eco-SPRAY - preeflow

Micro
spray system
Commissioning and
maintenance instructions
eco-SPRAY
Artikelnummer 21504 Druck 22.1.16
eco-SPRAY
Commissioning and maintenance instructions
Contents
1
2
3
4
5
These instructions
5
The dispenser
5
2.1
2.2
6
6
Safety
7
Connection options
7
Initial commissioning
8
5.1
5.2
5.3
6
7
8
9
10
11
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Spray head combinations
Retrofitting the spray head
Inserting the stator
Making the electrical connection
Supplying and bleeding the medium
8
10
11
Operation
12
Cleaning
12
Spare parts
15
Maintenance
17
9.1
9.2
17
17
Changing the stator
Troubleshooting
Disposal
18
Technical specifications
18
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eco-SPRAY
Commissioning and maintenance instructions
4 / 19
Version 1.0
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eco-SPRAY
Commissioning and maintenance instructions
1
These instructions
Dear customer,
These instructions form part of the operating and maintenance instructions for the dosing
system eco-CONTROL EC200.
The operating and maintenance instructions must have been read and understood in full
before commissioning or carrying out maintenance work on the eco-SPRAY.
2
The dispenser
The dispenser is supplied with these components and accessories:
B
A
C
D
E
F
H
G
Fig. 1
A
Dispenser with drive
B
Assembly aid
C
Nozzle mounting tool
D
Stator
E
3x precision dosing needles*
F
3x air caps*
G
Screwdriver
H
Allen wrench
*1 unit pre-mounted
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eco-SPRAY
Commissioning and maintenance instructions
Spray head combinations
We recommend selecting the air cap (B)
with the corresponding precision dosing
needle (A) depending on the medium
viscosity.
A
0,3
0,2
1,45
0,5
B
1,7
ig
h
The appropriate combination must be
selected and tested separately for each
application (viscosity, dosing quantity/
time and temperature).
Vi
sc
os
ity
Lo
w
2.1
H
2,0
Fig. 2
2.2
Retrofitting the spray head
• Undo the union ring (2)
• Remove the air cap (29). The seal (30) remains either in the spray head or stuck to the
air cap (29)
• Carefully attach the nozzle mounting tool (31) to the precision dosing needle (28),
unscrew the precision dosing needle and replace it with another one
• Attach an air cap (29) and re-tighten the union ring (2)
31
10
3
30
28
29
2
Fig. 3
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eco-SPRAY
Commissioning and maintenance instructions
3
Safety
All instructions in the Safety section of the maintenance and operating instructions for the
dosing system must be complied with and implemented.
4
Connection options
Supply of the medium from a cartridge (A) or a bottle (B).
D Power supply drive unit
E Controlled compressed air
F Heating (optional)
G Dosing control
H Compressed air control
J Compressed air connection
K Power supply
L External control (start/stop)
F
D
E
B
A
L
J
G
M
H
L
K
Fig. 4
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eco-SPRAY
Commissioning and maintenance instructions
5
Initial commissioning
Dispenser Do not switch on until medium has been delivered. Otherwise there is a risk
of damage to the equipment. Even a brief period of dry running can lead to the
stator being destroyed.
5.1
Inserting the stator
• Switch off the dosing control
• Unplug the power supply from the drive unit
• Undo the union ring (2)
• Remove the air cap (29). The seal (30) remains either in the spray head or stuck to the
air cap (29)
• Carefully attach the nozzle mounting tool (31) to the precision dosing needle (28) and
unscrew the precision dosing needle
• Unscrew the screws (8) and remove the air housing
31
10
30
3
8
28
29
2
Fig. 5
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eco-SPRAY
Commissioning and maintenance instructions
• Unscrew the screws (18) and remove the end piece (27)
• Loosen the grub screws (14) by approximately three rotations and remove the drive
unit (11) from the pump housing (10)
• Attach the star-shaped coupling (5) to the assembly aid (6)
14
5
10
11
14
6
27
18
Fig. 6
• Dock the assembly aid (6) with the star-shaped coupling (5) on the dispenser
housing (10)
• Turn the stator (7) on the rotor (4) – which is wet with medium – until the dowel pin (8)
begins to dip into the keyway (9)
• Lightly press the stator in the direction of the dispenser housing (10) and turn the
assembly aid (6) in the direction of the arrow until the stator has been guided into the
dispenser housing
6
5
10
Medium
9
7
8
4
Fig. 7
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eco-SPRAY
Commissioning and maintenance instructions
• Uncouple the assembly aid and re-attach the star-shaped coupling (5) to the drive
unit (11).
