AltaSpray Plus Applicators

Transcription

1 AltaSpray Plus Applicators Customer Product Manual Issued 5/3 This document contains important safety information Be sure to read and follow all safety information in this document and any other related documentation. NORDSON CORPORATION DULUTH, GEORGIA USA

2 For CE Declaration, refer to equipment documentation. Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: Address all correspondence to: Nordson Corporation Attn: Customer Service 475 Lakefield Drive Duluth, GA Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 203. 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. Trademarks AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, Build A Part, CanWorks, Century, CF, CleanSleeve, CleanSpray, ColorMax, Color on Demand, Control Coat, Coolwave, Cross Cut, cscan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo Coat, e.dot, EFD, Emerald, Encore, ESP, e stylized, ETI stylized, Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex O Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli flow, Horizon, Hot Shot, icontrol, idry, iflow, Isocoil, Isocore, Iso Flo, itrax, Kinetix, Lean Cell, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, Micromedics, MicroSet, Millennium, MiniBlue, Mini Squirt, Mountaingate, NexJet, Nordson, Optimum, Package of Values, Paragon, Pattern View, PermaFlo, PICO, PicoDot, Porous Coat, PowderGrid, Powderware, Precisecoat, Printplus, Prism, ProBlue, Prodigy, Pro Flo, ProLink, Pro Meter, Pro Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Signature, Slautterback, Smart Coat, Solder Plus, Spectrum, Speed Coat, SureBead, Sure Coat, Sure Max, Sure Wrap, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Tubesetter, Ultra, UpTime, u TAH, Value Plastics, Vantage, VersaBlue, Versa Coat, VersaDrum, VersaPail, Versa Screen, Versa Spray, VP Quick Fit, Watermark, When you expect more., and X-Plane are registered trademarks of Nordson Corporation. Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, Allegro, AltaBlue, AltaSlot, Alta Spray, Artiste, ATS, Auto Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat, Cobalt, Controlled Fiberization, Control Weave, ContourCoat, CPX, cselect, Cyclo Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E Nordson, Equalizer, Equi Bead, FillEasy, Fill Sentry, Flow Coat, Fluxplus, Freedom, Get Green With Blue, G Net, Genius, G Site, IntelliJet, ion, Iso Flex, itrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiMix, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet, Ready Coat, RediCoat, RollVIA, Quantum, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing, Spray Works, StediFlo, StediTherm, Summit, SureFoam, Sure Mix, SureSeal, Swirl Coat, TAH, ThruWave, Trade Plus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, YESTECH, and 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. Viton is a registered trademark of DuPont Dow Elastomers. L.L.C.

3 Table of Contents i Table of Contents Safety... Safety Alert Symbols... Responsibilities of the Equipment Owner... Safety Information... 2 Instructions, Requirements, and Standards... 2 User Qualifications... 2 Applicable Industry Safety Practices... 2 Intended Use of the Equipment... 3 Instructions and Safety Messages... 3 Installation Practices... 3 Operating Practices... 3 Maintenance and Repair Practices... 4 Equipment Safety Information... 4 Equipment Shutdown... 4 Relieving System Hydraulic Pressure... 4 De energizing the System... 5 Disabling the Guns... 5 General Safety Warnings and Cautions... 5 Other Safety Precautions... 8 First Aid... 9 Safety Labels and Tags... 9 Description... 2 Intended Use... 4 Limitations of Use... 4 Key Components... 5 Theory of Operation... 6 Optional Equipment... 6

4 ii Table of Contents Installation... 8 Unpacking... 8 Items Needed... 8 Applicator Installation... 8 Install Solenoid Valves... 9 Mount the Applicator... 2 Hose Installation Air Supply Installation Connect the Module Actuating Air Connect the Pattern Air Electrical Installation Connect the Solenoid Valve Connect Cordsets Applicator Flushing Prepare for Applicator Flushing Flush the Hose Flush the Filter Flush the Manifold Flush the Modules Nozzle Installation Applicator Testing Operation Startup Shutdown Adhesive Pattern Adjustment Maintenance Required Tools and Supplies Recommended Maintenance Schedule Relieving System Pressure... 4 Flushing a Filter Replacing a Filter Screen Remove the Filter Replace the Filter Screen Install the Filter... 45

5 Table of Contents ii Troubleshooting Troubleshooting Tables Applicator Heating Problems Adhesive Output Problems Adhesive Leakage Problems Air Supply Problems Pattern Control Problems TroubleShooting Procedures Checking for Blockages Checking a Module Checking Solenoid Valve Mechanical Operation Checking Solenoid Valve Electrical Operation Checking an Air Pressure Regulator Checking a Heater Checking a Sensor Repair Synchronizing Multi Module Adhesive Output (CF200 Only) Replacing a Module Remove a Module Install a Module Rebuilding a Module Removing a Nozzle Installing a Nozzle Cleaning Nozzles Replacing a Heater Replacing an RTD... 76

