ViscoTec preeflow eco-PEN450 Manual

OPERATION &
MAINTENANCE MANUAL
eco-PEN450

TABLE OF CONTENTS
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1 Introduction ...................................................................................................... 4
1.1 Delivery package ..................................................................................... 4
1.2 Incoming inspection ................................................................................. 5
2 Safety ................................................................................................................ 6
2.1 Explanation of symbols used ................................................................... 6
2.2 Intended use ............................................................................................ 7
2.3 Personnel................................................................................................. 8
2.3.1 Operators..................................................................................... 8
2.3.2 Maintenance staff ........................................................................ 8
2.4 Informal safety precautions...................................................................... 8
2.5 Preventing damage to equipment............................................................ 9
2.6 Organisational safety measures .............................................................. 9
2.7 Residual risks......................................................................................... 10
2.8 Transport and storage............................................................................ 11
3 Product description ....................................................................................... 12
4 Operation ........................................................................................................ 12
4.1 Initial commissioning.............................................................................. 12
4.1.1 Fitting the stator......................................................................... 13
4.1.2 Connecting the dosing unit to the drive unit............................... 13
4.1.3 Feeding material and bleeding the dispenser for the first time .. 14
4.1.4 Calibration.................................................................................. 16
4.2 Switching on, starting dosing process.................................................... 16
4.3 Switching off, ending dosing process..................................................... 16
4.4 Decommissioning................................................................................... 17
4.5 Re-commissioning ................................................................................. 17

TABLE OF CONTENTS
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5 Maintenance ................................................................................................... 18
5.1 Maintenance intervals............................................................................ 18
5.2 Troubleshooting ..................................................................................... 19
5.3 Stator change......................................................................................... 20
5.3.1 Disconnecting the dosing unit and drive unit ............................. 20
5.3.2 Removing the stator................................................................... 21
5.4 Dismantling before cleaning................................................................... 22
6 Cleaning .......................................................................................................... 23
7 Spare parts ..................................................................................................... 24
7.1 Item list of the spare parts...................................................................... 24
7.2 Overview drawing of the spare parts ..................................................... 25
8 Technical specifications................................................................................ 26
8.1 Installation declaration ........................................................................... 26
8.2 Technical data........................................................................................ 27
8.3 Materials used........................................................................................ 28
8.4 Dimensions ............................................................................................ 28
9 Disposal .......................................................................................................... 29
10 Accessories .................................................................................................... 29

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1Introduction
Dear customer,
We are delighted that you have decided to purchase a ViscoTec product. We have no doubt
that this product will meet all your requirements. We wish you trouble-free and successful
operation.
The dosing system consists of the eco-PEN450 dispenser and the eco-CONTROL EC200
dosing control unit or the plug´n´dose dosing control unit.
The eco-PEN450 dispenser is described in this operation manual. A separate operation and
maintenance manual is enclosed with the dosing control unit.
1.1 Delivery package
The scope of supply includes:
• 1 dosing unit (A)
• 1 stator (B)
• 1 drive unit (C) with connection cable
(1.5 m)
• 1 assembly aid (D)
• 1 screwdriver (E)
• 1 allen wrench (F)
• 1 syringe
• 1 Operation & maintenance manual
A
C
EF
eco-PEN450
D
B
Fig. 1
INTRODUCTION

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1.2 Incoming inspection
Damage in transit can lead to malfunctions, and consequently to personal injury and damage
to property. Damaged components must not be put into operation.
Check the delivery immediately on receipt for damage in transit and damage to the
packaging. Check that the delivery is complete according to the enclosed delivery note.
Make sure you have not left any part of the delivery in the packaging.
Compensation for damage during transport may be claimed only if the carrier is notified
immediately.
INTRODUCTION

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2Safety
2.1 Explanation of symbols used
The following symbols are used in this manual:
The following notices indicate safety instructions and must be followed:
This manual is structured so that text and the related figure are on the same page as far as
possible. In this way the information can be understood quickly. If reference is made to a
component in a figure, the part has a key number.
Work step
• List
Fig. 1 Legend number, reference to a figure
* Reference to a comment
COMMAND Designations of buttons/switches, menu items and input dialogs
DANGER
indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
indicates a hazardous situation which, if not avoided, may result in death or serious injury.
CAUTION
indicates a hazardous situation which, if not avoided, may result in minor injury.
NOTE
indicates a technical tip to avoid damage to property or equipment.
SAFETY

