Sames RegMaster Pneumatic Mastic Regulator Manuale del proprietario

Sames
Marca
Sames
Modello
RegMaster Pneumatic Mastic Regulator
Tipo
Manuale del proprietario
Mastic
Regulator
09.07_01en
1
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
Special Versions
Pneumatic Mastic Regulator
Mastic
Regulator
09.07_01en
2
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
INCORPORATION DECLARATION (DIRECTIVE 98/37/CE from the 22nd June 1998)
DECLARACION DE INCORPORACIÓN (DIRECTIVA 98/37/CE de 22 Juegos)
EINGLIEDERUNGSERKLÄRUNG (DIREKTIVE 98/37/CE des 22 Juni 1998)
DICHIARAZIONE D'INCORPORAZIONE (DIRETTIVA 98/37/CE del 22 Giugno 1998)
Le fabricant / The manufacturer / El fabricante / Der Hersteller / Il Costruttore :
SAMES KREMLIN GmbH
Moselstr. 19
41464 NEUSS - Germany
TÉL.: +49 (0) 2131 3692 0 - FAX: +49 (0) 2131 3692 110
www.sames-kremlin.com
...déclare que la machine ou le sous-ensemble désigné ci-dessous / …
declara que la maquina o el sub-conjunto así como designado aquí abajo /
...declares that the machine or the under group mentioned hereunder /
...deklariert daß die Maschine oder die Untergruppe die unten beschrieben ist / ...
dichiara che la macchina o i sottoinsime qui' sotto descritti :
Désignation / Designation / Designación /
Designation / Descrizione :
Numéro de l'équipement / Equipment number / Numeró del equipo /
Nummer der Machine / Numero della macchina :
Numéro de série / Serial number / Numeró de serie /
Serien Nummer / Numero di serie :
Marque / Trademark / Marca /
Marke / Marca:
...ne pourra être mis en service avant que la machine dans laquelle il sera incorporé ne soit déclarée conforme
aux dispositions de la directive 98/37CE et à la législation nationale la transposant /
...could not be used before the equipment with which it will be incorporated is declared in conformity
with the 98/37/CE directive clauses and international rules /
...no podría ser puesto en servicio antes que la maquina en la cual debe ser incorporado sea declarada conforme
a las disposiciones de la directiz 98/37/CE y a la legislación nacional la transponando.
...nicht in gang gesetzt werden kann, solange die Maschine in die es eingebaut wird, nicht den Direktiven
98/37/CE
und den nationalen Gesetzen für ihre transponierung entsprechend annerkannt worden ist /
...non potrà essere messo in servizio prima che la macchina nella quale sarà incorporato non sarà dichiarata
conforme
alle disposizioni della direttiva 98/37CE ed alla legislazione nazionale per la sua trasposizione :
...est également conforme aux dispositions des directives européennes suivantes /
...applies to the clauses of following european directive /
...así como es conforme a las disposiciones de las directriz europeas siguientes /
...und ebenfalls den folgenden Europäischen Direktiven entspricht /
...è inoltre conforme alle disposizioni delle direttive europee seguenti :
...est conforme aux dispositions des normes européennes harmonisées suivantes /
...and the following dispositions of the harmonised european norm /
...así como es conforme a las disposiciones de las normas europeas harmonizadas siguientes /
...und den folgenden Dispositionen der europäischen Normen angemessen sind /
...è conforme alle disposizioni delle norme europee armonizzate seguenti :
...est également conforme aux normes nationales et aux dispositions techniques suivantes /
...applies to the national norms and the following technical clauses /
...así como es conforme a las normas nacionales y a las disposiciones tecnicas siguientes /
...und ebenfalls den folgenden nationalen und technischen Normen angemessen sind /
...è inoltre conforme alle norme nazionali ed alle seguenti disposizioni tecniche :
PNEUMATIC FLUID
PRESSURE REGULATOR
B901001/B901002
EXEL Automotive Deutschland GmbH
ATEX/94/9/CE
EN 292 / EN 418 / EN 809
Mastic
Regulator
09.07_01en
3
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
Our scope of supply only includes the materials specified in our proposals and offers. The acceptance of
our offers does also imply the acceptance of our delivery terms. We do reserve the right to make
modifications or improvements, even after receipt of an order. Our materials are controlled and tested
before shipment. To be valid, any claim concerning an ordered material must be formulated in written
within 10 days after delivery.
