780S Series Spray Valves VALVEMATE™ 7040 Controller Operating Manual

A NORDSON COMPANY US: 888-333-0311 UK: 0800 585733 Mexico: 001-800-556-3484 If you require any assistance or have specific questions, please contact us.

US: 888-333-0311 Telephone: 401-434-1680 Fax: 401-431-0237 E-mail: [email protected] Mexico: 001-800-556-3484 UK: 0800 585733

EFD Inc. 977 Waterman Avenue, East Providence, RI 02914-1342 USA

Sales and service of EFD Dispense Valve Systems is available through EFD authorized distributors in over 30 countries. Please contact EFD U.S.A. for specific names and addresses. Contents Introduction ...... 2

Specifications ...... 3

How The Valve and Controller Operate ...... 4

Controller Operating Features ...... 5

Typical Setup ...... 6

Setup ...... 7-8

Adjusting the Spray...... 9

Programming Nozzle Air Delay ...... 10

Spray Patterns ...... 11

Troubleshooting Guide ...... 12-13

Valve Maintenance...... 14-16

780S Exploded View...... 17

Input / Output Connections...... 18-19

Connecting More than One 7040 Controller...... 20

7040 Schematic and Replacement Parts ...... 21

Warranty ...... 22

Meets CSA and CE standards. 780/7040-MAN ©2003 EFD Inc. This manual is for the express and sole use of EFD valve purchasers and users, and no portion of this manual may be reproduced in any form. EFD and VALVEMATE are trademarks of EFD Inc. Teflon is a registered trademark of DuPont. Introduction The 780S Series precision Low Volume Low Pressure (LVLP) liquid spray valves are manufactured to the highest quality standards. The VALVEMATE™ 7040 controller features an adjustable nozzle air flow regulator and a microprocessor-based timed air pressure output for controlling the ON time of the 780S valve. This equipment is produced to very close tolerances to ensure proper and reliable operation. Each valve and controller has been thoroughly tested prior to shipping.

The 780S and VALVEMATE™ 7040 are simple to use and will operate many millions of cycles without maintenance. Spray valve cleaning is accomplished by purging with the appropriate solvent. To obtain the maximum performance from this fine equipment, please read through these instructions carefully.

2 / Introduction Specifications

780S Spray Valve VALVEMATE™ 7040 Controller Size: 4.120" x 1.060" dia. (104.6 x 26.9 mm) Cabinet size: W 7.5" x D 5.6" x H 2.7" Weight: 780S: 8.3 oz (235 g) (W 19 x D 14 x H 7 cm) 780S-SS: 14.3 oz (405 g) Net weight: 3.1 lb (1.4 kg) Air cylinder body: 780S-SS: Type 303 stainless steel Air input required: 70 psi (4.8 bar) minimum 780S: Hard-coated aluminum Input voltage: 100/120/220 VAC selectable Fluid chamber: 780S-SS: Type 303 stainless steel 780S: Hard-coated aluminum Power required: 50/60 Hz 14/12VA Piston: Type 303 stainless steel Foot pedal voltage: 5 VDC Piston return spring: Type 303 stainless steel Time range: .001 to 99.9 seconds Needle and Nozzle: Type 303 stainless steel Timing control: Microprocessor-based CMOS logic Time cycle repeat 0.00005 seconds Air cap: 780S-SS: Type 303 stainless steel 780S: Plated brass Time reset: Less than 20 milliseconds Initiation: Dry contact closure or 5 to 24 VDC signal Needle packings: Teflon® Output pressure: Packing spring: Stainless steel Actuating air 70 psi (4.8 bar) Liquid inlet hole: 1/8 NPT female Nozzle air 1 to 30 psi (0.07 to 2.07 bar) Mounting: 1/4-28 UNF tapped hole Cycle rate: Exceeds 600 per minute Operating frequency: Exceeds 400 per minute Cycle end feedback circuit: N.C. solid-state switch Air pressure required: 70 psi (4.8 bar) 5 to 24 VDC, 250 mA maximum load Minimum mounting center distance: 1.067" (27.1 mm) Standard nozzle diameter: 0.046" (1.17 mm) Optional nozzle sizes: 0.028" (0.71 mm) 0.014" (0.36 mm) Spray patterns: Round (standard) Fan (optional)

Note: All stainless steel valve parts are passivated. Specifications and technical details are subject to engineering changes without prior notification.