6 iv Table of Contents Parts Single Module (50 mm) Applicator Parts mm Applicator Parts mm Applicator Parts mm Applicator Parts mm Applicator Parts mm Applicator Parts mm Applicator Parts mm Applicator Parts mm Applicator Parts mm Applicator Parts... 4 Applicator Service Kits... 9 Solenoid Valve Installation Kit Parts Module Parts Module Service Kits Insulating Jackets Pressure Regulators/Gauges T Style Splitter Cables T Style Extension Cables M Style Splitter and Adapter Cables... 3 M Style Extension Cables Nozzles Nozzle Adapter Part Numbers CF Nozzles Summit Nozzles SureWrap Nozzles Signature Nozzles Blank Nozzle... 4 Recommended Spare Parts and Supplies Technical Data Applicator Specifications Torque Specifications Dimensions and Clearances T Style Cable Wiring Diagrams M Style Cable Wiring Diagrams... 68

7 AltaSpray Plus Applicators AltaSpray Plus Applicators 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. 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.

8 2 AltaSpray Plus Applicators 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. 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 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.

9 AltaSpray Plus Applicators 3 Intended Use of the Equipment 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. Instructions and Safety Messages 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 at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices. This equipment has not been certified for compliance with the ATEX directive nor as incendive and should be installed in potentially explosive environments. 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.

10 4 AltaSpray Plus Applicators 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 Nordson authorized refurbished or 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. 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.

11 AltaSpray Plus Applicators 5 De energizing the System Isolate the system (melter, hoses, applicators, and optional devices) from all power sources before accessing any unprotected high voltage wiring or connection point.. 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. Disabling the Guns NOTE: Adhesive dispensing applicators are referred to as guns in some previous publications. All electrical or mechanical devices that provide an activation signal to the applicators, applicator solenoid valve(s), or the melter pump must be disabled before work can be performed on or around an applicator that is connected to a pressurized system.. Turn off or disconnect the applicator triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the applicator solenoid valve(s). 3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the applicator. General Safety Warnings and Cautions Table 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 as follows: HM = Hot melt (melters, hoses, applicators, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and applicators)

12 6 AltaSpray Plus Applicators Equipment Type Table General Safety Warnings and Cautions Warnings and Cautions HM 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 applicators 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.

13 General Safety Warnings and Cautions (contd) Equipment Type AltaSpray Plus Applicators 7 Warnings and Cautions HM, PC WARNING! Equipment starts automatically! Remote triggering devices are used to control automatic hot melt applicators. Before working on or near an operating applicator, disable the applicator's triggering device and remove the air supply to the applicator's solenoid valve(s). Failure to disable the applicator'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 has not been certified for the ATEX directive or as nonincendive. In addition, this equipment 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 to the equipment.

14 8 AltaSpray Plus Applicators Equipment Type Table General Safety Warnings and Cautions (contd) Warnings and Cautions HM CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of applicators, 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. 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.

15 AltaSpray Plus Applicators 9 First Aid If molten hot melt comes in contact with your skin:. 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. Safety Labels and Tags Figure illustrates the location of the product safety labels and tags affixed to the equipment. Table 2 provides an illustration of the hazard identification symbols that appear on each safety label and tag, the meaning of the symbol, or the exact wording of any safety message. Figure : Safety labels and tags

16 0 AltaSpray Plus Applicators Table 2 Safety Labels and Tags Item Part Description. Warning, CE, electrical shock (screen print) 2. Warning, CE, hot (screen print) 3. Warning, CE, pressure (screen print) WARNING: Fire, injury or equipment damage can result if cleanout materials do not meet the following requirements:. Minimum flash point to be 550 F (288 C). 2. Liquid and vapor to be non toxic at use temperature in equipment. 3. Chemical reactions with adhesive and equipment materials must not be violently heat producing. 4. Cleanout material must not corrode or otherwise weaken equipment materials. CAUTION: This equipment is factory tested with Nordson type R fluid containing Polyester Adipote plasticizer. Certain adhesives may react with the type R fluid residue to form solid gum which can be difficult to remove. To avoid equipment damage check with adhesive supplier regarding compatibility and cleanout procedure before putting adhesive into the system.

