SureMix Dispensing System - Nordsonemanuals.nordson.com/automotive/zfiles/1061906a.pdf · SureMix...

SureMix�Dispensing System

Customer ProductManual 1061906AIssued October 2005

NORDSON CORPORATION • AMHERST, OHIO • USA

Part 1061906A � 2005 Nordson Corporation

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulations and Approvals 1. . . . . . . . . . . . . . . . . Personal Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Fluids 1. . . . . . . . . . . . . . . . . . . . Fire Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Halogenated Hydrocarbon Solvent Hazards 2Action in the Event of a Malfunction 2. . . . . . . . . . Disposal 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 CC Gear-Metering Pumps 3. . . . . . . . . . . . . . . SureMix Controller 4. . . . . . . . . . . . . . . . . . . . . . . .

SureMix Controller Screens 5. . . . . . . . . . . . . . . . . . Main Menu 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timed Purge 6. . . . . . . . . . . . . . . . . . . . . . . . . . . Open Gun 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TCU Control 6. . . . . . . . . . . . . . . . . . . . . . . . . . . Mixer Tube Replaced 6. . . . . . . . . . . . . . . . . . .

Fault Lights 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Screen 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Display 6. . . . . . . . . . . . . . . . . . . . . . . . . System Setup Screens 8. . . . . . . . . . . . . . . . . . . . .

Pumps Delays Setup 8. . . . . . . . . . . . . . . . . . . . Gun Delays Setup 8. . . . . . . . . . . . . . . . . . . . . . Timer Presets Setup 8. . . . . . . . . . . . . . . . . . . . Mixer Tube Replaced 8. . . . . . . . . . . . . . . . . . . Set Flow Rate 8. . . . . . . . . . . . . . . . . . . . . . . . . . Dispense Time Setup 8. . . . . . . . . . . . . . . . . . . Config. Menu 8. . . . . . . . . . . . . . . . . . . . . . . . . . Return to Main Menu 8. . . . . . . . . . . . . . . . . . .

Config. Menu Screens 10. . . . . . . . . . . . . . . . . . . . . Component A and B Setup 10. . . . . . . . . . . . . . Meter Ratio Setup 10. . . . . . . . . . . . . . . . . . . . . . Mixer Tube Replaced 10. . . . . . . . . . . . . . . . . . . Display Time Screen 10. . . . . . . . . . . . . . . . . . . . Exit PanelView Screens 10. . . . . . . . . . . . . . . . . Return to Main Menu 10. . . . . . . . . . . . . . . . . . . . Return to Setup Menu 10. . . . . . . . . . . . . . . . . . .

Information and DiagnosticsDisplay Screens 12. . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guidelines 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Connections 13. . . . . . . . . . . . . . . . . . . . . . Fluid and Air Connections 13. . . . . . . . . . . . . . . . . . .

Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Motor 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Drive Motor 18. . . . . . . . . . . . . . . . . Install the Drive Motor 18. . . . . . . . . . . . . . . . . . .

Inline Gear Head 20. . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Inline Gear Head 20. . . . . . . . . . . . Install the Inline Gear Head 20. . . . . . . . . . . . . .

Pump 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Pump 22. . . . . . . . . . . . . . . . . . . . . . Install the Pump 22. . . . . . . . . . . . . . . . . . . . . . . .

Pump Seals 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Pump Seals 24. . . . . . . . . . . . . . . . Install the Pump Seals 24. . . . . . . . . . . . . . . . . .

Parts 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact UsNordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.Address all correspondence to:

Nordson CorporationAttn: Customer Service555 Jackson StreetAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2005. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

Nordson and the Nordson logo are registered trademarksof Nordson Corporation.

SureMix is a trademark of Nordson Corporation.

All other trademarks are the property of their respective owners.

SureMix Dispensing System 1

Part 1061906A� 2005 Nordson Corporation

Safety Read and follow these safety instructions. Task- andequipment-specific warnings, cautions, and instructions areincluded in equipment documentation where appropriate.

Make sure all equipment documentation, including theseinstructions, is accessible to persons operating or servicingequipment.

Qualified Personnel Equipment owners are responsible for making sure that Nordsonequipment is installed, operated, and serviced by qualifiedpersonnel. Qualified personnel are those employees orcontractors who are trained to safely perform their assignedtasks. They are familiar with all relevant safety rules andregulations and are physically capable of performing theirassigned tasks.

Intended Use Use of Nordson equipment in ways other than those describedin the documentation supplied with the equipment may result ininjury to persons or damage to property.

Some examples of unintended use of equipment include

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards or interlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximum ratings

Regulations and Approvals Make sure all equipment is rated and approved for theenvironment in which it is used. Any approvals obtained forNordson equipment will be voided if instructions for installation,operation, and service are not followed.

Personal Safety To prevent injury follow these instructions.

� Do not operate or service equipment unless you arequalified.

� Do not operate equipment unless safety guards, doors, orcovers are intact and automatic interlocks are operatingproperly. Do not bypass or disarm any safety devices.

