ST1 802 Permajector
Contents
1. 1 Part out of location 2 Defective solenoid valve Sol B 3 Slide Advanced Limit Switch LS 2 is out of adjustment 4 Blown fuse or bad relay Page 9 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Service Policy Components such as controls air valves air cylinders limit switches and the hopper motor are all standard parts that can be easily obtained from industrial suppliers Parts for the hopper assembly transmission pump and metering system must be ordered from the Permawick Company Replacement parts for the hopper assembly and metering system will be covered under a 1 year warranty by Permawick Standard and purchased components will be warranted by Permawick for 90 days Warranties will be voided if the damaged assembly has been tampered with It is not recommended that a Permawick customer attempt major repairs to a metering system rotary nozzle unit or the transmission pump assembly Although they rarely require major repair these units usually provide ample warning of impending failure If it is determined that an assembly is in need of remanufacture a replacement can be purchased then return the unit which is damaged to Permawick Machine Division for rebuild and the customer will only be charged for those parts that are required to restore the unit to new condition Ordering Information Permajectors components Permawick Executive Office Phone 810 433 3500 Fax 810 433 1824 32400 Telegraph Roa2. Valve Grease Fitting Breather Vent High Bypass 2 Pressure Relief Line Copper L Air Clutch Sight Gauge Transmission Assembly Page 6 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Metering System The Metering System Assembly controls the amount of Permawick that will enter the endshield cavity during the injection The amount of Permawick to be injected can be regulated by the metering system injection spacers For example a thinner spacer would increase the shot amount of Permawick material injected The top air cylinder 10149 4 on the metering system will locate the injection tooling to the endshield then the bottom air cylinder 10149 9 will lower and make the injection Refer to Sequence of Operation drawing 10240 Holding fixtures are individually designed per application to provide a suitable nest for mating parts to be properly positioned together Usually a rubber seal is used in the nozzle assembly and or the fixture assembly to ensure Permawick is injected in the proper areas and to permit proper bearing contact Check these rubber seals for wear frequently Replacements can be ordered from Permawick Company See the inject tooling assembly drawings for rubber seal part numbers Top Cylinder Bottom Cylinder Inject Spacer Metering Block Permawick return port to Hopper Permawick supply port from Hopper Inject Nozzle Assembly during injection is optiona
3. electrical supply see page 3 Power to supply the Permajector is usually 480 Volts 3 Phase unless a different voltage is specified Ex 380V After power is connected turn the machine on and open the top door to the hopper viewing the stirring paddle rotation direction during MORNING START cycle If the stirring paddle is rotating counter clockwise it will be necessary to switch two of the input supply wires reversing polarity Be sure to turn off the main power disconnect switch first To operate the machine after the MORNING START cycle is complete 1 With no parts on the holding fixture only a towel cycle the machine 3 times Then clean nozzle with air or wipe with a clean towel Do not use the Permawick material that has been shot into the towel it must be disposed of 2 Remove towel and place the designated endshield and associated parts on the holding fixture noting proper orientation see tooling assembly drawing 3 To operate press both CYCLE buttons and hold momentarily then release 4 After the injection is complete remove part from fixture and repeat Page 1 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Machine Setup and Operation If you plan to relocate the Hopper from the Permajector machine or you have purchased a stand alone inject station and Hopper the following are important guidelines to follow Always try to locate the Hopper as close as possible to the Metering System p
4. ERMAJECTOR Electrical Panel Power Input 480 Volt 3 Phase 60 Hz Main Power Disconnect Switch Power ON Starter 115 V Supply Transformer 115 Volt Fuse INPUTS Programmable Logic Controller N OUTPUTS A Motor Starter 1M Overload Reset Page 3 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Controls MORNING START To Cycle the Permajector depress both CYCLE buttons simultaneously then release The anti tie down function in the electrical program will POWER ON prevent the machine from repeating the cycle O POWER OFF MORNING START Amber pushbutton Cycle lasting approximately 2 5 minutes that circulates the Permawick providing even lubricant distribution throughout the material This cycle is recommended to be used after several hours of idle time at the beginning of the shift or when more Permawick is added to the hopper This cycle can be halted by either pressing one of the green cycle buttons or the red stop button Also the amber lamp will illuminate momentarily after each injection indicating the pump is on and turns off when metering system is charged EMPTY CHARGED Indicator lamps Will illuminate to describe the current state the metering system is in If the Metering System is empty the red lamp will be illuminated If the system is charged with Permawick the green lamp will be illuminated indicating it is ready for the next cycle POWER ON Green il
