ViscoTec preeflow eco-DUOMIX450, Operation & Maintenance Manual

Page 1: ...OPERATION MAINTENANCE MANUAL eco DUOMIX450 ...

Page 2: ...nsport and storage 11 3 Product description 12 4 Operation 13 4 1 Initial commissioning 13 4 1 1 Dismantling the dispenser 13 4 1 2 Installing the stator 15 4 1 3 Reassembling the dispenser 16 4 1 4 Connecting the dosing unit to the drive unit 17 4 1 5 Mounting sensors for monitoring dosing pressure 18 4 1 6 Feeding material and bleeding the dispenser for the first time 19 4 1 7 Calibration 20 4 2...

Page 3: ...5 3 Stator change 26 5 4 Dismantling before cleaning 27 6 Cleaning 28 7 Spare parts 29 7 1 Item list of the spare parts 29 7 2 Overview drawing of the spare parts 31 8 Technical specifications 32 8 1 Installation declaration 32 8 2 Technical data 33 8 3 Materials used 34 8 4 Dimensions 34 9 Disposal 35 10 Accessories 35 ...

Page 4: ...50 dispenser is described in this operation manual A separate operation and maintenance manual is enclosed with the dosing control unit 1 1 Delivery package The scope of supply includes 1 dosing unit A 2 stators B 2 eco PEN450 drive units C 1 drive unit for eco DUOMIX mixer D 1 assembly aid E 3 screwdrivers F 1 Allen wrench G 1 combination tool H 1 calibration adapter I 1 mounting kit 2 back plate...

Page 5: ...ust not be put into operation Check the delivery immediately on receipt for damage in transit and damage to the packaging Check that the delivery is complete according to the enclosed delivery note Make sure you have not left any part of the delivery in the packaging Compensation for damage during transport may be claimed only if the carrier is notified immediately INTRODUCTION ...

Page 6: ...e to a component in a figure the part has a key number Work step List Fig 1 Legend number reference to a figure Reference to a comment COMMAND Designations of buttons switches menu items and input dialogs DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided may result in death or serious inju...

Page 7: ...aused by failure to observe this operation manual or due to a lack of maintenance or checks Misuse Any use other than the stipulated intended use shall be considered as misuse This includes use outside the permissible operating limits use in explosive environments use underground use outdoors Misuse also includes the following actions carried out without the explicit written approval of the manufa...

Page 8: ... a regular basis at least once a year Training shall be conducted after any technical modifications 2 3 2 Maintenance staff The maintenance and repair staff must be authorised and adequately trained for the relevant activities familiar with and comply with the applicable technical rules and safety regulations Competent personnel are persons who by virtue of their training experience and knowledge ...

Page 9: ...the dispenser occurs the direction of rotation of the drive is always the same as the direction of flow of the dispenser the specifications in the product data sheet for the material are observed and adhered to 2 6 Organisational safety measures The necessary personal protective equipment must be provided by the operating organisation Personal protective equipment must be worn when carrying out al...

Page 10: ...material WARNING Risk of injury from moving components The machine is driven by an electrical drive unit These generate very high forces Touching the components during operation may result in serious injuries Do not operate the machine unless there is unrestricted visual contact with the moving component There must be no persons or foreign objects in the danger area WARNING Pressurised material De...

Page 11: ...e environment For storage always remove the stator and store separately at 15 20 C CAUTION Splashing material During initial commissioning and after being refilled air bubbles in the material could cause an uncontrollable spraying from the conveying area This may result in injury Always wear appropriate protective equipment Fully bleed the system before start of production CAUTION Pointed dosing n...

Page 12: ...ting inside the stator The rotor also moves radially within the stator The conveying spaces move forward continuously due to the movement The flexible shaft used to drive the rotor compensates for the eccentric movement of the rotor and is completely maintenance free The sealing effect of the conveying elements of the dispenser is dependent on the viscosity and pressure Since the direction of flow...

Page 13: ...ered the stator is not installed so as to avoid bearing damage to the elastomer of the stator 4 1 1 Dismantling the dispenser Unscrew clamping sleeve 26 with combination tool 42 Remove the 2 screws 24 Remove locking plate 23 and flat gasket 22 Remove the 4 screws 13 Remove bearing housing for mixer 14 13 14 26 24 23 22 S 1 2 3 4 5 S12345 42 Fig 2 OPERATION ...

Page 14: ... 18 19 During assembly grease seals with suitable lubricant e g OKS 469 Do not use silicone Pull out sliding bushing 16 and mixer shaft 15 Remove the 4 screws 27 Remove mounting plate 28 Separate the dispenser halves Fig 3 15 16 S 1 2 3 4 5 20 21 18 19 Fig 4 27 28 S 1 2 3 4 5 S12345 OPERATION ...