17 Safety Labels and Tags (contd) AltaSpray Plus Applicators Table 2 Safety Labels and Tags (contd) Item Part Description CAUTION: This unit is equipped with F preset thermostat. Use only adhesive formulated for application at this temperature. Before changing adhesive consult instruction manual for changing operating temperature. Failure to follow instructions may result in personal injury or property damage. CAUTION: This applicator is RTD (resistance temperature detector) controlled. Prior to operation and before changing adhesive consult instruction manual for changing operating temperature. Failure to follow instructions may result in personal injury or property damage WARNING: Disconnect power and remove system pressure before disassembly or maintenance. Failure to follow these instructions may result in serious personal injury.

18 2 AltaSpray Plus Applicators Description This manual describes the installation and use of Nordson AltaSpray Plus applicators. AltaSpray Plus applicators apply thermoplastic hot melt adhesive to various products. When necessary, the reader is referred to the documentation supplied with other Nordson products or products supplied by third parties. AltaSpray Plus applicators are available in a variety of configurations, including single module and multi module (up to 200 mm width) versions. Modules and solenoid valves are ordered separately. AltaSpray Plus applicators can accommodate CF200, UM25, and UM50 modules. A wide variety of compatible nozzles are available, as listed under Parts.

19 AltaSpray Plus Applicators 3 Description (contd) Figure 2: Typical AltaSpray Plus applicator configurations. Single module applicator with a UM25 module mm applicator with UM50 modules mm applicator with UM25 modules Note: Modules and solenoid valves are sold separately. Solenoid valves are not shown.

20 4 AltaSpray Plus Applicators Intended Use AltaSpray Plus applicators are specifically designed to: dispense liquified materials at temperatures below 9 C (375 F) be used with compatible hot melt equipment manufactured by Nordson Corporation be used in non explosive environments Limitations of Use Use AltaSpray Plus applicators only for the purpose for which they are designed. They should not be used: to dispense polyurethane reactive hot melt materials or any other material that creates a health or safety hazard when heated in environments that will require the equipment to be cleaned using a water wash or spray

21 AltaSpray Plus Applicators 5 Key Components Figure 3: Key parts of an AltaSpray Plus applicator (single module applicator shown). Mounting rod 2. Filter 3. Electrical cover 4. Air manifold 5. Nozzle location 6. Dispensing module (UM25 module shown; see Note) 7. Hose connection 8. Cordset 9. Drain valve 0. Pattern air connection Note: Modules and solenoid valves are ordered separately. The solenoid valve is not shown.

22 6 AltaSpray Plus Applicators Theory of Operation Adhesive is heated to application temperature, which is typically about 9 C (375 F), in a melter. The melter pumps the adhesive through a heated hose to the applicator. The applicator then dispenses the adhesive through dispensing modules onto a product. The type of nozzle used on the modules determines the type of adhesive pattern produced. The applicator requires two air supplies: one to actuate the modules (module actuating air) and one to supply the air that shapes or fiberizes the adhesive exiting the nozzles (pattern air). The module actuating air is controlled through one or more solenoid valves that are installed on the applicator and connected to a module actuating air supply line with an air pressure regulator. The pattern air is likewise controlled through an air pressure regulator installed in a pattern air supply line. The applicator is heated by cartridge type heaters. Power is supplied to the heaters through a cordset, which is connected electrically to the hose or to some combination of splitter and extension cables. Resistance temperature detectors (RTDs) sense the temperature of the adhesive or air in the applicator and relay the temperature through the cordsets, hoses, and/or cables to a melter control system or to a standalone temperature controller. The pattern in which adhesive is dispensed onto the product is determined by: the choice of nozzle the distance at which the nozzle is placed above the product the production line speed the adhesive add on weight (melter pump speed) the pattern air pressure the pattern air temperature (if applicable) the adhesive application temperature the type of adhesive used the viscosity of the adhesive used Optional Equipment Optional equipment may be ordered to expand the functionality of an AltaSpray Plus applicator, including, but not limited to, the following: insulating jackets pressure regulators/gauges Refer to Parts for a complete list of optional equipment.

23 AltaSpray Plus Applicators 7 This page intentionally left blank.

24 8 AltaSpray Plus Applicators Installation This section provides procedures for installing the applicator and preparing it for operation. Before performing any installation procedures, review Safety. Unpacking Exercise normal care to prevent equipment damage during unpacking. After unpacking the applicator, inspect if for any damage that may have occurred during shipping. Look for any dents and scratches and make sure all fasteners are tight. Report any damage to your Nordson representative. Items Needed You will need the following items to install the applicator: melter or temperature controller, hoses, and associated manuals solenoid valve(s) electronic control device for solenoid valve(s) air line tubing and fittings applicator mounting hardware device to lift and position the applicator personal protective equipment for working with hot adhesive tool kit, including wrenches and screwdrivers anti seize lubricant drain pans and waste containers suitable for waste adhesive PTFE paste or tape Applicator Installation Follow these procedures to install the applicator. Applicator installation includes installing a solenoid valve (if applicable) and mounting the applicator.