3 / Specifications How The Valve and Controller Operate

The 780S is a normally closed, air actuated needle type spray valve that uses a Low Volume Low Pressure (LVLP) design for high transfer efficiency without overspray or airborne mist. Air pressure from the VALVEMATE™ 7040 controller at 70 psi (4.8 bar) acts on a piston ➀ that retracts the nee- ➀ Piston and needle dle ➁ from its nozzle seat ➂ and allows liquid to flow from the nozzle ➃. At the same time, nozzle air, also from the 7040, is turned on and flows from an annulus ➄ around the liquid nozzle. This adjustable nozzle air creates a pressure drop around the nozzle, causing the liquid to atomize into fine droplets. When the timed actuating air from the 7040 shuts off, the piston spring moves the needle onto the nozzle seat, shutting off liquid flow. A preset nozzle air delay ensures that no liquid remains on the nozzle after the valve closes, eliminating after-deposit spatter. The amount sprayed is controlled by the valve open closed position time, reservoir pressure and needle stroke. Area of coverage is determined by the nozzle size and the distance between the 780S nozzle and the work surface. ➁ Needle

➃ Nozzle

➂ Nozzle seat

➄ Annulus

open position

Piston and needle assembly Fluid Nozzle air Operating air

4 / How The Valve and Controller Operate Controller Operating Features

1. Cycle Press to initiate one complete dispense Nozzle Nozzle cycle. Press this button again to interrupt a air gauge air regulator 123 timed cycle. Press and hold while in the time override mode for continuous cycle. Release to stop. VALVEMATE 7040 2. Time override Press to override time control. Display will show (---). While in this mode, dispensing is manual using the cycle button, voltage initiate source or foot pedal (optional, #2015A).

3. Decimal 4 5 Press to move decimal and change time range maximums from .999 to 9.99 or 99.9. Decimal does not appear in the display while Air input in the .999 second range. Input power quick-coupler Valve cord receptacle 70 psi (4.8 bar) operating 4. Program (see page 7 Power minimum input air output Press to clear display to zeros. Display for details) switch 6 pressure (white) flashes bright/dim while in program mode. Press cycle button and hold until proper Output A amount is sprayed. Total spray time will be 120 displayed. Press program button again to lock in spray time. Output B 5. Time set Press to change time setting up or down. Press and release to advance one digit at a time, or press and hold to scroll quickly. 9 pin D connector Air Nozzle I/O interface exhaust air output 6. Foot pedal connector (see page 18 for details) If using the optional foot pedal, press the (black) pedal momentarily to initiate the 7040 controller. To interrupt a timed dispense cycle, press the pedal again.

5 / Controller Operating Features Typical Setup

5 micron filter regulator Shutoff valve

Plant air 70 psi (4.8 bar) White quick connect To exhaust To pressurize minimum Air tee

Flexible air line

Black quick-connect Control air line Fluid feed hose

Pressurized reservoir Pressure relief valve with air regulator 5 0 20

VALVEMATE 7040

Fluid inlet fitting

ValveMate™ 7040 Controller #7543BP (installed) for 1/4" OD tube #7610BP (included) for 3/8" OD tube

Material Constant air Caution: Always depressurize the reservoir before Pulsed air for valve operation opening. To do this, slide the shutoff valve on the Pulsed nozzle air air line away from the reservoir. If using an EFD tank, open the pressure relief valve as well. Before opening the reservoir, check the pressure gauge to verify that pressure is zero (0). On all EFD cartridge reservoirs, the unique thread- ed design provides fail-safe air pressure release during cap removal.

