PR4. Operation - Maintenance C. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

Transcription

1 Operation - Maintenance PR C EN Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. Machine shown may be different from your machine 1

2 Contents Safety Precautions... 4 Machine Features... 5 Main Screen... 7 Pump Control Screen... 8 Timer/Counter Screen Status Screen LEVEL 1 CONTROL Screen LEVEL 2 CONTROL Screen SHOT SIZE Screen CALIBRATION Screen SUPERVISOR Screen Piston Stroke Limits Illustration Extend Verification Screen Initial Startup Dry Run Priming the Hoses Ratio Check Daily Operations Phasing the Pumps Shut Down Periodic Maintenance Troubleshooting Pump Rebuild... appendix C Graco Standard Warranty...Back Graco Information...Back

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4 Safety Precautions This manual provides installation, operation, and maintenance instructions for Liquid Control Corporation's meter, mix, and dispense machines. Read this manual before you install and operate your machine. Use your machine only as directed. Safety Terms within our manuals Cautions are given where failure to observe the instruction could result in damage to the equipment, associated equipment, and/or process. Warnings are given where failure to observe the instruction could result in injury or death to people. Some examples follow. Caution Snuff-back can be monitored with DV MODE in AUTO, but must be adjusted with DV MODE in OPEN WARNING Make sure EMERGENCY STOP is locked in before manually aligning the ratio block to the ratio beam. Safety Labeling on our machinery All our machines carry the following safety labels wherever necessary: Danger Labels indicate an imminently hazardous situation, which, if not avoided, could result in death or serious injury. Warning Labels indicate potentially hazardous situations which, if not avoided, could result in death or serious injury. Caution Labels indicate an unsafe practice that may result in moderate or minor injury. Notice Labels state a company policy. Some examples are: DANGER DO NOT OPERATE THIS MACHINE WITH GUARD(S) DETACHED WARNING UNPLUG MACHINE BEFORE OPENING ENCLOSURE NOTICE OVERCURRENT PROTECTION PROVIDED AT MACHINE SUPPLY TERMINALS CAUTION WEAR EAR PROTECTION CAUTION WEAR EYE PROTECTION 4

5 Machine Features PosiRatio Machine: CONTROL POWER Switch Provides power for the electrical circuitry in the console. OFF: ON: Electrical power is not applied to the electrical circuitry and the internal white lamp is dimmed. Electrical power is applied to the electrical circuitry and the internal white lamp is illuminated. EMERGENCY STOP Button When the EMERGENCY STOP button is pressed and released, all power and air is removed from the machine. The pumps will immediately stop in place. The dispense valve will close. PUMP AIR PRESSURE Gauge and Regulator The PUMP AIR PRESSURE regulator controls how much air pressure is fed to the air cylinder driving the pumps. The pump air pressure can be monitored on the PUMP AIR PRESSURE gauge. Touch Panel The Touch Panel is used to control all functions on the machine. See the following sections for operation of the different screens. Foot Switch The foot switch is used to initiate a pump cycle when operating in the SHOT pump mode. When the PUMP MODE switch is in the SHOT position, and the START device is pressed and released, the machine will cycle once then stop and wait for the next start signal. If the START device is pressed and held, the machine will run continuously. Throughout this manual the foot switch and the MAIN touch screen START button will be referred to as the START device. 5

6 Machine Features Cont. Valves: Check Valves Check valves allow material to flow from the pumps to the material hoses but prevents material from flowing back. Ratio Check Ball valve Assemblies At each pump outlet, after the check valve, is a ratio check ball valve assembly. One of the elbows will have a plastic nozzle threaded to one side. This is the ratio check outlet. The ball valve connected to this outlet is the ratio check ball valve. The other ball valves are the material hose ball valve. Dispense Valve This valve is opened and closed as required while dispensing material. Ratio Check Ball Valve Positions The following positions show the ball valve position for ratio check and dispense position. Note: In order not to lose material hose prime always close both ball valves prior to changing to the Dispense Position or to the Ratio Check Position. Dispense Position Ratio Check Position CAUTION Never cycle the machine with both the material hose ball valves (or the dispense valve closed) and the ratio check ball valves closed. 6

7 Main Screen Pump Control button When the Pump Control button is pressed the Pump Control Screen will appear. For more information on the Pump Control Screen see the Pump Control Screen section of this manual. Purge Timer button When the Timer/Counter button is pressed the Timer/Counter Screen will appear. For more information on the Timer/Counter Screen see the Timer/Counter Screen section of this manual. Level Control button When the Level Control button is pressed the Level Control Screen will appear. For more information on the Level Control Screen see the Level Control Screen section of this manual. Shot Size button When the Status button is pressed the Shot Size Screen will appear. For more information on the Shot Size see the Shot Size Screen section of this manual. Status button When the Status button is pressed the Status Screen will appear. For more information on the Status Screen see the Status Screen section of this manual. Calibration button When the Calibration button is pressed the Calibration Screen will appear. For more information on the Calibration Screen see the Calibration Screen section of this manual. Supervisor button When the Supervisor button is pressed the Supervisor Screen will appear. For more information on the Supervisor Screen see the Supervisor Screen section of this manual. 7

