PK1D Service Manual
Contents
1. Fluidic PK1D Service Manual PK1D Service Manual 20140618 This manual should be read and understood prior to installing operating or servicing the PK1D Unit PK1D Service Manual 20140618 Table of Contents UTI Neo M N 4 IMPORTANT SAFETY INFORMA TIO Nos 5 OVervieW at a do 6 1 1 Lolo Vo AAA E D T RO RENNES 6 1 2 Patented Pump TechfiolOBV sssens sederet demtet odes etie Dev a et bsiis 6 1 3 Meterine Unit Features ai ace hi e a E Per e t cir bob cada EU i ia Wien al e EORR IUE eR a dt eta SI MEVS 7 1 3 1 EIMGCE ene SEO Dent T oa 1 3 2 Low Ait Pressure SUC iicasetosssencavseceretgdevenentiianssipedeavetsanvansacteveraty das alei la a atat ei 7 1 3 3 Linear Displacement Pump LDP SysteM ccconocccnnncnnnnccnnnnonanocnnnnnnnnnccnnnononaronnnnonanccnnnnnnanioss 7 1 3 4 Pressure Trans UCSI O 7 1 3 5 Linear tTransdU Cer ioeie A aa 3 al a 7 1 3 6 Pump HUSN V lves Optional ets ia ecient seen 7 Whole gj iaiia RI RE e IE RR N oro 8 Upper CAME e de dee ti ee i citer 9 Regulator Tee Assemblees cu ti D e da ua Rin iau dedu io edi al 10 Upper Cabinete Side cloro lacio 11 Air Solenoid Assembly sec si caccchart a a et 12 Gear BOX aNd Servo MONO rr 13 EOWSI 52 A 14 Back View ot Cabinet dT cem 15 WI St a CONN aoe vac cece SS DTE 16 Scar aaa lati ata ua 17 IIa 18 Accessories A OpLONS eli am laica laica len 18 PK1D Serv2. 20140618 Upper Cabinet Side View DC AirRegulator _ OO7 PR AR 018 00 DD Brass Bulkhead X 005 PR FB 222 Strain Relief 009 PR SR 058 11 PK1D Service Manual 20140618 p 009 PR CP 095 Air Dispense Valve On Off 009 PR BF 012 Tube Fitting 006 PR ME 017 Air Solenoid Assembly A LLS da L i Fig 5 Legend EA Solenoid Right End Cap OO7 PR EC 008 EB Control Block 1 4 OO7 PR CBOO6 EC ControlBlock5 16 007 PR CB 009 24V Solenoid 007 PR SB 010 Air Exchange Block 007 PR AB 007 Solenoid Left End Cap 007 PR EC 004 12 PK1D Service Manual 20140618 Gear Box and Servo Motor 009 PR SM 125 FE Gear Box 10 1 016 MC GB 035 A or B C 20 1 016 MC GB 027 A or B C 23 1 016 MC GB 001 A or B C 60 1 016 MC GB 002 A or B C 13 PK1D Service Manual 20140618 Lower Cabinet Legend Linear Displacement Pump Assembly 100 SA LP 017 009 PR PT 162 ED Inlet Pressure Transducer Block 1 2 003 MT SS 026 A 3 8 003 MT SS 026 B MM 1 4 003 MT SS 026 C 14 PK1D Service Manual 20140618 Back View of Cabinet Fig 8 Legend Part Name Part Number Pressure Transducer 100 SA LS 090 FB Pressure Transducer Block 1 2 003 MT SS 026 A 3 8 003 MT SS 026 B 1 4 003 MT SS 026 C 15 PK1D Service Manual 20140618 Unit Installation 2 1 Grounding The cabinet must be grounded to prevent static and electric shock This is done b
3. ratio and flow rate accuracy to better than 1 They are provided with an Operator Interface Terminal OIT and a Programmable Logic Controller PLC control system for ease of use flexible configuration detailed diagnostics high performance and exceptional reliability 1 2 Patented Pump Technology The fixed ratio metering system is based on a closed loop PLC controlled DC servo drive system coupled to volumetrically efficient Linear Displacement Pumps LDP s The system is accurate and reliable and can be integrated with user PC PLC controls for automation The SPC Closed Loop Control System monitors controls and reports metering parameters such as flow rates pressures and material usage The patented LDP PATENT NO US 6 398 514 B1 is a double acting rod pump with two sets of metering cylinders As one set of cylinders is dispensing the other set is filling When the LDP reciprocates the dispense fill cycle is reversed between the two sets of cylinders The reciprocation happens in milliseconds to provide a continuous material flow In order to maintain the LDP 1 metering accuracy and smooth continuous material flow it is imperative that the material feed pressure input be balanced with the LDP dispense output pressure In short the PK units must be pressure fed from pressure pots or transfer pumps with pressure flow rates respective to the LDP pressure flow rates With a balanced material feed the PLC controlled LDP
