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PVA -5GPU Owner's Manual

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INNOVATION.
PRECISION.
EXCELLENCE.
PVA-5GPU
Owner's Manual
Revision C

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Summary of Contents for PVA PVA-5GPU

  • Page 1 INNOVATION. PRECISION. EXCELLENCE. PVA-5GPU Owner’s Manual Revision C...
  • Page 2 PVA-5GPU Manual This document is based on information available at the time of its publication. While efforts have been made to ensure the contents of this manual are accurate, the information contained herein does not purport to cover all specific details or variations in hardware, or to provide for every possible contingency in connection with installation, operation, or maintenance.

  • Page 3: Table Of Contents

    PVA-5GPU Manual Table of Contents Introduction ......................5 PVA Contact Information ......................5 Document History ........................5 Safety ............................6 Theory of Operation......................... 8 Personal Protective Equipment .................... 8 Waste Disposal .......................... 8 Pump Overview ....................9 HMI Overview ..................... 12 Ram Position and Pump Pressure Overview ..............
  • Page 4 PVA-5GPU Manual Drawings ......................38 Table of Figures ....................44 Notes ........................46 Warranty ......................47 Page 4 of 47 Revision C January 2025...

  • Page 5: Introduction

    Before you operate this system, read the operation and setup manual. This will help you to become familiar with the product and ensure successful operation. If any questions or problems arise, contact PVA’s Technical Support department. PVA Contact Information Main Office...

  • Page 6: Safety

    PVA-5GPU Manual Safety Certain warning symbols are affixed to the machine and correspond to notations in this manual. Before operating the system, identify these warning labels and read the notices described below. Not all labels may be used on any specific system.
  • Page 7 PVA-5GPU Manual Do not smoke near the machine. Always have a fire extinguisher available for emergency use. Before performing any repairs or maintenance to the system, turn off power and lock out the power disconnect switch. Warning notices are used to emphasize that hazardous voltages, current, temperatures, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.

  • Page 8: Theory Of Operation

    PVA-5GPU Manual Theory of Operation The PVA-5GPU Hydraulic Extrusion Pump is a heavy-duty extrusion pump designed for extruding thermal interface materials (TIM) to a dispense head. The PVA-5GPU extrudes the material from a 5-gallon pail with a hydraulic ram cylinder. This has no internal moving parts and transfers the material without changes to the material properties and with virtually zero maintenance required.

  • Page 9: Pump Overview

    PVA-5GPU Manual Pump Overview Figure 1: Pump Overview Page 9 of 47 Revision C January 2025...

  • Page 10: Figure 2: 5Gpu Front Side

    PVA-5GPU Manual Figure 2: 5GPU Front Side Page 10 of 47 Revision C January 2025...

  • Page 11: Figure 3: 5Gpu Rear Side

    PVA-5GPU Manual Figure 3: 5GPU Rear Side Page 11 of 47 Revision C January 2025...

  • Page 12: Hmi Overview

    PVA-5GPU Manual HMI Overview The HMI (human machine interface) is used to operate the system. The HMI has some buttons that are always used for the same functions and other buttons that change functions. The buttons that change functions are labeled on the display screen. The HMI is on the ram control panel.

  • Page 13: Ram Position And Pump Pressure Overview

    PVA-5GPU Manual Ram Position and Pump Pressure Overview Each mode will display two values: Ram Position and Pump Pressure. The pressure value displayed is hydraulic pressure. This operates at approximately a 2:1 ratio to fluid pressure. For example, if the hydraulic pressure displays 1,000 psi, the fluid pressure at the ram will be close to 500 psi.

  • Page 14: Operation

    PVA-5GPU Manual Operation E-Stop Figure 5: E-Stop Engaged Figure 6: Disengage E-Stop Page 14 of 47 Revision C January 2025...

  • Page 15: Remove The Pail

    PVA-5GPU Manual Figure 7: Power On Remove the Pail Warning: Doors must be always closed to operate the hydraulic ram. The hydraulic ram will not operate unless the doors are closed. DO NOT bypass the magnetic door interlocks or remove any guarding, the ram is under high pressure! 1.

  • Page 16: Figure 9: Unload

    PVA-5GPU Manual 2. Select F4 to unload. The ram should rise fully out of the pail. Figure 9: Unload 3. The ram will stop automatically when it is fully raised. If necessary at any point, select F4 again to stop the ram.

