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AeroJet Manual

This Document is to be used in Co-current with existing AeroJet Manual.

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Table of Content

1. Introduction

1.1. Parts List

1.1.1. Special Tools

1.1.2. AeroJet Head Parts

2. Maintenance

2.1. Assembly of AeroJet Head

2.2. Disassembly of AeroJet Head

2.3. Spare Parts List and Lifespan

3. Operation

3.1. Installation of Material

3.2. Fine-tuning of Parameters

3.2.1. Syringe Air Pressure

3.2.2. AeroJet Head Inlet Air Pressure

3.2.3. On Time

3.2.4. Off Time

3.2.5. Stroke

3.2.6. Nozzle Type

3.2.7. Valve Seat Type

3.2.8. Rod Type

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1. Introduction

This manual is to serve as a guide in the maintenance of our company’s AeroJet

System for accurate dispensing.

1.1 Parts List

1.1.1 Special Tools

1 3

2
6

1. Wetted Section Mounting/Removing Jig

2. Valve Seat Mounting/Removing Jig

3. Seal Insertion Jig

4. Seal Removing Jig

5. Torque Spanner

6. M3 Size Allen Key

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1.1.2 AeroJet Head Parts

5
6

2 3 4

9 7

12 8
11 10

1. Nozzle Cap

2. Nozzle

3. Valve Seat

4. Seal Holder

5. Syringe Joint

6. Joint Block

7. Main Unit of Wetted Section

8. Rod Seat (Both Male and Female parts)

9. Joint Packing (2 Pcs)

10. Bubble Removing Bolt with Packing

11. M3 x L25 Bolts (2 Pcs)

12. M3 x L15 Bolts (2 Pcs)

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2. Maintenance

In this section, step by step instructions and illustrations will guide you through the
process of maintaining the AeroJet Head in good condition.

2.1 Assembly of AeroJet Head

For the first step, we would require these few items. 1. Seal insertion jig, 2. Rod Seal,
3. Main body of Wetted Section.

First, place the female part (Translucent) onto the Seal Insertion rod with the groove
edge facing up. Next is to fix the male part (Black) onto the female part, with the
tapered edge inserted into the groove section. After that, put the Seal Insertion guide
cap onto the assembly. Each step should look like the 3 images as shown above.
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Mount the body of the Wetted Section onto the Mounting/Removing Jig. Place the
Seal Insertion Jig assembly onto the body as shown above on the left. Press down on
the rod section until you hear a “click” sound. Remove the Seal Insertion Jig and you
would see that the Rod Seal has been installed correctly as shown above on the right.
There should not be any edges that is protruding out and is a nice flat fit.

Next is to assemble the head of the AeroJet unit. In addition to the assembly that we
did previously, we would require these items: 1. Joint Packing x 2, 2. Joint Block, 3.
Syringe Joint with Bubble Removing Bolt.
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First, place the joint packing into both the main body of the Wetted Section and the
Syringe Joint as shown in the image above on the left. Next, assemble the main body,
the Joint Block and the Syringe Joint together. There is a guide pin on both sides of
the Joint Block that would help indicate the orientation of the assembled block. This
is shown in the image above on the right.

After assembling the 3 pieces together, secure it all together using the M3xL25 bolts.
Install the Bubble Removing Bolt too. The assembly would look like the image as
shown above.
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Now we are to assemble the Wetted Section assembly with the Solenoid Valve
assembly. As with the image above on the right, place the Seal Holder into the Wetted
Section assembly as shown.

Place the Solenoid Valve onto the Mounting/Removing Jig as shown in the images
above. Make sure that the micrometer securing knob is facing in a downwards
direction. Place the Wetted Section assembly onto the jig, and slowly slide it towards
the Solenoid Valve and make sure that it is a smooth fitting. Next, secure the Wetted
Section assembly and the Solenoid Valve together using the M3xL15 bolts. Do this
while the whole assembly is still on the jig, as this is to ensure that the assembly is in
a straight orientation and also to prevent any possible damage to the protruded rod.
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Once the Wetted Section and the Solenoid Valve is assembled, we can install the
Valve Seat and Nozzle onto the assembly. First, we need to ensure that the
micrometer setting is more than 3.0mm. This step is VERY IMPORTANT and
must not be overlooked, as improper installation could cause damage to the Rod and
Valve Seat, which in turn would affect the consistency and dispensing accuracy of the
entire system.