25 AltaSpray Plus Applicators 9 Install Solenoid Valves If the solenoid valve for your applicator is not already installed, install it at this time. An installation configuration like the one shown in Figure 4, 5, or 6 is recommended. The installation shown in Figure 6 is recommended only for continuous adhesive application and should not be used for applications in which the modules will be intermittently cycled on and off. Solenoid valves are used to control the module actuating air. All modules are normally closed, requiring air to open them. Use the following guidelines: Use only clean, dry, unlubricated air. Install the solenoid valve as close as possible to the module actuating air inlet to reduce the lag time between actuation and module opening. 2 8mm OR 5/6 O.D. TUBING, PART NUMBER PART NUMBER mm O.D. TUBING, PART NUMBER Figure 4: Recommended solenoid valve installation (straight fitting). Solenoid valve 3. Air transfer tube 2. Compression fitting 4. Silencer Note: These items are available in a service kit. Refer to Parts.

26 20 AltaSpray Plus Applicators SOLENOID ORIENTATION FOR RIGHT ANGLE FITTING Figure 5: Recommended solenoid valve installation (right angle fitting). Right angle fitting Note: The right angle fitting is included in the solenoid valve kit. Refer to Parts. 8mm OR 5/6 O.D. TUBING, PART NUMBER PART NUMBER mm O.D. TUBING, PART NUMBER PART NUMBER REF. ALTERNATE INSTALLATION (CUSTOMER SUPPLIED ACTUATION AIR) Figure 6: Alternate installation method customer supplied actuation air Note: The fittings shown in this illustration are included in the solenoid valve kit. Refer to Parts.

27 AltaSpray Plus Applicators 2 Mount the Applicator Mounting the applicator includes selecting an appropriate mounting location and installing any necessary mounting hardware on the production line.. Select a mounting location. Use the following guidelines: Make sure there will be enough clearance to remove the filter from the adhesive manifold drain adhesive from the drain valve replace heaters or sensors replace a solenoid valve, module, or nozzle route and replace air tubing and hoses NOTE: Refer to Technical Data for applicator dimensions and recommended clearances. Choose a location that will not subject the applicator to extreme temperature variations or equipment vibration. The ambient temperature should be 0-49 C (32-20 F). Choose a location that will allow you to properly route the hoses from the applicator to the melter. Figure 8 provides hose routing guidelines. Choose a location close to a supply of dry, regulated, unlubricated air. 2. See Figure 7. If applicable, install any hardware that will be required on the production line to accommodate the applicator mounting rods. If possible, use mounting hardware that will allow you to adjust the height of the applicator between 3-76 mm ( in.) after it is mounted. 3. Move the applicator into position on the production line (use an appropriate lifting device if needed) and secure the applicator at the mounting location. Adjust the applicator height and angle as appropriate. NOTE: For installation best practices, obtain an application guide specific to your application from or contact your Nordson representative for assistance. In most installations, the applicator should be perpendicular to the surface onto which the adhesive is to be applied.

28 22 AltaSpray Plus Applicators Figure 7: Location of the mounting hardware (single module and eight module applicators shown; solenoid valves not shown)

29 AltaSpray Plus Applicators 23 Hose Installation Follow this procedure for each hose hydraulic connection you are making. Do not connect the hose cordsets at this time.. Connect the hose to the adhesive supply port on the applicator, using a hose fitting as necessary. Use two wrenches to connect the hose as shown in Figure 8. NOTE: The hose cordset should be located at the melter end (where adhesive enters the hose). This ensures that the hose sensor measures the temperature of the adhesive exiting the hose. NOTE: Refer to the parts section of the melter manual for available hose fittings. 2. Install the insulation cuff from the ship with kit over the hose connection. CAUTION! Risk of equipment damage. Do not use nonconductive pipe compound or tape on hose fittings. CAUTION! Improper routing and venting of hoses could result in overheating, damage, and poor adhesive flow. To ensure proper operation, do not bundle or tie wrap hoses, do not bend hoses at sharp angles, and do not allow hoses to lay on concrete floors or other cool surfaces that could conduct heat away from the hoses. 3. Route the hose to the melter and connect it to the melter hydraulically and electrically as directed in the melter manual. Follow the hose routing guidelines shown in Figure 8.