  • Page 17: Figure 11: Remove The Pail Clamp Bolts

    PVA-5GPU Manual 5. Use a 15/16” socket to remove the three bolts on the left and right side of the pail clamp. Figure 11: Remove the Pail Clamp Bolts Page 17 of 47 Revision C January 2025...

  • Page 18: Figure 12: Open The Pail Clamp Door

    PVA-5GPU Manual 6. Open the pail clamp door. Figure 12: Open the Pail Clamp Door 7. Remove the pail from the clamp. Figure 13: Remove the Pail Page 18 of 47 Revision C January 2025...

  • Page 19: Remove The Pail Follower Seal

    PVA-5GPU Manual Remove the Pail Follower Seal 1. If the ram is not fully seated, use the Unload function on the HMI to raise the ram full out of the pail. 2. Use the pick to remove the pail follower seal. Be careful not to damage the pail follower seal.

  • Page 20: Install The Pail Follower Seal

    PVA-5GPU Manual Install the Pail Follower Seal 1. Clean the pail follower seal thoroughly using isopropyl alcohol and wipes. Figure 16: Isopropyl Alcohol for Cleaning 2. Examine the pail follower seal for wear or damage and replace if necessary. 3. Clean the bottom groove of the ram thoroughly with cotton swabs and solvent.

  • Page 21: Figure 18: Silicon Grease For The Seal

    PVA-5GPU Manual 4. Apply silicon grease to the pail follower seal. Figure 18: Silicon Grease for the Seal Figure 19: Applying Grease to the Seal Page 21 of 47 Revision C January 2025...

  • Page 22: Figure 20: Installing The Pail Follower Seal

    PVA-5GPU Manual 5. Put the pail follower seal in the bottom groove. Figure 20: Installing the Pail Follower Seal 6. Ensure the pail follower seal is not twisted in the groove. Figure 21: Pail Follower Seal Installed Page 22 of 47...

  • Page 23: Figure 22: Apply Grease To The Pail Support Base

    PVA-5GPU Manual Load a Pail Warning: Doors must be closed at all times when operating the hydraulic ram. The hydraulic ram will not operate unless the doors are closed. Do not bypass the magnetic door interlocks or remove any guarding, the ram is under high pressure.

  • Page 24: Figure 23: Ensure There Is Grease In The Pail Support Groove

    PVA-5GPU Manual 8. Use a cotton tipped applicator to ensure there is grease in the pail support groove. Figure 23: Ensure There is Grease in the Pail Support Groove Note: The pail will be very difficult to remove if you do not grease the pail support base every time a pail is installed.

  • Page 25: Figure 25: Install The Clamp Door

    PVA-5GPU Manual 10. Close the pail clamp door, ensuring that it closes completely. 11. Install and tighten the three bolts in the pail clamp. Figure 25: Install the Clamp Door 12. Engage the pail clamps to face inward so the clamps will engage the pail edge.

  • Page 26: Figure 27: Lowering The Ram

    PVA-5GPU Manual 14. The ram should lower into the pail until it contacts the material and builds up to the process pressure setting. Refer to Section 5.3 to change the process pressure setting. Figure 27: Lowering the Ram 15. Select the Down arrow again to stop the ram. The ram will stop automatically when it reaches the load position.

  • Page 27: Ready Mode

    PVA-5GPU Manual Ready Mode 1. Select the F4 key to enter Ready Mode. 2. The pump will move the ram into the material and build the preset hydraulic pressure. 3. After that pressure is reached, the system will activate the ready bit to the PLC and dispensing can start.

  • Page 28: Jog

    PVA-5GPU Manual The ram can be raised or lowered manually with the Jog function. 1. Select F1 from the home screen to enter Jog Mode. Figure 29: Jog Mode 2. Press and F2 to Jog Up or F4 to Jog Down.

  • Page 29: Setup

    PVA-5GPU Manual Setup Press the F2 (gear key) to enter Setup Mode. Note: Press the F1 key to scroll left or the ESC key to scroll right through the setup screens. Setup - Material Levels The Material Levels screen allows you to set the vertical position of the ram where the Empty Level and Low Level signals will activate an output through the I/O cable to a PLC.

  • Page 30: Figure 32: Adjust Empty Level Setting

    PVA-5GPU Manual 1. To adjust either setting, press the percentage value marked in blue. Figure 32: Adjust Empty Level Setting 2. Once in the value adjust screen, use the keypad to enter a new value. Figure 33: Enter Value in Keypad...

