Pro-Meter S2K-Series Dispensers

Transcription

1 Pro-Meter K-eries Dispensers Customer Product Manual Part Issued 0/ NORDON CORPORATION AMHERT, OHIO UA

2 afety... Qualified Personnel... Intended Use... Regulations and Approvals... Personal afety... High-Pressure Fluids... Fire afety... Halogenated Hydrocarbon olvent Hazards. Action in the Event of a Malfunction... Disposal... Description... Theory of Operation... Refill Phase... Idle Phase... Pre-Pressure... Dispense/Purge Phase... ARW Circuit... pecifications... 5 Installation... 7 Install the K Dispenser to a Fixture... 7 Connect the Controller Cables... 7 Connect the Material, Air, and Water Lines... 7 Connect an ARW Dispenser to the ystem Air Purge Circuit... 8 Operation... 0 tartup... 0 hutdown... 0 Maintenance... Water Treatment... Water Types... Corrosion Levels... Biocide Water Treatment... Troubleshooting... Repair... 5 Consumable Items... 5 Linear Actuator Assembly... 6 Remove the Linear Actuator Assembly... 6 Install the Linear Actuator Assembly... 6 Replace a Linear Actuator... 6 Proximity ensors... 6 Adjust the Retract and Extend Proximity ensors... 8 Adjust the Refill Proximity ensor... 8 Repair (continued) Hydraulic ection... 0 Replace the Inlet Valve Packing Cartridge... 0 Replace the Outlet Valve Packing Cartridge... 0 Replace the Inlet Valve... 0 Replace the Outlet Valve... 0 Replace the Pressure Transducer... Remove the Packing Gland and Plunger Assemblies... Install the Packing Gland and Plunger Assemblies... Rebuild the Packing Gland... Replace the Thermostat... 6 Replace a Heater Cartridge... 6 Replace the RTD... 6 Parts... 8 tandard K Dispenser /0 Volt Heated K Dispensers... Kits... 6 Packing Glands... 6 Inlet Valves... 6 Plunger Rod... 6 Pro-Meter K J-Block Module... 6 Application-pecific Components... 7 Adapter Block for Remote Gun Mounting... 7 Transducers... 7 Two-Component Dispensing Gun and Packing Cartridges... 7 ARW Circuit... 7 Tools... 7 J-Box chematic... 9 Contact Us Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: Address all correspondence to: Nordson Corporation Attn: Customer ervice 555 Jackson treet Amherst, OH 00 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 008. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks Nordson, the Nordson logo, and Pro-Meter are registered trademarks of Nordson Corporation. All other trademarks are the property of their respective owners. Part 0898A--0 E 00 Nordson Corporation

3 Change Record i Change Record Revision Date Change 0 6/09 Update linear actuator repair procedure 0 6/0 Add high-viscosity packing cartridge kit; change thermostat to 90 degree version. 05 0/ Add new proximity plate part number. E 0 Nordson Corporation Part

4 ii Change Record Part 0898A -0 E 00 Nordson Corporation

5 Pro-Meter K-eries Dispensers afety Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to persons operating or servicing equipment. Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks. Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. ome examples of unintended use of equipment include using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts using unapproved auxiliary equipment operating equipment in excess of maximum ratings Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. Personal afety To prevent injury follow these instructions. Do not operate or service equipment unless you are qualified. Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. Keep clear of moving equipment. Before adjusting or servicing moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment. While operating manual spray guns, make sure you are grounded. Wear electrically conductive gloves or a grounding strap connected to the gun handle or other true earth ground. Do not wear or carry metallic objects such as jewelry or tools. If you receive even a slight electrical shock, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. Obtain and read Material afety Data heets (MD) for all materials used. Follow the manufacturer s instructions for safe handling and use of materials, and use recommended personal protection devices. Make sure the spray area is adequately ventilated. To prevent injury, be aware of less-obvious dangers in the workplace that often cannot be completely eliminated, such as hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot be enclosed or otherwise guarded for practical reasons. E 0 Nordson Corporation Part

6 Pro-Meter K-eries Dispensers High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremely hazardous. Always relieve fluid pressure before adjusting or servicing high pressure equipment. A jet of high-pressure fluid can cut like a knife and cause serious bodily injury, amputation, or death. Fluids penetrating the skin can also cause toxic poisoning. If you suffer a fluid injection injury, seek medical care immediately. If possible, provide a copy of the MD for the injected fluid to the health care provider. The National pray Equipment Manufacturers Association has created a wallet card that you should carry when you are operating high-pressure spray equipment. These cards are supplied with your equipment. The following is the text of this card: WARNING: Any injury caused by high pressure liquid can be serious. If you are injured or even suspect an injury: Go to an emergency room immediately. Tell the doctor that you suspect an injection injury. how him this card Tell him what kind of material you were spraying MEDICAL ALERT AIRLE PRAY WOUND: NOTE TO PHYICIAN Injection in the skin is a serious traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or a reconstructive hand surgeon may be advisable. The seriousness of the wound depends on where the injury is on the body, whether the substance hit something on its way in and deflected causing more damage, and many other variables including skin microflora residing in the paint or gun which are blasted into the wound. If the injected paint contains acrylic latex and titanium dioxide that damage the tissue s resistance to infection, bacterial growth will flourish. The treatment that doctors recommend for an injection injury to the hand includes immediate decompression of the closed vascular compartments of the hand to release the underlying tissue distended by the injected paint, judicious wound debridement, and immediate antibiotic treatment. Fire afety To avoid a fire or explosion, follow these instructions. Ground all conductive equipment. Use only grounded air and fluid hoses. Check equipment and workpiece grounding devices regularly. Resistance to ground must not exceed one megohm. hut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Do not heat materials to temperatures above those recommended by the manufacturer. Make sure heat monitoring and limiting devices are working properly. Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material MD for guidance. Do not disconnect live electrical circuits when working with flammable materials. hut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shutoff valves, and fire extinguishers are located. If a fire starts in a spray booth, immediately shut off the spray system and exhaust fans. hut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Halogenated Hydrocarbon olvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system that contains aluminum components. Under pressure, these solvents can react with aluminum and explode, causing injury, death, or property damage. Halogenated hydrocarbon solvents contain one or more of the following elements: Element ymbol Prefix Fluorine F Fluoro- Chlorine Cl Chloro- Bromine Br Bromo- Iodine I Iodo- Check your material MD or contact your material supplier for more information. If you must use halogenated hydrocarbon solvents, contact your Nordson representative for information about compatible Nordson components. Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the system. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Part E 0 Nordson Corporation