WARRANTY
EXEL Automotive Deutschland GmbH warrants all equipment manufactured by us, as long as it is fitted
with the original identification plate, for a period of one year from ex-works date (for a single 8 h shift per
day), to be free from defects in material and workmanship. Warranty claims found to be defective shall be
verified and confirmed by EXEL Automotive Deutschland GmbH. Our warranty does not cover fair wear
and tear (including parts which are not indicated on our instruction leaflets), damage or wear caused by
misuse, non-observance of EXEL Automotive Deutschland GmbH recommendations and inadequate or
improper maintenance. Our warranty only consists of replacing the parts returned carriage paid to our
plant and proven defective by us. We shall not be liable for any losses resulting from a production
breakdown. Upon request, we can carry out service work at your premises but all expenses
(accommodation & transportation) for the EXEL Automotive Deutschland GmbH technicians will be
chargeable. Equipments found to of been tampered with will invalidate the warranty. Material bought in
equipment will be subject to the manufacturer's warranty.
CONFORMITY
The EXEL Automotive Deutschland GmbH equipment complies with the "MACHINES European
Regulation (98/37/CE).
SAFETY
The operating of our materials, which are using products submitted to different rules, including the rules
specific to the country of the consignee, must be made in accordance with safety regulations. These
regulations, and the ones described in this manual, as well as the user notices supplied by the
manufacturers and the suppliers of the products to be used must be known by the users and can in no
case commit our responsibility.
Mastic
Regulator
09.07_01en
4
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
6 bar
87 psi
NIP HAZARD
REF. 91480
WEAR OF
GLASSES IS
OBLIGATORY
REF.91490
WARNING : MOVING
ELEVATOR
REF. 91483
WARNING :
HOT PARTS
OR AREAS
RREF. 91494
RELIEF OR DRAIN
VALVE
REF. 91487
WARNING :
HOSE UNDER
PRESSURE
REF. 91488
READ THE USER
'INSTRUCTIONS
MANUAL
REF. 91481
PRODUCT VAPORS
HAZARDS
REF. 91491
WARNING :
ELECTRICAL
HAZARD
REF. 91492
WARNING :
MOVIONG PARTS
REF. 91485
EXPLOSION
HAZARDS
REF. 91495
DO NOT EXCED
THIS PRESSURE
REF. 91482
WEAR OF GLOVES
IS OBLIGATORY
REF. 91489
GROUNDING
WARNING :
HIGH PRESSURE
HAZARDS
REF. 91486
WARNING :
FIRE HAZARDS
REF. 91493
WARNING
(USER)
WARNING
(MATERIALS)
WARNING
SERIOUS
INJURIES
Mastic
Regulator
09.07_01en
5
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
GENERAL SAFETY INSTRUCTIONS
Before the use of the equipment, it is important that the users have read and
understood all instructions and warnings of this instructions manual, as well as
the instructions in the manuals of further installed parts and accessories.
Faulty operation of the equipment may cause serious injury. This equipment is only for
professional use. It must be used only for what it has been designed for.
Never modify nor amend the material. The parts and accessories must
only be supplied by EXEL Automotive Deutschland GmbH or must be in
conformance with EXEL Automotive Deutschland GmbH regulations. The
material must be regularly inspected. Defective or worn parts must be
replaced. Never exceed the working maximal pressures. The regulations
concerning security, fire risks, electricity in force in the country of final
destination of the material must be carefully followed. Use only products
and solvents which are compatible with the parts which are in contact
with the product. (Refer to data sheet of the product manufacturer).
Before any service work or commissioning of the machine, carefully read the
PRESSURE RELIEF INSTRUCTIONS. Check the right working of the air
relief valve or of "drain" valve.
PRESSURE HAZARDS
The safety requires an AIR RELIEF shut off valve to let the air off when closing
the supply circuit.
A PRODUCT DRAIN VALVE must be mounted in the product pipe to relieve
the pressure before any servicing on the material.
FIRE - EXPLOSION - ELECTRIC ARCS-STATIC - ELECTRICITY
A wrong grounding or sparks may cause explosion or fire.
To avoid these risks, specially during use of motor pumps, it is strongly advised
to :
- Ground material, parts to be handled, cleaner cans.
