Flo-Brush PDMP Applicator Tool

Transcription

1 Flo-Brush PDMP Applicator Tool Customer Product Manual Issued 4/09 NORDSON CORPORATION AMHERST, OHIO USA

2 Safety... 1 Qualified Personnel... 1 Intended Use... 1 Regulations and Approvals... 1 Personal Safety... 1 High-Pressure Fluids... 2 Fire Safety... 2 Halogenated Hydrocarbon Solvent Hazards. 3 Action in the Event of a Malfunction... 3 Disposal... 3 Description... 4 Specifications... 5 Installation... 5 Operation... 5 Maintenance... 6 Repair... 8 Solvent Purge Valve... 8 Remove the Solvent Purge Valve... 8 Install the Solvent Valve... 8 Applicator Module... 9 Remove the Applicator Module... 9 Install the Applicator Module... 9 Pump Remove the Pump Install the Pump Parts Kits Application-Specific Parts Mounting Plates Pumps Applicator Tips and Brushes 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 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 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 regestered trademarks of Nordson Corporation. All other trademarks are the property of their respective owners.

3 Flo-Brush PDMP Applicator Tool 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 S using incompatible materials S making unauthorized modifications S removing or bypassing safety guards or interlocks S using incompatible or damaged parts S using unapproved auxiliary equipment S 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. S Do not operate or service equipment unless you are qualified. S 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. S 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. S 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. S 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. S 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. S 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. S Make sure the spray area is adequately ventilated. S 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.

4 2 Flo-Brush PDMP Applicator Tool 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: S Go to an emergency room immediately. S Tell the doctor that you suspect an injection injury. S Show him this card S Tell him what kind of material you were spraying MEDICAL ALERT AIRLESS SPRAY WOUNDS: NOTE 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. Fire Safety To avoid a fire or explosion, follow these instructions. S 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. S 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. S Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. S Do not heat materials to temperatures above those recommended by the manufacturer. Make sure heat monitoring and limiting devices are working properly. S Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material MSDS for guidance. S Do not disconnect live electrical circuits when working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. S 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. S Shut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment. S Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. S Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice.

5 Flo-Brush PDMP Applicator Tool 3 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: S Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. S 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.

6 4 Flo-Brush PDMP Applicator Tool Description See Figure 1. The Flo-Brush PDMP applicator Tool dispenses black primer onto fritted glass or body surfaces. A typical applicator is shown in Figure 1. Refer to Table 1 for component descriptions. NOTE: Throughout the remainder of this manual, the Flo-Brush PDMP Applicator Tool is referred to as the applicator. Primer colors vary and are dependent upon your application. Although red primer, clear primer, Part-A primer, or glass cleaner may be used, this manual makes references to black primer Figure 1 Typical Applicator

7 Flo-Brush PDMP Applicator Tool 5 Table 1 Applicator Components Item Description Item Description 1 Solvent Connection solvent supply connection for the applicator. 2 Primer Connections primer supply connections for the applicator. 3 Solvent Purge Valve purges the gland in the primer pump. 4 Three-Way Valve used to select primer or solvent delivery to the pump. 5 Primer Dispense Valve Supplies primer to the applicator tip. 6 Applicator Tip Applies primer onto the fritted glass surfaces. 7 Solvent Purge Waste Nozzle exit point for waste material during a Gland Purge cycle: portioned over waste container. 8 Primer Metering Pump Supplies primer to the applicator tip. 9 Pump Outlet Pressure Transducer monitors fluid pressure to the applicator tip. 10 Pump Inlet Pressure Transducer monitors fluid pressure to the pump. 11 Manual/Solvent Shutoff Valve supplies solvent to the 3-way valve; normally closed; opened during the flushing procedure. 12 Mounting plate application-specific; mounts applicator to customer robot. Specifications RefertoTable2. Table 2 Specifications Item Specification Supply Air psi (8.3 bar) Requirements Height: 17.8 in. (44 cm) Dimensions Width: 10 (25.4 cm) (approximate) Depth: 11.3 (28.7 cm) Approximate Weight 16.4 lb (7.4 kg) Ceramic, EPDM Rubber Wetted Components (A), PTFE, Stainless Steel (A) EPDM rubber is used in the check valve shown in Figure 5 (Item 22). Installation Installation is dependent upon the application requirements. Refer to the system documentation that for electrical, pneumatic, and fluid connections. Operation Operation is dependent upon the application requirements and fluid delivery options. Refer to the System Operation Parameter Sheet included with the system documentation for operation parameters.

