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BetaCell 241 Maintenance Procedure

Description Procedure

Time

1. Access Machine Control screen via Main Menu on PV

2. Touch Auto Startup

3. Access Status screen via Main Menu on PV

4. System is ready when correct ratio is displayed, temperatures

have reached process temperatures and a green GO is at the
bottom of screen

5. Access Operator screen via Main Menu on PV

6. Select correct Sequence and touch Reset

Auto Startup from

Sleep Mode

7. Trigger

Gun

10 min

8. Access Machine Control screen via Main Menu on PV

9. Verify switches on front panel are in run position

10. Touch Auto Startup

11. Access Status screen via Main Menu on PV

12. System is ready when correct ratio is displayed, temperatures

have reached process temperatures and a green GO is at the
bottom of screen

13. Access Operator screen via Main Menu on PV

14. Select correct Sequence and touch Reset

Auto Startup from

Complete Shut Down

(Buffer tank temp. >

100ºF)

15. Trigger Gun

15-20

min

16. Access Tank Control Screen

17. Turn on Curative and Pre poly Agitators

Auto Startup from

Complete Shut Down

(Buffer tank temp. <

90ºF)

18. Turn on Tank heaters. Allow material temperature to increase

above 90ºF.

2 hours

Содержание BetaCell 241D

Страница 1: ...Operation BetaCell 241D Metering Unit 3A0258A Important Safety Instructions Read all warnings and instructions in this manual Save these instructions...

Страница 2: ...en 25 Flow Control Screen 27 Sequence Entry Screen 28 AutoStart Set Up Screen 30 Sleep Mode Set Up Screen 31 Pre Poly Refresh Set Up Screen 32 Flow Control Screen 33 Shot Calibration Screen 34 Toleran...

Страница 3: ...e 72 Directional Valve 72 Return Line Filter 73 INSTALLATION SET UP 74 Installation 75 Hoses 76 Buffer tanks 77 Hydraulic System 77 DAILY PROCEDURES 78 Daily Start Up 79 Daily Shutdown 79 FAULT MANAGE...

Страница 4: ...of this equipment must therefore make their own determination as to the suitability of the information contained in this manual to their specific operation and requirements There should be no assumpti...

Страница 5: ...source The electrical service must be installed and maintained by a qualified electrician High Pressure WARNING This equipment has or is used with equipment that has hydraulic components capable of p...

Страница 6: ...6...

Страница 7: ...irculation system ensures constant and accurate temperature control PID programming of the temperature controllers allows operation within a given temperature range Operation outside the designated ra...

Страница 8: ...Specifications System Dimensions 54 108 98 3 16...

Страница 9: ...e 6 cc rev 3 gpm Max pressure 3000 psi Max oper pres 2800 psi Max temp 160 F Reservoir 8 gal Accumulator 85 cu in Min cycle time 3 sec Buffer tanks Construction Pre Poly steel ASME certified Curative...

Страница 10: ...pressure sw 1500 psi Min pressure sw 40 psi Factory Settings Hydraulic Power Pack Max pressure sw 2800 psi Min pres sw 1500 psi Acum Pre charge 1200 psi Unload vlv upper 2400 psi Unload vlv lower 220...

Страница 11: ...11 DESCRIPTION OF CONTROLS 1...

Страница 12: ...12 Main Electric Panel Push to silence audible alarm White pilot light indicates that PLC power is ON White pilot light indicates that auxiliary 115 volt outlets are ON...

Страница 13: ...Turns ON control power green pilot light indicates that control power is ON Typical Motor Start momentary start to turn motor ON Switch must be in the RUN position to start the motor from the HMI pane...

Страница 14: ...enu is for qualified technicians and can only be accessed by password IMPORTANT This manual describes two chemical components the Pre Polymer A and the Curative B The HMI Screens follow the convention...

Страница 15: ...15 Help Screen A Help Screen is available for each of the Menu Screens...

Страница 16: ...es that a particular component is ON or set for normal operation A blue pilot indicates that a component is OFF A yellow pilot light indicate that a component is not set for normal operation SP window...

Страница 17: ...rol in MAN if the tolerance limits are DISABLED The following conditions must be satisfied for a GO signal No active faults A B pumps ON Recirculation valves CLSD Ratio control in AUTO Hydraulic press...