8 Pump Control Screen NOTE: The 1 indicates that the button is in the ON position and the 0 indicates that the button is in the OFF position. Pump Mode NOTE: The RETRACT button must be selected first prior to changing any button under PUMP MODE. Retract: The air cylinder and pumps will immediately retract and remain in the resting (retracted) position. Extend: The air cylinder and pumps will immediately extend and remain in the extended position. Shot: The machine will cycle when the start device is pressed and released. The machine will cycle continuously when the start device is pressed and held. Continuous button: The machine will continually cycle the pumps when the START DEVICE is pressed and released when the AUTO or OPEN button under DV MODE is selected or when the ratio check valve is in the open position. Retract must be selected to stop the machine. Operator Control: In this mode, pressing the START DEVICE will allow the machines to take multiple or partial strokes to allow the operator to control the amount of material to be dispensed. (When the START device is pressed and held the piston will extend allowing material to be dispensed until the START DEVICE is released, the piston will stop at its current position. If the START DEVICE is pressed and the held the machine will run continuously.) NOTE: In order to use the EXTEND, SHOT, CONT or the Operator Control buttons in normal operation the OPEN or the AUTO button must be selected under DV MODE or the ratio check valves must be in the open position. 8

9 Pump Control screen con t DV Mode Open: The dispense valve is manually held open. The open position is normally used to prime material hoses. Auto: The dispense valve automatically opens and closes to dispense the preprogrammed shot size. Close: The dispense valve is manually held closed and no material can be dispensed. START button When the START button is pressed, the machine will start its programmed cycle (This is also known as a Start Device). Shot Size button When the Status button is pressed the Shot Size Screen will appear. For more information on the Shot Size see the Shot Size Screen section of this manual. Main button When the Main button is pressed the Main Screen will appear. For more information on the Main Screen see the Main Screen section of this manual. 9

10 Timer/Counter Screen PURGE TIMER ON /OFF switch The PURGE TIMER switch is used to enable/disable the PURGE TIMER. NOTE: The 1 indicates that the button is in the ON position the 0 indicates that the button is in the OFF position. OFF: ON: The PURGE TIMER is disabled. The PURGE TIMER is enabled and the machine will cycle material through the mixer for the purposes of removing gelled material in the mixer when the time programmed on the purge timer expires. Enter purge time button (shown as =000.0 below the PURGE TIMER ON /OFF button) When the Purge Timer button is pressed to display 1 and the Pump Mode is in the Shot or operator control, the purge timer will begin to count up to the time entered, once when this time expires the machine will make one cycle dispensing gelled material from the mixer, the timer will reset. If the machine dispenses material by pressing the start device the purge time will reset to the preset time. It will continue to do this until the Purge Timer button is turned to the OFF position. To change the PURGE TIME, do the following: 1. Select PURGE TIMER button (shown as =00000) a numeric keypad should appear. 2. Enter in the purge time in seconds as required. 3. Press the button. The PURGE TIMER screen should appear. 4. The new purge time should appear in the PURGE TIME button. NOTE: The accumulated or the current time of the Purge Timer indicator is shown by <

11 Timer/Counter Screen Dwell Timer button/indicator This changes the time that the audio alarm that will be activated after the purge timer has timed down, and before the machine will take the purge shot. To change the Dwell Timer: 1. Select the Dwell Timer button (shown as =000.0) a numeric keypad should appear. 2. Enter in the Dwell Timer time in seconds as required. (With the use of the. button time can be enter in the terms of 0.1 seconds.) 3. Press the button. 4. The new Dwell Timer time should appear in the Dwell Timer indicator. NOTE: The accumulated or the current time of the Dwell Timer indicator is shown by < Number of Strokes During Purge indicator This indicator will display the number of strokes base on the Shot Size previously enter in the Shot Size button. If the Shot Size selected previously enter in was 150%; then the Number of Stroke indicator will display a 2. Amount per Stroke in % indicator This indicator will display the amount of piston stroke base on the Shot Size previously enter in the Shot Size button. If the Shot Size selected previously entered in was 150%; then the Amount per Stroke in % indicator will display 75%. Purge Shot Size% (shown as =000.00) button/indicator This button/indicator shows the volume setting of the material of the Purge Shot Size volume in terms of percent of piston stroke. To change the Purge Shot Size (shown as =000.00) volume, do the following: 1. Select Purge Shot Size (shown as =000.00) button a numeric keypad should appear. 2. Enter in the material shot size volume as required. 3. Press the button. The Purge Timer screen should appear. 4. The new shot size percentage should appear in the Purge Shot Size (shown as =000.00) indicator. 11

12 Status Screen Maintenance Totalizer indicator (resetable) This counter will increment 1 count for each time the machine cycles. The totalizer is resetable to 0 counts by pressing the Reset Maintenance Totalizer. This counter is used for maintenance purposes. # Of Times Maintenance Totalizer has been Reset indicator This counter will increment 1 count for each time the Reset Maintenance Totalizer button is pressed. Reset Maintenance Totalizer button This button resets the Maintenance Totalizer indicator. Cycle Totalizer indicator (non-resetable) This counter will increment 1 count when the machine makes 1 cycle. Number of Strokes indicator This indicator will display the number of strokes base on the Shot Size previously enter in the Shot Size button. If the Shot Size selected previously enter in was 150%; then the Number of Stroke indicator will display a 2. Amount per Stroke in % indicator This indicator will display the amount of piston stroke base on the Shot Size previously enter in the Shot Size button. If the Shot Size selected previously entered in was 150%; then the Amount per Stroke in % indicator will display 75%. Dispense Ready indicator This indicator will display 1 if the material piston are loaded with material and ready to dispense, and displays a 0 if the material piston is reloading or at the end of the dispense cycle. This indicator can be linked with a PLC output for system integration, for more information consult the factory on a customer signal integration kit. Dispense Complete indicator This indicator will display 1 if the material piston are reloaded with material or at the end of the dispense cycle, and displays a 0 if the material pistons is loaded with material and ready to dispense. This indicator can be linked with a PLC output for system integration, for more information consult the factory on a customer signal integration kit. 12

