

When no inline version of the machine is required you can use the HC-1100 static work
holder. This is a aluminium plate with M5 screw thread at a 50mm pitch in both the X and the
Y direction.
1. Adjustable
clamping blocks
HC-1101
2. Static work
holder HC-1100
3. Calibration plate,
mounted at the
static work
holder for
calibrating
purposes.
The software uses a Product Postion to locate a product during fiducial alignment and / or
production. When working with the static work holder, we advise to keep the position lower
right clamping block unchanged for different products. This will prevent you from
recalibrating the product position for different products. Refer to the section about machine
calibration of the Hybrid Reference Manual for more detailed information.
3.9.3 HC-1101 Adjustable Clamping blocks (4x) with M5 screws

For usage on a HC-1100 Static work holder, a set of clamping blocks is available. The HC-
1101 is a set of four clamping blocks with the M5 screws. The next figure shows a PCB
placed at a HC-1100 static work holder using the HC-1101 adjustable clamping blocks. See
also previous figure.
page 3-18
3.9.4 HC-1160 Transport Conveyor with Chain

The conveyor with chain consists of two rails in which the transport chains run. The conveyor
rail in the front is stationary and not adjustable. The rear conveyor rail is adjustable by knobs
at the left and right this is done to accommodate the width of the product. This chain
conveyor is intended for heavy products which otherwise could damage a similar belt.
1. Movable rear
conveyor rail
2. Chain in rear
conveyor rail
3. Stationary
front conveyor
rail
4. Calibration
plate
5. Stoppers for
product
Conveyor seen from rear between both rails.
page 3-19
6. Front panel
7. Chain in front
conveyor rail
8. Adjustable
proximity
sensor
The proximity sensor # 8 needs to be adjusted so that is recognizes the product on the
conveyor in time to give a signal to the controller which in time must slow down the product.
Products that are to far away from the sensor or are dull black might not be recognized by
the sensor. So it is possible to adjust the sensor in height. With a dull black surface at the
bottom of the product it might be useful to set the sensor at an angle.
With the software (see Machine Reference Manual) there also is a possibility to adjust the
overdrive this sometimes is necessary when a heavy product has to be stopped in time
before the stoppers. In this overdrive function in the PC there is the possibility to adjust the
brake time in order to stop the product in time. This feature is a needed to overcome the
difference between light and heavy products. The upward speed of the stoppers can be
adjusted with the speed regulator at the left hand machine side in bottom of rear
compartment (also see next Chapter).
3.9.5 HC-1170 Transport Conveyor with Belt and Clamping

For adjusting the proximity sensor see Chapter 3.9.4.
The upward and downward speed of the PCB clamping guide can be adjusted with two
speed regulators (# 1 and # 2) on the pneumatic cylinder on the side of the Conveyor. The
upward speed of the stoppers can be adjusted with the speed regulator at the left hand
machine side in bottom of rear compartment. Take care that the clamping guide goes down
within the Clamp Time as set in the Configuration Production window, or adjust this time.
page 3-20
1. Regulator on
clamp cylinder
for clamp
release speed
2. Regulator on
clamp cylinder
for clamping
speed
3. Regulator in
bottom of rear
compartment for
adjusting the
upward speed
of stoppers
The next pictures show the adjusting to accommodate the width of a product, the stopping of
a product and the clamping of a product.
page 3-21
1. Adjuster for
movable
conveyor rail
2. Movable
conveyor rail
3. Stationary
conveyor rail
4. Product
5. Clamping
pieces on both
rails
6. Clamping
guide and air
cylinder
7. Calibration
plate
8. Stoppers on
both rails
NOTE: for PCB’s which are too thick or when a high object on the side of the PCB interferes
with the clamping guide it is possible to remove a clamping guide.
Attention: when placing back the clamping guide watch out not to wedge the toothed
belt, see next figure.
page 3-22
1. Clamping guide
2. Inside leg of
clamping guide
3. Toothed belt
4. Main body
(rail) of
conveyor
NOTE: When remounting: Take care that leg # 2 of clamping guide # 1, is not mounted onto
the main body # 4 of the conveyor. This way there will be no clamping action! Also don’t
squeeze the toothed belt # 3 onto the guide block for the toothed belt which is underneath it.
3.9.6 HC-1200 Purge/Solvent bin holder (1 position)

These holders and bins are obtainable from DIMA SMT Systems, for details see accessory
list. Place these holders directly behind the front panel from the left to the right. Pay attention
not to let them intrude with the calibrating plate. The holders are adjustable in height, so after
repositioning, watch out no to let them intrude with the nozzles of the barrels!
1. Holder for one

bin HC-1200
2. Bins HC-1400
obtainable
from DIMA
3. Front panel
page 3-23
3.9.7 HC-1201 Large Solvent Bin

This large solvent bin is identical to the HC-1200, only the bin is made of stainless steel. It
can be used to park all four units at the same time. Normally it is placed in the back side of
the machine, behind the transport system.
NOTE: the size and position of the solvent bin can reduce the maximum width of the product
to be handled.
3.9.8 HC-1210 (0,175 L) and HC-1215 (0,350 L) Cartridge