7 Pro-Meter K-eries Dispensers Description NOTE: The Pro-Meter K-eries dispenser is referred to as the K dispenser throughout the remainder of this manual. ee Figure. The K dispenser is designed for high-speed application of two-component materials. The K dispenser achieves accurate dispensing by using two electric servo-controlled linear actuators and a closed-coupled dispense valve. Table lists the major components. Three aluminum and and three ARW K dispensers are available in the following versions: 0 Volt Heated 0 Volt Heated Water Conditioned K5 HEATED K THEE PART ARE APPLICATION PECIFIC. Figure K Dispensers Table K Dispensers Item Description ervo-controlled Linear Actuator This actuator drives the plunger rod into the cylinder cavity to displace the material. Connectors Interface connections for controller cables. Proximity ensors The proximity sensors feed positional information to the controller. Two proximity sensors serve as emergency stops and are are triggered by linear actuator anti-rotation plate. One proximity sensor indicates that the metering cylinder is full. Temperature Conditioning Ports Connections for the temperature control unit water lines. 5, 6 Inlet (5) and Outlet (6) Valves These high-cycle valves are mounted to the metering cylinder and control the flow of material into and out of the metering cylinder. The valves also serve as material inlet and outlet ports. 7 Metering Cylinder The metering cylinder mounts to the liner actuator through the use of six tie rods. Positive pressure from a Rhino bulk unloader fills the metering cylinder. A packing gland and plunger rod is mounted to the metering cylinder. The plunger rod displaces material when the actuator extends. 8 Cord et Cable connection to system controller or J-box for electric heater functions. E 0 Nordson Corporation Part

8 Pro-Meter K-eries Dispensers Theory of Operation Positive pressure from the Rhino bulk unloader fills the metering cylinder. As the linear actuator retracts, hydraulic pressure extends the metering cylinder piston to its starting position. The proximity switches provide positioning information to the linear actuator and the system controller. NOTE: The theory of operation for heated versions is identical with the exception that the system controller enables and disables the heater circuit to maintain the material setpoint temperature. Operation consists of the phases listed in Table. Table Inlet/Outlet Valve Positions Valve Positions Operation During Operation Inlet Valve Outlet Valve Refill Open Closed Idle Closed Closed Pre-Pressure Closed Closed Dispense/ Purge Closed Open Refill Phase ee Figure. During the refill phase, the actuator retracts. The material inlet valve opens. Material flows from the unloader and fills the metering cylinder. When the cylinder is full, the plunger is fully retracted and is registered by the proximity switch. The inlet valve closes. The metering cylinder is full of material and the unit is ready to dispense. Idle Phase ee Figure. During the idle phase, the material inlet and outlet valves remain closed until the dispense sequence begins. Pre-Pressure During the pre-pressure phase, the actuator drives the plunger into the metering cylinder and pressurizes the material to a set value. The actuator holds this position. The controller sends a Ready signal to indicate that the system is ready for the dispense phase. Dispense/Purge Phase ee Figure. During the dispense phase, the drive assembly forces the metering cylinder piston into the metering cylinder. The material outlet valve opens at the same time and material extrudes proportionally to the given input signal. ARW Circuit The ARW Air Circuit Module consists of a J-box that supplies regulated air to the ARW packing gland. The ARW packing gland is designed for use with anaerobic compounds. Air flows into the inlet port and through an air passage behind the primary seal of the ARW packing gland. The air prevents curing of material weepage that may occur past the primary seal. The material flows from the outlet port and into the ARW dump container. FROM INLET VALVE TO OUTLET VALVE REFILL PRE-PREURE/IDLE DIPENE/PURGE Figure Metering Cylinder Part E 0 Nordson Corporation

