2800
User’s Guide
®
A NORDSON COMPANY
Ultra
®
2800 Dispensing System
2800-3
3cc syringe barrels
2800-5
5cc syringe barrels
2800-10
10cc syringe barrels
2800-30
30cc syringe barrels
Electronic pdf files of EFD manuals are also available at www.efd-inc.com/manuals.html
The Ultra 2800 Dispensing System uses a patented positive displacement technology to provide
precise, controlled fluid dispensing. This User’s Guide will help you maximize the usefulness of your
new dispensing system.
Please spend a few minutes to become familiar with the controls and features. Follow our
recommended testing procedures. Review the helpful information we have included, which is based
on more than 30 years of industrial dispensing experience.
Most questions you will have are answered in this guide. However, if you need assistance, please do
not hesitate to contact EFD or your authorized EFD distributor.
In the USA, call 800-556-3484 between 8:30 a.m. and 5:30 p.m. Eastern time.
In Europe, call +44 (0) 1582 666334.
In Asia, call +86 (21) 5854 2345.
In all other areas, call your authorized EFD distributor or +1-401-434-1680.
The EFD Pledge
We pledge that you will be completely satisfied with our products. We endeavor to ensure that every
EFD product is produced to our no-compromise quality standards.
If you feel that you are not receiving all the support you require, or if you have any questions or
comments, I invite you to write or call me personally.
Our goal is to build not only the finest equipment and components, but also to build long-term customer
relationships founded on superb quality, service, value and trust.
Peter Lambert, President
Introduction
2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unpacking the dispenser and activating the warranty
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Features and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13
Attaching the Syringe Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removing the syringe barrel . . 14
Program Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to Make a Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Modify Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pre-Load Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Syringe Barrel Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Input/Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Productivity Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Contents
3
Safety
4
Introduction
Read and follow these safety instructions. Task- and equipment-specific warnings, cautions and
instructions are included in equipment documentation where appropriate.
Make sure all equipment documentation, including these instructions, is accessible to persons operating or
servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure that 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. They are familiar with all relevant safety rules and regulations and are
physically capable of performing their assigned tasks.
Intended Use
Use of EFD equipment in ways other than those described in the documentation supplied with the
equipment may result in injury to persons or damage to property.
Some examples of unintended use of equipment include:
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained
for EFD equipment will be voided if instructions for installation, operation and service are not followed.
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. Lock out power and secure the
equipment to prevent unexpected movement.
• If you receive even a slight electrical shock, shut down all electrical or equipment immediately. Do not
restart the equipment until the problem has been identified and corrected.
• Obtain and read Material Safety Data Sheets (MSDS) for all materials used. Follow the manufacturer’s
instructions for safe handling and use of materials, and use recommended personal protection devices.
• To prevent injury, be aware of less-obvious dangers in the workplace that often cannot be completely
eliminated, such as hot surfaces, sharp edges, energized electrical circuits and moving parts that
cannot be enclosed or otherwise guarded for practical reasons.
• Using incompatible materials
• Making unauthorized modifications
• Removing or bypassing safety guards or
interlocks
• Using incompatible or damaged parts
• Using unapproved auxiliary equipment
• Operating equipment in excess of maximum
ratings
Safety
5
High-Pressure Fluids
High-pressure fluids, unless they are safely contained, are extremely hazardous. Always relieve fluid
pressure before adjusting or servicing high pressure equipment. A jet of high-pressure fluid can cut
like a knife and cause serious bodily injury, amputation, or death. Fluids penetrating the skin can
also cause toxic poisoning.
If you suffer a fluid injection injury, seek medical care immediately. If possible, provide a copy of the
MSDS for the injected fluid to the health-care provider. A copy of the hydraulic fluid used in this unit is
included with this manual.
WARNING: Any injury caused by high pressure liquid can be
serious. If you are injured or even suspect an injury:
• Go to an emergency room immediately.
• Tell the doctor that you suspect an injection injury.
• Show the doctor this note.
• Tell the doctor what kind of material you were dispensing.
Fire Safety
To avoid a fire or explosion, follow these instructions.
• Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the
equipment until the cause has been identified and corrected.
• Do not smoke, weld, grind or use open flames where flammable materials are being used or
stored.
• Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors.
Refer to local codes or your material MSDS for guidance.
• Do not disconnect live electrical circuits when working with flammable materials. Shut off
power at a disconnect switch first to prevent sparking.
• Know where emergency stop buttons, shutoff valves and fire extinguishers are located.
• Clean, maintain, test and repair equipment according to the instructions in your equipment
documentation.
• Use only replacement parts that are designed for use with original equipment. Contact your EFD
representative for parts information and advice.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system immediately and perform
the following steps:
• Disconnect and lock out system electrical power.
• Slowly unscrew barrel retainer and remove barrel from actuator.
• Identify the reason for the malfunction and correct it before restarting the system.
Disposal
Dispose of equipment and materials used in operation and servicing according to local codes.
MEDICAL ALERT–
AIRLESS SPRAY
WOUNDS:
NOTE TO
PHYSICIAN
Injection in the
skin is a serious
traumatic injury.
It is important to
treat the injury
surgically as soon
as possible.
Do not delay
treatment to
research toxicity.
Toxicity is a
concern with
some exotic
coatings injected
directly into the
bloodstream.
The Ultra 2800 Dispensing System is designed to provide complete process control using a patented
positive displacement technology.
There are four core variables to the system: Deposit Volume, Dispense Rate, Pause and Pullback. To
achieve the ideal deposit size, adjust only one of these variables at a time, in small increments.
