DuraDrum Bulk Melters DD200

Transcription

1 DuraDrum Bulk Melters Manual English Issued 11/07 NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

2 Note This manual applies to the entire series. Order number P/N = Order number for Nordson products Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice All rights reserved. Trademarks AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, icontrol, iflow, Isocoil, Isocore, Iso-Flo, itrax, JR, KB30, Kinetix, Little Squirt, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure-Max, Tela-Therm, Tracking Plus, Trends, Tribomatic, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, BetterBook, Blue Series, CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail, E-Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G-Net, G-Site, HDLV, Ink-Dot, ion, Iso-Flex, itrend, KVLP, Lacquer Cure, Lean Cell, Logicomm, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, Minimeter, Multifil, Myritex, OptiStroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Viper, Vista, VersaDrum, VersaPail, WebCure, 2 Rings (Design) are trademarks of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners rights.

3 Table of Contents I Table of Contents Nordson International O-1 Europe O-1 Distributors in Eastern & Southern Europe O-1 Outside Europe / Hors d Europe / Fuera de Europa O-2 Africa / Middle East O-2 Asia / Australia / Latin America O-2 Japan O-2 North America O-2 Safety Safety Alert Symbols Responsibilities of the Equipment Owner Safety Information Instructions, Requirements, and Standards User Qualifications Applicable Industry Safety Practices Intended Use of the Equipment Instructions and Safety Messages Installation Practices Operating Practices Maintenance and Repair Practices Equipment Safety Information Equipment Shutdown Relieving System Hydraulic Pressure De-energizing the System Disabling the Guns General Safety Warnings and Cautions Other Safety Precautions First Aid

4 II Table of Contents Introduction Intended Use Unintended Use Examples Area of Use Residual Risks Definition of Term(s) Note on Manual ID Plate Description Electrical Cabinet Button Two-hand Control and Selector Raise/Lower Platen 2-6 Main Switch Fan with Filter Door Lock Control Panel Platen Melting Plates Exhaust Hood (Accessory) Light Tower (Accessory) High Drum Jacket for Cardboard Drums (Accessory) Function Raising and Lowering Platen Deaerating Drum Aerating Drum Melting Process and Material Flow Heating and Temperature Control Undertemperature Interlock Undertemperature Indication Overtemperature Indication / Shutdown Standby Modes Normal Mode Standby Setup Fault

5 Table of Contents III Installation Unpacking Lifting (Unpacked System) Lifting with a Crane Transport Storage Mounting the System Exhausting Material Vapors Electrical Connections Observe when Using Residual Current Circuit Breakers Laying Cable Line Voltage Power Supply External Control and Switching Circuits Hose Receptacles Assembly Handgun Operation Additional Hose Receptacles Installing Hoses Second Open-jawed Wrench Connecting Disconnecting Relieving Pressure Connecting and Adjusting Compressed Air Pneumatic Cylinder Working Pressure Pressure Controller Up Compressed Air for Aerating Drum Adapting the System to the Drum Used Limiting How Far the Platen is Lowered Speed Setpoint and Output Quantity Overtravel Time When Drum Empty Setting Overtravel Time Installing System Inputs Setting up an Input Installing System Outputs Setting up an Output Setting up Communication Setting up the Bulk Melter Quick Setup Operating Parameters Selecting Operating Parameters Reading or Editing Operating Parameters Setpoint Temperature of the Platen, Hoses and Guns Save and Restore Settings Review Parameter and Setpoint Temperature Changes Accessories Light Tower Installing Kit Exhaust Hood High Drum Jacket for Cardboard Drums Timer Relay Overtravel Time Installing the Timer Relay Initial Startup Detaching Disposing

6 IV Table of Contents Operation Initial Startup Heated Components Pump Starting the Bulk Melter To Start the System Monitoring the System Confirm that the System is Operating Correctly Drum Empty LED Monitor Component Temperatures To Check Component Temperatures Using the Normal Mode To Manually Check a Component s Temperature Monitoring Faults F1, F2 and F3 Faults F4 Fault Resetting System Fault Log Monitoring the Service Interval To Reset the Service LED Adjusting Component Temperatures Recommended Temperatures To Adjust the Setpoint Temperature Using the Global Method To Adjust the Setpoint Temperature Using the Global-by-component Method To Adjust the Setpoint Temperature of an Individual Component Enter Password Function Keys Heater Key Pump Key Setup Key Seven-day Clock Key Standby Key Inserting and Replacing Drum Raising Platen Lowering Platen Principle Wiring Diagrams Raising/Lowering Platen Motor Enable LED in Selector Raise/Lower Platen Switching System ON/OFF Daily Startup Daily Switchoff Switching Off in an Emergency Settings Record

7 Table of Contents V Maintenance Risk of Burns Relieving Pressure Important when Using Cleaning Agents Processing Materials Preventive Maintenance External Cleaning Visual Inspection for External Damage Changing Type of Material Purging with Cleaning Agent Cleaning Melting Plate Fan and Air Filter Safety Valve Activating the Piston Pump Checking for Leakage Tightening Gland Bolt Tightening Fixing Screws Motor / Gear Box Changing Lubricant Lubricant Selection Compressed Air Filter Draining Condensate Cleaning Filter Element Pressure Restrictor Valve Checking Function Pressure Restrictor Valve for Aerating Drum Pressure Restrictor Valve at Compressed Air Connection Cleaning Maintenance Record Form Troubleshooting Some Tips Light Tower (Accessory) Troubleshooting Tables Fault Codes System does not Function One Channel (Heating Zone) does not Heat Control Panel does not Function No Material (Motor does not Rotate) No Material (Motor Rotating) Too Little Material Material Pressure too High Material Pressure too Low Others LEDs of Motor Controller

8 VI Table of Contents Repair General Notes Replacing Sealing Ring Replacing O-rings Replacing Platen Temperature Sensor and Thermostat Identifying Installed Thermostat Replacing Control Panel Installing Service Kit Parts How to Use Illustrated Parts List Fasteners Component Designation Technical Data General Data Electrical Data Motors / Speed Output Quantity Temperatures and Thermostats Identifying Installed Thermostat Material Pressures Dimensions Weight Air Consumption Exhaust Hood (Accessory) General Instructions Regarding Working with Application Materials A-1 Definition of Terms A-1 Manufacturer Information A-1 Liability A-1 Risk of Burns A-2 Vapors and Gases A-2 Substrate A-2 Processing Temperature A-2 Operating Parameters B-1 Standard B-2 Temperature Control B-7 Input Setup B-11 Output Setup B-14 Seven-day clock B-15 To Set the Clock B-15 Example B-16 Example B-16 Example B-16 PID Selection B-22 Glossary C-1

9 Introduction O-1 Nordson International Europe Country Phone Fax Austria Belgium Czech Republic Denmark Hot Melt Finishing Finland France Germany Erkrath Lüneburg Nordson UV EFD Italy Netherlands Norway Hot Melt Poland Portugal Russia Slovak Republic Spain Sweden Switzerland United Kingdom Hot Melt Finishing Nordson UV Distributors in Eastern & Southern Europe DED, Germany All rights reserved NI_EN_M-0307

10 O-2 Introduction Outside Europe / Hors d Europe / Fuera de Europa For your nearest Nordson office outside Europe, contact the Nordson offices below for detailed information. Pour toutes informations sur représentations de Nordson dans votre pays, veuillez contacter l un de bureaux ci-dessous. Para obtener la dirección de la oficina correspondiente, por favor diríjase a unas de las oficinas principales que siguen abajo. Contact Nordson Phone Fax Africa / Middle East DED, Germany Asia / Australia / Latin America Pacific South Division, USA Japan North America Japan Canada USA Hot Melt Finishing Nordson UV NI_EN_M 0307 All rights reserved

11 Safety 1-1 Section 1 Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as use ) of the product described in this document (hereafter referred to as equipment ). Additional safety information, in the form of task-specific safety alert messages, appears as appropriate throughout this document. WARNING: Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property. Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all safety information that follows the signal word. WARNING: Indicates a potentially hazardous situation that, if not avoided, can result in serious personal injury, including death. CAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION: (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property Nordson Corporation A1EN 01 [XX SAFE] 10

12 1-2 Safety Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment are met, and for qualifying all potential users. Safety Information Research and evaluate safety information from all applicable sources, including the owner-specific safety policy, best industry practices, governing regulations, material manufacturer s product information, and this document. Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information. Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices. If applicable, receive approval from your facility s engineering or safety department, or other similar function within your organization, before installing or operating the equipment for the first time. Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re-evaluate safety practices and procedures whenever changes are made to the process or equipment. A1EN 01 [XX SAFE] Nordson Corporation

13 Safety 1-3 User Qualifications Equipment owners are responsible for ensuring that users: Receive safety training appropriate to their job function as directed by governing regulations and best industry practices Are familiar with the equipment owner s safety and accident prevention policies and procedures Receive, equipment- and task-specific training from another qualified individual NOTE: Nordson can provide equipment-specific installation, operation, and maintenance training. Contact your Nordson representative for information Possess industry- and trade-specific skills and a level of experience appropriate to their job function Are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities 2006 Nordson Corporation A1EN 01 [XX SAFE] 10

14 1-4 Safety Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in the manner described in this document. The information provided here is not meant to include all possible safety practices, but represents the best safety practices for equipment of similar hazard potential used in similar industries. Intended Use of the Equipment Instructions and Safety Messages Use the equipment only for the purposes described and within the limits specified in this document. Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non-standard auxiliary devices. Read and follow the instructions provided in this document and other referenced documents. Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags (if available) at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. A1EN 01 [XX SAFE] Nordson Corporation

15 Safety 1-5 Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices. Ensure that the equipment is rated for the environment in which it will be used and that the processing characteristics of the material will not create a hazardous environment. Refer to the Material Safety Data Sheet (MSDS) for the material. If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance. Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects. Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources. Properly ground all equipment. Contact your local building code enforcement agency for specific requirements. Ensure that fuses of the correct type and rating are installed in fused equipment. Contact the authority having jurisdiction to determine the requirement for installation permits or inspections. Operating Practices Familiarize yourself with the location and operation of all safety devices and indicators. Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist. Use the personal protective equipment (PPE) specified for each task. Refer to Equipment Safety Information or the material manufacturer s instructions and MSDS for PPE requirements. Do not use equipment that is malfunctioning or shows signs of a potential malfunction Nordson Corporation A1EN 01 [XX SAFE] 10

16 1-6 Safety Maintenance and Repair Practices Perform scheduled maintenance activities at the intervals described in this document. Relieve system hydraulic and pneumatic pressure before servicing the equipment. De-energize the equipment and all auxiliary devices before servicing the equipment. Use only new or factory-authorized refurbished replacement parts. Read and comply with the manufacturer s instructions and the MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation. Dispose of waste cleaning compounds and residual process materials according to governing regulations. Refer to the applicable MSDS or contact the authority having jurisdiction for information. Keep equipment safety warning labels clean. Replace worn or damaged labels. A1EN 01 [XX SAFE] Nordson Corporation

17 Safety 1-7 Equipment Safety Information This equipment safety information is applicable to the following types of Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices Equipment Shutdown To safely complete many of the procedures described in this document, the equipment must first be shut down. The level of shut down required varies by the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure. The levels of shut down are: Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal. Refer to the melter-specific product manual for instructions on relieving system hydraulic pressure. De-energizing the System Isolate the system (melter, hoses, guns, and optional devices) from all power sources before accessing any unprotected high-voltage wiring or connection point. 1. Turn off the equipment and all auxiliary devices connected to the equipment (system). 2. To prevent the equipment from being accidentally energized, lock and tag the disconnect switch(es) or circuit breaker(s) that provide input electrical power to the equipment and optional devices. NOTE: Government regulations and industry standards dictate specific requirements for the isolation of hazardous energy sources. Refer to the appropriate regulation or standard Nordson Corporation A1EN 01 [XX SAFE] 10

18 1-8 Safety Disabling the Guns All electrical or mechanical devices that provide an activation signal to the guns, gun solenoid valve(s), or the melter pump must be disabled before work can be performed on or around a gun that is connected to a pressurized system. 1. Turn off or disconnect the gun triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the gun solenoid valve(s). 3. Reduce the air pressure to the gun solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the gun. A1EN 01 [XX SAFE] Nordson Corporation

19 Safety 1-9 General Safety Warnings and Cautions Table 1-1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual. Equipment types are designated in Table 1-1 as follows: HM = Hot melt (melters, hoses, guns, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and guns) Equipment Type HM Table 1-1 General Safety Warnings and Cautions Warning or Caution WARNING: Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent-based material through a compatible Nordson melter, read and comply with the material s MSDS. Ensure that the material s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with MSDS requirements can cause personal injury, including death. HM WARNING: Reactive material! Never clean any aluminum component or flush Nordson equipment with halogenated hydrocarbon fluids. Nordson melters and guns contain aluminum components that may react violently with halogenated hydrocarbons. The use of halogenated hydrocarbon compounds in Nordson equipment can cause personal injury, including death. HM, CA WARNING: System pressurized! Relieve system hydraulic pressure before breaking any hydraulic connection or seal. Failure to relieve the system hydraulic pressure can result in the uncontrolled release of hot melt or cold adhesive, causing personal injury. HM WARNING: Molten material! Wear eye or face protection, clothing that protects exposed skin, and heat-protective gloves when servicing equipment that contains molten hot melt. Even when solidified, hot melt can still cause burns. Failure to wear appropriate personal protective equipment can result in personal injury. Continued Nordson Corporation A1EN 01 [XX SAFE] 10

