Pressure Dump Valve Service Kit for Series 3000 Units

Transcription

1 Instruction Sheet Pressure Dump Valve Service Kit for Series 000 Units. Overview The Nordson pressure dump valve is used to relieve hydraulic pressure instantly in Series 00, 400, 500, and 700 applicator tanks when the unit circuit breaker is turned off. Otherwise, you must trigger one or more guns and open the applicator manifold drain valve to relieve hydraulic pressure. NOTE: The pressure dump valve option cannot be used in units equipped with a : piston pump. The pressure dump valve replaces the standard pressure relief valve, though the pressure dump valve includes the standard pressure relief valve in its assembly. ÎÎ ÎÎÎÎÎÎ ÎÎ Ï ÎÎ ÎÎ 4064 Fig. Main Components of the Pressure Dump Valve Assembly. Standard pressure relief valve mechanism. Pressure dump valve mechanism. Valve screw body

2 Pressure Dump Valve Service Kit. Overview (contd.) There are seven pressure dump valve service kits for Series 000 applicators: Series 00 units without the low level indicator, kit P/N Series 400 units without the low level indicator, kit P/N Series 500 units without the low level indicator, kit P/N 58 Series 700 units without the low level indicator, kit P/N 59 Series 400 units with the low level indicator, kit P/N Series 500 units with the low level indicator, kit P/N Series 700 units with the low level indicator, kit P/N This instruction sheet covers all seven kits. NOTE: The pressure dump valve option cannot be used in units equipped with a : piston pump. The pressure dump valve uses compressed air from the applicator to maintain hydraulic pressure. During normal operation, molten adhesive from the tank flows up the central channel of the valve screw body and into the attached valve body. Compressed air from the applicator forces a piston-stem-ball assembly inside the valve body down against a nozzle seat. This keeps the valve closed, prevents hot melt adhesive from leaving the valve, and maintains system pressure A Fig. Pressure Dump Valve During Normal Operation. Piston (in DOWN position) 4. Hot melt adhesive. Spring 5. Pressure dump valve body. Ball valve (in CLOSED position) 6. Nozzle seat Note: Arrow indicates air flow and downward movement of piston-stem-ball assembly

3 Pressure Dump Valve Service Kit. Overview (contd.) When the applicator circuit breaker is turned off and air pressure is exhausted, the spring-loaded piston-stem-ball assembly is forced up and away from the nozzle seat. This allows molten adhesive in the valve screw body to flow immediately through a central channel in the valve body, out from the bottom of the valve, and into the tank Fig. Pressure Dump Valve with Unit Shut Down. Piston (in UP position) 4. Hot melt adhesive. Spring 5. Pressure dump valve body. Ball valve (in OPEN position) 6. Nozzle seat Note: Arrow indicates air flow and upward movement of piston-stem-ball assembly 4004-A. Installing the Pressure Dump Valve WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in the Safety Instructions section of the applicator manual. The pressure dump valve can be installed on Series 000 applicators with or without Nordson low level indicator kits. Refer to the Nordson product manual as needed when locating components named in the following procedure.

4 4 Pressure Dump Valve Service Kit Required Tools and Materials Flat head screwdriver Open end wrenches Socket wrench Torque wrench New tank gasket and new tank cover gasket (all Series 00 units and all Series 400, 500, and 700 units with the low level indicator kit installed) Replacing the Solenoid. Drain the applicator tank of as much hot melt adhesive as possible.. Switch the applicator circuit breaker OFF, then disconnect and lock out electrical power from the applicator. WARNING: Risk of electrical shock. The applicator contains energized components with potentials that could cause death. Disconnect and lock out input electrical power before continuing with this procedure.. Allow any remaining hot melt adhesive in the tank to cool but not solidify. 4. Use a socket wrench to remove the existing pressure relief valve from the tank. Do not remove the screen from the bottom of the tank. Fig. 4 Existing Pressure Relief Valve Location. Tank. Pressure relief valve 4000

