MicroCoat® System Operating Manual MC800 Series MC785M #7008020, MC785M-WF #7008013 Spray Valves IMPORTANT! Save this Sheet. Forward to Maintenance or Tool Crib Supervisors Electronic pdf files of Nordson EFD manuals are also available at www.nordsonefd.com www.nordsonefd.com info@nordsonefd.com Sales and service of Nordson EFD dispensing systems are available worldwide.
www.nordsonefd.com info@nordsonefd.com Sales and service of Nordson EFD dispensing systems are available worldwide.
Contents Introduction ................................................................................................................................4 Safety ....................................................................................................................................5-7 Specifications ............................................................................................................................8 How the System Operates ....................................................
Introduction The MicroCoat System provides precise lubrication control for metal stamping operations. The MC800 controller, MC785M series spray valves and the MicroCoat tank reservoirs are all produced to exacting specifications and thoroughly tested prior to shipment. The MC785M series valves are designed for long life without maintenance when clean lubricant is used. To obtain the maximum performance from your MicroCoat System, please read through these instructions carefully.
Safety Introduction Read and follow these safety instructions. Task- and equipment- specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Qualified Personnel Equipment owners are responsible for making sure that Nordson EFD equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks.
Personal Safety To prevent injury, follow these instructions. • • • • • • • Do not operate or service equipment unless you are qualified. Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. Keep clear of moving equipment. Before adjusting or servicing moving equipment, shut off the power supply and wait until the equipment comes to a complete stop.
Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system that contains aluminum components. Under pressure, these solvents can react with aluminum and explode, causing injury, death, or property damage.
Specifications MC785M (7008020) & MC785M-WF (7008013) Valves Size: (with fittings) 66.29 mm (2.61") length; 49.28 mm (1.94") width Weight: 206 gr (7.28 oz) Lubricant chamber: Hard-coated aluminum Return spring: Type 303 stainless steel Needle and nozzle: Type 303 stainless steel Air cap: Type 303 stainless steel Diaphragm: Viton® with Teflon® coating Lubricant inlet hole: 1/8 NPT Mounting: 6 mm tapped hole Operating frequency: Up to 60 per minute Nozzle diameter: 1.17 mm (0.046") U.S.
How the System Operates The MicroCoat System incorporates up to eight low volume low pressure (LVLP) spray valves; a lubricant reservoir; and a controller that regulates air pressure, meters lubricant flow and controls valve operation. Constant air pressure applied to the tank reservoir forces lubricant through precision fluid flow ]controls on the MC800 controller, then out to the spray valves. When the press is stamping, a 3-way air solenoid activates the system and opens the valves.
Controller Features 1. System Pressure Switch Turns the system air supply On and Off. 2. Mode Switch Use Manual/Setup position to prime and test the valves without running the press. In the Auto/Run position, the system will spray lubricant when the press begins stamping. Press air solenoid must be properly installed to allow the MicroCoat System to run in Auto/Run mode (refer to pages 14-16). 3 4 3. Tank Air Pressure Regulates air pressure in the lubricant reservoir. For most lubricants, 1.
6. Low Pressure Switch Registers low fluid pressure. Connects with low level switch for press protection. WARNING: Must be wired to the press Emergency Stop Circuit to prevent the press from operating without lubricant pressure (refer to page 18). 7. Tank Air Air from this port pressurizes the lubricant reservoir. 7 8. Nozzle Air Air from this port is used to spray the lubricant. 9 8 9. Valve Control Air 13 11 10 12 6 Air from this port controls the opening and closing of the spray valves. 10.
Tank Reservoir Features 1. Low Level Switch Prevents the system from operating without lubricant when connected to the press Emergency Stop Circuit. Switch opens when tank level is near empty. 2. Air Pressure Relief Valve Automatically exhausts air if tank reservoir pressure exceeds 2.76 bar (40 psi). Also used to manually exhaust air pressure before refilling the tank. 3. Fill Port Cap Ported threads relieve any residual reservoir air pressure when cap is loosened. 4. Drain Plug (not shown) 5.
System Assembly Step 1: Mount the Spray Valves Mount each valve with the mounting clamp (7021742) provided, or use the 6 mm mounting hole in the valve body to attach the valve to an alternative mounting bracket. aircap Note: Optional valve mounting fixtures provide easy installation of the valves without the need to drill or fabricate attachment hardware. See page 27 for further information.
Step 2: Installation/Removal of Flow Control/ Block-off Plug from Manifold To install a new flow control, lubricate the 0rings on the flow control with your stamping oil and push the flow control into the manifold while turning clockwise until the flow control slides into place. Continue turning until the zero on the knob is lined up with the zero reference on the flow control manifold. Tighten the manifold setscrew firmly.
Press Air Solenoid Diagram Fitting, 1/4 MPT X 8 mm elbow #7022191 Operating air pressure: Set regulator to 4.14 bar (60 psi) Compressed air input 4.14 to 8.62 bar (60 to 125 psi) Fitting, 1/4 NPT X (2) 8 mm elbow #7022193 Five micron filter regulator, optional - order separately #7022158 8 mm, black #7022180 Flow requirement: .06 cu. m. (2.0 cfm) at 4.
Step 4: Connect the Press Air Solenoid (cont’d.) 1. Select the appropriate 3-way solenoid. Flow must meet or exceed .06 cu. m./min. (2.0 cfm) at 4.14 bar (60 psi). 2. Cut the control air hose at a convenient location and install the solenoid as shown. 3. Connect the solenoid wires to the press control circuit. Step 5: Connect the Valve Hoses 1. Find a suitable location and mount the two air manifolds. One manifold is for the white Control Air hose and the other is for the black Nozzle Air hose. 2.
