45532694
Edition 2
August 2007
Doser - Docking Station
Maintenance Manual
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1 Docking station – DS
Use the drawings and the component list for the specified unit. In the description below, the figures
below (xx) refer to the corresponding figures on the drawing.
Always turn off the air and material supply & depressurize the entire
system before installing, removing or adjusting any accessory on this
product, or before performing any maintenance on this product or any
accessory. Failure to follow these instructions can result in personal injury.
1.1 Dismounting the Docking Unit
Drawings/Component lists:
•
•
DS-ATC complete
IR)
Docking unit
(T2X-16-500-IR/ -501-IR/ -505-
(T2X-16-502-IR/ -503-IR)
a) Turn of the pneumatic system, ensuring the clamps are off. The clamp is normally open when the
doser is away from the docking station. (Upper position – inside the guiding pins.)
b) Take off the cover plate (9) by removing the 3 hexagonal screws (14), use a 4 mm Allan key.
c) Disconnect material hose from the coupling (20 on T2X-16-502-IR/503-IR).
d) Disconnect the air hose and lubrication hoses. Disconnect electric connection (24 on T2X-16-502-
IR/503-IR).
e) Take off the docking unit (1) by removing the 4 hexagonal nuts and washers (16 and 17).
f) The docking unit (T2X-16-502-IR/-503-IR) can now be removed and exchanged.
g) Inspect locating pins (2 on T2X-16-502-IR/-503-IR). If they are damaged they can be changed by
unscrewing the screws (13 on T2X-16-502-IR/-503-IR).
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1.2 Change Pneumatic Clamps
Drawings/ Component lists:
•
•
Aut. Tool Changer
DS Docking unit
DS-ATC complete
T2X-16-502-IR
T2X-16-500-IR/-505-IR
Aut. Tool Changer- (onboard lub.)
DS Docking unit
DS complete
T2X-16-503-IR
T2X-16-501-IR
a) Follow step a) to e) in section 1.1. The docking station can be turned 180° and place back in the
same place.
• Disconnect electric contacts and remove pneumatic hoses on clamp unit.
b) Unscrew the four screws (15 on T2X-16-502-IR/-503-IR) and remove the pneumatic clamp (10 on
T2X-16-502-IR/-503-IR).
Mount the new clamp. The two alignment pins (16) are used for guidance and the eight hexagonal
screws (15 on T2X-16-502-IR/-503-IR) are mounted back. Connect the air hoses. The accompanying
shims are important for the docking sequence functionality. Do not lose or mix the shim to the
corresponding clamp.
c) Connect the air hoses.
See “Doser” Maintenance Manual Form 45532660.
d) Refit the docking station as reverse of above.
e) Put the cover plate (9 on T2X-16-500-IR/-501-IR/-505-IR) back by fastening the three screws (14
on T2X-16-500-IR/-501-IR/-505-IR).
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1.3 Change Male Docking Valve Complete
•
Drawings/Component lists:
T2X-16-500-IR/-501-IR/-505-IR
T2X-16-502-IR/-503-IR
T2X-16-511-IR
This operation requires, the following special tools and preparations:
• Mounting paste
a) Remove the cover plate (9) by removing the three screws (14).
• Take off the docking unit (1) by removing the four nuts and washers (16 and 17).
b) It is recommended to remove one of the clamps before continuing the dismounting of the docking
valve.
c) Loosen the three set screws (21 on T2X-15-511-IR) and remove Pt100 sensor (9 on T2X-16-511-
IR) and heating pins (10 on T2X-16-511-IR).
d) Unscrew the 4 hexagon screws (18 on T2X-16-502-IR/-503-IR) and dismantle the valve complete
(5 on T2X-16-502/-503) from the docking unit. Disconnect the air hose, lubrication hoses and the
electric connection.
Now the complete valve can be replaced.