Retainer with cap
These are small tanks for situating in the rear of the machine. This option contains a small
tank + retainer + clamp and is equipped with a quick-attach coupling and sufficient hose in
order to make the connection downwards. For both issues the clamps are identical.
Attention: During normal use the cartridge is under pressure! In order to release the
pressure, disconnect quick coupling # 2!
Small cartridge retainer HC-1210 (0.175 litres/ 6 Oz.) containing cartridge HC-1410
1. Supplied air
pressure
2. Quick coupling
3. Universal
holder for
cartridge
retainer
4. HC-1210
cartridge
retainer
5. Multiple
locating
positions for
universal
holder
page 3-24
Large cartridge retainer HC-1215 (0.350 litres/ 12 Oz.) containing cartridge HC-1415
6. Windows for
checking level
in cartridge
7. HC-1215
cartridge
retainer
8. Connection
block for
medium lines
to coating
head
9. Medium line to
connection
block
3.9.9 HC-1230 10 L = 2,6 Gal Tank/ HC-1231 10 L= 2,6 Gal Tank

Stainless Steel
For coating larger volumes it can be useful to use a tank instead of a cartridge retainer. The
tanks will be configured and connected to your Hybrid by DIMA authorized service personal.
The HC-1230 is useful for applications using solvent based coatings. The system consists of
a zinc plated lid, and all wetted parts in lid assembly including: fluid tube, lid bushing, outlet
elbow and fitting, and lift hook. The shell is also zinc plated.
1. Lift hook
2. Connection for
supplied air
under pressure
3. Connection for
discharged
coatings
4. Lid stainless
steel or zinc
plated
The HC-1231 is useful for applications using waterborne coatings. The system consists of a
300 grade stainless steel lid and all wetted parts in lid assembly including: fluid tube, lid
bushing, outlet elbow and fitting, and lift hook. The shell is zinc plated.
page 3-25
The HC-1230 and the HC-1231 come with one disposable tank liner each. Refer to the spare
part list for more information about tank liners (HC-1430).
Use the tanks as described in the documentation/safety instructions enclosed with

the tank.
ATTENTION: During normal use the tank is under pressure. Do not open the tank
when pressure is applied to the tank. This can result in personal injury. When the
tank is opened, solvent vapours can be released.
page 3-26
3.9.10 HC-1300 Container Empty Detection by Weight Scale 0-

30kg
See Chapter 3.9.11
3.9.11 HC-1305 Container Empty Detection by Weight Scale 1-

60kg
The HC-1305 Container Empty Detection unit matches the HC-1300 Container Empty
Detection unit, except for the weight range. See also ‘Analog in’ in Chapter 2 of the Machine
Reference Manual. For installation see Usage Notes enclosed with this option.
NOTE: When switching on the weight scale there must be no weight on the weight scale.
Use the weight scale as described in the documentation enclosed with the weight
scale.
page 3-27
3.9.12 HC-1320 Barrel/Syringe Empty Detection

This option enables the HYBRID to operate with a detection function in order to detect an
empty or nearly empty syringe. This kit contains a metal disc which follows the level in the
syringe and signals it on the sensor light. See also ‘Dispensers/Dispenser 1..4’ in Chapter 2
of the Machine Reference Manual.
This option contains two small metal discs which will fit either into a 10 ml or into a 25 ml
syringe. Place the appropriate metal disc # 3 on top of the fluid in the syringe and place the
syringe onto the coating head. The signal of the inductive sensor # 6 with the blue tip # 4 can
be adjusted so the sensor light # 7 becomes red when the fluid level in the syringe reaches
its lowest level. The height set arm # 2 can be adjusted to the required height of an empty or
nearly empty syringe. With set screw # 5 the distance of the inductive sensor # 6 towards the
syringe can be adjusted. The blue tip must be out of the height set arm and as close to the
syringe as possible. Otherwise it detects the height set arm.
This option only is available as a kit, which contains the sensor and the hardware. The
sensor cable needs to be made to fit, this action has to be performed by a DIMA authorized
service engineer. The kit contains all the parts needed for this.
Take care that the red sensor light is off after installation.
1. Set screw of
height arm
2. Height set arm
3. Metal disc
4. Blue tip of
sensor
5. Set screw of
sensor
6. Inductive
sensor
7. Light in sensor
page 3-28
3.9.13 HC-1570 ESI auto fiducial alignment software

This option supports automatic fiducial recognition.
Fiducial alignment is used to compensate for variations of the PCB relative to the expected
position. With this software option ESI Correctplace® system fiducial alignment is automated.
In a pre defined search area ESI Correctplace® system will search for the pre defined model.
Powerful algorithms provide superior speed and robustness. ESI Correctplace® works with
models and not with comparison of images. In this way the colour of the board or the
reflection of the solder mask is not influencing the quality of recognition and so not causing
any downtime of the production. Board alignment can be achieved through standard or user
defined fiducial shapes or PCB land patterns. The optional software also improves automatic
calibration of the machine.
3.10 Co-ordinate System

The positions in the machine are indicated by co-ordinates. The X- and Y-axis form the
horizontal plane. Standing in front of the machine, the X-axis goes from left to right, and the
Y-axis goes away from the user. The origin is the leftmost position at the front of the
machine.
Vertical movements go along the Y-axis. These movements can be defined in two ways.
Pure machine co-ordinates move from top to bottom, the origin being the position of the
dispense unit when the Z-axis is fully up. This results in a rather impractical co-ordinate
system where every dispense unit has a different origin. Therefore the product co-ordinates
are defined bottom-up, with the same origin for all dispense units: the calibration plate. So
this is the height reference.
When working with a product, the origin of the co-ordinate system is defined by the product
level, the stopper pin and the product size. The X- and Y-origin are the lower-left corner of
the product when it rests against the stopper pin. The product level is calibrated relative to
the calibration plate. The Z-origin is lifted by the thickness of the product as defined in the
product file, except when the HC-1170 transport conveyor with top clamping is used.
+Y
+X
+Z +Z
Machine co-ordinates
page 3-29
4. The User Interface

