Bossard KDG 1000 Series User manual

KVT-Fastening | CH-8953 Dietikon/Zürich |T 044.743.33.33 |F 044.740.65.66 |[e-mail] |www.kvt-fastening.ch
5100/01.15
All rights reserved
Proven Productivity
Operating Instructions
Dosing unit KDG 1000

Page
Introduction and safety instructions 3
Scope of delivery 4
Operating range 5
Control elements and connections 6
Description of functions 7 + 8
Intended use 8
Storage 8
Installation 8
Space requirements 8
Install 8
Pneumatic connection 8
Commissioning 9
Connecting the device 9
Device default settings 9
Setting the parameters 10
Example 11 + 12
Fill cartridge 13
Dosing 14
Setting the dosage in time-controlled operation 14
Setting the dosage in continuous operation 15
Interface operation 16
Decommissioning 17
Contents
1

Page
Maintenance 17
Recommended cleaning agents 17
Troubleshooting 18
Spare parts list and accessories 19
Technical data 20
Electrical components 20
Pneumatics 20
Connections and end connection sizes 20
Other data 20
Declaration of conformity 21
Contents
2

General
Read the entire manual before operating the device!
Please observe the safety instructions in particular.
The symbols used in this operating manual have the following meanings:
This note provides useful suggestions and information about improving the performance and
reliability of the device.
Store the operating manual in a place easily accessible by the operator.
Only skilled personnel may perform repairs (see EN 62079 Clause 3.17).
Immediately replace damaged power supply units and components!
Warning!
Always wear EYE PROTECTION when using compressed air and equipment operated by
compressed air!
Introduction and safety instructions
3

17
22
20
21
27
23
25
28
1 Dosing unit KDG 1000 17
1 Foot switch 18
1 Stand for cartridge 19
1 Compressed-air hose 2 m 20
1 Plastic hoses with connector 21/28
1 Power supply 22
1 Closure heads 5, 10, 30 ml 23
2 Cartridges 5, 10, 30 ml 24
2 Pistons 5, 10, 30 ml 25
3 Valve gates 26
1 Nozzle assortment 27
18
19
24 26
Scope of delivery
4
19

The KDG 1000 dosing unit is suitable for accurate application of fluid media such as adhesives (anaer-
obes, cyanoacrylates, silicones, epoxies, etc.), lubricants and solvents, paints, inks, pastes, etc. in the
viscosity range of:
1 mPa·s (water) to highly viscous and paste-like materials.
The device is designed for an autonomous product delivery point.
The quantity to be metered depends on the viscosity of the product, time setting, diameter of the dosing
nozzle and air pressure.
The KDG 1000-1 dosing unit is suitable for accurate dosing of liquid and low-viscosity products.
The KDG 1000-6 dosing unit is suitable for accurate dosing of high-viscosity and paste like products.
In other words, they are intended for creating pressure surges and vacuums with precisely defined
and reproducible properties. The pneumatic system in the device never comes into direct contact with
the dosing media when handled correctly.
Intended use
5

1. Power switch On / Off 9. Arrow key up
2. Pressure regulator 10. Arrow key down
3. Vacuum regulator 11. Power connector
4. LED 12. Interface ext. Controller
5. Display 13. Initiator port
6. Cartridge port 14. Compressed air supply
7. Menu key 15. Rating plate
8. Enter key
Control elements and connections
6
1. Net zschalt er On/Of f
2. Druckregler
3. Vakuumr egler
4 . LED
5. Display
6. Kart uschenanschluss
7. Menut ast e
8. Ent ert ast e
9. Pf eilt ast e auf
10. Pf eilt ast e ab
11. Net zanschluss
12. Schnittstelle ext. Steuerung
13. Init iat oranschluss
14. Druckluf t anschluss
15. Lei st ungsschild
Frontseite

Front
Back
1 3 5 4 7 9 2
6 8 10
11 12 13 14
15

Description of functions
7
Basic functions
Pressure: Manually set by turning the pressure regulator and controls the dosing pressure. Indicator on
display (5).
Vacuum: Manually set by turning the vacuum regulator (3) and prevents dripping during pauses in dosing.
Dosing time: Manually set by pressing the arrow keys (9+10) and controls the dosing duration. Indicator
on display (5).
(Only possible when the operating mode is set to Time)
Parameters
Operating mode
Time: Dosing duration based on the time entered.
Duration: Dosing continues as long as the button is pressed or there is an external signal.
Repetition: Repeats the starting pulses for dosing based on the time set as long as the button is
pressed or there is an external signal.
Triggering
Manual: Dosing is triggered by manually pressing a button (foot switch).
External: Dosing is triggered by external control (PLC).
Relay
On: The starting pulse and corresponding pause time are output to the relay.
Off: No output to the relay.
Unit of pressure
bar: Display of pressure in bar
PSI: Display of pressure in PSI
Language Display of texts in:
   •German•French•Italian•English
Contrast
The arrow keys can be used to set the display contrast.
Special functions
Default parameters
If the menu key (7) is pressed at the same time the device is switched on, the default
parameters are loaded and saved. A signal tone confirms the completed process.