6 / Typical Setup Setup supply. 4. Install the air tee with barb fitting Input Power (#1116) in the output of the filter regulator 1. View cartridge window in power cord and, using the screw clamp provided, install receptacle to ensure that fuse voltage the black hose with coupling to the barb fit- value matches your input voltage. ting. The quick-connect on the air tee is used to provide air pressure to the air pres- If it does not match, remove the fuse car- sure regulator on EFD fluid reservoirs. This tridge. Then remove the fuse holder connection will be made in step 10. from the cartridge, rotate the holder and 5. Remove the cap plug from the air input position the correct voltage to show of the VALVEMATE™ 7040 and attach the through the cartridge window. Replace input air hose coupling onto the controller the cartridge into the power cord recep- air input fitting. Adjust the filter regulator to tacle and ensure that both sides snap 70 psi (4.8 bar). securely into position. 6. Mount the 780S valve with an EFD Connect the power cord. Universal Valve Mount (#7002VM) or other appropriate fixture. Spare fuse 7. Connect the fluid feed hose to the reservoir outlet and the 780S inlet port using appropriate fittings shown on the

220 Setup Schematic, page 6.

120 100 8. The 780S is equipped with nozzle and control air hoses with male quick-connects Voltage value that plug into the VALVEMATE™ 7040. Plug Cartridge window the control air hose labeled “A” into output (check voltage indicated) “A” (white) on the rear panel of the 7040 Initiate Connection and the nozzle air hose labeled “B” into output “B” (black), also located on the 7040 2. The 7040 is normally operated by apply- rear panel. ing a 5 to 24 VDC pulse to terminal pins 9. Check that all connections are tight and 1 and 2, or providing contact closure attached to the proper output. across pins 5 and 7. Alternatively, a foot 10. Fill the fluid reservoir. After filling, pedal may be ordered (#2015A) and secure the cover and connect the reser- plugged into the connector located on voir air pressure regulator to the air tee the rear panel. Detailed electrical by using the connecting hose (#2310S). schematic and diagrams are shown on First, attach the black male quick-con- pages 18 and 19. nect on the connecting hose to the reservoir regulator and then attach the 3. Connect the VALVEMATE™ 7040 to plant air by first installing the EFD five-micron other end with the white male quick- filter regulator (#2000F755) to your air connect to the air tee.

NEXT 7 / Setup 11. Set the reservoir pressure regulator according to the fluid viscosity. For Stroke Control Reference example, low viscosity fluids require only Stroke 1 to 3 psi (0.07 to 0.2 bar). Higher pres- Control Knob sures are required for more viscous flu-

ids. Reference Stroke Mark 12. Close needle stroke control knob, fully Reference Ring Set Screw (clockwise), then set at one turn open. This is a starting point only. Final setting The Stroke Control Reference allows you will be determined by the desired to calibrate the stroke control setting or flow rate. document the dispensing process. To calibrate, close the stroke control knob 13. Check the nozzle air gauge. If not at all the way. Loosen the set screw and turn zero, turn the regulator knob clockwise the reference ring so the zero on the ring to turn off the nozzle air. aligns with one of the two reference marks on the valve body. When the set screw is Note: Regulator knobs on EFD tanks and conrollers tightened, the valve is calibrated. have a push-to-lock, pull-to-unlock feature. Existing 780S Series valves are easily upgraded with the Stroke Control 14. Place a container under the valve Reference Kit (#780SR-KIT). to collect the fluid during this setup procedure.

15. Turn on the power switch. Press the Tamper Resist Option time override button to place the 7040 into the manual mode (---). Removable stroke control 16. Press and hold the cycle button or knob optional foot pedal. Continue to hold until the fluid lines and the valve are Stroke primed and purged of all air. mechanism

Note: The area of spray coverage is determined by The 780S valve can be ordered in a tamper resist configuration to limit unauthorized the distance between the spray valve nozzle and adjustment. the work surface. Refer to the chart on page 11 to In the TR configuration, stroke adjustment determine this distance. can only be made when a special stroke control knob is inserted into the stroke mechanism. A tamper resist stroke kit can also be ordered as a retrofit for existing valves. Part # Description 780S-TR Tamper resist spray valve .046 7544SS Tamper resist stroke kit