9 Pro-Meter K-eries Dispensers 5 pecifications Refer to Table for specifications. Item InletPortOutletPortfor Remote Material Outlet Valve Operating Air Pressure Maximum Fluid Working Pressure Maximum Continuous Fluid Output Pressure Maximum Flow Rate Maximum Water Operating Pressure Maximum Operating Temperature for Water Conditioned and Electric Heat Versions Metering Cylinder Maximum Motor RPM Maximum Continuous Motor Current Operating Voltages and Power Consumption for Heated Versions (Heater Circuit Only) Table pecifications Aluminum Dispensers pecification ARW Dispensers /8 AE, ize --06 O-ring boss, 9/6-8 UNF B thread.--7 bar ( psi) 06 bar (000 psi) 0 bar (600 psi) Note: Contact the Nordson Automotive ystems Group Engineering department if higher fluid output pressures are required. Each Cylinder: 0 cc/sec (0.6 in. /sec) Combined Flow: 0 cc/sec (. in. /sec) 7 bar (00 psi) 8 _C (80 _F) Each cylinder: 5 cc (. cu in.) Combined at : Ratio: 70 cc (. cu in.) Note: ee Table for other ratios. 5 rpm RM:. amps 0V/0V 900W Weight (Approximate) 60 lb (7 kg) 85 lb (8.5 kg) Dimensions (Approximate) eefigure. Catalyst ide Wetted Component Materials Base ide Wetted Component Materials Air Consumption Instantaneous Air Flow Rate Aluminum, brass, carbon steel, chrome plated carbon steel, stainless steel, tungsten carbide, proprietary ceramic coating, Viton, UHMWPE Aluminum, brass, carbon steel, chrome plated carbon steel, stainless steel, tungsten carbide, proprietary ceramic coating, Viton, UHMWPE 0.5 scf/cycle 00-eries stainless steel, tungsten carbide, proprietary ceramic coating, plastic alloy Polymyte, Viton 5 scfm for quick valve response Continuous Air Flow Rate.6 scfm Table Maximum Combined Displacement Material Ratio : : : : 5: 6: 7: 8: 9: 0: Combined Displacement (cc) E 0 Nordson Corporation Part

10 6 Pro-Meter K-eries Dispensers 6.9 IN. (6.9 CM) 0.06 in. (5. cm) in. (9.0 cm).00 in. (. cm).00 in. (. cm) 9. IN. (7.9 CM) X 0.50 DOWEL PIN HT. X A DOWEL PIN X M8X.5 THD THRU C.50 in. (8.5 cm) A 0.05 A B C B 0.78 in. (7.75 cm).50 in. (8.5 cm) APPLICATION PECIFIC ONLY HOWN FOR REFERENCE in. (.9 cm) 6.75 in. (8.6 cm) GUN OPEN AIR / TUBE PREURE TRANDUCER GUN CLOE AIR / TUBE GUN CLOE AIR / TUBE GUN OPEN AIR / TUBE GUN CLOE AIR / TUBE TEMPERATURE CONDITIONING PORT / TUBE K GUN MATERIAL INLET PORT 9/6-8 AE INLET VALVE Figure Typical K Dispenser Dimensions Part E 0 Nordson Corporation

11 Pro-Meter K-eries Dispensers 7 Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. NOTE: Read and understand these procedures before installing an K dispenser into a system. Contact a local Nordson representative regarding these procedures if necessary. K dispenser installation is system-specific. Refer to the ystem Documentation manual that shipped with the system for controller schematics, air, water, and material circuit drawings. ee the chematic at the end of this manual for I/O analog signals if necessary. Install the K Dispenser to a Fixture ee Figure. M8 x mounting holes are provided for installing the K dispenser to a fixture. Use customer-supplied screws and washers to secure the K dispenser to a fixture. Connect the Controller Cables. ee Figure. Connect the cables from the controller to the connectors ().. Connect the cables from the controller to the proximity sensors ().. Connect the pressure transducer cables to the pressure transducers (5).. HEATED VERION ONLY: Connect the cord set () to the controller. Connect the Material, Air, and Water Lines. Connect at least 60 psi (. bar) of clean shop air to a filter regulator input.. ee Figure. Connect the base and catalyst material hoses from the Rhino bulk unloaders to the catalyst fitting (A) and base material inlet fitting (B).. Connect the air lines from the pneumatic control valve to the Gun Open fittings (0) and Gun Close fittings (9) on the outlet valve ().. Connect the air lines from the pneumatic control valve to the Gun Open fittings (6) and Gun Close fittings (7) on the inlet valves (8). 5. WATER-CONDITIONED VERION ONLY: Connect the water lines from the temperature conditioning unit to the fittings (). WATER-CONDITIONED 0/0 V HEATED A B 9 Figure Typical Connections E 0 Nordson Corporation Part

12 8 Pro-Meter K-eries Dispensers Connect an ARW Dispenser to the ystem Air Purge Circuit ee Figures 5 and 6. ARW dispensers must be connected to the system ARW Air Purge circuit. NEEDLE VALVE REGULATOR J-BOX UPPLY AIR ARW DUMP CONTAINER Figure 5 Typical ARW Air Purge Circuit Part E 0 Nordson Corporation

13 Pro-Meter K-eries Dispensers 9 Refer to the interconnect drawings provided with the ystem Documentation and to Rhino D/XD ARW Air Circuit Module instruction sheet for more data. J-BOX UPPLY GAGE METERING VALVE INDICATOR GAGE ARW PORT REGULATOR ARW DUMP CONTAINER Figure 6 Typical ARW Pneumatic chematic E 0 Nordson Corporation Part

14 0 Pro-Meter K-eries Dispensers Operation WARNING: Read and understand this entire section before performing any procedures. Review the following: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Do not remove any covers during operation. The moving parts under these covers could cause injury to personnel. High pressure fluids are extremely dangerous. Do not place any part of your body in front of a dispensing device, drain, or leak in a high pressure system. A jet of high fluid can cause serious injury, toxic poisoning, or death. Relieve system and material pressure before disconnecting hoses. Never exceed the maximum operating temperature of 8 _C (80 _F). NOTE: Operation of the K dispenser is dependent upon the system configuration. Refer to the ystem Documentation manual that shipped with the system or contact a Nordson representative for information about the operation of a specific component. tartup. Make sure all fittings, connections, and covers are tightened securely.. et the air pressure on the main air input filter to 60 psi (. bar) minimum.. Turn on the Rhino bulk unloader and cycle the pumps. Refer to the Rhino unloader documentation for more information.. tart the controller. Refer to the controller manual for more information. 5. tart the water circulation for temperature conditioning. Refer to the temperature controller manual for more information. 6. Wait until the system reaches the required material dispensing temperature. hutdown. Turn off and relieve the pressure from the Rhino bulk unloader pumps. Refer to the Rhino bulk unloader manual for more information.. Relieve the pressure from the material cylinder.. Turn off the temperature conditioned water circulation system. Refer to the temperature controller manual for more information.. Turn off the controller. Refer to the controller manual for more information. Part E 0 Nordson Corporation

