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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.
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Part 1061906A � 2005 Nordson Corporation
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.
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Part 1061906A� 2005 Nordson Corporation
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
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Part 1061906A � 2005 Nordson Corporation
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
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Part 1061906A� 2005 Nordson Corporation
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
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Part 1061906A � 2005 Nordson Corporation
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.
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Part 1061906A� 2005 Nordson Corporation
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.
Return toMainMenu[F8]
NNNNNN
NNNNNN
TCU Control Screen
The Start and Stop buttons willcontrol the TCU when it is in Remote Control mode.
Return toMainMenu[F8]
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
Return toMainMenu[F8]
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
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Part 1061906A � 2005 Nordson Corporation
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.
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Part 1061906A� 2005 Nordson Corporation
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
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Part 1061906A � 2005 Nordson Corporation
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.
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Part 1061906A� 2005 Nordson Corporation
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
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Part 1061906A � 2005 Nordson Corporation
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
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Part 1061906A� 2005 Nordson Corporation
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.
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Part 1061906A � 2005 Nordson Corporation
TEMPERATURE CONDITIONEDMATERIAL OUTPUT LINETO APPLICATOR
MATERIAL INPUT LINEFROM SUPPLY PUMPS
TEMPERATURE CONDITIONEDMATERIAL OUTPUT LINETO APPLICATOR
MATERIAL INPUT LINEFROM SUPPLY PUMPS
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
SureMix Dispensing System 15
Part 1061906A� 2005 Nordson Corporation
MATERIAL OUTPUT LINETO APPLICATOR
MATERIAL INPUT LINEFROM SUPPLY PUMPS
COMPONENT B
MATERIAL OUTPUT LINETO APPLICATOR
MATERIAL INPUT LINEFROM SUPPLY PUMPS
COMPONENT A
GEAR-METERING PUMP
GEAR-METERING PUMP
SUPPLY AIRCONNECTION
Figure 9 Typical Connections for Non-Temperature Conditioned Metering Pumps
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Part 1061906A � 2005 Nordson Corporation
Maintenance
WARNING Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions inthis document and all other relateddocumentation.
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.
SureMix Dispensing System 17
Part 1061906A� 2005 Nordson Corporation
Troubleshooting
WARNING Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions inthis document and all other relateddocumentation.
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.
SureMix Dispensing System18
Part 1061906A � 2005 Nordson Corporation
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).
SureMix Dispensing System 19
Part 1061906A� 2005 Nordson Corporation
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
SureMix Dispensing System20
Part 1061906A � 2005 Nordson Corporation
Inline Gear Head See Figure 12
Remove the Inline Gear Head 1. Make sure that all air and material pressures are
relieved from the SureMix Dispense stand.
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.
SureMix Dispensing System 21
Part 1061906A� 2005 Nordson Corporation
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
SureMix Dispensing System22
Part 1061906A � 2005 Nordson Corporation
Pump See Figure 13.
Remove the Pump1. Make sure that all air and material pressures are
relieved from the SureMix Dispense stand.
2. Loosen the screws (14) securing the shroud (1) to themounting bracket (16). Remove the shroud.
3. Loosen the mounting bracket screws (15). Slide themounting bracket (16) back and remove the centercoupling (2).
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
NOTEThe following step requires the use of a0.050-0.100-in. shim.
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).
5. Install the center coupling (2) onto the lowercoupling (3). 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.
6. Perform the following:
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.
SureMix Dispensing System 23
Part 1061906A� 2005 Nordson Corporation
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
SureMix Dispensing System24
Part 1061906A � 2005 Nordson Corporation
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
relieved from the SureMix Dispense stand.
2. See Figure 13. Loosen the screws (14) securing theshroud (1) to the mounting bracket (16). Remove theshroud.
3. Loosen the mounting bracket screws (15). Slide themounting bracket (16) back and remove the centercoupling (2).
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).
NOTEThe following step requires the use of a0.050-0.100-in. shim.
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).
8. Install the center coupling (2) onto the lowercoupling (3). 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.
9. Perform the following:
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.
SureMix Dispensing System 25
Part 1061906A� 2005 Nordson Corporation
1
2
5
3
4
PACK SHADED AREASWITH PETROLEUM JELLY.
Figure 14 Pump Seals
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Part 1061906A � 2005 Nordson Corporation
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
SureMix Dispensing System 27
Part 1061906A� 2005 Nordson Corporation
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.
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Part 1061906A � 2005 Nordson Corporation
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)
SureMix Dispensing System 29
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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