5 Pressure Dump Valve Service Kit 5 Replacing the Solenoid (contd.) 5. Lift and remove the pump enclosure from the applicator. To prevent damage to the pump, do not rock the enclosure back forth during removal Fig. 5 Removing the Pump Enclosure 6. Set the pump air pressure regulator to 0 psi/kpa, then turn off the air supply to the regulator. Fig. 6 Setting the Pump Air Pressure to 0 404

6 6 Pressure Dump Valve Service Kit Replacing the Solenoid (contd.) 7. Disconnect the air line from the elbow fitting on the front of the pump air valve. Then remove and discard the elbow fitting Fig. 7 Disconnecting the Existing Air Line from the Pump Air Valve Elbow Fitting 8. Replace the elbow on the front of the pump air valve with the male tee fitting from this service kit. Thread the leg of the tee fitting into the air valve, then position the tee fitting with the arms horizontal. Fig. 8 Orientation of the Pump Air Valve Tee Fitting. Tee fitting. Pump air valve 4064

7 Pressure Dump Valve Service Kit 7 Replacing the Solenoid (contd.) 9. Remove the electrical enclosure cover and detach the ground wire from its connection on the underside of the cover Fig. 9 Removing the Electrical Enclosure Cover 0. Loosen the captive screws at the top of the front and rear panels until they are free of the control frame assembly.

8 8 Pressure Dump Valve Service Kit Replacing the Solenoid (contd.). Tilt the control frame assembly forward and down to allow working room inside the electrical enclosure Fig. 0 Releasing the Control Frame Assembly. Captive screws. Rear panel. Front panel 4. Control frame assembly. Remove the applicator rear panel and detach the ground wire from its connection on the inside of the panel.

9 Pressure Dump Valve Service Kit 9 Replacing the Solenoid (contd.). Locate the upper elbow connector near the center frame at the rear of the electrical enclosure where the upper solenoid air line attaches Fig. Elbow Connector Locations Inside Electrical Enclosure. Rubber grommet. Air line to pump air valve. Upper elbow connector 4. Air line from input air supply 5. Lower elbow connector 6. Center frame Use an open end wrench to unthread the elbow connector hex nut until the upper solenoid air line is free Fig. Typical Connector and Air Line Details. Connector. Ferrule. Air line 4. Hex nut

10 0 Pressure Dump Valve Service Kit Replacing the Solenoid (contd.) 5. Remove and discard the old pump valve metal air line with its attached elbow connector. Do not remove the rubber grommet from its hole in the center frame. 6. Locate the lower elbow connector near the center frame at the rear of the electrical enclosure where the lower solenoid air line attaches (see Figure ). 7. Use an open end wrench to unthread the lower elbow connector hex nut where the input air line from the regulator attaches until the air line is free. 8. Unplug the solenoid electrical connector from its wiring harness, then remove and discard the solenoid valve and attached air lines. 9. Remove the existing solenoid spacer from the applicator base. If necessary, drill out any rivets that secure the old spacer in place. 0. Use the flat head screws from this kit to secure the new spacer to the new solenoid.. Install new elbow connectors from this service kit in the new solenoid.. Remove the hex nut and ferrule from the new upper elbow connector on the solenoid.. Insert the end of the new solenoid input air line from this service kit through the hex nut, then slide the ferrule onto the end of the air line. See Figure. 4. Align the end of the new solenoid input air line with the elbow connector.