4. e readings 3 Based on the pressure reading located the proper nut and loosen it to relieve the pressure re eS 17 PK1D Service Manual 20140618 Maintenance The XV2 Cross Over valves must be greased as well as the cylinder nut reservoirs on the LDP Refer to the Linear Displacement Pump manual 100 SA LP 017 and to the Cross Over manual 100 SA RK 053 065 for maintenance procedures Accessories and Options Foot Switch The Foot Switch hooks up to the trigger connector located on the side of the PK1D unit In shot mode the foot switch needs to be switch on and the system will dispense fluid for the time the operator has set Dispense Valve Hand Gun The Hand Gun hooks to the trigger connector located on the side of the PK1D unit and dispenses the fluid The Gun must be occasionally greased Robotic Interface The Robotic Interface enables the digital robotic input to start stop the pump Light Stack The Light Stack indicates the state of the machine The green light indicates the machine is operational The amber light indicates the machine is in stand by mode The red light indicates there is a fault 18 PK1D Service Manual 20140618
5. ice Manual 20140618 STATIC SHOCK Can cause fire or explosion resulting in severe injury or death Ground metering systems in accordance with all federal state and local regulations HAZARDOUS PRESSURE Sudden pressure release can cause severe injury or death The metering system can remain pressurized when the system is not operation Relieve system pressure before attempting service or adjustments EXPLOSION HAZARD Do not operate a PK electronic control unit in an environment of flammable gases or vapor unless it is equipped with a class division 1 air purge system SAFETY GOGGLES Must be worn at all times while installing servicing operating or observing this equipment Sudden release of air or fluid pressure can cause serious damage to the eyes ELECTROCUTION HAZARD Disconnect power before servicing electrical controls Never defeat electrical safety devices Doing so can cause electrocution resulting in severe injury or death INJECTION HAZARD Any material injected into flesh can cause severe injury or death Keep body parts away from material discharge ports If injection occurs seek medical attention immediately FIRE HAZARD When flammable solvents are used smoking or other ignition sources should be prohibited Provide adequate ventilation to prevent ignitable concentrations of flammable vapors Never allow the temperature of process fluids to reach or exceed their flash points Doing so can cause fire or explos
6. ick way to immediately stop pump operation in the event of an emergency of any kind It does not replace the previously detailed Safety Warning with regards to servicing or maintaining the equipment 1 3 2 Low Air Pressure Switch The PK system is provided with a low air pressure switch in the upper enclosure The switch must see at least 80 PSI in order to operate If the pressure falls below this then the system is disabled 1 3 3 Linear Displacement Pump LDP System Each LDP assembly consists of a Servo drive operating two brushless DC gear motor The gear motor turns a gearbox input shaft and gearbox output shafts turn a screw that moves the LDP The LDP s each have two sets of fluid cylinders that operate in pairs coupled with a four way cross over valve x over such that one set of cylinders is filling while the other is discharging All pump outlets are combined through a static mixing tube or other mixing devices dynamic mixer impingement which mixes the components The action of the Servo drives and cross over valves are fully controlled by the OIT PLC controls 1 3 4 Pressure Transducers Each LDP assembly outlet is provided with a pressure transducers monitored by the OIT PLC controls When the pressure for an active pump reaches the pressure set point all pumps stop The pressure transducers are also monitored for open loop and short circuit conditions 1 3 5 Linear Transducer Each LDP rod pump assembly is provided w
7. ion resulting in severe injury or death PK1D Service Manual 20140618 PINCH HAZARD Moving parts such as LDP s servo motor drives and transfer feed pumps can pinch or amputate your fingers Keep clear of moving parts when the pump is in operation IMPORTANT SAFETY INFORMATION Installation Fluidic Systems equipment should be installed by a qualified manufacturer s representative who can provide instruction on proper safety installation operating and maintenance procedures Operation Always disconnect electrical power and relieve pressure air and fluid before making adjustments or servicing Do not operate equipment if fluids have solidified A blockage in the fluid circuit hoses valves gauge etc can cause immediate damage to the system Before operating check entire system for loose fittings loose fasteners damaged or leaking hoses and air lines Only trained personnel should operate and or service this equipment Material Consult material manufacturer s technical representative or bulletins to determine if their materials are safe to use in this system Consult material manufacturer for safe handling procedure and what precautions are required when exposed to the materials 5 PK1D Service Manual 20140618 Overview 1 1 Introduction The Fluidic Systems PK Dispense and PK Spray units are positive displacement volumetrically accurate plural component metering systems capable of maintaining
