Twinmixer II (Medical)

Transcription

1 Operation - Maintenance Twinmixer II (Medical) 3A0154A Meter, mix, and dispense system for precise two-component dispensing of sealants and adhesives. Not for use in explosive atmospheres psi (6.9 MPa, 69 bar) Maximum Outlet Fluid Working Pressure 2000 psi (13.8 MPa, 138 bar) Maximum Inlet Fluid Working Pressure 100 psi (0.7 MPa, 7 bar) Maximum Air Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

2 Contents Warnings...3 Isocyanate Conditions...5 Material Self-ignition...5 Moisture Sensitivity of Isocyanates...5 Keep Components A and B Separate...5 Foam Resins with 245 fa Blowing Agents...5 Changing Materials...5 Grounding...6 Overview...6 Component Identification...7 Typical System Configurations...7 Dispense Valve...8 Setup...9 TypicalInstallation...9 Valve Mounting Diagram...10 Startup...11 AdjustingtheSnuffBack...12 Ratio Check...13 Operation...14 Pressure Relief Procedure...15 Shutdown...15 Maintenance...15 Troubleshooting...16 Schematics...17 Rebuild...18 Wet Section Disassembly...19 Wet Section Assembly...19 Air Cylinder Disassembly...19 Air Cylinder Assembly...20 TechnicalData Graco Ohio Standard Warranty...22 GracoOhioInformation A0154A

3 Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable. WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. Do not point gun at anyone or at any part of the body. Do not put your hand over the dispense outlet. Do not stop or deflect leaks with your hand, body, glove, or rag. Follow Pressure Relief Procedure in this manual, when you stop dispensing and before cleaning, checking, or servicing equipment. TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. Read MSDS s to know the specific hazards of the fluids you are using. Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. Always wear impervious gloves when spraying or cleaning equipment. If this equipment is used with isocyanate material, see additional information on isocyanates in Isocyanate Conditions Section of this manual. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to: Protective eyewear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: Use equipment only in well ventilated area. Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). Keep work area free of debris, including solvent, rags and gasoline. Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. Ground all equipment in the work area. See Grounding instructions. Use only grounded hoses. If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. Keep a working fire extinguisher in the work area. 3A0154A 3

4 Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. Do not operate the unit when fatigued or under the influence of drugs or alcohol. Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use. Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only. Do not alter or modify equipment. Use equipment only for its intended purpose. Call your distributor for information. Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not kink or over bend hoses or use hoses to pull equipment. Keep children and animals away from work area. Comply with all applicable safety regulations. MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts. Keep clear of moving parts. Do not operate equipment with protective guards or covers removed. Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply. 4 3A0154A

5 Isocyanate Conditions Isocyanate Conditions To prevent exposing ISO to moisture: Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area. To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area. Material Self-ignition Some materials may become self-igniting if applied too thickly. Read material manufacturer s warnings and material MSDS. Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts. NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature. Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container. Keep the ISO lube pump reservoir (if installed) filled with Graco Throat Seal Liquid (TSL), Part The lubricant creates a barrier between the ISO and the atmosphere. Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system. Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use. Never use solvent on one side if it has been contaminated from the other side. Always lubricate threaded parts with ISO pump oil or grease when reassembling. Keep Components A and B Separate NOTICE To prevent cross-contamination of the equipment s wetted parts, never interchange component A (isocyanate) and component B (resin) parts. Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperatures above 90 F (33 C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system. Changing Materials When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. Always clean the fluid inlet strainers after flushing. Check with your material manufacturer for chemical compatibility. Most materials use ISO on the A side, but some use ISOontheBside. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side. 3A0154A 5

6 Grounding Grounding This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. Metering valve: attach ground wire from grounding lug to true earth ground. See Component Identification starting on page 7. Fluid hoses: use only electrically conductive hoses. Feed system components: attach ground wire from grounding lug to true earth ground. See feed system manual for grounding points. See Warnings on page 3. Fluid supply container: follow local code. Solvent pails used when flushing: follow local code. Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity. Overview This plural component meter, mix, and dispense device accurately meters liquid and semi-paste materials. The machine is ideal for a two-component application requiring very small and precisely mixed shots. The ratio of the pneumatic cylinder area to pump shaft area provides the adjustable pressure intensification needed to move the separate liquids through the mixer with a flow rate suitable for production requirements. The complete system is enclosed. Mixing of the two materials takes place only in the mixer at the final stage of metering valve operation. 6 3A0154A

