PPG Semco 1088 User manual

PPG Semco
®
1088 CE Non-Twist Mixer
Operating instructions & troubleshooting guide

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Table of Contents
1 –Requirements & ratings ........................................................................................................................ 2
2 –Machine description .............................................................................................................................. 3
3 –Safety instructions ...................................................................................................................................... 4
4 –Safety features ........................................................................................................................................... 5
5 –Set-Up .........................................................................................................................................................5
6 –Lay-out ........................................................................................................................................................6
7 –Operation ................................................................................................................................................. 7-8
8 –Maintenance preparation ........................................................................................................................... 9
9 –Preventative maintenance ................................................................................................................... 10-13
10–Calibration procedure ............................................................................................................................... 14
11–Mixer setting adjustment ..................................................................................................................... 15-19
12–Troubleshooting ................................................................................................................................... 20-24
13–Spare parts .......................................................................................................................................... 25-27
14–Appendix ...................................................................................................................................................28
15–Schematic ..................................................................................................................................................29
Notice
This document is based on information available at the time of publication. While PPG, has made every effort to provide
current and accurate information, this manual will cover all contingencies regarding installation, startup, operation, and
maintenance based on data collected during factory acceptance testing and production simulation runs by PPG.
PPG assumes no responsibility for third-party or original equipment manufacturer (OEM) documentation used for this
publication or included as supplemental information that is to be used as an internally controlled document.
This publication may not be reproduced by any means or distributed, in whole or in part, without the express written
consent of PPG.

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1. Requirements & ratings
1.1 PPG SEMCO®Model 1088 CE non-twist mixer is not to be used in explosive environments.
1.2 Compressed Air, no oil, moisture, or dust particles. Use the supplied air filter to prevent contamination.
1.3 Pressure min/max: 85 psi (5.9 bar) –100 psi (6.6 bar). It is recommended that a regulator/filter be used
at the machine location to ensure clean, dry air is supplied.
1.4 Air rate required: Min. 3 CFM (80 l/min - 5 m³/h)
1.5 Length x width: 380 mm x 300 mm
1.6 Height min/max: 775/975 mm
1.7 Max. working stroke: 250 mm
1.8 Recommended motor speed: approx. 135 rpm (see Section 10)
1.9 Max. torque at driver: 29 Nm
1.10 Cartridge outer diameter: 43 mm
1.11 Recommended set-up height: normal workbench height
1.12 Weight: approx. (35 kg) –75 lb.

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2. Machine description
The PPG Semco 1088 CE non-twist mixer was developed for mixing of two-component cartridges holding 2.5
oz., 6 oz. and 8 oz. cartridges with 6", 8", or 20cc dasher rods. The mixer has the added ability to mix super-
viscous material filled cartridges. The two-stage motor speed ramp-up along with a customized cartridge
holder design allows hands-free automatic mixing with these difficult to mix materials.
The cartridges are ready for use directly after the mixing operation with Semco 1088 CE non-twist mixer. The
mixer ensures that the result of the mixture is uniform. During operation, the mixer injects the accelerator and
strokes up and down so the components are evenly distributed in the cartridge. Rotation of the dasher rod,
including the dasher, is affected by an air-operated motor.
The cartridge is inserted into an easy-to-operate slide plate assembly, and it is fixed securely by the cap
assembly during the mixing operation. The cylinder in the cap assembly ensures that uniform pressure is
exerted on the plunger during the mixing process, preventing any air from entering the cartridge during
mixing.
By utilizing the SEMKIT®package ruler on the left-hand side of the Semco 1088 CE non-twist mixer, operators
are able to identify what size cartridge and dasher rod length they have. With this information, the machine
can be adjusted to the correct setting utilizing the Semkit configuration switch on the right-hand side of the
machine. The stroke motion is adjusted automatically to the cartridge size and fill level. Any differences in fill
level, and/or tolerances between cartridges are detected and adjusted automatically by the Semco 1088 CE
non-twist mixer. Manual adjustment of the mixing stroke or pre-selection of the mixing time is not necessary.
The duration of the mixing operation is determined by the number of strokes performed.
The Semco 1088 CE non-twist mixer can be used with a high degree of flexibility for various products. Its
easy operation minimizes any operating errors. Together with the automatic stroke adjustment and automatic
mixing time, the mixer contributes towards a consistently high-quality mixing result. Its high strength
construction, dual-guided stroke, reliability, and fully pneumatic control system enable the Semco 1088 CE
non-twist mixer to have long intervals between maintenance and a long service life.

