Pro Meter VDK Dispensing System

Transcription

1 Pro Meter VDK Dispensing System Customer Product Manual Issued 7/14 This document contains important safety information Be sure to read and follow all safety information in this document and any other related documentation. NORDSON CORPORATION DULUTH, GEORGIA USA

2 For CE Declaration, refer to equipment documentation. 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 Service Lakefield Drive Duluth, GA Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date Nopartofthisdocument may be photocopied, reproduced, or translated to another language without the prior written consent of NordsonCorporation. Theinformationcontained in this publication is subject to change without notice. Trademarks AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, Build A Part, CanWorks, Century, CF, CleanSleeve, CleanSpray, ColorMax, Color on Demand, ControlCoat, Coolwave, Cross Cut, cscan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura Screen, Durasystem, EasyCoat, Easymove Plus, Ecodry, Econo Coat, e.dot, EFD, Emerald, Encore, ESP, e stylized, ETI stylized, Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex O Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli flow, Horizon, Hot Shot, icontrol, idry, iflow, Isocoil, Isocore, Iso Flo, itrax, Kinetix, KISS, LeanCell, LittleSquirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, Micromedics, Micro Meter, MicroSet, Millennium, MiniBlue, Mini Squirt, Mountaingate, NexJet, No-Drip, Nordson, Optimum, Package of Values, Paragon, Pattern View, PermaFlo, PICO, PicoDot, PorousCoat, PowderGrid, Powderware, Precisecoat, Printplus, Prism, ProBlue, Prodigy, Pro Flo, Program A Bead, Program A Shot, Program A Stream, Program A Swirl, ProLink, Pro Meter, Pro Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Sealant Equipment & Engineering, Inc, SEE and design, See Flo, Seal Sentry, SelectCharge, SelectCoat, Select Cure, Servo Flo, Shot A Matic, Signature, Slautterback, Smart Coat, Solder Plus, Spectrum, Speed Coat, SureBead, Sure Coat, Sure Max, Sure Wrap, TrackingPlus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Tubesetter, Ultra, UpTime, u TAH, Value Plastics, Vantage, VersaBlue, Versa Coat, VersaDrum, VersaPail, Versa Screen, Versa Spray,VP Quick Fit, Watermark, When you expect more., and X-Plane are registered trademarks of Nordson Corporation. Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, Allegro, AltaBlue, AltaSlot, Alta Spray, Artiste, ATS, Auto Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, CleanCoat, Cobalt, Controlled Fiberization, ControlWeave, ContourCoat, CPX, cselect, Cyclo Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E Nordson, Equalizer, EquiBead, FillEasy, FillSentry, Flow Coat, Fluxplus, Freedom, Get Green With Blue, G Net, Genius, G Site, IntelliJet, ion, Iso Flex, itrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiMix, OptiStroke, Optix, Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, PowderPilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet, Ready Coat, RediCoat, RollVIA, Quantum, Royal Blue, SelectSeries, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing, Spray Works, StediFlo, StediTherm, Summit, SureFoam, SureMix, SureSeal, SwirlCoat, TAH, ThruWave, TradePlus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, and 2Rings (Design) aretrademarks of NordsonCorporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners' rights. Krytox is a registered trademark of E. I. Du Pont De Nemours and Company Vaseline is a registered trademark of Unilever Supply Chain, Inc. Viton is a registered trademark of DuPont Dow Elastomers. L.L.C. All rights reserved

3 Table of Contents i Table of Contents Safety... 1 Safety Alert Symbols... 1 Responsibilities of the Equipment Owner... 2 Safety Information... 2 Instructions, Requirements, and Standards... 2 User Qualifications... 3 Applicable Industry Safety Practices... 3 Intended Use of the Equipment... 3 Instructions and Safety Messages... 4 Installation Practices... 4 Operating Practices... 4 Maintenance and Repair Practices... 5 Equipment Safety Information... 5 Equipment Shutdown... 6 Relieving System Hydraulic Pressure... 6 De energizing the System... 6 Disabling the Applicators... 6 General Safety Warnings and Cautions... 7 Other Safety Precautions First Aid Safety Labels and Tags Introduction Intended Use Pro Meter VDK Dispensing Module Pro Meter VDK Controller Installation Mounting the Dispensing Module Mounting Bracket Dimensions Mounting Bracket Configuration Connecting the Controller Cables Cable Types Internal Cable Routes Cable Connections Digital/Analog Cable Connections Digital/Analog Input Signal for Automatic Operation Digital/Analog Volume Output Connections Connecting Jumpers for Manual Operation Dispense On (Trigger) Volume Cable Trigger Input Connections Applicator Control Cable... 24

4 ii Table of Contents Programming Control Panel Display Controls System Control Buttons Display Readout Programming Buttons Programming the Displays System Programming Buttons Pressure Meter Method to Program the System Pressure Display.. 28 Programming Module 1: Scale by Key In Method Programming Module 6: Setpoint (Alarm) Output Parameters Flow Meter Method to Program the Volume/Flow Display Programming the Volume/Flow Display Programming Module 1: Counter A, Counter B, and Prescaler Output Totalizer Table: Programming Module 1 for Prescaler Output Programming Module 2: Rear Terminal User Inputs and Front Panel Function Keys Programming Module 4: Scale by Key In Method Flow Table: Programming Module 4 for Flow/Volume Display.. 33 Programming Module 6: Alarm/Setpoint Output Parameters Programming Module 8: Analog Output Parameters Operation Starting the System Shutting Down the System Setting Trigger, Applicator ON, and Motor ON Delay Timers About Trigger Delay About Applicator ON Delay About Motor ON Delay Maintenance Repair Drive Motor Replacement Drive Motor Removal Drive Motor Installation Speed Reducer Replacement Speed Reducer Removal Speed Reducer Installation Coupling Replacement Coupling Removal Coupling Installation Gear Pump Replacement Gear Pump Removal Gear Pump Installation Gear Pump Seal Replacement Pressure Transducer Replacement Controller Panel Meter Replacement Panel Meter Removal Preparation for Panel Meter Installation Volume/Flow Panel Meter Pressure Panel Meter Panel Meter Installation Controller Fuse Replacement Controller Light Bulb Replacement Controller Cable Replacement... 66

5 Table of Contents iii Troubleshooting Parts Using the Illustrated Parts Lists VAC and 380 VAC Controller Parts VAC Controller Additional Parts Dispensing Module Parts Coupling Parts AutoFlo and Remote Mount Manifold Parts, Unheated Applications.. 82 AG 900 and H 200 Manifold Parts, Unheated Applications AutoFlo and Remote Mount Manifold Parts, Heated Applications AG 900 Manifold Parts, Heated Applications H 200 Manifold Parts, Heated Applications Cables Pump Repair Kits Pumps Pump Modules Internal Pumps Recommended Spare Parts and Supplies Technical Data Dispensing Module Specifications Torque Specifications Dispensing Module Dimensions Controller Dimensions Factory Default Values for the Controller Digital Displays To return all settings to their factory default values: VAC Controller Schematic VAC Control Schematic

6 iv Table of Contents

7 Pro Meter VDK Dispensing System 1 Pro Meter VDK Dispensing System Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as use ) of the product described in this document (hereafter referred to as equipment ). Additional safety information, in the form of task specific safety alert messages, appears as appropriate throughout this document. WARNING! Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property. Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all safety information that follows the signal word. WARNING! Indicates a potentially hazardous situation that, if not avoided, can result in serious personal injury, including death. CAUTION! Indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION! (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property.