7 0 2 NUPRO SS-4CP PSI FILTER Component Identification Component Identification Typical System Configurations PUSH TO LOCK PULL TO RELEASE psi 160 DISPENSE VALVE STROKE ADJUST EXTEND FIG. 1 3A0154A 7

8 Component Identification Dispense Valve F D E H C C A B G Front View Rear View Key: A A Material Inlet B B Material Inlet C Spool Rods D Open Air Inlet E Close Air Inlet F Snuff Back Adjuster G Material Outlet Nose H Mounting Holes FIG A0154A

9 Setup Setup NOTE: See Typical Installation diagram Perform Setup procedure for feed system components. See feed system manuals. See Warnings on page Place an in-line air pressure regulator, air-water separator/filter, and shut-off/bleed valve between the air supply and the control solenoids. 3. Connect each 1/4 in. outside diameter supplied air line to the corresponding control solenoid. See Component Identification starting on page Connect chemical lines from feed system to metering valve material inlets. See Component Identification starting on page 7. Typical Installation Air Supply User Supplied Air Shut-off and Bleed Valve Air-Water Separator/Filter Air Pressure Regulator A Side Material Tank Control Solenoids A Side Pump A Side Fluid Shut-Off Valve Dispense Valve B Side Pump B Side Fluid Shut-Off Valve B Side Material Tank FIG. 3 3A0154A 9

10 Setup Valve Mounting Diagram As desired, use the following diagram to mount the dispense valve. (2) 3/8-24 TAP THRU TO WINDOW (1) NERSIDE, (1) FARSIDE.65 (4) 1/4-20 TAP THRU TO WINDOW (2) NERSIDE, (2) FARSIDE /64 3 3/4 FIG A0154A

11 Startup Startup 1. Perform Ratio Check, page Install mixer and shroud. 3. Pressurize the A and B material feed systems connected to the metering valve to prime the system. See Technical Data. on page 21 for maximum inlet feed pressures. 4. Dispense several full stroke shots until material is air-free and has good shut-off at the nose. NOTE: Very viscous, compressable materials may continue to droll after system is primed. Reduce flow rate as required to produce air-free dispense. NOTE: Very thin materials may require tilting the valve greater than 45 degrees and dispensing shots until material is air-free. Remove oil from cups before proceeding. 3A0154A 11

12 Adjusting the Snuff Back Adjusting the Snuff Back NOTICE Excess snuff-back can cause material crossover. The material output depends on the material pressure, size of nozzle or needle, the dispense time and the rate at which the dispense valve is moved by the system to which it is attached. The Twinmixer II allows material to be drawn back into the dispense mixer nozzle when the spools retract to minimize post-dispense dripping or drooling. This is the snuff-back feature. Snuff-back can be adjusted only while dispensing or with the valve in the open position. The snuff-back adjustment knob on the top of the valve controls this. Turn the knob in or clockwise to decrease snuff-back or turn the knob out or counterclockwise to increase snuff-back. If desired results are not achieved try adjusting through the full range of travel. 12 3A0154A

13 Ratio Check Ratio Check Perform ratio check procedure at startup and after rebuild. 1. Weigh six small cups and label as indicated. Record weights. 8. Subtract weight of empty cups from weight of filled cups to get material weights. 9. Complete ratio calculations. 2. Remove mixer. 3. Install the ratio check nozzle. 4. Dispense into a waste container to prime the ratio check nozzle. 5. Place cups as indicated under ratio check nozzle and cycle machine once. 6. Repeat until all three sets of cups have been used. 7. Re-weigh all six cups and record weights. 3A0154A 13

14 Operation Operation The pneumatically actuated Twinmixer is designed to isolate materials until they have reached the disposable Posimixer inlet. The "A" and "B" components enter through individual shut off spool valves and pass through the Twinmixer in separate streams. Upon exiting the Twinmixer nose, the "A" and "B" materials converge in the Posimixer and are thoroughly blended prior to reaching the mixer outlet. A wide selection of Posimixers is available to accommodate most materials, ratios, viscosities and flow rates. The shut off valve rods are operated together for synchronization of the two streams, and when closed, the valve rod spools create a snuff back in the outlet adapter and Posimixer which draws back material at the tip. The degree of snuff back is adjustable and can thus be set to give optimum control of anti-drip and stringing between shots, depending on material viscosity and pressure. Shut-off is positive and the large air cylinder drive gives a snap-action on the open and close sequences. Operation of the Twinmixer may be accomplished by one of several methods using an open/close limit switch. Lever Actuated Hand Held Trigger Actuated Foot Switch Actuated Control Panel Actuated 14 3A0154A