13 Status Screen CONTRAST + button This button increases the contrast of the touch screen. CONTRAST - button This button decreases the contrast of the touch screen. Main button When the Main button is pressed the Main Screen will appear. For more information on the Main Screen see the Main Screen section of this manual. 13

14 LEVEL 1 CONTROL Screen NOTE: Your machine may not have Level Controls. NOTE: If the A TANK STATUS and the B TANK STATUS indicators both displays 'LEVELS NOT ACTIVE' then the level control feature is not installed on this machine. Press the Main button to exit from this screen. A TANK STATUS indicator This indicator gives information on the A component tank filling process, the messages possible that this indicator can display are: MATERIAL HIGH MATERIAL LOW FILLING MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE AFILLFAULT B TANK STATUS indicator This indicator gives information on the B component tank filling process, the possible messages that this indicator can display are: MATERIAL HIGH MATERIAL LOW FILLING MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE BFILLFAULT For more information on the Tank Status Indicator Messages, see the Tank Fill Message table in this manual. Silence Alarm button This button will silence the audio alarm when pressed. 14

15 LEVEL 1 CONTROL Screen con t NOTE: The START FILL A, START FILL B and the STOP FILL buttons will be inoperative if the high level automatic tank refilling feature was not purchased with this machine. Also Engage Auto Fill button must be enabled Level 2 screen. START FILL A button When this button is pressed the A component transfer pump will fill the A component tank until the material level reaches the high level proximity switch on the A component tank or until the fill timer expires. START FILL B button When this button is pressed the B component transfer pump will fill the B component tank until the material level reaches the high level proximity switch on the B component tank or until the fill timer expires. STOP FILL button This button will stop the automatic tank refilling process for both A and B component material tank. 15

16 LEVEL 1 CONTROL Screen con t Tank Status Indicator Messages Indication TANK HIGH LEVEL TANK LOW LEVEL TANK FILLING Cause This will be displayed in the TANK STATUS indicator when the tank material level reaches the high level proximity switch (If equipped with high level proximity switch) This will be displayed in the TANK STATUS indicator when the tank material level reaches the low level proximity switch. (If equipped with low level proximity switch) This will be displayed in the TANK STATUS indicator when the tank material is currently refilling in the tank refilling process. (If equipped with auto refilling) MATERIAL PRESENT LEVEL SENSOR FAULT LEVELS NOT ACTIVE This will be displayed in the TANK STATUS indicator when the tank material is above the low level proximity switch. (If equipped with low level proximity switch) This will be displayed in the TANK STATUS indicator when the machine senses a high material level and a low material level of the tank simultaneously. (If equipped with low level and high level proximity switch). This will be displayed in both TANK STATUS indicators when the high or low level proximity switches are not installed. FILL TIMER FAULT This will be displayed in the TANK STATUS indicator when the tank material is currently refilling and the tank material level does not reach the high level proximity switch within the time previously entered into the FILL TIMER button seen in the LEVEL2 CONTROL screen. 16

17 LEVEL 2 CONTROL Screen NOTE: Your machine may not have Level Controls. NOTE: In the LEVEL 1 CONTROL Screen if the A TANK STATUS and the B TANK STATUS indicators both displays 'LEVELS NOT ACTIVE' then the level control feature is not installed on this machine. Press the Main button to exit from this screen. Low Level Shutdown button When this button displays 1 or active condition and the material level of either the A component tank or the B component tank reaches the low level sensor, the machine will shutdown. To recover, refill the component tank with material pass the low level sensor. When the button is pressed to display 0 the machine shutdown feature will be disabled. Alarm Engage button When this button displays 1 or active condition and the material level of either the A component tank or the B component tank reaches the low level sensor and audio alarm will be activated. Auto Fill Engage button When this button displays 1 or active condition the automatic filling function is activated. NOTE: If the automatic refilling option has not been purchased the Shutdown Timer button will be inoperative. Shutdown Timer button/indicator This changes the time that the FILL TIMER FAULT message is displayed to the corresponding A TANK STATUS or B TANK STATUS indicator seen in the LEVEL 1 CONTROL screen. If the material level is lower then the material component tank low level proximity switch past the preprogrammed the machine will shutdown. To change the Shutdown Timer: 1. Select the Shutdown Timer button (shown as =000.0) a numeric keypad should appear. 2. Enter in the Shutdown Timer time in 10 th of seconds as required. (If 10 were entered, the Shutdown time will be 1 second.) 3. Press the button. 4. The new Shutdown Timer time should appear in the Shutdown Timer indicator. NOTE: The accumulated or the current time of the Shutdown Timer indicator is shown by <000.0 this indicator will count up to the previous preset time. 17

18 LEVEL 2 CONTROL Screen (continued) NOTE: If the automatic refilling option has not been purchased the Fill Timer button will be inoperative. Fill Timer button/indicator This changes the time that the FILL TIMER FAULT message is displayed to the corresponding A TANK STATUS or B TANK STATUS indicator seen in the LEVEL 1 CONTROL screen. If the material level reaches the material component tank high level proximity switch before the fill time previously entered, then the TANK HIGH LEVEL message will be displayed in the TANK STATUS indicator and the fill timer will be reset. If the timer expires before reaching the high level switch, then the FILL TIMER FAULT will appear in the Level1 Control Screen To change the Fill Timer: 1. Select the Fill Timer button (shown as =000.0) a numeric keypad should appear. 2. Enter in the Fill Timer time in 10 th of seconds as required. (If 10 were entered, the fill time will be 1 second.) 3. Press the button. 4. The new Fill Timer time should appear in the Fill Timer indicator. NOTE: The accumulated or the current time of the Fill Timer indicator is shown by <000.0 this indicator will count up to the previous preset time. Clear Fill Fault button This button when pressed will clear the FILL TIMER FAULT message is displayed to the corresponding A TANK STATUS or B TANK STATUS indicator seen in the LEVEL 1 CONTROL screen. Silence Alarm button: This button will silence the audio alarm when pressed. 18