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2.2 Intended use
The eco-PEN450 dispenser is used to feed and precisely dose viscous materials.
The dispenser is controlled using the eco-CONTROL EC200 dosing control unit or the
plug´n´dose dosing control unit.
Check the chemical resistance of the materials that are in contact with the material before
commissioning. Information on the materials can be found in the order confirmation or in
Section 8.3 “Materials used” (page 28).
No liability can be accepted for damage caused by failure to observe this operation manual
or due to a lack of maintenance or checks.
Misuse
Any use other than the stipulated intended use shall be considered as misuse.
This includes
• use outside the permissible operating limits
• use in explosive environments
• use underground
• use outdoors
Misuse also includes the following actions carried out without the explicit written approval of
the manufacturer:
• Conversions and/or extensions
• Use of non-original spare parts (e.g. rotor)
• Repairs carried out by unauthorised companies or persons
• Use of non-approved materials
Misuse is not permissible, and will result in voiding of guarantee, warranty and liability claims.
SAFETY

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2.3 Personnel
The operating organisation shall ensure that only appropriately qualified and authorised
personnel work on this machine. It is responsible for ensuring that operators and
maintenance staff possess the necessary qualifications. Personnel must be at least 15 years
old.
All personnel working with or on the machine must have read and understood this
operation manual.
The operating company shall document the operators' and maintenance staff's
acknowledgement of this manual, and shall ensure their compliance with it by means of
regular training.
2.3.1 Operators
Before starting work, the personnel assigned as operators must be adequately instructed
regarding the nature and scope of their duties and the potential risks. Training shall be
conducted on a regular basis (at least once a year). Training shall be conducted after any
technical modifications.
2.3.2 Maintenance staff
The maintenance and repair staff must be authorised and
• adequately trained for the relevant activities
• familiar with and comply with the applicable technical rules and safety regulations
Competent personnel are persons who, by virtue of their training, experience and knowledge
of the relevant requirements, standards and safety regulations, can carry out the necessary
activities while recognising and avoiding potential hazards.
2.4 Informal safety precautions
The following documents must be read, understood and followed. They must always be
available at the machine's operating location, and must be kept in legible condition:
• The operation manual for this product
• Generally applicable and local accident prevention and environmental protection
regulations
• Safety data sheets for the conveyed materials, as well as for any cleaning products or
lubricants being used
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2.5 Preventing damage to equipment
In order to prevent damage to equipment and to ensure precision dosing, note that
• the dispenser must never be operated without material (the stator will be destroyed)
• the material inlet (feed) and the material outlet must never be closed during operation
• the material outlet (e.g. dosing needle or mixer) must not be damaged or blocked
• the dispenser is operated with a positive feed (inlet pressure)
• there is adequate inlet pressure when conveying highly viscous material
• when pumping without a positive feed (inlet pressure), no dry running or cavitation of the
dispenser occurs
• the direction of rotation of the drive is always the same as the direction of flow of the
dispenser
• the specifications in the product data sheet for the material are observed and adhered to
2.6 Organisational safety measures
The necessary personal protective equipment must be provided by the operating
organisation. Personal protective equipment must be worn when carrying out all work and
procedures.
To ensure the provision of suitable personal protective equipment, the safety data sheet for
the conveyed material must be observed. Specifications for e.g. cleaning products and
lubricants must also be checked and observed.
All personal protective equipment must be checked to ensure it is working properly before
starting work.
Eye protection Hand protection Body protection Foot protection
SAFETY

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2.7 Residual risks
Thorough training, observance of the operation manual and compliance with safety
regulations are key to permanently accident-free operation.
The following residual risks may occur when operating this machine:
WARNING
Material hazardous to health
The conveyed material may contain constituents which are hazardous to health.
Such constituents may cause serious acute or chronic harm to health if they come into
contact with skin, are inhaled or swallowed.
• Always wear appropriate protective equipment
• Observe the specifications in the safety data sheet for the material
WARNING
Risk of injury from moving components
The machine is driven by an electrical drive unit. These generate very high forces.
Touching the components during operation may result in serious injuries.
• Do not operate the machine unless there is unrestricted visual contact with the moving
component
• There must be no persons or foreign objects in the danger area
WARNING
Pressurised material
Depending on the setting of the machine, the material is conveyed under very high
pressure. If the delivery rate is not adapted to the dosing needle being used,
unwanted spraying of the material might occur. This may result in serious injury.
Defective components can also cause spraying.
• Shut down the machine immediately
• The leak must be repaired by qualified maintenance staff before operation is re-started
SAFETY

