Autosealer Hernon Manufacturing Autosealer

Size: px

Start display at page:

Download "Autosealer Hernon Manufacturing Autosealer"

Rudolf Green
5 years ago
Views:

1 Autosealer Tech Drive Sanford, FL Phone: (407) Fax: (407) August P a g e

2 About This Manual Thank you for selecting Hernon's Autosealer 2650 for your application. The Autosealer 2650 was developed with your needs in mind, and has been calibrated and tested to ensure optimal performance and long life. To ensure safe and trouble-free operation, please review the procedures and warnings contained in this manual before setting up or operating your Autosealer While safety is paramount, proper handling and operation of your Autosealer 2650 will also serve to produce quality product yield. If you have any problems or concerns, please contact Hernon Technical Support at (407) Trained Hernon professionals are standing by to serve you. 2 P a g e

3 Table of Contents Autosealer About This Manual... 2 Table of Contents... 3 Unpacking and Inspection... 4 Safety... 5 General... 5 Specifications... 5 SureShot R Autosealer 2650 Assembly Procedure Set-Up Operator Controls Main Menu Example Maintenance Troubleshooting Spare Parts Warranty Reference P a g e

4 Unpacking and Inspection Upon receipt of the unit, carefully remove the contents from the boxes and check for damage. Hernon is not responsible for damage from shipping all claims for shipping damage should be made with carrier. Check all boxes for contents and document any serial numbers for further reference. You may wish to retain original shipping cartons in case you need to repackage any item for return. If you observe or experience any problem with your equipment, notify Hernon Customer Support, your authorized distributor, or your Hernon representative immediately. NOTE: REPORT ANY SHORTAGE TO HERNON CUSTOMER SERVICE Phone: (407) Fax: (407) Before continuing with unpacking and installation, please read the following chapters of this manual for safety recommendations and installation, running, and troubleshooting instructions. WARNING! Always observe safety requirements! CAUTION! Risk of Electrical Shock when enclosure is removed! CAUTION! Enclosure is warm to the touch when unit is in operation! 4 P a g e

5 Safety For safe and successful operation of the unit, read these instructions completely. If the instructions are not observed, the manufacturer can assume no responsibility. Be sure to retain this manual for future reference. If chemical products are not properly handled, damage to health can result. Observe general safety regulations for the handling of chemicals. Observe manufacturer s instructions. When working with pressurized air, wear protective glasses. While under warranty, the unit may be repaired only by an authorized Hernon service representative. Request a material safety data sheet for the HERNON product used. General The Autosealer 2650 is a control unit for applying sealant to pipe thread nipples, using the SureShot The Autosealer 2650 allows control through included PLC and can be triggered through Manual Control with a footswitch and/or PLC start button. The spindle, located in the center between the SureShot 4000 and wiper, is designed to receive and hold pipe-thread nipples by compressing an O-ring and gripping the nipple from the inside bore. Validation Prior to production, Hernon advises customers to conduct testing to determine the desired dispense times. See the example provided on page 14. Specifications System Part Number Power Requirements 110 or 220VAC NOTE: This system in NOT auto Switching Internal Power Supply Voltage 24V and 48V Cooling Filtered, dual-fan arrangement Housing Dimensions 16.5 x 14 x 14.5 System Warranty 1 year from purchase Air Minimum 70psi, Maximum 100psi (Dry Filtered Air) 1/4 NPT Weight (approx.) 60lb (28kg) NOTE: For voltage change requirements, refer to wiring schematic at the end of the manual. 5 P a g e

6 System Includes: QTY. Name Part Number 1 Autosealer 2650 Controller R125 Reservoir Standard Regulator Kit (0 30psi) ¼ Dispense Tube Fitting Thermocouple No sensor Option (R125) Dispense Tubing 5ft. (white Teflon) ¼ O.D. x 0.15 wall SureShot 4000-T (straight) Teflon Piston ¼ NPT x ¼ Tube x 90 Kynar Fitting /8 male ¼ Tube Push-To-Connect (straight) Pneumatic Tubing 5ft (cut to desired length) ¼ O.D. Male Quick-Disconnect Foot Pedal Power Cable (not shown) Wiper Wiper Brush Spindle Tooling (for 3/4 Pipe Nipple) custom Custom Figure 1 - Included components, labelled by part number 6 P a g e