• Insert the drive unit (11) into the dispenser housing (10). Ensure that the anti-rotation
lock (A) is positioned within the designated recess in the dispenser housing (10)
• Tighten both grub screws (14) and secure the end piece (27) with the screws (18).
Ensure that the anti-rotation lock (B) is positioned within the designated recess in the
end piece (27)
14
10
11
5
A
27
18
14
B
Fig. 8
• Attach the air housing and precision dosing needle. Follow the steps in the reverse
order to the process shown in Fig. 5
5.2
Making the electrical connection
Connect the eco-CONTROL EC200 dosing control and eco-CONTROL SC1200 control
unit according to their respective operating and maintenance instructions.
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eco-SPRAY
Commissioning and maintenance instructions
5.3
Supplying and bleeding the medium
Follow the safety stipulations and instructions of the manufacturer of the medium
to be used to fill the unit. If applicable, use the required protective equipment. If
the medium is being conveyed for the first time, there is a danger from medium
spurting out. Air bubbles can cause uncontrollable spurting out. Ensure that you stand
back a safe distance.
• Connect the tank (supply line, cartridge) of the
medium to the dispenser medium (A)
• Connect the transparent hose (2) (with an inner
diameter of 4 mm) to the bleed valve (23)
• Pressurise the medium
23
• Slowly open the bleed valve (23) by
approximately half a turn until the medium
escapes without bubbles
2
A
• Close the bleed valve and remove the hose
Fig. 9
Tip Ensure the hose in use is sufficiently long (approx. 20 cm) and capable of holding the
entire medium required for the bleeding process. You can then dispose of this
conveniently at the end of the process.
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eco-SPRAY
Commissioning and maintenance instructions
6
Operation
Operation takes place according to the operating and maintenance instructions using the
eco-CONTROL EC200 dosing control and eco-CONTROL SC1200 control unit.
7
Cleaning
Follow the safety stipulations and instructions of the manufacturer of the medium
to be used to fill the unit. If applicable, use the required protective equipment. If
the medium is being conveyed for the first time, there is a danger from medium
spurting out. Air bubbles can cause uncontrollable spurting out. Ensure that you stand
back a safe distance.
• Switch off and disconnect the power supply from the drive unit and remove the medium
supply
• Dismantle the dispenser as outlined in section 5.1, Fig. 5 and Fig. 6
• Unscrew the valve attachment (32) for the bleed valve (23)
10
32
23
Fig. 10
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eco-SPRAY
Commissioning and maintenance instructions
• Dock the assembly aid (6) with the star-shaped coupling (5) on the dispenser
housing (10)
• Turn the assembly aid (6) in the direction of the arrow. The stator (7) will be pushed so
far out of the dispenser housing (10) by the rotor assembly (4) that the dowel pin (8) is
no longer in the groove (9)
• Uncouple the assembly aid (6) from the dispenser housing (10) and completely remove
the stator (7) from the rotor assembly (4) by turning and pulling
6
10
5
9
7
8
4
Fig. 11
• Unscrew four screws (26) and pull off the pump housing (19) from the bearing
housing (13)
26
19
26
13
23
Fig. 12
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eco-SPRAY
Commissioning and maintenance instructions
• Unscrew two screws (4) and pull off the sealing kit with housing (25) from the bearing
housing (13)
4
25
4
13
Fig. 13
Note Do not rinse out the bearing housing (13), as that could damage the bearings! Clean
it with a cloth and brush.
Assembly
Assembly takes place in reverse order to the process described above.
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eco-SPRAY
Commissioning and maintenance instructions
8
Spare parts
5
9
26
4
11
30
14
13
24
25
21
14
33
19
23
34
7
27
6
18
30
22
3
8
28
29
2
31
Fig. 14
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eco-SPRAY
Commissioning and maintenance instructions
Item Part No. x Item name
21500
Combi package comprising part no.: 21448, 20120
,21499
21448
eco-SPRAY dispenser
20120
eco-CONTROL EC200-K dosing control, compl.
21499
eco-CONTROL SC1200 control unit
21447
eco-SPRAY dosing unit, compl.
2
21374
eco-SPRAY union ring
A2
3
21373
Air housing spray
A2
4
20250
5
20050
6
20108
7
20001
8
20828
M3 Allen screw
9
20784
Connection cable for drive unit 300/450/600/700
M3 Allen screw
x Star-shaped coupling
Elastomer
Assembly aid / tool
Aluminium
x Stator, compl.
VisChem
11
21449
x eco-SPRAY drive unit, compl.
13
21507
x Bearing housing with eco-SPRAY rotor assembly, compl.