Note: To do maintenance work on the male docking valve, see chapter 1.6.2. To do maintenance
work on the female docking valve, see “Doser” Maintenance Manual Form 45532660.
e) Reassemble the heating pins (10 on T2X-16-511-IR) (with mounting paste) and the Pt100 sensor
(9 on T2X-16-511-IR) (without mounting paste). Secure the heating pin and temperature sensor
with the three set screws (21 on T2X-16-511-IR). Connect the air hose and the lubrication hoses.
f) When mounting the valve complete: The two alignment pins (17 on T2X-16-502-IR/-503-IR) are
used for guidance. Mount the 4 screws (18 on T2X-16-502/-503).
g) Mount the docking unit (1 on T2X-16-500-IR/-501-IR/-505-IR).
h) Mount the cover plate (9 on T2X-16-500-IR/-501-IR/-505-IR).
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1.4 Hydraulics of the Docking Station
Drawing/Component list:
•
•
•
•
DS ATC
DS ATC (OnBoard Lubrication)
Docking Unit ATC
T2X-16-500-IR/-505-IR
T2X-16-501-IR
T2X-16-502-IR
Docking Unit (Onboard lub.)
T2X-16-503-IR
For doser hydraulics and pneumatics, See “Doser” Maintenance Manual Form 45532660. NOTE!
Only lubrication of inlet valve for OnBoard Lubricetion. (No connection 4 and 5)
From
To
(1) Inlet hydraulics
(3) Outgoing inlet valve
(5) Inside doser
(7) Outlet hydraulics
(2) Incoming inlet valve
(4) Incoming docking unit
(6) Incoming docking unit
6
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1.5 Pneumatics of the Docking Station
Drawing/Component list:
•
•
•
•
DS ATC
DS ATC (OnBoard Lubrication)
Docking Unit ATC
T2X-16-500-IR/-505-IR
T2X-16-501-IR
T2X-16-502-IR
Docking Unit (Onboard lub.)
T2X-16-503-IR
Also see pneumatic scheme T2X-07-xxx
From
To
(1) Inlet pneumatics
(2) Pneumatic valves, connection 1
(4) Open clamp
(6) Close clamp
(3) Pneumatic valve, connection 2
(5) Pneumatic valve, connection 2
(7) Pneumatic valve, connection 4
(8) Open inlet valve
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1.6 Male Docking Valve
•
Drawing/Component list:
T2X-16-511-IR
Use the drawings and the component list for the specified unit. In the description below, the figures
(xx) refer to the corresponding figures on the drawing.
1.6.1 Dismantling of the Male Docking Valve
This operation requires, the following special tools and preparations:
• A T2000-17-005-IR to compress the spring (two threaded rods and a
bracket with three holes).
• A flat, 7mm, fork spanner.
a) After the valve has been removed from the docking station (see chapter 1.1), unscrew the four
screws (19) holding the pneumatic cylinder (3).
b) Pull the pneumatic piston (4) out from the cylinder (3).
c) The piston (4) and the spring (14) are now visible. Use the 7-mm spanner to hold the needle (7)
still. The spanner must be inserted into the compressed spring. Open the sealing nut (11) inside
the piston.
Note: Take care, the spring is loaded. Use the special tool T2000-17-005-IR to keep the spring
compressed.
d) Remove the piston (4) and the spring (14). Do not lose the distance shims (23) and (24).
e) The packing housing (2) can now be removed. Also the Variseal (15) can be removed.
f) To take out the Step seal (16) the retaining shim (5) has to be removed by unscrewing the two
countersunk screws (22).
g) Unscrew the four countersunk screws (20) holding the retaining flange (6) of the valve needle
complete (7), and pull it out from the centre of the middle housing (1).
h) Pull out the O-ring (17).
i) Pull out the O-ring (18).
Note: To remove the O-ring, squeeze it with one hand in a way that will force it to become oval and
in this way one side of it comes out of the groove. It is now easy to take it out from the grove
completely. Do not use a screwdriver; it is very easy to damage the surface of the grooves.
j) Clean all parts carefully. The valve seat and the needle should be closely examined. Search for
wearing out signs and for scratches. Especially the contact surfaces of the needle and the valve
seat must be smooth and even all over the surfaces, no scratches.