11 Pressure Dump Valve Service Kit Replacing the Solenoid (contd.) 5. Use an open end wrench to tighten the hex nut onto the elbow connector Fig. New Air Line and Solenoid Valve Details. Flat head screws. Spacer. Solenoid 4. Solenoid elbow connectors 5. Input air line to solenoid 6. Output air line from solenoid 7. Output air line elbow connector at center frame 8. Input air line elbow connector at center frame 9. Input air line from regulator 0. Pan head screws. Air line to pump air valve tee connector. Tee fitting. Solenoid electrical connector 6. Attach a new output air line from this service kit to the bottom elbow connector on the solenoid. See figures and. 7. Attach a new elbow connector from this service kit to the other end of the solenoid output air line. See Figures and. 8. On Series 700 units only, remove the existing short / 8 in. air line and coupling from the input air line and replace it with the short 0.5 in. air line and reducer from this kit.

12 Pressure Dump Valve Service Kit Replacing the Solenoid (contd.) 9. Attach a new elbow connector from this service kit to the input air line at the center frame. NOTE: On Series 00, 400, and 500 units, use the existing ferrule and hex nut already on the input air line. On Series 700 units, use the hex nut and ferrule from the new elbow connector installed in step Use the pan head screws from this service kit to secure the new solenoid and spacer assembly to the applicator frame.. Attach the new solenoid input air line to the lower elbow at the rear of the electrical enclosure.. Insert the new metal air valve air line from this service kit through the rubber grommet in the center frame.. Attach this new air line to the upper elbow at the rear of the electrical enclosure as shown in figures and. Do not connect the other end of this metal air line to the air valve tee connector yet. 4. Plug the solenoid electrical connector into its wiring harness inside the electrical enclosure. 5. Check to make sure that all air line connections are tight. 6. Reattach the ground wire to the applicator rear panel, then reinstall the rear panel to the applicator. 7. Swing the control frame assembly up and secure it in place with the captive screws loosened in step Reattach the ground wire to its connector on the underside of the electrical enclosure cover, then reinstall the cover.

13 Pressure Dump Valve Service Kit Replacing the Tank Cover NOTE: This procedure is for all Series 00 units and all Series 400, 500, and 700 units with the low level indicator feature installed. If your Series 400, 500, and 700 unit is not equipped with the low level indicator feature, proceed directly to the Installing the Pressure Dump Valve procedure.. Remove the screws and washers that secure the low level indicator assembly to the tank cover, then carefully lift the low level indicator assembly up and set it nearby on the electrical enclosure cover. Fig. 4 Low Level Indicator Removal. Low level indicator assembly. Screws and washers for low level indicator assembly. Pump pan 406

14 4 Pressure Dump Valve Service Kit Replacing the Tank Cover (contd.). Remove the screws and washers that secure the pump mount to the applicator.. Rotate the pump slightly in a circular motion to break the suction, then pull the pump straight up to disengage the crossover tube from the manifold. Fig. 5 Pump Mounting Screws and Washers Remove the pump pan. 5. Remove the screws that secure the lid assembly, then lift away the lid assembly, tank cover gasket, tank cover, and tank gasket. 6. Replace the tank gasket with a new one from this service kit, then install the replacement tank cover. 7. Replace the tank cover gasket with a new one from this service kit, then reinstall the lid assembly and secure it in place with the screws removed in step Reinstall the pump pan and pump.

15 Pressure Dump Valve Service Kit 5 Replacing the Tank Cover (contd.) 9. Reinstall the low level indicator assembly Fig. 6 Tank and Lid Details. Pump pan. Lid assembly. Tank cover gasket 4. Tank cover 5. Tank gasket 6. Tank Installing the Pressure Dump Valve. Connect the new metal air line to the pump air valve tee fitting arm that faces the rear of the unit.. Ensure that the air line connection is tight.. Power up the unit and allow it to reach application temperature. 4. Apply Never-Seez lubricant to the pressure dump valve threads, then install the pressure dump valve in the existing hole in the tank bottom. 5. Use a socket wrench on the valve screw body hex flats to torque the pressure dump valve to -4 N m (8-0 ft-lb).