20 1-10 Safety General Safety Warnings and Cautions (contd) Table 1-1 General Safety Warnings and Cautions (contd) Equipment Type HM, PC Warning or Caution WARNING: Equipment starts automatically! Remote triggering devices are used to control automatic hot melt guns. Before working on or near an operating gun, disable the gun s triggering device and remove the air supply to the gun s solenoid valve(s). Failure to disable the gun s triggering device and remove the supply of air to the solenoid valve(s) can result in personal injury. HM, CA, PC WARNING: Risk of electrocution! Even when switched off and electrically isolated at the disconnect switch or circuit breaker, the equipment may still be connected to energized auxiliary devices. De-energize and electrically isolate all auxiliary devices before servicing the equipment. Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injury, including death. HM, CA, PC WARNING: Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and should not be used with solvent-based adhesives that can create an explosive atmosphere when processed. Refer to the MSDS for the adhesive to determine its processing characteristics and limitations. The use of incompatible solvent-based adhesives or the improper processing of solvent-based adhesives can result in personal injury, including death. HM, CA, PC WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others and can damage the equipment. Continued... A1EN 01 [XX SAFE] Nordson Corporation

21 Safety 1-11 Equipment Type HM Warning or Caution CAUTION: Hot surfaces! Avoid contact with the hot metal surfaces of guns, hoses, and certain components of the melter. If contact can not be avoided, wear heat-protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. HM CAUTION: Some Nordson melters are specifically designed to process polyurethane reactive (PUR) hot melt. Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipment and cause premature reaction of the hot melt. If you are unsure of the equipment s ability to process PUR, contact your Nordson representative for assistance. HM, CA CAUTION: Before using any cleaning or flushing compound on or in the equipment, read and comply with the manufacturer s instructions and the MSDS supplied with the compound. Some cleaning compounds can react unpredictably with hot melt or cold adhesive, resulting in damage to the equipment. HM CAUTION: Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment. Before using the equipment, confirm that the hot melt is compatible with Type R fluid Nordson Corporation A1EN 01 [XX SAFE] 10

22 1-12 Safety Other Safety Precautions Do not use an open flame to heat hot melt system components. Check high pressure hoses daily for signs of excessive wear, damage, or leaks. Never point a dispensing handgun at yourself or others. Suspend dispensing handguns by their proper suspension point. First Aid If molten hot melt comes in contact with your skin: 1. Do NOT attempt to remove the molten hot melt from your skin. 2. Immediately soak the affected area in clean, cold water until the hot melt has cooled. 3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medical personnel providing treatment. A1EN 01 [XX SAFE] Nordson Corporation

23 Introduction 2-1 Section 2 Introduction Intended Use Bulk melters of the series DuraDrum hereafter also referred to as system may only be used to melt and feed suitable materials. When in doubt, seek permission from Nordson. CAUTION: Only undamaged and suitable drums may be used (Refer to Technical Data). CAUTION: PUR material may be processed only in models with exhaust hood (accessory)! Any other use is considered to be unintended. Nordson will not be liable for personal injury or property damage resulting from unintended use. Intended use includes the observance of Nordson safety instructions. Nordson recommends obtaining detailed information on the materials to be used. Unintended Use Examples The systems may not be used under the following conditions: In defective condition With electrical cabinet door open In a potentially explosive atmosphere With unsuitable operating/processing materials When safety valves and pressure restrictor valves are not lead-sealed When the values stated under Technical Data are not complied with. The systems may not be used to process the following materials: Explosive and flammable materials Erosive and corrosive materials Food products.

24 2-2 Introduction Area of Use The system is designed for use in industrial areas. When using in industrial areas and in small businesses, the system may cause interference in other electrical units, e.g. radios. Residual Risks In the design of the system, every measure was taken to protect personnel from potential danger. However, some residual risks can not be avoided. Personnel should be aware of the following: Risk of burns from hot material Risk of burns from hot system components Risk of burns when conducting maintenance and repair work for which the system must be heated up Risk of burns when attaching and removing heated hoses Material fumes can be hazardous. Avoid inhalation Risk of pinching parts of the body between platen and drum or drum jacket / bracket. The safety valve may malfunction due to hardened or charred material. Definition of Term(s) The safety valve is also referred to as bypass and bypass valve in Nordson literature. Note on Manual This manual is valid only in conjunction with all documents included in the complete set of documentation (blue binder) When the system has special features, customer specifications and/or supplements or a higher-ranking system description may be added to this manual The position numbers in the illustrations do not correspond to the position numbers in the technical drawings and parts lists. Refer to separate document Parts List for details.

25 Introduction 2-3 ID Plate DuraDrum Serial No: 5 Year Nordson Engineering GmbH Lilienthalstr. 6 D Lüneburg Germany Fig Bulk melter designation 2 Order number 3 4 Electrical connection, operating voltage, line voltage frequency, bulk melter fuse protection 5 Serial number

26 2-4 Introduction Description Fig. 2-2 Operating side 1 Electrical cabinet 2 Drum aeration (tube and hose) 3 Pressure controller Pneumatic cylinder 4 Drum jacket 5 Safety valve 6 Pump / Adapter plate 7 Drum deaeration 8 Drum aeration (rod) 9 Hose connection 10 Pneumatic cylinder 11 Motor 12 Hose holder

27 Introduction Fig. 2-3 Back 1 Cable gland Power supply 2 Compressed air connection 3 Additional hose receptacles 4 Pressure controller Aerating drum 5 Hose receptacles (XS10, XS11) 6 Receptacles Assembly handgun (XS18, XS19) 7 Bracket

28 2-6 Introduction Electrical Cabinet Fig Button Two-hand control 3 Selector Raise/lower platen 4 Main switch 5 Air filter / Fan with filter 6 Door lock 7 Control panel Button Two-hand Control and Selector Raise/Lower Platen Used to raise and lower the platen. WARNING: The two-hand control may only be operated by one person using both hands!

29 Introduction 2-7 Main Switch The main switch is used to switch the system on and off. Position 0/OFF = System is switched off. Position I/ON = System is switched on. Padlocks can be used to protect the main switch from being turned on by unauthorized personnel. Fan with Filter The fan reduces the temperature inside of the electrical cabinet. The filter must be serviced regularly. Refer to Maintenance. Door Lock The electrical cabinet can be opened for installation, maintenance and repair. Store the included key such that it is accessible only to qualified and authorized personnel. The system may not be operated when the electrical cabinet is open. Control Panel Fig. 2-5 Control panel 1 Fault LED 2 Ready LED 3 Component keys / LEDs 4 Keypad 5 Serial interface 6 Right display and scroll keys 7 Drum empty LED 8 Left display and scroll key 9 Function keys 10 Service LED

30 2-8 Introduction Platen The platen consists of a heating punch, a melting plate and sealing rings. NOTE: Models for cardboard drums have only the lower sealing ring on the platen Fig Heating punch 2 Sealing rings 3 Melting plate Melting Plates Depending on what the bulk melter is used for, one of these melting plates is used. The melting plates are all release coated. Fig. 2-7 Smooth melting plate Fine blade melting plate Axial melting plate

31 Introduction 2-9 Exhaust Hood (Accessory) If the system is used to process polyurethane hot melt adhesives (PUR), fumes are created that should be suctioned off directly at the drum. An exhaust hood is attached to the bulk melter for this purpose. The exhaust hood must be connected to the customer s exhaust device (Also refer to Installation, Exhausting Material Vapors and Technical Data). Light Tower (Accessory) The light tower shows the system operating modes. White Green Yellow Red Switched on Ready for operation Drum empty General alarm Also refer to Troubleshooting and Installation. High Drum Jacket for Cardboard Drums (Accessory) CAUTION: Do not use metal drums with this model! The drum jacket is desgned only for cardboard drums! NOTE: Models for cardboard drums have only the lower sealing ring on the platen.

32 2-10 Introduction Function Raising and Lowering Platen The pneumatic cylinders raise and lower the platen. When lowering the platen, a two-hand control must be operated for safety reasons until the platen is in the drum. The air pressure in the pneumatic cylinders is limited to 7.5 bar (0.75 MPa / psi) by a pressure restrictor valve. 1 Deaerating Drum For the air to be able to escape as the platen is lowered into the drum, the drum deaeration valve must be opened with the lever (1). Also refer to section Operation, Lowering Platen. Aerating Drum To prevent a vacuum from forming with the platen is lifted out of the drum, the drum must be aerated. Refer to section Operation, Raising Platen. The air pressure in the drum is limited to 1.0 bar by a pressure restrictor valve. Air Platen Platen Compressed air Drum Drum Fig. 2-8 Deaerating Aerating

33 Introduction 2-11 Melting Process and Material Flow The material is melted only directly below the melting plate (4). A gear pump (1) feeds the melted material to the hose connection (3). From there it flows through a heated hose to a gun or an assembly handgun, possibly to a melter, to fill that unit. A safety valve (2) limits the material pressure generated by the pump and keeps it constant Fig. 2-9 Prinziple drawing

34 2-12 Introduction Heating and Temperature Control The platen is heated by cast-in heating elements. Temperatures are measured by sensors and electronically controlled. Undertemperature Interlock The undertemperature interlock prevents the system from being started up before the material has exceeded the temperature setpoint minus undertemperature value. However, every time initial heating occurs, the interlock is not released until the actual temperature is 3 C (5.4 F) below the temperature setpoint. The undertemperature interlock locks the motor, solenoid valves and, in some cases, other components of the application system. Refer to the wiring diagram to determine which components are locked. Undertemperature Indication If during operation the actual temperature falls below the setpoint minus the undertemperature value, the relay output General alarm switches and the fault LED lights up on the control panel (Refer to Fig. 2-5). The system continues to operate despite the fault. Overtemperature Indication / Shutdown The independently operating overtemperature shutdown mechanisms protect the system and the material from overheating. For overtemperature shutdown, the heater and motor are switched off. Overtemperature indication through temperature controller: When the temperature setpoint plus overtemperature value has been reached, the relay output General alarm is switched and the fault LED lights up on the control panel. The system continues to operate or remains ready despite the fault. Overtemperature shutdown by temperature controller: The temperature controller switches the heater off if the temperature is more than 30 C above the highest temperature setpoint. Overtemperature shutdown by thermostat(s): Serves as an emergency switch OFF in case the overtemperature shutdown of the temperature controller does not function properly. Refer to section Technical Data for shutdown value. WARNING: When the overtemperature shutdown is triggered, there is either a fault in settings or system malfunction. Switch off the system and have the fault remedied by qualified personnel. Standby Serves to protect the material and save energy during interruptions in production or work stoppages. Standby value and standby period are adjustable.

35 Introduction 2-13 Modes DuraDrum bulk melters operate in the following modes: Normal Mode When the system is first switched on, it is in normal mode. In normal mode the system checks the current temperature of the platen, the hoses and the guns to verify that they are within the set temperature ranges. Standby The temperatures of the platen, the hoses and the guns are lowered from their operating temperature (hereafter referred to as setpoint temperature) by a set number of degrees. Setup Setup mode (configuration) is used to configure the control options and features of the system as well as to check the saved operating data. The system is protected by password from unauthorized changes to the configuration. Fault The system alerts the user when a fault occurs, e.g. a sensor fault (RTD) or a temperature that is not within the permitted range.

36 2-14 Introduction

37 Installation 3-1 Section 3 Installation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Unpacking Unpack carefully and check for damage caused during transport. Save pallet and fastening and packing material for later use, or dispose of properly according to local regulations. Lifting (Unpacked System) Refer to Technical Data for weight. Lift only with a suitable floor conveyor (lift truck or fork lift) or a crane. Lifting with a Crane There are four eye bolts in the base plate of the bulk melter. CAUTION: Guide the ropes such that they do not damage the bulk melter. Transport Refer to Technical Data for weight. Use only suitable transport devices. If possible, use the pallet on which the system was delivered, and fasten the system to the pallet. Protect from damage, moisture and dust with suitable packing material. Avoid jolts and vibrations.