15 Pro-Meter K-eries Dispensers Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. NOTE: The frequencies listed in Table 5 are only guidelines. It may be necessary to adjust frequencies due to the facility enviornment, process parameters, material being applied, or experience. Always perform preventive maintenance procedures according to your facility maintenance schedule. Table 5 Preventive Maintenance chedule Item Task Completion Time Inlet and Outlet Valves (A) Air Fittings and Tubing Material Fittings and Hoses Plunger Rod Packing Gland ARW Drop Container Plunger Rod Linear Actuator Temperature Conditioning Water Check for leakage at the weep holes. Replace cartridge if necessary. Inspect: 5 min. Replace: 0 min. Frequency Weekly Monthly Yearly Cycles Replace cartridge. 0 min. 00,000 Check for air leaks 5 min. D Check for material leaks Check for leakage and replace the gland assembly if necessary. Check container for waste material and empty if necessary. Replace if damaged or scored or after every other packing gland change Regrease roller screw and bearing assembly. Check water condition Change water and chemicals 5min. Inspect: 5 min. Replace: hours 5min. D D D 500,000 D hours,000,000 hours,500,000 (A) mall amounts of weepage may indicate a potential problem but will not affect dispensed material accuracy. Investigate and repair any weepage as soon as possible. Excessive leakage caused by blown O-rings or loose fittings will affect dispensed material accuracy and must be immediately repaired. D D E 0 Nordson Corporation Part

16 Pro-Meter K-eries Dispensers Water Treatment The temperature conditioning section is constructed of the following materials. Always refer to this list if different water, corrosion inhibitors or biocides other than those listed in the following sections are used. Black Iron Pipe tainless steel Nylon Brass PVC Plastic Copper Buna Rubber Aluminum Polyurethane teel Viton Teflon Water Types Biocide Water Treatment Do not use the following Biocides: oxidizers, such as chlorine, bromine, hydrogen peroxide, iodine, ozone, etc. cationic, or positively charged biocides. Biocides for use with Corrhield MD05 are BetzDearborn pectrus NX. The recommended concentration of pectrus NX is 50--PPM which is 0.07 oz./gal (0.5 ml/gal). The Ford Tox Number for pectrus NX is 870. Refer to Table 6. To minimize the introduction of contaminants that may degrade system components, review these guidelines before selecting the type of water to use. NOTE Water types are listed in order of preference. Corrosion Levels To maintain proper performance, minimum levels of corrosion to aluminum and copper must be maintained. To maintain safe operation keep the corrosion levels of aluminum at or below mil/year (0.00 in./yr). copper at or below mil/year (0.00 in./yr). When adding water to the system, corrosion inhibitor must be added. Corrhield MD05 corrosion inhibitor is shipped with temperature-conditioned systems. This is a Molybdate-based corrosion inhibitor that contains an Azole additive to protect copper and is used in the concentration of.5 ounces per gallon of water to maintain a concentration of ppm. The Ford Tox number for Corrhield MD 05 is 96. The GM FID number for Corrhield MD 05 is 58. Refer to the Parts section to order Corrhield MD 05. Part E 0 Nordson Corporation

17 Pro-Meter K-eries Dispensers Water Table 6 Water Types Description. Distilled No minerals and chemicals Lacks the nutrients necessary to support biological growth and the minerals that wear away at system components Neutral nature reduces interaction with additives used to protect the system NOTE Distilled water is the best choice for use in the temperature conditioning section.. Well Contains an abundance of minerals that can support plant and animal life Contains minerals like calcium and iron that are abrasive; accelerates wear and tear on components NOTE If well water is the only option available, it must be softened to reduce the mineral content.. City Contains chlorine that can degrade all metals including stainless steel Hard on most non--metals Usually contains an abundance of minerals that are capable of supporting plant and animal life; accelerates wear on components. Weld (Tower) Often heavily treated both for bacterial suppression and to make it more compatible with the welding and cooling tower processes Treatment process usually involves some aggressive chemicals that can degrade metals, plastics and other materials Usually contains an abundance of metals and other contaminants picked up from the welding and cooling tower processes that can interfere with the components of the temperature control system 5. DI! CAUTION! Do not use DI water in this system. DI water draws free electrons from metal to normalize ion levels. This process causes degradation of metals. E 0 Nordson Corporation Part

