. OBSOLETE, THIS DOCUMENT IS NO LONGER MAINTAINED. 2K Meter with Servo Drive

Transcription

1 ., THIS DOCUMENT IS NO LONGER MAINTAINED. K Meter with Servo Drive Customer Product Manual 3365C NORDSON CORPORATION AMHERST, OHIO USA

2 Safety Repair (continued) Qualified Personnel Ballscrew Nut Seal Intended Use Remove the Ballscrew Nut Seal Regulations and Approvals Install the Ballscrew Nut Seal Personal Safety Bearing Guide and Bearing Assembly High-Pressure Fluids Remove the Bearing Guide Fire Safety and Bearing Assembly Halogenated Hydrocarbon Solvent Hazards. Install the Bearing Guide Action in the Event of a Malfunction and Bearing Assembly Disposal Drive Belt Description Remove the Drive Belt Pump Ratios Install the Drive Belt Major Components Drive Belt Adjustment Theory of Operation Metering Cylinder Assembly Refill Phase Remove a Metering Cylinder Assembly Idle Phase Seal Cartridge Replacement Prepressure Phase Install a Metering Cylinder Assembly Dispense Phase Rupture Disk Assembly Installation Disassemble a Rupture Disk Assembly Operation Assemble a Rupture Disk Assembly Startup Pneumatic Control Valve Manifold Ratio Test Remove the Pneumatic Control Shutdown Valve Manifold Long Term Shutdown Install the Pneumatic Control Valve Manifold Maintenance Conditioning Plate Troubleshooting Remove the Conditioning Plate Repair Install the Conditioning Plate Servo Motor Inlet/Outlet and Metered Inlet Valves Remove the Servo Motor Disassemble a Valve Install the Servo Motor Assemble a Valve Gear Head Proximity Sensor Adjustment Remove the Gear Head Base and Catalyst Refill Clean the Gear Head Proximity Sensor Adjustment PCI Version.. 3 Install the Gear Head Base and Catalyst Refill Bearing Block Proximity Sensor Adjustment PLC Version. 3 Remove the Bearing Blocks Ballscrew/Sensor Block Proximity Install the Bearing Blocks Sensor Adjustment Ballscrew Assembly Pressure Transducer Remove the Ballscrew Assembly Remove the Pressure Transducer Install the Ballscrew Assembly Install the Pressure Transducer

3 Parts Manifold Assembly for Systems without Metering Valves PLC and PCI Controls 6 Manifold Assembly for Systems with Metering Valves PLC and PCI Controls Drive Train Conditioning Plate Pedestal Mounting for Aluminum Units Pedestal Mounting for Stainless Steel Units Covers Cover Mounting Brackets Cables and Tubing Cylinder Assemblies Inch Diameter Inch Diameter Inch Diameter Stainless Steel 0.65-Inch Diameter Stainless Steel 1.50-Inch Diameter Kits Seal Cartridges for Aluminum Versions Seal Cartridges for Stainless Steel Versions. 5 Piston Rods Bearing Guide and Bearing Assembly Bearing Block and Bushing Assembly Ballscrew Assembly Inlet/Metered Inlet/Outlet Valve Cartridge Pack Aluminum Body Valve Inlet/Metered Inlet/Outlet Valve Cartridge Pack Stainless Steel Body Valve Options Lockout Valve and Attaching Parts Ball Valve and Attaching Parts Specifications System Operating Pressures Weight Metering Cylinders Air Consumption Dimensions Hydraulic/Pneumatic Diagrams

4 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 Service 555 Jackson Street Amherst, OH 001 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 000. 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 and the Nordson logo are registered trademarks of Nordson Corporation. All other trademarks are the property of their respective owners.

5 K Meter with Servo Drive 1 Safety 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. Some 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 Safety 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 Safety Data Sheets (MSDS) 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. 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 MSDS for the injected fluid to the health care provider. The National Spray 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. Show him this card Tell him what kind of material you were spraying MEDICAL ALERT AIRLESS SPRAY WOUNDS: TO PHYSICIAN 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.

6 K Meter with Servo Drive Fire Safety 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. Shut 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 MSDS for guidance. Do not disconnect live electrical circuits when working with flammable materials. Shut 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. Shut 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 Solvent 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 Symbol Prefix Fluorine F Fluoro- Chlorine Cl Chloro- Bromine Br Bromo- Iodine I Iodo- Check your material MSDS 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.