8. ith a linear transducer monitored by the OIT PLC controls The linear transducers allow the controls to know the exact positions of the pumps in order to turn it around during normal operation and to provide over travel protection The linear transducers are also monitored for open loop and short circuit conditions 1 3 6 Pump Flush Valves Optional Each LDP rod pump assembly can be provided with a pump flush valve If this feature is enabled through the OIT PLC then the flush valves are pulsed during pump operation 7 PK1D Service Manual 20140618 Whole Unit Fig 1 Legend Part Name Part Number Programmable Logic Control PLC 009 PR TS 212 Emergency Stop Button 009 PR ES 004 Two Node Contact Block 009 PR CB 005 One Node Contact Block 009 PR CB 138 Upper Cabinet None S Lower Cabinet Nome 8 PK1D Service Manual 20140618 Upper Cabinet N B A lo a ooooooooodoooQoooo000004 Pood SE eli POSO AO ejeje ELBA JE a hono a A 00000000900090000000001 POOCOOSTSU LAs BJ e a BL Fig 2 Legend Water Trap Terminal Block MANY 110V Power Plug 009 PR FI 168 9 PK1D Service Manual 20140618 BD MANY 4 Unit Light Stack 009 PR SL 208 3 Unit Light Stack 009 PR SL 207 2 Unit Light Stack 009 PR SL 199 Regulator Tee Assembly JE HH H L e CD CE Fig 3 Brass Bulkhead 005 PR FB 222 Reduced Bushing 005 PR RB 113 009 PR PS 077 10 PK1D Service Manual
9. s provide smooth continuous and virtually pulse free outputs from 5 to 3500 psi Precision flow rates range from 5 cc minute to over 2 gallons per minute The LDP s can meter mix and dispense differential viscosities from water to heavy abrasive pastes The system functions without piston or gear pumps check valves and flow meters The fixed ratio PK units have one LDP for both material components The mix ratio of the components is achieved by the relative size of one pump rod to the other Example for 1 1 volumetric ratio both rods are the same size for 2 1 volumetric ratio one rod will be 1 in dia the other rod will be 0 707 in dia Variable flow rates are achieved by running the LDP slow for low flow rates or fast for higher flow rates To achieve the best performance from this system it is critical that operators understand and use the controls and safety features in the correct manner 6 PK1D Service Manual 20140618 1 3 Metering Unit Features 1 3 1 Emergency Stop The yellow mushroom head push pull button on the top of the PK system is the Emergency Stop button When pressed power to the pump motors is disabled The button must be twisted to re enable power to the pump motors Note that pushing the Emergency Stop button does not disable the OIT or PLC although the PLC monitors the position of the button If the Emergency Stop button is pushed then the PK system is disabled Warning The Emergency Stop is intended as a qu
10. y an escape wire that electrical current due to static build can travel through To ground the cabinet take the grounding clamp at the end of the ground wire and connect it to a true earth ground The other end of the grounding wire is already connected to the cabinet Grounding bands should be worn at all time by anyone who is operating the unit 2 2 Power To give unit power connect chord to 110 or 220 Volt power supply 16 PK1D Service Manual 20140618 Setup Priming the Pump 1 Load material fluid into the transfer pumps or pressure pots Using the touch screen set the flow rate to 30 Open the air valve Set pressure to set point inlet pressure should be about within 10 of outlet pressure Pump will begin to move Open the bleeder valve on transfer pump with a waste cup until air is completely out of material 6 On the LDP upstroke crack the upper hose nut at the cylinder manifold Then close the nut before the down stroke This removes the air from the rest of the system Flushing the Pump 1 Load the transfer pumps or the pressure pots with flushing material 2 Set the air pressure to the pressure set point 3 Connect the outbound hose to the flush inlet fitting 4 Using the touch screen locate the flush page Set the appropriate pump s to be flushed 5 Stop the flushing process when the material is completely out of the system Pressure Relief Procedure 1 Disable the PK unit 2 Check the touch screen to find the pressur
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