Страница 18: ...icates the state Data windows indicate the PV s NOTE Each time the Pre Poly pump is turned OFF it will default to 50 RPM and flow control to MAN Curative default is inches per second Press the set poi...

Страница 19: ...utoStart cycle Sleep Mode Press to ON automatically sets the machine to a pre set operating condition as follows Hydraulic motor OFF Pre Poly flow 30 grams sec Curative 2 grams sec Pre Poly heater 120...

Страница 20: ...OFF the motor pilot light indicates the state Press to turn ON and OFF the heater pilot light indicates the state Press the set point data window a keypad will appear select the temperature and press...

Страница 21: ...ically maintain the tank level to the set point The tank will operate below the set point level for the duration of the pre set dwell time At the expiration of the dwell time the AutoFill valve will O...

Страница 22: ...ing processed Indicates the active shot in a sequence Indicates the completed shots in a sequence Indicates an incomplete shot Indicates that this shot in a sequence is disabled and will be bypassed Y...

Страница 23: ...r sequences available At the completion of the last shot in a sequence it is necessary to reset to the first shot The gun will be NOGO when waiting for a reset Indicates gun status green pilot light i...

Страница 24: ...24 Maintenance Menu Press to access the Maintenance screen Password Required...

Страница 25: ...interlocks The following permissives are required Pre Poly pump OFF Curative pump OFF Hydraulic power pack ON Push to enable or disable the main panel alarm horn Press to OPEN the recirculation valves...

Страница 26: ...ned until this time has elapsed Press to turn the empty cycle ON and OFF If the AutoFill system is ON the tank will empty to the 20 level and automatically refill If the AutoFill system is OFF the tan...

Страница 27: ...ight indicates MAN Anytime MAN is selected the pumps will automatically be set to the default manual speed setting Enter manual set points as required Press the data windows a keypad will appear Selec...

Страница 28: ...e shots can then be dispensed in order starting at the first enabled shot and continuing in order through to the last enabled shot Only the ENABLED shots are active Press the list selector Scroll up o...

Страница 29: ...he shot for data entry Press the data window a keypad will appear Select the offset plus or minus and press enter Press to enter the new offset into the group Press to enable or disable a shot in the...

Страница 30: ...30 AutoStart Set Up Screen This screen is for qualified technicians only...

Страница 31: ...31 Sleep Mode Set Up Screen This screen is for qualified technicians only...

Страница 32: ...Tank Screen Refresh Mode To prevent exceeding the shelf life of the pre poly component the refresh mode allows the tank to be emptied to a pre set point and refilled with fresh material Must be in Sle...

Страница 33: ...chnicians only Calibration is performed one component at a time through the respective jet at operating pressure and temperature with the other component isolated from the mixing chamber by a blank je...

Страница 34: ...qualified technicians only Press the list selector Scroll up or down to select the shot group for data entry Press the data window a keypad will appear Select the offset plus or minus and press enter...

Страница 35: ...nce Setup Screen This screen is for qualified technicians only Scroll the list to select the parameter for data entry Press the data window a keypad will appear Select the offset plus or minus and pre...

Страница 36: ...36 Press to enter the new offset into the group Press to ENABLE or DISABLE the tolerance feature green pilot light indicates ENABLED and the yellow pilot light indicates DISABLED...

Страница 37: ...37 DESCRIPTION OF MAJOR COMPONENTS 2...

Страница 38: ...38 System Schematic...

Страница 39: ...selected temperature A low RPM mixer moves the material in contact with the heated walls of the tank to assure an even temperature gradient To assure adequate pressure at the inlet to the metering pu...

Страница 40: ...rms The pumps are protected on the outlet side by a pressure switch factory set to 1200 psi Should this pressure be exceeded both pumps will automatically stop and be accompanied by audible and visual...

Страница 41: ...on the proximity switch All timing functions are started and stopped by this switch Hydraulic Power Pack The hydraulic power pack is the prime mover for the pour gun and provides the pressure to open...

Страница 42: ...mer fumes with the Curative fumes the systems are isolated by means of separate check valves The recommended air pressure required to charge the buffer tanks is 60 psi NOTE The minimum recommended air...

Страница 43: ...will bleed excess tank pressure to maintain set point Recommended buffer tank pressure is 60 psi NOTE Pressure below 40 psi will cause a warning alert and both pumps will shutdown Maintenance There i...

Страница 44: ...44 Buffer tank 2 1 6 7 5 8 9 4 3...