4.1 Introduction
This chapter introduces the user interface of the HYBRID, the HybridC application. With this
MS-Windows orientated application, the machine is easily operated.
4.2 The Start-Up Dialog

After starting the HybridC application, the opening dialog box opens.
The title bar shows the application name (HybridC) and the name of the active file or
window.
The menu bar contains the main menus. These are explained in the machine reference
manual. Main menus and items in a main menu can be selected by mouse click or (after
pressing the ALT key) by pressing the underscored character.
The toolbar contains the buttons to open the most often used dialogs quickly.
page 4-1
In the opening dialog box, the user has to enter his/her name and a password. Besides
this, one of the following operation modes can be selected:
• On-line : the machine is started normally.
• Off-line : the machine is not started but the application simulates the machine as if it
was running normally.
After selecting the operation mode is selected, the Start button can be pressed to continue. If
the application was started by mistake, the Exit button can be pressed to quit the program.
The status bar shows all kinds of information. Refer to section 4.4 for more details.
4.3 The Workspace

The figure below shows an example of the workspace. The screen area with the product
view can also be used for several other kinds of views.
The display shows the image of the camera. The character in the upper left corner indicates
whether the display shows life video (L) or an image from the buffer. This buffer is a
temporary storage for images. Note that the vision system can handle images with up to 256
grey scales.
The move window, display and the production controls are shown when the option Move
window in the View menu or the button on the tool bar is activated. When the head is
moved over the product, a field of view (FOV) indicator shows up in the product view. If a
product is loaded and the fiducials are recognised, the display and the FOV indicator
represent the same part of the product.
page 4-2
Pressing the X, Y, XY, Z and Φ buttons in the move window activates the head movement.
The head can now be moved with the track ball, mouse or the arrow keys. The buttons
change into a white square (as seen above). Another click stops the movement.
When the cursor is stationary over an item, a so-called tool tip shows up. This tool tip gives
some useful information about the item. Double-clicking the item selects it in the production
elements list and places a marker in the graphic.
The product view shows the product layout and can be zoomed in by dragging a rectangle
over a section.
4.4 The Status Bar

The figure below shows an example of the status bar.
Information : This part of the status bar can show all kinds of information. For
example the meaning of the button on the tool bar or the menu in the
menu bar where the cursor is pointing at.
Position : The position of the cursor in the product view. When the cursor is on
an item, the reference of this item is shown too.
Zoom level : The amount of enlargement of the display (right) and the product view
(left).
Cur. prod. state : The current production state.
Name : The name of the current user. By double-clicking or right-clicking this

field, the user can log off. The application freezes but is not closed.
When working with multiple works environments, the user name is
followed by the name of the work environment between square
brackets. Right-click this field to select another work environment.
page 4-3
Production mode : By double-clicking this field, the machine can be set in demo mode.
This is indicated by DEMO. Another double-click in this field switches
to camera mode. This is the same function as the radio buttons
Normal, Demo and Camera in the Configurations/Production tab. To
switch the demo, production must be stopped first. Right-click this
field to open the production mode menu.
Event indicator : A light bulb in this field indicates that an event has been created. By
double-clicking this field, the event window is shown.
Machine status : This shows the machine status. The signals are the same as the light
tower on top of the HYBRID.
Product : This part of the status bar shows the state of the product on the
conveyor (if present) and of the SMEMA signals (when activated).
Right-clicking opens a SMEM menu to easily switch SMEMA
communication on and off..
page 4-4
4.5 User Management

Users of the HYBRID can be divided in groups, called user types. The user type determines
which windows and options a user can use.
On delivery of the machine, there are five types already entered in the software, each type
with a pre-set level of authorisation (called user rights):
Service : This type is only available to DIMA authorized service personnel.
Supervisor : This is the highest level available to the customer. Besides all production
related actions, a supervisor can perform machine related actions and all
actions in the user management.
Manager : This is the highest level available for normal operation. All production related
actions can be performed by the manager.
Operator : An operator can perform all actions needed to produce a product.
Guest : A guest can only perform a limited set of actions.
On delivery of the machine, there are two users entered in the software, they have the
following names, user types and passwords:
Name User type Password
Supervisor Supervisor DIMA
Manager Manager <no password>
Other users must be entered by the supervisor, he/she can also add new types and change
the user rights.
DIMA recommends to change the pre-set passwords into passwords of the customer’s own
choice and only to log on as a supervisor in special cases.
Sometimes a user of a certain type must change some settings but is not authorised to do
this. In this case, the user should log off. The application freezes and the opening dialog box
shows up. Another user (of the type that is allowed to make the changes) can now log on.
When the changes are made, the previous user should log on again and the application can
continue where it was stopped
page 4-5
5. Working with the HYBRID

5.1 Introduction
This chapter gives a step by step overview of working with the HYBRID. The emphasis is on
items that are directly related to coating a product, like: turning on the machine, setting up
the configuration, and adjusting the conveyor width. Particularly for those who have little
experience with the HYBRID, this chapter will be very useful.
Items that are less directly related to actual production, like entering packages in the
package library, and advance machine settings are described in the machine reference
manual. This reference manual also describes all menus and windows of the HybridC
application.
5.2 A General Introduction to Dispensing