- Ensure an adequate ventilation.
- Keep the working area clean from cloths, paper, solvents...
- Never use electrical switches with vapours or during application.
- Stop immediately working in case of electrical arcs.
- Keep all liquids out of the work area.
Mastic
Regulator
09.07_01en
6
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
INJECTION HAZARDS
The high pressure pump and application technology demands lot of precaution.
Hazardous leaks with injection risks in exposed parts of body that may cause severe
injuries or amputation risks.
- A product injection under the skin or in other parts of the body (eyes, fingers...)
requires immediate medical care.
Never point the spray gun at anyone. Never try to stop the spray with
the body (hands, fingers...) or with rags or similar things.
Follow imperatively the air relief & drain instructions before any
work for cleaning, checking or servicing of the material or
cleaning of the gun nozzles.
Keep the H.P. flexible hoses out of the circulation areas, of the moving
parts & hot surfaces.
Never expose standard "high pressure" product hoses to temperatures
higher than 140°F / 60°C or lower than -104°F / - 40°C.
Never pull on the H.fflexible hoses to move the material.
Tighten all couplings & H.P. flexible hoses before set-ting up the
equipment.
Check daily the H.P. flexibles hoses & couplings. Replace damaged or
worn parts. The couplings of high pressure flexible hoses can not be
repaired.
TOXICAL PRODUCT HAZARDS
Toxic products or vapours may cause severe injury through contact with the
body, eyes, under the skin but also through swallow or inhalation.
It is imperative to :
- Know the product & possible hazards.
- Store the product to be used in the appropriate areas.
- Keep the product used during dispensing in a suitable container.
- Dispose the product according to the regulation of hazardous products in force
in the country where the product is used.
- Wear protective equipment designed for that use.
- Wear glasses, gloves, shoes, clothes & mask for breath.
Mastic
Regulator
09.07_01en
7
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
WARNING: IT IS FORBIDDEN using any solvents with halogen carbide base -
and also products made with these solvents - facing ALUMINIUM & ZINC.
Serious or fatal injuries may occur.
USED PRODUCTS
Considering the variety of products and the impossibility to consider all
chemical data, of possible reactions of chemicals to each other and their
long term evolution, EXEL Automotive Deutschland GmbH can not be hold
responsible for: the bad compatibility of fluids to each other, for risks for
staff and surroundings, for worn or out of order parts, for wrong working
of equipments or units, as well as for the qualities of final product.
The user must know and prevent the possible risks owing to toxic
vapours, fires or explosions due to used products. He shall determine the
risks of immediate reactions or the cumulative effects pursuant to
repeated exposures of the staff.
EXEL Automotive Deutschland GmbH shall not be liable for expenses or
claims for bodily or psychic injuries or direct and indirect material
damages further to the use of chemicals.
Selection of the right Valve Size
The EXEL standard regulator is equipped with an eight 8 mm ball in the seat.
This seat should be used for a flow rate between 10cm³/s and 50cm³/s = 0,6 l/min – 3,0 l/min
(low viscous PVC)
For special applications EXEL has developed special inserts.
Small valve ball 6mm (part no. code z = 0)
For high inlet pressures and low flow rates up to 15cm³/s = 0,9l/min
Standard valve ball 8mm (part no. code z = 1)
For medium flow rates up to 50 cm³/s = 3,0 l/min
Big valve ball 12mm (part no. code z = 2)
For high flow rates up to 150 cm³/s = 9 l/min
Selection of the Control Piston
Big Control Piston
Regulated pressure max. 200 bar – for robot application max. 160 bar = 4 diaphragms
Each diaphragm increases the control range by 40 bar.
Small Control Piston
Regulated pressure max. 320 bar = 3 diaphragms
Each diaphragm increase the control range by 80 bar.