Страница 45: ...45 13 10 12 Fumes piped away by others in accordance with plant specifications 11...

Страница 46: ...8 3 Jacket drain valve 29 4 Jacket temperature limit switch 35 5 Water jacket heater 30 6 Material temperature thermocouple 32 7 Water jacket thermocouple 31 8 Water level indicator 9 Vented filler ca...

Страница 47: ...with approximately 15 gallons of heat transfer fluid before starting the heater Maintenance Service the jacket with a 50 solution of water and glycol as required and check the level monthly The syste...

Страница 48: ...n of rotation as indicated by the rotational arrow and must be maintained at all times If the rotation is incorrect change any two of the power leads on the main terminal strip Maintenance There is no...

Страница 49: ...egulator set point Operation Operation is automatic The valve is factory set to start relief at 70 psi and can be field adjusted by a qualified technician as required Maintenance There is no normal op...

Страница 50: ...een 80 100 psi The adjustment is lead sealed and must not be tampered with Breaking the lead seal and tampering with the factory setting is DANGEROUS and voids any warranty NOTE The valve outlet is 3...

Страница 51: ...51 Return Line Check Valve This valve is provided to isolate the buffer tank pressure from the return line Maintenance There is no normal operating maintenance Check Valve...

Страница 52: ...surface of the liquid and containing a magnet with positive polarity There is a magnetostrictive position feedback sensor mounted to the instrument which sends a continuous signal to the PLC indicatin...

Страница 53: ...nk pressure during refill to a minimum Bulk System By others The bulk storage circulation loop is temperature conditioned and pressurized to a pressure that exceeds the pressure in the buffer tank It...

Страница 54: ...om the Tank Control Screen and will permit the level to bypass the SP full point and continue to empty down to the pre set refresh point AutoFill ON at the refresh point the cycle will end and the tan...

Страница 55: ...55 AutoFill Valve Maintenance There is no normal operating maintenance Position Indicator...

Страница 56: ...y Stop The valve defaults to the CLOSED position when Main air is CLOSED Control power is lost The Gun Service Switch is selected ON The yellow indicator shows the position of the valve Perpendicular...

Страница 57: ...l occur and both pumps will shutdown This is an indication that The filter may need to be serviced The buffer tank pressure is too low The buffer tank is not up to temperature Maintenance During the f...

Страница 58: ...otary piston pump driven by a magnetic coupling The integrated closed loop control and motor drive maintain an accuracy of 0 1 of set point The pump provides excellent performance and resistance to co...

Страница 59: ...ng pump is a continuous delivery piston pump uniquely designed to deliver pulse less flow with no pressure fluctuations during reversals It is the ideal pump for accurate and reliable delivery of the...

Страница 60: ...60 Pressure Transducer Operation Operation is automatic The over and under pressure set points are factory set and cannot be changed Maintenance No routine maintenance is required...

Страница 61: ...e curative heater is constructed from stainless steel to prevent possible chemical reaction Heater Rod The pre heater contains 6 heating elements rated 1500 watts each Start Up Determine that the pre...

Страница 62: ...62 Flow Meters The flow meters are mass style on the pre poly and curative components Maintenance There is no periodic maintenance required Pre Polymer Curative...

Страница 63: ...hrough the gun This allows operation of the pumps at reduced pressures for start up and temperature conditioning Operation This valve is automatically opened during Normal operation It may also be man...

Страница 64: ...ode of operation For set up and trouble shooting purposes the valve can be operated externally by manually depressing the override button Turn clockwise to lock in place Maintenance There is no normal...

Страница 65: ...65 Hydraulic Power Pack Schematic...

Страница 66: ...s service factor will also determine the amount of cooling required if any to maintain the hydraulic fluid at temperatures below 150 F The more frequent the shots the more heat generated by the system...

Страница 67: ...e length of the hoses and the duty cycle For a moderate duty cycle and hose lengths of less than 50 feet location directly on the PowerPack manifold will provide satisfactory performance For operation...

Страница 68: ...mit switch 6 Manual unloading valve 7 Return line filter fill port 8 Level Temperature Gage Start Up The direction of rotation is indicated by the rotational arrow and must be maintained at all times...

Страница 69: ...periodically serviced as described in the Maintenance Manual Hydraulic Fluid The hydraulic unit is fully tested at the factory and drained of all hydraulic fluid prior to shipment Before operating ser...