7 K Meter with Servo Drive 3 Description See Figure 1. The K meter with servo drive is designed for high-speed application of two component materials. Mixed material is metered and applied by a dispensing gun. Pump Ratios Refer to Table 1 for pump ratios and stroke volumes. Verify your system s pump ratio and stroke volume by checking the identification tag description on the junction box. Consult your material safety data sheet (MSDS) regarding compatibility and material characteristics. PCI VERSION PLC VERSION Figure 1 K Meter with Servo Drive (covers removed) Model Pump Ratio by Volume Aluminum :1 Aluminum :1 Stainless Steel :1 Table 1 Pump Ratios and Volumes Base Piston Diameter mm (1.5 in.) Catalyst Piston Diameter mm (0.65 in.).3 mm (0.875 in.) mm (0.65 in.) Stroke Volume 75. cc (.60 cu. in.) 89.9 cc (5.9 cu. in.) 75. cc (.60 cu. in.)

8 K Meter with Servo Drive Major Components See Figure and refer to Table. PLC VERSION 10 PCI VERSION Figure Major Components

9 K Meter with Servo Drive 5 Table Major Components Item 1 Servo Motor The servo motor links directly to the gear head () on top of the bearing housing base. Encoder and power leads connect to the rear of the servo motor. Gear Head The precision gear head is directly linked to the servo motor. The gear head reduces the servo motor revolution at a fixed ratio of 7:1. 3 Drive Assembly The drive assembly includes the ballscrew nut and the ballscrew rod. A bearing supports the ballscrew assembly inside the bearing housing base. Metering Cylinders The metering cylinders mount to the metering manifold (7) and are filled by positive pressure from a Rhino bulk unloader. The base metering cylinder pumps the base material from the base inlet valve, through the outlet valve, and through the hose to the dispensing gun. The catalyst metering cylinder pumps the catalyst material from the catalyst inlet valve, through the outlet valve, and through the hose to the dispensing gun. The metering ratio is fixed and can not be changed unless the catalyst and base metering cylinders are replaced.the metering cylinders are equipped with a rupture disk assembly. Should the internal cylinder pressure exceed 35 bar (5000 psi), the rupture disk breaks and releases pressure, preventing serious equipment damage or personal injury. 5 Pneumatic Control Valve Manifold The pneumatic control valve manifold controls all pneumatic operations. It includes eight valve positions and provides connections for power and control signals. Pneumatic tubing to the inlet/outlet valves and the dispensing gun connects to pneumatic valve ports on the pneumatic control valve manifold. Shop air from the main air filter valve connects to the end plate on one side of the manifold. Two silencers are installed in the exhaust ports on the opposite side of the manifold. 6 Conditioning Plate The K meter with servo drive is temperature conditioned to eliminate material viscosity variations. This helps to ensure consistent material bead size and shape despite ambient temperature fluctuations in the plant. The conditioning plate mounts flush to the metering manifold. All ports are labeled. Water enters the conditioning plate, maintaining a constant material temperature inside the metering manifold.water branches off through water jacket supply and return ports to control the material temperature in the dispensing gun and the water-traced hoses. After circulating through the conditioning plate, the water traced hoses, and the dispensing gun, the water exits the system through the output. Refer to the stamped description on the conditioning plate to locate the connections. A drain plug at the lowest point of the system facilitates flushing during maintenance. 7 Metering Manifold The metering manifold directs the catalyst and base material flow from the metering cylinders () to the dispensing gun. The manifold-mounted inlet/outlet valves (8) control the material flow. 8 Inlet/Outlet Valves The four inlet/outlet valves are compact high-cycle valves. The valves are mounted to the metering manifold (7), serving as catalyst-inlet/outlet and base-inlet/outlet ports. The metered inlet valves are compact high-cycle valves that have smaller inlet orifices for precise inlet flow. The valves meter inlet flow during the Prepressure Sequence. 9 Proximity Sensors Two adjustable proximity sensors (9) are located above the metering cylinders feed positional information through the junction box to the controller. The two rear proximity sensors (not shown) triggered by the ballscrew and bearing blocks serve as emergency stops. 10 J-Box The J-Box houses fuses, modules, and terminal bridges, and links the controller with the proximity sensors and the transducers.