Key features include
• Repeatable, precise fluid control
• All electric; no requirement for compressed air
• Programmable Pullback to eliminate oozing
• Menu-driven touch pad
• 100 user-defined memory cells for storing barrel size, deposit volume, dispense rate, pause and
pullback
The Ultra 2800 Dispensing System provides consistent results, regardless of changes in fluid
volume, viscosity or temperature. It is ideal for use with 2-part epoxies and other fluids with
changing viscosities, or where a specific flow rate is needed.
First Steps
1. Unpack the dispenser.
2. For step-by-step setup instructions, see the Ultra 2800 Quick Start Guide.
3. Now is a good time to ACTIVATE your Two Year Warranty. Please follow the instructions in the
enclosed “Welcome” letter to register your warranty online. Or if you prefer, call the appropriate
toll-free number listed below, provide the serial number of your dispensing system and respond
to a few short questions.
In the USA, call 800-556-3484 between 8:30 a.m. and 5:30 p.m. Eastern time.
In Europe, call +44 (0) 1582 666334.
In Asia, call +86 (21) 5854 2345.
In all other areas, call your authorized EFD distributor or +1-401-434-1680.
Getting
Started
6
Cabinet size: 18.4 W x 8.1 H x 32.3 D cm (7.25 x 3.18 x 12.73")
Weight: 3.7 kg (8.2 lbs)
Flexible cable assembly length: 1.8 m (6 ft) to end of handset
Flexible cable assembly weight: .113 kg (4 oz)
Flexible cable assembly bend radius: 7.62 cm (3.0")
Internal power supply: Input voltage range, 100-240 VAC
Max inrush current: 50A/264 VAC
Input frequency range: 47-63 Hz
Output voltage: 24 VDC
Output current: 2.5A
Output power: 60W
Fuse rating: 1.0A/250 VAC (EFD part #28139 or equivalent)
Initiate circuit: Foot pedal, Cycle Start button or 5 to 24 VDC signal
Drive motor: 1.8º microstepping, 1,600 steps/rev
Control circuitry: CMOS microprocessor
Interface: Tactile keypad
Hydraulic fluid: Petroleum-based lubricant
Enclosure rating: NEMA 1
Dispense rate: Exceeds 20 cycles per minute
Minimum dispense volume: 0.1 microliters (with 3cc syringe barrel)
Meets or exceeds CE requirements
US Patent No. 6,575,331
Note: Specifications and technical details are subject to change without prior notification.
MSDS for hydraulic fluid enclosed separately. Contact EFD if extra copy is required.
Specifications
7
18.4 cm
7.25"
8.1 cm
3.18"
32.3 cm
12.73"
The Ultra 2800 Dispensing System uses a flexible hydraulic link to transfer linear force from the drive
motor to the syringe barrel. The motor lead screw and drive shaft are also linked mechanically. This
patented link allows the transfer of up to 200 pounds of force from the motor to the assembly fluid.
Once a dispense cycle is complete, a programmed mechanical pullback retracts the plunger,
attached to the EFD piston. The combined action of the plunger with the unit’s Forward steps,
programmed Pause function and Pullback feature creates a consistent deposit and prevents fluid
from oozing.
The bore and stroke of the syringe barrel are used to calculate deposit volume. For example, the
inside diameter of a 5cc syringe barrel measures 1.27 cm. One step moves the plunger 0.00008 cm,
resulting in 0.0001cc of fluid being displaced. With a 3cc barrel, it takes two steps to displace the
same amount of fluid.
Flexible cable assembly
The force of the stepper motor is transferred to the syringe barrel by a flexible cable assembly.
The plunger, attached at the end of the cable, drives into the EFD piston inside the syringe barrel.
This action forces the fluid out to make the deposit.
8
Adapter
Drive shaft
EFD piston
Plunger
Barrel retainer
Power Input Receptacle
The Ultra 2800 features a universal power supply. It automatically adjusts for input voltages ranging
from 100 VAC to 240 VAC. There is no adjustment required by the user.
Dispenser
Operation
Manual/Programmed Dispense Select
• Each mode allows you to access different features on the menu-driven display. Press the
“hand” icon to change from Manual mode to PROGRAMMED DISPENSE mode.
• In MANUAL mode, you can use the foot pedal to dispense a continuous bead of fluid. You are
in MANUAL mode when the red light next to the “hand” icon is on.
• In PROGRAMMED DISPENSE mode, you can set several variables, including Program Number,
Syringe Barrel Size, Deposit Volume, Dispense Rate, Pause and Pullback. You can also use the
foot pedal or the Cycle Start button to dispense a single dot of fluid. You are in PROGRAMMED
DISPENSE mode when the light next to the “hand” icon is off.
Cycle Start
Cycle Start in PROGRAMMED DISPENSE mode
• In PROGRAMMED DISPENSE mode, pressing the Cycle Start button once will return you to the
Home screen. Pressing it a second time will dispense a single deposit.
• Note: pressing the Cycle Start button accidentally while already in a dispense cycle can abort
your program. Therefore, we recommend that you use the foot pedal (instead of Cycle Start) to
activate the dispense cycle.
Cycle Start in MANUAL mode
• In Manual mode, pressing the Cycle Start button once cancels the Manual selection and returns
you to Programmed Dispense mode and the Home screen.
Program Number
In both PROGRAMMED DISPENSE and MANUAL mode, select the Program Number by pressing
the prg button. The Program Number will flash. Use the (+) or (-) buttons to change or select the
Program Number as needed. For more details, see the Program section on page 15.
Program
number
Reset
Barrel
select
Manual/Program
select
Cycle
start
Home
F1
F2
Jog
F3
Dispense rate &
Shot count/Volume
F4
Reset
shot count
Manual dispense rate
Decrease
Pullback/Back
Increase
Deposit volume/
Forward
Pause
Features &
Controls
9
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