� Keep clear of moving equipment. Before adjusting orservicing moving equipment, shut off the power supply andwait until the equipment comes to a complete stop. Lockout power and secure the equipment to prevent unexpectedmovement.

� Relieve (bleed off) hydraulic and pneumatic pressure beforeadjusting or servicing pressurized systems or components.Disconnect, lock out, and tag switches before servicingelectrical equipment.

� While operating manual spray guns, make sure you aregrounded. Wear electrically conductive gloves or agrounding strap connected to the gun handle or other trueearth ground. Do not wear or carry metallic objects such asjewelry or tools.

� If you receive even a slight electrical shock, shut down allelectrical or electrostatic equipment immediately. Do notrestart the equipment until the problem has been identifiedand corrected.

� Obtain and read Material Safety Data Sheets (MSDS) for allmaterials used. Follow the manufacturer’s instructions forsafe handling and use of materials, and use recommendedpersonal protection devices.

� Make sure the spray area is adequately ventilated.

� To prevent injury, be aware of less-obvious dangers in theworkplace that often cannot be completely eliminated, suchas hot surfaces, sharp edges, energized electrical circuits,and moving parts that cannot be enclosed or otherwiseguarded for practical reasons.

High-Pressure Fluids High-pressure fluids, unless they are safely contained, areextremely hazardous. Always relieve fluid pressure beforeadjusting or servicing high pressure equipment. A jet ofhigh-pressure fluid can cut like a knife and cause serious bodilyinjury, amputation, or death. Fluids penetrating the skin can alsocause toxic poisoning.

If you suffer a fluid injection injury, seek medical careimmediately. If possible, provide a copy of the MSDS for theinjected fluid to the health care provider.

The National Spray Equipment Manufacturers Association hascreated a wallet card that you should carry when you areoperating high-pressure spray equipment. These cards aresupplied with your equipment. The following is the text of thiscard:

WARNING: Any injury caused by high pressureliquid can be serious. If you are injured or evensuspect an injury:

� Go to an emergency room immediately.

� Tell the doctor that you suspect an injection injury.

� Show him this card

� Tell him what kind of material you were spraying

MEDICAL ALERT—AIRLESS SPRAY WOUNDS: NOTE TOPHYSICIAN

Injection in the skin is a serious traumatic injury. It is importantto treat the injury surgically as soon as possible. Do not delaytreatment to research toxicity. Toxicity is a concern with someexotic coatings injected directly into the bloodstream.

Consultation with a plastic surgeon or a reconstructive handsurgeon may be advisable.

The seriousness of the wound depends on where the injury is onthe body, whether the substance hit something on its way in anddeflected causing more damage, and many other variablesincluding skin microflora residing in the paint or gun which areblasted into the wound. If the injected paint contains acryliclatex and titanium dioxide that damage the tissue’s resistance toinfection, bacterial growth will flourish. The treatment thatdoctors recommend for an injection injury to the hand includesimmediate decompression of the closed vascular compartmentsof the hand to release the underlying tissue distended by theinjected paint, judicious wound debridement, and immediateantibiotic treatment.

SureMix Dispensing System2


Fire Safety To avoid a fire or explosion, follow these instructions.

� Ground all conductive equipment. Use only grounded airand fluid hoses. Check equipment and workpiecegrounding devices regularly. Resistance to ground must notexceed one megohm.

� Shut down all equipment immediately if you notice staticsparking or arcing. Do not restart the equipment until thecause has been identified and corrected.

� Do not smoke, weld, grind, or use open flames whereflammable materials are being used or stored.

� Do not heat materials to temperatures above thoserecommended by the manufacturer. Make sure heatmonitoring and limiting devices are working properly.

� Provide adequate ventilation to prevent dangerousconcentrations of volatile particles or vapors. Refer to localcodes or your material MSDS for guidance.

� Do not disconnect live electrical circuits when working withflammable materials. Shut off power at a disconnect switchfirst to prevent sparking.

� Know where emergency stop buttons, shutoff valves, andfire extinguishers are located. If a fire starts in a spraybooth, immediately shut off the spray system and exhaustfans.

� Shut off electrostatic power and ground the charging systembefore adjusting, cleaning, or repairing electrostaticequipment.

� Clean, maintain, test, and repair equipment according to theinstructions in your equipment documentation.

� Use only replacement parts that are designed for use withoriginal equipment. Contact your Nordson representativefor parts information and advice.

Halogenated Hydrocarbon SolventHazards Do not use halogenated hydrocarbon solvents in a pressurizedsystem that contains aluminum components. Under pressure,these solvents can react with aluminum and explode, causinginjury, death, or property damage. Halogenated hydrocarbonsolvents contain one or more of the following elements:

Element Symbol Prefix

Fluorine F “Fluoro-”

Chlorine Cl “Chloro-”

Bromine Br “Bromo-”

Iodine I “Iodo-”

Check your material MSDS or contact your material supplier formore information. If you must use halogenated hydrocarbonsolvents, contact your Nordson representative for informationabout compatible Nordson components.

Action in the Event of aMalfunction If a system or any equipment in a system malfunctions, shut offthe system immediately and perform the following steps:

� Disconnect and lock out system electrical power. Closehydraulic and pneumatic shutoff valves and relievepressures.

