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PVA PCP Series, Руководство по эксплуатации

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PCP Series Manual 

 

Revision A 

/

 September 2020 

Page 8 of 46 

 

 

System Description 

This manual applies to the following Precision Valve & Automation, Inc. valves: 

PCP-015 

PCP015-C 

PCP050 

PCP050-C 

PCP150 

PCP150-C 

PCP500 

PCP500-C 

PCP1000 

PCP1000-C 

 

The PCP Series of progressive cavity pumps feature a machined rotor that couples with a 
rubberized seal to assure drip-free operation with a wide range of viscous chemistries. 
Each servo-controlled rotor displaces a fixed volume of material per revolution. This true 
positive displacement process assures consistent volume regardless of slight material 
variations.  

The PCP Series features five different rotor sizes allowing the end user to select their ideal 
flow rate. An optional carbide rotor allows processing of filled or abrasive chemistries while 
extending the life of the rotor. 

 

 

Theory of Operation  

The PCP Progressive Cavity Pump is a high precision, rotating, positive displacement 
pump. It dispenses high precision beads or dots of almost any chemistry or viscosity. 

The pump contains a stainless steel or carbide rotor and an elastomeric seal (stator). The 
PCP 

uses the principal of the “endless piston,” 

and is a progressive cavity pump that 

provides pulse-free, drip free dispensing. Reverse operation of the pump 

will cause “suck 

back” or “snuff back” which gives excellent shut off.   

 

 

 

 

 

 

Содержание PCP Series

Страница 1: ...Progressive Cavity Pump PCP Series Operation Manual Revision A INNOVATION PRECISION EXCELLENCE ...

Страница 2: ... of this document 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 info...

Страница 3: ...0 Operation 11 Bleed the Pump 11 Fluid Pressure 12 Material Flow Rate 12 Install the Needle 12 Snuff Back 12 Pump Shutdown Procedure 13 Disassemble and Clean the Pump 14 Remove the Pump from the Workcell 14 Disassemble the Pump 15 Clean All Wetted Parts 21 Assembly Instructions 23 Assemble the Pump 23 Install the Pump on the Workcell 32 Maintenance 33 Replace the Dispense Needle 33 Replace the Sta...

Страница 4: ...ual Revision A September 2020 Page 4 of 46 Devices 36 Dispense 37 Calibration 38 Parts Breakdown 39 Spare Parts 40 Technical Specifications 41 Drawings 42 Troubleshooting 43 Table of Figures 44 PVA Warranty Policy 46 ...

Страница 5: ...mation Main Office PVA One Mustang Drive Cohoes NY 12047 Tel 1 518 371 2684 Fax 1 518 371 2688 Website http www pva net Email info pva net Technical Support Tel 1 844 734 0209 Email cs pva net Document History Revision Revision Date Reason for Changes A August 2020 Initial Release Note All photographs and CAD model representations in this document are a general representation of the system and its...

Страница 6: ...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 leaks immediately Always wear appropriate safety equipment when y...

Страница 7: ...sonal injury exist in this equipment or may be associated with its use Only qualified personnel should enter areas designated with this symbol Laser light source present Do not stare directly into the beam Do not use in the presence of highly reflective surfaces Pinch hazard from moving parts Avoid contact Hot surface Avoid contact Warning Ultraviolet UV light hazard Do not look directly at the UV...

Страница 8: ...regardless of slight material variations The PCP Series features five different rotor sizes allowing the end user to select their ideal flow rate An optional carbide rotor allows processing of filled or abrasive chemistries while extending the life of the rotor Theory of Operation The PCP Progressive Cavity Pump is a high precision rotating positive displacement pump It dispenses high precision be...

Страница 9: ...rns but has a perfect seal when the rotor is stopped Manifold The manifold is fed by the rotor stator and supplies it to the dispense needle through the material outlet Personal Protective Equipment Operators must use eye protection because material contents are under pressure Always wear gloves when handling materials and solvents Refer to MSDS sheets on the material being dispensed for other pre...

Страница 10: ...ll occur Always put pump conditioner on the rotor before the pump is assembled Refer to Section 9 for more information on how to order pump conditioner 1 Use the mounting holes to install the PCP onto the workcell 2 Attach the fluid supply line to the related fluid inlet Make sure the fluid fittings are tight and do not leak 3 Attach the motor cable and make sure the routing of the cable is correc...