This section tells you more about dispensing in general.
The amount of dispensed fluid (dot size or line width) is influenced by several factors:
• Viscosity of the dispense fluid
• Temperature of the working environment
• Applicator diameter
• Pressure / motor speed
• Movement speed
• Dispense time
All these factors also influence each other. For example: when a larger applicator
diameter is used, the dispense time can be set to a lower value to get the same dot
size, or the movement speed can be increased.
Starting point is the dispense fluid. Very important is the viscosity of the fluid. This
determines how easy the fluid flows; a high viscosity means that the fluid flows very slowly.
The viscosity of the dispensing fluid limits the minimum diameter of the applicator; fluids with
higher viscosity need larger diameters. Note that higher temperatures decrease viscosity.
Some dispense fluids like solder paste have fixed particles. The size of these particles also
determines the minimum internal diameter of the needle used to dispense the fluid.
Refer to the data delivered by your dispense fluid supplier for detailed information about your
specific fluid.
The maximum diameter of the applicator is determined by the surface on which the fluid must
be dispensed and by the viscosity of the dispense fluid. For example, when you are
dispensing solder paste, the needle diameter should not be larger than the size of the solder
pads on a PCB. But when the diameter is too large, the dispense fluid will easily drop out of
the needle. The needle diameter is the first factor to influence the amount of dispense fluid.
Besides the diameter of the needle, the length of the needle is important. A long needle
combined with a small diameter can cause the dispense fluid to stick in the needle. This
effect increases when the viscosity is higher.
page 5-1
Pressure/motor speed Once the dispense fluid and the applicator

have been determined, the amount of fluid
can easily be adjusted by a combination of
pressure/motor speed and dispense time.
Increasing the pressure/motor speed, the
dispense time or both, increase(s) the
amount of dispense fluid. The graphic on
the left shows how pressure and time
influence the amount of fluid.
0 Time
Note that dispensing valves from other manufacturers can be easily mounted on the
adapter plate of the HYBRID.
Dispensing methods
The most simple method of dispensing is air pulsed dispensing through a syringe (a barrel
with a needle). By putting pressurised air at the end of the barrel, the dispense fluid is
pushed through the needle at the front of the barrel. When no pressure is applied to the
barrel, a vacuum is placed at the end of the barrel to prevent dispense fluid from dripping out.
Dispensing through a syringe is well suited for applications that do not need very high
accuracy and repeatability of the amount of dispensed material. In cases where more
precision and repeatability is required, a valve should be used. This can be a rotary valve, or
an air actuated valve.
The rotary valve uses the rotation of a screw (an Archimedes screw) to force the dispense
fluid through the needle. To feed the valve, a barrel is placed on it. Constant air pressure on
the end of the barrel ensures that the valve keeps receiving dispense fluid. This pressure
should be just enough to keep the valve filled with dispense fluid.
The air actuated valves use the pulsed air to open the valve and dispense the fluid. To feed
the valve, a barrel is placed on it. Constant air pressure on the end of the barrel ensures that
the valve keeps receiving dispense fluid.
Refer to appendix A to see what dispense valve will be most suited for your dispense
material and application.
5.3 Dispensing Jobs

The HYBRID can be used for several types of dispensing jobs.
Sealing
With sealing, two parts of a housing are put together with a layer of sealing material at the
line of contact between the two parts. This line can have a complex, often 3-dimensional
page 5-2
shape that can be easily taught and dispensed with the HYBRID. The tilt-action of the head
can be very useful when dispensing in corners.
Potting
With potting, a hollow form is filled with material, mostly to seal it’s contents from the
environment. The fill-and-retract segment type of the HYBRID is especially useful for these
kinds of dispensing jobs.
Glob-top
Mostly used to cover bare chips with a layer of material to prevent the chip from corroding.
Underfill
Electronic BGA-components have a small clearance from the PCB. By inserting a dispensing
fluid from the sides, the fluid fills this clearance and seals the balls from the environment.
Dam-and-fill
To cover relatively high objects, first a line is dispensed around it, the dam. After an
appropriate waiting time, the interior of the dam is filled with the same or another material to
completely seal off the object.
Conformal coating
Mostly used to seal-off electronics on a PCB. Selected area’s on the PCB are coated with a
thin layer of material to shield the electronics from environmental influences. Since the height
of the components on the PCB can vary strongly, height adjustments may be necessary at
some parts of the PCB.
5.4 Valve overview

See Appendix A ‘Dispense Valve Selection Guide’ for complete list of available dispense
valves.
That is a list of dispensing valves, available from DIMA. This list is intended as an indication
of the possibilities, and may expand as different jobs are requested by our customers.
5.5 Files Overview

Data needed to coat a product on the HYBRID, is stored in files and libraries (database files).
This section gives a short overview of these files and libraries.
page 5-3
Product file
Dimensions Dispense library
Fiducials Profiles
Templates Lines/dots
Panels Configurations
Components Instruments
Dispense data Applicators
Dispense paths Fluids
Variants Distance holders
Fiducial library Work environment