18 Pro-Meter K-eries Dispensers Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. These procedures cover only the most common problems. If a problem cannot be solved with the information given here, contact a local Nordson representative for help. Problem Possible Cause Corrective Action Worn packing cartridge. Leakage through inlet/outlet valve weep hole. Leakage through the material outlet. Linear Actuator not responding. Metering cylinder not refilling 5. Material flow not stopping quickly when inlet/outlet valves are cycled 6. Temperature control unstable Worn ball seat or packing cartridge ball Loose wiring connections Controller switching error Pump ball valve closed High friction in metering cylinder packing glands Inlet valve did not open Controller switching error luggish operating inlet and outlet valves Heater cartridge or RTD failed Replace the packing cartridge. Refer to the Outlet Valve procedures in the Repair section. Replace the valve body and/or the entire valve. Refer to the Outlet Valve procedures in the Repair section. Contact your Nordson representative. Reset the controller program, check fill/dispensing routine. Refer to the controller documentation for more information. Check the material supply system. Replace packing gland if necessary. Check inlet valve; rebuild or replace if necessary. Refer to the Inlet Valve and Outlet Valve procedures in the Repair section. Reset controller program; check fill/dispensing routine. Replace the applicable valve. Refer to the Inlet Valve and Outlet Valve procedures in the Repair section. Check heater cartridge and RTD. Replace parts if necessary. Part E 0 Nordson Corporation

19 Pro-Meter K-eries Dispensers 5 Repair This section only covers procedures for shop repairs. Depending upon the mounting configuration, it may be possible to make some repairs without removing the K dispenser from the system. WARNING: Read and understand this entire section before performing repairs. Contact a Nordson representative regarding these procedures if necessary. Review the following: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. High pressure fluids are extremely dangerous. Do not place any part of your body in front of a dispensing device, drain, or leak in a high pressure system. A jet of high fluid can cause serious injury, toxic poisoning, or death. Relieve system and material pressure before disconnecting hoses. Perform the following before making repairs:. hut off and lock out power to the K dispenser.. If used, turn off the water circulation system at the temperature control unit.. Relieve system, material, and fluid pressures to the K dispenser. Consumable Items Keep the items listed in Table 7 on hand when performing repairs. Table 7 Consumable Items Item Part Application Never-eez 900 Apply to threads of Threadlocking 9006 applicable parts. Adhesive Pipe/Thread 9008 ealant TFE Grease 08 Aluminum Dispensers: Lubricate O-rings and applicable parts. ynthetic Grease 0089 ARW Dispensers: Lubricate O-rings and applicable parts. E 0 Nordson Corporation Part

20 6 Pro-Meter K-eries Dispensers Linear Actuator Assembly ee Figure 7 and use the following procedure to replace the linear actuator. Remove the Linear Actuator Assembly. Remove the screws () securing the mounting plate () to the linear actuator assembly () and housing flange (9).. Remove the screws () and washers () securing the shroud () to the linear actuator assembly () and housing flange (9).. Remove the screws (8) securing the proximity plate () to the linear actuator () and housing flange (9).. Place a wrench on the shaft flats (0). Remove the screws (5) and washers () securing the linear actuator assembly () to the K dispenser. 5. Remove the screw (6) from the anti-rotate arm (8). Loosen the set screws (7) and remove the anti-rotate arm from the shaft (0). 6. Remove the motor bumper (9) from the shaft (0). Install the Linear Actuator Assembly. Install the motor bumper (9) onto the shaft (0).. Perform the following: a. Install the anti-rotate arm (8) onto the shaft (0) using the screw (6). Tighten the screw finger tight. b. Apply Loctite (5) to the threads of the set screws (7). Install the set screws into the anti-rotate arm (8). Tighten the set screws finger tight. c. Tighten the screw (6) to.5 N m (0 ft-lb). Tighten the set screws (0) to N m (5 in.-lb).. Perform the following: a. Apply Loctite to the threads of the screws (5). Install the linear actuator assembly () onto the shafts (0). b. Place a wrench on the flats of the shafts (0). Install the washers () and screws (5) into the linear actuator. Tighten the screws to N m (5 ft-lb).. Install the proximity plate () onto the linear actuator () and housing flange (9) using the screws (8). Tighten the screws to 0 ft-lb (.5 N m). 5. Install the shroud () to the linear actuator () and housing flange (9). Install the washers () and screws (). Tighten the screws securely. 6. Install the mounting plate () to the linear actuator () and housing flange (9). Install the screws () and tighten to.75 N m (5 ft-lb). Replace a Linear Actuator NOTE: Linear actuators () can be replaced without removing the linear actuator assembly () from the K dispenser.. Remove the screw (6) from the anti-rotate arm (8). Loosen the set screws (7) and remove the anti-rotate arm from the shaft (0).. Remove the motor bumper (9) from the shaft (0).. Remove the nuts () and washers () from the rods ().. Remove the rods () from the flange (6) and remove the linear actuator (). 5. Apply Apply Loctite (5) to the threads of the rods () as shown. Thread the rods into the flange (6). Make sure that the rods are flush with the bottom of the flange. 6. Install the washers () and nuts. Tighten the nuts in a cross pattern to 90 in.-lb (0 N m). Proximity ensors Use the following procedure to replace and adjust a proximity sensor. The retract proximity sensor is used in this procedure. The procedures for replacing the refill and extend proximity sensors are typical. NOTE: Depending upon the mounting configuration, the proximity sensors can be replaced without removing the K dispenser from the system.. ee Figure 7. Disconnect the cable from the proximity sensor (7).. Remove the screws () and lock washers () securing the shroud () to the linear actuator assembly () and housing flange (9).. Loosen the jam nut (6). Remove the proximity sensor (7), jam nut (6), and lock washer (5) from the proximity plate ().. Install the jam nut (6) and lock washer (5) onto the new proximity sensor (7). 5. Adjust the proximity sensor. Refer to the Adjust the Retract and Extend Proximity ensor or Adjust the Refill Proximity sections for the adjustment procedures. Part E 0 Nordson Corporation

21 Pro-Meter K-eries Dispensers Figure 7 Linear Actuator Assembly and Proximity ensor Repairs E 0 Nordson Corporation Part

