LOW PRESSURE MATERIAL REGULATOR

Transcription

1 OPATO S MANUAL INCLUDING: OPATION, INSTALLATION & MAINTNANC LOW PSSU MATIAL GULATO 65179X-XXX-B LASD: VISD: (V. H) AD THIS MANUAL CAFULLY BFO INSTALLING, OPATING O SVICING THIS QUIPMNT. It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference. SVIC KITS Use only genuine AO replacement parts to assure compatible pressure rating and longest service life. Order XXX-B ebuild Kit (see chart below) for general repair of the regulator. This includes a diaphragm kit and a valve kit. Fluid diaphragm kit can be ordered separately (see page 4). kit can be ordered separately (see page 4). BUILD KIT DSCIPTION CHAT XX-B MOT X X X - B Type 2 - Downstream 3 - Back Pressure Ball Size A " B " C " Ball & Material 1 - Tungsten Carbide 2 - Stainless Steel (400 series) 4 - Stainless Steel (300 series) BUILD KIT SLCTION XAMPL: MODL # A2D-B BUILD KIT # A2-B SPCIFICATIONS Model Series X-XXX-B Type XXX-B Downstream XXX-B Back Pressure Material Inlet see model chart Material Outlet see model chart Dimensional Data see figure 9 PFOMANC DATA egulated Pressure ange see model chart Maximum regulated pressure see model chart Maximum inlet pressure A4X-B, -B4D-B, -BX-B p.s.i. (34.5 bar) A1X-B, -A2X-B, -A3X-B, -B1C-B. 750 p.s.i. (51.7 bar) B1D-B, -B3D-B, -BX-B p.s.i. (86.2 bar) BXD-B, -CXD-B p.s.i. (13.8 bar) BX-B p.s.i. (55.2 bar) Maximum temperature limits to 200 F (-18 to 93 C) XXX-B BACK PSSU XXX-B DOWNSTAM MODL DSCIPTION CHAT Type 0 - Downstream 1 - Back Pressure Port Size, (Ball Size) A - 3/8-18 N.P.T.F. (0.1875") B - 3/8-18 N.P.T.F. (0.250") C - 1-1/4-11-1/2 N.P.T.F. (0.500") Material, Body (, Stem) 1 - Zinc (Tungsten Carbide, Tungsten Carbide) 2 - Stainless Steel (Stainless Steel, Stainless Steel) 3 - Stainless Steel (Tungsten Carbide, Tungsten Carbide) 4 - Stainless Steel (Stainless Steel, Stainless Steel) 5 - Stainless Steel (Stainless Steel, Tungsten Carbide) egulated / Maximum Pressure ange B p.s.i. ( bar) Downstream C p.s.i. ( bar) Downstream D p.s.i. ( bar) -AXD Downstream models p.s.i. ( bar) -BXD Downstream models p.s.i. ( bar) Back Pressure p.s.i. ( bar) Downstream p.s.i. ( bar) Back Pressure p.s.i. ( bar) emote 300 series stainless steel 400 series stainless steel X - X X X - B INGSOLL AND COMPANY LTD P.O. BOX 151 ON AO CNT BYAN, OHIO (800) FAX (800) CCN