19 SHOT SIZE Screen ENTER SHOT SIZE section SHOT 1 SHOT 10 The (SHOT 1 - SHOT 10) buttons allow the operator to program 10 different shot sizes in the terms of percentage of stroke. Once the shot sizes are programmed the shot sizes can be selected using the SELECT SHOT SIZE 1-10 button. SELECT SHOT SIZE button The SELECT SHOT SIZE button allows the operator to choose one of the ten preprogrammed shot sizes seen in the ENTER SHOT SIZE section. ENTER SHOT SIZE (shown as =000.00) button/indicator This button/indicator shows the volume setting of the material of the SHOT SIZE volume in terms of percent of piston stroke. This volume will be dispensed during the ratio check. To change the SHOT SIZE (shown as =000.00) volume, do the following: 1. Select SHOT SIZE (shown as =000.00) button a numeric keypad should appear. 2. Enter in the material shot size volume as required. 3. Press the button. The SHOT SIZE screen should appear. 4. The new shot size percentage should appear in the SHOT SIZE (shown as =000.00) indicator. 19

20 SHOT SIZE Screen Number of Strokes indicator This indicator will display the number of strokes base on the Shot Size previously enter in the Shot Size button. If the Shot Size selected previously enter in was 150%; then the Number of Stroke indicator will display a 2. Amount per Stroke in % indicator This indicator will display the amount of piston stroke base on the Shot Size previously enter in the Shot Size button. If the Shot Size selected previously entered in was 150%; then the Amount per Stroke in % indicator will display 75%. 20

21 CALIBRATION Screen NOTE: Your machine may not have the Calibration screen. Calibration is used to establish the pump position in units of percent. Perform the Calibration procedure after any pump maintenance. Calibrate Mode button When this button is selected the machine calibration will start. Extend Pumps button This is selected to extend the air cylinder for the calibration sequence. Retract Pumps button This is selected to retract the air cylinder for the calibration sequence. TEACH button This button is used to teach or store the various data during the calibration mode. DONE button This button is used to complete calibration process. Transducer Position indicator This indicator shows the transducer position in the terms of transducer units. NOTE: There should be a range of 30,000 transducer units between the reload position and the extend position. Transducer Position in % indicator This indicator shows the transducer position in the terms percent of stroke. Shot Size Offset indicator (represented as <000.00) The Shot Size Offset button allows the operator to view the shot size offset percentage. The factory default is negative 0.5%. DV Position indicator (represented as <000.00) The DV Position indicator allows the operator to view were the dispense valve will open. The DV is factory preset negative 5%. Reload Position indicator (represented as <000.00) The Ext. Position indicator allow the operator to view transducer extend position. The factory setting is negative

22 CALIBRATION Screen con t To calibrate the pumps, do the following: 1) Orient ball valves to dispense out of the ratio check ports. 2) From the Pump Mode Screen select Shot button under PUMP MODE and select the Close button under Dispense Valve. 3) Select the MAIN button, from the Main screen select the Calibration button. 4) From the Calibration Screen Select Calibration Mode. 5) Press the Extend Pumps button. (Pumps will move forward). 6) Momentarily wait until the transducer position stabilize and press the Teach button. 7) Press the Retract Pumps Button. (Pumps will move back) 8) Momentarily wait until the transducer position stabilize and press the Teach button. 9) Press the Done Button 10) From the Main screen select Auto button under Dispense Valve and return Ball Valves the dispense position. 22

23 SUPERVISOR Screen This is a password-protected screen. Pump Reload Button The Pump Reload button sets the software pump reload limit of the piston stroke. The factory setting is negative 95. See the Software Piston Stroke Limits Illustration for more information. To change: 1) Press the Pump Reload Position button shown as =000.00, enter the new reload position, press the enter button. 2) Press Enter password button, enter password, press the enter button. 3) Press the ENTER DATA button the new Pump Reload Position will appear in the Current indicator. Shot Size Offset Button The Shot Size Offset button sets the software pump shot size offset of the piston stroke. The factory default is negative - 0.5%. See the Software Piston Stroke Limits Illustration for more information. To change: 1) Press the Shot Size Offset button shown as =000.00, enter the Shot Size Offset position, press the enter button. 2) Press Enter password button, enter password, press the enter button. 3) Press the ENTER DATA button the new Shot Size Offset will appear in the Current indicator. Enter Password button This button allows authorized personal to enter a password "5810" for the purposes of changing the data in the Supervisor Screen. When the password is accepted the ENTER DATA button will be active. NOTE: The password entered in this button will be active for a short time. ENTER DATA button Note: For this button to become active the password must be entered. This button allows all be data from the Pump Reload, Disp.Vlv Position, and Shot Size Offset Buttons to be saved. When this button is active and pressed the new data will be display in the Current indicator under each of the Supervisor button. 23