16 6 Pressure Dump Valve Service Kit Installing the Pressure Dump Valve (contd.) 6. Position the pressure dump valve so that it is oriented parallel to the front of the tank Fig. 7 Correct Orientation of the Pressure Dump Valve. Pump. Tank opening. Pressure dump valve 7. If your unit does not have a low level indicator, thread the dump valve input air line from this service kit through the hole in the tank cover to the side of the pump, then go to step 7. Otherwise go to step Fig. 8 Dump Valve Air Line Details for Units without Low Level Indicator. Dump valve input air line. Tee fitting. Elbow connector 4. Dump valve 5. Dump valve vent line 6. Hex flats

17 Pressure Dump Valve Service Kit 7 Installing the Pressure Dump Valve (contd.) 8. If your unit does have a low level indicator, thread the dump valve input air line from this service kit through the hole in the tank cover directly in front of the pump. 9. Locate the connector at the top of the pressure dump valve Fig. 9 Dump Valve Air Line Details for Units with Low Level Indicator. Dump valve input air line. Tee fitting. Elbow connector 4. Dump valve 5. Dump valve vent line 6. Hex flats 0. Remove the hex nut and ferrule from the connector.. Insert the end of the air line through the hex nut, then slide the ferrule onto the end of the air line.. Align the end of the air line with the elbow connector on the pressure dump valve.

18 8 Pressure Dump Valve Service Kit Installing the Pressure Dump Valve (contd.). Use an open end wrench to tighten the hex nut onto the elbow connector. Do not overtighten the hex nut Fig. 0 Typical Connector and Air Line Details. Connector. Ferrule. Air line 4. Hex nut 4. Repeat steps 8- to attach the other end of the dump valve input air line to the tee fitting on the pump air valve. 5. Thread the new / 8 inch metal dump valve vent line through the same hole in the tank cover as the air line to the pressure dump valve. 6. Repeat steps 8- to attach this dump valve vent line to the male connector on the side of the valve body inside the tank. Do not overtighten the connector hex nut. 7. Ensure that the dump valve vent line opening is unblocked. 8. Reinstall the pump cover. 9. Fill the tank with adhesive and proceed with normal operation. The pressure dump valve was designed to operate while submerged.

19 Pressure Dump Valve Service Kit 9. Operation The pressure dump valve works automatically. When you switch the applicator circuit breaker ON and set the applicator air pressure at the filter/regulator, air is directed through the solenoid, to the pump air valve, and to the pressure dump valve piston. As long as the applicator circuit breaker is switched ON, system air pressure is maintained and the piston remains in the DOWN position, keeping the valve closed. When you switch the applicator circuit breaker OFF, system air pressure is relieved and the pressure dump valve piston is forced up by the spring. This upward movement by the piston allows the pressure dump valve to open and relieve hydraulic pressure inside the manifold. A backup pressure relief valve in the pressure dump valve mounting stem automatically vents material through a hole in the side of the valve if the hydraulic pressure exceeds,600 psi (,0 kpa). 4. Maintenance No periodic maintenance is required. The pressure dump valve requires service only if: the valve fails to relieve hydraulic pressure when the applicator circuit breaker is switched OFF the valve fails to close and hold hydraulic pressure during normal operation In either case, contact your Nordson representative for the items required to properly repair the pressure dump valve.

20 0 Pressure Dump Valve Service Kit 5. Troubleshooting To check for hydraulic pressure, trigger a gun and check for hot melt material output. If the unit had been operating correctly prior to installation of the pressure dump valve, but has little or no hydraulic pressure now, the probable cause is either the pressure dump valve itself or one of its components. Problem Possible Cause Corrective Action Refer to No or little adhesive output due to insufficient hydraulic pressure Not enough air pressure to keep pressure dump valve piston in DOWN position Pressure dump valve incorrectly installed in tank Ensure that the input air pressure is set correctly Review the pressure dump valve installation steps Series 000 manual Installing the Pressure Dump Valve procedure in this publication Loose air line connections Review air line installation steps Replacing the Solenoid and Installing the Pressure Dump Valve procedures in this publication Faulty pressure dump valve Replace the pressure dump valve Removing the Pressure Dump Valve and Installing the Pressure Dump Valve procedures in this publication

