DG-1000 Dispenser Customer Product Manual Part 107 156C NORDSON CORPORATION D AMHERST, OHIO D USA
Nordson Corporation welcomes requests for information, comments and inquiries about its products. Address all correspondence to Nordson Corporation 555 Jackson Street Amherst, OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1997. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation.
Table of Contents i Table of Contents 1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Regulations and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Personal Safety . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents 10. Testing the Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 11. Watlow Temperature Controller Replacement . . . . . . . . . . . . . . . . . . 25 12. Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Using the Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 DG-1000 Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DG-1000 Dispenser 1 DG-1000 Dispenser 1. Safety Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to persons operating or servicing equipment. Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel.
2 DG-1000 Dispenser Personal Safety To prevent injury follow these instructions. S Do not operate or service equipment unless you are qualified. S Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. S Keep clear of moving equipment. Before adjusting or servicing moving equipment, shut off the power supply and wait until the equipment comes to a complete stop.
DG-1000 Dispenser 3 High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremely hazardous. Always relieve fluid pressure before adjusting or servicing high pressure equipment. A jet of high-pressure fluid can cut like a knife and cause serious bodily injury, amputation, or death. Fluids penetrating the skin can also cause toxic poisoning. If you suffer a fluid injection injury, seek medical care immediately.
4 DG-1000 Dispenser Fire Safety To avoid a fire or explosion, follow these instructions. S Ground all conductive equipment in the spray area. Use only grounded air and fluid hoses. Check equipment and workpiece grounding devices regularly. Resistance to ground must not exceed one megohm. S Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected.
DG-1000 Dispenser 5 Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system that contains aluminum components. Under pressure, these solvents can react with aluminum and explode, causing injury, death, or property damage.
6 DG-1000 Dispenser WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 2. Introduction See Figure 1. The DG-1000 dispenser is an air-actuated dispenser which can be used with several Nordson platforms. 1235001A Fig. 1 3. Operation DG-1000 Dispenser The following paragraphs provide operating procedures for the dispenser.
DG-1000 Dispenser Setting the Watlow Temperature Controller 7 CAUTION: Do not expose the solenoid valve to solvents or working fluid. Solvents could damage the valve and working fluid may clog it. Tables 1 and 2 list the setup and operation default menu parameters that must be set. Refer to the WATLOW Series 965 User’s Manual for detailed procedures on setting these parameters.
8 DG-1000 Dispenser Setting the Watlow Temperature Controller (contd) Table 2 Operation Default Parameters Function Parameter Pb1 (Proportional band 1) Factory Default rE1/lt1 (Reset 1/Integral 1) Factory Default rA1/dE1 (Rate 1/Derivative 1) Factory Default Ct1 (Cycle time 1) Factory Default Pb2 (Proportional band 2) Factory Default rE2/lt2 (Reset 2/Integral 2) Factory Default rA2/dE2 (Rate 2/Derivative 2) Factory Default Ct2 (Cycle time 2) Factory Default ALO (Alarm low) Factory Defau
DG-1000 Dispenser Shutdown 9 1. Shut down the system, following the procedure described in your system manuals. 2. Fill the fluid system with solvent according to the instructions in your system manuals. 3. Press GO TO ORIGIN on the controller front panel to reposition the Dispenser for purging the fluid delivery system. 4. Place a small waste container under the end of the extension. 5. Activate the purge program. 6. Remove the waste container after you run the purge program.
10 DG-1000 Dispenser WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 4. Repair NOTE: Some tools are shipped with the dispenser. Refer to the Parts section for a tool description.
DG-1000 Dispenser 5. Before Disassembling 11 Perform these steps before you disassemble the dispenser: 1. Complete the shut down procedure as described in the Operation section. 2. Shut down the entire system before removing the dispenser from the robot. Refer to the appropriate system manual for procedures. WARNING: System or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. 3. See Figure 2. Disconnect the fluid line (6) from the dispenser (5).
12 DG-1000 Dispenser 5. Before Disassembling (contd.) 2 3 1 4 4 8 6 5 7 SIDE FRONT 1235002A Fig. 2 Removing the Dispenser from the Robot 1. Solenoid valve connector 2. Robot mounting plate 3. Micro-adjustment assembly Manual 12-35 4. Socket head screws 5. Dispenser 6. Fluid line 107 156C Issued 11/98 7. Heater connector 8.