24 SUPERVISOR Screen This is a password-protected screen. Disp.Vlv Position (Open Dispense Valve Position) The Disp.Vlv Position button allows the operator to set were the dispense valve will open. The DV is set a little less than 0 (negative 5% by default) and should only need reset when maintenance or phasing has been performed on the pumps. See the Software Piston Stroke Limits Illustration for more information. To change or reset the Open Dispense Valve Position do the following: NOTE: The machine must be loaded and primed before doing this procedure. 1) From the Pump Control Screen press the Retract button under Pump Mode. 2) Set the pump air pressure to a low pressure setting (5 psi typical). WARNING: High pump pressure in this procedure may result in pump piston damage. 3) From the Pump Control Screen press the Close button under DV Mode. 4) Set the pump material ball valves to the dispense position. 5) From the Pump Control Screen press the Extend button under Pump Mode, and press the YES button the Extend screen.. Adjust the air pressure to a low setting so that the pumps will move slowly and will stall at the entrance of the piston tube. 6) From the Calibration screen write down the pump position seen in the Transducer Position in % indicator. 7) From the Supervisor screen, press the Disp.Vlv Position button (shown as =000.00), enter the new position recorded from the Transducer Position in % indicator and subtract 2% stroke and press the enter button. 8) Press Enter Password button, enter password, press the enter button. 9) Press the ENTER DATA button. The new Disp.Vlv Position will appear in the Current indicator. 10) From the Pump Control Screen press the Retract button under Pump Mode and press the Auto button under DV Mode. Set the pump air press back to normal limits. NOTE: When operating the machine with the DV Mode in AUTO if the dispense valve builds material pressure higher then normal prior to opening you may have subtract 2% piston stroke from the current indicator seen on the Disp.Vlv Position button. 24

25 Piston Stroke Limits Illustration 25

26 Extend Verification Screen This screen will appear when the Extend button is pressed and held. It is important that the ratio ball check valve is in the open position or the Open button is selected in the DV Mode in the Pump Control Screen prior to selecting the YES button on this screen. NOTE: If the Auto button under the DV Mode in the Pump Control is selected the dispense valve will not open when the YES button is pressed. Extend Pump Ball Valve Positions The following positions show the ball valve position for ratio check and dispense position. Note: In order not to lose material hose prime always close both ball valves prior to changing to the Dispense Position or to the Ratio Check Position. Dispense Position Ratio Check Position 26

27 Initial Startup The PosiRatio machine is completely factory assembled and tested. However, due to packing convenience, some on-site reassembly may be required. 1. Close all ball valves and close all other valves within feed systems unique to machine. 2. Place an in-line regulator and shutoff valve between the machine and the air supply. 3. Connect a 3/8 or larger diameter air supply line to the air inlet. Air Supply Specifications Air Cylinder cycles/minute 2.5 inches 4 inches 6 inches 8 inches 6 inch 6 inch 6 inch 6 inch 3 cfm at 80 psi 6 cfm at 80 psi 13 cfm at 80 psi 23 cfm at 80 psi 7 cfm at 80 psi 17 cfm at 80 psi 38 cfm at 80psi 68 cfm at 80 psi 4. Increase the pump air pressure to 20 psi and then reduce it to 0 psi. This will signal any air leaks. 5. Connect material hoses to the proper pump outlets. Secure remaining ends at dispense valve. If equipped with mild steel and stainless steel pump assemblies, make sure the hose fitting material matches the pump material. The pumps and hoses are color coded at the factory. When connecting hoses, match hose colored tape to the pump assembly colored tape for proper installation. 6. Lubricate the pump seal housing with grease. 7. Connect the required electrical power to the machine as indicate on the machine serial number plate and logic drawing enclose. 8. Check the tightness of all fittings before proceeding. 27

28 Dry Run 1. From the Pump Control Screen under PUMP MODE press the RETRACT button. 2. Adjust pump air pressure to 0 psi. 3. Set the SHOT SIZE for a large shot. See adjusting the Shot Size Screen. 4. From the Pump Control Screen under PUMP MODE press the SHOT. 5. Increase pump air pressure. Do not exceed 30 psi at this point. 6. Press and release the start device. Machine takes one cycle and stops. 7. Press and hold the start device. Machine cycles continuously. 8. Press and release the EMERGENCY STOP button. The air cylinder and pumps immediately stop in place and holds. Release the start device and make sure it is disabled before proceeding. 9. Press and release the POWER ON button. 10. From the Pump Control Screen under PUMP MODE press the RETRACT. 11. From the Shot Size screen select or change a shot size the 1000% of stroke. See the Shot Size screen for more information. 12. From the Pump Control Screen under PUMP MODE press the Shot button. 13. Press and release the start device. The machine cycles 10 times. 14. From the Pump Control Screen under PUMP MODE press the RETRACT button. Pump air pressure controls only the extend stroke. The machine will retract at the plant line air pressure. 28

29 Priming the Hoses Priming the Hoses ensures that air-free material is flowing through the material hoses and out the dispense valve outlet. Before proceeding, load the machine with materials. Priming is critical to keep the PosiRatio working properly. 1. Set the Shot Size to 100%. See adjusting the Shot Size Screen. 2. Reduce air pressure to 0 psi. 3. From the Pump Control screen under PUMP MODE press the SHOT button. 4. At the pump outlets, close the ratio check ball valves. 5. Remove the dispense valve from its mount if necessary. 6. Hold the material hose and dispense valve outlet at a constant incline from the pumps so that air can be pushed out by the material when the machine is cycled. Avoid sags in the hoses! 7. Position a waste container under the outlet to catch dispensed material. Select the start device. 8. While keeping the hoses at a constant incline, cycle the machine slowly until all signs of air have disappeared. Then release the start device. To avoid material spitting, keep air pressure low. 9. From the Pump Control Screen under PUMP MODE press the RETRACT button. 10. Remount the dispense valve before proceeding. 29