10 6 K Meter with Servo Drive Theory of Operation Tables 3 and list the valve positions during operation. The metering cylinders are filled by positive pressure from a Rhino unloader. As the servo motor moves both ballscrew rod assemblies backwards, hydraulic pressure pushes the metering cylinder plungers out to their starting position. Proximity switches, mounted behind the bearing housing base and above the metering cylinders, provide positioning information to the servo motor and the PLC. The operation of the K meter with servo drive has phases; Idle, Refill, Prepressure, and Dispense. Refill Phase During the refill phase, the drive assembly retracts. The base and catalyst inlet valves open. The unloader delivers material to both metering cylinders and causes them to fill. Once both cylinders are filled, the plungers are fully retracted and are registered by the proximity switches. The inlet valves close. The metering cylinders are full of dispensing material and the unit begins the Idle Phase. Idle Phase During the ready/idle phase, the catalyst and base outlet vales open. The system monitors mixer tube time-out. Prepressure Phase No Metering Valves During the prepressure phase, the catalyst and base outlet valves are open. The inlet valves and dispense gun valves are closed. The servo motor moves the plungers forward until one of the two cylinders reaches its preset pressure. The servo motor keeps the cylinder in this position and the controller sends a Ready signal indicating that the system is ready for the Dispense Phase. With Metering Valves During the prepressure phase, the catalyst and base outlet valves are open. The inlet valves and dispense gun valves are closed. The servo motor keeps the plungers in this position and the metering valve of the other cylinder opens. Material flows from the bulk unloader supply hose and into the cylinder. When the cylinder reaches its preset pressure, the metering valve closes and the controller sends a Ready signal indicating that the system is ready for the Dispense Phase. Dispense Phase During the dispense phase, the drive assembly forces the catalyst and base metering cylinder plungers simultaneously into the metering cylinders. The dispensing gun valves open and material extrudes.

11 K Meter with Servo Drive 7 Operation Catalyst Inlet Valve Table 3 Valve Positions for Systems without Metering Valves Catalyst Metering Inlet Valve Base Inlet Valve Base Outlet Valve Catalyst Gun Valve Base Gun Valve Refill Open Closed Open Closed Closed Closed Idle Closed Open Closed Open Closed Closed Prepressure Closed Open Closed Open Closed Closed Dispense Closed Open Closed Open Open Open Bleed/Purge (Catalyst) Bleed/Purge (Base) Manual Mode Open Open Closed Closed Open Closed Closed Closed Open Open Closed Open Operation Catalyst Inlet Valve Catalyst Metering Inlet Valve Table Valve Positions for Systems with Metering Valves Catalyst Outlet Valve System without Metering Valves Base Inlet Valve Base Metering Inlet Valve Base Outlet Valve Catalyst Gun Valve Base Gun Valve Refill Open Closed Closed Open Closed Closed Closed Closed Idle Closed Closed Open Closed Closed Open Closed Closed Prepressure Closed May Open Momentarily Open Closed May Open Momentarily Open Closed Closed Dispense Closed Closed Open Closed Closed Open Open Open Bleed/Purge (Catalyst) Bleed/Purge (Base) Manual Mode Open Closed Open Closed Closed Closed Open Closed Closed Closed Closed Open Closed Open Closed Open

12 8 K Meter with Servo Drive Installation Operation The K meter with servo drive ships fully assembled. A Nordson representative must be present for the initial system setup. The shop floor at the installation site should be clean and level. Refer to your system documentation for layout and electrical interconnect drawings that are specific to this system. Perform these steps to install the K meter with servo drive: 1. Find a suitable location near your workstation.. Use customer supplied bolts and washers to secure the K meter pedestal to the shop floor. Refer to the Specifications section for system dimensions. 3. Connect a minimum of.1 bar (60 psi) of clean shop air to the filter regulator input. Refer to the stamped port description on the conditioning plate for proper hook up.. Connect the temperature-conditioned water circulation system hoses to the conditioning plate. 5. Connect the dispensing gun hoses to the labeled ports on the metering manifold. 6. Connect the supply pump hoses to the metering manifold. WARNING Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Injection hazard. 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. Do not remove any covers during operation. The moving parts under these covers could cause injury. Operation of the K meter with servo drive is dependent upon the system configuration. Refer to your system manual or contact your Nordson representative for information about individual component operations. Startup Make sure all fittings and connections are tightened securely, and all system components have been installed according to instructions. 1. Set the air pressure on the main air input filter to.1 bar (60 psi) minimum.. Install a new static mixer tube on the -component dispensing gun. Refer to your two component dispensing gun manual for more information. 3. Turn on and cycle the Rhino unloader pumps. Refer to your Rhino unloader documentation for more information.. Start the controller. Refer to your controller system documentation for more information. 5. Start the water circulation through the temperature conditioning plate. 6. Wait until the system reaches the required material dispensing temperature. Refer to the material safety data sheets (MSDS) for more information. 7. Purge the material with the mixer tube attached. Refer to your -component dispensing gun manual for more information.