8 2 Pro Meter VDK Dispensing System Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment are met, and for qualifying all potential users. Safety Information Research and evaluate safety information from all applicable sources, including the owner specific safety policy, best industry practices, governing regulations, material manufacturer's product information, and this document. Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information. Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices. If applicable, receive approval from your facility's engineering or safety department, or other similar function within your organization, before installing or operating the equipment for the first time. Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re evaluate safety practices and procedures whenever changes are made to the process or equipment.

9 Pro Meter VDK Dispensing System 3 User Qualifications Equipment owners are responsible for ensuring that users: receive safety training appropriate to their job function as directed by governing regulations and best industry practices are familiar with the equipment owner's safety and accident prevention policies and procedures receive equipment and task specific training from another qualified individual NOTE: Nordson can provide equipment specific installation, operation, and maintenance training. Contact your Nordson representative for information possess industry and trade specific skills and a level of experience appropriate to their job function are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in the manner described in this document. The information provided here is not meant to include all possible safety practices, but represents the best safety practices for equipment of similar hazard potential used in similar industries. Intended Use of the Equipment Use the equipment only for the purposes described and within the limits specified in this document. Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non standard auxiliary devices.

10 4 Pro Meter VDK Dispensing System Instructions and Safety Messages Read and follow the instructions provided in this document and other referenced documents. Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices. Ensure that the equipment is rated for the environment in which it will be used. This equipment has not been certified for compliance with the ATEX directive nor as nonincendive and should not be installed in potentially explosive environments. Ensure that the processing characteristics of the material will not create a hazardous environment. Refer to the Material Safety Data Sheet (MSDS) for the material. If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance. Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects. Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources. Properly ground all equipment. Contact your local building code enforcement agency for specific requirements. Ensure that fuses of the correct type and rating are installed in fused equipment. Contact the authority having jurisdiction to determine the requirement for installation permits or inspections. Operating Practices Familiarize yourself with the location and operation of all safety devices and indicators. Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist. Use the personal protective equipment (PPE) specified for each task. Refer to Equipment Safety Information or the material manufacturer's instructions and MSDS for PPE requirements. Do not use equipment that is malfunctioning or shows signs of a potential malfunction.

11 Pro Meter VDK Dispensing System 5 Maintenance and Repair Practices Allow only personnel with appropriate training and experience to operate or service the equipment. Perform scheduled maintenance activities at the intervals described in this document. Relieve system hydraulic and pneumatic pressure before servicing the equipment. De energize the equipment and all auxiliary devices before servicing the equipment. Use only new Nordson authorized refurbished or replacement parts. Read and comply with the manufacturer's instructions and the MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation. Dispose of waste cleaning compounds and residual process materials according to governing regulations. Refer to the applicable MSDS or contact the authority having jurisdiction for information. Keep equipment safety warning labels clean. Replace worn or damaged labels. Equipment Safety Information This equipment safety information is applicable to the following types of Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices

12 6 Pro Meter VDK Dispensing System Equipment Shutdown To safely complete many of the procedures described in this document, the equipment must first be shut down. The level of shut down required varies by the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure. The levels of shut down are: Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal. Refer to the melter specific product manual for instructions on relieving system hydraulic pressure. De energizing the System Isolate the system (melter, hoses, applicators, and optional devices) from all power sources before accessing any unprotected high voltage wiring or connection point. 1. Turn off the equipment and all auxiliary devices connected to the equipment (system). 2. To prevent the equipment from being accidentally energized, lock and tag the disconnect switch(es) or circuit breaker(s) that provide input electrical power to the equipment and optional devices. NOTE: Government regulations and industry standards dictate specific requirements for the isolation of hazardous energy sources. Refer to the appropriate regulation or standard. Disabling the Applicators NOTE: Adhesive dispensing applicators are referred to as guns in some previous publications. All electrical or mechanical devices that provide an activation signal to the applicators, applicator solenoid valve(s), or the melter pump must be disabled before work can be performed on or around an applicator that is connected to a pressurized system. 1. Turn off or disconnect the applicator triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the applicator solenoid valve(s). 3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the applicator.

13 Pro Meter VDK Dispensing System 7 General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual. Equipment types are designated in Table 1 as follows: HM = Hot melt (melters, hoses, applicators, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and applicators) Equipment Type Table 1 General Safety Warnings and Cautions Warning or Caution HM WARNING! Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent based material through a compatible Nordson melter, read and comply with the material's MSDS. Ensure that the material's processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with MSDS requirements can cause personal injury, including death. HM WARNING! Reactive material! Never clean any aluminum component or flush Nordson equipment with halogenated hydrocarbon fluids. Nordson melters and applicators contain aluminum components that may react violently with halogenated hydrocarbons. The use of halogenated hydrocarbon compounds in Nordson equipment can cause personal injury, including death. HM, CA WARNING! System pressurized! Relieve system hydraulic pressure before breaking any hydraulic connection or seal. Failure to relieve the system hydraulic pressure can result in the uncontrolled release of hot melt or cold adhesive, causing personal injury. Continued...

14 8 Pro Meter VDK Dispensing System General Safety Warnings and Cautions (contd) Equipment Type Table 1 General Safety Warnings and Cautions (contd) Warning or Caution HM WARNING! Molten material! Wear eye or face protection, clothing that protects exposed skin, and heat protective gloves when servicing equipment that contains molten hot melt. Even when solidified, hot melt can still cause burns. Failure to wear appropriate personal protective equipment can result in personal injury. HM, PC WARNING! Equipment starts automatically! Remote triggering devices are used to control automatic hot melt applicators. Before working on or near an operating applicator, disable the applicator's triggering device and remove the air supply to the applicator's solenoid valve(s). Failure to disable the applicator's triggering device and remove the supply of air to the solenoid valve(s) can result in personal injury. HM, CA, PC WARNING! Risk of electrocution! Even when switched off and electrically isolated at the disconnect switch or circuit breaker, the equipment may still be connected to energized auxiliary devices. De energize and electrically isolate all auxiliary devices before servicing the equipment. Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injury, including death. HM, CA, PC WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and has not been certified for the ATEX directive or as nonincendive. In addition, this equipment should not be used with solvent based adhesives that can create an explosive atmosphere when processed. Refer to the MSDS for the adhesive to determine its processing characteristics and limitations. The use of incompatible solvent based adhesives or the improper processing of solvent based adhesives can result in personal injury, including death. Continued...