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2.8 Transport and storage
The following ambient conditions must be observed for transportation and storage:
• Temperature within the range -10 °C to +40 °C (263 K to 313 K)
• Relative air humidity less than 60 % (non-condensing)
• Uniform room climate
• Dry and free of dust
• No exposure to direct sunlight
• No aggressive, corrosive substances (solvents, acids, alkalis, salts, etc.) in the
environment
For storage always remove the stator and store separately (at 15–20 °C).
CAUTION
Splashing material
During initial commissioning and after being refilled, air bubbles in the material could
cause an uncontrollable spraying from the conveying area. This may result in injury.
• Always wear appropriate protective equipment
• Fully bleed the system before start of production
CAUTION
Pointed dosing needle
Depending on its size, the dosing needle can be very thin and pointed.
Carelessness during assembly work can lead to needle stick injuries.
• Carry out assembly work with appropriate care.
SAFETY

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3Product description
The dispenser has been developed and tested for precision dosing of materials ranging from
low to high viscosity with extremely high repeat accuracy.
preeflow dispensers are positive displacement pumps. The conveying elements comprise a
rotating part, the "rotor", and a stationary part, the "stator". The rotor, which is in the form of
a type of knuckle thread, rotates inside the stator, which has one more thread turn and twice
the pitch length of the rotor. As a result, conveying areas are produced between the stator
and the rotor rotating inside the stator. The rotor also moves radially within the stator.
The conveying spaces move forward continuously due to the movement. The flexible shaft
used to drive the rotor compensates for the eccentric movement of the rotor and is completely
maintenance-free.
The sealing effect of the conveying elements of the dispenser is dependent on the viscosity
and pressure.
Since the direction of flow is reversible, the material can be sucked back to allow a clean
thread break.
The dispenser can be dismantled very quickly.
Together with the eco-CONTROL EC200 dosing control unit, the dispenser forms a dosing
system which is typically installed in a dosing station. The dosing control unit controls the
required parameters (e.g. dosing quantity, dosing speed, etc.).
4Operation
4.1 Initial commissioning
All activities described below may only be carried out by qualified staff.
When delivered, the stator is not installed so as to avoid bearing damage to the elastomer of
the stator.
Preparation
Undo the cap nut (2).
Pull off the end piece (3).
Plug the star-shaped coupling (5) into the bearing housing (13).
Couple the assembly aid (6) to the bearing housing (13).
PRODUCT DESCRIPTION / OPERATION

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4.1.1 Fitting the stator
Coat the rotor (4) with material or a suitable lubricant.
Turn the stator (7) in the correct position (see detailed view) on the rotor (4) until the dowel
pin (8) begins to dip into the keyway (9).
Lightly press the stator (7) towards the pump housing (19) and turn the assembly aid (6) in
the direction of the arrow until the stator (7) has been guided into the pump housing (19).
Uncouple the assembly aid (6), install the end piece (3) and the cap nut (2), and put in place
the required Luer-Lock needle.
4.1.2 Connecting the dosing unit to the drive unit
Screw the set screws (14) into the thread so that they do not protrude into the coupling area.
Danger of damage to the fit.
Attach the star-shaped coupling (5) onto the coupling of the drive unit (11).
Set the anti-rotation lock (8) in the correct position relative to the dosing unit (20).
Fully assemble the dosing unit (20) and the dosing unit (11).
Lightly turn the set screws (14), the drive unit (11) has now been centred properly.
2
3
4
9
7
19
5
6
13
X
8
7
11
Fig. 2
8
11
5
14
20
14
Fig. 3
OPERATION

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4.1.3 Feeding material and bleeding the dispenser for the first time
Preparation
Connect the material supply (feed line, cartridge) to the material inlet (12) of the dispenser.
The dispenser can be bled in one of two ways after the medium has been supplied.
Version A
(e.g. supply via a hose, closed cartridge)
Tip: Connecting a hose can protect the dispenser from being wetted with the medium.
Move the dispenser to a position in which
the end piece (3) points upwards.
Connect the drive unit to the power supply
and run slowly until the material escapes
from the outlet nozzle (attached Luer-Lock
needle) without bubbles.
3
12
Fig. 4
OPERATION

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Version B
(e.g. open cartridge, dispenser fixed in place and supply of the material under pressure)
Tip: Alternatively, the air can also be extracted from the pump area with the syringe (9)
included in the scope of supply.
Turn the bleed screw (23) 180 degrees so
that the bleed hole (8) is in the position
shown (direction of the drive unit).
Pressurise the material.
Feed the material until it escapes from the
bleed hole (8) without bubbles.
Release (remove) the inlet pressure on
the material and wait until no more
material comes out of the bleed hole (8).
Close the bleed screw (23) again.
Remove any material which has escaped.
Pressurise the material.
Connect the drive unit to the power supply
and run slowly until the material escapes
from the outlet nozzle (attached Luer-Lock
needle) without bubbles.
9
23
8
Fig. 5
OPERATION