� Identify the reason for the malfunction and correct it beforerestarting the system.

Disposal Dispose of equipment and materials used in operation andservicing according to local codes.



Description See Figure 1. The SureMix Dispensing System isdesigned for application of two-component materials.

The system consists of two 4.5 CC gear-metering pumpsand a SureMix controller. Manual and automaticsystems are available. The system can be configuredeither with or without temperature conditioning.

4.5 CC Gear-Metering Pumps Each gear-metering pump is powered by a motor and isdriven by an inline gear head. The inline gear head usesthe motor input to increase torque and decrease speed.The motor speed determines the material flow rate. Flowrate adjustments are made at the SureMix controller.

COMPONENT–B

COMPONENT–AGEAR-METERING PUMP

GEAR-METERING PUMP

CONTROLLER

Figure 1 SureMix Dispensing System



SureMix Controller See Figure 2. The controller consists of a PanelView400 Plus terminal and operator controls.

Setup, configuration, and operating parameter screenscan be accessed using the function keys. Refer to theSureMix Controller Screens section for more informationabout the controller screens.

ON

OFFRESET

CONTROL POWERON

START STOP MIXER TUBETIME EXCEEDED

NUMERIC KEYPAD

BACKSPACE AND ENTER KEYS

TAB AND SHIFT KEYS

ESC, CRTL, ALT KEYS

NAVIGATION KEYS

FUNCTION KEYS

OPERATOR CONTROLS

SHIFT

ESC CRTL

F1 F2 F3 F4

F6 F6 F1 F1

1

4

7 8 0

5 6

2 3

0

ALT

Allen-Bradley PanelView 400 Plus

Figure 2 SureMix Controller



SureMix Controller Screens Figure 3 shows the SureMix Menu Tree. Refer to thefollowing paragraphs for a description of thecontroller screens.

SHIFT

ESC CRTL

F1 F2 F3 F4

F6 F6 F1 F1

1

4

7 8 0

5 6

2 3

0

ALT

Allen-Bradley PanelView 400 Plus

MAIN MENU

Timed PurgeOpen GunTCU ControlMixer Tube ReplacedFault LightsSystem Setup

Alarm ScreenSystem Display

Pumps Delays SetupGun Delays SetupTimer Presets SetupMixer Tube ReplacedSet Flow RateDispense Time SetupConfig. Menu

Return to Main Menu

Component A SetupComponent B SetupMeter Ratio Setup

Mixer Tube ReplacedDisplay Time

Exit PanelView ScreensReturn to Main MenuReturn to Setup Menu

Figure 3 SureMix Controller Menu Tree



Main Menu See Figure 4.

The following items appear on the Main Menu screen:

Timed Purge System Setup

Open Gun Alarm Screen

TCU Controls System Display

Fault Light Mixer Tube Replaced

Timed Purge

Use this screen to

� view component A and B pressures.

� enter and view the system purge time.

� perform ratio checks.

Open Gun

Use this screen to

� view Component A and B pressures.

� open the gun without turning on the pumps.

� bleed pressure in the hoses.

TCU Control

Use this screen to Start and Stop the TCU when it is inthe remote mode. The status of the TCU appears on thisscreen when it is in the remote mode.

Mixer Tube Replaced

Press [F4] to reset the Mixer Tube Time-Out Fault.

Fault Lights

Use this screen to view active faults.

System Setup

Use this screen to access and configure systemparameters. Refer to the System Setup Screens sectionfor more information.

Alarm Screen

Use this screen to

� view active alarms.

� acknowledge and reset alarms.

System Display

Use this screen to

� view component A and B pressures.

� reset the Mixer Tube Time Out fault.



TimedPurge[F1]

OpenGun[F2]

TCUControl

[F3]

MixerTube

[F4]

FaultLights[F5]

SystemSetup[F6]

Alarm Screen

[F7]

SystemDisplay

[F8]

Replaced

Component A Pressure:Component B Pressure:

Timed Preset [F1]:

Timed Actual:

Time Purge Screen

When on this screen, a timedpurge will be executed while thetrigger is held.

Return toMainMenu[F8]

NNNNNN

NNNNNN

NNNNNN

NNNNNN

Component A Pressure:Component B Pressure:

Open Gun Screen

When on this screen, the gun willopen and the pumps won’t turn whilethe trigger is held.


NNNNNN

NNNNNN

TCU Control Screen

The Start and Stop buttons willcontrol the TCU when it is in Remote Control mode.