 
Installation
8
Pneumatic connection
Connect the unit via the quick coupling piece (14) to the back of the device with the compressed-air hose
(20) to the compressed air supply (operating pressure max. 6 bar). If using a vacuum and there are power
fluctuations of more than 0,5 bar, it is imperative to install a pressure reduction valve upstream and to set it
to the lowest possible supply pressure. When processing products that react to moisture, a water-separat-
ing filter unit is recommended.
Observe environmental conditions:
•Nocondensingairhumidity
•Nosplashwater
The media to be dispensed may be negatively affected.
Space requirements
Installation
Install the dosing unit horizontally and in an elevated position (above the working height)!

Connecting the device
•Only use the hose sets and cables included!
•Please note the procedures on pages 11 and 12 before connecting.
•Connect the foot switch (18) to the connection socket.
•Mount the plastic hose with circular connector (21/28) to the cartridge closure head (23) and connect
the quick coupling (28) to the cartridge connection (6).
•Connect the empty cartridge (24) to the cartridge closure head (23) and plug in the selected dosing
nozzle (27).
Device default settings
•Set the vacuum regulator (3) to 0 (turn clockwise!)
•Set the pressure regulator (2) to 0 (turn counterclockwise!)
•Use arrow keys (9+10) to set the dosing time to 0.01 second
•Switch on the power switch (1)
Commissioning
9
1. Net zschalt er On/Of f
2. Dr uckregler
3. Vakuumregl er
4 . LED
5. Display
6. Kart uschenanschluss
7. Menut ast e
8. Ent ert ast e
9. Pf eil t ast e auf
10. Pf eil t ast e ab
11. Net zanschl uss
12. Schnittstelle ext. Steuerung
13. Init iat oranschluss
14. Druckluf t anschluss
15. Leist ungsschi ld
Frontseite

1 3 5 4 7 9 2
6 8 10

1. Press menu key 7.
2. Select the parameter by navigating with arrow keys 9 and 10.
3. Confirm the parameter by pressing the Enter key 8.
4. Set the parameter value in the submenu by navigating with arrow keys 9 and 10.
5. Confirm the new parameter value by pressing the Enter key 8.
6. Exit the submenu by pressing the menu key 7.
7. Save and return the default screen by pressing the menu key 7.
Setting the parameters
10
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

Setting the parameters
11
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












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
SwitchingthetriggeringoperatingfromMANUALtoEXTERNAL
Default display
Call up parameter list
Select parameter
Call up submenu
Press menu key
Press arrow key down
Press Enter key

Setting the parameters
12
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


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




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
SwitchingthetriggeringoperatingfromMANUALtoEXTERNAL
Set value
Confirm value
Back to parameter list
Save parameters and back
to default display
Press Enter key
Press menu key
Press menu key
Press arrow key down

Fill cartridge
Notethegeneralsafetyregulationsforhandlingchemicalproducts!Caution:Dangerof
chemical burn!
•Use the valve gate (26) to close the cartridge (24).
•Fill the medium through the cartridge opening Fill cartridge max.. 2/3!
•Insert piston (24) into the cartridge. (For paste-like and thick products)
If the piston (25) is not used, the medium can escape from the cartridge into and damage the
dosing unit when handled incorrectly!
Do not hold the cartridge high or turn upward!
Mediumflowsintothedevice.Caution:Riskofclogging.
Commissioning
13