7 SureShot 4000 The SureShot 4000 series dispense valve system accurately controls the application of most medium and high viscosity fluid. To prevent clogs in the dispense tips, use an orange Lock Cap Plug when the SS4000 is not being used. Features Compact weight and size Positive shut-off Easy cleaning Low-maintenance design Snuff back Figure 2 - SS4000 components and spare parts Dispense Tips Tip selection is critical to achieve optimum valve performance. SS400 series valves are packaged with an ultra-dispensing tip kit for maximum fluid control. The kit includes smooth-flow tapered tips in sizes from 14 to 25 gauge, precision stainless steel tips in sizes from 14 to 30 gauge. Tip kit is NOT included with the Autosealer P a g e

8 Technical Information Figure 3 SS4000 specifications R125 The R125 is a pressurized material reservoir for Hernon products. Contained in this section are the recommended procedures for setting up and maintaining various aspects of the R125 Pressure Reservoir. Strict adherence to these procedures will ensure safe and smooth operation and maximum sealant life. R125 Tube Installation 1. Assemble the ¼ NPT dispense tubing / compression connector into the pressure reservoir lid. For initial assembly convenience the ¼ NPT threads on the tubing connector should be prepared with pre-applied pipe sealant. 2. Assemble tubing through the nut and the back / front parts of the compression ferrule assembly as detailed below. 3. Insert the tubing assembly end into the male ¼ NPT connector body and loosely screw the nut onto the connector body. 4. Place the reservoir cap on the reservoir and push tubing through thermocoupler until the tube touches the bottom of the reservoir then retract the tubing about ¼ from the bottom. 5. Lightly tighten the nut on the ¼ NPT connector body to lock and seal dispense feed tubing and ferrule. Pull on the tube to verify ferrule is holding the tube. NOTE: Over tightening ferrule can close soft dispense tube. 6. Trimming the end of this tube at an angle will assure uninhibited liquid flow in case tube end contacts liquid container. 7. Connect the dispense end of the tube as required to a normally closed SS P a g e

9 Figure 4 - R125 components and spare parts Figure 5 - R125 input connector 9 P a g e

10 R125 Fill/Refilling Set-Up Procedure Note: For compatibility purposes, avoid placing sealant in reservoir without some sort of isolation barrier. Hernon recommends the use of reservoir liners (see replacement parts list) or placement of original sealant container directly in reservoir. Do not place liquid directly into Reservoir or wet internal surfaces. 1. Ensure pressure regulator is set for zero (0) PSI. Pull locked regulator knob out to unlock knob and turn counter clockwise to relieve air pressure to zero (0) PSI. 2. Turn clamp ring star nut counter clockwise and loosen clamp ring T-bolt. Once sufficiently loose the T-bolt can be turned 90 degrees and free clamp tie. Open clamp band slightly and lower ring just below cap clamp area. 3. Remove cap from pressure vessel using the handle on top and carefully set it aside. 4. Put liquid container inside pressure reservoir or use polyethylene bag as a liner ( ) and fill liquid to be dispense into bag lined reservoir. Do not pour liquid directly into pressure vessel. This can contaminate the Reservoir. 5. Insure that the O-ring stays in the groove of the cover. A light film of vacuum grease periodically wiped on the O-ring will prevent adhesives and sealants from adhering to the sealing surfaces. NOTE: Use only a small amount of vacuum grease on sealing surfaces. Excessive grease may migrate and contaminate dispense liquid. 6. Install cover on the pressure reservoir making sure to direct dispense tube end into container with dispense sealant. 7. Engage the reservoir cap clamp ring into clamp position, lock in T-bolt and tighten clamp as required for seal. 8. Connect dry filtered air supply to reservoir regulator input (¼ NPT) / quick disconnect. R125 Start-Up Pressurize Procedure 1. Pull pressure regulator knob out slightly and turn clockwise to increase air pressure. Never exceed 100 PSI maximum. Listen for possible air leaks and or any signs of dispense liquid / fluid leaking for connections. Start with lowest pressure and gradually increase as required. Autosealer 2650 Assembly Procedure 1. Connect power cord to rear of unit and plug into a grounded wall outlet, with the power switch on the off ( O ) position. 2. Connect the Foot Switch to the connection marked Foot Switch on the right side of the unit. 3. Mount SureShot tooling as shown in Figure Mount Wiper tooling as shown in Figure Connect SureShot 4000 air inputs, using pneumatic tubing: one end to the coupler marked Valve Air Output on the side panel, the other end to the air input on the SS Connect R125 Reservoir air inputs, using pneumatic tubing: one end to the coupler Reservoir Air Output on the back panel, and the other end to the coupler on the reservoir 7. Insert one end of the white Teflon sealant supply hose through the thermal couple fitting on the lid of R125 Reservoir and into the sealant container and connect the other end to the sealant supply fitting on SS4000 dispensing valve assembly. Refer to R125 guidelines on page Connect air supply hose to Air Input on the side panel of Autosealer 2650 (minimum 70psi, maximum 100psi). Use only dry filtered air. 9. Adjust pressure regulator on R125 to desired PSI. 10. Select and install a dispensing needle to the SS Turn the power switch to ON. 10 P a g e