StartTCU[F1]

StopTCU[F2]

TCUis

On

Component A Pressure:

Component B Pressure:

System Display ScreenReturn to

MainMenu[F8]

NNNNNN

NNNNNN

MixerTube

Replaced[F4]

AckAlarm[F1]

Close

[F4]

AlarmReset[F3]

PumpsDelaysSetup

MixerTube

[F4]

FaultLights[F5]

Config.Menu[F7]

Replaced[F1]

GunDelaysSetup[F2]

TimerPresetsSetup[F3]

DispenseTimeSetup[F6]

Return toMain

[F8]Menu

Setup MenuPanelView Version: 1.01PLC Version: NN NN


DC Power OK

In Auto Mode

PLC Battery OK

Mixer Tube OKA Not High

A Not Low

A Not Over

B Not High

B Not Low

B Not Over

Drive A Not FLT

Drive B Not FLT

Drive A Ready

Drive B ReadyA Not Under RG

A Not Over RNG

A Transducer OK

B Not Under RG

B Not Over RNG

B Transducer OK

A Out Not Under

A Out Not Over

A ALG OUT OK

B Out Not Under

B Out Not OverB ALK Out OK

RTC Battery OK

MCR Is OFF

TCU Not Ready

MCR is OFF and TCU Not Readyare examples of how faults appear.

Alarm data appears on this screen.

Figure 4 Main Menu Screens



System Setup Screens See Figure 5.

The following items appear on the Setup Menu:

Current PanelView and Mixer Tube ReplacedCurrent PanelView andPLC Program Versions Set Flow Rate

Pumps Delays Setup Dispense Time Setup

Gun Delays Setup Config. Menu

Timer Presets Setup Return to Main Menu

Pumps Delays Setup

Use this screen to set and view the On/Off time delaysfor pumps A and B.

Gun Delays Setup

Use this screen to set and view the On/Off time delaysfor the gun.

Timer Presets Setup

Use this screen to set and view the

� Mixer Tube Time-Out Preset.

� Cure Time Exceeded Preset.

Mixer Tube Replaced

Press [F4] to reset the Mixer Tube Time-Out fault.

Set Flow Rate

Use this screen to set and view the desired flow ratein CC/Min.

Dispense Time Setup

Use this screen to

� enable/disable the dispense timer.

� preset and view the dispense time.

When Dispense Time Setup is enabled, the DispenseTimer is used after the first trigger to allow time for fillingthe mixer tube.

Config. Menu

Use this screen to access and configure the meterparameters. Refer to the Config. Menu Screens sectionfor more information.

Return to Main Menu

Touch [F8] to return to the Main Menu screen.



Pump A On Time Delay [F1]:

Pump A Off TIme Delay [F2]:

Pump B On Time Delay [F3]:

Pump B Off Time Delay [F4]:

Pump Delays SetupReturn to

SetupMenu[F8]

NN NN

NN NN

NN NN

NN NN

Gun On Time Delay [F1]:Gun Off Time Delay [F2]:

Gun Delays SetupReturn to

SetupMenu[F8]

NN NN

NN NN

PumpsDelaysSetup

MixerTube

[F1]

SetFlow Rate

[F5]

Config.Menu[F7]

Replaced[F1]

GunDelaysSetup[F2]

TimerPresetsSetup[F3]

DispenseTimeSetup[F6]

Return toMain

[F8]Menu

Setup Menu

PanelView Version: 1.01PLC Version: NN NN

Mixer Tube Time-Out [F1]:Cure TIme Exceeded [F2]:

Timer Presets SetupReturn to

SetupMenu[F8]

NN NN

NN NN

Flow Rate in CC/Min [F1]:

Set Flow RateReturn to

SetupMenu[F8]

NNNNN

Set the desired flow rate in cc’sper minute.

Dispense Timer ScreenWhen enabled, the Dispense Return to

SetupMenu[F8]

EnableDispense

Timer

DispenseTimer isEnabled

Timer will be used after the firsttrigger. The first trigger will not betimed in order to fill the Mixer.

[F1]

DisableDispense

Timer[F2]

Dispense Time Preset [F4]: NNN NN

Dispense Time Actual: NNN NN

Compo-net ASetup

MixerTube

[F4]

DisplayTime[F5]

Replaced[F1]

Compo-net BSetup[F2]

MeterRatioSetup[F3]

ExitPanelviewScreens

[F6]

Return toSetup

[F8]Menu

Configuration Menu

Return toMain

[F7]Menu

Figure 5 Setup Menu



Config. Menu Screens See Figure 6.

The following items appear on the Config. Menu:

Component A Setup Display Time

Component B Setup Exit PanelView Screens

Meter Ratio Setup Return to Main Menu

Mixer Tube Replaced Return to Setup Menu

Component A and B Setup

Use these screens to setup the meter parameters forComponents A and B.

Meter Ratio Setup

Use this screen to

� setup the meter parameters for parts ofComponents A and B.

� enter the scale factors for Components A and B.

Mixer Tube Replaced

Press [F4] to reset the Mixer Tube Time-Out fault.

Display Time Screen

Use this screen to view the time/date. Press

� [F5] to reset the Mixer Tube fault.

� [F6] to exit this screen and return to the Main Menu.

� [F7] to exit this screen and return to the Setup Menu.

� [F8] to exit this screen and return to theConfig. Menu.

To change the date or time, exit the PanelView screensand access the PanelView Setup menu.

Exit PanelView Screens

Press [F6] to exit the PanelView screens and return tothe PanelView Setup screens. Use the PanelView Setupscreens to change the date, time, and load updated filesinto the PanelView.