2 OPATING AND SAFTY PCAUTIONS XCSSIV AI PSSU STATIC SPAK HAZADOUS MATIALS HAZADOUS PSSU ead and heed all Warnings and Safety Precautions before operation of this unit. Use only genuine AO replacement parts to assure compatible pressure rating and longest service life. Be certain anyone operating this equipment or fluid system has been trained to use it safely. WANING HIGH PSSU DVIC. IMPOP USAG OF THIS QUIPMNT COULD SULT IN SIOUS INJUY. The possibility of injection into the flesh is a potential hazard. Wear approved safety glasses or face shield and other equipment as needed to prevent injury. Never allow any part of the human body to come in front of or in contact with the material outlet, the tip, or the material outlet of the dispensing device. An injection injury can be serious. If an injection accident should occur, it is very important that you contact a qualified physician for immediate treatment. WANING MISAPPLICATION HAZAD. DO NOT US TH GULATO WHN TH FLUID INLT PSSU IS TOO HIGH FO TH DSIGND OPATING ANG. xcessive inlet pressure can cause a lock-out situation. Lock-out occurs when the inlet pressure is beyond the regulator s spring capacity. TH VALV WILL NOT OPN. Attempts to disassemble components while in a Lock-Out condition may result in injury. WANING COMPONNT UPTU. DO NOT OPAT GULATO AT AN INLT PSSU GAT THAN SP- CIFID. To avoid possible damage or personal injury DO NOT operate this unit at pressure higher than the stated operating range as it appears on the model plate. WANING DISASSMBLY HAZAD. DO NOT DISAS- SMBL THIS GULATO WHN IT IS UND PSSU. LIV PSSU IN TH PUMPING SYSTM BFO AT- TMPTING SVIC O DISASSMBLY POCDUS. Disconnect air lines and carefully bleed pressure off the system. Be certain the system is not maintaining pressure due to a material restriction in the hose, line, dispensing device, or the spray or extrusion tip. Failure to relieve pressure both up stream and downstream may result in an injury upon disassembly. WANING BONNT MOVAL HAZAD. DO NOT ATTMPT TO MOV TH FOU BONNT TAINING BOLTS WITH- OUT FIST LIVING TH TNSION ON TH MAIN SPING. Failure to relieve tension could result in an accident upon disassembly. CAUTION FLUSH SUPPLY LIN. Before installing fluid regulator blow the supply lines clear and flush to remove contaminates. INSTALLATION efer to the typical installation view which best applies. Locate the regulator as close as possible to the spray gun or dispensing device for best pressure control. Identify the regulator INLT / OUTLT (flow direction). The regulator is marked with an arrow on the body base. Flush supply line before installing regulator. emote models require maximum 100 p.s.i. (6.9 bar) signal pressure. Start with a signal pressure as low as possible and adjust upward until proper flow is reached. Filter TYPICAL DAD ND SYSTM Down Stream Down Stream TYPICAL CICULATING SYSTM Back Pressure Filter TYPICAL MOT SYSTM (Air) FL FL (Material) Filter Heater Down Stream Air to Gun Back Pressure Down Stream Air to Gun Back Pressure emote Automatic xtrusion Gun 4-Way Limit Switch Figure 1 Page 2 of 8 Teflon is a registered trademark of the DuPont Company AO is a trademark of Ingersoll-and Company Loctite and 242 are registered trademarks of Henkel Loctite Corporation Perma-Lok is a registered trademark of National Starch and Chemical Corporation

3 OPATING INSTUCTIONS efer to pages 4 and 5 for parts reference. To INCAS outlet pressure, turn the (6) adjusting screw CLOCK- WIS. To DCAS outlet pressure, turn the (6) adjusting screw COUN- TCLOCKWIS. NOT: AO part Y Allen wrench is included to make necessary pressure adjustments. FLUSH-OUT FATU FO DOWNSTAM MODLS ONLY. See figure 3. Flush the regulator periodically. The interval may vary depending on the amount and type of material used. By using a wrench and flush-out" plug (provided), the operator is able to move the entire spindle downward and force the ball off the seat which should purge the regulator of particle build-up. NOT: The flush-out procedure temporarily overrides the adjusted pressure. It will not, however, affect the regulator setting when flushing operation is completed. FLUSH-OUT POCDU 1. emove spray gun or dispensing device, this will allow any particles to clear from the system. 2. Insert (21) flush-out plug and turn clockwise until it touches the (4) washer (see view on page 5). 3. Turn up to two turns maximum. This will allow the ball to unseat and pass material at free flow (unregulated). DO NOT attempt to turn further to avoid damage. 4. Turn the plug back to its original position. SAT PLUG FATU The (47) plug located at the base of the regulator can be removed for access to the ball and seat assembly for cleaning and inspection for wear. With this feature, the regulator does not have to be unthreaded from the pumping system. Be certain to relieve system pressure (see WANING: DISASSMBLY HAZAD"). TOUBL SHOOTING No fluid pressure. Check for damaged or worn diaphragms. Look for possible obstruction by hardened material or foreign matter, periodically use the regulator flush-out" feature (Downstream models only). Use a fluid filter upstream from the regulator. Pressure creeps above the setting when system is dead ended and in a static (no flow) mode. Check for dirty seat and clean as appropriate. Check for worn or damaged seat and replace if necessary. Outlet pressure drops below setting. Check pump for proper operation and check for possible leakage problems. Look for a clogged supply line problem, flush the supply line. Fluid leakage from spring housing. Check the bonnet hold-down screws and the plate hold-down screws and re-torque as needed. Check for damaged diaphragm, replace as needed. will not function, even when dispensing device is opened. Check for possible obstruction in the fluid line. Inlet pressure is too high causing a lock-out" situation. ead WANING: MISAPPLICATION HAZAD" found on page 2. TYPICAL BACK PSSU GULATO COSS SCTION VIW SHOWING MAJO COMPONNTS Bearing MAINTNANC Disassembly should be done on a clean work bench and use clean cloths. If replacement parts are necessary, refer to the parts list and drawings on pages 4 and 5. Upon reassembly, lubricate parts and use Loctite where indicated. Follow the torque specifications as shown. Service kits are available which include parts typically needed for an overhaul. Keep good records of service activity and include the regulator in a preventive maintenance program. Certain AO Smart Parts" are indicated with a " in the parts list, these parts should be available for fast repair and reduction of down time. VIW OF SPING ADJUSTMNT POCDU. VIW OF FLUSH-OUT PLUG Adjusting Screw Adjusting Spring Ball / Stem Dual Diaphragm Figure 2 Figure 3 Figure 4 Plug Page 3 of 8