22 8 Pro-Meter K-eries Dispensers Adjust the Retract and Extend Proximity ensors CAUTION: To prevent damage to a proximity sensor when performing step, do not thread it into the proximity plate more than three turns.. ee Figure 8. Extend or retract the linear actuator until the anti-rotate arm stop pin is directly behind the sensor.. Push the anti-rotate arm toward the sensor to remove any backlash.. Perform the following: a. Turn the sensor clockwise until its face makes contact with the stop pin. b. Turn the sensor counterclockwise -- / turns. Lock the sensor in place using the lock washer and jam nut. c. Make sure that there is a mm ( in.) gap between the face of the sensor and the anti-rotate arm stop pin.. Connect the cable to the proximity sensor. 5. ee Figure 7. Install the shroud () to the linear actuator () and housing flange (9) using the washers () and screws (). Tighten the screws securely. Adjust the Refill Proximity ensor CAUTION: To prevent damage to the proximity sensor when performimg step, do not thread it into the proximity plate more than three turns.. ee Figure 8. Extend the plunger assembly until the proximity disc is directly behind the proximity sensor.. Perform the following: a. Turn the sensor clockwise until its face makes contact with the proximity disc. b. Turn the sensor counterclockwise -- / turns. Lock the sensor in place using the lock washer and jam nut. c. Make sure that there is a mm ( in.) gap between the face of the sensor and the proximity disc.. Connect the cable to the proximity sensor (7).. ee Figure 7. Install the shroud () to the linear actuator () and housing flange (9) using the washers () and screws (). Tighten the screws securely. Part E 0 Nordson Corporation

23 Pro-Meter K-eries Dispensers 9 GAP mm ( ) TYPICAL FOR EXTEND PROXIMITY ENOR ARM NOTE: When setting the gap for the retract and extend proximity sensors, push the arm toward the sensor to remove backlash. PROXIMITY DIC RETRACT PROXIMITY ENOR (NORAMLLY CLOED) ANTI-ROTATE ARM TOP PIN REFILL PROXIMITY ENOR (NORMALLY OPEN) GAP mm ( ) JAM NUT (TYPICAL) EXTEND PROXIMITY ENOR (NORAMLLY CLOED) Figure 8 Proximity ensor Adjustment E 0 Nordson Corporation Part

24 0 Pro-Meter K-eries Dispensers Hydraulic ection WARNING: Depressurize the dispense system before making any repairs to the hydraulic section. Use the following procedures to make repairs the hydraulic section. Replace the Inlet Valve Packing Cartridge. ee Figure 9. Remove the screws (0) securing the air cylinder cap (9) to the valve body (). Remove the spring (8) from the valve body.. Using a small screwdriver, remove the packing cartridge (7) from the valve body ().. Install the new packing cartridge (7) into the valve body ().. Install the spring (8) onto the packing cartridge (7). 5. Install the air cylinder cap (9) using the screws (0). Tighten the screws to N m ( in.-lb). Replace the Outlet Valve Packing Cartridge CAUTION: To prevent inadvertently switching packing cartridges or mixing base and catalyst materials, do not replace both packing cartridges at the same time. witching packing cartridges can damage the seals when exposed to agressive dispensing materials.. Depressurize the temperature conditioning system.. ee Figure 9. Remove the screws (0) securing the air cylinder cap (7) to the valve body (). Remove the air cylinder cap.. Place a screw driver into the slots on the valve body () and pry out the packing cartridge ().. Clean all parts. 5. Use the applicable grease (6) to lubricate the O-rings (5). 6. Insert the new packing cartridge into the valve body (). 7. Install the air cylinder cap (7) using the screws(0). Tighten screws to 5.65 Nm (50 in.-lb). 8. Repeat steps through 7 for the remaining packing cartridge (). Replace the Inlet Valve NOTE: Depending upon the mounting configuration, the inlet valve can be repaired without removing the K dispenser from the system.. ee Figure 9. Disconnect the following from the inlet valve (): cable from the pressure transducer () air lines from the elbow fittings (6) material line from the input port (). Remove the screws (5) securing the inlet valve () to the K dispenser ().. Remove the O-ring () and check it for damage. Replace the O-ring if necessary.. Remove these parts from the old inlet valve () and install them onto the new inlet valve: pressure transducer (); tighten to N m (5--50 in.-lb) elbow fittings (6) 5. Install the inlet valve () onto the K dispenser () using the screws (5). Tighten the screws to.5 N m (0 ft-lb). 6. Connect the following: cable to the pressure transducer () air lines to the elbow fittings (6) material line to the input port () 7. Check and re-calibrate the controller software pressure transducer settings if necessary. Replace the Outlet Valve ee Figure 9. This procedure only applies to configurations that have an outlet valve installed onto a K dispenser (). If a manifold () is installed on the K dispenser, refer to the manual that shipped with the applicable outlet valve for repair procedures.. Disconnect the air lines to the elbow fittings (8, 9).. Remove the screws () securing the outlet valve () to the K dispenser ().. Remove and discard the O-rings ().. Lubricate the new O-rings () with the applicable grease (6) and install them onto the housing (). 5. Install the new outlet valve () onto the housing () using the screws (). Tighten the screws to N m ( ft-lb). 6. Connect the air lines to the elbow fittings (8, 9). Part E 0 Nordson Corporation