13 K Meter with Servo Drive 9 Ratio Test Perform the ratio test on a daily basis, or before a new shift. Shutdown Perform these steps when shutting down the K meter with servo drive for more than one day: This test will only provide results in Mass Ratio. The ratio indicated on the meter and in this manual is Volume Ratio. 1. Label two 5-oz paper containers: B (base) and C (catalyst).. Weigh the containers on a digital balance capable of weighing 0.1 gram and record the weight. 3. Remove the mixer shroud and mixer tube from the two component gun. Clean the end of the nozzle.. Place container B so the base material will flow into container B; place container C so the catalyst material flows into container C. 5. Purge the base and catalyst metering cylinders and weigh both containers separately. Record the weights. 6. Subtract the empty container weight from the full container weight for both containers. 7. To calculate the mix ratio, divide the calculated weight from container C by the calculated weight from container B. 8. Install the mixer shroud and mixer tube to the two component gun. The mix ratio should be within the range specified by the material supplier. If it is not within these limits, repeat the ratio check. Keep a log for material weights and dispensing gun temperatures. If you suspect air is trapped inside the metering cylinder, evacuate the air by running the entire system until it delivers a continuous flow of material. The system cannot be bled. Trapped air must be pumped through the system and out the dispensing gun. If the results are still not within the limits, contact your Nordson representative. 1. Remove the shroud and the mixer tube from the two component dispensing gun. Refer to your two component dispensing gun manual for more information.. Clean and coat the two component dispensing gun nozzle end and threads with petroleum jelly. Refer to your two component dispensing gun manual for more information. Long Term Shutdown 1. Turn off and bleed the pressure from the Rhino unloader pumps. Refer to your Rhino bulk unloader manual for more information.. Remove the shroud and the mixer tube from the two component dispensing gun. 3. Bleed the pressure from the base and catalyst side.. Turn off the temperature conditioned water circulation system. 5. Turn off the controller. 6. Clean the nozzle of the two component dispensing gun and coat the nozzle and threads with petroleum jelly. Refer to your two component dispensing gun manual for more information. Maintenance Preventive maintenance and lubrication procedures should be performed according to your plant maintenance schedule or to listed intervals. WARNING Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. To prevent personal injury, shut off all power and relieve all pressure before performing any maintenance procedure on this equipment.

14 10 K Meter with Servo Drive Frequency Component Maintenance Task Daily Conditioning plate Check for leaks, tighten connecting hoses and tighten screws. Replace O-ring if necessary. Metering Cylinders Perform a ratio test. Refer to Ratio Test in the Operation section for the procedure. Weekly Hydraulic connections Inspect inlet/outlet valve weep holes, hoses, metering cylinders and fittings for leaks. Small amounts of weepage may indicate a potential problem, but will not affect the material ratios. Investigate and repair any weepage as soon as possible. Excessive leakage caused by blown O-rings or loose fittings will affect material ratios and must be fixed immediately. Monthly Pneumatic connections Check air tubing and hoses for air leaks. Replace damaged hoses, tubing, and connections if necessary. Refer to the Specifications section for the pneumatic system diagram. Electric connections Cylinder cartridge Check connectors and wires for wear. Replace if necessary. Refer to the Specifications section for the electric system diagram. Use Mobil SHC 100 synthetic grease for the following procedure. Refer to the Parts section for the grease part number. Purge the old grease: 1. Remove the 1 / 8 NPT plug located at the top of the packing cartridge.. Attach a grease gun to the fitting located on the bottom of the packing cartridge. 3. Pump grease until it flows from the top of the packing cartridge and all of the old grease is expelled.. Remove the grease gun from the fitting and install the 1 / 8 NPT plug. Tighten the plug securely. Yearly Conditioning plate To prevent corrosion inside the conditioning plate and in the adjacent system, change the water and add rust inhibitor hours Ballscrew assembly Lubricate with Mobil SHC 100 synthetic grease: 1. See Figure 1. Attach a grease gun to the ballscrew assembly grease fitting (8) and lubricate the ballscrew nut bearing.. Remove the grease gun from the fitting. Wipe off excess grease.

