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PC200 PVA

Revision G (2019)

33 of 56

Periodic Maintenance

How to Replace a Static Mixer

Remove the old static mixer and do the steps in Section 3.2 to install a new static mixer.

How to Replace Lip Seals

The PC200 valve will require lip seal replacement periodically. The interval between seal
replacement varies widely depending on duty cycle, material type, and day to day care
of the valve. It is highly recommended that spare parts kits and a tool kit be on hand for
fast and easy seal replacement. Refer to Section 9 for spare parts kits

information.

For a more extensive valve rebuild, refer to Sections 6 and 7 for a complete bill of
materials and exploded drawings.

Seal Plate Lip Seals

1.

Disassemble and clean the valve.

2.

Do steps 1-8 in Section 4.3 and replace the lips seals in the seal plate.

3.

Refer to Section 4.3 to assemble the valve again.

Fluid Section Lip Seals

1.

Disassemble and clean the valve.

2.

Do steps 1-11 in Section 4.3 and replace the lips seals in the seal plate.

3.

Refer to Section 4.3 to assemble the valve again.

How to Replace Valve Rods

1.

Disassemble and clean the valve.

2.

Do steps 1-2 in Section 4.3 and replace the rods.

3.

Refer to Section 4.3 to assemble the valve again.

How to Replace Sleeve Bearings

1.

Disassemble and clean the valve.

2.

Do steps 1-7 in Section 4.3 and replace the sleeve bearings in the separation
block.

3.

Refer to Section 4.3 to assemble the valve again.

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Содержание PC200 Series

Страница 1: ...Precision Valve Automation One Mustang Drive Cohoes NY 12047 www pva net PC200 Valve Series OWNER S MANUAL Rev G WHERE PRECISION DRIVES PRODUCTION ...

Страница 2: ...ument with respect to changes subsequently made Precision Valve and Automation Inc makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply This document including the information cont...

Страница 3: ...8 Waste Disposal 8 Tool Kit 8 Overview 9 Valve Operation 10 Startup 10 Install the Static Mixer 11 Shutdown 13 Maintenance 13 Disassemble the Valve 14 Procedure 14 Clean the Disassembled Valve 21 Assemble the Valve 23 Procedure 23 With a Press 28 To Engage by Hand 29 Periodic Maintenance 33 How to Replace a Static Mixer 33 How to Replace Lip Seals 33 Seal Plate Lip Seals 33 Fluid Section Lip Seals...

Страница 4: ...SS Bill of Materials 35 PC200R AL Bill of Materials 36 PC200R Series Mechanical Drawings 37 PC200R Series Exploded View 38 PC200RW Series Reference 38 PC200RW SS Bill of Materials 39 PC200RW AL Bill of Materials 40 PC200RW Series Mechanical Drawings 41 PC200RW Series Exploded View 42 How to Order 43 Accessories and Options 44 Spare Parts 46 Spare Parts Kits 46 Technical Specifications 50 Troublesh...

Страница 5: ...es NY 12047 Tel 1 518 371 2684 Fax 1 518 371 2688 Website http www pva net Email mailto info pva net Technical Support Tel 1 518 371 2684 Email mailto cs pva net Document History Revision Revision Date Reason for Changes Revision G March 2019 Part Number Updated Revision F February 2016 Initial Release of New Template NOTE All photographs and CAD model representations in this document are a genera...

Страница 6: ...erate the system read and understand the manuals provided with the unit Never put hands or tools in areas with this symbol when the machine is in operation A dangerous condition may exist Read and understand the manuals provided with the unit before any repairs or maintenance is done Only a qualified individual should do service Use caution when there are pressurized vessels Find and repair any le...

Страница 7: ...tion and the fluid section Air Section The air section is an aluminum body with a simple piston cylinder combination used to open and close the valve The stroke adjustment screw in the upper air body controls how far the piston and rod assembly can retract and controls snuff back Fluid Section The fluid section is available in two materials Stainless steel Aluminum decreased weight for handheld ap...

Страница 8: ...rs tool kits for dispense valves The tool kit for the PC200 series valve is part number B12 2602 This includes all necessary tools and lubricant to do maintenance on this valve Table 1 B12 2602 Contents List Qty Part Number Description 1 0266244 8 Adjustable Wrench 1 7122A47 3 16 Hex Key 2 26571 5 32 Hex Key 2 7122A44 1 8 Hex Key 2 7122A43 7 64 Hex Key 1 56945A13 3 16 Combination Wrench 1 B62 2048...

Страница 9: ...PC200 PVA Revision G 2019 9 of 56 Overview Before you operate the valve know the valve components Examine the valve components shown below for safe and correct operation Figure 2 Valve Components ...