Note: All damaged parts must be changed to secure a proper function.
Take notice: The valve seat and the valve needle are delivered as one unit, valve needle
complete, and are consequently grounded together as one pair.
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1.6.2 Assembly of the Male Docking Valve
This operation requires, the following special tools and preparations:
• A T2000-17-005 to compress the spring (two threaded rods and a
bracket with three holes).
• A flat, 7mm, fork spanner.
• Screw locking liquid - Loctite 270
• Special high temperature grease for the sealings, Uniway LIX 625.
• Torque wrench
• Two M6x35 screws
a) First place the valve needle complete (7) into the middle housing (1), together with the O-ring (17),
coated with a little grease, into its groove, and attach the retaining flange (6) with the four
countersunk screws (20). Tighten the screws crosswise, carefully and equal.
b) Insert the Stepseal® (16) in the immersion of the packing housing (2) and mount the retaining shim
(5) with the two countersunk screws (22). Check the orientation of the Stepseal (16). The step
must face the needle (see drawing).
c) Insert the Variseal (15) in the recess of middle housing (1) with the V-opening first (see drawing).
Note: Be careful not to harm the sensitive edge of the seal.
d) Put the packing housing (2) onto the middle housing (1) and keep them fixed with the two M6x35
screws mounted diagonally – temporarily.
e) Push the valve needle complete (7) in through the two seals (15) and (16) until the needle head
touches the valve seat (closed valve).
Note: One will feel a certain resistance each time the needle enters a seal.
f) The O-ring (18), lightly greased, is put onto the piston (4). The distance shim (23 and 24) is “glued“
with grease on the bottom surface of the piston (4). This shim prevents the sharp end of the spring
from wearing out the piston as the spring always turns a little when being compressed.
g) Mount the lightly greased spring (14) on top of the retaining shim (5).
h) The piston (4) is put into the spring (14).
i) Install the special (T2000-17-005-IR) tool into the two diagonally remaining holes of the middle
housing (1), for compressing the spring. The spring is compressed by spanning it until the threaded
part of the “valve needle complete” (7) reaches through the piston (4).
j) The seal lock nut (11) is screwed onto the thread with a torque wrench. Note: Always use a new
nut, and always use screw-locking-liquid (Loctite 270). Keep the needle fixed with the 7mm-
spanner, and tighten the nut to the torque 5 Nm.
k) The special tool and the two temporarily fitted M6 screws can now be removed because the spring
tension keeps the whole assembly together.
l) The inner surface of the air cylinder (3) must be greased carefully with Uniway LIX 625.
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m) Place the cylinder (3) on the piston, (4). Align it, and press it into the housing.
n) Position all parts on the docking valve according to the drawing. Tighten the four screws (19).
Torque is 10 Nm.
o) Finally, the pneumatic unit function should be tested. Connect the air and check the movement of
the needle.
1.7 Female Docking Valve
See “Doser” Maintenance Manual form 45532660.
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Length in mm =cable
1.8 Electrical contacts in docking station.
Från nr.
Name
T2X-nr.
Se drawing:
Till (nr)
WH - 18
Name
T2X-nr.