  • Page 31: Setup - Pressure Modes

    PVA-5GPU Manual 3. Press the Enter key in the lower right corner to save that value and return to the previous screen. Note: The ESC key can be used to exit this screen without saving changes. Figure 34: Enter Key on Keypad Setup - Pressure Modes 1.

  • Page 32: Figure 36: Adjust Time Setting

    PVA-5GPU Manual 2. Press the Select Single Pressure Mode button to switch it to the ON position. In this mode, the pump system will always operate at one constant pressure which will be entered as a value in the Setup – Pressure Settings screen as Pressure 1.

  • Page 33: Figure 37: Adjust Pressure Timer (Keypad)

    PVA-5GPU Manual 5. Once in the value adjust screen use the keypad to enter a new value then press the Enter key in the lower right corner to save that value and return to the previous screen. Note: The ESC key can be used to exit this screen without saving changes.

  • Page 34: Setup - Pressure Settings

    PVA-5GPU Manual Setup – Pressure Settings 1. Press the ESC key to scroll to the right and enter Setup – Pressure Settings mode. Figure 38: Setup - Pressure Settings Screen 2. In this screen you can adjust the values for Pressure 1 and Pressure 2. To adjust the pressure settings, press either of the boxes with a PSI value.

  • Page 35: Setup - Load/Unload

    PVA-5GPU Manual Setup - Load/Unload 1. Press the ESC key to scroll to the right and enter the Setup – Load/Unload screen. 2. In this screen you can manually Jog Up the RAM up with the up arrow key (F2) or manually Jog Down with the down arrow key (F4).

  • Page 36: Maintenance Schedule

    PVA-5GPU Manual Maintenance Schedule Refer to the manual for Eaton/Vickers Hydraulic Power Unit for more information on troubleshooting, spare parts, maintenance, and specifications. Interval Action 1. Examine the pail follower seal for wear or damage. Replace as necessary. 2. Clean the side of the pail follower and the pail follower seals before loading a new pail.

  • Page 37: Spare Parts

    PVA-5GPU Manual Spare Parts Below is a listing of spare parts. Refer to the bill of materials and schematic for specific options on your pump. Contact PVA for more information on replacement parts or to place an order. Description Part Number...

  • Page 38: Drawings

    PVA-5GPU Manual Drawings PVA-5GPU Measurements Figure 43: PVA-5GPU Measurements (Front) Page 38 of 47 Revision C January 2025...

  • Page 39: Figure 44: Pva-5Gpu Measurements (Back)

    PVA-5GPU Manual Figure 44: PVA-5GPU Measurements (Back) Page 39 of 47 Revision C January 2025...

  • Page 40: Figure 45: Electrical Schematic 1

    PVA-5GPU Manual Electrical Schematic Figure 45: Electrical Schematic 1 Page 40 of 47 Revision C January 2025...

  • Page 41: Figure 46: Electrical Schematic 2

    PVA-5GPU Manual Figure 46: Electrical Schematic 2 Page 41 of 47 Revision C January 2025...

  • Page 42: Figure 47: Electrical Schematic 3

    PVA-5GPU Manual Figure 47: Electrical Schematic 3 Page 42 of 47 Revision C January 2025...

  • Page 43: Figure 48: Io Cable

    PVA-5GPU Manual IO Cable Figure 48: IO Cable Page 43 of 47 Revision C January 2025...

  • Page 44: Table Of Figures

    PVA-5GPU Manual Table of Figures Figure 1: Pump Overview ......................... 9 Figure 2: 5GPU Front Side ........................10 Figure 3: 5GPU Rear Side ........................11 Figure 4: HMI Overview, Home Screen Shown ................. 12 Figure 5: E-Stop Engaged ........................14 Figure 6: Disengage E-Stop ........................
  • Page 45 PVA-5GPU Manual Figure 41: Replacement Parts and Accessories ................37 Figure 42: Technical Specifications ....................37 Figure 43: PVA-5GPU Measurements (Front) ................. 38 Figure 44: PVA-5GPU Measurements (Back) .................. 39 Figure 45: Electrical Schematic 1 ....................... 40 Figure 46: Electrical Schematic 2 ....................... 41 Figure 47: Electrical Schematic 3 .......................

  • Page 46: Notes

    PVA-5GPU Manual Notes Page 46 of 47 Revision C January 2025...

  • Page 47: Warranty

    Unauthorized repair or modification of the enclosed product, and/or the use of spare parts not directly obtained from PVA (or from factory authorized dealers) will void all warranties.

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