4 PATS LIST / 65179X-XXX-B GULATO 65179X-XXX-B COMMON PATS Item Description (size) Part No. Qty Mtl Item Description (size) Part No. Qty Mtl 1 Housing X-B (Downstream) (1) [A] X-B (Back Pressure) (1) [A] 2 Bolt (7/16" - 20 x 5") (4) [C] 3 Washer (7/16 i.d.) Y (4) [C] 4 Washer (1.162" o.d. x 0.125" thick) (1) [C] 5 Thrust Bearing (1.173" o.d.) (1) [C] 6 Adjusting Screw (5/8" - 24, left hand) (1) [C] 7 Plate (1) [SS] 8 Adjusting Nut (1) [C] 9 Spring 65179X-XXB-B (Green, in. lbs) (1) 65179X-XXC-B (Orange, in. lbs) (1) 65179X-XXD-B (Gray, in. lbs) (1) 65179X-XX-B (ed, in. lbs) (1) 10 Screw (#10-32 x 7/8") Y (1) [C] 11 Lock Washer (0.196" i.d.) Y14-10 (1) [C] 13 Small Plate (1) [C] 14 Button (1) [A] 15 Plate (1) [C] 16 Diaphragm (0.062" thick, black) (1) [N] 17 Diaphragm (0.020" thick, white) (1) [T] 18 O" ing (3/32" x 1-7/8" o.d.) Y (1) [T] 20 3/8" Allen Wrench Y (1) [C] Flow / Size -XXX Port Size N.P.T.F. Ball Size XXX-B DOWNSTAM GULATOS ebuild Kit Stem (40) 21 Flush-Out Plug models X only (1) [C] Kit (41,42,43,44) (see below) 22 Spring Stop XXB-B (1.597" long) (1) [SS] XXC-B (2.265" long) (1) [SS] XXD-B (2.125" long) (1) [SS] XX-B (2.359" long) (1) [SS] 23 Long Nipple (1/4-18 N.P.T. x 4") Y44-15-S (1) [SS] 24 Coupling (1/4-18 N.P.T. x 1-3/8") Y S (1) [SS] 25 Gauge models 65179X-X1B-B and -X1C-B (1) [Br/Bz] (0-60 p.s.i. / 0-4 bar) models 65179X-X1D-B (0-300 p.s.i. / 0-20 bar) (1) [Br/Bz] models 65179X-X1-B ( p.s.i. / 0-70 bar) (1) [Br/Bz] models 65179X-X3B-B, -X3C-B, -X4B-B and (1) [SS] -X4C-B (0-60 p.s.i. / 0-4 bar) models 65179X-X2D-B, -X3D-B and -X4D-B (1) [SS] (0-300 p.s.i. / 0-20 bar) models 65179X-X2-B, -X3-B and -X4-B (1) [SS] ( p.s.i. / 0-70 bar) 26 Stud (7/16" - 20 x 4") models B5-B (2) [C] all models except B5-B (1) [C] 27 Nut (7/16" - 20) models B5-B Y11-7-C (4) [C] all models except B5-B Y11-7-C (2) [C] 28 Lock Washer (7/16") models B5-B Y (2) [C] all models except B5-B Y (1) [C] Flow Tube (45) O" ing (46) Base Plug Asm. (47) Base (48) Pipe Plug (52) -A1X 3/8.1875" A1-B Y17-52-N STANDAD -A3X 3/8.1875" A1-B Y17-52-S -A4X 3/8.1875" A4-B Y17-52-S -B1X 3/8.250" B1-B Y17-52-N -B2X 3/8.250" B2-B Y17-52-S HI-FLOW -B3X 3/8.250" B1-B Y17-52-S -B4X 3/8.250" B4-B Y17-52-S -B5X 3/8.250" B4-B Y17-52-S Flow / Size -XXX Port Size N.P.T.F. Ball Size XXX-B BACK PSSU GULATOS ebuild Kit Stem (40) Kit (41,42) (see below) Flow Tube (45) O" ing (46) Base Plug Asm. (47) Base (48) Pipe Plug (52) -B1X 3/8.250" B1-B Y17-52-N HI-FLOW -B3X 3/8.250" B1-B Y17-52-S -B4X 3/8.250" B4-B Y17-52-S SYSTM -C3D 1-1/4.500" C1-B FLOW -C4D 1-1/4.500" C4-B Kit (41) O" ing (42) DOWNSTAM VALV KITS BACK PSSU VALV KITS (43) Ball (44) Spring Kit (41) O" ing (42) (43) Ball (44) Spring Kit (41) O" ing (42) Kit (41) O" ing Y Y Y Y Y Y Y Y Y Includes item 46 Smart Parts", keep these items on hand in addition to the service kits for fast repair and reduction of down time. Items not shown NOT: XXX-B rebuild kits include both diaphragm service kit and valve kit shown, in the chart above. xcept models XX-B Items included in diaphragm service kit. (42) Page 4 of 8