38 3-2 Installation Storage Do not store system outside! Protect from humidity, dust and extreme temperature fluctuations (formation of condensation). Mounting the System Mount only in an environment that corresponds to the stated Degree of Protection (Refer to Technical Data). Do not mount in a potentially explosive atmosphere! Protect from vibration. Remove transport protection (if present). Ensure that there is sufficient clearance around the system, especially above it. Refer to Technical Data for dimensions. Fig. 3-1

39 Installation 3-3 Exhausting Material Vapors Ensure that material vapors do not exceed the prescribed limits. Always observe the safety data sheet for the material to be processed. If necessary, exhaust material vapors and/or provide sufficient ventilation of the location of the system. On systems with exhaust hoods, material vapors are suctioned off directly at the drum. NOTE: The exhaust hood must be connected to the customer s exhaust device. Also refer to Technical Data. Customer s System without exhaust hood System with integrated exhaust hood Fig. 3-2 Prinziple drawing

40 3-4 Installation Electrical Connections WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Observe when Using Residual Current Circuit Breakers Local regulations in some geographic areas or industrial branches may require residual current circuit breakers. Then observe the following points: The residual current circuit breaker is to be installed only between the power supply and the bulk melter. Only residual current circuit breakers sensitive to pulsating current or universal current (> 30 ma) may be used. Laying Cable Line Voltage WARNING: Use only temperature resistant cable in the heating part of the system. Ensure that cables do not touch rotating and/or hot parts. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! WARNING: Operate only with the line voltage stated on the ID plate. NOTE: Permitted deviation from the rated line voltage is +5% / -10%. NOTE: The power connection cable must have a cross-section matching the power consumption P max. (Refer to ID Plate). Power Supply The system must be installed securely (permanent power supply connection). Refer to wiring diagram for connecting arrangement.

41 Installation 3-5 External Control and Switching Circuits WARNING: Connect external control and switching circuits using suitable NEC class I cables. In order not to cause short circuits lay cables such that they do not touch any printed circuit boards. Hose Receptacles 1 The hose receptacles (XS10 and XS11) are located in the terminal box (1). For electrical connection values, refer to Technical Data. Assembly Handgun Operation The receptacles for assembly handguns (XS18 and XS19) are located in the terminal box (1). Additional Hose Receptacles Depending on the model, two or four additional receptacles are available (1). Two heating zones (usually for hose and gun) can be controlled via each receptacle. 1

42 3-6 Installation Installing Hoses WARNING: Hot! Risk of burns. Wear heat-protective gloves. Second Open-jawed Wrench Use a second open-jawed wrench when connecting and disconnecting the hose. This prevents the hose connection from turning. Connecting If cold material can be found in the hose connection, the components (2, 3) must be heated until the material softens (approx. 70 C (158 F), depending on material). 1. First connect the hose (3) electrically to the unit. For more than one hose: Every hose connection is allocated to a corresponding receptacle. Do not mistakenly exchange! 2. Heat the system and hose to approx. 80 C (176 F). 3. Screw the hose onto the unit. NOTE: Close unused hose connections with Nordson port plugs. Disconnecting WARNING: System and material pressurized. Relieve system pressure before disconnecting hoses. Failure to observe can result in serious burns. Relieving Pressure 1. Switch off motor. 2. Place a container under the nozzle(s) of the gun/assembly handgun. 3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger of the assembly handgun. Repeat this procedure until no more material flows out. 4. Properly dispose of material according to local regulations.

43 Installation 3-7 Connecting and Adjusting Compressed Air Connect dry, clean and non-lubricated compressed air to the compressed air receptacle on the back of the system (2). Minimum air pressure: 2.5 bar / 0.25 MPa / psi The pressure restrictor valve (1) behind the compressed air receptacle limits the air pressure to 7.5 bar / 0.75 MPa / psi. 1 2 Pneumatic Cylinder Working Pressure Set the pneumatic cylinder working pressure to approx. 5 bar (0.5 MPa / 72.5 psi) on the pressure control valve with condensate collector (3) The setting must be modified according to the material processed (max. 7.5 bar / 0.75 MPa / psi) Pressure Controller Up Set the compressed air to raise the platen to approx. 1.5 bar (0.15 MPa / 21 psi) with the pressure controller (4, behind the cover (6)). The pressure restrictor valve limits the pressure to 2.0 bar (0.2 MPa / 29 psi).

44 3-8 Installation Compressed Air for Aerating Drum 5 6 Adjust the compressed air for aerating the drum with the pressure controller (5, behind the cover (6) ). The pressure restrictor valve limits the air pressure to 1,0 bar (0,1 MPa / 14,5 psi). Adapting the System to the Drum Used Limiting How Far the Platen is Lowered The proximity switch Drum empty (-197B5) limits how far the platen is lowered: Drum is not completely emptied: Slide proximity switch down Drum empty is not indicated: Slide proximity switch up -197B5

45 Installation 3-9 Speed Setpoint and Output Quantity WARNING: Disconnect the system from line voltage before opening the electrical cabinet. The speed is set with the terminal blocks (1 and 2) in the electrical cabinet. 1 2 Fig Terminal 1 2. Terminal 3 Terminal 1 Terminal 3 Speed SN0371 (PR12m2) The resulting output quantity is a factor of the pump used. NOTE: Refer to separate document Parts List to identify the pump used. Pump / Output quantity in kg/h SN0773 PU15/85 PU 25/85 PU35/85 PU50/85 (PR25m2) In Out 50 min Out In 65 min 1 14, In In 129 min Out Out 0 min

46 3-10 Installation Overtravel Time When Drum Empty If the accessory Timer relay is used, an Overtravel time can be set. During the overtravel time, feeding can continue despite the Drum empty indication. NOTE: The accessory Timer relay must be installed for the function Overtravel time. Refer to Accessories, Timer Relay Overtravel Time. Setting Overtravel Time WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. 1. Locate the timer relay -197K4 in the electrical cabinet. 2. Verify that the selectors Time range and Mode on the timer relay are set as shown in the wiring diagram. 3. Set time as required. CAUTION: Do not operate Nordson pumps without material. For this reason, the overtravel time should be set as short as possible. If necessary, slide the proximity switch Drum empty (-197B5) up somewhat so that the indication Drum empty occurs when there is still some material in the drum. -197B5

47 Installation 3-11 Page remains empty.

48 3-12 Installation Installing System Inputs DuraDrum bulk melters are equipped with four standard inputs. Fig. 3-4 XL2 The customer wires each input all the way to the system and then configures it for one of the following control options: Change system to standby Switch heaters on or off Enable or disable a certain hose or gun Switch motor on or off The inputs can be activated with the 24V DC signal (terminal 20) via the external relay contact. WARNING: The operator can bypass the inputs via the function keys on the control panel. Ensure that the control unit for external devices that transmit a signal to the system is programmed such that unsafe conditions can not occur when the operator bypasses an external input on the system.

49 Installation 3-13 Setting up an Input Set up the parameter control option for each input connected to the system. Table 3-1 shows the control options available. Information on selecting operating parameters and editing control options can be found under Setting up the Bulk Melter. Tab. 3-1 Input data Input Terminals XL2 Operating parameter Control options Note Standard inputs NOTE: Terminals 9, 11, 13, 14, 18, 19 (0V DC ) are jumpered at the factory. Refer to wiring diagram 1 8 and and Input disabled 1 - Enter/exit standby 2 - Heaters on/off 3 - Enable/disable motor Enable/disable hose/gun Enable/disable hose/gun Enable/disable hose/gun Enable/disable hose/gun Enable/disable hose/gun Enable/disable hose/gun Automatic standby (default) 11 - Enable/disable motor Input disabled 1 - Enter/exit standby (standard) 2 - Heaters on/off 3 - Enable/disable motor Enable/disable hose/gun Enable/disable hose/gun Enable/disable hose/gun Enable/disable hose/gun Enable/disable hose/gun Enable/disable hose/gun Enable/disable motor 2 A B A 3 12 and Like parameter 31 (default = 2) 4 7 and Like parameter 31 (default = 4) NOTE A: If control option 3 is selected, the motor will not turn on even if you press the pump key if voltage is not present on the input s contacts. B When control option 10 is selected for the input, a time must be set in parameter 24.

50 3-14 Installation Installing System Outputs The system has three outputs that the customer can configure as needed. The outputs are used to exchange data with the customer s production equipment and control hardware such as a PLC. NOTE: If a light tower (accessory) is installed, the outputs are already assigned and can not be used otherwise. Fig. 3-5 XL2 The customer wires each output and then configures it in the system s firmware for one of the following control options: System ready A fault has occurred Material level low Service LED on A potential fault is detected Refer to wiring diagram for connecting arrangement.

51 Installation 3-15 Setting up an Output Set up the parameter control option for each output connected to the system. Table 3-2 shows the control options available. Information on selecting operating parameters and editing control options can be found under Setting up the Bulk Melter. CAUTION: If a light tower (accessory) is installed, the outputs 1-3 must be set to the default. Terminals Output XL2 Standard outputs Operating parameter Tab. 3-2 Output data Control options NOTE: Terminals 1, 3, 5, 15, 20 (24V DC ) are jumpered at the factory. Refer to wiring diagram 1 1 and Output disabled 1 - Ready (default) 2 - Ready and the motor is ON 3 - Fault 4 - Drum empty 5 - Service LED is ON 6 - Alert C 2 33 and Same as parameter 40 (Default=3, may not be modified) 3 5 and 6 42 Same as parameter 40 (Default=4) NOTE A: B: C: Control option 6 provides an output signal when a potential fault is detected. If control option 3 and 6 are both used, then both a fault output and an alert output signal will be present when the fault LED turns on. Note

52 3-16 Installation Setting up Communication 1 With a computer connected to the system s serial interface (1), all settings can be displayed and changed, settings can be transferred between systems and the system s operating firmware can be up- and downgraded. Setting up the Bulk Melter The system can be set up to suit your manufacturing process, meaning that the settings can deviate from the factory setup. System setup consists of enabling or making changes to factory-set operating parameters that affect the use and function of the system. The operating temperature (setpoint) of the platen, each hose and each gun is established during setup. The system is shipped from the factory with the most commonly used operating parameters already set up. The factory setup can be modified at any time to suit your manufacturing process. Quick Setup Table 3-3 describes the most commonly used operating parameters and their factory settings. Review the table to determine whether the factory settings for each parameter will support your manufacturing process. If the default values for the operating parameters are appropriate for your manufacturing process, then no system setup is required. To complete the installation process, refer to Setpoint Temperature of Platen, Hoses and Guns. If you need to make changes to the factory setup or if you want to learn about other operating parameters, go to the next part in this section, Operating Parameters.

53 Installation 3-17 Tab. 3-3 Common operating parameters Parameter Parameter name Purpose Default value 4 Ready delay time A timer that delays enabling of the ready LED for a pre-defined time period after the platen, hoses and guns have reached the desired setpoint temperature. The ready delay timer will only enable if the temperature of the platen, at the time the system is turned on, is below its assigned setpoint temperature by 27 C (50 F) or more. 0 minutes 5 Service interval A timer that turns on a service LED when the value set for the timer equals the number of hours that the heaters have been on. The service LED signals the need for maintenance. 500 hours 7 Motor off delay If the switch receptacle is used, this parameter determines the amount of time the motor will remain on after the switched device is turned off. 0 seconds 8 Automatic pump on Switches the pump on automatically as soon as the system is ready. Prerequisite: The pump has been enabled by pressing the pump key. Enabled 11 Create password 20 Temperature units Sets a password that must be entered before any operating parameter or setpoint temperature can be changed. Sets the units of the temperature display to degrees Celsius (C) or degrees Fahrenheit (F) C 21 Overtemperature delta Sets the number of degrees that any heated component can exceed its assigned setpoint temperature before an overtemperature fault occurs. 15 C (25 F) 22 Undertemperature delta Sets the number of degrees that any heated component can drop below its assigned setpoint temperature before an undertemperature fault occurs. 25 C (50 F) 23 Standby delta 26 Manual standby time 50 to 77 Seven-day clock Sets the number of degrees that the temperature of all heated components will be decreased when the system enters the standby mode. Sets the amount of time that the system will remain in the standby mode after the standby key is pressed. A group of parameters that control the system s clock. The clock is used to automatically turn the heaters on and off and to enter standby. 50 C (100 F) Disabled Disabled

54 3-18 Installation Operating Parameters The system uses operating parameters to store noneditable and editable values. Noneditable values are those that provide information about the historical performance of the system. Editable values are either a numeric setpoint or a control option setting. Control option settings affect the display of information or the function of the system. Operating parameters are stored in the system s firmware in the form of a sequentially numbered list. The list is divided into the groups described in table 3-4. Tab. 3-4 Parameter groups Group Parameters Description Standard 0 to 11 Frequently used parameters Temperature Control 20 to 29 Controls heater function Input setup 30 to 38 Configure the standard and optional inputs Output setup 40 to 46 Configure the standard and optional outputs Seven-day clock 50 to 77 Configure the clock function PID selection 80 to 91 Changes preset PID settings In addition to the ability to read and edit parameter values, you can also save and restore the current value of every operating parameter and review a log of the last ten changes that were made to editable parameters. Selecting Operating Parameters Table 3-5 lists all of the operating parameters. Review the list to determine which operating parameters would best support your manufacturing process. Refer to Appendix B, Operating Parameters, for detailed information about each parameter. Appendix B contains a complete description of each parameter, including its effect on the system, default value and format. NOTE: Parameters that are used to configure optional equipment or that are otherwise reserved in the firmware are excluded from Table 3-5 and Appendix B.

55 Installation 3-19 Reading or Editing Operating Parameters Regardless of whether a parameter s value is editable or not, the procedure for accessing each parameter in order to read or edit its current value is the same. To Read or Edit a Parameter 1. Switch on the system. The system performs a startup check. 2. Press Setup key. Parameter 1 flashes in the left display. 3. Use the keypad to enter the number of the desired parameter. Refer to Table 3-5 for a complete list of parameters. Setup key NOTE: If you incorrectly enter the parameter number, press the Clear/Reset key to return to parameter 1, then re-enter the correct parameter number. When you have finished entering the one- or two-digit parameter number, the right display indicates the parameter s current value. 4. Do one of the following: Clear/Reset key If the value is noneditable, refer to Monitoring the System in section 4, Operation. If the value is editable, proceed to step Press the Enter key. The right display flashes. Enter key 6. Use the keypad to enter the desired numeric setpoint or control option in the right display. Refer to Appendix B, Operating Parameters, for information about the numeric value or control option choices for each parameter. NOTE: If the information you entered does not appear in the right display, the system is protected by a password. You must enter a valid password before parameters can be edited. Refer to section 4 Operation, Enter Password.

56 3-20 Installation To Read or Edit a Parameter (contd.) 7. Press the Enter key. The system checks that the new value or control option is acceptable. If the numeric setpoint or control option is accepted, the left and right displays show the next parameter number and value. If the numeric setpoint or control option is not accepted, the right display shows dashes (----) for three seconds and then changes back to the original value. 8. Repeat steps 5 to 7 to read or change the next parameter number, or press the Setup key to exit the setup mode. Tab. 3-5 Operating parameters Parameter Name Value range Default value Standard 0 Enter password 0 to Total hours with heater on (noneditable) Fault log (noneditable) _- F0 (empty) 3 Change history log (noneditable) P-_ (empty) 4 Ready delay time 0 to 60 minutes 0 minutes 5 Service interval 0 to 8736 hours 500 hours 6 Service LED heater hours 0 to 9999 hours 0 7 Motor off delay 0 to 360 seconds 0 seconds 8 Automatic pump on 0 (disabled) or 1 (enabled) 1 (enabled) 10 Enable or disable password 0 (disabled) or 1 (enabled) 0 (disabled) 11 Create password 0 to Change hose 1 output to electric gun activation 0 (disabled) or 1 (enabled) 0 (disabled) 13 Change hose 2 output to electric gun activation 0 (disabled) or 1 (enabled) 0 (disabled) Continued...

57 Installation 3-21 Parameter Name Value range Default value Temperature control 20 Temperature units (degrees C or F) C (degrees Celsius) or F C (degrees Celsius) (degrees Fahrenheit) 21 Overtemperature delta 5 C (10 F) to 60 C (110 F) 15 C (25F) 22 Undertemperature delta 5 C (10 F) to 60 C (110 F) 25 C (50F) 23 Standby delta 25 C (50 F) to 190 C (350 F) 50C (100F) 24 Automatic standby timeout 0 to 1440 minutes 0 (disabled) 25 Automatic heaters off time 0 to 1440 minutes 0 (disabled) 26 Manual standby time 0 to 180 minutes 0 (disabled) 27 A Hose standby delta 1 C to 190C (1F to 350F) 0 (disabled) 28 A Gun standby delta 1 C to 190C (1F to 350F) 0 (disabled) 29 A Internal zone temperature offset 0 C to -15 C (0 F to -30 F) 0C (0F) Input setup 30 Standard input 1 10 (Automatic 0 11 standby) 31 Standard input 2 1 (Enter/exit 0 9, 11 standby) 32 Standard input 3 0 9, 11 2 (Heaters on/off) 33 Standard input 4 4 (Hose/gun 1 0 9, 11 enable/disable) Output setup 40 Standard output (Ready) 41 Standard output (Fault) 42 Standard output Low level Continued...

58 3-22 Installation Parameter Name Value range Default value Seven-day clock 50 Current day 1 to 7 (1 = Monday) 51 Current time 0000 to Schedule 1 Heaters on 0000 to :00 56 Schedule 1 Heaters off 0000 to :00 57 Schedule 1 Enter standby 0000 to 2359 : 58 Schedule 1 Exit standby 0000 to 2359 : 60 Schedule 2 Heaters on 0000 to 2359 : 61 Schedule 2 Heaters off 0000 to 2359 : 62 Schedule 2 Enter standby 0000 to 2359 : 63 Schedule 2 Exit standby 0000 to 2359 : 65 Schedule 3 Heaters on 0000 to 2359 : 66 Schedule 3 Heaters off 0000 to 2359 : 67 Schedule 3 Enter standby 0000 to 2359 : 68 Schedule 3 Exit standby 0000 to 2359 : 71 Schedule for Monday Schedule for Tuesday Schedule for Wednesday Schedule for Thursday Schedule for Friday Schedule for Saturday Schedule for Sunday PID Settings PID selection for receptacles, hose/gun 1 and 2 NOTE A: Only with software version and higher 0=hose; 1=standard gun; 2=large gun; 3=air heater 0 or 1 (depending on selected component)

59 Installation 3-23 You can exit the setup mode at any time by pressing the Setup key. Parameter numbers that are not applicable are skipped when scrolling through the operating parameter list in the left display. When the right display is flashing, you can set the value of the current parameter to its lowest possible value by simultaneously pressing both of the right display scroll keys. If no key is pressed for two minutes while in setup mode, the system will return to the normal mode. You can also use the right display scroll keys to enter or change a parameter s value or control option. After entering the parameter number in the left display, press either of the right display scroll keys to change the value or control option. Using a personal computer that is connected to the system through the serial interface, you can view and change all of the operating parameters. If password protection is enabled, the system will return to the password protected mode whenever you exit the setup mode. Appendix B, Parameter 10

60 3-24 Installation Setpoint Temperature of the Platen, Hoses and Guns The system is shipped from the factory with the platen setpoint temperature at 175 C (350 F) and the hose and gun setpoint temperature at 0 degrees (turned off). Before the system can be used, a setpoint temperature must be assigned to the platen, hoses and guns. Setpoint temperatures are assigned with any of the following methods: Global The platen and all hoses and guns are set to the same setpoint temperature. Global-by-component group All of the hoses or all of the guns are set to the same setpoint temperature. Individual component The setpoint temperature of the platen and each hose and gun is set individually. Since most manufacturing processes require the platen, hoses and guns to be set to the same temperature, only the global method of assigning setpoint temperatures is described in this section. For information about the other two methods, refer to Adjusting Component Temperatures in Section 4, Operation. As with operating parameters, setpoint temperatures can be saved and restored, and past changes that were made to setpoint temperatures can be reviewed.

61 Installation 3-25 To Assign a Global Setpoint Temperature 1. Press and hold the Platen key for three seconds. The left display flashes 1. Platen key 2. Scroll the left display to 0. The right display shows dashes (----) and the LEDs on the platen, hose and gun keys turn green. 3. Press the Enter key. The right display flashes. Left display and scroll key 4. Use the keypad to enter the setpoint temperature recommended by the manufacturer of the material. Refer to the data sheet provided by the manufacturer of the material for the optimal setpoint temperature. 5. Press the Platen key. Enter key Each component begins to heat or cool to the new global setpoint temperature, and the system returns to normal mode. When all of the components have reached their global setpoint temperature, the ready LED turns on (green). Ready LED

62 3-26 Installation Save and Restore Settings The current value of all editable operating parameters and the setpoint temperature of each component can be saved and, if necessary, restored at a later time. When saved settings are restored, they overwrite the settings that are presently in use. This save-restore feature is useful in instances where the settings that are in use are deliberately or accidentally changed and the system is to be returned to its original state. + To Save Current Settings With the system in normal mode, simultaneously press the number key 1 and the Setup key. S-1 appears briefly in the right display. Saving current settings To Restore Saved Settings CAUTION: All settings will be deleted! Before restoring saved settings, ensure that use of the restored settings will not disrupt the current process or create unsafe operating conditions. + With the system in normal mode, simultaneously press the number key 2 and the Setup key. S-2 appears briefly in the right display. Restoring saved settings If the restore feature is used before the save feature is used for the first time, the factory default setpoint temperatures will be restored. This will cause the hoses and guns to stop heating. Settings can be transferred from one system to another using the Nordson Configuration Manager software utility.

63 Installation 3-27 Review Parameter and Setpoint Temperature Changes The system stores in a change history log a record of the last ten changes that were made to either operating parameters or setpoint temperatures. Since the log only stores ten changes, old log entries are overwritten beginning with the first log entry, by the eleventh and following log entries. To Review the Change Log History Setup key 1. Press Setup key. Operating parameter 1 flashes in the left display. 2. Press the left display scroll key to change the display to parameter 3 (change history log). Left display and scroll key Component key LEDs The following occurs: If the last change was to an editable parameter, all of the component key LEDs remain off. or If the last change was to a setpoint temperature, the LED on the associated component key(s) turns on. and The right display shows the four-digit log entry associated with the last change that was made. Table 3-6 indicates the meaning, from left to right, of each digit in the log entry. Two sample log entries are shown following the table. 3. Press a right display scroll key to review each of the remaining nine log entries. Each time a scroll key is pressed, a progressively older log entry appears. 4. Press the Setup key to return to the normal mode. Scrolling through the log

64 3-28 Installation First digit P (Parameter) Second digit Tab. 3-6 Change history log Third and fourth digit Indicates the number of the parameter that was changed Used in conjunction with the LEDs on the component keys to indicate the location and method of a setpoint temperature change. When this LED is on.. And the fourth digit indicates.. The change was to.. And the method of change was.. S (Setpoint) Platen key 1 Platen Individual Hose key 1 6 A single hose Individual Gun key 1 6 A single gun Individual All keys 0 All components Global Hose key 0 All hoses Gun key 0 All guns Global-bycomponent Global-bycomponent Change History Log Examples Example 1: Example 2: Parameter 4 (ready delay) was changed. If the LED on the gun key is on, then this display would indicate that the global-by-component method was used to change the temperature of the guns.

65 Installation 3-29 Unused log entries in the change history log are indicated by P-_ in the right display. To view how many heater hours have elapsed since the last change, simultaneously press both of the right display scroll keys.

66 3-30 Installation Accessories The following components can also be installed later as accessories: Light Tower Installing Kit WARNING: Disconnect the system from the line voltage Fig. 3-6 CAUTION: If a light tower (accessory) is installed, the outputs 1-3 must be set to the default.

67 Installation Fig Break out the plate from the top of the tower (1, Fig. 3-6) along the punched lines and remove. 2. Swivel tower open. 3. Guide cable through the resulting hole. 4. Use the two screws M5 to fasten the light tower. 5. Guide the cable through the top opening of the tower and to the inside wall (drum side) of the electrical cabinet. 6. Release knurled nut (4) from the bracket Cable duct (3). Slide bracket up in the slot. 7. Guide the cable through the resulting opening to the terminal blocks (6, Fig. 3-7) in the electrical cabinet door. 8. Place wire ends and bridges according to their designations (e.g. no. 5 to terminal 5). Refer to wiring diagram. 9. Use a cable tie to fasten the cable to one of the metal teeth (5) below the bracket Cable duct. 10. Slide the bracket down and tighten knurled nut. 11. Close tower. Exhaust Hood If the system is used to process polyurethane hot melt adhesives (PUR), fumes are created that should be suctioned off directly at the drum. An exhaust hood is attached to the bulk melter for this purpose. The exhaust hood must be connected to the customer s exhaust device (Also refer to Installation, Exhausting Material Vapors and Technical Data). High Drum Jacket for Cardboard Drums CAUTION: Do not use metal drums with this model! The drum jacket is desgned only for cardboard drums! NOTE: Bulk melters for cardboard drums have only the lower sealing ring on the platen.

68 3-32 Installation Timer Relay Overtravel Time If the accessory Timer relay is used, an Overtravel time can be set. During the overtravel time, feeding can continue despite the Drum empty indication. Installing the Timer Relay WARNING: Disconnect the system from the line voltage. 1. Refer to Fig. 3-8, A: Find the relay -197K4 in the electrical cabinet. NOTE: The relay -197K4 is not standard until April The timer relay can not be used in older systems. 2. Refer to Fig. 3-8, B: Release the clips (1) and extract the relay. 3. Press the strap (3) down with a screwdriver and remove the relay base from the top hat rail (2). 4. Remove the clips and insert the new, longer clips. 5. Put the relay base back into place and secure with the strap. 6. Refer to Fig. 3-8, C: Verify that the selectors Time range and Mode on the timer relay are set. 7. Insert the timer relay and secure with the clips. 8. Set the overtravel time. Refer to Overtravel Time When Drum Empty. A B C 1 TIME RANGE MODE X X X X -197K4 2 3 Fig. 3-8

69 Installation 3-33 Initial Startup After the system has been correctly installed, initial startup may begin. Refer to section Operation. Detaching Disposing 1. Convey all material out of the system and remove drum. 2. When system will not be used for longer periods of time, purge with cleaning agent if necessary (Refer to Maintenance). 3. Wipe off sealing ring and clean melting plate (Refer to Maintenance). 4. Disconnect all lines to the system, and allow system to cool. When your Nordson product has exhausted its purpose and/or is no longer needed, dispose of it properly according to local regulations.