Страница 70: ...anual unloading valve is CLOSED Turn on the hydraulic motor and allow the pressure to stabilize Adjust the overpressure O limit clockwise to raise the pressure Slowly crack the manual unloading valve...

Страница 71: ...re charge pressure The pre charge pressure and ambient temperature should be recorded at installation Be sure the pressure is zero in the hydraulic chamber before checking the pre charge that is recom...

Страница 72: ...s automatic however for setup and maintenance the valve can be operated manually by pressing in on the solenoid plunger To maintain the maximum performance of the gun the directional valve and accumul...

Страница 73: ...73 Return Line Filter Maintenance Service periodically to maintain the condition gage in the green Maintain the service schedule following the procedures in the Maintenance Manual Filter Inside...

Страница 74: ...74 INSTALLATION SET UP 3 IT IS RECOMMENDED THAT THE BetaCell 241 BE COMMISSIONED BY A FACTORY TRAINED TECHNICIAN...

Страница 75: ...to be installed on a flat surface in an area that permits 360 degree access for maintenance and operation The metering unit was plumbed wired and tested at the factory For transporting purposes the un...

Страница 76: ...76 Hoses 1 A pressure yellow 2 A return yellow white 3 B pressure green 4 B return green white 5 Hydraulic pressure close black 6 Hydraulic return open black white 1 3 4 6 5 2...

Страница 77: ...ge with a 50 water and Glycol mixture Tanks Slowly pressurize each tank to 60 psi while checking for any leaks Hydraulic System Service the reservoir with 8 gallons of approved hydraulic oil Charge th...

Страница 78: ...78 DAILY PROCEDURES 4...

Страница 79: ...olation valves and the gun manual valves are OPEN Machine Cont Screen 4 Switch ON Autostart and wait until the AutoStart cycle is completed approximately 25 min DAILY START UP IS NOW COMPLETE THE MACH...

Страница 80: ...80 FAULT MANAGEMENT 5...

Страница 81: ...81 Alarm system Alarm Status Screen IMPORTANT During any alarm condition the gun will automatically default to the CLOSED position...

Страница 82: ...ive audible and visual alarms as well as cause one or more of the following events Default to the Alarm Status screen Stop the metering pumps Turn off the respective heaters Close the MixHead or preve...

Страница 83: ...C MOTOR OVERLOAD FAULT Alarm screen Red fault light ON Fault horn ON Hydraulic motor OFF Prepoly pump OFF Curative pomp OFF Gun locked CLSD Reset thermal overload Reset one time only HYDRAULIC POWER P...

Страница 84: ...IGH TEMP FAULT Alarm screen Red fault light ON Fault horn ON Cur tank heater OFF Water level Temperature set point DRIVE FAULT Alarm screen Red fault light ON Fault horn ON Respective motor OFF Gun lo...

Страница 85: ...rness Gun switch OUT OF TOLERANCE ALARM Alarm screen Red fault light ON Fault horn ON Gun locked CLSD Check temperature Check pressure Check flow rate COMPLETE FAULT LIST Curative Agitator Motor Overl...

Страница 86: ...t Of Tolerance High Flowrate Out Of Tolerance Low Ratio Out Of Tolerance Low High Speed Counter Card Electronic Fuse Open High Speed Counter Card Initialization Failure PLC Battery Low Prepoly Autofil...

Страница 87: ...ne Thermocouple Fault Prepoly Supply Line Thermocouple Fault Prepoly Supply Pressure Transducer Fault Prepoly Tank High Level Prepoly Tank Low Level Shutdown Prepoly Tank Low Level Warning Prepoly Tan...

Страница 88: ...88 MAINTENANCE 6...

Страница 89: ...rol screen via Main Menu on PV 9 Verify switches on front panel are in run position 10 Touch Auto Startup 11 Access Status screen via Main Menu on PV 12 System is ready when correct ratio is displayed...

Страница 90: ...ntrol screen via Main Menu on PV 28 Touch Sleep Mode Sleep Mode NOTE Sleep Mode should only be used after system is fully operational 1 min 29 Access Machine Control screen via Main Menu on PV Auto Sh...

Страница 91: ...n PV 46 Touch Flow Control Manual 47 Touch Curative Start Motor 48 Access Flow Control Auto system will increase output settings 49 Verify ratio and temperatures are at Setpoint 50 Access Operator scr...