Dosing
14
Setting the dosage in time-controlled operation
(Cycle mode)
•Install device (see page 13)
•Set the device to the default settings (see page 13)
•Switch on the power switch (1)
•Fill cartridge (see page 17)
•Press the keys (9+10) for 0.3 seconds to set the dosing time
(see page 13)
•Remove the valve gate (26)
•For low-viscosity products, set the vacuum to prevent the product from escaping
from the cartridge when removing the valve gate (26) and mounting the dosing needle (27).
Allow 1 or 2 drops to flow out of the dosing needle.
Then use the vacuum regulator (3) to slowly adjust the vacuum.
Turn counterclockwise: The back pressure increases.
Turn clockwise: The back pressure decreases.
Depending on the viscosity and size of the cartridge, the vacuum will have to be adjusted again
as the cartridge empties!
If the vacuum is set too high – when dosing with no piston – the medium can escape from the
cartridge into and damage the dosing unit.
Press the foot switch (18) repeatedly with the pressure regulator (2) to increase the dosing pressure gradu-
ally from 0 until the required quantity is reached.
Once the approximate dosage is reached, the quantity can be accurately set by adjusting the dosing time.
If the required dosage is not reached, repeat the repeat the steps using larger or smaller dosing nozzles.
1. Net zschal t er On/Of f
2. Druckr egler
3. Vakuumregl er
4 . LED
5. Display
6. Kart uschenanschluss
7. Menut ast e
8. Ent ert ast e
9. Pf eil t ast e auf
10. Pf eil t ast e ab
11. Netzanschluss
12. Schnittstelle ext. Steuerung
13. Init iat oranschluss
14. Druckluf t anschl uss
15. Leist ungsschi ld
Frontseite

1 3 5 4 7 9 2
6 8 10

Dosing
15
Setting the dosage in continuous operation
(Continuous mode)
•Install device (see page 13)
•Set the device to the default settings (see page 13)
•Fill cartridge (see page 17)
•Switch on the power switch (1)
•Set operating mode to «Continuous»
•Remove the valve gate (26)
•Press and hold the foot switch (18)
•Use the pressure regulator (2) to increase from 0
to the required quantity
•For low-viscosity products, set the vacuum to prevent the product from escaping
from the cartridge when removing the valve gate (26) and mounting the dosing needle (27).
Allow 1 or 2 drops to flow out of the dosing needle.
Then use the vacuum regulator (3) to slowly adjust the vacuum.
Turn counterclockwise: The back pressure increases.
Turn clockwise: The back pressure decreases.
Depending on the viscosity and size of the cartridge, the vacuum will have to
be adjusted again
If the vacuum is set too high – when dosing with no piston – the medium can escape from the
cartridge into and damage the dosing unit.
Press the foot switch (18) repeatedly with the pressure regulator (2) to increase the dosing pressure gradu-
ally from 0 until the required quantity is reached.
If the required dosage is not reached, repeat the repeat the steps using larger or smaller dosing nozzles.
1. Net zschalt er On/Of f
2. Druckregl er
3. Vakuumregler
4 . LED
5. Display
6. Kart uschenanschluss
7. Menut ast e
8. Ent ert ast e
9. Pf eil t ast e auf
10. Pf eil t ast e ab
11. Net zanschl uss
12. Schnittstelle ext. Steuerung
13. Init iat oranschluss
14. Druckluf t anschluss
15. Lei st ungsschi ld
Frontseite

1 3 5 4 7 9 2
6 8 10

Dosing
16
Interface description
The interface (12) for external dose triggering is on the back of the device. In addition to the foot switch
(18), a potential-free contact or inductive proximity switch can be used for triggering.
Pin assignment
Connection diagram for
potential-free contact
Connection diagram for
inductive proximity switch
Relay
The dosing time is output via the device-internal relay contact on pin 4 and 5.
24V
Sensor IN
GND
Relay point


3 wire-DC PNP-closer
+
A
-

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Schnittstellenbeschrieb
Die Schnittstelle (12) für die externe Auslösung einer Dosierung befindet sich
an der Rückseite des Gerätes. Nebst dem Fusstaster (18) kann sie auch mit
einem potentialfreien Kontakt oder einem induktiven Näherungsschalter
ausgelöst werden.
Pinbelegung:
Ansicht von
Hinten
Anschluss-Schema für potentialfreien
Kontakt :
Anschluss-Schema für induktiven
Näherungsschalter :



View from behind

Dosing
17
Decommissioning
During longer periods of non-use (more than approx. 5 hours), it makes sense to decommission the sys-
tem to prevent the product from hardening!
•Switch the power switch (1) to OFF!
•Use the valve gate (26) to close the cartridge (24) and disconnect the plastic hose with circular
connector (21/28) from the device!
•Interrupt the compressed-air supply from the compressed-air system
•Set the device to the default settings (see page 9)
Care and maintenance
Only use cleaning agents recommended by the manufacturer.
LOCTITEcleanertype7070,Art.No.118225(400ml)
Storage
Always keep the KDG 1000 away from electricity and compressed air and in dry rooms.