15 K Meter with Servo Drive 11 Troubleshooting Theses procedures only cover the most common problems that you may encounter. Contact your local Nordson representative if you cannot solve the problem using this data. WARNING Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Problem Possible Cause Corrective Action 1. Leakage through Worn packing cartridge Replace the packing cartridge. inlet/outlet valve or inlet metering valve weep hole. Leakage through the material outlet Worn ball seat or packing cartridge ball Replace the valve body and/or the entire valve. 3. Blown rupture disc Material hose blockage Clean or replace the hoses. Replace the rupture disk.. Servo motor not responding 5. Metering cylinder not refilling 6. Material flow not stopping quickly when inlet/outlet valves are cycled Metering valves do not open Dispensing gun valves do not open Gun nozzle or mixing tube clogged Valve switching error Loose wiring connections Controller switching error Pump ball valve closed High friction in metering cylinder packing glands Inlet valves do not open Check metering valves and solenoids; replace if necessary. Replace the rupture disk. Check dispensing gun valves; replace if necessary. Replace the rupture disk. Clean nozzle or replace mixing tube. Replace rupture disk. Reset the controller program, check fill/dispensing routine. Refer to your controller documentation for more information. Replace the rupture disk. Contact your Nordson representative. Reset the controller program, check fill/dispensing routine. Refer to your controller documentation for more information. Check the material supply system to make sure all valves are open. Check grease in the packing gland; replace packing glands if necessary. Check inlet valves; rebuild or replace if necessary. Reset controller program; check fill/dispensing routine. Replace inlet/outlet valve. Controller switching error Sluggish operating inlet/outlet valve

16 1 K Meter with Servo Drive Repair WARNING Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. To prevent personal injury, shut off all power and relieve all pressure before performing any maintenance procedure on this equipment. Servo Motor Use the following procedures to replace the servo motor. The servo motor is not field serviceable. Servo motor repair is limited to complete component removal and installation. Remove the Servo Motor 1. See Figure 3. Remove the threaded plug from the pinion bolt access hole (1).. See Figure 18. Remove the upper gear and belt cover (). 3. See Figure 3. Rotate the gear head pinion (6) until the head of the pinion bolt () is aligned with the pinion bolt access hole.. Insert a -mm-hex wrench through the pinion bolt access hole and loosen the pinion bolt. 5. Remove the screws (5) and lockwashers (). Remove the servo motor (3). Install the Servo Motor 1. See Figure 3. Rotate the gear head pinion (6) until the head of the pinion bolt is aligned with the pinion bolt access hole.. Insert a -mm-hex wrench through the pinion bolt access hole into the head of the pinion bolt. Apply thread locking compound to the pinion bolt threads. The pinion bolt should be loose. Do not tighten at this point. 3. Remove the grease from the shaft of the servo motor (3) shaft and the bore of the gear head pinion (6).. Insert the servo motor shaft into the gear head pinion (6). 5. Align the servo motor flange mounting holes with the holes in the gear head mounting flange. 6. Install the screws (5) and lockwashers (). Tighten the screws to N m (5 8 lb-ft). 7. Tighten the pinion bolt () to N m (80 90 lb-in). Install the plug into the pinion bolt access hole and tighten securely. 8. See Figure 18. Install the upper gear and belt cover () Figure 3 Gear Head

17 K Meter with Servo Drive 13 Gearhead Use the following procedures to replace the gear head. The gear head is not field serviceable. Repair procedures are limited to component removal and installation. Remove the Gear Head 1. See Figure 18. Remove the lower and upper covers (3, ).. See Figure 1. Loosen the screws (1B, 38) securing the mounting bracket () to the support shaft (6). Do not remove the screws at this time. 3. Loosen the nut (0) and turn the swivel pad () counter clockwise to relieve tension on the drive belt (8). Remove the drive belt.. See Figure. Note the orientation of the screws () to the bushing slot (6). Remove the screws from the bushing (3). 5. Insert one screw () into the hole () located 180 degrees from the bushing slot (6). Loosen the taperlock bushing by tightening the screw. 6. Remove the sprocket (1) and the bushing (3). Remove and save the key (5). 7. See Figure 1. Remove the screws (38A) securing the gear head to the mounting bracket and pull the gear head/servo motor assembly from the servo mount bracket. 8. Remove the servo motor from the gear head. Refer to Servo Motor Removal for the procedures. 6 Installation 7 1 Installation Clean the Gear Head! CAUTION! To prevent damage, do not lubricate the bushing taper, bushing bore, sprocket taper, or the gear head shaft. Clean and degrease the gear head shaft, the taper-lock bushing bore and outer diameter, and the tapered inner diameter of the sprocket. Install the Gear Head 1. See Figure. Insert the bushing (3) into the gear head sprocket (1) and match the hole pattern as shown. The installation holes are only threaded on one side.. Apply Loctite to the threads of the screws (). Insert the screws into holes as shown. 3. Insert the key (5) into the shaft (6).. Alternately tighten the screws () in.5 N m (0 lb-in.) increments until 6. N m (55 lb-in.) is obtained. 5. See Figure 1. Align the gear head mounting holes with the mounting holes in the servo mount bracket (). 6. Insert the screws (38A) that secure the servo motor to the servo mount bracket. Tighten the screws to N m (5 8 lb-ft). 7. Install the drive belt and turn the swivel pad () clockwise to tighten the drive belt. Refer to the section Drive Belt Adjustment for more information. 8. Tighten the nut (0) to 67.8 N m (50 lb-ft). 9. Tighten the screws (1B, 38B) to N m (5 8 lb-ft). 10. See Figure 18. Install the lower and upper covers (3, ). 5 3 Removal Figure Taperlock Bushing