8 / Setup Adjusting the Spray Check to be sure steps 11 through 16 under Setup have ➀ been completed, then proceed to adjust the spray. 1. Using the needle stroke control knob ➀ on the 780S valve, set the fluid flow rate to one or two drops per second. Check flow rate by actuating the controller in the time override mode. Make valve stroke adjustments when the controller is off. 2. Set the nozzle air pressure on the VALVEMATE™ 7040 controller to 10 psi and actuate the controller. The valve will produce a fine spray. To change fluid flow, use the needle stroke control knob ➀. To change nozzle air, use the nozzle air pressure ➅ ➂ ➄ regulator ➁. Higher pressures will provide finer spray.

VALVEMATE 7040 To Make Timed Deposits Return to the time control by pressing the time override button ➂. The display should show the time setting. Adjust the deposit time to 0.5 seconds by using the time set ➃ and decimal ➄ buttons. (See page 5 for ➁ ➃ operation of these buttons.) Press the cycle button ➅. The 7040 will open the valve for 0.5 seconds. Adjust time up or down and test deposits until desired output is obtained. Optimal results will be obtained with the proper combi- nation of time setting, needle stroke control knob, and reservoir and nozzle air pressure.

9 / Adjusting the Spray Programming Nozzle Air Delay The nozzle air time delay can be changed from the factory setting of 0.24 seconds to fine-tune the shutoff characteristics of the 780S spray valve. When making small deposits of low viscosity fluid, it may be necessary to shorten the time delay to eliminate a hollow center in the deposit. To change the time delay: 1. Turn the power switch off. 2. Press and hold the time override button while turning power switch on. 3. The display will read "SEL" (select). Release the time override button. 4. Press either the up or down time set buttons once and release. The current nozzle air delay setting will be displayed. (The delay is preset to 0.24 seconds for all new controllers.) 5. Press the up or down time set button again to program the new nozzle air delay. (Available range is 0.00 to 2.50 seconds.) 6. To exit the nozzle air delay program mode, momentarily press the time override button. The spray time setting will be displayed.

Note: The VALVEMATE™ 7040 controller will not operate while in the nozzle air delay program mode.

10 / Programming Nozzle Air Delay Spray Patterns

Round Pattern Spray Area Coverage Nozzle Distance from the Work Surface: 1" 2" 3" 6" Nozzles 25.40 mm 50.80 mm 76.20 mm 152.40 mm #7857-46SS Standard 0.046" 0.250" 0.500" 0.750" 1.500" (1.17 mm) 6.35 mm 12.70 mm 19.05 mm 38.10 mm

#7857-46WA-SS Wide-angle 0.046" 0.750" 1.500" 2.000" Not (1.17 mm) 19.05 mm 38.10 mm 50.80 mm Recommended

#7857-28SS 0.028" 0.200" 0.400" 0.600" 1.200" (0.71 mm) 5.08 mm 10.16 mm 15.24 mm 30.48 mm

#7857-14SS 0.014" 0.170" 0.340" 0.500" 1.000" (0.36 mm) 4.32 mm 8.64 mm 12.70 mm 25.40 mm

Fan Pattern Spray Area Coverage Nozzle Distance from the Work Surface: Side view of 1" 2" 3" 6" fan air cap Nozzles 25.40 mm 50.80 mm 76.20 mm 152.40 mm #7857F-46SS 0.046" 1.000" 1.500" 2.000" 3.250" Round Fan (1.17 mm) 25.40 mm 38.10 mm 50.80 mm 82.60 mm

#7857F-28SS 0.028" 0.400" 0.800" 1.200" 2.400" (0.71 mm) 10.16 mm 20.32 mm 30.48 mm 60.96 mm

#7857F-14SS 0.014" 0.340" 0.680" 1.000" 2.000" (0.36 mm) 8.64 mm 17.27 mm 25.40 mm 50.80 mm

#7857-46WF-SS 0.046" 1.500" 2.500" 3.250" 6.500" (1.17 mm) 38.10 mm 63.50 mm 82.60 mm 165.10 mm

11 / Spray Patterns Troubleshooting Guide Valve Trouble Possible cause and correction If valve operating pressure is too low, the valve will not open. Increase air pressure to 70 psi (4.8 bar) minimum. No fluid flow. The reservoir air pressure may not be high enough. Increase pressure. The nozzle may be clogged. Clean the nozzle. The stroke adjustment control may be closed. If it is closed, open counterclockwise one turn. The control and the nozzle air lines may be reversed. Check for proper connection (see Setup Schematic on page 6).