Figure 6 - Side Panel Inputs and Outputs Motion Stop Dispense Tooling Spindle Wiper Figure 7 - Front face of Autosealer 2650, showing

This can be confirmed by viewing PLC screen initialization.

user can quickly disable the servo motors and stop them from functioning, in the event of an error, even if the footswitch is pressed.

11 Figure 6 - Side Panel Inputs and Outputs Motion Stop Dispense Tooling Spindle Wiper Figure 7 - Front face of Autosealer 2650, showing Dispense Needle, Spindle, Wiper, and Motion-Stop. Set-Up The PLC should begin to function as soon as the power is switched ON. This can be confirmed by viewing PLC screen initialization. Yellow Motion-Stop Button The guarded, yellow motion-stop button is located on the front Panel of the controller included so that the user can quickly disable the servo motors and stop them from functioning, in the event of an error, even if the footswitch is pressed. NOTE: The Autosealer will only function if the button is pulled out. When the button is pushed in, servo motors will not function. The motion stop is also used as a servoenable in the event of a servo error. 11 P a g e

Spindle Tooling Installation Procedure Ensure that the correct spindle tooling is installed.

Power OFF, and press motion-stop button to ensure the machine is totally depowered. 2.

Place the O-ring in the groove on the cap and screw the cap in by hand. The O-ring should be seated in between the body and the cap. 4.

12 Spindle Tooling Installation Procedure Ensure that the correct spindle tooling is installed. Each set of tooling includes the main spindle body, an O-ring, and a cap. 1. Power OFF, and press motion-stop button to ensure the machine is totally depowered. 2. Slide the spindle body over the center shaft, and align the set-screw with the flat on the shaft. 3. Place the O-ring in the groove on the cap and screw the cap in by hand. The O-ring should be seated in between the body and the cap. 4. To install the tooling, use a 7/16 wrench to keep the shaft from turning, and tighten the cap to 40 to 50 in-lb (4.5 to 5.6 N-m) of torque with a 5/16 wrench. Removal is the reverse of installation, with the exception of the torque. The spindle tooling can be changed to different sizes to handle different size pipe nipples and/or threaded fittings. Figure 8 How to install Spindle Tooling Figure 9 - Spindle Tooling Exploded View 12 P a g e

13 Operator Controls After making sure all the appropriate lines and hoses are connected, the correct spindle tooling is installed, and the motion-stop button is pulled out; place a pipe nipple over the spindle and position the SureShot 4000 micro-tip to desired location. The Needle tip should be within 1/8 (3mm) from the surface of the dispense target. The position of the nozzle can be modified as required. Main Menu The dispense cycle can be modified via the adjustable options on the main menu: Spindle RPM (Min. 30, max. 300) Controls the rate at which the spindle turns, measured in revolutions per minute. Wiper Torque (Min. 30%, max. 50%) Controls the intensity with which the wiper arm presses against the work piece on the spindle Dispense Time Defines the amount of time that the SureShot 4000 dispenses sealant onto the work piece Drag Time Defines the amount of time that the wiper arm is pressed against the work piece after Dispense is complete. NOTE: The format for setting time is MM:SS.hh (where M = minutes, S = seconds, h = hundredths of a second) All parameters will affect the final application of the thread sealant, and will likely require adjusting for different size pipe nipples and/or threaded fittings. The Cycle Counter, if enabled, will begin counting up cycles from zero. The Reset Count button can be pressed to set the count back to zero. Note: the counter will NOT reset when system is turned off. Machine Status The system status allows the user to identify current machine states and or current system faults. In the event of a servo error you must depress the motion stop button to clear any error before normal operation will resume. The following statuses can be displayed: System Status: OK: system ready for operation Cycle in Progress: Current Cycle is in progress Motion Stop: Motion Stop Depressed Servo System Error: spindle and Wiper servo error active Wiper Motor Error: Wiper servo error only Spindle Motor Error: Spindle servo error only NOTE: The Autosealer will not begin a cycle unless the system status is listed as OK. Maintenance Menu The Maintenance menu can be accessed from the main menu. Here, the user can view the status of individual Inputs and Outputs. The Inputs screen will show the current status of inputs (spindle, motionstop, footswitch, and wiper status), and the Outputs screen will allow the user to individually activate different component signals for troubleshooting and/or maintenance. Spindle rotation, spindle part clamp, and wiper direction can all be individually activated to check function. Also in the Outputs menu 13 P a g e

is the Purge option, which will purge sealant from the SureShot 4000. Purge can also be used for cleaning the SureShot 4000.

14 is the Purge option, which will purge sealant from the SureShot Purge can also be used for cleaning the SureShot Manual Start and Foot Pedal Activation The Foot Pedal and/or the Manual Start key on the Main Menu, is used to initiate the dispense cycle. A cycle cannot be interrupted while the Machine Status reads Cycle in Progress. Example The following is an example recommended parameters for a dispense cycle, with given parameters: Sealant: SelfSealer 616 Pipe Nipple Size: ½ Male-to-Male x ¾ Spindle RPM: 300rpm Wiper Torque: 35% Dispense Time: 2.0 seconds Drag Time: 0 seconds Reservoir Pressure: 10psi The foot pedal trigger and/or the Manual Start key on the main menu PLC, will initiate the automated dispense cycle as follows: the spindle will begin turning and grip the pipe-nipple, the sealant will be applied to the threads, and the wiper will press against the threads and spread the sealant. The system status should read Cycle in Progress. Once the sealant is applied and the wiper is retracted, the spindle will let go of the nipple, come to a stop, and the System Status will change back to OK. This completes one cycle, and the nipple can now be removed. Figure 10 - An example of proper sealant application. Maintenance The Autosealer 2650 was designed to operate with minimum maintenance. Follow the schedule below to ensure top unit performance. 14 P a g e

Cleaning the SureShot 4000 To clean your SS4000, Hernon recommends running water through the valve-reservoir system. Use the Purge function on the maintenance menu to help prime the valve.

It is recommended that you call Hernon to find more information based on your application.

15 Cleaning the SureShot 4000 To clean your SS4000, Hernon recommends running water through the valve-reservoir system. Use the Purge function on the maintenance menu to help prime the valve. A Lock Cap Plug can delay the drying of sealant, be sure to cover the dispense tip with the plug when the machine is not being used. It is recommended that you call Hernon to find more information based on your application. Fan Filters The external fan filters should be inspected and cleaned periodically to prevent dust buildup from affecting airflow through the unit. The fan filters are washable and may be reused. Remove the fan filter by removing the Snap-on cover from the rear of each fan. DO NOT OPERATE AUTOSEALER 2650 UNIT WITHOUT FAN FILTERS IN PLACE. DOING SO WILL ALTER THE RUNNING TEMPERATURE AND MAY LEAD TO PREMATURE FAILURE. Figure 11 - Fan Filter Assembly Fuse Replacement The unit incorporates dual fuses that are installed in the power receptacle switch assembly. To remove the fuse, unplug the unit and remove the fuse holder with a small screwdriver. Remove the old fuses from the holder and install new fuses. Replace the fuse holder into the power receptacle. Consult Spare Parts information on page 14. Figure 12 - Fuse Replacement 15 P a g e

16 Troubleshooting WARNING: ONLY QUALIFIED MAINTENANCE PERSONNEL SHOULD ATTEMPT THE FOLLOWING PROCEDURES: Frequently Asked Questions Q) My Autosealer 2650 will not turn on. A. Check the power cord connection. B. Check the fuses located where the power cord plugs into the unit. Q) My foot switch is not operating. A. Check the connection of the foot switch into the unit. Q) Why does my Autosealer 2650 seem to run very hot? A. Replace the fan filter media on both the intake and exhaust fans located in the back of the equipment. This is your first line of defense against airborne dust and debris. B. Ideal operation of this equipment suggests at least 12 of clearance behind the unit for proper ventilation. Confirm intake fan is not feeding from the exhaust of other equipment. C. Confirm both intake and exhausts fans are operating. D. Equipment may already be full of dust and debris; overheating the internal electronics. Q) The dispense tip is clogged up with sealant. A. Replace micro-tip. B. Use the orange Lock Cap Plug to cover the dispense tip when the SS4000 is not being used. Q) The dispense cycle does not begin when the footswitch is pressed. A. Check that the foot switch is plugged into the port labelled Foot Switch on the side panel. B. Make sure the Motion-Stop Button is pulled out. If not, push in and retract again. Spare Parts ITEM QTY. REQ. PART # SureShot Fuse Fan Filter Media Dispense Needles Dispense Tubing (1/4 Teflon) Spindle Tooling - Custom ¼ NPT x ¼ Tube x 90 Kynar Fitting Thermal Couple Ferrule Set Luer Lock cap plug Pneumatic Tubing 5ft (cut to desired length) ¼ O.D. Male Quick-Disconnect P a g e

17 Warranty CAUTION! HERNON CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES, EXPRESSED OR IMPLIED, DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON HERNON EQUIPMENT WITHOUT WRITTEN AUTHORIZATION FROM HERNON. THOSE CORRECTIVE ACTIONS LISTED BELOW ARE LIMITED TO THIS AUTHORIZATION. Hernon offers a one-year warranty against defects in material and workmanship on all system components, except the bulb, with proof of purchase date. Unauthorized repair, modification, or improper use of equipment may void warranty. The use of aftermarket replacement parts not supplied or approved by Hernon will void any effective warranties and may result in damage to the equipment. The data contained in this bulletin is furnished for information only and is believed to be reliable. We cannot assume responsibility for results obtained by others over whose methods we have no control. It is the user s responsibility to determine suitability for the user s purpose of any product or methods mentioned herein and to adopt such precautions as may be advisable for the protection of property and persons against any hazards that may be involved in the handling and use thereof. Nothing in this bulletin is to be interpreted as a representation of freedom from domination of patents owned by others or a license under a Hernon patent. We recommend that each prospective user test his proposed application before repetitive use, using the data as a guide. 17 P a g e

18 Reference 18 P a g e

19 19 P a g e

20 20 P a g e

DO NOT INSTALL, OPERATE, OR MAINTAIN AN ATI PRODUCT UNLESS TRAINED AND QUALIFIED IN PRODUCT AND ACCESSORY INSTALLATION, OPERATION AND MAINTENANCE.

DO NOT INSTALL, OPERATE, OR MAINTAIN AN ATI PRODUCT UNLESS TRAINED AND QUALIFIED IN PRODUCT AND ACCESSORY INSTALLATION, OPERATION AND MAINTENANCE. IOM Supplement IOMS003 ATI HO1/HO2 HYDRAULIC OVERRIDE Scope of Supplement This supplement is intended to assist those who are involved with the installation, operation and maintenance of ATI Linear Actuators