Se drawing:
Comments
T2X-SF-008- T2X-20-029-IR,sheet
T2X-SF-005- T2X-20-029-IR,sheet
IR 302.0
WH - 18 XP62/19 Poles
XP61/36POL
Length: 400mm
IR
302.0
T2X-SF-008-
IR
T2X-20-029-IR,sheet
3021
T2X-SF-005- T2X-20-029-IR,sheet
IR 302.1
WH -17 XP62/19 POLES
WH - 17
WH - 27
XP61/36POL
XP61/36POL
Length: 400mm
Length: 400mm
T2X-SF-008-
IR
T2X-20-029-IR,sheet
302.1
T2X-SF-005- T2X-20-029-IR,sheet
IR 302.1
WH - 16 XP62/19 POLES
T2X-SE-002-
IR
WH – 8
WH/BU – 16
T2X-SF-008- T2X-20-029-IR,sheet
IR 302.7
Heater/inlet valve
Heater/inlet valve
10 on T2X-16-511-IR
10 on T2X-16-511-IR
XP61/36POL
XP61/36POL
Length: 300mm l
Length: 300mm
T2X-SE-002-
IR
WH – 35
WH/BU - 25
T2X-SF-008- T2X-20-029-IR,sheet
IR 302.7
T2X-SF-008- T2X-20-029-IR,sheet
IR 505.5
T2X-SF-008- T2X-20-029-IR,sheet
IR 503.0
T2X-SF-005- T2X-20-029-IR,sheet
IR 503.0
T2X-SF-005- T2X-20-029-IR,sheet
WH - 4
XP62/19 POLES
WH - 30
WH - 34
XP61/36POL
XP61/36POL
Length: 400mm
Length: 400mm
WH - 14 XP62/19 POLES
IR
503.0
BK – 13
BN– 31
BU – 22
WH – 4
T2X-SK-008- T2X-20-029-IR,sheet
IR 505.4
T2X-SF-008- T2X-20-029-IR,sheet
IR 505.4
Sensor cable clamp
XP61/36POL
XP61/36POL
Length: 270mm
Length: 270mm
BK – 15
BN– 33
BU – 24
WH – 6
T2X-SK-008- T2X-20-029-IR,sheet
T2X-SF-008- T2X-20-029-IR,sheet
IR 505.7
Sensor cable clamp
IR
505.7
T2X-SF-005- T2X-20-029-IR,sheet
IR 508.1
T2X-SF-008- T2X-20-029-IR,sheet
WH – 3 XP62/19 POLES
WH –12 XP62/19 POLES
WH - 3
XP61/36POL
XP61/36POL
Length: 400mm
Length: 400mm
IR
508.1
T2X-SF-008-
IR
T2X-SF-005- T2X-20-029-IR,sheet
IR 509.2
T2X-20-029-IR,sheet
509.2
WH - 1
T2X-SF-008-
IR
T2X-SF-005- T2X-20-029-IR,sheet
IR 509.2
T2X-20-029-IR,sheet
509.2
WH – 13 XP62/19 POLES
WH – 10 XP62/19 POLES
WH – 11 XP62/19 POLES
WH - 10
WH - 19
WH - 28
XP61/36POL
XP61/36POL
XP61/36POL
Length: 400mm
Length: 400mm
Length: 400mm
T2X-SF-008-
IR
T2X-SF-005- T2X-20-029-IR,sheet
IR 509.4
T2X-20-029-IR,sheet
509.4
T2X-SF-008-
IR
T2X-SF-005- T2X-20-029-IR,sheet
T2X-20-029-IR,sheet
509.4
IR
509.4
T2X-SC-004-
IR
T2X-SP-099- T2X-20-029-IR,sheet
IR
T2X-SP-099- T2X-20-029-IR,sheet
IR 526.1
T2X-SP-099- T2X-20-029-IR,sheet
WH – 2
RD - 11
BK – 12
BK - 21
BK – 29
BK - 20
T2X-SF-008- T2X-20-029-IR,sheet
IR 509.8
T2X-SF-008- T2X-20-029-IR,sheet
IR 522.9
T2X-SF-008- T2X-20-029-IR,sheet
IR 526.1
PT100-givare
9 on T2X-16-510
XP61/36POL
XP61/36POL
XP61/36POL
Length: 300mm
Length: 320mm
Length: 320mm
Contact/ inlet valve
522.9
Contact/close
clamp
BK – 32
BK - 23
T2X-SF-008- T2X-20-029-IR,sheet
Contact/open clamp
XP61/36POL
Length: 320mm
IR
526.2
IR
526.2
Length: 400mm +
150mm ring terminal
4mm
T2X-20-029-IR,sheet
302.0
T2X-20-029-IR,sheet
302.0
PE
Ground
Gul/Grn - 26 XP61/36POL
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© 2007 Ingersoll Rand Company
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