5. Excutive Office Machine Division 255 E Brown Street 3110 Permawick Drive PERMAWI K Birmingham MI 48009 Columbus IN 47201 Phone 248 433 1824 Phone 812 376 0703 Premium Specialty Lubricants Fax 248 433 1824 Fax 812 376 8305 Fax2 248 594 3433 PERMAWICK The Industry Standard for Fractional Horsepower Motor Lubrication Service Manual for the ST 1 802 Permajector SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Ver 1 3 Table of Contents Machine Setup and Operation 1 2 Power Connections Electrical Panel 3 Controls 4 Air System Connections 5 Permawick Hopper 6 Metering System 7 General Preventive Maintenance 8 Troubleshooting Guide 9 Service Policy 10 Seal Chart 11 Standard Cycle 12 13 14 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Machine Setup and Operation Remove the Permajector from shipping crate and place it level on the floor It is not advised to use the shipping skid as a machine base Connect air supply to the Filter Regulator Lubricator see page 5 and maintain approximately 80 to 90 PSI A fitting to adapt to your air system may be required Using at least one bucket of Permawick to start with place the bucket upside down on the floor for 15 to 30 minutes before putting the Permawick in the hopper This will provide even distribution of oil throughout the Permawick material Note Never exceed a total of 2 buckets in the Hopper see max fill level page 6 Connect
6. INITIATED THE SYSTEM IS SUPPLIED WITH A 2 5 MINUTE PUMPING CYCLE MORNING START TO MIX THE PERMAWICK AT SYSTEM START UP AND WHEN NEW MATERIAL IS ADDED TO THE HOPPER Page 12 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Permajector Standard Cycle LS LS non PS 4 LS ug LS 4 LIMIT SWITCH 1 NORMALLY OPEN HELD CLOSED SIGNALS METERING SYSTEM RETURNED LIMIT SWITCH 2 NORMALLY OPEN SIGNALS THAT THE SYSTEM HAS ADVANCED TO THE INJECT POSITION PRESSURE SWITCH NORMALLY OPEN CLOSES ON RISING PRESSURE SHOULD BE SET AS CLOSE TO SYSTEM LINE PRESSURE AS POSSIBLE IT SIGNALS THAT CYLINDER 2 HAS REACHED FULL CLAMPING PRESSURE LIMIT SWITCH 3 NORMALLY OPEN SIGNALS THAT THE INJECTION IS COMPLETE LIMIT SWITCH 4 NORMALLY OPEN HELD CLOSED SIGNALS THAT THE METERING SYSTEM HAS BEEN REFILLED Page 13 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Permajector Standard Cycle Customer Supplied SOL A Outputs 120 VAC 50 60 Hz SOLENOID A CONTROLS CYLINDER 1 WHICH ADVANCES TOOLING TO THE INJECT POSITION IT SHOULD NOT CYCLE UNLESS LS 4 HAS BEEN MADE SOLENOID B CONTROLS CYLINDER 2 CYLINDER 2 DOES THE ACTUAL INJECTION IT SHOULD NOT CYCLE UNTIL LS 2 AND PS 1 ARE MADE SOLENOID C CONTROLS THE AIR CLUTCH ON THE PERMAWICK PUMP AND SHOULD ENERGIZE UPON SYSTEM RETURN LS 2 IS MADE AND DE ENERGIZE 0 5 SECONDS AFTER LS A IS MADE
7. THE PUMP MOTOR SHOULD RUN CONTINUALLY SOL C SHOULD NEVER ENERGIZE UNLESS LS 1 IS CLOSED Page 14
8. d Suite 102 Bingham Farms MI 48025 Technical Support Machine Division Phone 812 376 0703 Fax 812 376 8305 3110 Permawick Drive Columbus IN 47201 Page 10 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Seal Chart 802 Metering System Manville Piston Uneepac Quantity Order Diameter SealNo Description Required in sets 1 9883 Standard 4 4 sets 13691 Flat Bottom 2 15000 C Transmission Assembly Seal Quantity Numbers Description Required Worm Shaft 8700 7 8 2 Auger Shaft 12336 1 1 4 1 Piston 1 1 2 8919 Standard 2 14210 Flat Bottom 1 Rod 1 1 4 9901 Standard 2 14108 Flat Bottom 1 Permawick Equivelant 10149 23 Permawick Equivelant 7308 13 7308 42 7308 27 7308 32 Select the corresponding piston diameter for your metering system When using the Permawick part number specify piston diameter Page 11 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Permajector Standard Cycle METERING SYSTEM IS CHARGED LS 4 IS CLOSED SOL A ENERGIZES ADVANCES TOOLING LS 1 OPENS DISABLING SOL C LS 3 CLOSES PS 1 CLOSES INITIATING INJECTION SOL B PRESSURE SWITCH IS ONLY USED ON THE 800 2 METERING SYSTEM LS 3 CLOSES INJECTION COMPLETE SOL B DE ENERGIZES RETURNING CYLINDER 2 THEN A 0 2 SECOND DWELL SOL A DE ENERGIZES RETURNING CYLINDER 1 LS 1 CLOSES SOL C ENERGIZES AND REMAINS SO UNTIL 0 5 SECONDS AFTER LS 4 CLOSES OR UNTIL CYCLE IS RE