15 Pro Meter VDK Dispensing System 9 Equipment Type Table 1 General Safety Warnings and Cautions (contd) Warning or Caution HM, CA, PC WARNING! Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others and can damage to the equipment. HM CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of applicators, hoses, and certain components of the melter. If contact can not be avoided, wear heat protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. HM CAUTION! Some Nordson melters are specifically designed to process polyurethane reactive (PUR) hot melt. Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipment and cause premature reaction of the hot melt. If you are unsure of the equipment's ability to process PUR, contact your Nordson representative for assistance. HM, CA CAUTION! Before using any cleaning or flushing compound on or in the equipment, read and comply with the manufacturer's instructions and the MSDS supplied with the compound. Some cleaning compounds can react unpredictably with hot melt or cold adhesive, resulting in damage to the equipment. HM CAUTION! Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment. Before using the equipment, confirm that the hot melt is compatible with Type R fluid.

16 10 Pro Meter VDK Dispensing System Other Safety Precautions Do not use an open flame to heat hot melt system components. Check high pressure hoses daily for signs of excessive wear, damage, or leaks. Never point a dispensing handgun at yourself or others. Suspend dispensing handguns by their proper suspension point. First Aid If molten hot melt comes in contact with your skin: 1. Do NOT attempt to remove the molten hot melt from your skin. 2. Immediately soak the affected area in clean, cold water until the hot melt has cooled. 3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medical personnel providing treatment.

17 Pro Meter VDK Dispensing System 11 Safety Labels and Tags Figure 1 illustrates the location of the product safety labels and tags affixed to the equipment. Table 2 provides an illustration of the hazard identification symbols that appear on each safety label and tag, the meaning of the symbol, or the exact wording of any safety message. 1 Figure 1 Safety labels and tags Table 2 Safety Labels and Tags Item Part Description 1. N/A WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage.

18 12 Pro Meter VDK Dispensing System Introduction The Nordson Pro Meter VDK Dispensing System combines gear metering technology to provide precision and control in dispensing high viscosity silicones, butyls, epoxies, and hot melt materials. The dispensing system consists of two main components: Pro Meter VDK dispensing module Pro Meter VDK controller Intended Use The controller is used only to control the dispensing module. The dispensing modules may be configured in several different ways. The pumps, manifolds, and dispensing valves change depending on system requirements, in every case the servo drive motor remains the same.

19 Pro Meter VDK Dispensing System 13 Pro Meter VDK Dispensing Module The dispensing module is designed for use in form in place gasketing, bonding, and sealing operations, with heated or unheated materials. Mounted on the arm, wrist, or end effector of standard industrial controller, the dispensing module meters materials close to the point of application. This close proximity minimizes the effects of supply system pressure variations, material viscosity changes, and drops in system pressure due to material output. The dispensing module achieves precise bead profiles, precise shot weights, consistent gasket sizes, and material savings. Material can be supplied to the dispensing module by a bulk unloader, bulk melter, FoamMix, FoamMelt, or by any other positive pressure material supply system. Figure 2 Pro Meter VDK dispensing module

20 14 Pro Meter VDK Dispensing System Pro Meter VDK Controller The Pro Meter VDK dispensing system can be operated manually or automatically. In the manual configuration, the controller receives an input signal or trigger from a customer supplied device. When the signal is received the dispensing module starts dispensing at a fixed pump speed. The pump speed can only be adjusted manually from the front panel of the controller using the FLOW ADJUST potentiometer. In the automatic configuration, the controller is given the same input signal or trigger as the manual configuration, and an additional 0 10 VDC analog signal, usually from the controller. The input signal starts the dispensing module and the analog signal controls the pump speed (proportionately from 0 100% [0 10 VDC]). The controller is capable of supplying individual outputs to signal whether the controller is ready or is in a certain fault condition. A volume OK output can be utilized to signal that the last cycle dispensed was within a set limit. A 0-10 VDC signal can also be supplied to the controller or a customer supplied data logger to signify the amount of material dispensed where the voltage reading is proportionate to the volume in cubic centimeters (cc). Figure 3 Pro Meter VDK controller

21 Pro Meter VDK Dispensing System 15 Installation This section provides procedures for mounting the dispensing module and connecting the cables to the controller. WARNING! Do not turn the controller on until all cables are connected. Mounting the Dispensing Module The dispensing module needs to be securely attached to a metal plate (customer supplied), and then mounted on either a robot or on the wall. The metal plate should be made according to the mounting bracket's dimensions as shown in Figure 4. The metal plate needs to meet the following requirements for the dispensing module to be securely attached: four holes to secure 6 mm screws two holes to secure 8 mm dowels

22 16 Pro Meter VDK Dispensing System Mounting Bracket Dimensions This illustration gives the dimensions of the mounting bracket. The metal plate needs to be prepared according to the dimensions given below. 1 2 Figure 4 Mounting bracket dimensions 1. Four mounting hole locations (See NOTE below) 2. Location for 8 mm dowels NOTE: Use any of the following options for the mounting hole location: Option #1: Clearance holes for mounting to bracket with 6 mm screws. Option #2: Threaded for 8 mm screws when mounting to a bracket containing clearance holes.

23 Pro Meter VDK Dispensing System 17 Mounting Bracket Configuration This illustration shows how to position the mounting bracket so that it fits securely to the metal plate A B Figure 5 A: Mounting bracket, B: Metal plate configuration (customer supplied) 1. Screw holes 2. Dowel holes

24 18 Pro Meter VDK Dispensing System Connecting the Controller Cables The controller requires a 240V or 380V single phase power. The maximum power requirement for the controller is 15 amps. Cable Types The following cables connect to the controller: Motor power cable (available in 3, 6, 9, and 15 meters) Encoder cable (available in 3, 6, 9, and 15 meters) Applicator solenoid cable (available in 3, 6, and 9 meters) Transducer cable (available in 3, 6, and 9 meters) Trigger/volume cable (available in 9 meter only) Digital/analog cable (available in 9 meter only)

25 Pro Meter VDK Dispensing System 19 Internal Cable Routes This illustration shows the cable routes inside the controller Figure 6 Internal cable routes 1. DC wire duct 2. Location where incoming power should enter 3. AC wire duct 4. Motor and encoder duct

26 20 Pro Meter VDK Dispensing System Cable Connections See Figure 7 for the location of the connections on the controller Figure 7 Controller connections 1. Motor power entrance point (connects to X3, terminals L1, L2, and PE, on the motor controller) 2. Transducer pressure cable connection 3. Applicator control cable connection 4. Motor encoder entrance point (connects to X10 on the motor controller) 5. Digital/analog cable connection 6. Dispense on (trigger) volume cable connection 7. Control panel