18 1 K Meter with Servo Drive Bearing Block Use the following procedures to replace a bearing block. Remove the Bearing Blocks 1. See Figure 18. Remove the cover (1).. See Figure 1. Disconnect the cordsets (33), and remove the proximity sensors (3). 3. Remove the nut (30).. Remove the screws (3) and washers (35) from the rear sensor mounting bracket (31). Remove the rear sensor mounting bracket and the rear shock absorbers (6). 5. Remove the bearing blocks (9). Save the key (18). 6. Remove the shafts (7) from the bearing housing base. The bushings (8) are press-fit into the bearing blocks. Do not remove the bushings. Contact your Nordson representative for more information. Install the Bearing Blocks 1. See Figure 1. Insert the shafts (7) into the counter bores on the back of the bearing housing base.. Install the rear shock absorbers (6). 3. Install the key (18) to the ballscrew.. Line-up the shafts with the bores in the bearing blocks (9) and slide the bearing blocks onto the ballscrew. 5. Install one shock absorber to each shaft and align the rear sensor mounting bracket (31) with the shafts. Insert the screws (3) and washers (35). Tighten the screws to N m (90 95 lb-ft). 6. Apply thread locking compound to the nut (30). Tighten the nut to N m (100 lb-ft). 7. Install the proximity sensors (3) and connect the cordsets (33). 8. See Figure 18. Install the cover (1).

19 K Meter with Servo Drive 15 Ballscrew Assembly Use the following procedures to replace the ballscrew assembly. Remove the Ballscrew Assembly Perform these steps to remove a ballscrew assembly: 1. See Figure 18. Remove all of the covers (1 6) to gain access to the drive assembly.. See Figure 1. Disconnect the proximity cordsets (33) from the proximity sensors () and remove the screws (6). Do not change the position of the sensor plate () for this procedure. 3. Remove the adjustable sensor mount bracket (1), with the proximity sensors attached, from the shafts (7).. Remove the nut (30). 5. Loosen the screws (1, 38), on the front of the servo mount bracket (). 6. Loosen the nut (0), and turn the swivel pad () counterclockwise to release tension on the drive belt (8). Remove the drive belt. 7. Remove the toggle pad nut (9) and the screw (10).! CAUTION! To prevent the ball bearings from being damaged and from falling out of the ballscrew, do not remove the rod from the ballscrew. 8. Remove the screws (1), and remove the rod and ballscrew assembly (13). Save the key (18) from the ballscrew assembly. 9. Remove the sprocket (15). Install the Ballscrew Assembly Apply Never-Seez to all aluminum/steel mating surfaces before assembly. 1. See Figure 1. Insert the screws (1) into the ballscrew assembly (13), and install the sprocket (15).. Insert the ballscrew assembly into the guide (16). 3. Tighten the screws (1) to N m (5 8 lb-ft).. Install the key (18) into the ballscrew. Rotate the ballscrew if necessary to insert it into the ballscrew and bearing block (9). 5. Use thread locking compound and install the nut (30) to the end of the ballscrew. Tighten the nut to N m (100 lb-ft). 6. Install the screw (10) and the toggle pad nut (9). 7. Install the drive belt (8). WARNING Never operate the drive assembly without aligning the ballscrews. Misaligned ballscrews can damage the metering cylinders. 8. Align the ballscrews by manually spinning the ballscrews counterclockwise until both bearing blocks contact the rear shock absorbers. 9. To adjust the drive belt tension, turn the swivel pad () clockwise. 10. Verify that both bearing blocks make contact with the rear shock absorbers at the same time. If they do not, loosen the drive belt and adjust. 11. Tighten the nut (0), and tighten the screws (1, 38) accessible on the front of the servo mount bracket (). 1. Install the adjustable sensor mount bracket (1) to the shafts (7). Install the screws (6). 13. Connect the proximity cordsets (33) to the proximity sensors. 1. See Figure 18. Install all the covers (1 6).