5 PATS VIW / 65179X-XXX-B GULATO TOQU QUIMNTS NOT: DO NOT OVTIGHTN FASTNS. (2) Torque alternately. 1.) Snug. 2.) ft lbs ( Nm). (10) in. lbs ( Nm). LUBICATION SALANTS Apply Perma-Lok LH150 anaerobic pipe sealant to threads. Apply Loctite nickel anti-seize to threads. Apply grease. Apply Loctite nickel anti-seize to threads (except on models 65179X-X1X-B). MATIAL COD [A] = Aluminum [Br] = Brass [Bz] = Bronze [C] = Carbon Steel [N] = Neoprene [SS] = Stainless Steel [T] = Teflon PTF UPP GULATO SCTION XX MOT MODLS (see page 6) (black) (white) ( CXX-B) ( AXX-B) ( BXX-B) ( BXX-B) 40 VALV SCTION (see page 6) 52 PATS AVAILABL IN VALV KIT ( BXX-B) (0.250") ( AXX-B) (0.1875") ( BXX-B) Figure 5 Page 5 of 8

6 PATS LIST 65179X-XX MOT MODLS Item Description (size) Part No. Qty Mtl 30 Air Cap (1) [A] 31 Diaphragm (1) [B] 32 Spacer (1) [A] 33 ivet Y (1) [A] 34 Washer (1) [C] 35 Piston (1) [C] 36 Bolt (7/16" - 20 x 1-1/2") Y (4) [C] 37 Adapter (1) [A] 38 Bolt (M8 x g x 40 mm) (4) [C] 53 Pipe Plug (1/4-18 N.P.T.)(see page 5) models X1-B only Y17-51-N (1) [C] models A3-B, -A4-B, -B4-B Y17-51-S (1) [SS] and-b5-b Smart Parts", keep these items on hand in addition to the service kits for fast repair and reduction of down time MATIAL COD [A] = Aluminum [B] = Nitrile [C] = Carbon Steel [SS] = Stainless Steel TOQU QUIMNTS NOT: DO NOT OVTIGHTN FASTNS. (36) Torque alternately. 1.) Snug. 2.) ft lbs ( Nm). (38) Torque alternately. 1.) Snug. 2.) 10 ft lbs (13.6 Nm). Apply Loctite 242 to threads. Figure 6 FO WANINGS", F TO OPATING AND SAFTY P- CAUTIONS" ON PAG 2 FO DTAILS. BFO SVICING, AD WANING: DISASSMBLY HAZ- AD." FOUND ON PAG 2. TOOLS QUID: Small bench vise, 3/8" Allen wrench (Y is included), 5/32 Allen wrench, a 9/16" Allen wrench for -CXX-B models, torque wrench and Loctite 242. NOT: It is not always necessary to remove the regulator from the fluid line to service or inspect only the valve section. BFO DOING ANY IN-LIN SVIC, ALL FLUID PSSU MUST B LIVD. HD ALL WANINGS FOUND ON PAG 2. ALLN WNCH NOT: The Y (3/8") Allen wrench is included and can be used for several functions including: adjustment (spring type models), removal and assembly of the long bonnet bolts and the short plate bolts. GULATO DISASSMBLY F TO PAGS 4 AND 5. BACK PSSU STYL MODLS 2. emove the (46 / 47) base plug / O" ring which will allow the removal of the (45) flow tube, (41) seat and (42) O" ring. 3. Inspect the (41) seat for dirt, damage or wear. AD WANING: BONNT MOVAL HAZAD" FOUND ON PAG emove the four (2) long bolts to allow removal of the bonnet / adjusting screw assembly. NOT: The (6) adjusting screw, (5) thrust bearing and (4) washer are retained by (7) plate which is pressed into place. It should not be necessary to disassemble these parts during normal service. 5. emove the (9) regulator spring and (22) spring stop. 6. emove the (15) plate. 7. emove the stem / diaphragm and piston assembly. 8. Place the stem in a vise, locate and secure on the stem flats provided. 9. Using a 5/32" hex Allen wrench, remove the (10) screw. 10. emove the (11) lockwasher, (13) small plate, two (16, 17) diaphragms, (18) O" ring, from the (40) valve stem. VALV SAT NOT: Before deciding to order a general repair kit to service the whole regulator, check the easiest things first. emove and inspect the valve seat for dirt, foreign matter, damage or wear (steps 1-3). DOWNSTAM STYL MODLS 1. emove the (46 / 47) base plug / O" ring assembly which will allow removal of the (44) spring, (43) ball, (45) flow tube, (42) seat and (41) O" ring. MOT MODLS (efer to figure 6) 1. emove four (38) screws from (30) air cap and separate the diaphragm assembly from the (37) adapter. 2. Separate the two halves to allow inspection of the (31) diaphragm and replace, if necessary. 3. emove the four (36) bolts, releasing (37) adapter from the base. 4. eassemble in reverse order. Page 6 of 8