27 Pro Meter VDK Dispensing System 21 Digital/Analog Cable Connections The digital outputs for the controller use dry contacts to interact with the controller. A +/- 24V or 120 VAC from the controller may be used. Pin Number Table 3 Digital/Analog Cable Pin Description Input/ Wire Color Signal Name Voltage Output Description 1 White/red Robot Signal Power (+) +/-24 VDC or 120 VAC Input This input power comes from the controller or other controlling device. It is used as the positive supply for the System Ready, Low Pressure Fault, High Pressure Fault, and Volume OK output signals. 2 White/black System Ready (+) Signal Power Output 3 White/green Low Pressure Fault (+) Signal Power Output This output indicates that the control circuit is active. This signal should be monitored by the controller. If this signal is not present, the system will not dispense material. This output indicates that a below minimum pressure condition exists at the gear pump outlet. This signal should be monitored during the dispense cycle to ensure that proper material pressure is present. 4 White/yellow High Pressure Fault (+) Signal Power Output This output indicates that an above maximum pressure condition exists at the gear pump outlet. This signal should be monitored during the dispense cycle to ensure that proper material pressure is present. The controller automatically disables the motor, if a high pressure fault occurs. 5 White Volume OK (+) Signal Power Output 6 Red Analog Signal (+) 0-10 VDC Input 7 Black Analog Signal (-) 0 VDC Input This output indicates that the most recent dispense cycle dispensed above the minimum material flow for that appropriate part. This signal should be monitored after the completion of the dispense cycle, to ensure that enough material was dispensed. This input is the command control signal used to set the motor speed for changes throughout the dispense cycle. The input from the controller or external source needs to be between 0 10 VDC. This signal can be adjusted globally with the three digit FLOW ADJUST potentiometer on the front panel. This is the common or minus of the drive signal. 8 Green Ground

28 22 Pro Meter VDK Dispensing System Digital/Analog Input Signal for Automatic Operation The analog input signal can be adjusted globally, using the FLOW ADJUST potentiometer on the front panel. It should preferably be set to 500. This allows the pump speed to be increased or decreased depending on material variation. Incoming pressure should be within 500 psi ( kpa). 1. Before connecting the analog signal, verify that the analog voltage provided is correct. 2. Connect the digital/analog cable to the controller. NOTE: The insulation may have to be stripped more to span the distances between inputs and outputs in the controller. 3. Connect the positive analog signal wire (red) to the positive analog output terminal in the controller. NOTE: If the wires get reversed the servo motor will run in reverse. The pump should rotate in a clockwise direction when looking down from the motor assembly. Digital/Analog Volume Output Connections 1. Connect the positive volume analog output signal wire (red) and the common volume analog output wire (black) to the controller's analog input controller. 2. The controller is setup to give a 2 to 10 V signal based on the programmable set points in the Volume/Flow Rate Display. NOTE: In programming module 8 (Pro 8), a low or high limit can be set to represent the 2 and 10V signal. Connecting Jumpers for Manual Operation CAUTION! Do not connect an external analog signal if jumpers are installed. Failure to follow this warning can result in severe damage to the equipment. If an external analog signal is not going to be used to control the speed of the pump, the following jumpers must be installed for the pump speed to be controlled manually. Jumper: Connects to: Jumper VDC terminal 2151 to terminal number 2361 Jumper 2 DC COMM terminal 1062 to terminal number 2381 With the jumpers installed, the FLOW ADJUST potentiometer will read the pump speed. For example, if it is set to 455 the pump speed will be at 45.5rpm.

29 Pro Meter VDK Dispensing System 23 Dispense On (Trigger) Volume Cable Table 4 Dispense On (Trigger) Volume Cable Pin Description Pin Number Wire Color Signal Name Voltage Input/Output Description 1 White/red Signal Power (+) 24 VDC Output Provides power for use with the trigger (pin 2). 2 White/black Dispense On Trigger Signal (+) 24 VDC Input This input signal controls the cycle start and stop of the dispense module. The signal is also used to mark the beginning and end of the dispense cycle for the purpose of flow monitoring. 3 Red Volume (+) 2 10 VDC Output This output signal indicates the volume of material dispensed on the preceding cycle. 4 Black Volume (-) 0 VDC Output This output signal represents common for volume out signal. 5 White/green Spare (+) This input signal is used to interlock the controller with an external device. By removing the jumper at locations 1061 and 1061A in the controller an external contact closure is used to enable the Pro Meter dispensing system. This is typically used in heated applications to prevent the Pro Meter dispensing system from operating until the system set point temperatures are achieved. 6 White/yellow Spare (+) 7 White No Pin 8 Green Ground NOTE: For the location of 1061 and 1061A refer to the schematics provided at the end of this manual.

30 24 Pro Meter VDK Dispensing System Trigger Input Connections 1. Connect the signal power wire (white/red) and the trigger/dispense on signal wire (white/black) to a dry contact (controller relay or output). 2. Use a selector switch, if the controller is intended to be manually controlled. 3. This input will trigger the applicator to start dispensing. NOTE: Purge material lines before attempting to start the gear pump. Applicator Control Cable Table 5 Applicator Control Cable Pin Description Pin Number Wire Color Signal Name Voltage Input/Output Description 1 Red #1 Signal Power (+) 24 VDC Output +24 VDC activates the solenoid for applicator control. 2 Red #2 Signal Power 0 Output Common 3 Not Used 4 Not Used 5 Not Used 6 Not Used 7 Not Used 8 Green/yellow Ground

31 Pro Meter VDK Dispensing System 25 Programming System programming is done using the system programming buttons on the control panel. The programming mode is divided into nine modules. The System Pressure display and the Flow/Volume display are factory configured and the settings should not need to be adjusted. Refer to Factory Default Values for the Controller Digital Displays under Technical Data. However, if the displays need to be reconfigured, use the Pressure Meter Method to Program the System Pressure Display or the Flow Meter Method to Program the Volume/Flow Display. Control Panel The control panel allows the operation and control of system functions. It also provides system information through status lights and display readouts. Figure 8 Control panel 1. Display controls 2. System control buttons 3. Display readout programming buttons 4. ON/OFF switch Refer to the following tables for an explanation of the control panel controls and buttons.

32 26 Pro Meter VDK Dispensing System Control Panel (contd) System Display SYSTEM PRESSURE FLOW (CC/MIN)/ VOLUME (CC) 1. Display Controls Function The controller monitors the system pressure as indicated by the pressure transducer located in the manifold. It also includes programmable high and low pressure limits that signal the controller via the digital/analog cable interface and the operator via the front status lights. The controller displays and monitors the material flowing through the system. An encoder (integrated into the servo motor mounted on the positive displacement gear pump) records pulses to display dispensed volume or material flow rate. By programming low and high dispense volume thresholds, a Volume OK signal is generated by the unit to communicate to the controller via the trigger/volume cable or to the operator via the front panel status light that sufficient material was dispensed on the most recent cycle. Material volume is displayed only at the end of the dispense cycle. The next trigger signal resets the counter and marks the entire cycle. This is an accurate record of the displayed material in totalized flow or flow rate. Note: A dispense cycle is each time the applicator turns off and on. System Controls SYSTEM STOP button SYSTEM ON button VOLUME OK light FLOW ADJUST potentiometer LOW PRESSURE fault status light HIGH PRESSURE fault status light DRIVE FAULT/RESET button MANUAL PURGE button 2. System Control Buttons Function Disables the control circuitry and the dispense head. Activates the control circuits. The system does not dispense material unless the control circuits are active. Indicates that the material dispensed most recently was within the high and low limit set points. Refer to Programming the Displays. Scales the controller supplied analog signal. By adjusting this potentiometer, the pump speed can be globally increased or decreased throughout the entire dispense cycle. A setting of 500 scales the analog input voltage to 50%, i.e., a 6V input with a 500 setting will give a 3V supply to the drive (3 volts translates to 30 rpm pump speed). In manual configuration, the FLOW ADJUST potentiometer adjusts the 0-10V signal. Indicates that the pressure transducer has detected pressure below the low limit set point. Refer to Programming the Displays. Indicates that the pressure transducer has detected pressure above the high limit set point. Refer to Programming the Displays. Lights up when a servo drive or high pressure fault occurs. Pressing this button resets either fault. The cause of the fault must be corrected for the fault light to go off. Dispenses material from the Pro Meter VDK applicator. While manually purging, the pump speed is set to 45% full speed. 3. Display Readout Programming Buttons The programming modules can be individually accessed and programmed by using the PAR button and the F1 or F2 buttons.

