AMCOL 6000P User manual

AMCOL CORPORATION

6000P PNEUMATICALLY

CONTROLLED PRECISION

LUBRICATION SYSTEM

Operator’s Manual

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 1

File ID: 6000P-OM04

Approved for Use

LSB: AA-0025

LSD: 3/7/2022

FDR: PS04

Contents

1 Introduction ......................................................................................................................................2

2 Included Components....................................................................................................................3

3 Assembly and Installation ...............................................................................................................4

PRIOR TO GETTING STARTED............................................................................................................4

Installation .........................................................................................................................................4

4 Recommended Settings.................................................................................................................5

5 Operation .........................................................................................................................................6

6 Priming/Re-priming the System ......................................................................................................8

7 System Troubleshooting ..................................................................................................................8

8 T60A Posi-pump Troubleshooting...................................................................................................9

9 Maintenance .................................................................................................................................11

Recommended Spares .................................................................................................................11

Recommended Tools ....................................................................................................................11

Repair of the T60A Posi-Pump ......................................................................................................12

T60A Posi-pump Bill of Materials ...................................................................................................13

Preventative and Predictive Maintenance ...............................................................................13

Daily .............................................................................................................................................13

Quarterly......................................................................................................................................13

Yearly ...........................................................................................................................................13

10 Recommended Fluids .................................................................................................................14

11 Schematics and Drawings..........................................................................................................15

AMCOL Corporation

21435 Dequindre, Hazel Park, MI 48030

248-414-5700

fax: 248-414-7489

www.amcolcorp.com

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 2

1 Introduction

The AMCOL 6000P Pneumatically Controlled Precision Lubrication Applicator is an air

operated spray system used to accurately dispense minute quantities of liquid lubricants

and coatings used in the production and fabrication of metal. With this system, fluids are

injection metered from a gravity reservoir using patented positive displacement piston

pumps and then mixed with air at the spray point. Multi-point lubrication is accomplished

with multiple injectors or by splitting outputs at the spray point.

This operator’s manual describes the installation, operation, and maintenance of

your new AMCOL 6000P Precision Applicator. For more information on the system and the

individual components, please refer to the preceding document: “AMCOL 6000P

PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM - Technical Description.”

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 3

2 Included Components

1. System Controls

2. Gravity Feed Reservoir

3. Air/Liquid Hose to Spray Point

4. Air/Liquid Spray Assembly

Shown is a 6000P Precision Applicator System with a two injector T60A Posi-pump, ½ Gallon

Reservoir, urethane bonded biaxial hose, and B2 Manifold with Air Propelled Wet Tips on a

Multifunctional Mounting Bracket.

For additional information about spray manifolds, nozzle extensions, spray tips, and

mounting brackets, please see the AMCOL 6000 Series Spray Assemblies- Technical

Description and Operator’s Manual.

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 4

3 Assembly and Installation

PRIOR TO GETTING STARTED

•WARNING! The AMCOL 6000P series applicator is serviced by a high-pressure air source.

Pressurized air is inherently dangerous and only qualified individuals should be allowed to

work on these systems.

•WARNING! Wear safety glasses at all times.

•WARNING! Lock out service air during assembly, disassembly, and related repairs.

•WARNING! Tighten all hose and fittings prior to operation.

•WARNING! Only use fluids that are compatible with aluminum, brass, steel, urethane,

nylon, and acrylic.

Installation

1. Review your applicator to see that no damage has occurred in shipment.

2. See that all your components and the related mounting are appropriate for your

piece of equipment.

3. Ensure that your plant air source has the required capacity and is available, clean,

and dry.

4. Mount the system controls in a protected area, which can be easily accessed by

operations and maintenance personnel. Some components may require minor

assembly as they have been shipped independently to avoid damage in transit.

5. Attach liquid reservoir to the system controls.

6. Mount transition blocks/manifold to the machine, while carefully observing that

these items will not interfere with the activities associated with the use, maintenance,

and adjustment of your machine.

7. Spray tips should be mounted at the maximum distance from and directly at the

spray target. This may require additional adjustments once the system is fully

operational.

8. Connect system actuation to your machine controls.

9. Connect plant air source and set the filter-regulator to 60 psi.

10. Fill the liquid reservoir and then open the shut-off valve on the bottom of the

reservoir.

11. Manually actuate system, observing that system is leak free and all adjustments are

operational. The manual actuator is a push button over-ride recessed toward the

top of the solenoid.

12. Under careful observation, operate system in production environment.

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 5

4 Recommended Settings

Item ID

Description

Recommended Setting

System Air Pressure

60 PSI

System Actuation Solenoid

According to machine cycle rate and volume

Pulse Frequency Generator

According to injection rate and volume

Dispersing Air Pressure

20 PSI as a starting point. Adjustment of the flow

control at the transition block is highly

dependent on spray tip. Adjust as needed, DO

NOT mist or fog!