7 GULATO ASSMBLY Also refer to parts list and views on pages 4 and 5. Install (42) seat. 1. Place the (10) screw and (11) lockwasher through the (13) plate and Install the (45) flow tube. into the (14) button. Install the (43) ball. NOT: Be certain the radius faces the (16) diaphragm. Install the (44) spring with the narrow end against the ball. 2. Locate the (15) plate over the (14) button. Install the (47) valve plug and O" ring assembly. 3. Position the (16) black diaphragm on the (10) screw. Tighten until snug. 4. Position the (17) white colored diaphragm in the same manner. 5. Thread the (40) or (49) valve stem onto the small screw and snug BACK PSSU MODLS hand tight. Install (41) O" ring. 6. Flip the assembly over and place in vise, locate on the valve stem Install (42) seat. flats. Use one of the (2) long bolts to align the diaphragms and the Install the (47) valve plug and O" ring assembly. plate. The bolt is to help maintain alignment of the diaphragms only Tighten until snug. at this point (see figure 7). 7. Hold the plate in this position and tighten the (10) small screw into the stem. Torque to in. lbs ( Nm). 8. emove the stem / diaphragm assembly from the vise. 9. Place the (18) O" ring into the base groove. 10. Place the stem / diaphragm assembly on the base and align the bolt holes. 11. Place the (9) spring and (22) spring stop on plate. NOT: Spring references do not apply to -XX" emote models. 12. Place (1) housing and align the four bolt holes. 13. Place four (3) lockwashers on four (2) long bolts and install. 14. Flip the assembly over. 15. Turn regulator over and vise on flats. DOWNSTAM MODLS Install (41) O" ring. Figure 7 PFOMANC DATA G U L A T D P.S.I. (BA) 200 (13.8) 180 (12.4) 160 (11) 140 (9.7) 120 (8.3) DOWNSTAM LOW PSSU GULATO MODLS TST MDIA 55 CNTIPOIS P.S.I AXX (BA) G U L A T D 800 (55.2) 700 (48.3) 600 (41.4) 500 (34.5) BXX P S S U 100 (6.9) 80 (5.5) 60 (4.1) 40 (2.8) 30 (2.1) 15 (1) P S S U 400 (27.6) 300 (20.7) 200 (13.8) 100 (6.9) 5 (.3) G.P.M. Liter / min..5 (1.9) 1 (3.8) 1.5 (5.7) 2 (7.6) 2.5 (9.5) 3 (11.3) G.P.M. Liter / min. 1 (3.8) 2 (7.6) 3 (11.3) 4 (15.1) 5 (18.9) 6 (22.7) Figure 8 Page 7 of 8

8 DIMNSIONAL DATA 65179X-AXX-B 65179X-BXX-B MODLS CXD-B BACK PSSU MODLS 9.856" (250 mm) " (257 mm) 7.318" (186 mm) 7.570" (192 mm) 1.167" (30 mm) 1.526" (39 mm) 1.313" (33 mm) 3.078" (78 mm) 4.124" (105 mm) 0.625" (16 mm) 5.689" (145 mm) XX-B MOT MODLS 4.500" (114 mm) 4.503" (114 mm) 1.167" (30 mm) 1.526" (39 mm) 3.078" (78 mm) 4.124" (105 mm) 0.625" (16 mm) Figure 9 Page 8 of 8 PN