20 16 K Meter with Servo Drive Ballscrew Nut Seal Use the following procedures to replace the ballscrew nut seal. Bearing Guide and Bearing Assembly Use the following procedures to replace the bearing guide and bearing assembly. Remove the Ballscrew Nut Seal 1. See Figure 1. Remove the ballscrew assembly (13) from the bearing housing base. Refer to the Ball Screw Assembly Replacement section for more information. See Figure 5. To prevent the ball bearings (3) from falling out of the assembly, never turn the ballscrew rod more than 1 / 8 -inch below the seal.. Hold the ballscrew nut () while turning the ballscrew rod () down to 1 / 8 -inch below the seal (1). 3. Use a flat blade screw driver to pry out the old ballscrew nut seal. Install the Ballscrew Nut Seal 1. See Figure 5. Insert the new nut seal (1) with the inscription facing inwards. Locate the raised portion in the recess.. Press the seal in until it snaps into the groove in the ballscrew nut (). 3. Turn the ballscrew rod () past the ballscrew nut seal. Observing the seal lip and align the seal if necessary.. See Figure 1. Install the ballscrew assembly (13) to the bearing housing base. Refer to the Ball Screw Assembly Replacement section for more information. 1 The press-fit assembly can not be serviced in the field, due to close tolerances. Contact your Nordson representative for more information. Remove the Bearing Guide and Bearing Assembly Perform these steps to remove a worn bearing guide and bearing assembly: 1. Remove the ballscrew assembly. Refer to Ballscrew Assembly Removal for more information.. See Figure 1. Remove the screws (17), and the bearing retainer (19). 3. Pull the bearing guide and bearing assembly from the bearing housing base (3).. Remove the screws (5), and the bearing guide cap (). Install the Bearing Guide and Bearing Assembly Perform these steps to install a new bearing guide and bearing assembly: 1. See Figure 1. Install the bearing guide cap () using the screws (5). Tighten the screws to N m (5 8 lb-ft).. Lubricate the outside radius of the bearing (0) with Never Seez lubricant. 3. Insert the bearing guide and bearing assembly into the bearing housing base (3).. Install the bearing retainer (19) using the screws (17). Tighten the screws to N m (5 8 lb-ft). 5. Install the ballscrew assembly. Refer to the Ballscrew Assembly Installation section for more information. 3 Figure 5 Ballscrew Nut Seal

21 K Meter with Servo Drive 17 Drive Belt Use the following procedures to replace the drive belt. Drive Belt Adjustment Use the following procedures to adjust the drive belt. Accumulation of small white particles on the drive belt and the sprockets is normal and do not represent excessive drive belt wear. Remove the Drive Belt 1. See Figure 18. Remove the covers (1 6).. See Figure 1. Disconnect the proximity cordsets (33) from the proximity sensors () and remove the screws (6). Do not change the position of the sensor plate () for this procedure. 3. Remove the screws (6) securing the adjustable sensor mount bracket (1), with the proximity sensors () attached, from the shafts (7).. Loosen the screws (1, 38), on the front of the servo mount bracket (). 5. Loosen the nut (0) and turn the swivel pad () counterclockwise to release tension on the drive belt (8). Remove the drive belt. Install the Drive Belt 1. See Figure 1. Install the new drive belt (8).. Manually spin the ballscrew until both bearing blocks make contact with the rear shock absorbers. 3. Verify that both bearing blocks make contact with the rear shock absorbers at the same time. If they do not, loosen the drive belt and adjust.. Adjust the drive belt tension. Refer to the Drive Belt Adjustment procedure. 5. Tighten the nut (0) and tighten the screws (1, 38) on the front of the servo mount bracket (). 6. Using the screws (6), install the adjustable sensor mount bracket (1), with the proximity sensors (3), to the shafts (7). Tighten the screws securely. 7. Connect the proximity cordsets (33) to the proximity sensors (). 8. See Figure 18. Install the covers (1 6). The following procedure requires the use of a tension tester. Perform these steps to tighten the drive belt tension: 1. See Figure 6. Place a tension tester at the center of the span (5) between the drive assembly sprocket (1) and the catalyst sprocket (3).. Applied force () must be perpendicular to the span to achieve a belt deflection (6) of in. from its normal position. 3. Be sure the force is applied evenly across the entire belt width. Use a deflection force of kg (6 7 lb). 3 Figure Drive Belt Adjustment 1