Страница 10: ...break in the flow of the material shows there is still air in the system 6 Bleed air from the bleed screws if necessary NOTE Part A and B materials may not start to dispense from the valve at the same time flow depends on the necessary mix ratio 7 Use a 3 16 hex key to adjust the stroke adjustment screw to get the necessary amount of snuff back Turn the stroke adjustment screw clockwise to decreas...

Страница 11: ...2 Hold the static mixer on the PC200 manifold with your hand 3 Use the purge function in Manual mode on the machine controller to purge material through the static mixer 4 Continue to purge until the static mixer is fully filled with material Figure 4 Fill the Static Mixer Now the trapped air must be released from the top of the static mixer ...

Страница 12: ...c mixer and PC200 valve Figure 5 Purge the Static Mixer 9 Put the static mixer retaining nut on and use a wrench to tighten 10 Install the desired needle on the end of the static mixer 11 Use the purge function on the machine controller to purge material through the static mixer Purge the volume of the entire static mixer to fill it with fresh material 12 Push and release the purge button Examine ...

Страница 13: ...rt number 214 3832 on the manifold nozzle 5 Release the pressure in the system refer to the workcell manual Figure 6 PC200 Night Cap NOTE Refer to Sections 6 and 7 for part reference numbers Maintenance Interval Action Daily Examine the material outlets for contamination and cured material Weekly Examine component A and B material containers or cartridges for signs of cured or dried material Befor...

Страница 14: ...rvice department Procedure Put valve sections seals parts and screws in solvent to soak if material can be seen on them Do not combine materials A and B or they will cure Examine all parts for wear and damage Replace parts if necessary 1 Relieve system pressure Disconnect material and air fittings Disconnect the valve from the dispense system 2 Remove the retaining nut and the static mixer and nee...

Страница 15: ...s in the fluid manifold 7 Clean the O rings and examine them for damage 8 Use a hex key to remove the two shoulder bolts from the seal plate Figure 10 Valve Shoulder Bolts 9 Use a hex key to remove the four machine screws from the air cap Figure 11 Remove Air Cap Screws 10 Remove the air cap ...

Страница 16: ...sen the air fittings and then use your hand to remove them Figure 13 Remove Air Fittings 12 Use a correctly sized hex key to push on the rods engaged in the seal plate Figure 14 Push Rods to Disengage 13 Push on the rods one at a time until the piston rod assembly disengages from the air cylinder ...

Страница 17: ...gure 16 Seal Plate Removed 15 Remove and clean the O rings in between the seal plate and the fluid section 16 Remove and clean the lip seals in the fluid section 17 Pull the piston rod assembly out of the air cylinder Figure 17 Piston Rod Assembly Removed NOTE RW series PC200 uses two different size rods ...

Страница 18: ...aration block for damage or wear If there is any sign of wear replace them 20 To remove the sleeve bearings install a correctly sized tap into the sleeve bearing in the bottom of the separation block Figure 19 Install the Tap into the Sleeve Bearing 21 Push the tap in and turn it clockwise to engage the tap in the sleeve bearing Figure 20 Engage the Tap into the Sleeve Bearing ...

Страница 19: ...rn the tap clockwise and pull out as you turn The sleeve bearing will start to pull out of the separation block Figure 21 Turn the Tap and Pull Out 24 Pull the sleeve bearing out of the separation block Do the procedure again for the other sleeve bearing Figure 22 Remove the Sleeve Bearing 25 Clean any pieces of the sleeve bearings from the separation block 26 Use the hook and pick set to remove t...

Страница 20: ...n G 2019 20 of 56 Figure 23 Remove Lip Seals From Fluid Section 27 Clean the lip seals 28 Use the hook and pick set to remove the O ring in the air cylinder Figure 24 Air Cylinder O ring 29 Examine and clean the O ring ...

Страница 21: ... you clean the valve remove all grease and material before the valve is assembled again All O rings seals and screws should be cleaned 1 Clean every part completely with appropriate solvent Do not mix material A with material B or they will cure 2 Clean the seal plate Figure 25 Clean the Seal Plate 3 Clean the air cylinder Figure 26 Clean the Air Cylinder 4 Clean the cylinder cap Figure 27 Clean t...

Страница 22: ...ean all grooves and ports 9 Clean the piston rod assembly NOTE RW series PC200 uses two different size rods 10 Clean the rods 11 Use a wrench to hold one rod and a use hex key to loosen the screw that holds the rod in position in the piston 12 Remove both rods Examine the rods and make sure there is no material on them Clean the screws if necessary 13 Use the hook and pick set to remove the O ring...