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4.1.4 Calibration
To obtain a precise dosing result, the dosing quantity must be calibrated. This is performed
using the eco-CONTROL EC200 dosing control unit. The exact procedure can be found in
the dosing control unit manual.
4.2 Switching on, starting dosing process
Daily at the start of the shift / when starting work, perform the activities as described in
Section 5.1 “Maintenance intervals” (page 18).
Start supply of material to the dispenser.
If present, remove cover.
Switch on the dosing control unit.
Check the dosing quantity to ensure that the dosing result is consistent. If there are
deviations, dosing must be calibrated. The exact procedure can be found in the dosing control
unit manual. The result of the check must be recorded together with the name of the tester,
date and time.
Start dosing process via the dosing control unit.
4.3 Switching off, ending dosing process
The dosing process is switched off via the dosing control unit. The exact procedure can be
found in the dosing control unit manual.
Switch off the material supply to the dispenser.
Clean the end piece / dosing needle.
Seal outlet opening (e.g. with cover).
NOTE
The supply of material to the dispenser must be ensured before dosing starts.
Dry running may destroy the stator.
OPERATION

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4.4 Decommissioning
All activities described below may only be carried out by authorised maintenance staff.
Switch off the drive to the dispenser and lock it to prevent it from being switched on again.
Shut down material supply to the dispenser (depressurise).
Relieve inlet pressure via bleed screw.
Remove material supply and seal openings with suitable plug.
Disconnect the power supply to the drive units.
Remove the dosing unit and the drive unit from the holder or system.
Disconnect the dosing unit and drive unit.
Remove the stator, clean and store separately.
Disassemble and clean dispenser.
Store dispenser according to the storage conditions as described in Section 2.8 “Transport
and storage” (page 11).
4.5 Re-commissioning
Re-commissioning is the same as initial commissioning. The same specifications and work
steps apply as described in Section 4.1 “Initial commissioning” (page 12). It must be ensured
that the dispenser is free of medium residues, dust and dirt.
The stator must be installed before recommissioning (see Section 4.1.1 (page 13)).
OPERATION

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5Maintenance
In the event of a fault, or if there is any doubt that the machine/system is not
completely ready for operation, it must be shut down immediately and inspected by
competent maintenance staff before operation continues.
5.1 Maintenance intervals
In order to ensure problem-free operation, we recommend complying with the following
maintenance intervals.
1 = Operating staff
2 = Maintenance staff
The recommended change cycles are based on empirical values for dosing applications.
The empirical values are based on different material properties, pressure conditions and
dosing settings. Depending on the material used, the required change cycles may differ from
the recommended cycles.
Ambient conditions, such as temperature and humidity, may affect the change cycles.
WARNING
Maintenance and cleaning work may only be carried out when the machine has been shut
down safely and secured against unauthorised restarting. Otherwise, serious injuries may
result.
• Switch off the dosing control unit.
• Disconnect the dosing control unit's power cable from the power supply
When Activity Who
Start of shift/daily • Visual check for leaks / contamination / damage. 1
End of shift • Clean the end piece / dosing needle. 1
Every year • Disassemble the dispenser, clean and check all
parts such as stator, rotor assembly, seals,
bearings and housing and replace if required.
2
MAINTENANCE

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5.2 Troubleshooting
If you have any questions about commissioning, maintenance, repairs or ways to optimise
your processes, our Service employees will be happy to help.
You can reach us at: [email protected]
We will respond to your service enquiry in German or English.
Fault Possible cause Action
No or too little material
feeding
Motor not connected Connect the motor
Fault with mains supply Check electrical installation
Material hardened/set Dismantle and clean the
dispenser
Dosing needle blocked Clean/replace dosing needle
Dosing needle too small or too
long
Use a different needle cross-
section. Reduce the speed/
flow rate volume.
Stator/rotor worn Replace stator/rotor
Stator swollen Check resistance of the stator
to the material and replace
stator
Revolution too low Correct revolution
Inadequate supply of material Feed material, check inlet
pressure and correct if
required
Dripping or running on
of material
Suck-back not set correctly Adjust the suck-back
Air bubbles in the material Bleed dispenser / material
pipes
Material compressible Degas the material
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5.3 Stator change
All activities described below may only be carried out by authorised maintenance staff.
Preparation
Disconnect the dosing control unit from the power supply.
Unplug the power supply to the drive unit.
Shut down material supply (depressurise).
Relieve inlet pressure via bleed screw.
Remove material supply and seal openings with suitable plug.
5.3.1 Disconnecting the dosing unit and drive unit
Undo set screws (14).
Disconnect the dosing unit (20) and drive unit (11).
Remove the star-shaped coupling (5).
Fig. 6
11
5
14
20
14
MAINTENANCE