Страница 11: ... the bleed clip 2 Turn the bleed clip counterclockwise to loosen Turn one full rotation then slowly until material appears 3 Turn one full rotation and then slowly until the material begins to bleed 4 Let the material flow from the material outlets until there are no breaks in the material flow NOTE Any break in the flow of the material shows there is still air in the system Bleed the pump until t...

Страница 12: ...ach it 2 Use the purge function to release all air from the needle Snuff Back The snuff back function prevents strings or drips of material at needle tip after material is dispensed Snuff back is the when the pump operates in the opposite direction for a short period and causes the material to flow in the opposite direction also Snuff back removes the fluid pressure from the static mixer and needl...

Страница 13: ...own Procedure 1 Remove the needle from the manifold 2 Purge material through the manifold 3 Completely clean the manifold material outlet 4 Install a night cap on the manifold material outlet 5 Release the fluid supply pressure Refer to the workcell manual if necessary ...

Страница 14: ...mp 2 Turn the luer lock dispense tip counterclockwise and pull to remove 3 Discard the luer lock dispense tip 4 Use a wrench to remove the material fitting from the fluid body 5 Install a cap on the material fitting 6 Use a 2 5 mm hex key to remove the bolt from the back of mount plate in the back of the fluid body Figure 2 Remove Pump from Workcell 7 Remove the pump from the workcell ...

Страница 15: ...pump on a clean work surface 2 Use a 2 5 mm hex key to remove the two M3 x 55 mm socket head cap screws from the rotor assembly 3 Separate the motor from the rotor assembly Figure 3 Separate Motor from Rotor Assembly 4 Remove the blue coupling from the rotor assembly Figure 4 Remove Coupling ...

Страница 16: ...on A September 2020 Page 16 of 46 5 Twist to unscrew the luer lock and remove it from the stator sleeve Figure 5 Remove Luer Lock 6 Twist to unscrew the union cap and remove it from the stator sleeve Figure 6 Remove Union Cap ...

Страница 17: ...PCP Series Manual Revision A September 2020 Page 17 of 46 7 Remove stator sleeve Figure 7 Remove Stator Sleeve 8 Install the stator tool onto the rotor assembly Figure 8 Install Stator Tool ...

Страница 18: ...sion A September 2020 Page 18 of 46 9 Hold the stator tool to stabilize and twist counterclockwise to remove the stator Figure 9 Remove Stator 10 Twist to remove the bleed clip from the vent port Figure 10 Remove Bleed Clip ...

Страница 19: ...gs for damage Save it if it is not damaged Replace it if it is damaged Figure 11 Remove O Ring 13 Use a 2 5 mm hex key to remove the two M3 x 35 mm socket head cap screws from the rotor assembly Figure 12 Remove Screws from Rotor Assembly 14 Separate the fluid block from the seal block rotor assembly Figure 13 Separate Fluid Block ...

Страница 20: ...16 Examine the o ring for damage Save it if it is not damaged Replace it if it is damaged Figure 14 Remove O ring from Fluid Block 17 Remove the o ring from the seal block 18 Examine the o ring for damage Save it if it is not damaged Replace it if it is damaged Figure 15 Remove O Ring from Seal Block ...

Страница 21: ...towels to clean all wetted parts of the pump When cotton tipped applicators and towels get dirt and material on them discard them and use a new one Do not mix the materials 2 Make sure all material is removed from the inside and outside 3 Clean the fluid port 4 Make sure all material is removed from the rotor and the groove at the base of the rotor Figure 17 Clean Rotor Note Do not flush the rotor...

Страница 22: ...material is removed from the inside and outside of the stator using a pipe cleaner Figure 18 Clean the Stator 6 Make sure material is removed before assembling the pump 7 Clean both the mix clip and manifold with solvent cotton tipped applicators and lint free disposal wipes ...

Страница 23: ...bly Note When installed the four small holes on the seal block should be facing away from the rotor assembly The side in the image below should be facing towards the rotor assembly Figure 20 Seal Block Direction 2 Press the seal block and rotor assembly together To avoid damage to the seals ensure that the seal block and rotor assembly are concentric Figure 21 Seal Block and Rotor Assembly ...