Once making sure the micrometer setting is more than 3.0mm, we can proceed to
install the Valve Seat. With the flat side facing out, gently place the Valve Seat into
the groove and it should just fit into the groove nicely. Do not force the Valve Seat
into place as it could damage it. If it does not fit nicely, remove it and try again till it
is installed. When installed, it should look like the image above on the right, which no
protruding edge and a clean finish.
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Next, place the Nozzle on top of the Valve Seat, then secure it together using the
Nozzle Cap as shown in the 2 images above. Tighten the Nozzle Cap using the
Torque Spanner with a torque of approximately 2.5 Nm.

Once done, assembly of the AeroJet Head is now completed.

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2.2 Disassembly of AeroJet Head

Disassembly of the AeroJet Head is very much similar to the assembly except that it
is carried out in reversed. However, there are certain steps that are different which
would be illustrated under this section.

Removal of the Nozzle Cap and Nozzle is the same as the assembling part, and in
addition the importance of making sure that the micrometer setting is more than
3.0mm to prevent any damage to the Rod and the Valve Sheet. Once the Nozzle Cap
and Nozzle is removed, make use of the Valve Seat Mounting/Removing Jig
(Tweezers) and pick up the Valve Seat through the gap openings on the Wetted
Section body. Once removed, disassemble the unit as per the assembly steps.

In order to assist in the removal of the Joint Packing from the Main Body and Syringe
Joint, we would make use of the Seal Removing Jig as shown in the image above on
the right
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In order to remove the Rod Seal (both male and female parts), we would make use of
the Seal Removing Jig and the Wetted Section Mounting/Removing Jig. We first
place the Seal Removing Jig into the Mounting/Removing Jig as shown in the above
image to the left. Next, we insert the Main Body of the Wetted Section onto the rod,
and we proceed to press it down until the Rod Seal comes out, as shown in the above
image to the right.

However, should the material being used is the same, it is actually not necessary to
remove the Rod Seal, as constant removal and installation could damage the Rod Seal
that would result in possible leakage within the entire assembly during operation.
Only remove and clean the Rod Seal if a different material is being used.
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2.3 Spare Parts List

Below is a list of spares that would be required for the regular maintenance of the
AeroJet system and their expected lifespans.

Part Name Symptoms Replacement Guide

Rod Seal  Liquid sealing cannot 20 – 30 million shots

MJET-A-RS be achieved.
Joint Packing  Liquid Leaks 10 - 15 times
MJET-2T1-JP disassembly and
cleaning or Period of
use of 2 – 3 weeks.
Valve Seat  Target amount cannot 100 – 200 million shots
MJET-2T1-VS_ be adjusted
 Liquid leaks from
Nozzle tip
 Low dispensing
stability
Nozzle  Target amount cannot 100 – 200 million shots
SNJ21-__G-_L be adjusted.
SNJ21-__G-SHN  Clogged with liquid
material
 Needle tip is damaged
or bent

For other parts that are required to be replaced, please contact your distributor or
approach Musashi Engineering personnel for assistance.
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3. Operation

This section serves to educate on how to carry out the filling of material and operation
of the JETMASTER 3 dispenser to work with the AeroJet system.

Before going into the detailed operation instructions, some introduction to the
dispenser settings and functions would be talked about here.

On the dispenser, there are a couple of parameter settings

that we can modify to suit various dispensing. On the top
left image under AIR PRESS., we have the Air Pressure
setting for the inlet air to the syringe. This is to push the
material into the AeroJet body.
To the top right under the COUNT/TIME, we can modify
the number of counts of dispensing, or to dispense up to a
preset time range.
Lastly to the left under ON TIME and OFF TIME, we can
control the dispensing time and interval between each shot
using the On / Off Time setting.
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When the dispenser is turned on, both

LINE/DOT and MAN/SET buttons
would be lighted.
To carry out Line dispensing, both
buttons would be lighted.
To carry out Dot dispensing (1 or
multiple dots), only LINE/DOT
button would be lighted.
To carry out purging of AeroJet body
via opening the valve, only
MAN/SET button would be lighted.
By pressing the SHOT button we
would open up the internal valve and
allow material to be purged via the
nozzle.