9. l as is a second station to assemble press fit parts Motor Endshield to an endshield Holding Fixture Page 7 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR General Maintenance Overall the Permajector all components included requires minimal maintenance However listed below are some typical maintenance guidelines to follow Hopper Transmission 1 Check the belts for wear and proper tension 2 Grease fitting apply a minimal amount only after rebuilding transmission 3 Inspect tighten the flathead bolts mounting the tie plate to the rod and piston 4 The desired oil level in the transmission can be determined by inspecting the level from the sight glass window In the event that a leak develops use 90W grade gear oil after correcting the leak See page 11 for seal information 5 If the unit requires to be rebuilt remove it from the hopper as follows a Disconnect the Permawick supply line from the right side of the metering block then pump the material if possible from the hopper into an empty yet clean container using the morning start cycle Turn the power off b Loosen the auger bolt and remove the stirring paddle If a hoist is available replace auger bolt with an eyebolt or hook assembly then remove mounting and lower the unit exiting through a side access panel Metering System 1 If the metering block assembly is damaged worn and requires to be rebuilt it is strongly recommended
10. lum pushbutton Push on illuminated when power is on POWER OFF Red pushbutton Push to turn machine off when not in use Page 4 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Air System Supply Filter Regulator Lubricator i Mounting Bracket Sight Glass Lubricator Fill Plug a ounting Bracke Outlet Fitting we Shut off Valve Supply to Machine pply Air Inlet Fitting Disconnect Latch Lubricator Bowl amp Guard Filter Bowl amp Guard ie Regulator Adjustment Manual Flex Drain After connecting your air supply turn the shut off valve to the ON position Proper air pressure 80 90 PSI can be obtained using the regulator adjustment knob WARNING Before performing any maintenance to the F R L turn valve to the OFF position and vent any pressure in the system The Filter unit will seperate contaminated liquids from the air and will collect in the bowl The Bowl can then be cleared of liquids using the Manual Flex Drain by pushing it to one side The Lubricator will continuously supply lubricant throughout the air system Add oil to the Lubricator bowl as needed via the Fill Plug Recommended oil is SAE 10 or similar light oil for air systems Page 5 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Hopper and Transmission Permawick Return x Lines from the Metering Block Stirring Paddle amp Auger Permawick Supply to Metering Block fl Air
11. referably 2 to 4 feet do not exceed 10 feet Long runs can cause pumping and injection problems N Use steel hydraulic tubing 5 8 inch minimum diameter at 042 060 inches thick A high quality steel braided hydraulic hose with Teflon lining could be used for short runs if necessary but is not recommended The hose could deteriorate over time and can cause plugging and injection problems W Minimize the number unions used and number of bends in the tubing Avoid sharp corners when forming the tubing a 3 to 6 inch radii is recommended 4 Avoid using reducers and adapters when possible Never use 90 degree fittings If it becomes necessary to use a reducer and the Permawick is to flow through a smaller diameter you must then chamfer the small diameter at least to match the large diameter to prevent plugging Use the following chart to reference the type of Metering System being utilized Sytem 5 8 dia input line and 5 8 dia return line 3 4 dia input line and 3 4 dia return line 3 4 dia input line and 3 4 dia return lines 3 4 dia input lines and 5 8 dia return lines 5 8 dia input lines and 5 8 dia return lines For 800 2 applications where the hopper is located over 6 feet from the metering system a 3 4 inch return line is recommended On special 800 applications Metering Block porting and Permawick lines may be reduced to 5 8 Page 2 SERVICE MANUAL ST 1 802 SINGLE STATION P
12. that these components be sent to Permawick Machine Division to be remanufactured If only the seals are worn new seals can be ordered from Permawick 2 To remove metering block simply remove limit switches from backplate leave wires connected then remove the metering block assembly and ship it to Permawick Machine Division in a crate Electrical 1 Occasionally inspect the relay and starter contacts CR1 CR2 CRM M1 2 The programmable controller is equipped with an EEPROM memory chip which permanently contains the electrical program Therefore when power is removed from the machine the program will be maintained Page 8 SERVICE MANUAL ST 1 802 SINGLE STATION PERMAJECTOR Troubleshooting Guide I Machine will not cycle or will not complete the cycle A The air supply is not turned on B LS 1 Slide Returned is out of adjustment C Blown fuse or a bad relay D Pump motor starter overload reset is tripped E The red EMPTY lamp is on the green CHARGED lamp is off 1 Pump did not run metering system not charged a The Hopper is out of Permawick b The Charged Limit Switch LS 4 is out of adjustment c Slide Returned Limit Switch LS 1 is out of adjustment II Partial cycle A System lowers and stops will not return 1 Nozzle tooling may be plugged with Permawick material 2 The Inject Advanced Limit Switch LS 3 is out of adjustment B System will not actuate the Inject Cylinder Cyl 2
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