Страница 23: ...ou have questions about procedure steps parts or content contact PVA s customer service department Procedure 1 Apply removable thread lock to a machine screw 2 Put the screw with thread lock in the piston 3 Put a rod in into the countersunk side of the piston Figure 30 Install Screw in the Piston Rod Assembly 4 Use a 3 16 wrench or an adjustable wrench on the flats of each rod to hold them in plac...

Страница 24: ...th the two holes in the top of the separation block 8 Use a press to push the sleeve bearings into the bottom holes of the separation block until they are flush with the bottom of the block Figure 34 Sleeve Bearings Installed in the Separation Block Note RW series PC200 uses two different size sleeve bearings 9 Use your hands to push two lip seals Teflon seals shown O ring side up into the seal pl...

Страница 25: ... and put it on the top of the fluid section Install the flared side into the fluid section first Figure 36 Lip Seal Alignment Tool and Fluid Section 13 Put the lip seal insertion tool onto the top of the lip seal and use it to push the seal into the fluid section so it is flush with the surface Figure 37 Lip Seal Insertion Tool 14 Do steps 11 13 again for the last lip seal 15 Apply silicone grease...

Страница 26: ...to attach the assembly Tighten the first bolt 1 2 turns and then the second bolt 1 2 turns Repeat this procedure until the bolts are fully engaged NOTE When bolts are tightened in small increments of 1 2 turns the lip seals stay correctly positioned Figure 40 Assemble the Separation Block Fluid Body and Seal Plate 18 Apply silicone grease to two 108 Buna O rings and put them in the bottom openings...

Страница 27: ...der Openings Aligned with the Assembly 21 Put the air cylinder on the fluid assembly Make sure the air port is on the right side Figure 43 Air Cylinder and Fluid Assembly 22 Apply silicone grease to the cylinder wall Figure 44 Apply Grease to the Cylinder Wall 23 Apply silicone grease to the O ring on the piston rod assembly ...

Страница 28: ...assembly straight down through separation block slowly with pressure that stays the same until resistance is met position as shown below Figure 47 Install Piston To fully engage the piston rod assembly you can use a press or do it by hand To use a press continue to step 26 To engage the piston rod assembly by hand continue to step 28 With a Press 26 Put the valve on the press with the piston up ...

Страница 29: ...r Continue to step 30 To Engage by Hand 28 Carefully flip the valve assembly upside down on a flat surface so that piston head touches the surface and the red air cylinder section is down 29 Push down hard on the assembly with pressure that stays the same until a pop is heard the rods go through the lip seals and the piston is fully engaged into the air cylinder Figure 49 Piston Fully Engaged in V...

Страница 30: ...er groove 32 Apply grease to the top of the installed O ring with your finger Figure 51 Apply Grease to O ring 33 Use a 3 16 hex key to tighten the stroke adjustment screw on the cylinder cap Figure 52 Tighten Stroke Adjustment Screw 34 Put the sealing washer on the stroke adjustment screw and slide it down to the cylinder cap ...

Страница 31: ...m Nut 36 Put the cylinder cap on the air cylinder 37 Install the four machine screws 38 Use a 5 32 hex key to tighten the screws to the separation block NOTE Line up the air hole on the cylinder on the right side of the separation block Figure 55 Cylinder Cap Installed on the Valve 39 Apply silicone grease to two 016 O rings and put them in the grooves of the fluid manifold ...

Страница 32: ...l plate and install four machine screws Figure 57 Fluid Manifold Aligned with Valve 41 Use a 5 32 hex key to tighten the screws 42 The PC200 valve and its mechanical portion are now assembled 43 Additional air and fluid fittings should be correctly sized and installed in the applicable ports on the valve for operation Figure 58 Assembled Valve ...

Страница 33: ...ions 6 and 7 for a complete bill of materials and exploded drawings Seal Plate Lip Seals 1 Disassemble and clean the valve 2 Do steps 1 8 in Section 4 3 and replace the lips seals in the seal plate 3 Refer to Section 4 3 to assemble the valve again Fluid Section Lip Seals 1 Disassemble and clean the valve 2 Do steps 1 11 in Section 4 3 and replace the lips seals in the seal plate 3 Refer to Sectio...

Страница 34: ...mble the valve again Air Cylinder O rings 1 Disassemble and clean the valve 2 Do steps 1 18 in Section 4 3 and replace the O rings in the air cylinder with new O rings from the spare parts kit 3 Do steps 19 31 and replace the 016 O ring in the air cylinder groove 4 Refer to Section 4 3 to assemble the valve again Fluid Manifold O rings 1 Disassemble and clean the valve 2 Do steps 1 39 in Section 4...