8 6 Flo-Brush PDMP Applicator Tool Maintenance Always perform preventive maintenance and lubrication procedures according to your facility maintenance schedule. Use the frequencies listed in Table 3 if your facility does not have a maintenance schedule. See Figure 1 and refer to Table 1 for location of the components if necessary. WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. NOTE: Only use solvents that your material supplier and facility representative have approved for use with black primer. Frequency Item Task Start of Shift 1/8-Inch Solvent Supply Tubing Solvent Purge Waste Nozzle Brush or Felt Tip Table 3 Maintenance Schedule Check tubing for discoloration. Some discoloration is normal. Confirm that the solvent discharges from the solvent purge waste nozzle. Inspect fluid orifice for blockages. Clear blockages if necessary. Brush Inspection: Ensure that the bristles are soft, straight, and equal in length. Felt Inspection: Ensure that the felt piece is straight and there are no loose fibers. Both: Check the primer passageway for blockages. Clear blockages if necessary. TIme to Complete 2min. 1min. 2min. H200 Dispense Valve Clean and remove residual primer. 1min. Inspect the nozzle tip O-ring for wear or damage and replace if necessary. Inspect: 1 min. Replace: 1 min. Every Four Hours Brush or Felt Tip Brush Inspection: Ensure that the bristles are 2min. soft, straight, and equal in length. Felt Inspection: Ensure that the felt piece is straight and there are no loose fibers. Both: Check the primer passageway for blockage. Clear blockage if necessary. End of Shift 1/8- and 1/4-Inch Flush with solvent to remove primer and inspect Inspect: 1 min Primer Fluid for clarity. Replace tubing if fluid path does not Supply Tubing flush clear solvent. Replace: 5 min Metering Pump Flush the dispense pump with solvent until a clear 3min. stream of fluid appears. Weekly H200 Dispense Valve Inspect the nozzle tip for material leakage. Replace the needle/nozzle set if required. Inspect: 1 min Replace: 10 min Note: These items are a matched set and must be replaced at the same time. Inspect weep hole for leakage. Replace seals if necessary. Inspect: 1 min Replace: 30 min Monthly 1/8- and 1/4-Inch Replace tubing. 15 min. Primer Fluid Supply Tubing 1/8-Inch Solvent Replace tubing. 15 min. Supply Tubing Annually Metering Pump Replace metering pump. 30 min. Primer and Solvent Pneumatic 3-Way Ball Valves Replace or rebuild 3-way ball valves. Replace: 1 hour Rebuild: 2 hours

9 Flo-Brush PDMP Applicator Tool 7 Notes:

10 8 Flo-Brush PDMP Applicator Tool Repair WARNING S Allow only qualified personnel to perform the tasks in the following sections. Follow the safety instructions in this document and all other related documentation. S High pressure fluids are extremely dangerous. Relieve all fluid and air pressure to the applicator before performing these procedures. S 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. Solvent Purge Valve Use the following procedures to replace the solvent purge valve. Remove the Solvent Purge Valve 1. Make sure that all fluid and air pressure is relieved. 2. See Figure 2. Place a waste container under the solvent line (4). Disconnect the solvent line from the fitting (3). 3. Remove the screws (2) securing the solvent valve (1) to the manifold (6). 4. Remove the O-rings (5) from the solvent valve (1). Discard the O-rings. 5. Remove the fitting (3) from the solvent valve (1). Install the Solvent Valve Installation is the reverse order of the removal procedure. Apply O-ring lubricant to the new O-rings (5). Tighten the screws (2) to 30 in.-lb (3.3 N m) Figure 2 Solvent Valve

11 Flo-Brush PDMP Applicator Tool 9 Applicator Module See Figure 3. Use the following procedures to replace the applicator module. Remove the Applicator Module 1. Make sure that all fluid and air pressure is relieved. 2. If installed, remove the applicator tip (3) from the applicator module (1). 3. Remove the screws (2) securing the applicator module (1) to the manifold (5). 4. Remove the O-rings (4) from the applicator module. Discard the O-rings. Install the Applicator Module Installation is the reverse order of the removal procedure. Apply O-ring lubricant to the new O-rings (4). Tighten the screws (2) to 30 in.-lb (3.3 N m) Figure 3 Applicator Module

12 10 Flo-Brush PDMP Applicator Tool Pump See Figure 4. Use the following procedures to replace the pump. Remove the Pump 1. Make sure that all fluid and air pressures are relieved to the applicator. 2. Flush the black primer from the pump. After flushing the black primer, turn the solvent valve (1) to the off position. 3. Disconnect the air supply line (14) from the fitting (13). 4. Disconnect the connectors (11, 15) from inlet (6) and outlet (10) pressure transducers. 5. Place a suitable waste container under the pump (5). 6. Disconnect the primer supply lines (8, 12) and the solvent lines (4) from the pump (5). 7. Remove the primer supply fitting (7) from the pump (5). 8. Disconnect the connector (3) from the flow rate proximity sensor (2). Remove the flow rate proximity sensor from the pump (5). 9. Remove the screws (9) securing the pump (5) to the mounting plate (16). Install the Pump 1. Install the primer supply fitting (7) onto the pump (5) and tighten securely. 2. Apply Locktite 242 to the threads of the screws (9). Install the pump (5) to the mounting plate (16) using the screws. Tighten the screws to 36 in.-lb (4 N m). 3. Install the proximity sensor (2) onto the pump (5). Make sure that the gap between the face of the proximity sensor (2) and primer spindle button head screw (17) is in ( mm). Tighten the lock nut (18) securely. 4. Connect the connector (3) to the proximity sensor (2). 5. Connect the primer supply lines (8, 12) and solvent lines (4) to the pump (5). 6. Connect the connector (15) to the inlet pressure transducer (6). 7. Connect the connector (11) to the outlet pressure transducer (10). 8. Connect the air supply line (14) to the fitting (13).