Страница 92: ...atio and temperatures are at setpoint 68 Access Operator screen via Main Menu on PV 69 Verify GO condition exists at bottom of screen 70 Select correct Sequence and touch Reset 71 Trigger Gun NOTE If...

Страница 93: ...e air ball valve on top of Curative Buffer tank 84 Open inlet air ball valve 85 Access Flow Control screen via Maintenance Menu on PV 86 Put system from Auto Flow control to Manual 87 Start Curative m...

Страница 94: ...ice due to thermal expansion 103 Touch alarm banner on PV to acknowledge fault 104 Close and Lock out inlet air ball valve 105 Open air ball valve on top of Pre Poly Buffer tank 106 Close Pre Poly Buf...

Страница 95: ...quence and touch Reset 124 Trigger Gun NOTE After Orifice has been in for several minutes shut system down and re torque the Orifice due to thermal expansion 1 Verify Pre Poly and Curative Motors are...

Страница 96: ...tainer 139 Open lid of filter assembly and remove bag filter and dispose of accordingly 140 Replace with new and verify proper fit in housing 141 Wipe o ring on lid clean of any residual chemical and...

Страница 97: ...valve in front of machine into appropriate container 159 Close and Lock out ball valve 160 Remove SHCS that secure inlet flange to pump 161 Remove SHCS that secure outlet flange to pump 162 Disconnec...

Страница 98: ...Remove main disconnect lock out and main power Remove and Replace Hydraulic Filter 182 Perform an Auto Start from complete shutdown 15 min 183 Perform an Auto Shut Down 184 Lock out main disconnect 1...

Страница 99: ...ve Tanks 201 Touch Enable Empty Cycle this allows tanks to be depleted to the 30 level point before system will stop 202 System will not allow operator to dispense material after one of the tanks reac...

Страница 100: ...5 Proximity Switch 54100 2 Remote Pour Handle 54193 011 Orifice AS NEEDED 54193 061 Orifice AS NEEDED GX 15 Dispensing Gun 54150 CSTM 54150 3 61 11 GX 15 Dispensing Gun Grease OR 100K SHOTS 54250 5 3...

Страница 101: ...ump Rebuild 6317 58 Prepolymer Pump Replace Wet Calibrate Shot Size Calibration 6318 41 6318 43 Buffer tank Water glycol Check Change 6312 42 6312 42 1 Inlet Pre Poly Filter Replace Betacell 241 6312...

Страница 102: ...s Hex Key Set Open End Wrenches 10 min 6690 7 15 Proximity Switch 54150 CSTM 54150 3 61 11 221 Turn off hydraulic Power unit 222 Remove hydraulic pressure from system 223 Remove Proximity harness atta...

Страница 103: ...wrench 10 min 54150 CSTM 54150 3 61 11 GX 15 Dispensing Gun 241 Turn Chemical pumps off 242 Turn hydraulic power unit off via HMI 243 Relieve pressure by turning valve CCW and verify pressure is 0 psi...

Страница 104: ...mulator CCW and verify pressure is 0 psi 262 Remove union and attach hose ends to dispensing gun black pressure attaches to 90 fitting on back of gun black white return attaches to extended gun fittin...

Страница 105: ...k free 15 min Tools Open End Wrenches 6690 7 56 6690 7 57 3 Trigger Harness 3 Proximity Harness 287 Remove harness 288 Replace with new harness 5 min 38810 15 Curative Pump 289 Turn Curative pumps off...

Страница 106: ...ith new repeat steps in opposite order 312 Open ball valves 313 Open locked out valves 314 Apply air to system 315 Start chemical pump and recirculate chemical 316 Pump will need to cycle to remove ai...

Страница 107: ...air from Buffer tank 337 Lock out ball valve on bottom of buffer tank 338 Lock out inlet air ball valve 339 Open filter drain to remove residual chemical 340 Remove filter cover 341 Remove and replace...

Страница 108: ...ose needle valve 362 Remove lock out 363 Follow startup procedure Tools Charging Harness 10 min Fluid 364 Turn hydraulic power unit off via HMI 365 Lock out electrical panel 366 Drain tank utilizing d...

Страница 109: ...l panel 374 Remove and replace battery with PLC power on 375 Remove lock out 376 Follow startup procedure 5 min Indicator Lights 377 Remove lens from indicator light 378 Remove and replace bulb 379 Re...

Страница 110: ...bove The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or conseque...

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