Fiducial details Component details
Dispense library
Fiducial library
Component library Component library
Component details Package library
Package library
Package details
Glue dots
Solder paste dots
The Product file contains all product-specific information needed to produce a product, like
item positions, product dimensions and links to libraries.
The product file contains information not only for the HybridC Conformal Coating
machine, but potentially for all DIMA machines, like Pick-and-Place machines,
Stencil Printers, Dispense Robots, etc.
All information needed to produce lines and dots of coating material is stored in the
dispense library. Here, the various hardware items like instruments, applicators, distance
holders and fluids can be combined to configurations. These, in turn, can be used with
profiles to dispense dots and lines of specific widths and thickness.
The fiducial library contains all information about fiducials and their characteristics.
Fiducials are markers (reference points) placed on the product, they are used to determine
the exact position of the product.
Component-specific information is stored in the component library. Most important entries

are the name and the package of a component. The name shows which component it is (e.g.
10K resistor), the package (e.g. RC-1206) indicates what the component looks like and how
it must be handled. Because different components can look the same, the data about the
packages is stored in a separate library; the package library.
Since the HYBRID is basically designed for conformal coating, not many users will
have to deal with component and package libraries.
5.6 Turning on the Machine and Starting the Application

To start the HYBRID you must first turn on the machine, this also starts the PC. Then you
must start the HybridC application which starts machine initialisation. During initialisation, the
head moves over the whole working area to check the limits of this area and to make sure
that the machine exactly knows the position of the head.
To turn on the machine and start the application:

1. Turn on the main switch. This will start up the PC and the monitor.
page 5-4
2. Log on to your PC.

3. Press the I-button on the On-off switch. This turns on the machine itself.
4. Close the hoods.
5. Double-click on the desktop. Now the application will start up.

6. Enter your (user) Name and Password.
Refer to section 4.5 for more information about passwords.
7. Select the On-line operation mode.
8. Press the Start button. The machine will now start the initialisation.
5.7 Opening a Product file

To produce a product on the HYBRID, a product file is needed. If there is no product file
available or if the product file is incomplete, it should be created or completed; refer to
section 4.4 of the Machine Reference Manual for more information.
When a product file is opened, the application checks if the libraries contain all data required
for the production of this product. If data is missing, a warning will be shown and the missing
data will be marked red in the production elements list on screen. During the production
preparation the missing data should be added.
To open a product file:

1. Select the menu options File, Open.
2. Select the menu option File.
3. Select the file.
If data is missing, a warning will appear. This warning contains a list of missing data and it
shows in which library this data is missing. Press OK to continue, but remember to add the
data later on.
4. Select the product variant (only for opening a file for which variants are available).
When you want to open a file, you can also use the button.
5.8 Preparing for Production

The HybridC application provides the Prepare Production function. Besides all library data
(same check as during opening of a file or project), this function also checks if the machine is
ready for operation, if all configurations are present, and if the pressures are correct. The
result of this check is a list of actions you must perform before you can start production.
To prepare for production:

1. Select the menu options Product, Prepare Production.
If the machine is ready to start production, the message “Ready for production” will
appear.
If the machine is not ready to start production, the event window will open. This window
show a list of problems that must be resolved before you can start production. Items that
concern library data were already mentioned on opening the product file.
2a. (Ready for production) Press OK to close the message box.
page 5-5
2b. (Not ready for production) Solve the items mentioned in the event window. Most likely
these will be one of the following:
Dispense configuration undefined : the dispense library does not contain the
configuration. Create a configuration as described in section 3.1.2 of the Machine
Reference Manual.
No dispense unit : the configuration is not available on any dispense unit. The head of
the machine should be fitted with the correct configuration, and the configuration should
be selected in the Configuration, Dispense units tab.
Dispense profile undefined : the dispense library does not contain the profile. Create
a profile as described in section 3.1.2 of the Machine Reference Manual.
Package not defined : the package library does not contain this package. Enter the
package as described in section 3.3.4 of the Machine Reference Manual.
Component not defined : the component library does not contain this component.
Enter the component as described in section 3.4.3 of the Machine Reference Manual.
Fiducial not defined : the fiducial library does not contain this fiducial. Enter the fiducial
as described in section 3.2.5 of the Machine Reference Manual.
5.9 Adjusting the Conveyor Width

Different product types can have different dimensions so the width of the conveyor (if
present) must be adjusted to fit the product. This adjustment must be made manually.
Width adjust knob
To adjust the conveyor width:

1. Make sure that the motors are turned off. When a key is visible in the move window,
the motors are on and the hoods are locked. Press to turn off the motors.
2. Open the machine hood.
3. Loosen both knobs on the adjustable ledge of the conveyor.
4. Slide the adjustable rail to the new width. Take care to keep this rail aligned with the
fixed rail. Use a product to determine the exact width, making sure the width runs parallel
over the total length of the conveyor.
5. Fasten both knobs.
6. Close the machine hoods.
page 5-6
5.10 Producing a Product

When all machine settings are correct, the dispensers are ready, and the conveyor width is
set, you can start producing.
First step is to load the product in the machine. After that, you can press the start button.
Now the machine automatically checks the product position (by checking the position of the
fiducials on the product) and once this is found, the machine starts coating the product.
When the product is finished, the machine either stops to enable you to take out the product,
or the machine automatically unloads the product to the next machine in the production line.
To produce a product:
1. Select the production tab on the production window.
2. Enter or check the Batch size. This is not strictly required but in this way you will get a
reminder if you finished the batch.
The way you must handle the products will depend on the machine type.
Product handling and production start on a machine without a conveyor:

1. Open the machine hood.
2. Place the product on the work holder.
3. Close the machine hood.
4. Press to start production.
Product handling and production start on a machine with a conveyor:
1. Press to start the production.