4. Cut the clear fluid hose from the tank to the controller so the end of the hose coming from the tank can be installed into the “IN” port of the filter adapter. 6. Lubricate the filter gasket and screw the filter onto the adapter until the gasket makes contact and then tighten an additional 3/4 turn. 5. Connect the fluid hose from the controller to the “OUT” port on the filter adapter. 7.
Step 7: Connect the Emergency Stop Circuit The Emergency Stop Circuit on the press must be properly wired to the MicroCoat System to prevent the press from stamping without lubricant and to alert the operator if the lubricant pressure drops below 0.69 bar (10 psi). Connect the red and black wire to the Emergency Stop Circuit located on the press. Review with Plant Electrician M C800 controller Warning: These switches must also be wired in series with the Emergency Stop Circuit from the press.
System Setup Check All Connections 1. Check that all connections are correct and secure. 2. Verify that the System Pressure switch is set to the Off position and the mode switch is set to the Auto/Run position. 3. Check that the input air supply is connected and set at 4.14 bar (60 psi). Fill the Tank Reservoir 1. Unscrew the tank cap and fill the tank reservoir with lubricant to the level indicated on the tank label. Caution: Do not overfill.
System Setup (cont’d.) IMPORTANT: Each valve must be fully primed (lubricant flows in a steady stream) before adjusting the spray. Adjust the Spray 1. As a starting point, select one valve and adjust the Flow Control knob so that lubricant flows from the valve at the rate of approximately one drop per second. 2. Note the number set on the graduated dial of the open Flow Control. Set the flow for each remaining valve to the same setting. 3.
Preventive Maintenance The MicroCoat System is designed for long life with minimal maintenance. To ensure trouble-free performance, follow these precautions and preventive maintenance steps: 1. Always use clean lubricant. 2. Check for residue at the bottom of the tank reservoir and clean if necessary. 3. Do not clean the MC685M or the MC686M tank with chlorinated solvents, aromatic hydrocarbons or any fluid that will attack acrylics.
Spray Valve Maintenance WARNING: Before performing any maintenance, set the System Pressure Switch to the Off position and depressurize the tank reservoir by lifting the lever on the tank pressure relief valve. When using filtered plant air and clean lubricants, the MC785M series spray valves are designed for long- term performance without scheduled maintenance. If lubricant flow stops or becomes erratic, first review Troubleshooting on page 26.
MC785M Series Spray Valve Part Numbers Push-in elbow 10-32 x 4 mm OD #7007019 Optional: Straight push-in fitting 10-32 x 4 mm OD #7021724 Maintenance Tools 8" adjustable wrench 7/8" open end wrench 5/16" box end wrench 1/4" nut driver Diaphragm chamber cap #7021698 Diaphragm return spring #7021700 Spring locating washer #7021704 Diaphragm retaining nut #7021709 Diaphragm #7021727 Teflon side (blue-grey) Needle #7021702 Mounting clamp #7021742 Push-in elbow 10-32 x 4 mm OD #7007019 Fluid body #7021
Controller Air Schematic 4 1 18 8 PilotValve Regulator 0-30 psi 2 System pressure 4 ON/OFF 9 10 18 17 17 13 18 3 8 11 Regulator 0-30 psi Auto/Run M anual/Setup 11 9 17 5 13 Valve controlair Tank air Constantairinput (60 psim in.) 3 11 5 Valve nozzle air Controlairinput from solenoid (60 psim in.) Flow controls 6 Oil Flow Schematic 14 6 6 7 7 12 12 12 12 Fluid outlets 15 Pressure switch 16 Fluid inlet www.nordsonefd.com info@nordsonefd.
Controller and Tank Replacement Part Numbers Controller (Refer to schematic on page 24.) 1. 7016572 Tank air pressure gauge 0 to 30 psi (0 to 2.07 bar) 11. 7022165 Air output fitting 12. 7022186 Fluid manifold outlet fitting 2. 7016574 Nozzle air pressure gauge 0 to 30 psi (0 to 2.07 bar) 13. 7022166 Fitting 1/8 NPT x 8 mm elbow 3. 7002004 6 mm OD tubing 4. 7016767 5. 7022164 5/32" OD x 3/32" ID tubing Air input fitting 14.
Troubleshooting Guide MC800 Controller Air pressure regulator will not maintain set pressure. Possible cause and correction Contaminated air supply. Remove the controller cover to access the regulator. Remove the brass hex plug, spring and poppet from the regulator. Clean poppet and reinstall the poppet, spring and plug. Tank pressure may be too low. Minimum operating tank air pressure is 12 psi (0.83 bar). No lubricant flow to valve.
Accessories Valve Mounting Clamp Mounting Brackets #7021742: Use to mount MC785M series valve or to secure mounting rod on press. Supplied with bolts. Included with each #7008020 and #7008013 valve. #7023855: For mounting controller to MC7300 stand or press enclosure. Included with each MC800 controller. #7023858: For mounting MC685M tank to MC7300 stand or press enclosure. Included with each MC685M #7023855 or MC686M #7023843 tank.
Nordson EFD Two Year Limited Warranty All components of the Nordson EFD MicroCoat System are warranted for two years from date of purchase to be free from defects in material and workmanship (but not against damage caused by misuse, abrasion, corrosion, negligence, accident, faulty installation or by dispensing material incompatible with equipment) when the equipment is installed and operated in accordance with factory recommendations and instructions.