33 Pro Meter VDK Dispensing System 27 Programming the Displays To program the system pressure display or volume/flow display, use the system programming buttons. Figure 9 System programming buttons System Programming Buttons To start programming: Press the front panel button labeled PAR momentarily to enter the selected programming module. The display alternately flashes between Pro and the present module number. The PAR button is used to save the new value and progress to the next step in a module. Upon completion of the programming module, the indicator returns to the Pro no stage. Pressing the PAR button at this point causes the unit to exit the programming mode and return to the normal display mode. Press the front panel F1 or F2 buttons to select a module number. NOTES: In all of the programming modules, the F1 or F2 buttons are used to either select from a list of choices or change a value. Pressing the PAR button stores and activates the displayed selection/value. Nordson Corporation recommends using module 1 (Pro 1) for counting and module 4 (Pro 4) for rate.

34 28 Pro Meter VDK Dispensing System Pressure Meter Method to Program the System Pressure Display Use this method only after a pressure transducer has been replaced or the set parameters are suspect to be in error. To replace a transducer, refer to Pressure Transducer Replacement under Repair. NOTE: Programming modules 2, 3, 4, 5, 7, 8, and 9 (Pro 2, Pro 3, Pro 4, Pro 5, Pro 7, Pro 8, and Pro 9) are not applicable (N/A). NOTE: The values contained in the following tables represent those for a 5000 psi rated transducer. If a transducer of another rating is used, the shaded values will change proportionately in programming modules 2 and 6. Programming Module 1: Scale by Key In Method Parameter Description psi units kpa units Range (PAXS input range) 0.02v 0.02v decpnt (decimal point for scaled display) 0 0 round (rounding factor) PtS (scaling points) 2 2 StYLE (scaling style) key key INP 1 (input value for scaling point 1) dsp 1 (display value for scaling point 1) INP 2 (input value for scaling point 2) dsp 2 (display value for scaling point 2) NOTE: The display can be programmed to show units in psi or kpa. Use the correct settings for your unit. Programming Module 6: Setpoint (Alarm) Output Parameters Parameter Description psi units kpa units SPSEL (setpoint select for alarm 1) SP-1 SP-1 Act 1 (alarm 1 action [high or low]) AU-LO AU-LO SP-1 (setpoint value for alarm 1) HYS 1 (hysteresis value for alarm 1) SPSEL (setpoint select for alarm 2) SP-2 SP-2 Act 2 (alarm 2 action [high or low]) AU-HI AU-HI SP-2 (setpoint value for alarm 2) HYS 2 (hysteresis value for alarm 2)

35 Pro Meter VDK Dispensing System 29 Flow Meter Method to Program the Volume/Flow Display Use this method only when there is an error in the parameter or the pump has been changed to a different size. For the display to read the correct volume or flow rate, the controller must be programmed to the proper pump size (e.g., 1.2 cc/rev). NOTE: Programming modules 3, 5, 7, and 9 (Pro 3, Pro 5, Pro 7, and Pro 9) are not applicable (N/A). Programming the Volume/Flow Display For details on the programming buttons, refer to System Programming Buttons under Programming the Displays. See Figure 9. The front panel buttons are not only used to input data during the programming mode, but to control other functions as well. In the normal mode, front panel buttons perform the following functions: Press the F1 button to switch the display to rate. Press the F2 button to switch the display to totalizer. Press and hold the F1 button and press PAR to reset the totalizer to zero. Press PAR to enter the programming mode. Programming Module 1: Counter A, Counter B, and Prescaler Output Parameter Description Value A CNt (counter A operating mode) cnt ASCFAC (counter A scale factor) * *See Totalizer Table on the next page. Calculation Example for Programming Variable: Module 1\ASCFAC (Totalizer) The multiplying scale factor is calculated as follows: 1.2 cc/rev pump with a 20:1 gear reducer and Kollmorgen MT1504A1-E1C1 motor and CE G1504A1 drive with ENCOUT = 256 (encoder equivalent output pulses per rev. PPR) and decpnt = 0.0 (decimal point factor x 10) Formula: (total time base tbase) x (pump cc/rev) (decimal point factor x 10) (motor pulses/rev) (gear reducer ratio) Calculation: (3600) (1.2 cc/rev) (10) = 3600 x 1.2 x 10 = = ppr)(20:1 256 x ASCFAC = 8.438

36 30 Pro Meter VDK Dispensing System Pump Size (cc/rev) Decimal Places Totalizer Table: Programming Module 1 for Prescaler Output Time Base ASCFAC Pump Size (cc/rev) Decimal Places Time Base ASCFAC N/A N/A N/A N/A N/A 2 N/A N/A Continued...

37 Pro Meter VDK Dispensing System 31 Pump Size (cc/rev) Decimal Places Totalizer Table: Programming Module 1 for Prescaler Output (contd) Time Base ASCFAC Pump Size (cc/rev) Decimal Places Time Base ASCFAC N/A N/A N/A 2 N/A N/A N/A 2 N/A 2 N/A N/A NOTE: Preferred N/A 2 N/A Not available

38 32 Pro Meter VDK Dispensing System Programming Module 2: Rear Terminal User Inputs and Front Panel Function Keys Parameter Description Value Usr-1 (user input 1 momentary edge reset) A CNt (for counter A) CtrStE YES Programming Module 4: Scale by Key In Method Parameter Description Value LO Udt (low update time, display update) 0.5 HI Udt (high update time, display zero) 1.1 rte dp (rate decimal position) 0.0 RdSP 0 (rate display value for scaling point 1) 0 RINP 0 (rate input value for scaling point 1) 0 RdSP 1 (rate display value for scaling point 2) ## RINP 1 (rate input value for scaling point 2) round (rounding factor) 1 ##Refer to the Flow table and calculation on the next page