Valve does not provide clean shutoff, Nozzle air pressure may be too low. Increase air pres leaving a buildup on the nozzle. sure. Nozzle air time delay is too short. Increase time.

A continuous drip can be caused by improper seating of the needle in the nozzle seat. Remove the nozzle, clean Fluid continuously drips from the the needle and nozzle, replace worn or damaged parts. nozzle after the valve shuts off. If the liquid chamber has not been fully turned onto the air cylinder body during reassembly, the needle will not seat in the nozzle. Check to be sure the liquid chamber is properly installed (see Maintenance Instructions on pages 14-16). Needle packings may be binding due to leakage, pre- venting the needle from fully closing. Disassemble the valve in accordance with the Maintenance Instructions. Replace the packings if there is evidence of leakage.

Fluid flows from the nozzle Nozzle air pressure may be too low. Increase air pres- but will not spray. sure. The air passageway between the nozzle and air cap may be obstructed. Remove the air cap, and clean the air cap and nozzle. If the fluid viscosity is too high, it will not atomize. Reduce viscosity.

12 / Troubleshooting Guide NEXT VALVEMATE™ 7040 Trouble Possible cause and correction No power. Be sure that there is power at the wall receptacle. Check the input power fuse. If the fuse has blown, check the voltage value in the fuse cartridge window. Be sure that it matches the input voltage.

Ensure that the external voltage to the circuit is between End-of-Cycle Feedback Circuit 5 and 24 VDC and that the load does not exceed 250 mA. is not functioning. If the circuit has been overloaded, the fuse may have blown. See internal diagram on page 21 and replace if necessary.

Valve does not spray Response delay in pneumatic circuit does not allow the below .015 second time setting. valve to open when time is at or below 0.015 seconds. Increase time.

1. Valve operating pressure lower than 60 psi (4.1 bar) can cause inconsistent output. Check to be sure pressure is set at 70 psi (4.8 bar). 2. Check VALVEMATE™ 7040 and reservoir air pres- Inconsistent deposits. sure readings to be sure air pressure is not varying. 3. Air bubbles in the material can cause inconsistency. For best results, remove all air bubbles.

Timer seems inoperative. Check to be sure time override mode is off.

Note: The EFD timer is very reliable. Any failure will be total, so that no inconsistency is possible. Most questions regarding the timer are resolved by simply turning the time override mode off.

If trouble cannot be corrected, or if you need further assistance, please call us. In the U.S., 888- 333-0311. In the U.K., phone 0800 585733. In Mexico, 001-800-556-3484.

13 / Troubleshooting Guide Valve Maintenance Normal cleaning is accomplished by purging with Caution: Always release the reser- appropriate solvent. The air cap and nozzle can be voir pressure and disconnect the removed, soaked in solvent and reinstalled without power before performing any mainte- demounting the valve. (Refer to Exploded View on page nance on the system. On all EFD 17.) tanks, there is a pressure relief valve that should be activated before open- To thoroughly clean valve chamber and replace needle ing the tank to ensure that all pres- packings: sure is bled off. 1. Remove the needle stroke control knob and spring to prevent damage to the needle and nozzle during Maintenance Tools reassembly. 6" adjustable wrench 2. Remove the air cap retainer, then the air cap, nozzle snap ring pliers and fittings from the liquid chamber. packing extraction tool #7803 3. Remove the fluid chamber from the air cylinder body by turning counterclockwise until free. Then remove the O-ring from the fluid chamber. Packing extraction 4. Clean the fluid chamber, air cap and nozzle in tool #7803 appropriate solvent. 5. Remove the needle packings from the fluid chamber, using tool #7803 supplied with the valve. Insert Fluid through nozzle end of the fluid chamber and gently chamber push out the packings (see Figure 1). Do not use sharp instruments to scrape or clean O-ring these components. Scratches may cause the valve Teflon to leak. packing Teflon seat 6. Remove any remaining packings and the spring needle packings Metal packing expander Figure 1 Pushing needle packings from the fluid chamber.