Страница 35: ...fold Bayonet Style SS 114 5810 1 9 Nut Retaining 214 3833 1 10 Bolt Shoulder 10 24 x 1 00 01473 2 11 Bearing Sintered Sleeve 188 x 375 x 250 Long 01502 2 12 Set Screw 3 8 24 x 1 01426 1 13 Washer Sealing 3 8 01427 1 14 Nut Jam 3 8 24 01428 1 15 Standard U Seal Loaded Lip Urethane 12500187 4 Option T Seal Loaded Lip PTFE Contact PVA 4 16 O Ring 030 Buna VLV 030B 1 17 O Ring 123 Buna VLV 123B 1 18 O...

Страница 36: ...net Style SS 114 5810 1 9 Nut Retaining 214 3833 1 10 Bolt Shoulder 10 24 x 1 00 01473 2 11 Bearing Sintered Sleeve 188 x 375 x 250 Long 01502 2 12 Set Screw 3 8 24 x 1 01426 1 13 Washer Sealing 3 8 01427 1 14 Nut Jam 3 8 24 01428 1 15 Seal Loaded Lip Urethane 12500187 4 16 O Ring 030 Buna VLV 030B 1 17 O Ring 123 Buna VLV 123B 1 18 O Ring 108 Buna VLV 108B 2 19 O Ring 016 Viton VLV 016V 6 20 Fast...

Страница 37: ...PC200 PVA Revision G 2019 37 of 56 PC200R Series Mechanical Drawings Figure 59 Mechanical Drawings PC200R ...

Страница 38: ...vision G 2019 38 of 56 PC200R Series Exploded View Figure 60 PC200R Exploded View PC200RW Series Reference NOTE If your valve has Teflon lip seals you must use Kalrez O rings To order these parts please contact PVA ...

Страница 39: ...leeve 125 x 250 x 250 Long 01503 1 14 Set Screw 3 8 24 x 1 01426 1 15 Washer Sealing 3 8 01427 1 16 Nut Jam 3 8 24 01428 1 17 Standard U Seal Loaded Lip Urethane 12500187 2 Option T Seal Loaded Lip PTFE Contact PVA 2 18 O Ring 030 Buna VLV 030B 1 19 O Ring 123 Buna VLV 123B 1 20 O Ring 108 Buna VLV 108B 2 21 O Ring 016 Viton VLV 016V 6 22 O Ring 006 Viton VLV 006V 2 23 Fastener 6 32 x 375 SHCS Sta...

Страница 40: ...2 1 13 Bearing Sintered Sleeve 125 x 250 x 250 Long 01503 1 14 Set Screw 3 8 24 x 1 01426 1 15 Washer Sealing 3 8 01427 1 16 Nut Jam 3 8 24 01428 1 17 Seal Loaded Lip Urethane 12500187 2 18 O Ring 030 Buna VLV 030B 1 19 O Ring 123 Buna VLV 123B 1 20 O Ring 108 Buna VLV 108B 2 21 O Ring 016 Viton VLV 016V 6 22 O Ring 006 Viton VLV 006V 2 23 Fastener 6 32 x 375 SHCS Stainless Steel SHSS6 32X 375 2 2...

Страница 41: ...PC200 PVA Revision G 2019 41 of 56 PC200RW Series Mechanical Drawings ...

Страница 42: ...PC200 PVA Revision G 2019 42 of 56 Figure 61 Mechanical Drawing PC200RW PC200RW Series Exploded View Figure 62 Exploded View PC200RW ...

Страница 43: ...PC200 PVA Revision G 2019 43 of 56 How to Order Figure 63 Part Number Configuration ...

Страница 44: ... 8 4M C04L 1 KZ SS Check Valve 1 4 NPT 1 psi cracking pressure Kalrez 9 6 1 4AOEG S Fitting 9 16 18 SAE x 1 4 NPT Elbow Carbon Steel 10 6 1 4AOEG SS Fitting 9 16 18 SAE x 1 4 NPT Elbow Stainless Steel 11 KJL07 32 Fitting One Touch 1 4 Tube 12 AS1201F U10 32 07 Fitting One Touch Speed Control 1 4 Tube 13 6HP5ON SS Recirculation Hole Plug Hollow Hex 9 16 18 SAE SS 14 214 0544 Tool Lip Seal Alignment...

Страница 45: ...PC200 PVA Revision G 2019 45 of 56 Figure 64 Accessories and Options ...