Return to Main Menu

Press [F7] to exit this screen and return to theMain Menu.

Return to Setup Menu

Press [F8] to exit this screen and return to theSetup Menu.



Motor Pulses Divide Factor [F2]:

Gearhead Ratio xx:1 [F3]:

Pump volume in CC’s [F4]:

Over Pressure Fault in PSI [F5]

Component A SetupReturn toConfig.Menu[F8]

NNNNN

NNNNN

N.NNN

NNNNN

Compo-net ASetup

MixerTube

[F4]

DisplayTime[F5]

Replaced[F1]

Compo-net BSetup[F2]

MeterRatioSetup[F3]

ExitPanelviewScreens

[F6]

Return toSetup

[F8]Menu

Configuration Menu

Return toMain

[F7]Menu

High Pressure Fault in PSI [F6] NNNNN

Low Pressure Fault in PSI [F7]: NNNNN

Motor Pulses per rev. [F1]: NNNNN

Component B SetupReturn toConfig.Menu[F8]

Parts of Component B [F2]:

Component A Scale Factor [F3]:

Component B Scale Factor [F4]:

Meter Ratio SetupReturn toConfig.Menu[F8]

NNNNN

N.NNNN

N.NNNN

Parts of Component A [F1]: NNNNN

MixerTube

[F5]Replaced

Return toSetup

[F7]Menu

Display Date & Time

Return toMain

[F6]Menu

Return toConfig.

[F8]Menu

3/28/2005 8:39:43 AM

Motor Pulses Divide Factor [F2]:

Gearhead Ratio xx:1 [F3]:

Pump volume in CC’s [F4]:

Over Pressure Fault in PSI [F5]

NNNNN

NNNNN

N.NNN

NNNNN

High Pressure Fault in PSI [F6] NNNNN

Low Pressure Fault in PSI [F7]: NNNNN

Motor Pulses per rev. [F1]: NNNNN

Figure 6 Config. Menu Screens



Information and DiagnosticsDisplay Screens See Figure 7.

Information and diagnostic data appear onthese screens.

TimedPurge[F1]

OpenGun[F2]

TCUControl

[F3]

MixerTube

[F4]

FaultLights[F5]

SystemSetup[F6]

Alarm Screen

[F7]

SystemDisplay

[F8]

Replaced

Ack[F1]

Close[F2]

Clear

[F1] [F4][F3]

Clear

[F2]All

Close

[F4]

Information Display Diagnostics Display

Figure 7 Information and Diagnostic Screens



Installation

WARNING Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions inthis document and all other relateddocumentation.

Unpack the system and inspect it for dents, scratches,corrosion, or other physical damage. If there is anyvisible damage, call your Nordson Corporationrepresentative immediately.

Table 1 lists the installation specifications.

Table 1 Installation Specifications

Item Specification

Main Air Supply 60 psi minimum at 1 scfm

Main Air SupplyBall Valve

1/2 NPT

Pump ManifoldFluid Ports

9/16-18 UNF-B

Material Supply Filtered to 200 microns

Main ElectricalSupply

480 VAC, 1 phase, 25 amp,60 Hz, 10 FLA

GuidelinesReview the following guidelines:

� Make sure that the desired installation location hasthe required clearances, environmental conditions,and utilities to safely operate the system.

� Hard-wire the controller to a dedicated power supplyto provide safe operation and reduce interferencefrom electrical noise.

� Install all electrical connections to local code.

� Install a locking disconnect switch or breaker in theservice line ahead of any electrical equipment.

� Make sure that there is enough slack in all hose andcable routings to allow for proper system operation.

Electrical ConnectionsElectrical connections are dependent upon applicationrequirements. Use the Electrical Interconnect drawingsprovided with the system documentation for connections.

Fluid and Air ConnectionsFluid and air connections are dependent upon applicationrequirements. See Figures 8 and 9 for typicalinstallations. Use the System Layout drawings providedwith the system documentation for connections.

Operation Operation is dependent upon application and fluiddelivery requirements. Refer to the System ParameterSheet provided with the system documentation.



TEMPERATURE CONDITIONEDMATERIAL OUTPUT LINETO APPLICATOR

MATERIAL INPUT LINEFROM SUPPLY PUMPS

TEMPERATURE CONDITIONEDMATERIAL OUTPUT LINETO APPLICATOR


TCU WATER SUPPLY

MATERIAL INPUTSHUTOFF VALVE

MATERIAL INPUTSHUTOFF VALVE

COMPONENT B

COMPONENT A

GEAR-METERING PUMP

GEAR-METERING PUMP

SUPPLY AIRCONNECTION

WATER HOSE

CONNECTION

WATER HOSE

THESE ARE APPLICATION-SPECIFIC COMPONENTS THATARE ONLY SHOWN FOR PROPER SYSTEM CONNECTIONS.