18
Troubleshooting
FAULT
No display
No change in value in the pressure
display
No dosing
Too little or too much product
Product drips
CAUSE
• Nosupplyvoltage
• Defectivepowersupply(22)
• Powerswitch(1)inOFFposition
• Defectivepowerswitch(1)
• Defectivedisplay
• Nocompressedair
• Defectivepressureregulator(2)
• Defectivecontrolunit
• Footswitch(18)notconnected
• Nocompressedair
• Dosingpressurenot
set correctly
• Connectionhose(21)betweendevice
and cartridge not plugged in
• Dosingnozzle(27)clogged
• Defectivecontrolunit
• Dosingpressurenot
set correctly
• Wrongdosingnozzlemounted
• Vacuumregulator(3)settoolow
• Vent(14)clogged
REMEDY
• Checksupplyvoltage
• Powerswitch(1)inONposition
• Replacepowerswitch(1)(servicecenter)
• Replacepowersupply(22)
• Replacedisplay(servicecenter)
• Checkcompressedairsupply
• Servicecenter/supplier
• Servicecenter/supplier
• Connectfootswitch(18)
• Checkcompressedairsupply
• Correctdosingpressuresetting
• Insertconnectionhose
• Replacedosingnozzle(27)
• Servicecenter/supplier
• Correctdosingpressuresetting
(see page 15)
• Switchdosingnozzle
• Turnvacuumregulator(3)counterclock-
wise until the dripping stops
(see page 15)
• Checkventilation

Spare parts list and accessories
Designation  TypeArt.No.
Foot switch KDG 146 109 116 1
Power supply KDG 1102 173 892 1
Interface connector KDG 1101 173 893 1
Cartridge stand KDG 147 109 050 1
Compressed-air hose 2 m KDG 170 109 047 1
Plastic hose with circular connector KDG 142 109 046 1
Cartridge closure head 5 ml KDG 201 109 028 1
10 ml KDG 202 109 030 1
30 ml KDG 203 109 032 1
O-Ring, nitrile 5 ml KDG 205 109 038 10
10 ml KDG 206 109 039 10
30 ml KDG 207 109 040 10
O-Ring, silicone 5 ml KDG 210 109 043 10
10 ml KDG 211 109 041 10
30 ml KDG 212 109 045 10
Cartridge termination 5 ml KDG 235 109 034 40
10 ml KDG 236 109 035 30
30 ml KDG 237 109 036 20
Cartridge piston, neoprene 5 ml KDG 230 109 027 40
10 ml KDG 231 109 026 30
30 ml KDG 232 109 025 20
PistonFW 5ml KDG290 122840 40
10 ml KDG 291 122 841 30
30 ml KDG 292 122 842 20
Cartridge, polypropylene, transparent 5 ml KDG 215 109 010 40
10 ml KDG 216 109 011 30
30 ml KDG 217 109 012 10
UV cartridge, polypropylene, transparent 5 ml KDG 220 113 997 40
10 ml KDG 221 113 996 30
30 ml KDG 222 113 986 10
Cartridge valve gate KDG 240 109 037 50
Metal nozzles, internal ø 1.60 KDG 250 109 015 50
1.37 KDG 251 109 016 50
0.84 KDG 252 109 017 50
0.58 KDG 253 109 018 50
0.51 KDG 254 109 019 50
0.41 KDG 255 109 020 50
0.33 KDG 256 109 021 50
0.25 KDG 257 109 022 50
0.15 KDG 258 117 493 50
Plastic nozzles, flexible, internal ø 0.5 KDG 150 109 023 50
0.8 KDG 241 109 216 50
1.5 KDG 242 109 217 50
Special nozzles with Teflon nozzles, internal ø 0.25 KDG 247 109 058 50
0.51 KDG 248 109 057 50
Polypropylene nozzles, flexible, internal ø 1.25 KDG 280 111 359 50
0.81 KDG 281 109 053 50
0.60 KDG 282 109 054 50
0.35 KDG 283 109 055 50
Polypropylene nozzles, conical, internal ø 1.20 KDG 270 109 059 50
0.84 KDG 271 109 060 50
0.58 KDG 272 109 061 50
0.41 KDG 273 109 062 50
Nozzle assortment KDG 300 121 864 1
Brush tip needle, soft KDG 304 130 227 1
Brush tip needle, hard KDG 305 130 235 1
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