Ingersoll-Rand DOSER 45532694 User Manual

Aug

Doser - Docking Station

Maintenance Manual

45532694

Edition 2
ust 2007

INDEX

1 DOCKING STATION – DS .................................................................................... 3

1.1 Dismounting the Docking Unit.............................................................................................................3

1.2 Change Pneumatic Clamps..................................................................................................................4

1.3 Change Male Docking Valve Complete ................................................................................................5

1.4 Hydraulics of the Docking Station .......................................................................................................6

1.5 Pneumatics of the Docking Station......................................................................................................7

1.6 Male Docking Valve..............................................................................................................................8

1.6.1 Dismantling of the Male Docking Valve.............................................................................................8

1.6.2 Assembly of the Male Docking Valve................................................................................................9

1.7 Female Docking Valve ...................................................................................................................... 10

1.8 Electrical contacts in docking station............................................................................................... 11

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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 (T2X-16-500-IR/ -501-IR/ -505-
IR)

• Docking unit (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 T2X-16-502-IR
DS-ATC complete T2X-16-500-IR/-505-IR

• Aut. Tool Changer- (onboard lub.) DS Docking unit T2X-16-503-IR

DS complete 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 T2X-16-500-IR/-505-IR

• DS ATC (OnBoard Lubrication) T2X-16-501-IR

• Docking Unit ATC 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 (2) Incoming inlet valve
(3) Outgoing inlet valve (4) Incoming docking unit
(5) Inside doser (6) Incoming docking unit
(7) Outlet hydraulics

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1.5 Pneumatics of the Docking Station

Drawing/Component list:

• DS ATC T2X-16-500-IR/-505-IR

• DS ATC (OnBoard Lubrication) T2X-16-501-IR

• Docking Unit ATC 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
(3) Pneumatic valve, connection 2 (4) Open clamp
(5) Pneumatic valve, connection 2 (6) Close clamp
(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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1.8 Electrical contacts in docking station.

Från nr. Name T2X-nr. Se drawing: Till (nr) Name T2X-nr. Se drawing: Comments

WH - 18 XP62/19 Poles

WH -17 XP62/19 POLES

WH - 16 XP62/19 POLES

Heater/inlet valve

Heater/inlet valve

WH - 4 XP62/19 POLES
WH - 14 XP62/19 POLES

Sensor cable clamp

Sensor cable clamp

WH – 3 X P62/19 POLES

WH –12 XP62/19 POLES

WH – 13 XP62/19 POLES

WH – 10 XP62/19 POLES

WH – 11 XP62/19 POLES

PT100-givare
Contact/ inlet valve

PE Ground

Contact/close
clamp

Contact/open clamp

T2X-SF-008­IR

T2X-SF-008­IR

T2X-SF-008­IR

T2X-SE-002­IR

T2X-SE-002­IR

T2X-SF-005­IR
T2X-SF-005­IR

T2X-SK-008­IR

T2X-SK-008­IR

T2X-SF-005­IR

T2X-SF-005­IR

T2X-SF-005­IR

T2X-SF-005­IR

T2X-SF-005­IR

T2X-SC-004­IR
T2X-SP-099­IR

T2X-SP-099­IR

T2X-SP-099­IR

T2X-20-029-IR,sheet

302.0
T2X-20-029-IR,sheet

3021
T2X-20-029-IR,sheet

302.1

10 on T2X-16-511-IR

10 on T2X-16-511-IR
T2X-20-029-IR,sheet

503.0
T2X-20-029-IR,sheet

503.0

T2X-20-029-IR,sheet

505.4

T2X-20-029-IR,sheet

505.7
T2X-20-029-IR,sheet

508.1
T2X-20-029-IR,sheet

509.2
T2X-20-029-IR,sheet

509.2
T2X-20-029-IR,sheet

509.4
T2X-20-029-IR,sheet

509.4
9 on T2X-16-510

T2X-20-029-IR,sheet

522.9
T2X-20-029-IR,sheet

526.1
T2X-20-029-IR,sheet

526.2
T2X-20-029-IR,sheet

302.0

WH - 18 XP61/36POL

WH - 17 XP61/36POL

WH - 27 XP61/36POL

WH – 8
WH/BU – 16

WH – 35
WH/BU - 25

WH - 30 XP61/36POL
WH - 34 XP61/36POL

BK – 13
BN– 31
BU – 22
WH – 4

BK – 15
BN– 33
BU – 24
WH – 6

WH - 3 XP61/36POL

WH - 1 XP61/36POL

WH - 10 XP61/36POL

WH - 19 XP61/36POL

WH - 28 XP61/36POL
WH – 2

RD - 11
BK – 12
BK - 21
BK – 29
BK - 20

BK – 32
BK - 23

Gul/Grn - 26 XP61/36POL

XP61/36POL

XP61/36POL

XP61/36POL

XP61/36POL

XP61/36POL
XP61/36POL

XP61/36POL

XP61/36POL

T2X-SF-005­IR

T2X-SF-005­IR

T2X-SF-005­IR

T2X-SF-008­IR

T2X-SF-008­IR

T2X-SF-008­IR
T2X-SF-008­IR

T2X-SF-008­IR

T2X-SF-008­IR

T2X-SF-008­IR
T2X-SF-008­IR

T2X-SF-008­IR

T2X-SF-008­IR

T2X-SF-008­IR

T2X-SF-008­IR
T2X-SF-008­IR

T2X-SF-008­IR

T2X-SF-008­IR

Length in mm =cable

T2X-20-029-IR,sheet

302.0
T2X-20-029-IR,sheet

302.1
T2X-20-029-IR,sheet

302.1
T2X-20-029-IR,sheet

302.7
T2X-20-029-IR,sheet

302.7
T2X-20-029-IR,sheet

505.5
T2X-20-029-IR,sheet

503.0

T2X-20-029-IR,sheet

505.4

T2X-20-029-IR,sheet

505.7
T2X-20-029-IR,sheet

508.1
T2X-20-029-IR,sheet

509.2
T2X-20-029-IR,sheet

509.2
T2X-20-029-IR,sheet

509.4
T2X-20-029-IR,sheet

509.4
T2X-20-029-IR,sheet

509.8
T2X-20-029-IR,sheet

522.9
T2X-20-029-IR,sheet

526.1
T2X-20-029-IR,sheet

526.2
T2X-20-029-IR,sheet

302.0

Length: 400mm

Length: 400mm

Length: 400mm

Length: 300mm l

Length: 300mm

Length: 400mm
Length: 400mm

Length: 270mm

Length: 270mm

Length: 400mm

Length: 400mm

Length: 400mm

Length: 400mm

Length: 400mm

Length: 300mm
Length: 320mm

Length: 320mm

Length: 320mm

Length: 400mm +
150mm ring terminal
4mm

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