Страница 24: ...re 22 Install O Ring on Seal Block 5 Install the fluid block onto the seal block rotor assembly Figure 23 Install Fluid Block Note When installing the fluid block ensure that the bleed port is on the front and the fluid inlet is on the outer side of the pump For example in the left pump pictured above the fluid inlet is on the left side Bleed Port Fluid Inlet ...

Страница 25: ... mm socket head cap screws onto the rotor assembly and fluid block Tighten with a 2 5 mm hex key Figure 25 Install Screws onto Rotor Assembly Fluid Block 7 Lubricate the AS013 O ring with pump conditioner 8 Install the o ring on the bottom of the fluid block assembly Figure 26 Install O Ring on Fluid Block Assembly ...

Страница 26: ...stall the SS5 O ring onto the vent port Figure 27 Install O Ring on Vent Port 11 Lubricate the SS5 O rings with pump conditioner 12 Install the SS5 O rings on the bleed clip based on the picture below Figure 28 Install O Rings on Bleed Clip 13 Install the bleed clip onto the vent port Figure 29 Install Bleed Clip ...

Страница 27: ... conditioner to the rotor 15 Install the stator tool onto the rotor assembly Figure 30 Install Stator Tool 16 Face the tabs of the stator toward the fluid block assembly Hold the stator tool to stabilize and twist on the stator Figure 31 Install Stator onto Rotor Assembly ...

Страница 28: ... Revision A September 2020 Page 28 of 46 Note Align the tabs with the locating features Figure 32 Align Tabs with Locating Features Note The rotor should be flush with the bottom of the stator Figure 33 Rotor and Stator ...

Страница 29: ...al Revision A September 2020 Page 29 of 46 17 Slide the stator sleeve over the stator Figure 34 Install Stator Sleeve 18 Slide the union cap over the stator sleeve Twist until it is secure Figure 35 Install Union Cap ...

Страница 30: ...eries Manual Revision A September 2020 Page 30 of 46 19 Install the blue coupling onto the rotor assembly Figure 36 Install Blue Coupling 20 Install the motor onto the rotor assembly Figure 37 Install Motor ...

Страница 31: ...evision A September 2020 Page 31 of 46 21 Install the two M3 x 55 mm socket head cap screws Tighten with 2 5 mm hex key Figure 38 Install Screws 22 Install the luer lock onto the stator sleeve Figure 39 Install Luer Lock ...

Страница 32: ...mp on the Workcell 1 Install the bolt through the mount plate into the back of the fluid body 2 Connect the material fitting to the fluid body 3 Install the new luer lock dispense tip onto the stator sleeve 4 Turn the luer lock dispense tip clockwise until it is tight 5 Attach the motor connection ...

Страница 33: ...r twists Replace the Dispense Needle It is necessary to change the dispense needle when the pressure goes out of range How frequently you change the dispense needle depends on the type of material being dispensed and the number of cycles done per day Each time the dispense needle is changed it is necessary to clean the material outlet on the manifold Figure 41 Material Outlet 1 Turn the luer lock ...

Страница 34: ...remove the star shaped coupling 3 Put the new star shaped coupling in the bearing block 4 Use the pick to position it correctly 5 Push on the coupling to make sure it is correctly installed Figure 42 Replace Coupling Replace the Stator 1 Perform the procedure to disassemble and clean the pump Discard the used stator 2 Install the new stator 3 Assemble the pump and install it in the workcell ...

Страница 35: ...tion The screens that relate to the PDP are in Manual mode under PDP050 When you are in this screen a row of tabs will be shown under the row of manual mode tabs Use the left and right arrows to scroll through the tabs Setup Mode The settings that are used in Auto Cycle can be changed in Setup Mode as shown below 1 Select Setup mode 2 Select the Setup Tree tab 3 Select the symbol next to a Paramet...

Страница 36: ...ces 1 Select Manual from the cycle stop screen 2 Select the Devices tab 3 Select the valve from the Select Valve drop down menu 4 Select Purge Valve to purge material from the selected valve 5 Select the Z Slide Up or Down buttons to move the Z slide Figure 44 Devices Screen ...