21 Pressure Dump Valve Service Kit 6. Removing the Pressure Dump Valve Complete this procedure if the pressure dump valve must be removed for any reason.. Drain the applicator tank of as much hot melt adhesive as possible.. Switch the applicator circuit breaker OFF, then disconnect and lock out electrical power from the applicator. WARNING: Risk of electrical shock. The applicator contains energized components with potentials that could cause death. Disconnect and lock out input power before continuing with this procedure.. Allow any remaining hot melt adhesive in the tank to cool but not solidify. 4. Remove the pump enclosure. To prevent damage to the pump, do not rock the enclosure back and forth. 5. Set the pump air pressure regulator to 0 psi/kpa, then turn off the air supply to the regulator. 6. Disconnect and remove the dump valve vent line from the male connector on the side of the pressure dump valve body. 7. Disconnect the input air line from the male elbow connector at the top of the valve body. 8. Disconnect the other end of this air line from the air control valve tee fitting.

22 Pressure Dump Valve Service Kit 6. Removing the Pressure Dump Valve (contd.) 9. Use a socket wrench on the valve screw body hex flats to remove the pressure dump valve from the tank bottom Fig. Dump Valve Air Line Details (Typical). Dump valve input air line. Tee fitting. Male elbow connector 4. Dump valve 5. Dump valve vent line 6. Hex flats

23 Pressure Dump Valve Service Kit 7. Illustrated Parts Lists Item Number Column The number in the Item column is the number assigned to the part in the accompanying illustration. Part Number Column The six-digit number in the Part column is the Nordson Corporation part number assigned to that part. Description Column The Description column gives the Nordson Corporation name of the part, along with its dimensions and other physical properties, where appropriate. Quantity Column The number in this column is the quantity required per unit or assembly. A dash appears in this column for o-ring lubricant because it is applied directly to o-rings. Note Column A letter in the Note column refers to a note at the end of the parts list which gives additional information about the part.

24 4 Pressure Dump Valve Service Kit Pressure Dump Valve Service Kits Parts List Service kit P/N applies to all Series 00 units. Service kit P/N applies to all Series 400 units without the Low Level Indicator, service kit P/N 58 applies to all Series 500 units without the Low Level Indicator, and service kit P/N 59 applies to all Series 700 units without the Low Level Indicator. Item Part Description Quantity Note Spacer, Solenoid, Dump Valve Solenoid with Wiring, Pressure Dump Valve Connector, Elbow, Male, / 4 Tube x / 8 NPT Screw, Flat, 0- x 0.50 in Screw, Pan Head, Slotted, M4 x mm Air Line, Metal A Air Line, Metal B Fitting, Tee, Male Branch, Brass, / 4 x / Air Line, Metal, Series 00 C 9 49 Air Line, Metal, Series 400 C 9 60 Air Line, Metal, Series 500 C Air Line, Metal, Series 700 C Air Line, Metal D Air Line, Metal E Connector, Elbow, Male, Stainless Steel, / 4 x 7 / Connector, Male, / 8 x / 6 NPT 4 7 Valve Assembly, Pressure Dump F Cover, Tank, Series 00, Pressure Dump Valve G Gasket, Tank, Series 00 G 7 88 Gasket, Tank Cover, Series 00 G Connector, Elbow, / 4 Tube 9 5 Tube Connector, 0.5 in. OD, Series Union, Reducing, in. OD, Series Lubricant, Never-Seez NOTE A: Input air line to solenoid on all units B: Air line from solenoid on all units C: Air line to pump tee fitting on all units D: Air line to dump valve on all units E: Dump valve vent line on all units F: See separate parts list and illustration G: Series 00 units only