22 18 K Meter with Servo Drive Metering Cylinder Assembly Use the following procedures to replace the metering cylinder assembly. Remove a Metering Cylinder Assembly Perform these steps to remove and disassemble the metering cylinder assembly: 1. See Figure 18. Remove the covers (1, 5, 6).. See Figure 1. Relieve all material supply pressure to the metering stand. 3. Cycle the meter to purge material from the metering cylinder (8 or 9).. Verify that all material pressure is bled from the system. When performing the following step, make sure that you do not remove the screws that are installed in the counter bores of a metering cylinder. 5. Remove the screws (1) securing the metering cylinder to the manifold (). Remove the metering cylinder assembly (8 or 9) from the manifold. 6. Remove and discard the O rings (5, 16). Seal Cartridge Replacement To replace the seal cartridges, refer to the K Seal Cartridge Replacement Kits instruction sheet included with this manual and the seal cartridge kit. Install a Metering Cylinder Assembly 1. See Figure 1. Clean the mating surfaces of the metering cylinder assembly (8 or 9) and the manifold ().. Lubricate the new O-rings (5, 16) with synthetic oil and install them into the grooves on the metering manifold.! CAUTION! Take care not to pinch the O-rings between the mating surfaces of the metering cylinder O ring groove and the manifold. Pinching the O-rings could compromise the seal. 3. Align the cylinder assembly on the manifold, making sure that the O-rings stay in place.. Insert and alternately hand-tighten the screws. Use a torque wrench to tighten to 50 lb-ft (67.8 N m). 5. See Figure 18. Install the covers (1, 5, 6).

23 K Meter with Servo Drive 19 Rupture Disk Assembly Use the following procedures to replace a rupture disk assembly. Disassemble a Rupture Disk Assembly 1. See Figure 18. Remove the covers (5, 6).. See Figure 7. Using an adjustable wrench on the flats of the inlet base (), remove the complete rupture disk assembly. 3. Place the inlet base in a vise. Remove the outlet nut (5), the hold down ring (), and the rupture disc (3). Discard the old rupture disk.. Remove the O-ring (1) from the inlet base. Check the O ring for damage and replace if necessary. Figure Rupture Disk Assemble a Rupture Disk Assembly All surfaces must be completely clean and free of rust, corrosion, and foreign material to ensure a proper seal. You can use solvents and steel wool to clean the rupture disk assembly. 1. See Figure 7. Clean the rupture disk sealing area to remove dispensing material.! CAUTION! Do not re-machine parts. Do not use scrapers or abrasives. The rupture disk assembly may not operate according to specifications.. Inspect the rupture disk sealing area for nicks, scratches, or pitting. 3. Place the inlet base () in a vise.. Insert a new rupture disk (3) convex side up and the hold down ring () with the tapered side down into the inlet base. 5. Install the outlet nut (5) and tighten to 71. N m (00 lb-ft).! CAUTION! Do not use the outlet nut to tighten the rupture disk assembly into the metering cylinder. The rupture disk could be damaged. 6. Apply synthetic oil to the threads of the inlet base. 7. See Figure 1 Install the rupture disk assembly to the metering cylinder (8 or 9) and tighten to 5. N m (0 lb-ft). 8. See Figure 18. Install the covers (5, 6).

24 0 K Meter with Servo Drive Pneumatic Control Valve Manifold Repair procedures are limited to removal and installation. Contact your Nordson representative for more information. Remove the Pneumatic Control Valve Manifold 1. See Figure 8. Shut off and bleed the supply air to the metering system.. Disconnect the main air supply tube (). 3. Disconnect the air tubing from the pneumatic control valve ports ().. PLC Version Disconnect the power and the controller cables on the front of the pneumatic control valve manifold (1). PCI Version Disconnect the cable from the front of the pneumatic control valve manifold (1). 5. Insert a 3-mm hex key into the holes on the front of the pneumatic control valve manifold and loosen the captive screws. 6. Remove the pneumatic control valve manifold from the mounting bracket (3). 3 Install the Pneumatic Control Valve Manifold 1. PLC Version Only See Figure 8. Access the DIP switches that are behind the front cover plate of the pneumatic control valve manifold (1). Make sure that the DIP switch settings match the settings of the old pneumatic control valve manifold. DIP switch settings can also be found in your system s electrical schematic documentation.. Install the front cover plate of the pneumatic control valve manifold. 3. Align the pneumatic control valve manifold with the mounting bracket (3).. Insert a 3-mm hex wrench into the holes on the front of the pneumatic control valve manifold. Guide the captive screws into the mounting bracket and tighten. 5. PLC Version Connect the power and the controller cables on the front of the pneumatic control valve manifold (1). PCI Version Connect the cable to the front of the pneumatic control valve manifold (1). 6. Connect the air tubing to the pneumatic control valves ports (). Connect the main air supply tube (). 1 Unit without metering valves shown. C EXTEND RETRACT Figure 8 Pneumatic Control Valve Manifold