14
20029
Set screw
18
20828
M3 Allen screw
19
21501
21
20011
x R 13 O-ring
FKM
x R 15 O-ring
FKM
eco-SPRAY pump housing
A2
22
20084
23
21464
24
20007
x R 16 O-ring
25
21508
x Sealing chamber with eco-SPRAY housing
26
20585
M3 Allen screw
27
21411
eco-SPRAY end piece
28
21455
x Conical precision dosing needle ø 0.2 mm
A2
21454
x Conical precision dosing needle ø 0.3 mm
A2
21453
x Conical precision dosing needle ø 0.5 mm
29
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Material
21378
Bleed valve with M5 nipple, shortened
FKM
eco-SPRAY air cap ø 1.45
A2
A2
A2
21379
eco-SPRAY air cap ø 1.7
A2
21380
eco-SPRAY air cap ø 2.0
A2
30
21460
31
21291
x R 11 O-ring
Nozzle mounting tool for precision nozzles
FKM
20204
Electronic screwdriver, 2.5
Version 1.0
A2
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eco-SPRAY
Commissioning and maintenance instructions
20203
Allen wrench, 1.5
20366
3m6 dowel pin
34
120308
Push-in L fitting
33
21502
Blanking plate for eco-SPRAY heating assembly
A2
x = recommended spare parts and wearing parts
Other precision dosing needles and air caps available on request
9
9.1
Maintenance
Changing the stator
• Remove the defective stator (see description for Fig. 11 on page 13)
• Install the new stator (see “Assembly” in section 7, Cleaning,, page 12)
9.2
Troubleshooting
Fault
No or too little
medium conveyed
Possible cause
Action
Blockage in precision dosing
needle
Clean/replace the needle
Medium hardened
Clean Dispenser
Precision dosing needle and/or Use another precision dosing
air cap not suitable for the
needle profile and/or air cap.
medium, output and/or air
Change the speed / flow rate
pressure
Stator swollen
Replace the stator
Inadequate supply of medium
Supply the medium, check the
hose, check the primary pressure
and increase it if necessary
Motor not connected
Connect the motor
Sucking back not set correctly
Set the sucking back
Dripping / running on of the Air bubbles in the medium
medium
Medium compressible
Follow-up spray time too short
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Version 1.0
Bleed the medium
Degas the medium
Increase follow-up spray time
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eco-SPRAY
Commissioning and maintenance instructions
10
Disposal
Dispose of the Dispenser in an environmentally safe way. All materials and
products left in containers must be treated in accordance with the appropriate
recycling requirements.
Electrical components must not be disposed of together with household waste.
They must be taken to the collection points provided for this purpose.
2002/96/EC – EU Directive on waste electrical and electronic equipment (WEEE)
11
Technical specifications
General
Dimensions
Weight
Heating
Operating conditions
Storage conditions
Repeat accuracy
Maximum dosing pressure
Self-sealing a)
Parts touched by medium
Seals
Motor
General
Dosing volume, approx.
Length 228 mm, ø 35 mm
Approx. 510 g
Optional
+10°C to +40°C (ambient temperature), air pressure 1 bar
Dry / dust free -10°C to +40°C
> 99%
16 to 20 bar
Approx. 2 bar (reference medium approx. 10 mPas at 20°C)
HD-POM / stainless steel / PEEK
High-molecular PE, VisChem
18 to 24 V DC, incremental encoder, planetary gear
0,05 ml/rotation
Volume flow b)
Medium
Connection
Temperature
Pressure
Viscosity
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0.5 to 6.0 ml/min
1/8"cylindrical Whitworth pipe thread DIN/ISO 228
+10°C to +40°C
0 bar, with self-levelling liquid/ max. 6 bar
Low to high viscosity
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eco-SPRAY
Commissioning and maintenance instructions
Spray head
Connection
Hose connection, outer diameter 4 mm
(M5 process connection)
0.1 to 6 bar
Dust free, oil free, dehumidified
Over 100 cycles/min
Nozzle diameter: 0.2 mm, 0.3 mm, 0.5 mm
Circular jet (variable)
15 to 30°
50 µl
Pressure of the atomiser air
Quality of the atomiser air
Switching frequency
Precision dosing needle
Spray pattern
Spray angle
Minimum spray amount
Spray accuracy c)
Spray amount ±1%
a)
Max. dosing pressure and self-sealing decrease with decreasing viscosity and increase
with increasing viscosity. Consult manufacturer
b)
Volume flow dependent on viscosity and primary pressure
c)
Volumetric dosing as absolute deviation relative to one dispenser rotation. Depending on
the viscosity of the dosing medium
Materials used
Dispenserhousing, spray head
A2
Shaft sealing rings
Z80
Motor housing
Anodized
aluminium
O-rings
FKM
Screws, washers, etc.
A2
Drive shaft, rotor
A4
Stator elastomer, flexible shaft covering VisChem
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