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3. Safety instructions
3.1 Before operating mixer, read manual and follow all safety instructions.
3.2 General laws and regulations concerning safety and accident prevention must also be used when
operating any machinery.
3.3 Only trained and authorized personnel shall operate and service this machine.
3.4 Never operate machine without safety guards in place.
3.5 To maintain the warranty of the machine, an external air filter and trap is required.
3.6 Wear approved industrial safety glasses and gloves.
3.7 Long hair, rings, watches, jewelry, or other loose items could become caught in moving parts.
3.8 Keep all parts of your body away from moving parts (belts, gears, etc.).
3.9 Do not attempt to bypass safety measures by placing hands, arms, legs, or any other body parts
around or through the safety enclosure when safety devices are activated closed.
3.10 Use proper point of operation safeguarding.
3.11 Prior to servicing the machine, isolate all hazardous energy from the machine (electrical power,
compressed air, etc.) also perform standard lockout/tag-out procedure.
3.12 Prior to performing service on commercial items, refer to the appropriate commercial item maintenance
instruction sheet.
3.13 Do not trigger safety devices to regularly stop the machine. The safety devices are not intended to be
used as the stop button.
3.14 Take special caution when opening the machine. The machine may not stop immediately when a safety
device is triggered.
3.15 If an emergency arises and the machine must be stopped immediately, press the stop button located on
the front of the machine.

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4. Safety features
4.1 There are two primary safety features on this machine: machine safety guard door and stop push
button.
4.2 The guard door is intended to prevent entry into the machine operating area while the machine is in
operation. The mixer may not stop immediately when door is opened. Therefore, caution must be taken
before opening the machine.
4.3 The stop button is located on the front of the machine. This button is to be used when an emergency
arises, and the machine needs to be stopped immediately.
5. Set-up
5.1 Make sure the mixer is placed on a firm level surface to withstand the weight of the machine. Check the
working surface area and operation area.
5.2 Prior to use, verify mixer is in good and safe operational condition. Do not operate mixer if safety
guards, operating parts, or components are damaged or missing.
5.3 Never operate mixer without a cartridge.
5.4 Never release a cartridge when the mixer is in operation.
5.5 Always place cap assembly onto its holder when mixer is not in use or between cartridge cycles.
5.6 When mixing dangerous or hazardous contents, please follow the safety precautions for handling
and processing the product specified by the manufacturer or supplier.
5.7 If necessary, the Semco 1088 CE non-twist mixer can be mounted to a flat surface using bolts and
mounting holes drilled through the base plate.
5.8 NOTE: After a long period of storage or initial use, the compressed air motor may not start immediately
when the start button is pressed. In this case, the spindle may need to be manually turned several
revolutions in a counterclockwise direction. Afterwards, press start button to begin mixing.

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6. Lay-out
Part Number
Description
235154
Semco model 1088 CE non-twist auto mixer for Semkit packages.
Start button
Stroke counter
Cartridge up
button
Stop button
ON/OFF valve
(side)
Spindle
Limit toggle
switch
Semkit package
ruler
Cartridge holder
Cartridge pusher
assembly
Cartridge pusher
holder
Selector switch