39 Pro Meter VDK Dispensing System 33 Flow Table: Programming Module 4 for Flow/Volume Display Pump Size (cc/rev) Decimal Places round RdSP Value Pump Size (cc/rev) Decimal Places round RdSP Value N/A N/A N/A N/A NOTE: The values in this table assume a gear reduction ratio of 40:1. Calculation Example for Programming Variable: Module 4/rdSP 1 (Flow) The rdsp 1 reading for scaling point number 2 is calculated as follows: 1.2 cc/rev pump with a 40:1 gear reducer and Kollmorgen MT1504A1-E1C1 motor Formula: (gear pump cc/rev.) x (max motor rpm) (gear reducer ratio) Calculation: (1.2 cc/rev) x (6000 rpm) = 1.2 x 6000 = 180 cc/min 40:1 40 rdsp 1 = 180 Pump Size rdsp

40 34 Pro Meter VDK Dispensing System Programming Module 6: Alarm/Setpoint Output Parameters Parameter Description SPSEL (setpoint select for alarm 1) ACt 1 (alarm 1 action [high or low]) Value SP-1 bound SP-1 (setpoint value for alarm 1) * typ-1 (setpoint boundary type for alarm 1) SPSEL (setpoint select for alarm 2) ACt 2 (alarm 2 action [high or low]) LO SP-2 bound SP-2 (setpoint value for alarm 2) ** typ-2 (setpoint boundary type for alarm 2) HI *Value for the minimum Volume OK in cc units **Value for the maximum Volume OK in cc units Volume OK switches ON when the volume reaches the SP-1 value and remains on until the volume exceeds the SP-2 value. Programming Module 8: Analog Output Parameters Parameter Description Value type (analog type) 4-20 ASIN (analog assignment) A CNt AN-LO (analog low scale value) 0.0 AN-HI (analog high scale value) 10.0

41 Pro Meter VDK Dispensing System 35 Operation This section provides procedures for the basic operation of the Pro Meter dispensing system. Starting the System Make sure that the controller has incoming material supply pressure. Set the incoming supply pressure as close to the output dispense pressure as possible. 1. Place the controller disconnect switch to on position. 2. Push the SYSTEM ON button to activate the control circuits. 3. Make sure that the dispense valve is in proper location for purging or place a container under the nozzle to catch the material. 4. Push and hold the MANUAL PURGE button. Observe the applicator dispensing process. NOTE: Depending on the material type and how it is being processed, the system may have to be purged for several minutes. 5. Depending on how the controller was installed (manual or automatic dispense), use the FLOW ADJUST potentiometer to adjust the speed of the servo motor. Shutting Down the System Make sure that the controller has finished dispensing before turning the system off. To shut down the controller, push the SYSTEM STOP button. NOTE: Depending on the length of the shutdown and the type of system, the system pressure may need to be relieved.

42 36 Pro Meter VDK Dispensing System Setting Trigger, Applicator ON, and Motor ON Delay Timers The controller features three adjustable timers: Trigger delay timer: This timer is used to delay the applicator and motor trigger signals until the timer/counters are fully activated, reset, and ready to process incoming data. Applicator On delay timer: This timer is used to delay the opening of the applicator. Motor ON delay timer: This timer is used to delay the rotation of the motor after a trigger signal has been received Figure 10 Location of the three timers inside the controller 1. TD1141 Motor On Delay 3. TD1122 Trigger Delay 2. TD1121 Applicator On Delay About Trigger Delay This delay must be set to a value greater than zero to ensure accurate data display. A setting between 250 msec and 500 msec is recommended. This ensures that the volume/flow rate counter is fully enabled and ready to receive incoming data from the servo motor encoder. This data is essential to provide accurate volume and flow rate information at all ranges of flow and dispense times.

43 Pro Meter VDK Dispensing System 37 About Applicator ON Delay If Applicator ON delay is set to a value other than zero, the applicator opening will be delayed the specified amount of time. This allows pressure to build before dispensing begins, resulting in additional material being dispensed at the beginning of a bead. This can offset the effects of a cold nozzle or compensate for a low pressure situation in a system in which the applicator is mounted remotely from the Pro Meter module. WARNING! Delaying the applicator opening will increase pressure in the dispensing module. If the Applicator ON delay is set too high, excessive pressure can occur in the module prior to the module opening. This may damage the pressure transducer and/or cause damage to the applicator seals or other components in the system. In addition, personal injury will result if the operator is exposed to high pressure material that unexpectedly splatters or extrudes. About Motor ON Delay If Motor ON delay is set to a value other than 0, the motor will begin rotating the specified amount of time after the applicator opens. Using the Motor ON delay can minimize the problem of too much material being dispensed at the beginning of a bead (known as the hammerhead effect). The hammerhead effect is usually caused by high system pressure that occurs when the applicator is off. NOTE: The Applicator ON and Motor ON delay timers can be adjusted to achieve optimum bead performance, but for most applications the timers should be set to zero. In general, if your system setup results in a need for more material at the beginning of a bead, it is best to adjust the Applicator ON delay timer. If your system setup results in a need for less material at the beginning of a bead, the Applicator ON delay timer should be set at 0 and the Motor ON delay timer should be adjusted.

44 38 Pro Meter VDK Dispensing System Maintenance Follow this schedule to maintain the controller. Frequency Course of Action Daily Keep the controller door closed except when performing maintenance or repairs inside the controller. Do not use solvents to clean any part of the controller. Be sure to record all system settings. Weekly Visually inspect all electrical connections and cables for damage. Repair and replace if necessary. Monthly Semi annual General Check control panel lights for proper operation. Tighten connections in the controller. Have spare parts available to make system repairs as quickly as possible, in case of a failure.

45 Pro Meter VDK Dispensing System 39 Repair This section contains replacement procedures for the dispensing module and controller components. WARNING! Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Drive Motor Replacement Follow these procedures to remove or install the drive motor. Drive Motor Removal WARNING! Disconnect equipment from line voltage. Failure to observe this warning may result in severe personal injury or equipment damage Disconnect the power from the motor and lock out power at the main electrical disconnect. 2. Disconnect the power and signal cables from the motor. 3. See Figure 11. Use a 3 mm wrench to remove the screws (2) that secure the drive motor (1)to the speed reducer (3). 4. Remove the two (or four) plastic plugs (4) from the sides of the speed reducer. Removing these plugs allow access to the coupling located between the drive motor and the speed reducer. 5. Align the Allen head setscrews on the coupling by manually turning the drive shaft and loosen them. 6. Physically separate the drive motor and the speed reducer. 3 4 Figure 11 Drive module removal 1. Drive motor 2. Drive motor screws 3. Speed reducer 4. Two or four holes

46 40 Pro Meter VDK Dispensing System Drive Motor Installation 1. Wipe off the oil from the motor shaft. 2. Scrape the motor shaft with an emery cloth before assembling the motor and reducer. This ensures that the compression coupling remains tight during operation. 3. Line up the screw openings on the drive motor with those on the speed reducer. 4. Align the Allen head setscrews on the coupling by manually turning the drive shaft and tighten them. 5. Install the four plastic plugs in the sides of the speed reducer. 6. Install the four drive module screws. 7. Reconnect the power and signal cables to the motor. 8. Restore power.