Страница 46: ...M DESCRIPTION SYMBOL QTY 1 Seal loaded lip Urethane 12500187 4 2 O ring 030 Buna VLV 030B 1 3 O ring 123 Buna VLV 123B 1 4 O ring 108 Buna VLV 108B 2 5 O ring 016 Viton VLV 016V 6 6 Bearing sintered sleeve 188 x 375 x 250 long 01502 2 7 Washer nylon 214 5368 2 Contact PVA for information on replacement parts or to order ...

Страница 47: ...TION SYMBOL QTY 1 Seal loaded lip Teflon Contact PVA 4 2 O ring 030 Buna VLV 030B 1 3 O ring 123 Buna VLV 123B 1 4 O ring 108 Buna VLV 108B 2 5 O ring 016 Kalrez VLV 016K 6 6 Bearing sintered sleeve 188 x 375 x 250 long 01502 2 7 Washer nylon 214 5368 2 Contact PVA for information on replacement parts or to order ...

Страница 48: ...0187 2 2 O ring 030 Buna VLV 030B 1 3 O ring 123 Buna VLV 123B 1 4 O ring 108 Buna VLV 108B 2 5 O ring 016 Viton VLV 016V 6 6 O ring 006 Viton VLV 006V 2 7 Bearing sintered sleeve 188 x 375 x 250 long 01502 1 8 Bearing sintered sleeve 125 x 250 x 250 long 01503 1 9 Washer nylon 214 5368 2 Contact PVA for information on replacement parts or to order ...

Страница 49: ...ontact PVA 2 2 O ring 030 Buna VLV 030B 1 3 O ring 123 Buna VLV 123B 1 4 O ring 108 Buna VLV 108B 2 5 O ring 016 Kalrez VLV 016K 6 6 O ring 006 Kalrez VLV 006K 2 7 Bearing sintered sleeve 188 x 375 x 250 long 01502 1 8 Bearing sintered sleeve 125 x 250 x 250 long 01503 1 9 Washer nylon 214 5368 2 Contact PVA for information on replacement parts or to order ...

Страница 50: ...hnical Specifications Weight PC200R AL PC200RW AL Approximately 2 3 lbs 36 8 oz Approximately 3 7 lbs 59 2 oz PC200R SS PC200RW SS Material inlets 9 16 18 SAE Air ports 10 32 UNRF Operating Air Pressure 60 100 psi Maximum Fluid Pressure 1500 psi Viscosity Range 1 cps 250 000 cps ...

Страница 51: ...urn stroke adjustment screw counter clockwise to increase snuff back Replace lip seals Bleed valve until air is removed Air Bubbles In Fluid Valve is not correctly bled Problem with fluid delivery system Bleed the valve until the air is removed Diagnose and repair No Flow From Valve Manifold is blocked Air cylinder does not operate Static mixer is plugged Problem with material supply Examine and c...

Страница 52: ...aterial Material has abrasive fillers Contact PVA for seal options Contact PVA for seal options Valve Has Air Leak Jam nut is loose Air cylinder O rings are worn Tighten jam nut against stroke adjustment sealing washer Replace air cylinder section O rings Valve Leaks at Separation Block Lip seals are defective or worn Valve rods are defective or worn Sleeve bearings are worn Examine and replace li...

Страница 53: ...PC200 PVA Revision G 2019 53 of 56 Notes ...

Страница 54: ...nties All PVA warranties extend only to the original purchaser Third party warranty claims will not be honored at any time Prior to returning a product for a warranty claim a return authorization must be obtained from PVA s customer service department Authorization will be issued either via the telephone facsimile or in writing upon your request To qualify as a valid warranty claim the defective p...

Страница 55: ...ve Sections 18 Figure 19 Install the Tap into the Sleeve Bearing 18 Figure 20 Engage the Tap into the Sleeve Bearing 18 Figure 21 Turn the Tap and Pull Out 19 Figure 22 Remove the Sleeve Bearing 19 Figure 23 Remove Lip Seals From Fluid Section 20 Figure 24 Air Cylinder O ring 20 Figure 25 Clean the Seal Plate 21 Figure 26 Clean the Air Cylinder 21 Figure 27 Clean the Cylinder Cap 21 Figure 28 Clea...

Страница 56: ...d Assembly 29 Figure 49 Piston Fully Engaged in Valve Assembly 29 Figure 50 Apply Grease to Air Cylinder Groove 30 Figure 51 Apply Grease to O ring 30 Figure 52 Tighten Stroke Adjustment Screw 30 Figure 53 Sealing Washer 31 Figure 54 Jam Nut 31 Figure 55 Cylinder Cap Installed on the Valve 31 Figure 56 O rings in the Fluid Manifold 32 Figure 57 Fluid Manifold Aligned with Valve 32 Figure 58 Assemb...

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