Mastic
Regulator
09.07_01en
8
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
GENERAL FEATURES
Product inlet :
3/4"BSP
Product outlet:
3/4"BSP
Air inlet :
1/4"BSP
Maximum inlet product pressure : 400 bars – 5800 psi
Max. air pressure : 6 bars – 87 psi
Regulator aluminium Art.-No. B901001.wxyz
Regulator stainless steel Art.-No. B901002.wxyz
Definition of *.wxyz
w
x
y
z
0
Control Piston “big“
Inlet “side“
No. of pressure stages
6mm Valve
1
Control Piston “small“
Inlet “bottom“
8mm Valve
2
12mm Valve
3
4
5
Examples ’w, x, y and z’
w x y z
B901001.0 0 1 2
Aluminium Regulator – “Big” Piston (40mm) – Inlet from the side –
one pressure stage = control range 40bar – 12mm Ball (Ind.16+17)
w x y z
B901001.1 1 1 0
Aluminium Regulator – “Small” piston (28mm) – Inlet from below –
one pressure stage = control range 80bar – 6mm Ball (Ind.16+17)
w x y z
B901002.0 1 2 0
Stainless Steel Regulator – “Big” piston (40mm) – Inlet from bottom–
two pressure stages (diaphragms) = control range 80bar – 6mm Ball (Ind.16+17)
Mastic
Regulator
09.07_01en
9
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
Regulator with one stage
B9001001.wx1z
B9001002.wx1z
Regulator with two stages
B9001001.wx2z
B9001002.wx2z
Regulator with three stages
B9001001.wx3z
B9001002.wx3z
Regulator with four stages
B9001001.wx4z
B9001002.wx4z
Regulator with five stages
B9001001.wx5z
B9001002.wx5z
Mastic
Regulator
09.07_01en
10
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
Mastic
Regulator
09.07_01en
11
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
Parts List 1
Ind.
Option
pcs.
B901001.wxyz
B901002.wxyz
Description
1
y = 1
6
933 151 332
933 151 332
Screw
y = 2
6
88 138
88 138
Screw
y = 3
6
88 140
88 140
Screw
y = 4
6
88 617
88 617
Screw
y = 5
6
88 755
88 755
Screw
2
-
1
204 819
204 819
Cover
3
y = 1
1
204 818
204 818
Diaphragm (PU)
y = 2
2
y = 3
3
y = 4
4
y = 5
5
4
y = 1
1
204 820
204 820
Plate
y = 2
2
y = 3
3
y = 4
4
y = 5
5
5
y = 1
0
204 822
204 822
Spacer
y = 2
1
y = 3
2
y = 4
3
y = 5
4
6
-
4
88 189
88 189
Screw
7
w = 0
1
204 823
B001354
Piston Housing
w = 1
1
B001418
B001418
8
w = 0
1
204 828
B001352
Control Piston
w = 1
1
B001417
B001417
9
-
1
204 824
B001351
Body
10
-
1
B001372
B001419
Plug
11
-
2
631 121
631 121
O-Ring
12
-
4
88 176
88 176
Srew
13
x = 0
1
206 827
B001384
Inlet block
x = 1
1
204 993
15
-
1
203 617
B001374
Spring
16
z = 0
1
B001431
B001431
Valve Ball with guide
z = 1
1
204 826
B001322
z = 2
1
B001313
B001313
17
z = 0
1
B001429
B001429
Seat
z = 1
1
204 825
B001321
z = 2
1
B001312
B001312
Mastic
Regulator
09.07_01en
12
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
Parts List 2
Pos.
Variante
Stk.
B901001.wxyz
B901002.wxyz
Benennung
18
-
1
B001355
B001355
Push Pin
20
w = 0
1
84 163
84 163
Seal
w = 1
1
B001416
B001416
21
-
1
84 173
84 173
O-Ring
22
w = 0
1
90 025
90 025
Ball bearing traveller
w = 1
1
B001392
B001392
23
y = 1
1
204 915
204 915
Screw
y = 2
2
y = 3
3
y = 4
4
y = 5
5
24
y = 1
0
204 821
204 821
Pressure transfer element
y = 2
1
y = 3
2
y = 4
3
y = 5
4
25
y = 1
0
85 010
85 010
Air module seal
y = 2
1
y = 3
2
y = 4
3
y = 5
4
26
y = 1
0
88 427
88 427
Pin
y = 2
1
y = 3
2
y = 4
3
y = 5
4
30
x = 0
0
-
-
Plug
x = 1
1
-
B001385
31
x = 0
0
-
-
Inlet
x = 1
1
-
B001365
32
x = 0
0
-
-
Diffusor
x = 1
1
-
B001385
33
x = 0
0
-
B001373
Plug
x = 1
1
-
-
Mastic
Regulator
09.07_01en
13
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
MAINTENANCE
Before dismantling or doing any operation on the regulator, it is essential to decompress the
material, to avoid any serious injury that may be caused by product splashing into the eyes or
being injected under the skin and causing blood poisoning.