30 Ratio Check The Ratio Check is a simple procedure where individual samples of material are collected, weighed, and compared to the manufacturer s desired outputs. We recommend that you do a ratio check by weight at least once a day, and if the machine is used in production for more than one shift, then once a shift. A ratio check log is included with this binder. Before proceeding, phase the pumps and prime the ratio check valves (if equipped) and material hoses. 1. Close the material hose ball valves and open the ratio check ball valves. Cycle the machine several times into a waste container to clear and prime. 2. Weigh six small empty cups and label as A1, A2, and A3. Record on Ratio Check form. 3. Set the shot size to 100%. See Adjusting the Shot Size Screen. 4. From the Pump Control Screen under PUMP MODE press the Shor button. 5. Place empty cups under the nozzles. 6. Press and release the start device. 7. Repeat steps 5 and 6 with all three sets of labeled cups. Always take a dump shot into a waste container before taking weights. 8. Reweigh all three cups and record results on form. 9. Complete weight calculations. If significantly different, see Troubleshooting section. 30

31 Daily Operations The following steps illustrate the day-to-day operation of the PosiRatio. Before proceeding, perform all Daily Maintenance listed in the Periodic Maintenance section. Also complete all loading, priming, phasing, and ratio check procedures. 1. From the Pump Control Screen under PUMP MODE press the Shot button. 2. Select the Shot Size from the Shot Size screen. 3. Set air pressure to 20 psi. Adjust if necessary. 4. Use the start device to cycle the machine. 31

32 Phasing the Pumps When the machine begins pumping material, both pistons must enter the metering tubes at precisely the same time so that both materials start flowing simultaneously. This will ensure proper mixing and a very repeatable metered ratio. Follow these instructions at initial start-up and after a pump repair. Before proceeding, if your model is equipped with ratio check ball valves, first close the material hose ball valves and then open the ratio check ball valves. 1. Press and release CONTROL POWER ON. 2. From the Pump Control Screen under PUMP MODE press the Shot button. 3. From the Pump Control screen select the CLOSE button under the DV MODE. (For more information see the PUMPS screen section.) 3. Remove the pump guard by turning the quarter-turn fastener counterclockwise. 4. Turn air pressure to 0 psi. 5. Press and release the start device. 6. Increase air pressure to slowly cycle the machine, dispensing material into waste containers. 7. Shorten the stroke so that a pulse of material dispenses when the machine is cycled. 8. The pumps are in phase when the material begins to flow from the ratio check nozzle outlets at exactly the same time. If the material from the A pump flows before the material from the B pump, loosen the jam nut and set screw. Then rotate the shaft of the B piston counterclockwise a quarter turn with an open end wrench positioned on the wrench flats. Cycle the machine again and, as before, sight across both outlet ports. Repeat until both materials flow simultaneously. If the material in the B pump begins to flow before the material in the A pump (overcompensation), rotate the shaft of the B piston clockwise in quarter-turn increments until both materials flow simultaneously. Always retighten the jam nuts and set screws, securing both pump shafts in the phased position. (see the Illustration next page) 32

33 Phasing the Pumps Throughout this manual, references to the A pump and B pump are used. The A and B pumps correspond to the particular material originally specified for use in this machine and relate to the corresponding label on the material supply and to the hoses. Any change of resin supplier may cause a need to relabel the supply, pumps, and hoses accordingly. Connecting Block Pump Shaft Shaft Lock Screw and Lock Nut Connecting Block Pump Shaft Adapter and Flats 33

34 Shut Down 1. Press and release the EMERGENCY STOP button. 2. Ensure everything is OFF. 3. Turn main air supply valve off. 4. Bleed air from the machine. This also empties the filter of water collected from the air supply. Water contamination will dramatically shorten, if not end, pneumatic valve life! 5. Inspect the pump shafts for a material buildup. Clean and lubricate. 34

35 Daily (once a shift or as required) Periodic Maintenance Water Trap Bowl Material Reservoirs Check air circuit water trap valve and release any water, as necessary, through the base outlet. Check material levels and refill as necessary. Ensure that the material reservoirs are vented properly. (Dry Air, Nitrogen, etc.) Air Dryer Pump Shafts Check the condition of the desiccant air dryer. Clean both pump shafts with solvent and lubricate with Mesamoll. Dispense Head Dismantle, clean thoroughly, and reassemble. Lubricate all parts with a thin coat of Mesamoll. *Refer to Daily Operation and Shutdown Sections of the manual, if material is leaking refer to the Troubleshooting Section of this manual. 35

36 Troubleshooting Pumping (after satisfactory startup) Problem Cause Solution Pump stalling and no material being pumped despite adequate input pressure. Blocked mixer. Turn off air supply and remove hoses from mixer. Check hoses for flow. Pumps cycling satisfactorily but total material output dropped off, or one pump output lags behind the other. Pumps not discharging normal or full volume. Pumps not cycling at all or pumps not completely cycling. Pumps drawing material back down from hose. Closed outlet ball valves. Blocked check valve. One pump metering incorrectly. Low material level in reservoirs. Air in material (normally only high viscosity material). Piston worn or broken. Check valve malfunction. Flow controls set differently Air circuit failure. Check valve stuck open. Open ball valves Unlikely to be fully restricted, but possible. Dismantle, clean, and reinstall. Check both outputs from the hoses. If pumps are out of phase or if one pump is not discharging a full shot of material, see next solution. Refill reservoirs. Prime pump and hoses. Reload reservoir with minimum air entrapment. (Ask for technical advice.) See air in hose solution. Remove and inspect suspected piston. Replace if worn, damaged. Remove, clean, and reinstall the check valve. Readjust flow controllers. SeeLogicCircuit troubleshooting. Remove check valve and clean or replace. 36