13 Flo-Brush PDMP Applicator Tool OFF ON A A in. ( mm) Figure 4 Pump Replacement

14 12 Flo-Brush PDMP Applicator Tool Parts See Figures 5 and 6. To order parts, call the Nordson Customer Service Center or a local Nordson representative INCLUDED WITH ITEM INCLUDED WITH ITEM 32 ORDER SERVICE KIT TO REBUILD MODULE. ORDER SERVICE KIT TO REBUILD MODULE. REFER TO APPLICATION-SPECIFIC PARTS SECTION TO ORDER THIS PART. Figure 5 Flo-Brush Parts

15 Flo-Brush PDMP Applicator Tool 13 Item Part Description Qty Note Applicator, Flo-Brush, Piston Pump S Bracket, mounting, Flo--Brush applicator S Transducer, pressure, flush diaphragm S Nut, 1/4--28 x 1/8 OD tube S Screw, socket, M6 x S Elbow, male, 1/4 tube x 1/8 NPT, PFA S Sensor, proximity, M S Screw, socket, 8-32 x S J--box, 4x 4-pin Eurofast, 12-pin Multifast S Elbow, male, pipe, hyd, 1/8 NPT SS S Bushing, pipe, hyd, 1/4 x 1/8, SS S Valve, 3-way, 1/4 NPT, air actuated S Connector, male, 37, 9/16-18 x 1/4, SS S Tube fitting, connector, swivel, 3/8 tube x 3/8 NPTF, SS S Tee, pipe, hydraulic, 3/8, SS S Ell, male, 37 degree, 3/4-16 x 3/8 NPT, SS S Connector, male, 37 degree, 3/4-16 x 3/8, SS S Connector, male, 1/4 tube x 1/8 NPT S Washer, flat, M, narrow, M6, zinc S Screw, socket, M6 x S Elbow, male, 1/4 tube x 1/8 NPT S Connector, female, 37 degree, 1/2-20 JIC x 1/8 NPT S Valve, check, Swagelok, 1/8 NPT male S Tee, male branch, auto, 1/8, SS S Elbow, male, 1/8 tube x 1/8 NPT PFA S Valve, 2-way, manual, ball, 1/8 NPT S Screw, socket, M6 x S Kit, label, J-block, Flo-Brush applicator S Manifold, clear & black module, felt tube tip S Service kit, module, Classic Blue S Tag S Screw, drive, round, 2 x 0.187, zinc S Module, clean and black, H200, diameter felt nozzle S Not used on this configuration S Screw, socket, M3 x S Nozzle, solvent purge, orifice S Connector, male, 1/8 tube x 1/8 NPT PFA S Adapter, hex, 3/8-24 x 1/8 NPT brass S Cable, 4-pin Micro dc, 18 AWG, 0.5 m 1 A S Cable assembly, 4-pin to 6-pin, 2 conductor, 20-in. 2 A S Tubing, PTFE, 1/4 OD x 1/8 ID 11 IN. A S Tubing, PTFE, 1/16 ID x 1/8 OD 40 IN. A S Strap, cable, , natural S Ferrule, 1/8 OD tube, Tefzel S Screw, button, socket, 3/8-16 x 2.5l S Jelly, petroleum AR S Adhesive, pipe AR S Adhesive, Loctite 242, blue, removable, 50 ml AR S Mounting plate S Pump S Applicator tip S Brush 1 NOTE A: See Figure 6.

16 14 Flo-Brush PDMP Applicator Tool IN IN IN. 11 IN IN INSERT TUBING UNTIL IT BOTTOMS OUT. TYPICAL TUBING AND FERRULE INSTALLATION Figure 6 Cables and Tubing

17 Flo-Brush PDMP Applicator Tool 15 Kits The following kits are available. Part Description Note Kit, rebuild, Classic Blue module A Kit, rebuild, Clean and Black module B NOTE A: Kits contains parts and to rebuild Item 29 shown on Figure 5 B: Kits contains parts to rebuild Item 32 shown on Figure 5 Application-Specific Parts See Figure 5 and the following parts lists. Contact a local Nordson representative to order application-specific parts if necessary. Mounting Plates Pumps Item Part Description S Mounting plate, KAWASAKI ZX S Mounting plate, FANUC 210F S Mounting plate, ABB IRB S Mounting plate, ABB IRB S Mounting plate, NACHI SC S Mounting plate, KUKA KR210 L150 Item Part Description S Pump assembly, metering, cc/rev, calibrated S Pump assembly, metering, cc/rev, calibrated S Pump assembly, metering, cc/rev, calibrated S Pump assembly, metering, cc/rev, calibrated Applicator Tips and Brushes Item Part Description S Tip, applicator S Applicator, felt, 1-in S Brush, applicator, 2-in. roller guide S Brush, applicator, 0.75 d x 0.59 t x orifice S Brush, applicator, 0.50 d x 0.39 t x orifice

18 16 Flo-Brush PDMP Applicator Tool Notes: