EQUIPMENT
Operation Manual
MODE/TIME DISPLAY
MODE DECIMAL
MODE/TIME SET
WARNING:
Unplug power cord and disconnect
air supply prior to removing cover.
FOR SPARE PARTS, MANUALS, REPAIRS,
OR TECHNICAL ASSISTANCE:
Visit us at equipment.loctite.com
or call Henkel Corp. at:
USA - (1) 860-571-5174
Germany - (49) 89-9268-0
Singapore - (65) 6482-3881
Label P/N: 988341
P/N: 98521
PORT A PORT B
Loctite
®
Spray Valve Controller
Part Number 98521
Table of Contents
1 Please Observe The Following..................................................................................................... 3
1.1 Emphasized Sections............................................................................................................................... 3
1.2 For Your Safety....................................................................................................................................... 3
1.3 Unpacking and Inspection ....................................................................................................................... 4
1.4 Items supplied.......................................................................................................................................... 4
2 Description............................................................................................................................................... 4
3 Technical Data....................................................................................................................................... 5
4 Installation................................................................................................................................................ 6
4.1 Space requirements.................................................................................................................................. 6
4.2 Features Description................................................................................................................................6
4.3 Fuse Installation/Voltage Selection Assembly ........................................................................................ 7
4.4 Connecting the unit.................................................................................................................................. 8
4.5 I/O Configuration and End of Cycle Switching....................................................................................... 8
5 Operation................................................................................................................................................... 9
5.1 Mode Menu ............................................................................................................................................. 9
5.2 Manual spray cycle setting: ................................................................................................................... 10
5.3 Automatic Spray cycle setting............................................................................................................... 10
6 Troubleshooting.................................................................................................................................. 11
7 Care and Maintenance..................................................................................................................... 11
8 Accessories and Spare Parts........................................................................................................ 11
9 Appendix................................................................................................................................................. 12
9.1 Electrical Diagram................................................................................................................................. 12
9.2 Pneumatic Diagram............................................................................................................................... 12
10 Warranty.............................................................................................................................................. 13
1 Please Observe The Following
1.1 Emphasized Sections
Warning!
Refers to safety regulations and requires safety measures that protect the operator or
other persons from injury or danger to life.
Caution!
Emphasizes what must be done or avoided so that the unit or other property is not
damaged.
Notice:
Gives recommendations for better handling of the unit during operation or adjustment
as well as for service activities.
1.2 For Your Safety
For safe and successful operation of the unit, read these instructions
completely. If the instructions are not observed, the manufacturer can assume no
responsibility.
To ensure proper voltage setting, all units are shipped from the factory with the
Fuse Holder/Voltage Selector disassembled from the AC Connector
Do not expose the connecting cable to heat, oil, or sharp edges.
Make sure the Unit stands stable and secure.
Use only original equipment replacement parts.
Always disconnect the power supply before servicing the unit.
Observe general safety regulations for the handling of chemicals such as Loctite
®
adhesives and sealants. Observe the manufacturer’s instructions as stated in the
Material Safety Data Sheet (MSDS).
While under warranty, the unit must be repaired by an authorized Loctite
®
brand
service representative.
1 Please Observe The Following (continued)
1.3 Unpacking and Inspection
Carefully unpack the Loctite
®
Spray Valve Controller and examine the items contained in the
carton. Inspect the unit for any damage that might have occurred in transit. If such damage
has occurred, notify the carrier immediately. Claims for damage must be made by the
consignee to the carrier and should be reported to the manufacturer.
1.4 Items supplied
• Controller Unit
•
Power Cord & Cord Lock
•
Foot Pedal – Item #98461
•
Air Supply Line, 5 micron Filter & Fittings
•
Fuse Assembly and Fuses (0.25 amp & 0.1 amp)
2 Description
The Loctite
®
Spray Valve Controller 98521 is a microprocessor based control unit that
provides a 3-segment time sequenced spray cycle for the Loctite
®
Spray Valve 98520.
The unit allows individual programming for each time segment
• Pre-spray atomizing
• Valve on time
• Post spray atomizing
These individually controlled time ranges provide for complete atomization of a wide
variety of fluid and ensure “no-drip” positive valve shut-off.
When the spray cycle is activated by depressing the Foot Switch, a pulse of air through
Port A is transmitted to the valve’ air cylinder to open the valve and a second pulse of
air through Port B is transmitted to the valve’s spray cap to spray the fluid.
The amount of fluid sprayed is controlled by the spray cycle on time, fluid pressure
and stroke setting on the Loctite
®
Spray Valve.
3 Technical Data
1. SPECIFICATIONS
a) Size W=9.2 in. (23.4 cm)
D=8.1 in. (20.6 cm)
H=2.4 in. (6.1 cm)
b) Weight 4.5 lbs (2.0 kg)
100-120 VAC 60 Hz
c) Input Voltage 200-240 VAC 50 Hz
Mains voltage fluctuation not to
exceed 10% of nominal voltage
Fluctuation max: 10%
d) Rated Power 20W
e) Air Input 100 Psi (689 Kpa) max
f) Internal Voltage 24VDC
g) Indoor Use Altitude up to 2,000 m
h) Operating Temperature 0
o
F to 120
o
F (-18
o
C to +50
o
C)
i) Maximum Relative Humidity 80% for temperature up to 31
o
C
Decrease linearly to 50% relative
humidity at 40
o
C
j) Air Output 100 psi (689 Kpa) Max.
k) Timer Programmable 0.008- 99.99 Sec.
l) Cycle Initiation Maintained or Momentary
m) Repeat Tolerance +/- 0.05%
p) Cycle Rate 900 cycles/minute
4 Installation
4.1 Space requirements
WARNING:
Unplug power cord and disconnect
air supply prior to removing cover.
FOR SPARE PARTS, MANUALS, REPAIRS,
OR TECHNICAL ASSISTANCE:
Visit us at equipment.loctite.com
or call Henkel Corp. at:
USA - (1) 860-571-5174
Germany - (49) 89-9268-0
Singapore - (65) 6482-3881
Label P/N: 988341
P/N: 98521
MODE/TIME DISPLAY
MODE DECIMAL
MODE/TIME SET
PORT A PORT B
2.5 [63.1MM]
12.4 [316.0MM]
7.6 [194.3MM]
6.1 [156.0MM]
2.3 [57.8MM]
4.2 Features Description
Item Function
2
34 6 7
11 1
14
1. Power Switch Turn power on to the unit
2. Air Pressure Gauge Displays dispense air pressure
3. Air Pressure Regulator Regulates dispense air pressure
4. Port A Provide valve actuating air signal
5. Port B Provide atomizing air signal
6. Mode/Time Set Scrolls menu/adjusts dispense time
7. Display Displays time, voltage and mode setting
8. Decimal Switch Change decimal point position
AIR IN
ACC. OUT
MADE USA IN
MODE/TIME DISPLAY
MODE DECIMAL
MODE/TIME SET
5
12
13
9
8
10
9700−
SERIAL NO.
PORT A PORT B
4 Installation (continued)
9. Mode Switch Indicates mode setting
10. AC Connection with Fuse Holder Connects to AC power supply.
Provides pull out for easy fuse replacement.
11. Foot Switch Receptacle Activates dispense circuit
12. I/O Connection Provides alternate activation source
13. Air Inlet Air supply connection
14. Accessory Air Outlet Provide constant unregulated air
outlet
4.3 Fuse Installation/Voltage Selection Assembly
1. The AC Connector on the rear panel of the unit is the Fuse holder and the Voltage Selector.
2. To ensure proper voltage setting, all units are shipped from the factory with the Fuse
Holder/Voltage Selector disassembled from the AC Connector.
"X" V~
VOLTAGE SETTING VOLTAGE RANGE FUSE RATING
100 NOT CONNECTED ----
120 100V-120V .250 Amp, Type F
220 NOT CONNECTED ----
240 220V-240V .100 Amp, Type T
4 Installation (continued)
3. Using the chart (previous page), select Fuse & Voltage setting required.
4. If the voltage in not correctly set, remove the voltage selector from the fuse holder and
reinstall it with the desired voltage shown at the window of the fuse holder.
NOTE: Make certain fuse replacement is proper type and rating.
5. Reinsert the fuse holder into the AC Connector casing until it snaps into place.
4.4 Connecting the unit
1. Connect 70-100 psi dry, filtered air supply to air inlet fitting. Make sure the air
inlet pressure is at least 70 psi.
The 5-micron filter should be installed with the unit to ensure proper ai
r
filtration 985397.
2. Install the cord lock to the cord lock mount with the slot at the bottom.
3. Lift the cord lock and connect the foot switch plug to foot switch receptacle.
4. Fit the cord lock over the foot switch cable.
5. For circuit protection, the unit is shipped with fuse unassembled. Follow
instructions in the Fuse Installation section 4.3 to install fuse and set proper
voltage.
6. Connect the power cord to a grounded, properly rated voltage outlet.
Connect the valve air hose to Port A and atomizing air hose.
4.5 I/O Configuration and End of Cycle Switching
Upon completion of a dispense cycle, an open collector circuit closes and remains
closed until the next dispense cycle. This circuit can be used to signal back to a
host computer, start another device in sequence, or drive any other operations that
needs to be tied to the completion of the dispense cycle.
Upon closure, (end of dispense cycle), power from an external source is allowed to
pass through the circuit to operate a 5 to 24 VDC load. Power consumption must
not exceed 250 mA. The load could be a relay, solenoid, counter, LED, or any
device that will operate within a 5 to 24 VDC range and a maximum of 250 mA.
4 Installation (continued)
5 Operation
5.1 Mode Menu
DISPLAY FUNCTION
SP-1
Pre-spray time—Atomized air turns on for preset time before valve
opens
SP-2
Valve on time—Actual Spraying time
Post-spray time—Atomized air spray stays on for preset time after
valve closed
SP-3
5 Operation (continued)
5.2 Manual spray cycle setting:
1. Turn on the unit by switching the Power Switch (1) to the “ON” position. The
switch should light up in the “ON” position.
2. Set atomizing air pressure by rotating the Air Pressure Regulator Knob (3)
until the desired pressure is indicated on the Air Pressure Gauge (2).
3. Push the Mode Switch (9) and rotate Mode /Time Set Knob (6) until “SP-1”
appears in the display.
4. Push the Mode Switch (9) a second time to set the Pre-spray cycle time
5. Push the Mode Switch (9) and rotate Mode /Time Set Knob (6) until “SP-2”
appears in the display.
6. Push the Mode Switch (9) a second time and set the time to “0”
7. Push the Mode Switch (9) and rotate Mode /Time Set Knob (6) until “SP-3”
appears in the display.
8. Push the Mode Switch (9) a second time to set the Post-spray cycle time.
9. Depress and hold on to foot switch to activate timed dispensed cycle.
5.3 Automatic Spray cycle setting
1. Push the Mode Switch (9) and rotate Mode /Time Set Knob (6) until “SP-1”
appears in the display.
2. Push the Mode Switch (9) a second time to set the Pre-spray cycle time.
3. Push the Mode Switch (9) and rotate Mode /Time Set Knob (6) until “SP-2”
appears in the display.
4. Push the Mode Switch (9) a second time to set spray cycle time.
5. Push the Mode Switch (9) and rotate Mode /Time Set Knob (6) until “SP-3”
appears in the display.
6. Push the Mode Switch (9) a second time to set the Post-spray cycle time
7. Depress foot switch to activate timed dispensed cycle.
8. To change the amount of fluid sprayed, increase or decrease atomized pressure,
valve open time, or valve stroke.
NOTE: In both Manual and Automatic Mode, pre-spray time and post spray time
must be entered in the unit, otherwise the unit will not activate
.
NOTE: All spray time entered into the Controller will be stored in its memory even
with the unit disconnected from the AC source. All entries can be cleared from the
memor
y
b
y
turnin
g
the unit off
,
then back on while holdin
g
the Decimal Switch
(
8
)
6 Troubleshooting
PROBLEM POSSIBLE CAUSE CORRECTION
Power light, not on
• No Power input
• Fuse open
• Power Switch not “ON”
• Power Switch defective
• Check Power Cord connections and Power
Supply
• Replace Fuse
• Turn on Power Switch
• Replace Power Switch
System will not actuate
• Foot Switch not plugged in or
improperly plugged in
• Defective Foot Switch
• Broken wire or loose connection inside
unit
• Defective Solenoid
• Defective Timer Board
• Unit in “Menu Mode”
• No time set in “SP-1” and “SP-3”
• Check Foot Switch connection
• Foot Switch needs to be repaired or replaced.
• Unplug Power Cord and disconnect air
supply. Remove cover and check for broken
wires or loose connections
• Replace Solenoid
• Replace Timer Board
• Press Mode Switch to change to activation
mode
• Enter desired pre-spray time in “SP-1” and
post-spray time in “SP-3”
System will not
pressurize
• Insufficient air pressure
• Air hoses not plugged in
• Regulator defective
• Increase air supply pressure
• Check connection
• Replace Regulator
Inconsistent spray
• Air bubbles in fluid
• Spray valve damage
• Remove air from fluid
• Refer to Spray valve manual
7 Care and Maintenance
The dispenser is designed and built to be relatively maintenance free. To assure
trouble free operation, the following recommendations should be followed:
1. Make certain air supply is clean and dry.
2. Make certain AC outlet is grounded and of proper voltage rating.
3. Avoid turning Adhesive barrels upside down or laying barrel so that material may
run through airline to internal components.
4. Avoid connecting the unit to excessive moisture or solvent saturation.
5. Avoid connecting the unit to air supply exceeding 100 psi.
6. Always replace fuse with proper type and amperage rating.
8 Accessories and Spare Parts
• Foot Pedal – 984621
•
5 micron Air Filter 985397
9 Appendix
9.1 Electrical Diagram
TIMER BOARD 5110-000-003
CONNECTOR
FOOT SWITCH
FOOT
SWITCH
GRN
1
6
5
9
BLK
WHT
SOLENOID
ATOMIZING
DECIMAL LED
MODE LED
BLKBLK
GRN
DECIMAL SW
MODE SW
COM
BLK
WHT
FS
ORG
ORG
SHOT
RED
AUTO
ORG
ORG
BLK
RED
BLK
QUADRATURE
POT
SOLENOID
VALVE
BLU -
YEL
RED
BLK
BRN +
OUTPUT SIGNAL
BLU
BLU
RED
YEL
BLK
24VDC INITIATE
0240
120
W
H
T
DISPLAY
RED +
BLK -
B
L
K
BR
N
GND
POWER
SWITCH
WHT
BLK
BRN
3
2
1
B
L
K
WHT
GND
+10V
BLK
COM
+24V
RED
+24V
+36V
BLU
+10V
GND
GRN
POWER
SUPPLY
9.2 Pneumatic Diagram
3
21
Air Inlet
Air Manifold
Regulator
Air Pressure Gauge
Solenoid Valve
3
21
Solenoid Valve
Air Outlet
Air Outlet
Air Outlet
(White)
10 Warranty
Henkel expressly warrants that all products referred to in this Instruction Manual for (
Loctite
®
98521
Spray Valve Controller ) (hereafter called “Products”) shall be free from defects in materials and
workmanship. Liability for Henkel shall be limited, as its option, to replacing those Products which are
shown to be defective in either materials or workmanship or to credit the purchaser the amount of the
purchase price thereof (plus freight and insurance charges paid therefor by the user). The purchaser’s
sole and exclusive remedy for breach of warranty shall be such replacement or credit.