DG-1000 Dispenser 6. Disassembly 13 CAUTION: Special care should be taken when handling O-rings and seals. If O-rings and seals are damaged, the dispenser may leak, or may fail prematurely. CAUTION: Protect the solenoid valve from contact with coating material or solvents. Contamination could cause solenoid failure. Micro-Adjustment Assembly See Figure 3. CAUTION: Back off the micro-adjustment assembly to prevent damage to the needle and seat during assembly. 1.
14 DG-1000 Dispenser Heater (contd) 1 2 3 4 2 6 7 17 5 16 15 14 13 12 8 11 10 9 1235003A Fig. 3 Dispenser Disassembly 1. 2. 3. 4. 5. 6. Micro-adjustment assembly Preload set screws Preload locking ring Preload screw Screws Cap Manual 12-35 7. 8. 9. 10. 11. 12. Compression spring Socket head screws Nozzle Nozzle gasket Heater Heater extension 107 156C Issued 11/98 13. 14. 15. 16. 17.
DG-1000 Dispenser Dispenser Bodies 15 See Figure 4. CAUTION: To prevent damage to the ball and needle, do not use tools to grip the needle threads. 1. Carefully push the needle (5) out of the body assembly. 2. Inspect the needle (5) and the air piston seal (4) for damage. If the air piston seal is damaged, perform the following steps: a. Remove the spring retainer (1) from the needle (5). Use a wrench to hold the top of the seal lock nut (2). Use another wrench to loosen and remove the retainer. b.
16 DG-1000 Dispenser Dispenser Bodies (contd) CAUTION: Do not use a U-cup seal once it has been removed from the dispenser. Removing a U-cup seal may damage it, and cause fluid to leak from the dispenser. 5. Remove the U-cup seal (8) from the upper body (11): a. Insert the tapered end of the needle (5) into the lower body side of the upper body. b. Use the needle to push the U-cup seal (8) out of the upper body (11). 6. Remove the U-cup seal (8) from the lower body (10): a.
17 DG-1000 Dispenser 1 2 3 4 5 13 9 8 12 6 8 11 7 10 6 1235004B Fig. 4 Removing the Needle, Piston, and Seals 1. 2. 3. 4. 5. 6. 7. 1998 Nordson Corporation All rights reserved Spring retainer Seal lock nut O-ring Air piston seal Needle Fillister screws O-ring 107 156C Issued 11/98 8. 9. 10. 11. 12. 13.
18 DG-1000 Dispenser 7. Assembly CAUTION: Handle O-rings and seals carefully. If O-rings or seals are damaged, leakage or premature dispenser failure may occur. CAUTION: Protect the solenoid valve from contact with coating material or solvent. Contamination could cause solenoid failure. NOTE: Assemble the dispenser on a flat surface. Dispenser Bodies See Figure 5. 1. Place the dispenser bodies on their backs. Mate the upper body (15) with the lower body (14) and secure with the fillister screws (5).
19 DG-1000 Dispenser 1 2 3 4 6 16 5 6 7 15 8 14 10 5 9 11 13 12 11 1235005B Fig. 5 Assembling the Upper Body, Lower Body, and Heater 1. 2. 3. 4. 5. 6. Socket head screws Solenoid valve Plug Male connector (fluid) Fillister screws U-cup seal 1998 Nordson Corporation All rights reserved 7. 8. 9. 10. 11. 12. O-ring O-ring Heater extension Heater Cap head screws Nozzle 107 156C Issued 11/98 13. 14. 15. 16.
20 DG-1000 Dispenser Air Piston See Figure 6. 1. Insert the needle (7) through the seal in the upper body (8) and the internal seal in the lower body (9). The needle is properly seated when the needle ball is almost flush with the end of the heater extension. 2. To properly seat the piston in the piston insertion tool (4), roll the seal lip (5) of the new air piston (6) on a clean flat surface. The seal lip must be formed so that the lip hangs down toward the dispenser. 3.
DG-1000 Dispenser 21 CAUTION: To prevent damage to the needle, do not overtighten the spring retainer. 11. Place the spring retainer (1) on the needle (7). Using the module-adjusting wrenches hold the seal lock nut in place and tighten the spring retainer snugly. 12. Seat the needle. Check the height of the seal lock nut (2). 13. Make sure that the ball and seat is properly seated. 1 2 3 4 5 6 7 8 9 1235006A Fig. 6 Installing the Air Piston 1. 2. 3. 4. 5.
