AMCOL 6000E - User Manual

AMCOL CORPORATION
6000E ELECTRONICALLY
CONTROLLED PRECISION
LUBRICATION SYSTEM
Operator’s Manual

Summary

Introduction

Included Components

Assembly and Installation

Prior to Getting Started Safety Warnings

Essential safety warnings and precautions before assembling and installing the lubrication system.

Recommended Settings

SMART Metering Settings

Configuration details for the SMART Metering system to ensure consistent spray volume and pattern.

Operation

Pre-Operation Checks

Steps to ensure all connections and the system are ready before starting operation.

Solenoid Operation and Timing

How to operate dispensing and injection solenoids, and system timing.

Manual and Automatic Actuation

Procedures for manual system testing and automatic operation via PLC.

Priming and Troubleshooting

System Priming Procedures

Step-by-step guide for priming and re-priming the lubrication system.

System Troubleshooting

Common issues with fluid volume, mist, and backflow, with solutions.

T60 A Posi-pump Troubleshooting

Specific troubleshooting steps for issues related to the T60A Posi-pump.

Maintenance

Recommended Spares and Tools

List of recommended spare parts and tools for maintaining the lubrication system.

T60 A Posi-Pump Repair

Detailed instructions for repairing the T60A Posi-Pump assembly.

T60 A Posi-Pump Bill of Materials

Itemized list of components for the T60A Posi-pump with part numbers.

Preventative Maintenance Schedule

Recommended daily, quarterly, and yearly maintenance tasks for system longevity.

Recommended Fluids

Schematics and Drawings

General System Schematic

Overview schematic illustrating the general dual air source setup of the system.

Component Assemblies and Parts Lists

Diagrams and parts lists for various system components like reservoirs and enclosures.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The AMCOL 6000E Electronically Controlled Precision Lubrication System is an air-operated spray system designed for accurately dispensing minute quantities of liquid lubricants and coatings in metal production and fabrication. It utilizes patented positive displacement piston pumps to injection meter fluids from a gravity reservoir, which are then mixed with air at the spray point. The system supports multi-point lubrication through multiple injectors or by splitting outputs at the spray point.

Function Description:

The core function of the 6000E system is precision lubrication. It operates by controlling both the injection of fluid and the dispersion of air electronically. The system's dual solenoid control package, including an Injection Pulse Rate Solenoid and a Dispersing Air Solenoid, eliminates the variability often associated with traditional pneumatic controls. The Injection Pulse Rate Solenoid controls the frequency of fluid injections, while the Dispersing Air Solenoid manages the air pressure for spraying. This electronic control allows for consistent spray volume and pattern, crucial for applications requiring precise fluid delivery. The system is designed to be interfaced with a control PLC for automatic operation, allowing for programmed actuation of the solenoids based on machine cycle rates. Manual actuation is also possible for testing, verification of settings, and troubleshooting.

Important Technical Specifications:

• System Air Pressure: Recommended at 60 PSI.
• Dispersing Air Pressure: Starting point of 20 PSI, adjustable as needed to avoid misting or fogging.
• Injection Volume: Adjustable, starting at 1.5 turns open from off. Fixed injection volume options are also available.
• Injection Pulse Rate: T60A Posi-pumps can be cycled up to 10 times per second.
  • Injection Pulse Rate Solenoid open: 20ms
  • Injection Pulse Rate Solenoid closed: 80ms
• Fluid Compatibility: Designed for use with fluids compatible with aluminum, brass, steel, urethane, nylon, and acrylic. AMCOL recommends using CANMIST High Performance Lubricants for optimal performance and compatibility.
• Components: The system typically includes System Controls (enclosure with air valve and solenoids), Gravity Feed Reservoir (available in various sizes like 10oz, 1/2 gallon, 1 gallon, 2.5 gallon, 5 gallon, 10 gallon, with or without low-level indicators), Air/Liquid Hose (biaxial hose), and Air/Liquid Spray Assembly (e.g., B2 Manifold with Air Propelled Wet Tips on a Compact Multifunctional Mounting Bracket).
• Pump Type: Utilizes T60A Posi-pumps, which are positive displacement piston pumps.

Usage Features:

• Electronic Control (SMART Metering): The dual solenoid control package, combined with fixed position hex caps and non-adjustable regulators, minimizes variability in spray volume and pattern. This allows the spray volume to be primarily based on the injection rate of the T60A pump.
• Adjustable Settings: Key parameters like system air pressure, dispersing air pressure, and injection volume are adjustable to fine-tune lubrication for specific applications.
• PLC Integration: Designed for seamless integration with a control PLC for automated operation, allowing for precise timing and control of lubrication cycles.
• Manual Override: A manual override button on the solenoid allows for manual actuation, useful for initial setup, testing spray output, verifying settings, and troubleshooting.
• Safety Warnings: Emphasizes the importance of safety, including wearing safety glasses, locking out service air during maintenance, and tightening all hoses and fittings prior to operation, due to the high-pressure air source.

Maintenance Features:

• Troubleshooting Guide: Provides a comprehensive troubleshooting section for common issues such as inappropriate fluid volume, inconsistent spray volume, misting/fogging, liquid leaks, and pump malfunctions.
• Recommended Spares: Lists essential spare parts, including biaxial hose, repair kits for T60A pumps, and complete T60A pump assemblies.
• Recommended Tools: Specifies specialized tools like the O-ring repair tool (ORT-T60) and T-60A repair tool (RT-T60) for pump maintenance.
• T60A Posi-pump Repair: Detailed instructions are provided for disassembling, cleaning, and rebuilding the T60A Posi-pump, including a bill of materials for all internal components (O-rings, seals, springs, piston sub-assembly, etc.).
• Preventative and Predictive Maintenance Schedule:
  • Daily: Observe fluid level (fill as necessary), observe system settings, and check for system damage.
  • Quarterly: Empty, clean, and refill the reservoir; replace liquid and air hoses.
  • Yearly: Rebuild or replace T60A Posi-pumps.
• Fluid Management: Advises on filling the reservoir, opening the shut-off valve, and checking for clogs in the strainer.
• Leak Detection: Instructions for checking for leaks in hoses, fittings, and injector seals.

AMCOL 6000E Specifications

General

Brand	AMCOL
Model	6000E
Category	Lubrication systems
Language	English