Now the product will be loaded into the machine. The way this is done, depends on the
configuration of your HYBRID.
2a. Production line with SMEMA: loading in done automatically.

2b. Production line without SMEMA: you must manually deliver the product to the
machine, depending on the production line. Take care of the correct orientation of the
product.
2c. Stand-alone HYBRID: you must manually place the product on the conveyor at the
machine entrance. Take care of the correct orientation of the product.
During and after the production run

During the production run, the product view on screen will simulate the situation on the real
product. In the item lists in the Production tab, the states of the items will change from “not
dispensed” to (finally) “dispensed”. By selecting the check box Hide you can hide all
dispensed items from this lists, leaving only those that haven’t been dispensed yet.
page 5-7
Press to interrupt production. If a path is being dispensed at that time, you are prompted
to stop at the end of the path or to break off production immediately. To avoid this question,
and unconditionally stop production (as you would if the result is not at all what you
expected), you can press the Break key at the upper right hand corner of the keyboard.
A path that has been interrupted can NOT be completed later.
If production is halted, you can press to continue or to abort the production run.
When an error occurs, the machine will stop and show a message. Solve the
problem and press to continue.
When the product is completed, the orange status light will light up and on screen, the yellow
production indicator starts blinking. The product can now be unloaded. Depending on the
machine type and settings this must be done manually or it is done automatically.
5.11 Shutting Down the Application and Turning off the Machine
When the job is finished, the application must be shut down properly and the machine must
be turned off.
To shut down the application and turn off the machine:

1. Select the menu options File, Exit. This will close the software and disable the machine.
2. Shut down MS-Windows.
3. Press the O-button on the On-off switch to turn off the machine.
4. Turn off the main switch. This will completely turn off the machine and the PC.
page 5-8
6. Troubleshooting
6.1 Introduction
This chapter offers a guide to solve problems that may occur while working with the HYBRID.
It starts with some frequently asked questions. Next are sections with troubleshooting
diagrams. These sections are arranged according to process step.
When the suggested solutions do not solve the problem, please call your local distributor.
Write down the problem or the description and the number of the error message.
This may be useful in finding the solution for the error.
6.2 Frequently Asked Questions

How can I rotate one panel on a multiple PCB over 180°?
Turn off the Shift check box in the PCB Panels tab and enter the angle (Phi). The first
panel fiducial serves as rotation point.
I want to replace one item on a product by another one. What must I do?
That depends. If you want to replace the item permanently, you just have to change the
product file. If you want to replace the component temporarily, you should make a variant
of this product.
page 6-1
6.3 Machine Start-up

Machine doesn’t start up properly
Machine doesn’t start-up properly
- Check power connection

no
PC and monitor on? - Check if on-switch of PC
and monitor are on
yes
- Check emergency
no
LEDs on electronics switches (pull out)
active? - Push I-button
yes
Machine initialises - Restart software and

no
when start-button in select online operation
software is pressed? mode
yes
Machine started
successfully
6.4 General
No cross/grid or scale marks in the display image during recognition of fiducials
The pixel size may be set to zero. Contact your local distributor to recalibrate the machine.
The message “Mapping value out of range” shows up.

This message indicates that the distance between fiducials found, differ more than
maximum size error from the distance as entered in the product file, and/or lead to a
product angle of more than the maximum angle error. Check if the product is loaded
correctly into the machine and check if the correct fiducials are indicated by the operator.
The maximum values can be modified in the Configuration window.
Fiducial not recognised

Refer to section 3.3.5 of the Machine Reference Manual.
page 6-2
Park-and-purge causes an ‘Cannot reach’ error
One or more dispense units may have been recalibrated, causing the park or purge
position to get just out of reach. Re-teach the positions with sufficient margin to allow for
calibration differences.
6.5 Product Loading/Unloading

Product not transported (properly)
Product not transported (properly)
no no - Check in configuration if
Transport belt/chain running? Working with SMEMA?
SMEMA is turned off
yes yes
- Check SMEMA signals
- Check conveyor width

Product stuck on belt/chain?
yes -Check if clamping is clean
no
Problem should be
solved.
Call for help if it isn’t
page 6-3
Transport belt doesn’t stop over the stop pin during loading of product
Transport belt doesn’t stop

When product is over sensor
- Check if sensor works at all

no
Product detected by sensor? - Check/adjust sensor’s
sensitivity
yes
yes - check transport speed in

Loading from the right? combination with waiting time
in Configuration
no
- Call for help
6.6 Production
The ‘Start production’ button is disabled
Run Prepare production from the Product menu to see what problems prevent production
from starting.
All panels on a multiple product are automatically badmarked.