15 Pressure Relief Procedure Pressure Relief Procedure Maintenance Perform the following procedures once a shift. 1. Retract the metering pistons. 2. Remove static mixer. 3. Dispense 5 shots. Shots should be at least 75% of the full stroke. 4. Close the incoming air shut-off/bleed valve that supplies air to the metering valve. Shutdown NOTE: If material is leaking, see Troubleshooting on page 16. Material Reservoirs Check material levels and refill as necessary. Ensure that the material reservoirs are properly vented. Air Dryer Check the condition of the desiccant air dryer. Replace as necessary. Ratio Check See Ratio Check on page Perform Pressure Relief Procedure. 2. Inspect the spool rods for material buildup. Clean as necessary. 3. Install storage cap on outlet nose. 3A0154A 15

16 Troubleshooting Troubleshooting Perform Pressure Relief Procedure before performing any troubleshooting procedure. Problem Cause Solution No Flow Air Pressure too Low Requires 80 PSI Inlet Pressure Leaks Drools Clogged Mixer Dispense Valve (DV) Switch Closed Seals not Seated Seals Damaged Worn Spool Rods Air Trapped Replace the Mixer Reset to Auto Check the Seals Replace the Seals Replace Spool Rods and Seals Review Start-up Procedure for Priming Snuff-Back out of Adjustment Re-adjust the Snuff-Back (If Applicable) Off Ratio Metering Pumps/System Check Priming, Check-Valves, and/or Pistons Not Mixing Fouled Mixer Out of Phase Condition A:B Replace the Mixer Check the Phasing at the Pumps 16 3A0154A

17 Schematics Schematics PLANT AIR 80 PSIG 1/2" DIA ENC-1 EXTERNAL WARNING USE DRY AIR ONLY DRAIN FILTER DAILY 100 FL-1 LUB-1 PUMP PRESSURE G REG EA P EB SOL-EXT A A B EXTEND AIR CYLINDER RETRACT 508 B 509 SOL-RET SOL-ODV EA P EB A B QD OPEN QD DISPENSE VALVE CLOSE 517 MF-3 MF-1 MF A0154A 17

18 Rebuild Rebuild FIG. 5: Dispense Valve General Illustration 18 3A0154A

19 Rebuild Wet Section Disassembly See FIG. 5 on page Turn off the material supply and remove the material line from both Material Inlets (3). 2. Turn off the air supply and disconnect the air lines. 3. Remove the valve from its mounting. 4. Remove the 2 cap head screws attaching the nose, then remove nose (14). 5. 5Remove the 4 cap head screws attaching the Material Inlet (3). 6. Pull the Material Inlet (3) away from the Air Cylinder Assembly; remove the Posipak seals (10A) and (11A) and washers (8). 7. Grasp the end of the Spool (6) and pull it down to the fully extended position. 8. Wipe off the Spool rods (6) and inspect it for wear. Remove and replace the Spool rod (6) if worn. 9. Remove the Adapter (4) from the Material Inlet (3). 10. Remove the Posipak seals (10A) and (11A). Remove and discard the O-ring (16). 11. Remove and discard the O-ring (9). 12. If the air cylinder assembly needs to be rebuilt, remove spool rod nuts (5) remove Spool rods (6) and rebuild air cylinder assembly. See Air Cylinder Disassembly section to continue. The Twinmixer II Dispense Valve Wet Section is now ready for cleaning and assembly. Wet Section Assembly See FIG. 5 on page 18. Clean all valve parts with an appropriate solvent prior to assembly. Always install new, lightly lubricated o-rings and seals when assembling the valve. Use light mineral oil for lubricating valve parts including seals and o-rings. Lubricate the outside of the Spool (2) before assembly. Check the Spool (2) for wear and if it is worn secure a replacement before proceeding. Use caution as you install new Posipak seals so that they are not pinched or torn. Do this by making sure they are lubricated, and by tucking the lips of the seal inward before uniformly pushing them into position. Always consult the illustrations and drawings to be sure that seals face the correct direction. 1. Install the Spool rods (6) if you removed them. 2. Install the O-ring (16) in the bottom end of the Material Inlet (3). 3. Install the Posipak Seal (10A)(10B) in the top end of the Material Inlet (3). Some models have a single seal in this location and some have 3 seals in this location. Check the drawings for your exact model. Note: The o-ring side of the Posipak seal faces towards the material inlet 4. Install Washer (8). 5. Slide the Material Inlet (3) carefully over the Spool rods (6) until it seats in the Air Cylinder Assembly. 6. Install the 4 cap head screws attaching the Material Inlet (3). 7. Install the other Posipak Seals (10)(11) into the Adapters (4) Note: The o-ring side of the Posipak seal faces towards the material inlet. 8. Install o-rings (16) (9). 9. Screw the Adapters (4) into the Material Inlet (3), taking care that the Posipak Seals (6) slide over the extended Spool (2) without rolling the lip. 10. Install nose (14). Install the nose and the cap head screw attaching the nose. Perform the Dry System Checkout, Material Loading and Wet System Checkout procedures. The Twinmixer II Dispense Valve is now ready to be placed back in service. Air Cylinder Disassembly See FIG. 5 on page Unscrew the Floating Spool beam (17) from the Piston Rod (4). 2. Unscrew the End Cap (2) from the Air Cylinder Body (5). 3. Remove and discard the O-ring (8). 3A0154A 19