22 DG-1000 Dispenser Micro-Adjustment Assembly and Dispenser Cap See Figure 7. CAUTION: To prevent damage to the seat assembly, install a nozzle on the dispenser. 1. Place the compression spring (7) on the spring retainer (10). 2. Install the cap (6) on the upper body (8) and secure using the fillister screws (9). 3. Make sure the locking nut (5) is installed on the preload screw (4). NOTE: If desired, use the spanner to install the preload screw. 4. Install the preload screw (4) in the cap (6).
DG-1000 Dispenser 23 1 2 3 4 5 6 7 9 11 10 8 2.54 mm (.010) 0.00 mm (.000) 1235007A Fig. 7 Installing the Micro-Adjustment Assembly and Cap 1. 2. 3. 4. Set screw Micro-adjustment assembly Preload set screws Preload screw 1998 Nordson Corporation All rights reserved 5. 6. 7. 8. Locking nut Cap Compression spring Upper body 107 156C Issued 11/98 9. Fillister screws 10. Spring retainer 11.
24 DG-1000 Dispenser 8. Installation See Figure 2. 1. Use the socket head screws (4) to secure the dispenser (5) to the robot mounting plate (2). 2. Connect these connectors to the dispenser (5): S heater connector (7) S solenoid valve connector (1) 3. Connect the air line (8) to the dispenser (5). 4. Connect the fluid line (6) to the dispenser (5). 5. Calibrate the micro-adjustment assembly (3), if necessary. Refer to How to Calibrate the Micro-Adjustment Assembly in this manual. 9.
DG-1000 Dispenser 10. Testing the Dispenser 25 Perform the following steps to test the dispenser: 1. Fill the fluid system with a compatible solvent and check for leaks. Refer to the DG-1000 Flux Fluid System manual for the procedures. 2. Flush and fill the fluid system with coating material. 11. Watlow Temperature Controller Replacement Perform the following procedure to replace the temperature controller: 1. Set the setup and operation default menu parameters.
26 DG-1000 Dispenser 12. Parts To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use this five-column parts list, and the accompanying illustration, to describe and locate parts correctly. Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code NS (not shown) indicates that a listed part is not illustrated.
27 DG-1000 Dispenser See Figures 8, 9 and 10. DG-1000 Dispenser Item Part Description Quantity — 226 301 Dispenser, DG-1000 1 1 226 289 S Micro-adjustment, with lock 1 2 982 745 S Screw, set, preload 2 3 226 276 S Screw, preload 1 4 145 461 S Nut, locking 1 5 234 170 S Cap, dispenser, DG-1000 1 6 981 029 S Screw, fillister, 6-32 x 0.500 in.
28 DG-1000 Dispenser DG-1000 Dispenser (contd) Item Part Description Quantity Note 24 226 285 S Body, upper 1 25 971 728 S Fitting, 1/4 T x 10-32 1 26 226 250 S Plug, 10-32 x 0.13 in., brass 1 27 226 290 S Valve, 3-way, solenoid, 24 Vdc, 120 psi 1 28 982 746 S Screw, socket head, 4-40 x 1.00 in.
29 DG-1000 Dispenser 1 2 3 4 2 5 28 7 6 27 8 9 10 11 26 12 22 20 25 18 24 20 19 23 21 29 18 Part of 12 15 17 13 14 16 13 1235008B Fig.
30 DG-1000 Dispenser DG-1000 Dispenser (contd) 30 37 36 31 35 32 34 33 1235009B Fig. 9 DG-1000 Dispenser Tools 38 39 1235010B Fig.
31 DG-1000 Dispenser 13. Nozzle Cleaning Kit Part Description Quantity 901 934 Kit, nozzles cleaning 1 901 916 S Vise, pin 1 901 935 S Probe, vial, 0.003 in. 1 901 922 S Probe, vial, 0.007 in. 1 901 923 S Probe, vial, 0.011 in. 1 14. Broaches Part Description Quantity 094 000 Broach, nozzle, 0.003 in. 1 094 002 Broach, nozzle, 0.007 in. 1 15.
32 DG-1000 Dispenser 16. Dispenser Schematic See Figure 11. TO WORKCELL 120V LINE 120VAC NEUT WORKCELL WIRE # 1235013A Fig.