Check the following:
• Open the Product panels tab and check if the check box Last fiducial is badmark fiducial
is accidentally turned on.
Some paths are dispensed with an offset
Check if a needle for a dispense unit, or a complete dispense unit, has been replaced
recently. If so, recalibrate the dispense unit(s).
Production starts but nothing is being dispensed

Check if Camera or Demo mode is not selected.
page 6-4
7. Maintenance and Support

7.1 Maintenance
Maintenance intervals as described in this Chapter are based on machine operation of 8
hour/day and 5 days/week. If your machine is in operation more frequently, the maintenance
schedule should be adjusted accordingly.
Ensure you fully understand the safety instructions applied in the safety section.
Always turn off the machine and disconnect the air supply, before you
are going to start maintenance or repairs to the machine.
Consult the Material Safety Data Sheet (MSDS) for all fluids used with
the Hybrid. The MSDS provides material usage instructions, safety
precautions, information about personal protective equipment, and
disposal instructions. Also check for compatible fluids when using more
than one fluid.
7.1.1 Daily Maintenance

The following items should be checked daily:
• Air system
Ensure that the main air regulator is set to the 6 Bar.
Ensure that the pressure regulators for the fluid pressure and atomising air pressure are
set to the pressure required for your application.
Ensure that the solvent position is filled with the right solvent material.
Ensure that the material purge bin is emptied.
Check air connections for leakage and repair if required.
• Coating materials
Check levels of material and refill the fluid reservoir as required.
Check the material feed tubes for any damage and replace if required.
7.1.2 Monthly Maintenance

The following items should be checked monthly:
• Cleaning the HYBRID
Keep your HYBRID clean to let the machine perform at its best.
• Clean the outside of the machine with moist cloth. Do never use detergent or
aggressive cleaners.
• Clean the PCB compartment with solvent that can be used in combination with the
material used at your machine.
• Clean the sensors on the conveyor with a soft cloth (only when a conveyor is
present).
• Ensure that the openings of the exhaust system are not blocked or covered.
page 7-1
• Air connections
Disconnect the air connection to turn off the air pressure. Empty the water separator. This
is located behind the PC in the PC compartment.
Take care that no water is spilled into the PC compartment.
7.1.3 Yearly Maintenance

The following maintenance should be performed every year.
• Mapping the motion system (only for machines with HC-1570 ESI option)
To maintain accuracy of the motion system, a mapping calibration must be performed.
• If you have a calibration plate, this can be done by yourself. Refer to section 7.2.
• If you don’t have a calibration plate, the DIMA authorized service engineer will
perform the mapping calibration on the service visit.
• Service visit from a DIMA authorized service engineer
DIMA advises to have a DIMA authorized service engineer to visit you, to perform the
following maintenance:
• Lubrication of X, Y, Z and Φ bearing
• Check of operation PCB clamping and other conveyor parts (when a conveyor is
placed).
• Check condition of Z and Φ belt and tension of the belt.
• Check the internal ventilation system.
• Check operation of the access doors and the gas springs.
7.2 Mapping the Motion System

Due to mechanical deviations, the position as measured by the motion system may differ
from the actual position. To correct these position errors, a calibration array (a kind of map)
can be created, that links positions of the motion system to actual positions. For this
mapping, a calibration plate (ordering number HP-110-SS-58) is available (not delivered with
the machine).
Note that mapping the motion system may take up to an hour.
To map the motion system:

1. Start up the HYBRID and the HybridC software. Note that only user types “service” and
“supervisor” are allowed to perform a mapping calibration.
2. Select the menu options Options, Calibration.
3. Select the menu options Motion machine part.
4. Place the calibration plate in the machine, in the same position a were normally a PCB is
placed.
5. Press Calibrate.
6. Select the calibration variant. This determines the number of measuring points that will be
used. The calibration is now performed automatically
If the calibration stops before all measuring points have been measured, some adjustment
of the fiducial setting may be needed.
page 7-2
To adjust the fiducial settings:
• Press the Ctrl button and simultaneously select the button. Now, the calibration
library (as set in the Configuration window) will open.
• Press the Test button to check if the measuring point is recognised.
• If the measuring point is not recognised, adjust the illumination by adjusting the slider in
the move window.
• Keep on testing and adjusting until the measuring point is recognised. Than you can
restart the calibration.
7. Press Apply when the calibration is completed, to save the calibration array.
7.3 Support
For questions about the HYBRID including the software, please contact your local supplier.
In case of problems, write down the problem or the description and the number of an error
message first before calling your local supplier. The better you can tell what happened, the
better and faster your supplier can help you.
Parts replacement should only be performed by DIMA authorised

service personnel. DIMA assumes no liability for personal injury or
damage to the product that may occur as a result of reparations done by
other than DIMA authorised service personnel.
page 7-3
8. Spare Parts
The following spare parts are available for the user, and can be exchanged by the operator.
Coating accessories:
• HC-1400 Set of 12 Polyurethane bins for use with the HC-1200
• HC-1410 Set of 64 cartridges for use with the HC-1210
• HC-1415 Set of 32 cartridges for use with the HC-1215
• HC-1430 Set of 10 disposable tank liners for use with the HC-1230 / 31
General:
• SO-9515 Cable for SMEMA interface (1.5 m)
When you have any questions, please call your local supplier.
page 8-1
Dispense Valve Selection Guide Ver1.0 Appendix A
A. Dispense Valve Selection Guide