Injection Volume

Start at 1.5 turns open from off

System

Air In

Liquid

Liquid Out

To Spray Point

Air Out

To Spray Point

Air

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 6

5 Operation

Before Getting Started

•Ensure all hoses are connected to the appropriate fittings and are tightly secured.

•Ensure all wiring connections to the solenoids are secure.

•Refill reservoir if low or empty.

•Securely connect an air source to the system air regulator. Check system pressure

(60 psi recommended).

•Re-prime the system if liquid is not at the spray point.

Operating the System Actuation Solenoid

•Observe 0 psi on the Dispersing Air Regulator when closed.

•Observe no fluid output when the Pulse Rate Solenoid is closed.

•Manually open the solenoid and set the Dispersing Air Pressure.

•Manually actuate the solenoid and observe the fluid output. Modify injection volume

settings accordingly (clockwise to decrease, counterclockwise to increase).

Setting Injection Pulse Rate

•The Pulse Frequency Generator can be modified through the dial on the face of the

PFG.

•Pulse Frequency Generators should not be set less than ¼ of a turn, which is

equivalent to approximately 2 cycles per second.

Proper Operation

System Timing

System timing can be seen to the left. This is the normal

operation when the system actuation solenoid is opened.

SV1 represents the Dispersing Air and is kept on during for the

full duration of the spray cycle (T1). SV2 represents the

Injection Pulse Rate set by the PFG, which should be

actuated according to the desired cycle rate (T2), up to 2

times per second.

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 7

Manual Actuation

To manually test the system to observe spray output, perform

the following:

•Activate System Actuation Solenoid. This solenoid

should remain open while testing spray volume and

pattern. Modify Dispersing Air and Injection Rate and

Volume settings as necessary.

Manual operation should be used to verify current settings, test

spray coating, and troubleshoot.

Automatic Actuation

To automatically use the 6000P system, it

should be interfaced with the control PLC,

which should contain the following

sequence:

•Activate the System Actuation Solenoid

whenever the system is operating.

While running automatically, the spray

volume and pattern should be consistent.

No misting or fogging should be present.

See Section 7 for troubleshooting.

To manually activate the solenoid, press the manual

override button

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 8

6Priming/Re-priming the System

1. Fill the reservoir.

2. Open the ball valve on the bottom of the reservoir.

3. Open pumps by turning the T60A liquid adjustment screw counterclockwise.

4. Repeatedly cycle the injectors.

5. Once liquid reaches the spray point, readjust the T60A Posi-pump to

the desired setting.

6. Adjust spray air pressure if necessary.

7 System Troubleshooting

Check in order as listed

Fluid Volume Inappropriate

•Injectors misadjusted: adjust individual injectors.

•Incorrect cycle timing: readjust Injection Pulse Rate.

Inconsistent Spray Volume to One Spray Point

•Spray tip is clogged: simply remove, clean, and replace spray tip.

•Spray tip is not properly attached: be sure spray tip is tightly threaded and secured,

and that the 1/8” liquid line is properly installed onto barbed connectors.

•Spray tip is damaged: remove and replace.

•Liquid or air hose is severed or incorrectly attached: reconnect or replace.

•T60A Posi-pump needs to be rebuilt: see instructions on page 12.

Inconsistent Spray Volume to All Spray Points

•Be sure the fluid reservoir ball valve is open.

•Fluid level is low: refill reservoir.

•Strainer on reservoir is clogged: clean or replace.

Mist or Fog

•Manifolded dispensing air pressure set too high: adjust.

•Individual spray point flow set too high: adjust.

Liquid from Back of Injector

•Injector contact seals leaking: clean injector and replace O-ring.

6000P PNEUMATICALLY CONTROLLED PRECISION LUBRICATION SYSTEM Operator’s Manual PAGE | 9

No or Low Dispersing Air

•Manifolded dispersing air pressure set too low: adjust.

•Air hose is kinked or cut: repair or replace.

•Spray tip is clogged: clean or replace.

•Spray tip is damaged: replace.

Air in Liquid Line

•Fluid line is not properly attached to pump: replace hose or fitting.

•Injector seal is failing: rebuild or replace.

Liquid Drains from Spray Tip

•Injector check valve is failing: rebuild or replace.

•Liquid line in single point nozzle assembly is damaged or disconnected: replace

8 T60A Posi-pump Troubleshooting

No Liquid

•Pump is turned off: turn liquid adjustment screw counterclockwise.

•Pump is seized: remove, clean, and rebuild.

•Reservoir is empty: fill.

•Air pressure is too low: adjust to over 60 PSI.

Bubbles from Injectors

•Air seals are leaking: replace.

•Exit fitting is leaking: replace.

Liquid Drains from Injector Outlet

•Exit fitting is leaking: replace.

•Evacuation valve is ineffective: clean or replace.

•Biaxial hose is trimmed incorrectly: be sure hose is cut straight with no burrs or

deformities.

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