Page 15: ... the rotor 37 with material or a suitable lubricant Screw the stator 5 onto the rotor 37 with the correct orientation until the rotor assembly 38 begins to dip into the groove 39 Lightly press the stator towards the pump housing 3 and turn the assembly aid 35 in the direction of the arrow until the stator 5 has been guided into the pump housing 3 Uncouple the assembly aid 35 6B 7 S 1 2 3 4 5 Fig 5...

Page 16: ... order When doing this observe the following Only tighten up the screw 7 very slightly Assemble the halves of the dispenser Mount dosing head 20 with screws 21 Tighten screws 7 using the holes in the dosing head 20 NOTE Do not exceed a tightening torque of 0 35 Nm when mounting the screws Fig 7 6B 7 S 1 2 3 4 5 21 21 7 S 1 2 3 4 5 S12345 20 Fig 8 OPERATION ...

Page 17: ... the coupling of the drive unit Set the anti rotation device 40 in the correct position relative to the dispenser Join dispenser and the drive unit together completely Observe the respective engraving on the drive unit eco PEN450 eco DUOMIX Lightly screw in the set screws 29 the drive unit is centred in the correct position S 1 2 3 4 5 S12345 e c o P E N 4 5 0 eco PEN450 eco DUOMIX 29 40 29 30 eco...

Page 18: ...n the sensors 41 Mount the sensors 41 together with the seal 8 using the supplied combination tool 42 so that they are hand tight NOTE The sensor cables must not be twisted during assembly The surface of the sensors 41 is extremely sensitive Do not bring into contact with sharp objects S 1 2 3 4 5 S12345 8 41 41 e c o P E N 4 5 0 eco DUOMIX eco PEN450 9 Fig 10 OPERATION ...

Page 19: ...ed with the material When filling for the first time the blocking medium is first removed from inside the dispenser stator Pressurise the material Connect the drive unit to the power supply and run it slowly until material escapes from the calibration adapter 36 without bubbles Unscrew the bleed screw 12 and sealing washer 8 to bleed Tighten the bleed screw 12 and the sealing washer 8 again Remove...

Page 20: ...or this Check whether both components escape without bubbles and that the outlet opening are not blocked or stuck together Check the dosing quantity of each of the two components in order to guarantee a consistent dosing result If there are deviations dosing must be calibrated The exact procedure can be found in the dosing control unit manual The result of the check must be recorded together with ...

Page 21: ...ucial factor in the result Suck back with dual component materials Suck back ensures a clean thread break If it is set too large already mixed material enters the dosing pumps causing them to react with each other The max suck back volume is saved in the dosing control unit Note the pot life During breaks in work purge shots prevent the mixed materials from hardening in the mixing capsule In the m...

Page 22: ...ean connection thread for mixing capsule and holes outlet openings Ensure that the two components are not mixed Hold the mixing head downwards and purge bores A and B individually Catch any material leakage and clean the mixing head again Ensure that the two components are not mixed Use separate cloths Switch off material supply to the dosing pump Switch off dosing control unit and secure it again...

Page 23: ...e drive units Disconnect the dispenser and drive unit Remove dispenser from holder or system Remove the stator clean and store separately Disassemble and clean dispenser Store dispenser according to the storage conditions as described in Section 2 8 Transport and storage page 11 4 6 Re commissioning Re commissioning is the same as initial commissioning The same specifications and work steps apply ...

Page 24: ...red change cycles may differ from the recommended cycles Ambient conditions such as temperature and humidity may affect the change cycles WARNING Maintenance and cleaning work may only be carried out when the machine has been shut down safely and secured against unauthorised restarting Otherwise serious injuries may result Switch off the dosing control unit Disconnect the dosing control unit s pow...

Page 25: ...f the stator to the material and replace stator Revolution too low Correct revolution Inadequate supply of material Feed material check inlet pressure and correct if required Material not mixed sufficiently e g streaks Mixer not switched on Switch on mixer Speed of the mixer too low Increase speed Mixing capsule has hardened Replace mixing capsule Dripping or running on of material Suck back not s...

Page 26: ...essure via bleed screw Remove material supply and seal openings with suitable plug Disconnect the dispenser and drive unit Remove dispenser from holder or system Disassemble the dispenser as described in Section 4 1 1 page 13 On both dispenser halves perform Plug the star shaped coupling 30 into the bearing housing 1 Fit assembly aid 35 onto bearing housing Unscrew stator 5 with assembly aid 35 As...