Rotary Diaphragm Needle Spray Valve Spray Valve
Dispense
Round Beam Wide Beam
Valves ⇒ (DD-5100) (DD-5110) (DD-5130) (DD-5140) (DD-5141)
Applications
⇓
Sealing ♥ # U U
Potting/Filling # ♥ U U
Coating U ♥ ♥
Dots ♥ # U
Materials
Activators U ♥ ♥
Acrylics # U ♥ ♥
Alcohol U ♥ ♥
Anaerobics U U U U
Conformal
Coatings
U ♥ ♥
Cyanoacrylates U U U U
Epoxies # # U U
Flux (Acid
U U U U
based)
Flux (Non Acid) U
Grease # # #
Heat Sink
Compound
# ♥ # #
Inks U # #
Lacquers U
Oils U ♥ ♥
Paints U # ♥ ♥
RTV/Silicone U # # ♥ ♥
SMD-adhesive # U U
Solder Mask ♥ # # #
Solder Paste U U U U
Solvents U # #
UV-cure (UV
only)
U ♥ ♥
UV-cure (+
U U U U
anaerobic)
Other Consult DIMA SMT Systems
Viscosity
Low U
Medium # ♥ ♥ ♥ ♥
High U ♥ # #
Explanation of used symbols:
Excellent ♥ Good # Average/testing required U Do not use
page A-1
Ventilation Calculation Appendix B
B. Ventilation Calculation
Here you will find an example calculation, used to determine the minimal required ventilation.
Explosion properties are determined by the solvent involved. A critical solvent is n-

Butylacetat.
Product: Elpeguard SL 1400 ECO FLZ
Data source:
• MSDS provided by manufacturer of coating: Peters GmbH+Co KG
• ESIS (European Chemical Substances Information System)
Upper explosion limit (UEL) [vol %] 1,2
Lower explosion limit (LEL) [vol %] 7,5
Minimum ignition temperature [°C] 370
Minimum ignition energy (MIE) [mJ] -
Gas group -- IIA
Temperature group -- T2
Flash point [°C] 22
K-class -- K2
Max. explosion pressure (pmax) [bar] -
Max. experimental safe gap (mesg) [mm] -
Molecular weight * 116,2
Melting point [°C] -77
Boiling point [°C] 127
Density [kg/dm3] 0,88
Vapor density [kg/m3] 4,01
Leaking flow
Assumed is processing of 2 liters product per hour.
It contains 50 % n-butyl acetate = 1 liter/hour
Density is 0.88 kg/dm3
This is 0,2 g/s
To convert to m3/h:
a = am x (1/M) x 25 x3,6 (see NPR 7910-1, par. 8.3.2, formula 3)
where:
am = leaking flow in g/s
M = molar weight in g/mol
25 = approximate mol volume at room temperature, in m3/kmol
3,6 = conversion factor
result a= 0.16 m3/h
Ventilation capacity (VC)

The VC is calculated with the following formula:
VC = a x (100/LEL) x (100/k) (see NPR 7910-1, par. 8.3.2, formula 2)
where:
VC = ventilation capacity, in m3/h air
a = leaking flow in m3/h (see above): 0,16 m3/h
LEL = lower explosion limit in vol%: 7,5
page B-1
Ventilation Calculation Appendix B
k = safety margin applied on the LEL, in vol%: 10

result: VC = 21 m3/h
Check of ventilation rate (VR)
The calculated VC must produce a ventilation rate of the area concerned of at least 4. This is
calculated with the following formula:
VR = VC/V (see NPR 7910-1, par. 8.3.2, formula 6)

where:
VC = 21 m3/h
V = volume of the area concerned: 1m x 1,1m x 1m (l x w x h)
VR=19
The resulting has to be > 4
Furthermore the ventilation has to meet the technical requirements of EN-IEC 60079-10:
2002 Annex B.5.
page B-2

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HybridC

(C) Copyright 2007 DIMA SMT Systems NL. B.V.

The following trademarks are being acknowledged:

MS-Windows ™ is a trademark of the Microsoft Corporation.

CorrectPlace ™ is a trademark of ESI.

Not complying with the safety recommendations can result in injury to

General safety precautions:

Fluids can be extremely dangerous when working with high pressure.

Next figure shows the positions on the HYBRID.

Situated in left rear

DIMA SMT Systems NL. B.V.

1. Product Information 1-1

4.3 The Workspace 4-2

The HYBRID is operated through a MS-Windows oriented user interface.

At the moment there are two types available:

1.2 Field of Application and Intended Use

1.3 Technical Specifications

Controller : Processor-controller dedicated electronics

Temperature : Machine : 18-30 °C

Noise : In operation < 70 dB(A)

Weight : 440 kg without tanks

Inlet for air hose,

Outlet for power

2.4.1 Power connection

V 110 VAC V 220 VAC

2.4.2 Air Connection

2.4.3 SMEMA connection

2.4.4 Exhauster Connection

3.1 Machine Exterior

The status light shows the status of the machine:

Green light on : The machine is coating a product.

Green light blinks : The machine is ready to start production.

3.2 Product Compartment HC-100 / HC-200

3.3 Coating Head HC-100

11. Right hand

12. Air through

13. Air through

14. Air through

15. Air through

20. Drive motor for

21. Main switch for

3.4 Coating Head HC-200

Front view of base

Side view of base coating head with tools HC-

1. Motor for motion in

2. Main air switch for

P5. Connector 01 for

P6. Connector 02 for

P11 till P14.

P21 till P24.

3.5 HC-100 Specific Options

For different types of adapter plates are available

1. Base coating head

2. Adapter plate HC-

5. Mounting holes for

6. Mounting holes for

7. Mounting holes for

3.5.3 HC-100 Specific Option: HC-1030 / HC-1031 Valve Mount

1. Air lines from

2. Wires from rear

To mount a valve mount assembly in combination with a HC-1020 to the Hybrid:

10. Clamp guide of

12. Wires from D25