ViscoTec preeflow plug n dose Manuel
OPERATION &
MAINTENANCE MANUAL
Dosing control unit
plug´n´dose
TABLE OF CONTENTS
2 / 16 INST-002766 / Aplug´n´dose
1 Introduction ...................................................................................................... 3
1.1 Delivery package ..................................................................................... 3
1.2 Incoming inspection ................................................................................. 3
2 Safety ................................................................................................................ 4
2.1 Explanation of symbols used ................................................................... 4
2.2 Intended use ............................................................................................ 5
2.3 Personnel................................................................................................. 6
2.3.1 Operators..................................................................................... 6
2.3.2 Maintenance staff ........................................................................ 6
2.4 Informal safety precautions...................................................................... 6
2.5 Preventing damage to equipment ............................................................ 7
2.6 Organisational safety measures .............................................................. 7
2.7 Residual risks........................................................................................... 8
2.8 Transport and storage.............................................................................. 8
3 Product description ......................................................................................... 9
3.1 General overview ..................................................................................... 9
3.2 Cable assignment, system plug 1 ............................................................ 9
4 Operation ........................................................................................................ 10
4.1 Start-up .................................................................................................. 10
4.2 Decommissioning................................................................................... 11
4.3 Operation ............................................................................................... 11
5 Maintenance ................................................................................................... 12
5.1 Maintenance intervals ............................................................................ 12
5.2 Troubleshooting ..................................................................................... 12
6 Cleaning .......................................................................................................... 13
7 Technical specifications................................................................................ 14
7.1 EU Declaration of Conformity ................................................................ 14
7.2 Technical data........................................................................................ 15
8 Disposal .......................................................................................................... 15
3 / 16INST-002766 / A plug´n´dose
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 is made up of a master control unit, the plug´n´dose dosing control unit
and a dispenser.
This operation manual describes the plug´n´dose dosing control unit. A separate operation
and maintenance manual is supplied with the dispenser.
1.1 Delivery package
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.
The scope of supply includes:
• 1 plug´n´dose dosing control unit
• 1 Connecting cable
• 1 Operation & maintenance manual
Fig. 1
INTRODUCTION
4 / 16 INST-002766 / Aplug´n´dose
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
5 / 16INST-002766 / A plug´n´dose
2.2 Intended use
The dosing control unit plug´n´dose controls the dispensers in order to convey and precisely
dispense viscose material.
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-genuine spare parts
• 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
6 / 16 INST-002766 / Aplug´n´dose
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
SAFETY
7 / 16INST-002766 / A plug´n´dose
2.5 Preventing damage to equipment
In order to prevent damage to equipment and to ensure precision dosing, note that
• The dispenser connecting cable may only be connected and disconnected when the
power supply is switched off.. The electronics in the drive motor could be damaged if this
precaution is not taken.
• Only use the original enclosed connection cables between the dispenser and the dosing
control. The connecting cables must not be extended or shortened. This can lead to
damage to the controller.
• the dispenser must never be operated without material (the stator will be destroyed).
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
8 / 16 INST-002766 / Aplug´n´dose
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:
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
DANGER
Danger to life from electrical voltage
There is a risk of fatal electric shock if equipment covers are removed or cables are
defective.
• Work and repairs on live parts may only be carried out by competent maintenance staff.
All applicable standards and safety, directives and regulations (e.g. EN 50110-1).
EN 50110-1) must be complied with.
SAFETY
9 / 16INST-002766 / A plug´n´dose
3Product description
The plug´n´dose dosing control unit controls the dispenser based on the signals generated
by a master control unit. The speed of the dispenser (dosing quantity and suck-back) are
therefore adjustable.
3.1 General overview
3.2 Cable assignment, system plug 1
ALED Displays the operating modes
• ON – ready for operation
• ON - dosing/suck-back running
• Flashing – fault
1Plug 1 Control signal
3Plug 3 Dispenser
1 White Start dispensing 1) (+24 V)
2 Brown Start suck-back 2) (+24 V)
3 Pink Fault, interval 0.5 sec + +24 V / 0 V
6 Green UNSet (setpoint selection 0–10 V3))
7 Grey GND (Ground)
8 Yellow Power supply (+ +24 V)
1) Dispenser motor runs, medium is delivered
2) Dispenser motor runs in reverse, medium is sucked back in to avoid
dripping
3) Speed of the dispenser
Fig. 2
A3
31
1
6
8
7
3
52
4
1
Fig. 3
PRODUCT DESCRIPTION
10 / 16 INST-002766 / Aplug´n´dose
4Operation
4.1 Start-up
Set the dispenser (D) to function standby condition as described in the operation and
maintenance manual supplied.
Connect the dispenser (D) connecting cable to plug 3.
Connect the connecting cable to the master control unit (B).
Connect the connecting cable to plug 1.
Fill the dispenser with material as described in the operation and maintenance manual.
NOTE
The dispenser connecting cable (plug 3) may only be connected and disconnected when
the power supply is switched off. The electronics in the drive motor could be damaged if
this precaution is not taken.
NOTE
Only use the original enclosed connection cables between the dispenser (D) and the
plug 3. The connecting cables must not be extended or shortened. This can lead to
damage to the controller.
The dosing control unit is not ready for operation until the dispenser is connected.
Fig. 4
B13
D
OPERATION
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