Страница 37: ...Rate in grams per minute Select the value box and use the up and down arrows or use the keyboard to type the value 5 Select the Suckback On button to toggle it on and off 6 Set the Suckback time in seconds Select the value box and use the up and down arrows or use the keyboard to type the value 7 Select Apply to Auto to apply the set values to Auto Mode Figure 45 Dispense Screen ...

Страница 38: ... After the shot finishes weigh the dispensed material and type it into the Lo Wgt g text field 6 In the Shot Speed dropdown menu select High 7 Under Begin Shot select Go After the shot finishes weigh the dispensed material and type it into the High Wgt g text field 8 Under Calculate Offset select Go The calibration for the selected pump is now complete Select the next pump and repeat the calibrati...

Страница 39: ...M PCP050 1 6 12821 LUER STANDARD ADAPTER PCP050 1 7 12822 UNION CAP PCP050 1 8 12823 STATOR SLEEVE SS PCP050 1 9 12824 FLUID BODY SS LEFT PORTED 1 4 NPT PCP050 1 10 12825 BLEED CLIP BLEED PORT PCP050 1 11 12827 O RING AS013 PCP050 1 12 12830 O RING SS5 PCP050 3 13 12831 O RING AN016 PCP050 1 14 12837 O RING FKM P9 PDP050 1 15 12840 Cable Motor PCP PDP shielded high flex 5 meter 1 16 M3 X 35 MM SOC...

Страница 40: ...rts A spare parts kit is available to prevent machine downtime Part Number 612 10811 1 ITEM PART NUMBER DESCRIPTION QTY 1 12830 O RING SS5 PCP050 8 2 12831 O RING AN016 PCP050 2 3 12836 O RING FKM AS013 PDP050 2 4 12837 O RING FKM P9 PDP050 2 Figure 49 Spare Parts Kit ...

Страница 41: ...ber Flow Rate Dimensions mm Fluid Inlet PCP 015 0 15 1 8 ml min 27 x 27 x 230 1 4 NPT PCP 015 C 0 12 0 15 ml min 27 x 27 x 230 1 4 NPT PCP050 0 5 6 ml min 27 x 27 x 230 1 4 NPT PCP050 C 0 5 0 5 ml min 27 x 27 x 230 1 4 NPT PCP150 1 2 15 ml min 29 x 29 x 280 1 4 NPT PCP150 C 1 2 1 5 ml min 29 x 29 x 280 1 4 NPT PCP500 4 50 ml min 29 x 29 x 280 1 4 NPT PCP500 C 4 5 ml min 29 x 29 x 280 1 4 NPT PCP10...

Страница 42: ...PCP Series Manual Revision A September 2020 Page 42 of 46 Drawings Figure 51 PCP Drawing Dimensions ...

Страница 43: ...bent Rotor is broken Install a new rotor assembly Material leaks from the pump tip Fluid pressure too high 5 8 bar max Decrease inlet fluid pressure Not enough snuff back on rotor Increase snuff back Stator is worn Replace stator Air bubbles in material Refer to the Air bubbles in material section under the Troubleshooting Problem heading in this table Material is compressible Degas the material P...

Страница 44: ... Clean the Stator 22 Figure 19 Install Seal Block on Rotor Assembly 23 Figure 20 Seal Block Direction 23 Figure 21 Seal Block and Rotor Assembly 23 Figure 22 Install O Ring on Seal Block 24 Figure 23 Install Fluid Block 24 Figure 24 Fluid Block Installed 25 Figure 25 Install Screws onto Rotor Assembly Fluid Block 25 Figure 26 Install O Ring on Fluid Block Assembly 25 Figure 27 Install O Ring on Ve...

Страница 45: ...42 Replace Coupling 34 Figure 43 Setup Screen 35 Figure 44 Devices Screen 36 Figure 45 Dispense Screen 37 Figure 46 Calibration Screen 38 Figure 47 PCP Disassembled 39 Figure 48 Part Number List 39 Figure 49 Spare Parts Kit 40 Figure 50 Model Specifications 41 Figure 51 PCP Drawing Dimensions 42 ...

Страница 46: ...l warranties 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 Technical Support department Authorization will be issued either via the telephone facsimile or in writing upon your request To qualify as a valid warranty claim the def...

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