14 / Valve Maintenance NEXT from the needle. 7. Clean the needle with a cloth dampened in solvent. 8. Lubricate the needle with Nye Lubricant #865 gel and reinstall the needle packing spring and packings in accordance with Figure 2 below. 9. Install a new O-ring (#7517) on the fluid chamber. Screw the air cylinder onto the fluid chamber. Hand tighten only. The chamber can be backed off 1/2 turn from the air cylinder body to orient fittings. 10. Reinstall the nozzle, air cap, retainer and fittings. Reinstall the needle stroke control and spring. Turn back to the desired setting.

Air cylinder Metal body Retaining packing washer expander Teflon packing seat

O-ring Teflon Spring needle packings Figure 2 Proper assembly order for reinstalling needle packings.

Note: The small O-ring on the bottom of the air cylinder body is held in place by a flat retaining washer that also serves as the packing spring seat. It may come out with the spring. Ensure that it is back in place before reinstalling the packing spring (see Figure 2).

15 / Valve Maintenance To replace the piston and needle assembly or Note: The piston and needle assembly is replaced the piston O-ring: as a unit and cannot be disassembled. 1. Remove the needle stroke control knob by turning counterclockwise until free. To reseat the needle and nozzle assembly: 2. Remove the piston return spring and 1. Disconnect or shut off all air to the valve. thrust washers located on each end of the spring. 2. Rotate the stroke adjustment knob to the closed position by turning clockwise. 3. Remove the snap ring using snap ring pliers. 3. Rotate the stroke adjustment further clockwise one additional reference mark 4. Pull the piston and needle assembly out to compress the needle into the nozzle. of the air cylinder using small pliers on the spring pilot (at the top of the piston). 4. Return the adjustment knob to normal setting and cycle the valve a few times. Note: The piston and needle assembly is replaced If there is still a slight leak, repeat steps as a unit and cannot be disassembled. 1 and 2 again. 5. If the leak continues, replace the nozzle. 5. Clean the air cylinder body wall and apply lubricant. 6. Reinstall a new O-ring on the piston, apply lubricant to the needle and O-ring then reinstall in the air cylinder. 7. Reinstall the snap ring. 8. To reinstall the piston return spring, first put one thrust washer over the spring pilot, then the other thrust washer into the needle stroke control, followed by the spring. 9. Reinstall the needle stroke control knob by aligning the piston return spring with the spring pilot. Turn the needle stroke control clockwise until it stops and then back it out to the desired setting.

16 / Valve Maintenance 780S Series Needle stroke reference control Items included in repair kit #780SSR-KIT (stainless steel) #780S-RK are listed in blue. #780SR-KIT (aluminum)

Thrust washer Piston return spring #7802 #7809 B A Snap ring #7526

O-ring (Buna-N) #7519

Air hose assembly Piston and needle #7830 assembly includes O-ring (Buna N) #7805-SS

Air cylinder body #7811-SS (stainless steel) #7811 (hard-coated aluminum) O-ring #7806 Retaining washer Packing spring #7807 #7808

Needle packing assembly #7810

O-ring 7517 Fluid inlet fitting Fluid chamber #7543BP - for 1/4" OD tube #7812-SS (stainless steel) #7610BP - for 3/8" OD tube #7812 (hard-coated aluminum)

Nozzle/air cap Nozzle O-ring (Viton) (see below) #7825

Nye gel lubricant, 1 gram foil packet (not shown) Nozzle air cap retainer #7819SS (stainless steel) Nozzle and Air Cap Assembly

Round pattern Fan pattern Wide fan pattern Round wide-angle Nozzle Size Stainless Steel Stainless Steel Stainless Steel Stainless Steel

0.046" (1.17 mm) #7857-46SS #7857F-46SS #7857-46WF-SS #7857-46WA-SS 0.028" (0.71 mm) #7857-28SS #7857F-28SS N/A N/A 0.014" (0.36 mm) #7857-14SS #7857F-14SS N/A N/A 17 / 780S Exploded View Input/Output Connections Note: For applications using more than one 7040, see page 20 for con- 1. Voltage Initiate Circuit nection instructions. The VALVEMATE™ 7040 may be initiated with a 5 to 24 VDC signal across pins 1 and 2. The signal can be momentary (no less than 0.02 seconds) or maintained. A new cycle will begin once power is removed and then applied again. Refer to the schematic on page 19 for proper installation. I/O Connection 2. End-of-Cycle Feedback Circuit The 9-pin D connector and internal circuitry pro- Upon completion of a dispense cycle, an open collector vide external initiate and circuit closes and remains closed until the next dispense end-of-cycle feedback sig- cycle. This circuit can be utilized to signal back to a nal. The pin connections host computer, start another device in sequence or are shown below.

other operations that need to be tied into completion of 5 4 3 2 1 the dispense cycle. 9 8 7 6 Upon closure, power from an external 5 to 24 VDC source is allowed to pass through the circuit to operate Pin Function a load. The load illustrated is a relay, but this could be 1. Initiate + 5-24 VDC any device that will operate within the 5 to 24 volt range. 2. Initiate - ] Power consumption of the load must not exceed 250 3. Output + ] 5-24 VDC mA. 4. Output - 250 mA Max 5. Contact Closure 3. Mechanical Contact Initiate 6. Chassis Ground ™ 7. Contact Closure The VALVEMATE can be initiated via the closure of 8. Not Used mechanical contacts such as a relay or switch using pins 9. Not Used 5 and 7. Closure of the contacts can be momentary (no less than 0.02 seconds) or maintained. A new cycle will begin once the contacts are opened and then closed Note: 9-pin male connector assembly again. Refer to the schematic on page 19 for proper is included (replacement part # 7154). installation.

18 / Input / Output NEXT Connections Voltage Initiate Circuit Programmable + 5 to 24 VDC power source display power consumption 1 _ Micro- Opto 2.2 mA at 5 VDC controller coupler 15.0 mA at 24 VDC 2

+ End-of-Cycle Feedback Circuit 5 to 24 VDC power Fuse _ source maximum 3 Opto load 250 mA coupler 4 A relay is Nonvolatile illustrated memory as one example for utilizing the feedback circuit.

5 Mechanical Contact Initiate Solenoid 2 7 atomizer Mechanical contact power control consumption contact load Protector = 5.5 VDC / 100 uA Power Solenoid 1 NOTE: DO NOT APPLY supply 780S VOLTAGE across pins + 5 VDC control 5 and 7. 100/120/220 VAC 50/60 Hz 14/12 VA Foot Pedal + 24 VDC

19 / Input and Output Connections Connecting more than one 7040 Controller Follow these instructions and diagrams when the Voltage Initiate or End-of-Cycle Feedback features are 5 4 3 2 1 used in a multiple 7040 installation. 9 8 7 6 1. Voltage Initiate Circuit To start the dispense cycle for multiple 7040's at the 5 4 3 2 1

same time, connect the Voltage Initiate Circuit in paral- 9 8 7 6 lel as illustrated.

Note: The amperage consumption for the Voltage Initiate Circuit 5 4 3 2 1 ™ will increase with each VALVEMATE 7040 that is connected. 9 8 7 6 The initiate power supply should be sized accordingly. Example: First 7040 consumes 15.0 mA at 24 volts. Second one will consume another 15.0 mA; total now is 5-24 VDC - Source + 30.0 mA. Third one will consume another 15.0, making the total 45.0 mA and so on. 1. Parallel circuit diagram for Voltage Initiate.