Page 27: ...staff Preparation Remove the stator as described in Section 5 3 page 26 Removing the rotor assembly Unscrew the bleed screw 12 with washer 8 Remove the 4 screws 4 Remove the pump housing 3 and O ring 2 Assembly After cleaning the dispenser is assembled in reverse order NOTE Do not purge the bearing housing 33 and the seal housing 31 This can damage the bearings Clean it only with a cloth and brush...

Page 28: ...in the pump must be checked before use The cleaning agent must be used according to the manufacturer s specifications e g application time Cleaning agents must not penetrate electrical or mechanical system components Do not use high pressure cleaners for cleaning Completely remove cleaning agent again Dispose of cleaning agent properly Re attach any protective and safety devices or cladding remove...

Page 29: ...MIX450 complete with drive 22059 Drive unit eco PEN450 2 20081 Drive unit for mixer eco DUO MIX 1 22262 O ring 17 x 1 25 between drive unit and bearing housing 14 a 33 3 20041 NBR eco PEN connection cable complete 1 5 m 2 20784 Mixer connection cable complete 1 5 m 1 22263 eco DUOMIX450 21972 41 Sensor dosing pressure monitor 2 20598 42 Allen wrench size 1 5 1 20203 43 Screw driver size 2 0 hexago...

Page 30: ...sing for mixer 1 20378 AlMgSi 1 15 Mixer shaft 1 21908 A2 16 Sliding bushing x 1 21965 17 O ring 3 x 1 0 x 2 21731 FFKM 18 Shaft seal x 1 20389 PE 19 X ring x 1 21960 FFKM 20 Dosing head 1 21998 AlMgSi 1 21 Allen screw M3 x 25 4 21125 A2 22 Flat gasket x 1 22057 FFKM 23 Locking plate 1 21944 AlMgSi 1 24 Allen screw M3 x 6 2 22077 A2 25 Mixing capsule Mixing ratio 1 1 to 5 1 x 1 22011 PA 11 Mixing ...

Page 31: ...MIX450 7 2 Overview drawing of the spare parts Fig 16 S 1 2 3 4 5 S12345 S 1 2 3 4 5 S 1 2 3 4 5 4 5 6B 3 2 7 10 8 12 32 31 33 34 27 1 14 13 15 28 35 36 26 25 24 23 22 16 18 19 17 20 21 30 29 29 30 17 28 42 30 8 6A 9 SPARE PARTS ...

Page 32: ... incomplete machine corresponds in addition to the stipulations of Directives 2014 35 EC on electrical equipment and 2014 30 EC on electromagnetic compatibility Product designation eco DUOMIX450 We undertake to convey to the market supervisory authorities at their justifiable request the special documents concerning the incomplete machine in electronic form via our documentation department The inc...

Page 33: ...age conditions see page 11 Dosing volume approx 0 05 ml U per dispenser Dosing accuracy 2 1 Repeatability 99 Mixing ratio 1 1 to 10 1 Minimum dosing quantity 0 008 ml Volume flow 3 0 2 to 12 ml min Speed of the mixer 10 4 83 to 800 rpm 1 Max dosing pressure and self sealing decrease with decreasing viscosity and increase with increasing viscosity Consult with the manufacturer 2 Volumetric dosing a...

Page 34: ...rews washers etc Stainless steel A2 Stator elastomer flexible shaft covering VisChem Shaft sealing rings PE O rings flat gaskets FKM FFKM Drive shaft rotor Stainless steel A4 Mixer shaft Stainless steel A2 Mixing capsule PA 11 ec o P EN 45 0 ec o P E N 45 0 eco DUOMIX 250 84 5 56 33 163 27 Made in Germany Made in Germany SN12345 SN12345 64 5 15 5 10 M8 Ø4 5 Fig 17 TECHNICAL SPECIFICATIONS ...

Page 35: ...osing needles Mixing capsules Please contact us if required info preeflow com The dispenser must be removed by competent maintenance staff Disposal may only be performed in line with the currently applicable country specific specifications standards and legislation Ensure environmentally friendly recycling of all materials Electrical parts must not be disposed of with household waste 2012 19 EU Th...

Page 36: ... must not be modified extended reproduced or distributed to third parties without written consent Subject to technical and editorial change Translation of original operation manual Document no Version INST 008757 0 z_letzte_Seite Table of contents OPERATION MAINTENANCE MANUAL eco DUOMIX450 Project number 14X XX XXXX Order number 14X XX XXXX ...