47 Pro Meter VDK Dispensing System 41 Speed Reducer Replacement Follow these procedures to remove or install the speed reducer. Speed Reducer Removal 1. Disconnect the power from the motor and lock out power at the main electrical disconnect. 2. Disconnect the power and signal cables from the motor. 3. See Figure 12. Remove the screws (2) that secure the drive motor (1) to the speed reducer (4). 4. Remove the plastic plugs (3) from the sides of the speed reducer. Removing these plugs allows access to the coupling located between the drive motor and the speed reducer Figure 12 Drive module 1. Drive motor 2. Drive motor screws 3. Plastic plugs 4. Speed reducer 5. Speed reducer screws 6. Coupling cover 7. Mounting bracket

48 42 Pro Meter VDK Dispensing System Speed Reducer Removal (contd) 5. See Figure 13. Align the coupling set screws (5) by manually turning the drive shaft; then loosen the set screws. 6. Separate the drive motor from the speed reducer. 7. See Figure 12. Remove the coupling cover (6) by removing the six Allen head screws. 8. Remove the screws that secure the speed reducer to the mounting bracket (7). 9. Remove the entire speed reducer and upper coupling hub (Figure 13, item 1) from the mounting bracket. 10. See Figure 13. Loosen the upper coupling hub set screw and slide the upper coupling hub off of the speed reducer shaft Figure 13 Coupling 1. Upper coupling hub 2. Center coupling hub 3. Lower coupling hub 4. Pump 5. Set screws

49 Pro Meter VDK Dispensing System 43 Speed Reducer Installation 1. Slide the upper coupling hub onto the new speed reducer shaft. 2. Tighten the set screw on the upper coupling hub. 3. Place the new assembly into the mounting bracket and secure it with the four speed reducer screws. 4. Install the coupling cover. 5. Align the drive module back onto the speed reducer. 6. Align the Allen head set screws on the coupling by manually turning the drive shaft and then tighten them. Use the following torque settings: Pre torque: 22 Ncm (2 in. lb) Final torque: 441 Ncm (39 in. lb) 7. Attach the drive motor to the speed reducer by inserting and tightening the four drive motor screws. 8. Install the plastic plugs in the sides of the speed reducer. 9. Reconnect the power and signal cables to the motor. 10. Restore power.

50 44 Pro Meter VDK Dispensing System Coupling Replacement Follow these procedures to remove or install the coupling. Coupling Removal WARNING! Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury or equipment damage. 1. Disconnect the power from the motor and lock out power at the main electrical disconnect. WARNING! System or material pressurized. Relieve pressure. Failure to observe this warning may result in personal injury or equipment damage. 2. Relieve system pressure. Refer to the supply system manual as needed. 3. Bleed off pressure from both the supply and discharge lines of the gear pump. 4. Remove the coupling cover.

51 Pro Meter VDK Dispensing System Remove the screws (2) that secure the drive motor and speed reducer assembly to the mounting bracket (4). 6. Remove the entire drive motor, speed reducer, and upper coupling hub from the mounting bracket Figure 14 Drive module 1. Speed reducer 2. Speed reducer screws 3. Coupling cover 4. Mounting bracket

52 46 Pro Meter VDK Dispensing System Coupling Removal (contd) 7. See Figure 15. Loosen the upper coupling (1) hub set screw and slide the upper coupling hub off of the speed reducer shaft. 8. Remove the center coupling hub (2). 9. Loosen the lower coupling hub (3) set screw and slide the lower coupling hub off of the pump shaft Figure 15 Coupling 1. Upper coupling hub 2. Center coupling hub 3. Lower coupling hub 4. Pump 5. Setscrews

53 Pro Meter VDK Dispensing System 47 Coupling Installation CAUTION! When installing the coupling onto the pump, do not place great force on it or strike it with a hammer. Striking the hub with a hammer could damage the hub and the external seals of the pump. 1. Install the new coupling hubs on the pump shaft and speed reducer shaft using the appropriate keys to match the pump and speed reducer shafts. 2. Secure the lower coupling hub first, making sure that the gap between the lower coupling hub and pump seal housing is approximately 10mm(0.4 in.) and that the drive keys are fully engaged in the shaft keyways. Tighten the set screw to 6.78 Nm (5ft lb). 3. Place the center coupling hub in position over the lower coupling hub. The cam follower bearings in the lower coupling hub will fit into the slot in the coupling center plate. 4. Slide the drive module with the upper hub loosely attached to the reducer shaft onto the mounting bracket. Manually rotate the reducer shaft to align the cam follower bearings in the speed reducer coupling hub with the slot in the coupling center plate. NOTE: When viewed from overhead, the coupling hubs and center plate should appear concentric and rest flat against each other. If adjustment is necessary, loosen the speed reducer screws and move the drive module assembly to align the coupling. When concentricity is achieved, tighten the screws. NOTE: The pump shaft and speed reducer shaft should be in line and parallel. 5. Space the speed reducer coupling hub away from the coupling center hub using a in. shim. Tighten the set screw to 6.78 Nm (5 ft lb) and remove the shim. 6. Install the coupling cover. 7. Restore power and pressure to system.

54 48 Pro Meter VDK Dispensing System Gear Pump Replacement Follow these procedures to remove or install the gear pump. For programming information, Flow Meter Method to Program the Volume/Flow Display under Programming. Gear Pump Removal WARNING! Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury or equipment damage. 1. Disconnect the power from the motor and lock out power at the main electrical disconnect. WARNING! System or material pressurized. Relieve pressure. Failure to observe this warning may result in personal injury or equipment damage. 2. Relieve system pressure. Refer to the supply system manual as needed. 3. Check to see that all material supply pressure has been relieved. Make sure that all residual pressure has been relieved between the gear pump and applicator by manually actuating the applicator over a waste container.

55 Pro Meter VDK Dispensing System See Figure 16. Remove the four bracket shoulder screws (2) and then carefully lower the manifold pump module and lower coupling hub (as a single assembly) away from the mounting bracket. The center hub of the coupling will be loose and should be safely set aside. 1 2 Figure 16 Removing the manifold and pump module from the bracket 1. Shoulder screws 2. Mounting bracket

56 50 Pro Meter VDK Dispensing System Gear Pump Removal (contd) 5. See Figure 17. Loosen and remove the four cap screws (2) that fasten the pump (3) to the manifold (4). Remove the pump and coupling hub from the manifold. 6. Loosen the lower coupling hub set screw (1) and remove the hub from the pump shaft Figure 17 Pump and manifold assembly 1. Coupling hub setscrew 2. Cap screws 3. Pump 4. Manifold

57 Pro Meter VDK Dispensing System 51 Gear Pump Installation 1. Grease the end of the pump shaft (area between the gear pump and the manifold). On heated systems use high temperature grease, such as Krytox240AC, and on silicone applications use Vaseline. 2. Install the hub removed from the pump in the preceding procedure onto the new pump, using the appropriate key to match the pump shaft and hub. Do not tighten the set screws. NOTE: Changing the pump does not normally require that the supply hose or heater cable be disconnected from their manifold connectors, but this may be done to gain easier access. 3. Replace the O rings on the manifold. Discard the old ones. Refer to Parts for part numbers. 4. Secure the new pump to the manifold. Tighten the cap screws to Nm (33-40 ft lb). 5. Remove the coupling cover by removing the six cover screws. 6. Place the center coupling hub onto the lower hub, then secure the manifold shoulder screws through the bracket into the manifold, making sure that the entire assembly realigns properly. Space the gear pump coupling hub away from the center hub using a in. shim. 7. Tighten the set screw on the lower hub to 6.78 Nm (5 ft lb). 8. Install the coupling cover. 9. Restore power and air pressure to the system and test the pump operation.