Figure 8 Typical Connections for Temperature Conditioned Metering Pumps



MATERIAL OUTPUT LINETO APPLICATOR


COMPONENT B

MATERIAL OUTPUT LINETO APPLICATOR


COMPONENT A

GEAR-METERING PUMP

GEAR-METERING PUMP

SUPPLY AIRCONNECTION

Figure 9 Typical Connections for Non-Temperature Conditioned Metering Pumps



Maintenance


Table 2 lists general maintenance procedures for theSureMix system. The frequency of maintenance isdependent upon operating conditions.

Table 2 Maintenance Schedule

Frequency Item Task

MonthlyPump seals

Check pump seals and replace if necessary. Refer to the Pump Seals procedure inthe Repair section.

Semi-AnnuallyPump seals

Grease pump seals. Refer to the Pump Seals procedure in the Repair section.



Troubleshooting


Problem Possible Cause Corrective Action1. Motors do not spin when

gun trigger is pulled; nofault from controller

Faulty gun trigger or gun cable Check gun trigger, cables, andconnectors. Repair or replace parts ifnecessary.

2. Motors begin to spinwhen gun trigger ispulled but controllerdisplays High Pressurefault

No air or low air pressure to system Check air supply.

Pneumatic gun solenoid did not open Check pneumatic control valve and cable.Repair or replace parts if necessary.

Gun did not open when pneumaticsignal was present

Rebuild gun.

Gun opened but little or no materialwas dispensed

Check the following and repair ifnecessary:

� supply hoses to gun for clogs orrestrictions

� restricted or clogged gun passages

Clogged mixer tube Replace mixer tube.

3. Mix ratio not withinspecifications

Controller parameters not properly set Check system parameters and reset ifnecessary.

Pumps have excessive wear Replace pumps.

Slippage between motor and gearhead connection

Check and adjust coupling torque ifnecessary.



Repair

WARNING

� Allow only qualified personnel to perform the followingtasks. Follow the safety instructions in this documentand all other related documentation.

� To prevent serious injury, relieve system and materialpressure before performing these procedures.

Drive MotorUse the following procedure to replace a drive motor.

Remove the Drive Motor 1. Make sure that all air and material pressures are

relieved from the SureMix Dispense stand.

2. See Figure 10. Disconnect the applicable cables (1)from the controller cable set (2).

11

BOTTOM VIEW

2

Figure 10 Cable Set Location

3. See Figure 11. Disconnect the coupling between thedrive motor (5) and inline gear head (8):

a. Remove the plugs (7) from the inline gearhead (5) to access the coupling.

b. Manually turn the drive shaft to expose the hubscrews. Use a hex wrench (6) to loosen the hubscrews.

4. Remove the screws (3) and lock washers (4)securing the drive motor (5) to the inline gearhead (8). Remove the drive motor from theinline gear head.

Install the Drive Motor 1. De-grease the drive motor shaft and inline gear head

bore using an approved solvent.

2. Rotate the inline gear head hub to align the hubscrews to the access holes.

3. Perform the following:

a. Install the new drive motor (5) onto the inline gearhead (8).

b. Make sure that the inline gear head hub screwsare aligned to the access holes. Pre-tighten thehub screws to 2-in.-lb. (0.2 N•m).

c. Secure the drive motor to the inline gear headusing the screws (3) and lock washers (4).Tighten the screws securely.

d. Tighten the hub screws to 39-in.-lb. (4.4 N•m)Install the plugs (7) into the inline gear head.

4. See Figure 10. Connect the drive motor cables (1) tothe controller cable set (2).



4

5

8

7

6

3

ACCESS HOLE

HUB

HUBACCESS HOLE HUB

HUBSCREW

SCREW

ALIGNING THE INLINE GEAR HEAD HUB SCREWS

Figure 11 Drive Motor Replacement



Inline Gear Head See Figure 12

Remove the Inline Gear Head 1. Make sure that all air and material pressures are


2. Remove the drive motor (15) from the inline gearhead (14). Refer to the Drive Motor procedures inthis section.

3. Loosen the screws (10) securing the shroud (1) to themounting bracket (11). Remove the shroud.

4. Loosen the mounting bracket screws (12). Slide themounting bracket (11) back and remove the centercoupling (5).

5. Remove the screws (13), lock washers (9), andnuts (8) securing the inline gear head (14) to themounting bracket (11).

6. Loosen the screw (3) securing the upper coupling (2)to the inline gear head (14). Remove the uppercoupling and key (4).

Install the Inline Gear Head 1. Install the upper coupling (2) and key (4) onto the

new inline gear head (14). Tighten the screw (3) to45-in.-lb (5 N•m).

2. Install the inline gear head (14) onto the mountingbracket (11) using the lock washers (9), nuts (8), andscrews (13). Tighten the screws securely.

3. Install the center coupling (5) onto the lowercoupling (6). It may be necessary to rotate the lowercoupling to keep the center coupling on thelower coupling.

NOTEThe following step requires the use of a0.020-0.030-in. shim.

4. Make sure that there is a 0.020-0.030-in gap betweenthe upper coupling (2) and the center coupling (5).Perform the following if the gap needs to be reset:

a. Place the 0.020-0.030-in. shim between theupper coupling (2) and center coupling (5).

b. Slide the mounting bracket (11) toward the uppercoupling (2) until it makes contact with the shim.

c. Tighten the Mounting bracket screws (12) to25-30 ft-lb (34-40 N•m). Remove the shim.