25 Pressure Dump Valve Service Kit Fig. Pressure Dump Valve Service Kit for All Series 00 Units and Series 400, 500, and 700 Units without Low Level Indicator 40648

26 6 Pressure Dump Valve Service Kit Pressure Dump Valve Service Kits Parts List Service kit P/N applies to all Series 400 units with the Low Level Indicator, service kit P/N applies to all Series 500 units with the Low Level Indicator, and service kit P/N applies to all Series 700 units with the Low Level Indicator. Item Part Description Quantity Note Spacer, Solenoid, Dump Valve Solenoid with Wiring, Pressure Dump Valve Connector, Elbow, Male, / 4 Tube x / 8 NPT Screw, Flat, 0- x 0.50 in Screw, Pan Head, Slotted, M4 x mm Air Line, Metal A Air Line, Metal B Fitting, Tee, Male Branch, Brass, / 4 x / Air Line, Metal, Series 400 C 9 60 Air Line, Metal, Series 500 C Air Line, Metal, Series 700 C Air Line, Metal D Air Line, Metal E Connector, Elbow, Male, Stainless Steel, / 4 x 7 / Connector, Male, / 8 x / 6 NPT 4 7 Valve Assembly, Pressure Dump F Cover, Tank, Series 400, Pressure Dump Valve Cover, Tank, Series 500, Pressure Dump Valve Cover, Tank, Series 700, Pressure Dump Valve Gasket, Tank, Series Gasket, Tank, Series Gasket, Tank, Series Gasket, Cover, Tank, Series Gasket, Cover, Tank, Series Gasket, Cover, Tank, Series Connector, Elbow, / 4 Tube 9 5 Tube Connector, 0.5 in. OD, Series Union, Reducing, in. OD, Series Lubricant, Never-Seez

27 Pressure Dump Valve Service Kit 7 NOTE A: Input air line to solenoid on all units B: Air line from solenoid on all units C: Air line to pump tee fitting on all units D: Air line to dump valve on all units E: Dump valve vent line on all units F: See separate parts list and illustration Fig. Pressure Dump Valve Service Kit for all Series 400, 500, and 700 Units with Low Level Indicator

28 8 Pressure Dump Valve Service Kit Pressure Dump Valve Parts List (P/N 7 ) Item Part Description Quantity Note 900 Lubricant, O-Ring Seal, Spring, / 8 x 7 / 6 x / PTFE Spring, Compression Body, Valve, Pressure Dump Cap, Valve, Pressure Dump Screw, Valve, Pressure Dump Block, Pivot, Valve, Pressure Dump 8 7 Spring, Compression Needle w/piston, H00 0 Not Used Not Used 76 5 Seat w/carbide, H Seal, Hat, Unformed Ball Screw, Adjustment O-Ring, Viton, / 4 in. ID x / 6 in O-Ring, Viton, / 8 in. ID x / 6 in O-Ring, Viton, 7 / 6 in. ID x / 6 in O-Ring, Viton, 5 / 6 in. ID x / 6 in Screw, Slotted, Oval Head Screw, Cap, Socket Head Screw, Cap, Socket Head 98 0 Disc, Seal Support Ring, Retaining, External Retaining Ring, Internal, Push-on Spring, Compression

29 Pressure Dump Valve Service Kit 9 5 A A ÎÎ ÎÎ ÎÎ ÎÎÏ ÎÎÎÎÎÎ ÎÏ ÎÎ ÎÎ ÎÎÏ ÎÎ ÎÎÏ ÎÎÏ ÎÎÎ ÎÎÎÎ ÎÎÏ ÎÎÎÎ Ï ÎÎ Ï ÎÎ Ï Ï Ï Ï 0 7 Ï Ï Ï Ï Ï B Fig. 4 Pressure Dump Valve

30 0 Pressure Dump Valve Service Kit Nordson and the Nordson logo are registered trademarks of Nordson Corporation.