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Safety
guard door
Cartridge
pusher holder
Stroke counter
Cartridge
up button
Semkit
configuration
kit
Cartridge
pusher
assembly
Cartridge
holder
Semkit ruler
Spindle &
drive pins
7. Operation
7.1 Open safety guard door.
7.2 If machine is holding a Semkit cartridge from
earlier cycle. Open the latches on both sides
of the cartridge pusher assembly clockwise to
release and place into the cartridge pusher
holder on the top of the machine. Release the
dasher rod from the spindle drive pins and
move the cartridge upwards, lift and remove
Semkit from the cartridge holder.
7.3 New cartridge - Adjust to size. Use the Semkit
package ruler to determine cartridge size and
rod length. Semco sizes: 2.5 oz.-6" rod, 6 oz.-
6" rod, 2.5 oz.-8" rod,6 oz.-8" rod & 8 oz.-8"
rod are supported. Fully extend the dasher rod
on the Semkit package all the way to the top
of the cartridge and measure the length
against the Semkit package ruler. Use Semkit
configuration switch to select the configuration
of dasher rod and cartridge. The machine will
automatically adjust to the selected con
figuration. See Appendix 1 for Semkit package
diagram (barrier and injection style).
7.4 For barrier style Semkit packages,
remove tape surrounding cartridge and break
the dasher free (loosen barrier) before loading
into mixer.
7.5 Load the Semkit into the cartridge holder and
take the cartridge pusher assembly and place
into the open end of the Semkit cartridge.
Press the cartridge holder up button while
pushing down on the cartridge pusher
assembly. Close the latches on both sides of
the holder to keep the cartridge firmly in place.
(For mixers with twist style cartridge pushers,
firmly turn the pusher assembly
counterclockwise to lock the pins in place. The
red or black indicator lines should be aligned
to verify correct orientation.)
7.6 Check the toggle switch (roller valve) at the
top of the machine to make sure it’s not
depressed or jammed in any way by the two
flags on the rear of the cartridge pusher
assembly.
Toggle switch

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7. Operation (cont.)
7.7 Align the dasher rod drive holes on to the spindle drive pins.
Twisting the spindle counterclockwise will help engage
the pins to the dasher rod prior to start.
7.8 Read the bag of the Semkit package and identify how many
strokes are required (this will be referenced under ‘Hand-mix’,
but this process is acceptable for mixing on the Semkit 1088
CE non-twist mixer). Set the double-stroke preset counter.
7.9 Presetting Counter. Hold the white button down on the counter
to change the stroke count. On cycle counter select desired
number of up/down strokes. Lower display is for preset
number and the upper is the actual number stokes completed.
If the machine door is opened during operation or if the stop
button is pressed, the stroke count will return to zero. The
machine will not restart from where it was interrupted.
7.10 Before starting each mixing cycle, make sure the cartridge
is clamped into the cartridge holder and the dasher rod is
inserted to the drive pins.
7.11 Close safety door.
7.12 Press the “Start” push button (black) to begin operation.
7.13 Mixing will perform entire sequence without operator’s
intervention. Wait until machine switches off automatically.
7.14 Once the mixer stops cycling, the operation is over.
7.15 Removing Cartridge. Simply follow steps 7.1 & 7.2
When the stop button is pressed or door is opened during
operation, the system will reset the counter.
Automatic Catalyst Injection
The Semco 1088 CE non-twist mixer features an injection rod that
automatically travels through the dasher rod during the mixing cycle.
The injection rod is designed to completely dispense all catalyst into
the cartridge during mixing. No pre-injection using the ram rod is
needed.
Keep the injection rod clean by following instructions in Preventative
Maintenance (Section 9).

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8. Maintenance Preparation
Before carrying out any maintenance work, repairs, or cleaning, release the air from the mixer by
opening the main valve. This is done by turning the on/off valve to the off position. Also, disconnect
mixer from the compressed air supply.
Some preventative maintenance activities will require the removal of the rear or front panels. Listed below are
instructions.
Removing the rear panel
The rear panel is attached by 10 Allen wrench bolts.
1. Using Allen wrench, remove all 10 bolts from the rear panel.
2. When maintenance work is completed, re-install the bolts. Do not overtighten.
Removing the front panel
The front panel is attached by 4 Allen Wrench bolts.
1. Remove the four screws (McMaster-Carr 92125A210) using a 3 mm
Metric Allen wrench on the front lower panel of the mixer.
2. Remove the lever on the start & stop switches (on the inside panel) from
the lock position to unlock which will release the door panel from the
switches.
3. Reattach the start and stop buttons to the door panel and lock them in
place. Put door panel back on and screw in the four screws in the
corners of the front panel back on the machine. Do not overtighten.
Switches after being released
from the panel