70 3-34 Installation

71 Operation 4-1 Section 4 Operation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Initial Startup NOTE: Some of the following steps are described in detail in this section. 1. Set selector Raise/lower platen to Set main switch to I/ON. 3. Operator panel: Set values and parameters. 4. Wait until the system has heated up and is ready for operation (LED on the control panel lights up green). 5. Insert drum. 6. Pre-select motor and switch on. 7. Optimize settings and record in settings record form. NOTE: All system functions were tested before the system left the factory. Special test material was used. There may be residue from this material on the melting plate, in the pump, etc. To remove such residue, melt and feed several kilograms of material before starting production.

72 4-2 Operation Heated Components Component keys (platen, hose and gun) The system contains three groups of heated components: the platen, the hose group and the gun group. Component groups are represented on the control panel by the component keys shown to the left. Heated components within each group are identified by their position number. The position number of the platen is fixed at 1. Hose and gun position numbers are automatically assigned based on the hose/gun receptacle they are connected to. For example, the position numbers of a hose/gun pair that is connected to the second receptacle would be hose position 2 and gun position 2. NOTE: In some installations, auxiliary devices (such as a heated air manifold) may be connected to a hose/gun receptacle. In such cases, you should label (or otherwise identify) the auxiliary device as to the hose or gun position number that represents the device. The control panel will identify such devices as a hose or gun, regardless of what the device actually is. Pump After initial startup check the pump for leakage; tighten the gland bolt if necessary. Refer to Maintenance.

73 Operation 4-3 Starting the Bulk Melter Before starting the system for the first time, confirm that The system is fully installed, including any required inputs and outputs, gun drivers, pattern controllers or timers. The system s operating parameters are set up to support the current manufacturing process. Refer to section 3, Installation, if any of the items listed above are not complete. To Start the System 1. Switch on the system. Heater LED The system Tests the control panel LEDs Turns on the heaters (the heater LEDs turn green) Begins to automatically scan through and display the actual temperature of the platen, hoses and guns. The sequence of the automatic scan is: platen, each hose/gun pair and then back to the platen. Turns on the ready LED (green) when the platen and all of the hoses and guns are within 3 C (5 F) of their assigned setpoint temperature. CAUTION: Do not operate pump without material. Before switching on the motor, ensure that the system is equipped with a filled drum. Automatic scan sequence Ready LED 1 2. Press the pump key (1) to enable the pump. If the system has not reached the system-ready state at the time that the pump key is pressed, the LED on the pump key will turn yellow, indicating that the pump is enabled but not started. The pump will start automatically when the system-ready state is reached. If the system has reached the system-ready state at the time that the pump key is pressed, the pump will start and the LED on the pump key will turn green, indicating that the pump is running. NOTE: You can change the way the pump key operates by changing parameter 8 (automatic pump on). Refer to Appendix B, Operating Parameters. NOTE: The key for pump 2 has no function. Pump key

74 4-4 Operation If the system is switched on when the temperature of the platen is 27 C (50 F) or greater below its assigned setpoint temperature (cold start condition), the Ready LED will not turn on until the ready delay (defined when the system was set up) has elapsed. The time remaining on the ready delay (in minutes) appears in the right display at the end of every scan cycle. When less than one minute remains in the ready delay time, the right display counts down in seconds. Appendix B, Parameter 4 Appendix B, Parameter 4 You can bypass the ready delay time by pressing the Heater key twice. The appearance of F4 in the right display immediately after the system is switched on indicates a problem with the system s processor or main board. The appearance of F1 in the right display immediately after starting the system indicates that a hose or gun cordset may be loose or disconnected. If the system is set up for manual pump activation and the parameter 7 (motor off delay) has been changed from the default, the pump will not stop until a user-specified amount of time has elapsed. The (logical) state of one or more inputs may prevent the heaters from being turned on. If the seven-day clock feature was set up and turned on when the system was last switched off, the clock will automatically turn on the next time the system is switched on. Monitoring Faults Section 6, Troubleshooting. Appendix B, Parameter 7 Installing System Inputs in section 3, Installation Function Keys If a power failure occurs, the system will restart in its normal heat-up cycle, even if the heaters were off or the system was in standby prior to the power failure. If the seven-day clock was on prior to the power failure, the system will restart in the mode dictated by the clock schedule at the time the system restarts.

75 Operation 4-5 Monitoring the System The system has display elements that Quickly confirm that the system is operating correctly Monitor the actual temperature of the melting plate and each hose and gun Identify faults Alert the operator when service is required. Indicate Drum empty. The system automatically determines the number and location of all hoses and guns that are connected to it. Refer to Heated Components, earlier in this section, for information on the identification of heated components. A computer can also be used to monitor the system. Confirm that the System is Operating Correctly The ready LED turns on (green) when all of the heated components are within 3 C (5 F) of their assigned setpoint temperature. Ready LED The ready LED will not turn on, or will turn off, if any of the following events occur: The ready delay is still counting down The operator or a remote input places the system in standby mode The seven-day clock places the system in standby mode There is a fault (the fault LED will turn on). Drum is empfty. Refer to Monitoring Faults and Function Keys later in this section for information on system faults and using the seven-day clock and standby functions. Refer to Appendix B for information on the ready delay. Drum Empty LED When the platen is far enough down a proximity switch on the pneumatic cylinder closes and the Drum empty LED (yellow) will turn on. Drum empty LED

76 4-6 Operation Heated components with a setpoint temperature of zero degrees are skipped during the automatic scan cycle. The time remaining on the ready delay appears in the right display at the end of every scan cycle. You can override the seven-day clock at any time. If the clock has turned the heaters off, pressing the heater key will turn the heaters back on. If the clock has placed the system in standby mode, pressing the standby key will return the heated components to their assigned setpoint temperatures. Appendix B, Parameter 4 Function Keys Monitor Component Temperatures LEDs on component keys The actual temperature of each heated component platen and each hose and gun can be checked using the normal mode or by manually selecting and checking each component. By default, the system remains in the normal mode except when: The system is in setup mode The setpoint temperature of all hoses and guns is set to zero degrees A fault occurs. To Check Component Temperatures Using the Normal Mode 1. When the Ready LED is on, observe the LEDs on the component keys. 2. When the LED on the key that represents the desired component group (platen, hose or gun) turns on, observe the left display until it shows the position number of the specific component to be checked. 3. When the position number of the desired component appears in the left display, the right display shows the component s actual temperature.

77 Operation 4-7 To Manually Check a Component s Temperature 1. Press the key (platen, hose or gun) that represents the component group to be checked. Left display and scroll key The automatic scan stops and the left display indicates the number of the first sequential component in the selected component group. The right display shows the component s actual temperature. NOTE: When the platen key is pressed, the left display does not show a component number (blank display). 2. If the first sequential component is not the component to be checked, use the left display scroll key to move to the correct component number. The right display shows the actual temperature of the selected component. Component temperature display 3. Press the Setup key twice to return to the normal mode. When you scroll the left display past the number of the last sequential component on a component group, the number of the first component in the next group appears. The systems returns to normal mode two minutes after the last key is pressed. The default for the temperature display is degrees Celsius (C). This may be changed to degrees Fahrenheit with parameter 20. Appendix B, Parameter 20 The LEDs on each component key will change from green to yellow if any component in the group drops more than 3 C (5 F) below its assigned setpoint temperature. The setpoint temperature of a component can be checked at any time by pressing the right display UP scroll key. Holding down the scroll key while the system is in normal mode reveals the setpoint of each component that is scanned.

78 4-8 Operation Monitoring Faults The system alerts the operator to the faults listed in Table 4-1. Tab. 4-1 Fault codes Fault code Type of fault Description F1 RTD (resistance temperature detector) The RTD for the component indicated has failed or the component was disconnected from the system. F2 F3 F4 Undertemperature Overtemperature Electrical or control failure The actual temperature of the component indicated has dropped below the undertemperature delta, which was set using parameter 21. The actual temperature of the component indicated has increased beyond the overtemperature delta, which was set using parameter 21. Problem with a board, cable harness or control component. The sub-code in the left display shows the failed component or the cause of the fault. F1, F2 and F3 Faults When the system detects an F1, F2 or F3 fault: 1. The automatic scan stops and the system begins to monitor the potential fault for up to two minutes. The ready and heater LEDs remain on during the two minute period. If the system detects during this time that the fault condition no longer exists, the system returns to normal mode. 2. The LED on the affected component key (platen, hose or gun) turns on to indicate the type of component that has, or is, failing. 3. The right display indicates the type of fault (F1, F2 or F3). Typical error code display Fault LED (red) 4. The left display indicates the component that has, or is, failing. If the LED on the heater key is lit, the left display shows either 1 for the platen or 2 for the pump. If the LED on the hose or gun key is lit, the left display shows the number of the affected hose or gun. 5. If the fault condition still exists at the end of the two minutes, the Ready LED turns off, the red fault LED lights up and the system records the fault in the fault log. Refer to section Fault Log in this section. To be able to put the system back into operation, the fault must be remedied and the system reset (reset key). Refer to section 6, Troubleshooting for information on diagnosis and remedies. Also refer to Resetting System.

79 Operation 4-9 To view the temperature of a heated component when an F2 or F3 fault exists, simultaneously press and hold down both of the right display scroll keys. An F1 fault (RTD) can be temporarily dismissed and the system returned to normal mode by pressing the Clear/reset key. The heaters will remain off. If the fault condition still exists two minutes after pressing the clear/reset key, the fault LED will light up again. When an F1 fault code appears, you can determine whether the fault was caused by an open or shorted RTD by simultaneously pressing both of the right display scroll keys. If the right display indicates OP, the RTD is open; if it indicates SH, the RTD has shorted. If, for any reason, a component reaches 235 C (458 F), an immediate F3 fault will occur (no two minute monitoring period). F4 Fault When the system detects an F4 fault: 1. The Ready LED turns off and the red fault LED lights up. Fault LED (red) 2. All of the component key LEDs (platen, hose and gun) turn off. 3. The right display indicates F4. 4. The left display shows a fault subcode. The subcode identifies the faulty component or the specific source of the fault. NOTE: If the F4 fault is nonfatal (subcode 3, 4 or 5 in the left display), the fault LED lights up for five seconds and the system returns to normal mode. Nonfatal F4 faults affect only the functions dependent on the seven-day clock. 5. The system records the fault in the fault log. Refer to Fault Log in this section. To be able to put the system back into operation, the fault must be remedied and the system reset (reset key). Refer to section 6, Troubleshooting for information on diagnosis and remedies. Also refer to Resetting System.

80 4-10 Operation Resetting System 1. Correct the fault. Refer to section 6, Troubleshooting for information on diagnosis and remedies. Clear/Reset key 2. Return the system to normal mode by pressing the Setup key twice. 3. Press the Clear/Reset key. 4. Press the Heater key to switch on the heaters. Heater key If the clock key is pressed when a nonfatal F4 fault has occurred, the right display shows F4 and the clock does not work.

81 Operation 4-11 Fault Log 1. Hold down Setup key. The automatic scan stops, and parameter 1 appears in the left display. 2. Scroll the left display to parameter 2 (fault log). Setup key Left display and scroll key The right display indicates the last fault as follows: If the last fault was an F1, F2 or F3 fault, then the LED on the affected component key turns yellow. If the last fault was an F4 fault, all of the component key LEDs turn off. The right display indicates the log entry for the most recent fault. Table 4-2 provides the meaning of each digit in the log entry. Two sample fault log entries are shown following the table. 3. Press a right display scroll key to review each of the remaining nine log entries. Each time a scroll key is pressed, a progressively older log entry appears. NOTE: The fault log only stores the last ten faults. After ten faults occur, the existing log entries are overwritten, beginning with the oldest entry, by the eleventh and subsequent log entries. 4. Press the Setup key to return to the normal mode. Scrolling through the fault log Tab. 4-2 Fault Log First digit Second and third digit Fourth digit Component: Type of fault: 1 = Platen or hose/gun 1 0 = Unused log entry 2 = Pump or hose/gun 2 1 = RTD (open or short) - F 3 = Hose 3 or gun 3 2= Component undertemperature 4 = Hose 4 or gun 4 3 = Component overtemperature 5 = Hose 5 or gun 5 4 = Processor or electrical failure 6 = Hose 6 or gun 6 Subcode for fault type F4: Assigned by Nordson

82 4-12 Operation Fault Log Examples Example 1: Example 2: Unused log entry If the LED on the platen key is lit, the log entry indicates platen undertemperature. If the LED on the hose key is lit, the log entry indicates hose 1 undertemperature. To view the number of heater hours since the last log entry, simultaneously press both of the right display scroll keys. The hours appear in the right display. The system will return to the normal mode if the fault log is left open for a period of two minutes without any key being pressed. When an F1 fault is the result of a hose/gun pair being disconnected from the system, two fault log entries are created. The first entry is for the gun, the second for the hose.