5. Install the shroud (1) onto the mounting bracket (11)and tighten the screws securely.



1

2

5

3

13

9

10

12

8

11

15

4

7

614

INLINE GEAR HEAD

0.020/0.030-INCH SHIMBETWEEN UPPER COUPLING

AND CENTER COUPLING

PUMP

Figure 12 Inline Gear Head Replacement



Pump See Figure 13.

Remove the Pump1. Make sure that all air and material pressures are


2. Loosen the screws (14) securing the shroud (1) to themounting bracket (16). Remove the shroud.


4. Remove the screws (9) securing the pump (7) andspacer plate (6) to the manifold (12).

5. Remove the O-rings (5, 10) from the spacer plate (6)and manifold (12). Discard the O-rings.

6. Loosen the screw (4) securing the lower coupling (3)to the pump (7). Remove the lower coupling andkey (8).

Install the Pump


1. Install the lower coupling (3) and key (8) onto thepump (7). Do not tighten the screw (4) at this time.

2. Make sure that there is a 0.050-0.100-in gap betweenthe lower coupling (3) and the pump (7) screw head.Tighten the lower coupling screw (4) screw to45-in.-lb (5 N•m).

3. Install new O-rings (5, 10) onto the spacer plate (6)and the manifold (12).

4. Apply Never-Seez to the threads of the screws (9).Install the spacer plate (6) and pump (7) onto themanifold (12) using the screws. Tighten the screwsto 35-40 ft-lb (48-54 N•m).




a. Make sure the upper coupling (13) is properlyaligned to the center coupling (2).

b. Place the 0.020-0.030-in. shim between theupper coupling (13) and center coupling (2).

c. Slide the mounting bracket (16) toward the uppercoupling (13) until it makes contact with the shim.

d. Tighten the Mounting bracket screws (15) to25-30 ft-lb (34-40 N•m). Remove the shim.

7. Instal the shroud (1) onto the mounting bracket (16)and tighten the screws (14) securely.



1

2

3

6

7

9

15

14

8

1213

16

5

11

4

10

5

INLINE GEAR HEAD

0.020/0.030-INCH SHIMBETWEEN UPPER COUPLING

AND CENTER COUPLING

PUMP

0.050/0.100-INCH SHIMBETWEEN PUMP SCREW HEADAND LOWER COUPLING

Figure 13 Pump Replacement



Pump Seals See Figure 14.

NOTEThis procedure requires 2 pump seals. The partnumber for the seals is 333127.

Remove the Pump Seals 1. Make sure that all air and material pressures are


2. See Figure 13. Loosen the screws (14) securing theshroud (1) to the mounting bracket (16). Remove theshroud.


4. Loosen the screw (4) securing the lower coupling (3)to the pump (7). Remove the lower coupling andkey (8).

5. See Figure 14. Remove the screws (1) securing theseal housings (3) to the pump (2).

6. Note the orientation of the seals (4). Use an O-ringpick to remove the seals from the housings (3).

Install the Pump Seals

NOTEThis procedure requires the use of petroleum jelly.

1. Make sure that the seal housings (3) are freeof debris.

2. Apply a small amount of petroleum jelly to theseals (4) and the inside diameter of the sealhousings (3).

3. Install the seals (4), smaller diameter side first, intothe seal housings (3).

4. Pack the seals (4) with petroleum jelly as shown.

5. Install the seal housings (3) onto the pump (2) shaftusing the screws. Tighten the screws to75–85 in.-lb (8.5–9.6 N•m).


6. See Figure 13. Install the lower coupling (3) and key(8) onto the pump (7). Do not tighten the screw (4) atthis time.

7. Make sure that there is a 0.050-0.100-in gap betweenthe lower coupling (3) and the pump (7) screw head.Tighten the lower coupling screw (4) screw to45-in.-lb (5 N•m).




a. Make sure the upper coupling (13) is properlyaligned to the center coupling (2).

b. Place the 0.020-0.030-in. shim between theupper coupling (13) and center coupling (2).

c. Slide the mounting bracket (16) toward the uppercoupling (13) until it makes contact with the shim.

d. Tighten the Mounting bracket screws (15) to25-30 ft-lb (34-40 N•m). Remove the shim.

10. Instal the shroud (1) onto the mounting bracket (16)and tighten the screws (14) securely.



1

2

5

3

4

PACK SHADED AREASWITH PETROLEUM JELLY.

Figure 14 Pump Seals



Parts See Figures 15 and 16 and refer to the followingparts lists. To order parts, call the Nordson CustomerService Center or your local Nordson representative.