Maintenance consists in checking the seals and diaphragms as well as the all parts of the
regulator consequently to some leaks or just for preventive maintenance.
It is advisable to replace the parts showing an unusual wear.
BRINGING THE EQUIPMENT INTO SERVICE
The regulators are tested in our workshops with a neutral lubricant.
Before putting the equipment into service you have to rinse the lubricant with a solvent (naphta
or chlorinated solvent for example), if it is not compatible with the product to be pumped.
DISMANTLING
First - decompress the regulator, then loosen the product inlet and outlet fittings, unplug the
regulator air feeding and remove the regulator.
A - REPLACING THE DIAPHRAGMS
1 - Unscrew the 8 screws (Ind. 1),
2 - Take off the cover (Ind. 2),
3 - Take off, check and replace if necessary, the diaphragm (Ind. 3),
B - DISMANTLING THE LOWER VALVE
1 - Unscrew the 4 screws (Ind. 12),
2 - Take the fitted inlet block out,
3 - Keep the seat holder (Ind. 17), check its seat and replace the whole unit if necessary,
4 - Take out and check the O-rings (Ind. 11), replace them if necessary,
5 - Remove the valve (Ind. 16).
6 - Remove and check the spring (Ind. 15).
7 - Remove the inlet block (Ind. 13).
NOTE: Check the seat. Should be damaged, replacing the seat/seat holder unit systematically
leads to replacing the valve.
C - REPLACING THE NEEDLE AND THE UPPER VALVE SEALS
1 - Unscrew the screw (Ind. 23),
2 - Keep the plate (Ind. 4),
3 - Unscrew the 4 screws (Ind. 6),
4 - Take the fitted valve guide,
5 - Take out and check the seals (Ind. 21), replace it if necessary, and (Ind. 20), This
seal should be replaced systematiquely at each remounting,
6 - Keep the valve rod (Ind. 8),
7 - Unscrew the needle (Ind. 18), replace if necessary. The needle (Ind. 18)
and the valve rod (Ind. 8) should be assembled with ‘’Loctite n° 243’’ glue or
equivalent.
8 - Remove the valve guide (Ind. 7),
Mastic
Regulator
09.07_01en
14
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
MAINTENANCE
When using an abrasive product, it is recommended to make a periodical preventive
maintenance after a determined number of hours or operation which is defined by the plant
maintenance department. This is according to the type of product, the operation rate, the flow
rate and the operation pressure.
Maintenance consists in checking the seals and the sealing bushes.
- Replace the parts which show an unusual wear,
- Lubricate generously the parts which are subjected to some frictions,
- Check that these parts have no scratch,
- Clean carefully all parts without using any metal item or abrasive materials,
- Always check that the seals have no cut or scratch.
IMPORTANT NOTE : When assembling the unit always sure that no seal is damaged, should
one off them be cut this could cause bad functioning of the regulator
REASSEMBLING
Proceed inversely to dismantling in accordance with above recommendations.
Mastic
Regulator
09.07_01en
15
SAMES KREMLIN GmbH
Tel: +49 (0) 2131-36 92 0
Fax: +49 (0) 2131-36 92 110
info@exel-gmbh.com
TROUBLE SHOOTINGS
PROBLEMS
LIKELY CAUSE
SOLUTION
No regulation
Seat worn out
Change the seat
Seat dirty
Clean the seat
Mechanical unit blocked in low
position
Dismantle, clean and check the
mechanical unit
Diaphragm damaged
Spring broken
Replace the spring
No output pressure
No piloting air
Check the above air network
Push pin broken
Replace the pin
Bad regulation
Pressure or feeding output too
low
Increase piloting pressure on the
pump motor
Air module seal damaged
Replace the air module seal(s)
Ball cage damaged
Replace the ball cage
Too low output pressure
Piloting pressure too low
Increase piloting pressure
Hole(s) in the diaphragm(s)
Replace the diaphragm(s)
Air leak
Diaphragm damaged
Replace diaphragm
Air module seal damaged
Replace the air module seal(s)
Product leak through vent
hole
Control Piston seal worn out
Replace the seal
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Sames RegMaster Pneumatic Mastic Regulator Manuale del proprietario

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