37 Troubleshooting Pumping (after satisfactory startup) Continued Problem Cause Solution Material continues to flow after pumps stop dispense stroke, or air bubble apparent at some part of the dispense stroke each time. Air in hose. Hose not primed correctly. Air in material entrapped during reservoir refill. Incline hose from check valve to outlet of hose. Avoid sags in hose. Cycle machine until all trapped air is discharged. Reload reservoir with minimum air entrapment. (Ask for technical advice.) Air in material being drawn into pump from behind check valve. Remove check valve and fitting in front of pump. Reinstall with PTFE tape. Air in material being drawn Tighten or seal as necessary. into pump through inlet hoses or coupler. Severe leaks at pump shaft. Pump shaft seals worn. Remove pump packing assembly and replace shaft seal set. 37

38 Troubleshooting Pumping (after satisfactory startup) Problem Cause Solution Pumps remain in extended position and will not return. Roller trip switch faulty. If roller trip switch has air pressure applied but does not function when checked, replace. Pumps remain at rest in retracted position and do not move when the machine is signaled to start. Pump air cylinder operating erratic/will not finish stroke. Four-way air cylinder directional control valve needs servicing or replacement. Pump is out of calibration. Main input air pressure or machine ON/OFF switch Four-way air cylinder directional control valve needs servicing or replacement. Material cured on piston rod. Pump is out of calibration. Input air pressure to machine exceeds 110 psi. Material on piston shafts. Air cylinder wearing out. If roller trip switch does not return the pumps, check the signal through to the four-way valve. If OK, then four-way valve may be at fault. Recalibrate pump. If no main input air pressure is evident on the inlet to the starting device, check the main input air switch. If this switch has air into it but does not give air out when switched, the switch is faulty. If main input air signal comes from the starting device, then the four-way control valve is not changing over. Remove and service. (Ask for technical advice.) Clean piston rod, apply Mesamoll. Recalibrate pump. Place air regulator in supply line to machine. Cleanpistonshafts. Rebuild air cylinder. 38

39 Troubleshooting Motionless Mixer (after satisfactory startup) Problem Cause Solution Material leaks past inlet valves of dispense valve, mixing block, or dispense block. Inlet valve O-ring or seals damaged or worn. Replace O-rings or seals. 39

40 Pump Rebuild C-1 Pump rebuilding is required when the material is leaking from the piston shaft forward housing, or the when piston wears to the point that it will no longer seal against the metering tube, thus producing inaccurate output. 1. Press and release CONTROL POWER ON. Green lamp lights. 2. Turn PUMP MODE to CONT. Turn PUMP MODE to RETRACT and set the STROKE ADJUST control to the maximum size. See Adjusting the Shot Size. 3. Turn DV MODE to CLOSE. 4. Close all ball valves within feed systems unique to your machine. 5. Reduce pump air pressure to 0 psi. 6. At pump outlets, close the material hose ball valves, if equipped. Material Hose Ball Valves 7. Open the ratio check ball valves, if equipped. 8. Place clean containers under both ratio check nozzles to collect recyclable materials OR Remove material hoses from the Twinmixer inlets and place them in clean containers to collect recyclable materials OR If equipped with Twindispense, remove the nondrip valves from the dispense block and place clean containers beneath each to collect recyclable materials. Ratio Check Ball Valves Caution Never cycle the machine with both the material hose ball valves and the ratio check ball valves closed.

41 Pump Rebuild C-2 9. Increase air pressure and cycle the machine slowly until both pumps are empty. Traces of material will remain in the bottom of the pump, even when flow ceases. 10. Reduce air pressure to 0 psi. 11. There will be a substantial vacuum between the pump inlet, the piston / metering tube and the check-valve area. The vacuum can be released by removing the pump outlet check-valve or by loosening the material inlet hose clamp and hose. Releasing the vacuum allows the metering tube to be removed more easily. 12. With the vacuum released from both pumps, increase air pressure and cycle the machine slowly so that the machine moves to the retract position. Loosen the shaft lock screw located on the connecting block. Using a 7/8 inch open end wrench: For models with 1 pump shaft disconnect the pump shaft from the connecting block. or For models with less than 1 pump shaft - disconnect the pump shaft adapter from the connecting block. Make sure to leave the adapter tight on the pump shaft. 13. Place rags under the pump outlet; remove the three socket-head cap screws on the front of the pump housing. Remove the metering tube. 14. Place rags under the pump; remove the three socket-head cap screws from the back of the pump. Push the pump shaft toward the pump outlet until the pump shaft flats are next to the rear seal housing. Connecting Block Connecting Block Pump Shaft Adapter and Flats Pump Shaft 15. Using a long drift punch inserted from the front of the pump housing lightly tap out the rear seal housing along with the pump shaft. Shaft Lock Screw and Lock Nut Shaft Adapter Back Cap Screws Front