A claim of defect in materials or workmanship in any Products shall be allowed only when it is
submitted in writing within one month after discovery of the defect or after the time the defect should
reasonably have been discovered and in any event, within (12) months after the delivery of the
Products to the purchaser. This warranty does not apply to perishable items, such as, but not limited
to: (o-rings, seals, gaskets, washers, filters, tubing, fittings, lights, etc.). No such claim shall be allowed
in respect of products which have been neglected or improperly stored, transported, handled, installed,
connected, operated, used or maintained. In the event of unauthorized modification of the Products
including, where products, parts or attachments for use in connection with the Products are available
from Henkel, the use of products, parts or attachments which are not manufactured by Henkel, no
claim shall be allowed.
No Products shall be returned to Henkel for any reason without prior written approval from Henkel.
Products shall be returned freight prepaid, in accordance with instructions from Henkel.
NO WARRANTY IS EXTENDED TO ANY EQUIPMENT WHICH HAS BEEN ALTERED,
MISUSED, NEGLECTED, OR DAMAGED BY ACCIDENT, OR IF THE SYSTEM WAS USED TO
DISPENSE ANY LIQUID MATERIAL OTHER THAN LOCTITE
®
PRODUCTS.
EXCEPT FOR THE EXPRESS WARRANTY CONTAINED IN THIS SECTION, HENKEL MAKES
NO WARRANTY OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO
THE PRODUCTS.
ALL WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE,
AND OTHER WARRANTIES OF WHATEVER KIND (INCLUDING AGAINST PATENT OR
TRADEMARK INFRINGEMENT) ARE HEREBY DISCLAIMED BY HENKEL AND WAIVED
BY THE PURCHASER.
THIS SECTION SETS FORTH EXCLUSIVELY ALL OF LIABILITY FOR HENKEL TO THE
PURCHASER IN CONTRACT, IN TORT OR OTHERWISE IN THE EVENT OF DEFECTIVE
PRODUCTS.
WITHOUT LIMITATION OF THE FOREGOING, TO THE FULLEST EXTENT POSSIBLE
UNDER APPLICABLE LAWS, HENKEL EXPRESSLY DISCLAIMS ANY LIABILITY
WHATSOEVER FOR ANY DAMAGES INCURRED DIRECTLY OR INDIRECTLY IN
CONNECTION WITH THE SALE OR USE OF, OR OTHERWISE IN CONNECTION WITH, THE
PRODUCTS, INCLUDING, WITHOUT LIMITATION, LOSS OF PROFITS AND SPECIAL,
INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER CAUSED BY NEGLIGENCE FROM
HENKEL OR OTHERWISE.
Henkel Corporation
1001 Trout Brook Crossing
Rocky Hill, CT 06067-3910
Henkel Canada Corporation
2225 Meadowpine Boulevard
Mississauga, Ontario L5N 7P2
Henkel Capital, S.A. de C.V.
Calzada de la Viga s/n Fracc. Los Laureles
Loc. Tulpetlac, C.P. 55090
Ecatepac de Morelos, Edo. de México
Henkel Automotive
Technology Center
2455 Featherstone Road
Auburn Hills, Michigan 48326
Henkel Ltda.
Rua Karl Huller, 136 – Jd.
Canhema 09941-410
Diadema/SP, Brazil
www.loctite.com
Loctite is a trademark of Henkel Corporation, U.S.A. © Copyright 2004. Henkel Corporation
All rights reserved. Data in this operation manual is subject to change without notice.
Manual P/N: 989375, Date: 04/2005
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