20 Rebuild 4. Remove the Screw (10) and Lock Washer from the Snuff-Back Adjustment Knob remove upper O-ring (7). 5. Remove the Piston (3) from the Air Cylinder Body (5). 6. Remove and discard the O-ring (9). 7. Screw the Floating Spool beam (17) into the Piston Rod (4). Needle nose pliers can be used to hold screw in place so the Allen wrench can be inserted. 8. Screw the End Cap (2) into the Air Cylinder Body (5). Return back to the Wet Section Assembly. 7. With use of a pick remove and discard the O-rings (7). The Twinmixer II Dispense Valve Air Cylinder Assembly is now ready for cleaning and assembly. Air Cylinder Assembly See FIG. 5 on page 18. Note: Clean all valve parts with an appropriate solvent prior to assembly. Always install new, lightly lubricated o-rings and seals when assembling the valve. Use light mineral oil for lubricating valve parts including seals and o-rings. Lubricate the inside of the Air Cylinder Body (5) and the outside of the Piston Rod (4) before assembly. Check the Piston Rod (4) for wear and if it is worn secure a replacement before proceeding. 1. Install the lower O-ring (7) into the groove in the Air Cylinder Body (5). This is easiest if performed from the top. Squeeze the O-ring to an oblong shape to get it started in the groove, then push it gradually into place with a small, blunt tool. 2. Install the O-ring (9) around the Piston (3). 3. Insert the Piston (3) assembly carefully into the Air Cylinder Body (5) until the Piston Rod (4) passes through the lower O-ring (7). 4. Install the upper O-ring (7) into the groove in the End Cap (7). 5. Install the Screw (10) and Lock Washer through the upper O-ring (7) and into the Snuff-Back Adjustment Knob. Make sure the Lock Washer is fully compressed. Screw Snuff-Back Adjustment mid way. 6. Install the O-ring (8) into the Air Cylinder Body (5). 20 3A0154A

21 Technical Data Technical Data Maximum Ambient Temperature F (43 C) Maximum Operating Temp F (65 C) Maximum Outlet Fluid Working Pressure psi (6.9 MPa, 69 bar) Maximum Inlet Fluid Working Pressure psi (13.8 MPa, 138 bar) Maximum Air Working Pressure psi(0.7 MPa,7 bar) Supplied Air Requirements.... 1to3cfmat80psito100psi Shot Size Range (depending on metering rods selected) 1 to 360 cc Maximum Cycle Rate (application dependent).... Upto30cycles per minute Dimensions (H xlxw),heighttoendofmaterialinlet block x8.40x1.75in.(71x213x44mm) Weight lb( kg) WettedParts /304, 316, perfluoroelastomer, ethylene, propylene, polymyte 3A0154A 21

22 Graco Ohio Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Ohio Information For the latest information about Graco products, visit TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Toll Free: or Fax: All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. This manual contains English. MM 3A0154 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO OHIO INC PORT JACKSON AVE NW, NORTH CANTON, OH Copyright 2009, Graco Ohio Inc. is registered to ISO