83 Operation 4-13 Monitoring the Service Interval Service LED (yellow) The system can be set up such that the service LED on the left side of the control panel lights up after a customer-defined time period has elapsed. The service LED can be used to signal any customer-specified maintenance task. When maintenance is completed, the service LED must be reset. To Reset the Service LED Press the Clear/Reset key to turn off the service LED and reset the service interval. Clear/Reset key The default setting for the service interval is 500 hours. Appendix B, Parameter 5

84 4-14 Operation Adjusting Component Temperatures The setpoint temperatures of the heated components can be adjusted as follows: Global The platen and all hoses and guns are set to the same setpoint temperature. Global-by-component group All of the hoses or all of the guns are set to the same setpoint temperature. Individual component The setpoint temperature of the platen and each hose and gun is set individually. Before adjusting setpoint temperatures, verify that each hose/gun pair is connected to the correct receptacle. For example, hose/gun pair 1 should be connected to receptacle 1. Refer to Heated Components, earlier in this section, for information on hose/gun positions. Recommended Temperatures The temperature setting is determined by the processing temperature prescribed by the material supplier. The maximum operating temperature for the system and heated components described here may not be exceeded. CAUTION: Nordson will grant no warranty and assume no liability for damage resulting from incorrect temperature settings. Platen Undertemperature value (warning) Undertemperature value (fault) Overtemperature value (warning) Overtemperature value (fault) Gun (accessory) Hose (accessory) Prescribed processing temperature (Material quantity used < 50 g/min: up to 10 C (up to 18 F) below prescribed processing temperature) 10 C (18 F) below set processing temperature 15 C (18 F) below set processing temperature 10 C (18 F) above set processing temperature 15 C (27 F) above set processing temperature Prescribed processing temperature Prescribed processing temperature

85 Operation 4-15 To Adjust the Setpoint Temperature Using the Global Method 1. Press and hold the Platen key for three seconds. The left display flashes 1. Platen key 2. Scroll the left display to 0 (flashing). The right display shows dashes (----) and the LEDs on all components turn green. 3. Press the Enter key. The right display flashes. Left display and scroll key 4. Use the keypad to enter the setpoint temperature recommended by the manufacturer of the materal. Refer to the data sheet provided by the manufacturer of the materal for the optimal setpoint temperature. Enter key NOTE: If the keypad or the right display scroll keys have no effect on the right display, the system is protected by a password. Enter a valid password before changing the setpoint temperatures. Refer to Enter Password in this section. 5. Press the Platen key. All of the components begin to heat or cool to the new global setpoint temperature. When all of the components have reached their setpoint temperatures, the Ready LED lights up (green). Ready LED

86 4-16 Operation To Adjust the Setpoint Temperature Using the Global-by-component Method 1. Press and hold the Hose or Gun key for three seconds. The left display indicates the number of the first sequential hose or gun. The right display indicates the current setpoint temperature of the hose or gun. 2. Scroll the left display to 0. Platen, hose and gun keys The right display indicates all dashes ( ). 3. Press the Enter key. The right display flashes. 4. Use the keypad to enter the setpoint temperature recommended by the manufacturer of the materal. Refer to the data sheet provided by the manufacturer of the materal for the optimal setpoint temperature. NOTE: If the keypad or the right display scroll keys have no effect on the right display, the system is protected by a password. Enter a valid password before changing the setpoint temperatures. Refer to Enter Password in this section. 5. Press the Enter key. The hoses or guns begin to heat or cool to the new global setpoint temperature.

87 Operation 4-17 To Adjust the Setpoint Temperature of an Individual Component 1. Press and hold the Platen, Hose or Gun key for three seconds. If the platen key has been pressed, the left display flashes 1. If a hose or gun key was pressed, the left display flashes the number of the first sequential hose or gun. The right display then indicates the current setpoint temperature of the component shown in the left display. 2. Scroll the left display to the number of the desired component. The right display then indicates the current setpoint temperature of the component selected in the left display. 3. Press the Enter key. The right display flashes. 4. Use the keypad to enter the setpoint temperature recommended by the manufacturer of the materal. Refer to the data sheet provided by the manufacturer of the materal for the optimal setpoint temperature. NOTE: If the keypad or the right display scroll keys have no effect on the right display, the system is protected by a password. Enter a valid password before changing the setpoint temperatures. Refer to Enter Password in this section. 5. Do one of the following: To register the new setpoint temperature and then move on to change the setpoint temperature of the next sequential component, press the Enter key. Then repeat steps 4 and 5. To register the new setpoint temperature and return to normal mode, go to step Press any component key (platen, hose or gun). The selected component begins to heat or cool to its new setpoint temperature.

88 4-18 Operation If you enter a valid setpoint temperature for a hose/gun that is not connected to the system or if you enter a setpoint temperature that is out of range, the right display will indicate dashes (----) for three seconds and then change back to the original setpoint temperature. When the right display is flashing, you can change the current setpoint temperature to 0 degrees by simultaneously pressing both of the right display scroll keys. If the global or global-by-component method is used to set the setpoint temperature and then a hose or gun is added later, the setpoint temperature of the hose or gun must be adapted or adjusted. If a hose or gun is removed, use the individual component method to set the setpoint temperature of the removed component to 0 degrees. This will avoid an F1 fault. When a hose or gun is added, use the individual component method to set the desired temperature. The factory setpoint temperature of the platen is 175 C (350 F). The factory setpoint temperatures of all other components is zero degrees (off). When the temperature unit is set to degrees Celsius, the minimum and maximum setpoint temperatures are 40 C and 230 C. When the temperature unit is set to degrees Fahrenheit, the minimum and maximum setpoint temperatures are 100 C and 450 C. When a setpoint temperature is set with the right scroll keys, the right display automatically jumps from 0 to 175 C or from 0 to 350 or 450 F. If you make a mistake while changing a setpoint temperature but have not yet pressed the Enter key, press the Clear/Reset key to reset the right display to the original temperature. The systems exits setup mode and returns to normal mode two minutes after the last key is pressed. A global setpoint temperature of zero degrees (Celsius or Fahrenheit) turns all components off. When scrolling through component numbers in the left display, component numbers assigned to unused hose/gun receptacles are skipped. The system stores a record of the last ten changes made to setpoint temperatures (and operating parameters) in a change history log. Changes to setpoint temperatures can be saved by simultaneously pressing the keys 1 and Setup. Section 3, Installation, Review Parameter and Setpoint Temperature Changes Section 3, Installation, Save and Restore Settings

89 Operation 4-19 Enter Password If a system is password protected, a valid password must be entered before any setpoint temperature can be entered or any parameter changed. 1. Press Setup key. Parameter 0 flashes in the left display, and the right display shows Press the Enter key. The right display begins to flash. 3. Enter the password with the keypad. NOTE: The password is created and enabled/disabled during system setup. 4. Press the Enter key. Then the following occurs: If the password is correct, the left display indicates parameter 1. If the password is incorrect, the left display remains at 0, while the right display briefly indicates dashes (----) then returns to If the password is incorrect, reenter it and then press the Enter key. The system reverts to password protected mode 2 minutes after the last key (any key) is pressed. To return to password protected mode before 2 minutes have elapsed, press the Setup key twice. The password is created and enabled/disabled during system setup. Setting Up the System in section 3, Installation

90 4-20 Operation Function Keys The control panel provides the following standard and special function keys: Standard function keys Heater Pump Setup Special function keys Seven-day clock Standby VORSICHT: Unintentionally activating function keys can have undesirable effects on the system or the manufacturing process. Only personnel familiar with the system s setup and its connection with the manufacturing process should use the function keys. Improper use of the function keys can result in erratic process behavior or personal injury. Heater Key Heater key Use the heater key to manually turn the component heaters on and off. Pressing the heater key overrides the heater control by the seven-day clock feature or a remote input. The LED on the heater key is lit when the heaters are on. When a fault occurs (Refer to Monitoring Faults in this section) the heaters automatically turn off. The heater key is used to turn the heaters back on after correcting a fault condition.

91 Operation 4-21 Pump Key Pump key 1 Press the pump key (1) to enable, start or stop the pump. The LED on the pump key is yellow when the pump is enabled (not yet running) and green when the pump is running. Switching the pump on or off has no effect on the heater control. If the automatic pump on feature (parameter 8) is disabled, then the pump key must be used to start the pump when the system is ready. If any of the inputs are set up to use the pump enable/disable control option (option 3 and option 11), the pump motor will not start until the pump is enabled and the correct voltage is applied to the input contacts. If the pump is enabled but the input voltage is not present, the pump LED will flash green. NOTE: The key for pump 2 has no function. Setup Key The setup key is used to place the system into and take the system out of setup mode. In setup mode the automatic scan stops. The left and right displays are used to select, read and edit operating parameters. Setup key

92 4-22 Operation Seven-day Clock Key Use the seven-day clock key to turn the clock feature on and off. When the clock is on, the temperature of each heated component is automatically regulated based on a set of user-defined schedules. Seven-day clock key Four clock schedules are available to accommodate daily shift work and non-working days. Three of the schedules are used to specify when the heaters should turn on or when the system should enter and exit standby mode. The fourth schedule determines the days on which the system should be switched off. When the heaters switch on as dictated by the schedule, they are regulated to their assigned setpoint temperatures. When the clock activates the standby mode, the setpoint temperatures are all temporarily reduced by a preset standby delta. For information about setting up the seven-day clock and the standby delta, refer to Setting up the Bulk melter in section 3, Installation as well as to appendix B, Operating Parameters. If the system is switched off while the clock is on, the clock will automatically turn back on the next time the system is switched on. If the heaters are manually turned off during the time that a clock schedule calls for the heaters to be on, the heaters will not turn back on until the next clock schedule calls for them to be on. The clock will still operate when the system is faulting or in setup mode. If F4 appears in the right display when the clock key is pressed, the clock function has failed. Contact Nordson customer service to remedy the fault.

93 Operation 4-23 Standby Key Standby key The standby key is used to enter and exit standby mode. Using the standby mode during periods when no material is being fed helps to conserve energy and allows heated components to quickly return to their setpoint temperatures when the system is once again needed. When the system enters standby mode, the temperatures of all components are reduced from their setpoint temperatures by a preset standby delta. The system remains in standby mode until the standby key is pressed or one of the operating parameters causes the system to exit standby mode. If the system was set up to use the manual standby timer (parameter 26), pressing the standby key places the system in standby mode for the period of time specified by the timer. After the manual standby time has expired, the system once again begins heating all of the components to their assigned setpoint temperatures. Using the standby key overrides the control of the system (on or off) by the seven-day clock or a remote input. For information on setting the standby delta and the standby timer, refer to Setting up the Bulk Melter in section 3, Installation as well as to appendix B, Operating Parameters. The system may be set up to automatically enter standby mode using a variety of operating parameters. Whenever manual standby is activated, the standby LED flashes. Appendix B, Parameters 25, 26, 30 33, 57, 62 and 67 Appendix B, Parameter 26

94 4-24 Operation Inserting and Replacing Drum CAUTION: Place only undamaged, suitable drums in the system; otherwise the platen sealing ring will be damaged. Always keep the base plate of the system clean so that the drum is positioned straight. WARNING: Risk of burns! Hot material can splash out when the platen exits the drum. Hot material may flow out of the deaeration valve. Wear suitable protective clothing! 1. Raise platen (Refer to the next page). If there is no drum in place e.g. upon initial startup the two hand control must be operated to raise the punch: a. Set selector Raise/lower platen to Raise. b. Operate the two hand control until the platen is higher than the base plate by more than the height of one drum. 2. Set selector Raise/lower platen to 0/Stop. 3. Insert or replace drum. 4. Lubricate sealing ring. Refer to Processing Materials in the section Maintenance. 5. Lower platen (Refer to the page after next). 6. Properly dispose of empty drum according to local regulations.

95 Operation 4-25 Raising Platen NOTE: Refer to Principle Wiring Diagrams in this section Fig. 4-1 If the platen is inside of the drum, the drum must be aerated to support raising. Aerating means that compressed air is forced under the platen. 1. Verify that the selector Raise/lower platen (1) is set to Screw the rod (4) out of the aeration connection (5). 3. Screw in the aeration tube (3). 4. Open the shutoff valve Compressed air to aerate drum (2). 5. Set selector Raise/lower platen to Raise. The air pressure in the drum is limited to 1.0 bar (100 kpa / 14.5 psi) by a pressure restrictor valve.