25 Pro-Meter K-eries Dispensers Replace the Pressure Transducer. ee Figure 9. Disconnect the cable from the pressure transducer ().. Remove the pressure transducer () from the inlet valve ().. Lubricate the new pressure transducer O-ring () with the applicable grease. Install the pressure transducer () into the inlet valve () and tighten to N m (5--50 in.-lb).. Connect the cable to to pressure transducer (). 5. Check and re-calibrate the controller software pressure transducer settings if necessary Figure 9 Inlet and Outlet Valve Repair E 0 Nordson Corporation Part

26 Pro-Meter K-eries Dispensers Remove the Packing Gland and Plunger Assemblies NOTE: The following procedure requires the use of an arbor press and a /6-in. spanner wrench.. To remove the gland and plunger assemblies without removing the cylinder assembly, purge the metering cylinder: a. Lockout and relieve system, material, and fluid pressures to the K dispenser. b. From the system controller, perform the meter Purge routine. The following occurs: The meter will not refill after the Purge routine because the supply pump is locked out and material pressure is relieved. The linear actuator retracts and the controller displays a Refill Fault.. ee Figure 0. Remove the screws () and washers () securing the shroud () to the linear actuator assembly () and housing flange (5).. ARW PACKING GLAND ONLY: Disconnect the air tubing if necessary. Remove the packing gland inlet (5) and outlet (6) port fittings.. Remove the screws (8) securing the gland assembly (7) to the housing flange (5). Perform the following if the gland assembly cannot be removed from the housing flange: a. Insert two screws (8) into the threaded holes (6) of the gland assembly. b. Alternate tightening the screws to remove the gland assembly from the housing flange. 5. Remove the O-ring (0) from the gland assembly (7). Discard the O-ring. 6. Using an arbor press, remove the plunger assembly (9) from the gland assembly (7). 7. Disassemble the plunger assembly (9): a. Remove the plunger bumper (0) from the plunger (). b. Insert the spanner wrench pin into the hole on the plunger. Remove the screw () securing the proximity disc () to the plunger. 8. Clean the parts with a compatible solvent. 9. Inspect the parts for wear and damage. Replace parts if necessary. Install the Packing Gland and Plunger Assemblies NOTE: The following procedure requires the use of an arbor press and a /6-in. spanner wrench.. ee Figure 0. Lubricate the gland assembly O-ring (0) and the inner diameter of the gland assembly (9) with TFE grease ().. Assemble the plunger assembly (9): a. Install the proximity disc () onto the plunger (). b. Thread the screw () into the plunger. Insert the spanner wrench pin into the hole on the plunger and tighten the screw to.5 N m (0 ft-lb ). c. Install the plunger bumper (0) onto the plunger. Make sure that the plunger bumper makes contact with the proximity disc. d. Apply the applicable grease () to the shaft of the plunger.. Using an arbor press, insert the plunger assembly (9) into the gland assembly (7).. Install the gland assembly (7) onto the housing flange (5) using the screws (8). Tighten the screws in a cross-pattern to.5 N m (0 ft-lb). 5. ARW PACKING GLAND ONLY: Connect the air tubing if necessary. Install the packing gland inlet (5) and outlet (6) port fittings. 6. Install the shroud () to the linear actuator assembly () and housing flange (5) using the lock washers () and screws (). Tighten the screws securely. NOTE: The packing gland on the Base side of the K ARW stainless steel dispenser cannot be rebuilt. Refer to the Parts section and order a new Base side stainless steel ARW packing gland. Part E 0 Nordson Corporation

27 Pro-Meter K-eries Dispensers PART REMOVED FOR CLARITY. 5 Figure 0 Plunger and Gland Assembly Repairs E 0 Nordson Corporation Part

28 Pro-Meter K-eries Dispensers Rebuild the Packing Gland NOTE: The packing gland on the Base side of the K ARW stainless steel dispenser cannot be rebuilt. Refer to the Parts section and order a new Base side stainless steel ARW packing gland. This procedure requires the use of either a hydraulic or an arbor press to remove the internal parts of the packing gland.. ee Figure. Place the packing gland housing () on a fixture ().. Coat the bore (8) of the packing gland housing with the applicable grease (9). 5. Insert the scraper ring (7), sharp edge down, into the the packing gland (). 6. Using the insertion tool (6) and arbor press, insert the new internal parts into the packing gland housing (). Make sure that the brass seal retainer or backup washer (0) is flush or slightly below the packing gland housing as shown. NOTE: During removal of the internal parts, the retainer groove will break the O-ring (5).. Insert the removal arbor () into the packing gland housing. Using the press, push out the internal parts ().. Thoroughly clean the packing gland housing in a compatible solvent to remove all sealant material and O-ring debris. Part E 0 Nordson Corporation

29 Pro-Meter K-eries Dispensers CRAPER RING HARP EDGE DOWN PACKING GLAND HOUING BRA EAL RETAINER LIGHTLY BELOW PACKING GLAND HOUING 0 Figure Replacing the Internal Parts of the Packing Gland E 0 Nordson Corporation Part