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9. Preventative maintenance
Daily
1. Complete a quick visual inspection of the unit to ensure surfaces are clear from dust, sealants/ adhesives,
other liquids, etc. Use a clean cloth to clear machine surfaces. If debris remain, use only a mild solvent
(like IPA) approved by your location and clean cloth to clear surfaces and use solvent sparingly.
•Check the spindle to ensure the item is clean and clear of any residual sealant/ adhesive. If not clean,
apply mild solvent to a clean cloth to remove sealant/adhesive.
Harsh solvents like acetone, paint thinners, isocyanate, and MEK should not be used.
2. Inspect injection rod –With machine in off position, pull up the injection rod and inspect surface for
contamination. Clean with cloth as needed.
Pull injection up Wipe rod with cloth
3. Ensure start/stop buttons work –If not, refer to Troubleshooting (Section 12).
4. Inspect hose that connects to the cap assembly and assure there is no damage, such as a kinked hose,
which will affect the performance of the machine.
5. Listen for air leaks when the mixer is turned off. If an air leak is heard, contact your maintenance
department, or refer to Troubleshooting (Section 12).
6. The filter /regulator should be checked on at least a weekly basis, more often if usage is heavy. This will
ensure the longevity of the mixer.

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9. Preventative maintenance (cont.)
Turn OFF/ON Switch to OFF and disconnect compressed air supply prior to opening any mixer
panels. Work should be done in non-hazardous area. Refer to Maintenance preparation (Section 8) for
instructions on opening/closing mixer panels.
Quarterly (monthly for heavy usage)
Main guide shafts –
The main guide shafts and bushings should be inspected for damage
and cleaned. This will reduce the amount of the contamination that
may develop on the shafts or in the linear bearing housings and help
to ensure smooth operation of the unit.
1. Remove rear panel.
2. Clean shafts and bushings with dry cloth as needed. If the
shafts are coated with sealant or other contaminant, use IPA with
cloth to clean surfaces.
3. Reinstall rear panel.
Lubricate air motor –
The Semco 1088 CE non-twist mixer is designed with a motor that
does not require constant lubrication However, with heavy
usage or without a dedicated dryer treating the air at the mixer
input it is CRITICAL to lubricate the motor at least monthly.
Remove front panel.
1. Identify the hose going into the air motor labeled as 1a and
depress the Push-In fitting to release the hose.
2. Once the hose has been released from the air motor, insert 4-5
drops of pneumatic tool oil into the hose and re-insert the hose
into the air motor.
3. Re-install front panel.

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9. Preventative maintenance (cont.)
Turn OFF/ON Switch to OFF and disconnect compressed air supply prior to opening any mixer panels.
Work should be done in non-hazardous area.
Quarterly (monthly for heavy usage) (cont.)
Inspect air motor muffler –
1. Remove front panel.
2. Remove muffler assembly on bottom of motor using
17mm Wrench and turning counterclockwise.
3. Inspect for contamination. Only a thin oil film should
be present; debris or black/brown coloration
indicates damage to the motor. Note that plastic ring is
on top of the metal muffler. Using cloth with IPA wipe
down the inner shaft and inside the metal muffler.
4. Re-install front panel.
Do not turn set screw at the end of the shaft, this will
affect the rpm of the mixer. After cleaning, re-calibration of
the spindle rpm may be needed.
Inspect under spindle and clean –
1. Use thin 19 mm wrench to hold the rotating bearing
underneath the engagement spindle in place.
2. Hold on to spindle with an adjustable wrench as shown.
(If there are no flat areas on the spindle, use the
engagement pins to loosen.)
3. Turn adjustable wrench counterclockwise to loosen and
remove.
Wipe area with clean cloth. IPA solvent is OK. When done,
lightly thread spindle back on shaft; do not overtighten,
regular use will tighten spindle appropriately.

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9. Preventative maintenance (cont.)
Turn OFF/ON Switch to OFF and disconnect compressed air supply prior to opening any mixer
panels. Work should be done in non-hazardous area.
Annually (quarterly for heavy usage)
Inspect air motor belt –
The timing belt drives the rotary bearing shaft,
turning the dasher rod during the mixing cycle.
Cured materials in and around the spindle assembly
can cause it to stall and will result in damage to the
belt.
1. Remove front panel.
2. Inspect physical condition of the timing belt,
looking for any frayed threads or other signs of
wear.
3. The belt should also have minor flexibility when
pressed on. If too loose or tight, the belt could
be damaged.
Changing air motor belt (if damaged) –
1. Remove front panel, rear panel.
2. Remove spindle (see page 12)
3. Remove four M5 bolts around the spindle.
4. Loosen the four bolts on the rear of the mixer
holding the air motor.
5. Slide the air motor toward the injection
assembly.
6. The rotary bearing shaft will slide up and allow
for the old belt to come out and the new belt to
be placed. Tension the new belt appropriately
during step 3 (two people may be needed) while
following steps in reverse order to complete
installation.
Often a damaged belt is caused by a seized rotary
assembly (spindle), so it may require overcoming
any cured material or rust to remove the belt. The
rotary assembly or its components should also be
inspected and may require replacement.