96 4-26 Operation Lowering Platen NOTE: Refer to Principle Wiring Diagrams on the following pages. CAUTION: If the platen is lowered when no drum is inserted e.g. to transport the system place a squared timber underneath. This protects the sensor Drum inserted from damage. Fig. 4-2

97 Operation Fig. 4-3 The drum must always be deaerated when the platen is moved into the drum. When the drum is deaerated, the air that is under the platen escapes. 1. Set selector Raise/lower platen (1) to Lower. 2. Place the drip pan (3) in front of the deaearation valve (4). 3. Open the deaeration valve with the lever (2). 4. Press both buttons on the two-hand control at the same time (within 0.5 seconds) until the platen is inside of the drum. Lowering continues automatically as soon as the platen reaches the material. The green LED on the selector Raise/lower lights up when the platen reaches the material. 5. Close deaeration valve when material flows out free of bubbles. 6. Properly dispose of material according to local regulations.

98 4-28 Operation Principle Wiring Diagrams Raising/Lowering Platen 24 VDC Drum empty Proximity switch Drum not empty P Pressure switch Two hand control Sensor Drum in place Selector Lower Selector Raise LED Drum empty Solenoid valve Lower Solenoid valve Raise Fig. 4-4

99 Operation 4-29 Motor Enable Proximity switch Drum empty Drum not empty Pressure switch Enable motor to motor controller Fig. 4-5

100 4-30 Operation LED in Selector Raise/Lower Platen Pressure switch Selector LED Platen has contact with adhesive Fig. 4-6

101 Operation 4-31 Switching System ON/OFF NOTE: Before initial startup, read and observe the instructions in Initial Startup. Start up only as described under Initial Startup. NOTE: The main switch must be set to I/ON (switched on) when using the week timer. Daily Startup NOTE: Do not operate Nordson pumps without material. Before switching on motor, ensure that a drum that is not empty is in the system and that the platen has contact with the material. 1. Set main switch to I/ON. 2. Set selector Raise/lower platen to Lower. 3. Wait until system is ready. 4. Switch on motor. Daily Switchoff 1. Set main switch to 0/OFF and protect from unauthorized access with padlocks if necessary. 2. Set selector Raise/lower platen to 0/stop. 3. Perform daily maintenance. Switching Off in an Emergency WARNING: Immediately switch off the system in any emergency situation. 1. Set main switch to 0/OFF. 2. Set selector Raise/lower platen to 0/stop. 3. After standstill and before switching the system back on, have the fault remedied by qualified personnel.

102 4-32 Operation Settings Record Production information: Material: Cleaning agent: Reference channel: Manufacturer Processing temperature Viscosity Manufacturer Flash point Factory-set Processing temperatures (setpoint temperatures) Platen Hose (accessory) 1) 2) 3) 4) Gun (accessory) 1) 2) 3) 4) Assembly handgun (accessory) 1) 2) 3) 4) Motor/pump speeds: Motor/pump Air pressure: bar MPa psi Operating pressure Notes: Name Date

103 Maintenance 5-1 Section 5 Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. NOTE: Maintenance is an important preventive measure for maintaining operating safety and extending the lifetime of the unit. It should not be neglected under any circumstances. Risk of Burns Some maintenance work can only be done when the system is heated up. WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. Relieving Pressure WARNING: System and material pressurized. Relieve system of pressure before disconnecting hoses, guns and hot melt handguns. Failure to observe can result in serious burns. 1. Switch off motor. 2. Place a container under the nozzle(s) of the gun/assembly handgun. 3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger of the assembly handgun. Repeat this procedure until no more material flows out. 4. Re-use the material or dispose of properly according to local regulations.

104 5-2 Maintenance Important when Using Cleaning Agents Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. Properly dispose of cleaning agent according to local regulations. Processing Materials Before using, read the included EU safety data sheet. Designation Order number Use High temperature grease To be applied to O-rings and Can 10 g P/N threads NOTE: The grease may not be Tube 250 g P/N mixed with other lubricants. Cartridge 400 g P/N Oily/greasy parts must be cleaned before application. Grease Centoplex H0 P/N Lubricating platen sealing ring 1 k g Temperature-resistant adhesive Loctite ml P/N Heat transfer compound 500 g P/N Secures screw connections To improve heat conducting of temperature sensors

105 Maintenance 5-3 Preventive Maintenance The maintenance intervals are general guidelines based on experience. Depending on the surrounding conditions, production conditions and operating time of the system, other maintenance intervals may prove necessary. NOTE: Coupling and motor controller are maintenance-free. System part Activity Interval Refer to Complete system External cleaning Daily 5-4 Inspect for external damage 5-4 Power cable Inspect for damage Air hoses Inspect for damage Melting plate Check melting plate for charred material, clean if necessary Every time the drum is changed 5-5 Base plate Pressure switch Electrical cabinet ventilation Check base plate for material residue or other impurities, clean if necessary Check that the green LED on the selector Raise/lower lights up when the platen reaches the material. Clean fan screens, clean or replace filter Every time the drum is changed Every time the drum is changed Daily, if dust accumulation is severe Safety valve Activate the safety valve piston Weekly 5-6 Pump Tighten gland bolt After initial startup 5-6 Check for leakage, tighten gland bolt if necessary Tighten fixing screws Dependent on hours of operation, pump speed and pump temperature Recommendation: Monthly Every 500 hours of operation Motor / gear box Clean fan cover Depending on dust accumulation; daily if necessary Change lubricant Every hours of operation or every 2 to 3 years Compressed air filter Drain condensate Weekly 5-8 Clean filter element Every three months Cleaning condensate collector When cleaning filter element Pressure restrictor Performance check Every six months 5-9 valves Clean When not functioning correctly

106 5-4 Maintenance External Cleaning External cleaning prevents pollution created by production from causing system malfunctions. CAUTION: Observe the unit s Degree of Protection when cleaning (Refer to section Technical Data). CAUTION: Do not damage or remove safety labels. Damaged or removed safety labels must be replaced by new ones. Remove material residue only with a cleaning agent recommended by the material supplier. Heat with an air heater if necessary. Remove dust, flakes etc. with a vacuum cleaner or a soft cloth. Visual Inspection for External Damage WARNING: When damaged parts endanger the operating safety and/or the safety of personnel, switch off the system and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. Changing Type of Material NOTE: Before changing the material type, determine whether the old and new material can be mixed. May be mixed: Remaining old material can be flushed out using the new material. May not be mixed: Purge thoroughly and clean melting plate with a cleaning agent recommended by the material manufacturer (Refer to Cleaning Melting Plate). NOTE: Properly dispose of the old material according to local regulations.

107 Maintenance 5-5 Purging with Cleaning Agent Insert drum filled with cleaning agent for purging the system. Feed cleaning agent until it comes out free of adhesive residue. CAUTION: Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. Before starting production again, flush out residue of the cleaning agent using the new material. NOTE: Properly dispose of cleaning agent according to local regulations. Cleaning Melting Plate The melting plate is standardly release-coated. This makes it easy to clean. Cooled material can usually be pulled off of the melting plate; if necessary, first heat to approx. 60 C / 140 F. CAUTION: Do not use hard or metallic tools to clean. Do not use wire brushes! This could damage the release coating. Use only soft aids (wooden or PTFE spatula or soft brush). Fan and Air Filter Depending on dust accumulation, the air filters in the fan and for the air outlet must be cleaned (knocked out) or replaced. Refer to separate document Parts List for filter order numbers. 2 1 Fig Fan 2 Air filter, air outlet

108 5-6 Maintenance Safety Valve Activating the Piston NOTE: Activating the piston helps to prevent adhesive from causing blockage. Operate the system at maximum motor speed and with hose connections closed. Switch the motor on and off several times. Pump Checking for Leakage The pump is equipped with a self-sealing pump shaft seal. Material may seep out of the seal at irregular intervals. The gland bold must then be tightened. NOTE: When the pump shaft seal needs to be replaced, Nordson recommends replacing the pump and sending the old one in to be repaired. Only trained personnel can replace the pump shaft seal. Tightening Gland Bolt NOTE: Tighten only when the system is warm. Tighten the gland bolt approx. ¼ of a revolution in the operating direction of the pump. If tightening is no longer possible, the pump must be replaced. Fig. 5-2 Tightening Fixing Screws Normal heat cycling (heating and cooling) can cause the fixing screws to become loose. NOTE: Tighten the fixing screws only using a torque wrench (25 Nm / 220 Ibin) and only when the system is cold.

109 Maintenance 5-7 Motor / Gear Box Changing Lubricant NOTE: Use only the stated lubricant or one that has proven to be equivalent. Using any other lubricant can result in premature wear and/or damage to the gear box. NOTE: Drain lubricant when warm. Unscrew gear box from motor to change lubricant. Wash out casing with suitable cleaning agent and remove lubricant residue. NOTE: Properly dispose of the old lubricant according to local regulations. Lubricant Changing Interval Operating temperature < 100 C / 212 F: Every hours of operation or at least every 2 to 3 years. Capacity The lubricant quantity is indicated on the power plate. Ensure that the upper gears and rolling bearings are properly lubricated. NOTE: Never mix different types of lubricants. Lubricant Selection Lubricant manufacturer Mineral oil CLP 220 AGIP Blasia 220 ARAL Degol BMB 220 or Degol BG 220 BP Energol GR-XP 220 DEA Falcon CLP 220 ESSO Spartan EP 220 or GP 90 KLÜBER Klüberoil GEM OPTIMOL Optigear 220 SHELL Omala Oil 220 TEXACO Geartex EP-A SAE 85 W-90

110 5-8 Maintenance Compressed Air Filter The compressed air filter dehydrates and cleans the compressed air. Draining Condensate Drain condensate before it reaches a level approx. 10 mm below the filter disk. To do this, open the condensate drain valve (7). 10 mm 7 Cleaning Filter Element Under normal conditions, clean filter element (5) approx. every three months. Clean sooner if compressed air filter outlet pressure falls. 1. Shut off compressed air supply and release residual pressure by opening the condensate drain valve (7). 2. Unscrew condensate collector (6). 3. Unscrew filter element (5) by turning to the left. 4. Rinse filter element (5) with suitable cleaning agent. Then blow out from the inside. The condensate collector (6) may not come into contact with the cleaning agent! 5. Clean condensate collector (6) if necessary. Use only water! 6. Reassemble compressed air filter. 6 7

111 Maintenance 5-9 Pressure Restrictor Valve The factory-set, lead-sealed pressure restrictor valves prevent unpermissibly high pressurization of subsequent pneumatic components. When the factory settings are exceeded, compressed air audibly escapes. Checking Function Functioning of the pressure restrictor valves should be checked approx. every six months. When functioning is not correct, a pressure restrictor valve should be cleaned. If it still does not function, it must be replaced. NOTE: A defective pressure restrictor valve may be replaced only with an original spare valve. Repairs to the pressure restrictor valve may be made only by the manufacturer! Pressure Restrictor Valve for Aerating Drum If the customer s equipment has a pressure gauge with a 1/4 fitting: 1. Reduce compressed air to 0 bar on pressure controller (1). 2. Release the fitting (2) on the tube (3) far enough that it can be turned forward. 3. Replace the tube with a pressure gauge (4). 4. On the pressure controller, increase the compressed air to higher than 1.0 bar and observe whether the pressure restrictor valve (behind the cover (5)) opens Fig. 5-3

112 5-10 Maintenance Pressure Restrictor Valve for Aerating Drum (contd.) 6 If the customer s equipment has no pressure gauge with a 1/4 fitting: 1. Reduce compressed air to 0 bar on pressure controller. 2. Unscrew cover (5, Fig. 5-3). 3. Detach the pressure restrictor valve (6). 4. Check pressure restrictor valve functioning outside of the system, in the customer s compressed air system. Pressure Restrictor Valve at Compressed Air Connection On the compressed air connection (2), increase the compressed air to higher than 7.5 bar and observe whether the pressure restrictor valve (1) opens. 1 2

113 Maintenance 5-11 Cleaning Impurities that have penetrated seat surfaces and conical nipples can be removed by unscrewing the entire top piece without changing the minimum operating pressure. Use a sickle wrench to unscrew. ÂÂ Performance check Unscrewing top Fig. 5-4

114 5-12 Maintenance Maintenance Record Form System part Date / name Date / name Date / name Electrical cabinet ventilation Compressed air filter Pressure restrictor valves Safety valve Pump Motor / gear box

115 Troubleshooting 6-1 Section 6 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. WARNING: Troubleshooting activities may sometimes have to be carried out when the system is energized. Observe all safety instructions and regulations concerning energized unit components (active parts). Failure to observe may result in an electric shock. Some Tips Before systematic troubleshooting is begun, the following should be checked: Are all parameters set correctly? Do all plug connections have sufficient contact? Have circuit breakers been activated? Are external, inductive loads (e.g. solenoid valves) equipped with recovery diodes? The recovery diodes must be directly allocated to the inductive load. Light Tower (Accessory) White = Switched ON. After switching on and during the heatup phase, at first only the white indication lamp is lit (normal condition). A fault has only occurred when the temperature does not increase (observe temperature display) and when the green indication lamp is not lit after the heatup phase has ended (1 hour and longer). Green = Ready. The green indication lamp lights when all channels have reached their setpoint temperatures. Orange = Drum empty. Red = General alarm.