2. End-of-Cycle Feedback Circuit This circuit will ensure that the End-of-Cycle signal will come from the last 7040 to complete a dispense cycle. Connect in series as illustrated. 5 4 3 2 1 Note: There will be a maximum voltage drop of 2.0 VDC through the Feedback Circuit with each 7040 that is added to the series. 9 8 7 6 The input power should be adjusted for this drop to ensure that the required voltage is available to operate the load. Maximum 5 4 3 2 1

input voltage to terminals 3 and 4 must not exceed 30.0 VDC. 9 8 7 6 Example: The device to be controlled through the Feedback Circuit operates at 12 VDC. Four 7040's are 5 4 3 2 1 to be used. 4 x 2.0 = 8.0 VDC drop. Power supply should provide (12.0 + 8.0) or 20.0 VDC to ensure that 9 8 7 6 12.0 VDC is available to run the load.

_ + REMEMBER: Maximum current through the Feedback Circuit must not exceed 250 mA. 2. Series circuit for End-of-Cycle Feedback feature. A relay is illustrated as one example for utilizing the feedback circuit.

20 / Connecting More Than One 7040 Controller Replacement Parts for the 7040 Controller

1. 2-2002-7040 Regulator assembly 0 to 30 psi, 0 to 2.07 bar 2. 2-2003-7040A Control solenoid assembly 3. 2-2003-7040B Nozzle air solenoid assembly 4. 2-2006DB-VC Display PCB assembly 5. 2-2006PS-VC Power supply PCB assembly 6. 2-2017-1500 Foot pedal receptacle assembly 7. 2001A Gauge 0 to 30 psi, 0 to 2.07 bar 8. 2004B Female quick-connect - black (hidden from view - below item #9) 9. 2004B-W Female quick-connect - white 10. 2024-160 1/4" OD x .160" ID tubing 11. 2081A Air input quick-connect 12. 2085 1/8 NPT x 1/4 barb - low profile 13. 2086 1/8 NPT x 1/4 barb 90° - brass 14. 2087 1/8 NPT x 1/4 barb elbow - brass 15. 2088 Fitting - 1/8 NPT x 1/4 barb - brass 16. 7108 Exhaust muffler 18 17. 7109 Power switch 18. 7111 Fuse - .125A 16 11

19. 7143-01 Output circuit fuse 2 6 9 12 14 17

14 19

10 14

13 7 4

1 Input Air Regulated Air

21 / 7040 Schematic and Replacement Parts EFD ONE YEAR LIMITED WARRANTY All components of EFD spray valves and VALVEMATE™ controllers are warranted for one year from date of purchase to be free from defects in material and workmanship (but not against damage caused by misuse, abrasion, corrosion, negligence, accident, faulty installation or by dispensing material incompatible with equipment) when the equipment is installed and operated in accordance with factory recommendations and instructions. EFD will repair or replace free of charge any part of the equipment thus found to be defective, on authorized return of the part prepaid to our factory during the warranty period. For the spray valve, the only exceptions are those parts which normally wear and must be replaced routinely such as, but not limited to, needles, needle packings and nozzles. In no event shall any liability or obligation of EFD arising from this warranty exceed the purchase price of the equipment. This warranty is valid only when oil-free, clean, dry, filtered air is used. EFD makes no warranty of merchantability or fitness for a particular purpose. In no event shall EFD be liable for incidental or consequential damages.

A NORDSON COMPANY

977 Waterman Avenue, East Providence, Rhode Island 02914-1342 USA Toll free: 888-333-0311 Mexico: 001-800-556-3484 Telephone: 401-434-1680 Fax: 401-431-0237 www.efd-inc.com e-mail: [email protected]

Printed on Unit 14, Apex Business Centre, Boscombe Road, Dunstable, Bedfordshire LU5 4SB UK recycled paper Telephone: 01582 666334 Fax: 01582 664227 Freephone: 0800 585733 Ireland: 00800 8272 9444 e-mail: [email protected] ©2003 EFD Inc. 780/7040-MAN 1.5B803 EFD International Inc. is incorporated with limited liability in the U.S.A.