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10. Calibration Procedure
The Semco 1088 CE non-twist mixer is calibrated to function at the optimal rate to completely mix all sizes of
Semkit packages. The mixer’s main functions should be checked on an annual basis to ensure consistent
operation. These functions are listed below. They include a visual inspection of mixed sealant, generally
verifying the mixer is working appropriately, and mixing the materials according to the work instructions.
Detailed procedures to the following checks are in Mixer setting adjustment (Section 11). Factory calibration is
performed at 100psi.
1. Spindle rpm - the spindle rotations with no cartridge installed: 135 +/- 10rpm.
2. Catalyst injection rod –steady upward movement when activated: 5 +/- 2 second travel time until fully
extended, then return to retracted position afterwards. Check with no kit installed on any “-8” setting.
3. Stroke cycles –up/down cycles per minute: 20 +/- 2 cycles/min. on the 6 oz.-8” selector switch setting.
Use 6 oz.-8” Semkit fully water filled cartridge (plunger within 1” from the flange)
4. Visual cartridge checks –Homogeneity & end wiping of cartridge.
a.The mixed sealant should be the homogeneous with no distinctive striations.
b.The dome and plunger surfaces should be generally wiped and little unmixed base material.
(Minor unmixed material on edges or flat area of plunger OK.)

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11. Mixer setting adjustments
Factory calibration is performed at 100psi. The factory settings are as follows:
1. Spindle rpm (the rotations of the dasher rod per minute): 135 +/- 10rpm
2. Stroke cycles (up and down cycles, using water filled 6 oz.-8" cartridge kit): 20 +/- 2 cycles/min.
3. Toggle switch: activates at perpendicular to center panel (~15-30 degrees above when at rest)
4. Sensors and cartridge height settings –See pictures
Calibration –Spindle rpm
High and low RPM impacts the speed at which the base and catalyst are mixed. If too fast, elevated
temperatures may cause premature cure; too slow, insufficient mixing will cause delayed or incomplete
curing.
1. Use non-contact tachometer and place reflective sticker
on the spindle. Depending on tachometer model, it may
be necessary to dull the spindle sides with something
like masking tape before adding the reflective sticker
2. Close door and activate mixer with NO Semkit package
installed. The mixer will not cycle up/ down; however, the
spindle should spin at 135 +/- 10 rpm. If mixer is outside
that range, refer to Preventative maintenance (Section 9)
for cleaning, inspection, and maintenance of all
motor/belt/spindlecomponents, then check again. If no
problems are found, but the spindle rpm remains outside
the desired range, then perform steps 3 through 5 below:
3. Open front panel.
4. The speed control is on the bottom of the muffler. Using a
short/small flathead screwdriver, twist the screw until the
required speed is obtained.
If after all preventative maintenance is performed the
required speed cannot be achieved, the motor is likely
damaged and will require specialized repair or complete
replacement.
5. Re-install front panel.
Use caution when activating the machine
with the front panel open. There are moving
parts, including the timing belt.