Part of 18

18

17

16

20

19

1413

11

5

13

7

68

910

12

21

21

15

15

32

31

1

A

B C

C

A

B

23

4

910

24

27

26

25

23

29

22

30

28

Figure 15 SureMix Dispensing System Parts



Item Part Description Qty Note1051712 SureMix 2K Dispensing System 1

1 - - - - - - � Controller 1 A2 981402 � Screw, hex, 3/8-16 x 1.000 in., cap, zn 43 983530 � Lock washer, split 3/8, zinc,14451–KA 44 345929 � Washer, flat regular, 3/8, zinc 45 1052163 � Valve, ball,1/2 NPT, vent, lock, blue handle 16 973212 � Elbow male, pipe, HYD, 1/2, stl, zn 17 1057517 � Tee, interface, branch, 1/2 NPT 18 345750 � Screw, socket, 1/4-20 x 0.750 49 983085 � Washer, lock, E, external,1/4, zn 4

10 345913 � Washer, flat, regular,1/4, zn 411 972183 � Elbow, male, 3/8 tube x 1/4 NPT 112 1057516 � Regulator, air,1/4 NPT, 150 psi, relieving 113 1057518 � Spacer, with bracket, Y300T 214 1057514 � Filter, air, 1/4 NPT, 150 psi, 5-micron filter 115 972893 � Connector, barbed, 3/8T, 9/16-18, brass 216 973275 � Tee, pipe, 1/4, brass 117 1056155 � Manifold assembly, 6-passages, 5/32 orifice 118 981171 � Screw, socket, 10-32 x 1.250, zn 219 345864 � Washer, flat, #10, regular, stl, zn 220 1056300 � Insulator, manifold 121 1045605 � Hose, air, 3/8 ID x 5/8 OD, 300 psi 322 981441 � Screw, socket,1/4-20 x 2.000 223 1044954 � Valve, ISO size 1, 2-position, 4-way, 24 VDC 124 1043426 � Base, manifold, 3/8 NPT, 5-port, ISO size 1 125 177452 � Muffler, exhaust, 3/8 inch NPTF 126 972216 � Elbow, male,1/4 tube x 3/8 NPT 127 345836 � Nut, hex, regular,1/4–20, stl, zn, 14441–GA 228 1042063 � Cable assembly, 4 conductor, 1 m, 18 AWG, 250 V 129 971672 � Connector, male,1/4 tube x 3/8 NPT 230 170269 � Muffler, exhaust, 1/8-inch NPT 231 1051753 � Gear-meter, Servo, 4.5 CC, temperature conditioned 2 B32 1051770 � Stand, servo gear meter assembly 1

NOTE A: The controller is designed to system specifications. Refer to the controller drawings provided with theSystem Documentation to order parts.

B: See Figure 16 for detailed parts breakdown.



24

25

28

21

22

22

27

23

16

17

18

15

20

14

13

1211

10

9

8

7

6

5

4

3 2

1

32 31

30

29

19

23

26

Figure 16 SureMix Dispensing System Parts (continued)


Part 1061906AE 2005 Nordson Corporation

Item Part Description Qty Note1051753 Gear-meter, Servo, 4.5 CC, temperature conditioned 1 A

1 1051773 S Shroud, coupler, gear-meter, servo 12 983410 S Washer, flat, M, narrow, M6, stl, zn 43 983409 S Washer, lock, M, SPT, M6, stl, zn 44 982176 S Screw, socket, M6 x 16 45 320991 S Motor, servo, 4000 RPM 16 320990 S Gear head, inline 17 982029 S Screw, socket, M5 x 30 48 982160 S Screw, socket, M8 x 25, zn 49 983404 S Washer, lock, M, SPT, M8, stl, zn 410 983013 S Washer, flat, M, regular, 8, stl, zn 411 1051952 S Bracket, mounting, support, gear-meter, servo 112 983035 S Washer, flat, M, regular, 5, stl, zn 413 276141 S Nut, lock, M5 414 322637 S Coupling assembly,12 x 16 115 1054348 S Nut, T-slot, M8 x 1.25 416 815208 S Screw, 3/8-16 x 1.5 417 983530 S Lock washer, split 3/8, zinc, 14451-KA 418 345929 S Washer, flat, regular, 3/8, zinc 419 1051763 S Plate, spacer, gear-meter, servo 120 1054566 S Pump assembly, 4.5 CC, double seal 1NS 333127 S S Seal, KH1 PTFE 2 B21 982006 S Screw, socket, M8 x 20, zn 422 972121 S Connector, 37 HYD, 9/16-18 223 973574 S Plug, O-ring, 9/16-18 224 1051768 S Base, plate, gear-meter, servo 125 1051765 S Insulator plate, gear-meter, servo 126 1054304 S Cable assembly, transducer, AMP, 8 ft 127 1063881 S Transducer, pressure, 0--2000 PSI, 4-20mA 129 973411 S Plug, pipe, socket, flush,1/4, zn 228 1051760 S Manifold, gear-meter, servo, temperature conditioned 130 940166 S O-ring, Viton, 0.625 x 0.750, 10416 131 940138 S O-ring, Viton, 0.438 x 0.563 332 1054581 S Screw, socket, M10 x 75 MM 4

NOTE A: The SureMix Dispensing System is configured with two gear meters. The quantities listed in the Qtycolumn are for one gear meter.

B: This part is included with item 20 but can be ordered separately.

NS: Not Shown



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