Air Outlet

Air Inlet

Before we start, we must ensure that the air

connections (Top: Air Outlet, Bottom: Air
Inlet), Temperature Controller Cable
(Optional) and the Solenoid Valve
Controller Cable are all properly connected.
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3.1 Installation of Material

After preparing the material, load the syringe onto the AeroJet body via the Syringe
Joint and secure it tight. Make sure that the Air Pressure is set to 0 kPa before
attaching the adaptor tube to the syringe and connecting it to the dispenser. As the
airflow from the dispenser is free-flowing, if the air pressure is anything more than 0
kPa, there will be pressure flowing and it would start pushing the liquid.

Next step is to slowly fill the AeroJet head with the material without allowing a build-
up of air within the body that could cause problems with the dispensing later. Before
starting, make sure that air pressure is set to 0 and MAN/SET button light is the only
one lid up. Now, press down the SHOT button, and very slowly turn the air pressure
knob to increase the air pressure. Eventually, material would be seen coming out from
the nozzle tip area. The body is now fully filled with the material.
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For low viscosity materials, the amount of pressure should not be required to go
beyond 10 kPa. However for high viscosity materials, air pressure required to push
the material could go as high as 150 kPa. Try to keep the air pressure to allow
material flow to as low a value as possible so as to prevent any air pockets to be
trapped inside the body.

3.2 Fine-tuning of Parameters

Fine-tuning for the AeroJet system has many different variables that could be used.
They are listed as follows:

i. Syringe Air Pressure

ii. AeroJet Head Inlet Air Pressure
iii. On Time
iv. Off Time
v. Stroke
vi. Nozzle Type
vii. Valve Seat Type
viii. Rod Type

As one would notice, there are too many variables that could be involved in the fine-
tuning of the dispensing. Depending on experience, different engineers would fine-
tune using different parameters. For this manual, it would only go into the information
on what happens when changing each particular parameter, as in only used as a guide.
For further enquiry please approach the respective distributor’s engineers or Musashi
Engineering engineers.

3.2.1 Syringe Air Pressure

Increase in air pressure would increase amount of material flow into the body and
in turn increase amount of material being dispensed. Decreasing it would have the
reversed effect of decreasing volume.

3.2.2 AeroJet Head Inlet Air Pressure

Standard operating pressure for the head inlet valve that controls the solenoid is
set to 450 kPa. However depending on situation, this valve may be changed.
However advice from Musashi Engineering engineers should be seek first before
doing so.
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3.2.3 On Time

On Time is the time setting that controls the duration that the jetter valve is kept
open to allow material flow to be dispensed. Increasing it would increase amount
of material dispensed, while decreasing it would have the opposite effect.

3.2.4 Off Time

Off Time is the time setting that controls the duration of the interval between each
dispensing shot. This is mainly use in applications where multiple shots on the
same spot is required, and to control the time delay interval between shots when
executing a line drawing.

3.2.5 Stroke

Stroke is the setting for the distance that the rod travels within the jetter head
when given the command to open the valve. The bigger the stroke the more
material is allowed to flow through. On the micrometer, every full rotation is
0.5mm. Settings can be between 0.1mm to 3.0mm.

3.2.6 Nozzle Type

There are many nozzle types available for AeroJet dispensing that comes in
different sizes and design for different application. Please approach Musashi
Engineering engineers for support.

3.2.7 Valve Seat Type

Various types of Valve Seats are also available, and are used co-current with the
nozzles to allow indefinite numbers of configuration. Stability of the dispensing is
usually associated with the Valve Seat selection. Please approach Musashi
Engineering engineers for support.

3.2.8 Rod Type

There are a total of 3 types of Rod that could be used for the AeroJet system, S, M
and L rods. Different rod provides different amount of pushing force when jetting
the material. Please approach Musashi Engineering engineers for support on
which rod is most suitable for your application.