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11. Mixer setting adjustments (cont.)
Calibration –stroke speed
Speed is set with 6 oz.-8" cartridge kit filled with water.
Using another kit size will affect the stroke speed, i.e., 2.5
oz. will be faster, 8 oz. will be slower at the same setting.
The stroke setting determines the total mixing ‘work’ goes
into the cartridge at a given motor speed.
1. Install 6 oz.-8" cartridge kit on the mixer and activate
machine.
2. Remove rear panel.
3. On lower section of the mixer, the main cylinder moves
the cartridge holder up/down.
The stroke speed is adjusted by opening/closing the
flow valves at the top and bottom of the main air
cylinder
Using small flathead screwdriver, turn both upper and
lower flow valves equally to adjust stroke speed. Start
with half turns of the set screw (do NOT turn the
hexagonal fitting head), then measure stroke speed
with stopwatch and repeat as needed. (20 +/-2 per
minute)
Clockwise: Slower
Counter-clockwise: Faster
4. When done, reinstall rear panel.
Calibration –Pressure Regulators
There are 2 pressure regulators in the mixer. One to control
the cartridge up speed and the other to apply pressure to the
plunger during mixing. They are factory set according to their
function and maintained by a locknut or locking cap. It is not
necessary to check the regulators unless there is an
observable problem with excess sealant ‘weeping’ or air
content or the cartridge up function is too fast/slow. The
factory settings are as follows:
Cartridge Pusher Regulator –37psi
Cartridge Up Button Regulator –22psi
The regulators cannot be accurately adjusted while installed
on the mixer. An external dedicated pressure indicator circuit
is needed to properly adjust. Please note the cartridge up
regulator is set to improve operator safety while
installing Semkits. Take caution in adjusting pressure.

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11. Mixer setting adjustments (cont.)
Calibration –cartridge holder height adjustment
Adjustment should only be performed if multiple sensors and
toggle are significantly out of alignment in uniform direction
(very uncommon).
1. Remove rear panel.
2. On upper section of the mixer, the cartridge holder plate
(knuckle height) should be 2 5/32" from the middle plate.
Measure from bottom side of plate to middle plate.
3. To adjust the height, the locking bolt needs to be
loosened. Twist locking bolt and adjustment knuckle bolt
in opposite directions. Use 17 mm and 13 mm open end
wrench.
4. Turn adjustment knuckle until desired height is achieved.
5. Tighten locking bolt while holding adjustment knuckle in
place with another wrench.
Calibration –toggle switch
The toggle switch is activated at the bottom of the down
stroke. Its proper function allows mixing of the plunger side
in the cartridge. Too low and the mixer may stall or cause
excess movement of the plunger in the cartridge. Too high
and there will be unmixed product near the plunger.
The toggle switch should be approximately 15 to 30 degrees
above the horizontal position at rest, but a horizontal
‘engagement point’ is the critical aspect. The engagement
point can be felt when lightly pressing down on the toggle
switch with your finger. There is a resistance increase that
can be felt at the point when the internal valve is engaged
inside the toggle switch.
If adjustments are needed:
1. Use a 2.5 mm Allen wrench to loosen the underside bolt.
2. Move the toggle to the correct position and re-tighten
bolt. (If lever does not turn on the shaft, use flathead
screwdriver to hold the shaft while moving the lever
manually.)
3. Re-check the engagement point by lightly pressing down
on the lever with your finger to feel a slight resistance to
the lever motion downward. This point should be when
the toggle lever is exactly horizontal.
15-30 Degrees

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11. Mixer setting adjustments (cont.)
Calibration –Semkit package sensor locations
1. Remove rear panel.
2. On lower section of the mixer, the main cylinder has 5
sensors mounted to the cylinder:
Configuration
Sensor Location
SW1
2.5 oz. 6"
8 & 17/32"
216.7 mm
SW2
6 oz. 6"
5 & 7/16"
138.1 mm
SW3
8 oz. 8"
1 & 11/16"
42.8 mm
SW4
6 oz. 8" or
6 oz. 20cc
3 & 18/32"
90.5mm
SW5
2.5 oz. 8"
6 & 21/32"
169.1mm
3. Check the sensor location. It is measured from the top of
the cylinder to the top edge of the sensor. See red lines
in picture.
4. If sensors are greater than 1/32" from the locations listed
above, proceed to step 5 below.
5. Using 2.5 mm Allen wrench, loosen the sensor block bolt.
6. Move sensor up or down until proper distance from top
of cylinder is located.
7. Tighten sensor block bolt firmly.
8. When all checks/adjustments are completed, re-install
rear panel.
When properly activated, the sensor “pin” should come out. If
this does not happen during mixer, the sensor is out of
position or needs replacement. If replacing sensor, the
orientation of the sensor should be the same when placed
back on the air cylinder. The ‘pin’ should be on lower right
side.