58 52 Pro Meter VDK Dispensing System Gear Pump Seal Replacement Follow this procedure to replace the seals in each seal housing. WARNING! Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury or equipment damage. 1. Disconnect the power from the motor and lock out power at the main electrical disconnect. WARNING! System or material pressurized. Relieve pressure. Failure to observe this warning may result in personal injury or equipment damage. 2. Relieve system pressure. Refer to the supply system manual as needed. 3. Check to see that all material supply pressure has been relieved. Make sure that all residual pressure has been relieved between the gear pump and applicator by manually actuating the applicator over a waste container. 4. See Figure 16. Remove the four shoulder screws; then carefully lower the manifold pump module and lower coupling hub (as a single assembly) away from the bracket. The center section of the coupling will be loose and should be safely set aside. 5. See Figure 18. Loosen the lower coupling hub set screw (1) and remove the hub from the pump shaft. NOTE: Seal change does not normally require that the pump be removed from the manifold. However, if accessibility is a problem, perform the replacement procedure for the gear metering pump and remove the pump. Refer to Gear Pump Replacement. 6. Remove the three cap screws (2) from the seal housing (3); then remove the seal housing from the pump.

59 Pro Meter VDK Dispensing System Figure 18 Coupling, pump, and manifold assembly 1. Lower coupling hub set screw 3. Seal housing 2. Cap screws

60 54 Pro Meter VDK Dispensing System Gear Pump Seal Replacement (contd) 7. Remove the old seal with an O ring pick or other seal removal tool. Make sure the housing is clear of debris. 8. Install a new seal, making sure that the smaller diameter side goes into the housing first. Refer to Parts for the part number of the seal. 9. Place a small amount of high temperature grease, such as Krytox240AC, on the inside diameter of the housing and the seals. For silicone applications, use Vaseline on the inside diameter of the housing and on the seals. 10. Install the seal housing on the shaft and tighten the three cap screws to Nm ( ft lb). 11. Remove the coupling cover. 12. Install the gear pump if necessary, then reassemble the coupling. Refer to Gear Pump Installation. 13. Install the coupling cover. 14. Restore power and air pressure to the system. 15. Ensure proper pump seal and operation.

61 Pro Meter VDK Dispensing System 55 Pressure Transducer Replacement Follow this procedure to replace the pressure transducer. For programming information, refer to Pressure Meter Method to Program the System Pressure Display under Programming the Displays. WARNING! Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury, death, or equipment damage. 1. Disconnect the power from the motor and lock out power at the main electrical disconnect. WARNING! System or material pressurized. Relieve pressure. Failure to observe this warning may result in personal injury, death, or equipment damage. 2. Relieve system pressure. Refer to the supply system manual as needed. 3. Bleed off pressure from both the supply and discharge lines of the gear pump. 4. Disconnect the transducer cable. 5. Unscrew the pressure transducer from the 1 / 4 in. port on the manifold.

62 56 Pro Meter VDK Dispensing System Pressure Transducer Replacement (contd) 6. Screw the new transducer into the 1 / 4 in. port on the manifold. 7. Reconnect the transducer cable. 8. If the new transducer has a different rating from the original, refer to Pressure Meter Method to Program the System Pressure Display under Programming the Displays. Figure 19 Transducer location

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64 58 Pro Meter VDK Dispensing System Controller Panel Meter Replacement Follow this procedure when replacing either of the panel meters in the controller. Panel Meter Removal 1. Disconnect and lock out power to the controller. 2. Open the controller cabinet. 3. Locate the panel meter to be replaced. 4. Unplug the connectors located at the rear of the meter. 5. Remove any wire ties that may be securing the wiring to the meter. 6. Disconnect the ground wire from the right side (as viewed from the rear) of the panel meter. 7. Loosen the two panel mounting screws as shown below. Remove the mounting clips (see Figure 21). 1 Figure 20 Mounting screws location 1. Mounting screws

65 Pro Meter VDK Dispensing System Carefully remove the panel meter by sliding it out of the cut out in the controller panel. 9. Prepare the replacement meter by installing the mounting screws and mounting clips as shown below. 1 2 Figure 21 Preparing the replacement meter 1. Mounting screw 2. Mounting clip

66 60 Pro Meter VDK Dispensing System Preparation for Panel Meter Installation Volume/Flow Panel Meter 1. Before mounting the volume/flow panel meter into the controller, locate the selector switches. NOTE: The selector switches are located on the right side (when viewed from the rear) of the panel meter. 2. Set the switch positions to: down up down. See the following figure for the switch position: 1 Figure 22 Setting the switch 1. Sensor switch positions: down up down

67 Pro Meter VDK Dispensing System Select the AC power ( VAC). The AC power to the unit must be selected for 230 VAC. NOTE: The selector switch is located through an access slot on the side of the replacement meter, for location see Figure 23. The unit is shipped from the factory with the switch in 230 VAC position. Figure 23 Selector switch location

68 62 Pro Meter VDK Dispensing System Pressure Panel Meter 1. Before mounting the pressure panel meter into the controller, locate the four sets of selector pins. NOTE: The four sets of selector pins are located on the rear of the meter. 2. Place the jumpers over the pins in positions 1 and Figure 24 Placing the jumpers 1. Position 1 2. Position 3

69 Pro Meter VDK Dispensing System Select the AC power ( VAC). The AC power to the unit must be selected for 230 VAC. NOTE: The selector switch is located through an access slot on the side of the replacement meter, for location see Figure 23. The unit is shipped from the factory with the switch in 230 VAC position. Figure 25 Selector switch location

70 64 Pro Meter VDK Dispensing System Panel Meter Installation 1. Carefully slide the panel meter through the front cut out opening on the Pro Meter controller. 2. Make sure that the mounting clips and mounting screws have been installed on each side of the replacement meter. See Figure Figure 26 Cut out view of the panel 1. Cut away view of the case 2. Existing panel 3. Gasket 4. Bezel 5. Mounting clip 6. Mounting screw 3. Tighten the mounting screws to secure the panel meter in place. 4. Connect ground wire to the right side (when viewed from the rear) of the panel meter. 5. Replace the connectors on the back of the panel meter. 6. Secure any loose wires with the wire ties. 7. Close the controller door. 8. Apply power to the controller. 9. Program the display that has been replaced. Refer to Programming the Displays under Programming.