30 6 Pro-Meter K-eries Dispensers Replace the Thermostat. ee Figure. Remove the screws () securing the cover () to the housing ().. Loosen the screws () on the connector (0) and remove the thermostat wires.. Remove the screws (7) and lock washers (8) securing the thermostat (9) to the housing ().. Apply heat sink compound () to the new thermostat (9). Install the thermostat using the lock washers (8) and screws (7). Tighten the screws securely. 5. Crimp new ferrules onto each wire. 6. Insert the thermostat wires into the connector (0) and tighten the screws (). ee Figure for wiring diagram if necessary. 7. Install the cover () onto the housing () using the screws (). Tighten the screws securely. Replace the RTD. ee Figure. Remove the screws () securing the cover () to the housing ().. Loosen the screws (5) on the connector (6) and remove the RTD wires.. Carefully remove the RTD () from the housing ().. Apply heat sink compound () to the RTD (). Install the RTD into the housing. 5. Crimp new ferrules onto each wire. 6. Insert the RTD wires into the connector (6). Tighten the screw (5). 7. Install the cover () onto the housing () using the screws (). Tighten the screws securely. Replace a Heater Cartridge. ee Figure. Remove the screws () securing the cover () to the housing ().. Cut the applicable heater wires from the crimp connections.. Carefully remove the heater cartridge () from the housing ().. Apply heat sink compound () onto the new heater cartridge (). Install the heater cartridge into the housing (). 5. trip back the wire insulation on all of the cut wires. Crimp new connectors onto each wire. ee Figure for wiring diagram if necessary. 6. Install the cover () onto the housing () using the screws () tighten the screws securely. Part E 0 Nordson Corporation

31 Pro-Meter K-eries Dispensers 7 0 TO CORDET VOLT CIRCUIT TYPICAL CRIMP CONNECTOR 0 VOLT CIRCUIT TYPICAL CRIMP CONNECTOR HEATER CATRIDGE HEATER CATRIDGE HEATER CATRIDGE HEATER CATRIDGE HEATER CATRIDGE HEATER CATRIDGE HEATER CATRIDGE HEATER CATRIDGE WIRE B HEATER CATRIDGE HEATER CATRIDGE HEATER CATRIDGE HEATER CATRIDGE THERMOTAT WIRE A CORDET THERMOTAT WIRE WIRE CORDET RTD WIRE C WIRE D WIRE H RTD WIRE WIRE 5 GND Figure Heater and RTD Repairs E 0 Nordson Corporation Part

32 8 Pro-Meter K-eries Dispensers Parts To order parts, call the Nordson Customer ervice Center or your local Nordson representative. tandard K Dispenser ee Figures and along with the following parts list PART OF 7 THEE PART ARE APPLICATION PECIFIC. THEE PART ARE INCLUDED WITH THE GUN AND MANIF Figure tandard K Dispenser Parts Part E 0 Nordson Corporation

33 Pro-Meter K-eries Dispensers 9 Item Part Part Description Qty Note Dispenser, assembly, T/C Pro-Meter K Dispenser, assembly, T/C Pro-Meter K5, ARW, CE Actuator assembly, linear, dual, 5.9 stroke, Nut Washer Rod Actuator, linear, 5.9 stroke, 0 A, B Flange, motor, dual, Pro-Meter K, Bumper, motor, Pro-Meter, Arm assembly, anti-rotate, Pro-Meter, crew, stop, motor, 7/6--0, Pro-Meter, crew, set, M5 x 0 mm Plate, mounting, dual, Pro-Meter K, crew, socket, M8 x ensor,proximity,pnp,n.c.,m B ensor, proximity, PNP, N.O., M B Plate, proximity, Pro--Meter, crew, socket, M6 x Valve, inlet, Auto-Flo, Pro-Meter, UHMW / C crew, socket, M8 x.5 x Washer, flat. x x haft, mm OD x mm, M8, Pro-Meter, hroud, dual, Pro-Meter K, crew, socket, cap, M6 x x 8 mm Washer, flat, narrow, M6 Continued... E 0 Nordson Corporation Part

34 0 Pro-Meter K-eries Dispensers tandard K Dispenser (contd) Figure tandard K Dispenser Parts (Continued) Part E 0 Nordson Corporation

35 Pro-Meter K-eries Dispensers Item Part Part Description Qty Note Dispenser, assembly, T/C Pro-Meter K Dispenser, assembly, T/C Pro-Meter K5, ARW, CE crew, stop, plunger, M8, Pro--Meter Disc, proximity, Pro--Meter, Plunger, D, 0.75 Diameter B, D Bumper, plunger, 0.75 diameter, Pro--Meter Plug, pipe, flush, /6 w/sealant Plug, pipe, flush, /6 stainless steel Elbow, male, / tube x /8 NPT Housing, plunger, dual, 0.75 diameter, Pro--Meter K, CE 0 Housing, plunger, dual, diameter, Pro--Meter K, T/C, ARW 975 Plug, O-ring, straight thread, 7/ Plug, O-ring, straight thread, 7/6--0, stainless steel Flange, housing, plunger, dual, Pro--Meter K, crew, socket, M6 x Gland assembly, 0.75 diameter, Pro-Meter / B, C, E crew, socket, M8 x Lubricant, TFE grease, 5lb, gal AR 0089 Grease Mobil ynthetic, HC 00,.5 oz AR Adhesive, Loctite, blue, removable, 50 ml AR Transducer, pressure F Elbow, male, / T x /8 NPT Valve, inlet, Auto-Flo, Pro-Meter, UHMW stainless steel Never eeze, 8-oz can AR Gland assembly, ARW base, 0.75 diameter, low viscosity material, Pro-Meter B, E, G NOTE A: This part is included with Item but can be ordered separately. B: Keep these parts on hand to reduce downtime. C: Dispenser uses two. Dispenser uses one. D: This part is included in Plunger Rod Kit E: This part is included in the following Packing Gland Housing Kits: Kit for Item ; tandard Dispenser; ARW Dispenser Catalyst ide Kit for Item ; ARW Base ide F: Pressure transducers are application specific: 500 psi: Order psi: Order psi: Order psi: Order 6088 (used on earlier systems; no longer recommended) G: Order Packing Cartridge Kit 00 for high viscosity materials. AR: As Required E 0 Nordson Corporation Part