116 6-2 Troubleshooting Troubleshooting Tables The troubleshooting tables serve as an orientation for qualified personnel. They cannot, however, replace targeted fault location with the help of wiring diagrams and measuring instruments. They also do not include all possible problems, only those which most typically occur. Fault Codes Display Code/Subcode Name Affect on System Cause Corrective Action F1/None RTD The RTD for the component indicated has failed or the component was disconnected from the system. Replace RTD Check hose/gun connections F2/None Under temperature Heaters turn off The actual temperature of the component indicated has dropped below the under temperature delta, which was set using parameter 22. Check for conditions that may cause a drop in ambient temperature Raise the set-point temperature of the component Replace RTD F3/None Over temperature The actual temperature of the component indicated has increased beyond the over temperature delta, which was set using parameter 21. Replace RTD F4/1 RAM test System stops functioning Internal RAM failure Replace CPU F4/2 Internal Clock time Internal clock failure Replace CPU F4/3 F4/4 Internal Clock time Internal clock battery backed RAM Heaters remain on, but fault condition persists Internal time failure Battery-backed RAM failure Replace CPU Replace CPU F4/5 Internal clock battery Battery-backed RAM battery dead Replace CPU F4/6 Analog-to-digital RTD analog-to-digital converter failed Replace main board or CPU F4/7 Analog-to-digital calibration RTD analog-to-digital converter could not be calibrated Replace main board or ribbon cable, or CPU F4/8 F4/9 Main board feedback Expansion board feedback System stops functioning Communication failure between main board and CPU Communication failure between expansion board and CPU Replace main board, ribbon cable, or CPU Replace expansion board, ribbon cable, or CPU F4/A Thermostat Tank or manifold thermostat is open Replace thermostat, J7 harness, or main board F4/C Expansion board connection Faulty connection between expansion board and CPU Check or replace four single wires between main board and expansion board

117 Troubleshooting 6-3 Display Code/Subcode Name Affect on System Cause Corrective Action F4/d Communications with optional I/O card Heaters remain on, but fault condition persists Communication failure between CPU and the optional I/O card Replace the I/O card or CPU F4/E Fieldbus communications failure Alert output (if output option 6 is selected) System continues to operate normally Fieldbus card failure. Replace the Fieldbus card NOTE: Sub-code F4/b does not exist. Thus, confusion with F4/6 is avoided. System does not Function Problem Possible Cause Corrective Action 1. No line voltage Connect line voltage 2. Main switch not Switch on main switch switched on 3. Main switch defective Replace main switch 4. Main circuit breaker Switch on main circuit breaker activated 5. Main circuit breaker Check for short circuit in system or activated again accessories 6. System has no pneumatic function There is no compressed air Connect compressed air One Channel (Heating Zone) does not Heat Problem Possible Cause Corrective Action 1. Channel is disabled / switched off Enable / switch on

118 6-4 Troubleshooting Control Panel does not Function Problem Possible Cause Corrective Action 1. Display is blank PLC broad-band cable not connected Connect No Material (Motor does not Rotate) Problem Possible Cause Corrective Action 1. System not yet ready Wait until system is heated up. for operation (heatup phase) 2. Motor not switched Switch on motor on 3. Proximity switch Drum empty does not switch Cable pulled off Switch defective Connect Replace 4. Pressure switch does Switch defective Replace not switch 5. Standby entered Exit or wait until standby period has expired 6. Motor overheated Ambient temperature too high Decrease ambient temperature by cooling or airing out Fan cap dirty Clean Pump blocked by foreign matter Replace pump Pump operates too sluggish Replace pump Material too cold Set temperature accordingly 7. Motor defective Replace 8. Motor not supplied Technical inspection with voltage 9. Motor controller defective Replace

119 Troubleshooting 6-5 No Material (Motor Rotating) Problem Possible Cause Corrective Action 1. Drum empty Replace drum 2. Material supply hole to pump or pump suction hole clogged Remove pump and clean supply hole or suction hole Too Little Material Problem Possible Cause Corrective Action 1. Material supply hole to pump or pump suction hole partially clogged Remove pump and clean supply hole or suction hole 2. Processing Correct temperature setting temperature set too low 3. Pump block is worn Replace pump Material Pressure too High Problem Possible Cause Corrective Action 1. Safety valve dirty and Disassemble and clean or replace thus clogged 2. Safety valve defective Replace 3. Too much pressure applied to safety valve Reduce pressure

120 6-6 Troubleshooting Material Pressure too Low Problem Possible Cause Corrective Action 1. Pump is worn Replace pump 2. Safety valve does not Replace close any more Others Problem Possible Cause Corrective Action 1. Leakage at pump Pump shaft seal is worn Tighten gland bolt shaft seal Replace pump 2. Material pressure too Pump is worn Replace pump low, output quantity too low 3. Pump blocked Processed material too cold Correct temperature setting (observe data sheet of material manufacturer) Foreign material in pump Replace pump 4. Leakage at gun Safety valve does not open Replace safety valve during heatup phase (expansion pressure) 5. Platen lifts the drum Lifting speed too high Refer to Installation, Adapting the 6. Drum is not completely emptied 7. Drum empty is not indicated Proximity switch Drum empty is set incorrectly System to the Drum Used

121 Troubleshooting 6-7 LEDs of Motor Controller During operation the operating mode of the motor controller is displayed by two LED s on the front of the unit. Fig. 6-1 LEDs LED display Operating mode Green Red On Off Motor controller enabled On On Mains switching and automatic start blocked Flashing Off Motor controller blocked Off Flashing (every 1 s) Fault message Off Flashing (every 0.4 s) Undervoltage shutdown Off Off Programming mode or no voltage supply

122 6-8 Troubleshooting

123 Repair 7-1 Section 7 Repair WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. WARNING: Hot! Risk of burns. Wear appropriate protective clothing/equipment. Some maintenance work can only be done when the system is heated up. WARNING: System and material pressurized. Relieve system of pressure before disconnecting hoses, guns and hot melt handguns. Failure to observe can result in serious burns. General Notes Material hoses can not be repaired. However, defective hoses can be exchanged for overhauled hoses with full guarantee through Nordson s AT program (replacement program). The processed material must be soft for disassembly of some components. Heat the system to softening temperature. Use a hot air fan if necessary. Use only original Nordson spare parts. Refer to separate document Parts List for details. Also refer to separate manuals for the individual components.

124 7-2 Repair Replacing Sealing Ring WARNING: Hot! Risk of burns. Wear heat-protective gloves. NOTE: Models for cardboard drums have only the lower sealing ring on the platen (configurations code: Box 16 = F). 1. Heat platen to operating temperature. 2. Aerate drum. 3. Set pneumatic switch to Raise until the platen exits the drum. 4. Set pneumatic switch to 0/Stop. 5. Place a clean, hard, heat-resistant resting surface (e.g. metal plate) on the drum under the melting plate. 6. Set pneumatic switch to Lower until the melting plate reaches the resting surface. 7. Set pneumatic switch to 0/Stop. 8. Cut old sealing rings with a knife and dispose of it properly. CAUTION: Do not damage release coating. 9. Heat solid rubber or PTFE-coated sealing rings in an oven. 10. Clean and lubricate grooves. For information on lubricant refer to Processing Materials in section Technical Data. 11. Put heated sealing rings into place on heated platen with two people C F Fig. 7-1

125 Repair 7-3 Replacing O-rings When leakage occurs, e.g. at the hose connections, the O-rings must be replaced. Observe the following: Clean and lubricate O-ring groove. Nordson recommends high-temperature grease; refer to Processing Materials in section Maintenance. Also lubricate O-ring. Do not use removed O-rings again. Tighten hose connection and blind covers with a torque wrench to 9.5 Nm.

126 7-4 Repair Replacing Platen Temperature Sensor and Thermostat WARNING: Hot! Risk of burns. Wear heat-protective gloves. 1. Heat platen to operating temperature. 2. Aerate drum. 3. Set pneumatic switch to Raise until the platen exits the drum. 4. Set pneumatic switch to 0/Stop. 5. Place a clean, hard, heat-resistant resting surface (e.g. metal plate) on the drum under the melting plate. 6. Set pneumatic switch to Lower until the melting plate reaches the resting surface. 7. Set pneumatic switch to 0/Stop. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. 8. Disconnect the system from the line voltage. 9. Remove the cover (1) Fig. 7-2

127 Repair 7-5 NOTE: If the temperature sensor is defective: Continue with step Remove thermostat (2) along with fastening screws and spring washers. 11. Extract connecting cable from porcelain terminals. 12. Apply heat transfer compound to contact surfaces of the new thermostat (Refer to Processing Materials in section Technical Data), then install the thermostat with spring washers and screws. 13. Connect thermostat wires to porcelain terminals. 14. Screw on cover. 15. Start up system. Replacing Temperature Sensor First perform steps 1 to Remove temperature sensor (3). 17. Apply heat transfer compound to the new temperature sensor, then fasten the sensor. 18. Attach cover again (1). 19. Start up system. Identifying Installed Thermostat NOTE: Refer to section Parts to identify the thermostat installed.

128 7-6 Repair Replacing Control Panel WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Installing Service Kit WARNING: Disconnect the system from the line voltage. Service kit P/N: Required tools: Electrical cabinet key Open-jawed or box wrench, size 7 1. Set main switch to 0/OFF. 2. Open electrical cabinet door. 3. Unplug bus cable from old control panel. 4. Release the M4 hexagon nuts and remove with the tooth lock washers. 5. Press old control panel and old seal forwards and out of the electrical cabinet door. 6. Insert new control panel with new seal. 7. Screw on new control panel. Use tooth lock washers. 8. Plug bus cable into new control panel. 9. Close the electrical cabinet door. 2 NOTE: When a new control panel has been installed, two default settings must be renewed: 1. Simultaneously turn on the main switch and hold down the key Motor 2 and the scroll key on the control panel until the LEDs on the control panel light up. 2. Switch off main switch. 3. Simultaneously turn on the main switch and hold down the key Heater and the platen icon on the control panel until the LEDs on the control panel light up.

129 Parts 8-1 How to Use Illustrated Parts List Section 8 Parts The parts lists in the separate document Parts List are divided into the following columns: Item Identifies illustrated parts that can be obtained from Nordson. Part Nordson part number for each spare part shown in the illustration. A row of hyphens in the column Part ( ) indicates that this part can not be ordered separately. Description This column contains the name of the part and, when appropriate, its dimensions and other properties. The points in the column Description show the relationship between assemblies, subassemblies and single parts. Quantity The quantity needed per unit, assembly or subassembly. The abbreviation AR (as required) is used when this item is a bulk item or when the quantity per assembly depends on the product version or model. NOTE: Refer to separate document Parts List, P/N Fasteners Fasteners are shown as Fx in every illustration, whereby x indicates the number of the fastener in the list Schedule of Fasteners at the end of the separate document Parts List. Component Designation The electrical components are labeled in accordance with DIN 40719, part 2.

130 8-2 Parts

131 Technical Data 9-1 Section 9 Technical Data General Data Type of heating Cast-in electrical resistance heating elements Temperature sensor Ni 120 Heating time 30 to 60 minutes, depending on system, material used and ambient temperature Noise emission < 72 dba Electrical Data WARNING: Operate only at the operating voltage shown on the ID plate. Operating voltage Refer to ID plate Operating voltage frequency 50/60 Hz Fuse rating Refer to ID plate Power consumption P Refer to ID plate Power consumption P max Refer to ID plate Max. load per hose receptacle (2 channels) 1000 W per individual hose or gun 1200 W per hose/gun pair 2000 W total, hose/gun pairs 1 and W total, hose/gun pairs 3 and 4 Degree of protection IP 54

132 9-2 Technical Data Motors / Speed Motor Fixed speeds 3-phase AC motor with helical gear 50 min 1 65 min min 1 Output Quantity Note: The maximum output quantity is a factor of the pump type used and different parameters. Refer to Installation, Speed Setpoint and Output Quantity Max. 270 kg/h Max. 595 lb/h Temperatures and Thermostats Temperatures System / components C F Min. ambient temperature Max. ambient temperature Min. operating temperature Identifying Installed Thermostat NOTE: Refer to separate document Parts List to identify the thermostat used.

133 Technical Data 9-3 Material Pressures Motor/pump model (standard) bar MPa psi 3-phase AC motor with gear pump 5 to to to 870 Note: Safety valve setting is decisive for maximum 35 3,5 507,5 outlet pressure. Factory setting: Dimensions Drum diameter 567 or 571 mm, depending on the melting plate used. Refer to separate document Parts List Max. drum height 900 mm 1830,00 max ,00 760,00 Fig. 9-1