42 Pump Rebuild C Remove the piston, locknut and washers. Remove pump shaft from rear seal housing (if not previously done). 17. Prior to installing new pump o-rings and packings do the following: a) Clean all pump parts with approved solvents. b) When the pump has been disassembled for rebuild, inspect all items for wear or damage. If the wear or damage seems excessive the suspected items should be replaced. Replace the pump shaft or metering tube if there is any scratch or groove that can be felt by moving a fingernail over the marked area. c) Inspect all retaining screw holes for sharp burrs on the inside of the pump housing. Remove any burrs to prevent them from cutting the o-rings on reassembly. d) Lubricate all parts with the appropriate assembly lubricant prior to installation. WARNING: Make sure that the assembly lubricant being used is compatible with the material that is going into the pump. If something is used that is not compatible, a reaction may occur that could cause damage to the machine and/or people. 18. Prior to installing the o-rings and packings in the rear seal housing it is very important to refer to the assembly drawings included in this manual for the seal configuration on your machine. Follow the instructions applicable to your configuration, referencing the assembly drawings. Note that seal kits include the items with ** beside the part number on the pump assembly drawing. Pump Shaft Packing Nut Posipak Seal Bearing Posilube Seal Posipak Seal Configuration Piston and Washers Note: Check the assembly drawings which are included with this manual for your pump configuration. Pistons may not have front and backup washers. The seal kits do not contain the pistons and front and backup washers needed to rebuild the pump. These will need to be ordered separately or reuse the washers previously installed. Rear Housing Posipak Seal Configuration Reassembly a) Install the Posipak seal into the rear seal housing with the o-ring facing the material portion of the pump. b) Install the bearing next up against the Posipak. c) If the pump assembly is equipped with Posilube, then install the Posilube seal into the packing nut groove with the open V of the packing facing the hex flats of the packing nut as shown. d) Install the packing nut: tighten until it bottoms out on the rear seal housing. e) Insert the pump shaft carefully through the packing nut/rear seal housing assembly. Care must be taken to avoid rolling the lips of the Posilube seal. Do not allow pump shaft flat to enter the rear seal housing. f) Install the o-ring on the outside of the rear seal housing. g) Install the pump shaft/rear seal housing assembly into the pump housing. h) Install the three socket-head cap screws that retain the rear seal housing.

43 Pump Rebuild C-4 Pump Shaft Packing Nut Chevron Packing Wyclip Seal Bearings Chevron Seal Configuration Posilube Seal Piston and Washers Note: Check the assembly drawings which are included with this manual for your pump configuration. Pistons may not have front and backup washers. The seal kits do not contain the pistons and front and backup washers needed to rebuild the pump. These will need to be ordered separately or reuse the washers previously installed. Rear Housing Chevr on Seal Configuration Reassembly a) Install the Wyclip seal into the front of the rear seal housing. The Wyclip snaps into place when installed correctly. Note: The Wyclip seal is very brittle and may crack when installed. To prevent the Wyclip from cracking, it can be warmed by letting the Wyclip set in a cup of very hot tap water for a few minutes. This will soften the seal and make installation much easier. The following Wyclip installation tools are available. Description Part Number TOOL 3/8" WYCLIP 95/0854/77 TOOL 1/2" WYCLIP 95/0855/77 TOOL 1" WYCLIP 95/0856/77 b) Install one of the bearings into the rear seal housing. c) Install the Chevron packing set up against the bearing. Every packing set includes several thin packings and a thick packing. Always insert the stack first so that the thin packing touches the installed bearing. d) Install the remaining bearing. e) If the pump assembly is equipped with Posilube, then install the Posilube seal into the packing nut groove with the open V of the packing facing the hex flats of the packing nut as shown. f) Install the packing nut finger tight into the rear seal housing at this time. g) Insert the pump shaft carefully through the packing nut/rear seal housing assembly. Care must be taken to avoid rolling the lips of the Posilube seal. Do not allow pump shaft flat to enter the rear seal housing. h) Tighten the packing nut 1/4 to 1/2 turn to preload the packings. Note: Final tightening will not occur until after the pump has been returned to service. The Chevron Seal Configuration is designed to allow retightening of the pack ing nut as the pack ings wear. This is why it is best to return the pump to service and watch for leakage, then tighten the packing nut only as needed. Over-tightening the pack ing nut will wear the pack ing out early. i) Install the o-ring on the outside of the rear seal housing. j) Install the pump shaft/rear seal housing assembly into the pump housing. k) Install the three socket-head cap screws that retain the rear seal housing.

44 Pump Rebuild C Piston Reassembly - Check the assembly drawings for the washer and piston configuration. Always use the designated front and backup washers to avoid premature piston failure. Install the backup washer if applicable. Before installing piston, add PTFE tape on the piston shank area. Avoid excessive tape that will bunch up behind the piston (PTFE tape behind the piston will keep the piston from seating properly). Install the front washer if applicable. Install the piston nut tightening to the point that the piston will not turn on the pump shaft by hand. This is normally done by turning the piston nut an additional ¼ to ½ of a turn after the piston nut contacts the piston. Install PTFE Tape 20. Reconnect the pump shaft to the connecting block. 22. Lubricate the new metering tube o-ring. Reinstall the metering tube. Install the three socket-head cap screws. On the 50mm and the 55mm pump assemblies, do not over -tighten the metering tube retaining screws or the metering tu be will be damaged and require replacement. Perform all Loading, Priming, Phasing, and Ratio Check procedures before resuming production. Verify that the pump shaft adapter, if required, does not turn from the pump shaft after installation. This adapter is used to adjust pump phasing after it is installed on the Connecting Block. If the pump shaft turns in the adapter, the machine phasing will change as the machine cycles. If the shaft adapter turns from material shaft, apply red.locktite to the shaft threads and then retighten shaft adapter to shaft.