30 24 AltaSpray Plus Applicators P/N 940 X X=3 mm (0.50 in.) R=203 mm (8.00 in.) P/N mm (5/6 in.) P/N mm (5/8 in.) P/N mm ( /8 in.) ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ ÎÎÎÎÎ Figure 8: Hose installation guidelines

31 AltaSpray Plus Applicators 25 Air Supply Installation Follow these procedures to connect air supplies to the applicator. Air is supplied to the applicator for two reasons: () to actuate the modules (module actuating air) and (2) to supply the modules with the air that shapes or fiberizes the adhesive being applied by the modules (pattern air). Connect the Module Actuating Air See Figures Figure 4, 5, or 6, as applicable. Connect a supply of dry, regulated, unlubricated air to the module actuating air inlet on the applicator solenoid valve. Nordson Corporation recommends installing an air pressure regulator and filter in the module actuating air supply line that is capable of regulating the air pressure up to 6.2 bar (90 psi). For the module actuating air pressure range, refer to Applicator Specifications under Technical Data. NOTE: Nordson Corporation offers a selection of air pressure regulators/gauges. Refer to Parts for part numbers.

32 26 AltaSpray Plus Applicators Connect the Pattern Air See Figure 9. Use the 8 mm or 5 / 6 in. internal diameter (ID) tubing () from the ship with kit to connect a supply of dry, regulated, unlubricated air to the to the compression fitting (4). As an alternate, a clamp (2) and fitting (3) may be used with / 4 in. ID tubing (not supplied). Be sure to connect the high temperature end of the tubing assembly (white or clear tube) to the applicator pattern air fitting. To determine where the pattern air inlet on your applicator is located, refer to the applicator specific reference drawing under Parts. Nordson Corporation recommends installing an air pressure regulator and filter in the pattern air supply line that is capable of regulating the pattern air flow up to a 56.6 nlm (2 scfm) flow rate per module. For the pattern air pressure operating range, refer to Applicator Specifications under Technical Data. Figure 9: Pattern air supply connection (single module applicator shown). Tubing 2. Clamp 3. Fitting 4. Compression fitting

33 AltaSpray Plus Applicators 27 Electrical Installation Electrical installation involves connecting the solenoid valve to a triggering device and connecting the cordset. Before making any electrical connections, complete the procedures under Applicator Installation, Hose Installation, and Air Supply Installation. Connect the Solenoid Valve Electrically connect the solenoid valve to a triggering device so that the module will open and close at the appropriate times.. Ensure that the voltage ratings of the solenoid valve and the triggering device match. The solenoid valve power requirement is 8.5 W, 24 VDC. 2. See Figure 0. Remove the electrical connector () screw and disconnect the connector. Save the gasket. 3. Separate the terminal block from the connector housing. 4. Loosen the electrical connector strain relief nut (2). 2 Figure 0: Removing the quick disconnect connector from a solenoid valve. Electrical connecter 2. Strain relief nut

34 28 AltaSpray Plus Applicators CAUTION! Solenoid valves must be rated for the output voltage of the triggering device. Make sure the ratings match. 5. See Figure. Thread a mm 2 (8-22 AWG) three conductor cable through the strain relief; then connect the positive and negative leads to terminals and 2 [normal polarity, = (+) and 2 = (-)] the ground wire to the ground terminal 6. Ensuring correct configuration of the terminal block (see Figure ), snap the block back into the connector and tighten the strain relief nut. 7. Align the gasket on the connector and plug the connector into the solenoid valve, securing it with the screw removed earlier. 8. Connect the three conductor cable to the triggering device. Refer to the instructions that came with the triggering device. Normal polarity: =(+) positive, high 2=( ) negative, neutral = ground Figure : Solenoid valve terminal block configurations

35 AltaSpray Plus Applicators 29 Connect Cordsets Cordsets provide heater power and temperature sensing and establish an electrical ground. There are two basic ways to connect cordsets: through the hose or through extension and/or splitter cable(s). See Figures 2-6 for the most typical ways in which cordsets are connected. Use this illustration to make your cordset connections, or contact your Nordson representative for assistance. Refer to Parts for splitter, adapter, and extension cable part numbers. NOTE: T style applicator cordsets for channels with up to 800 W use a rectangular connector and may be powered through the hose. T style cordsets for channels greater than 800 W use a square connector and must be connected through an extension cable. M style applicator cordsets for channels with up to,000 W use a square connector and may be powered through the hose. M style cordsets for channels greater than,000 W use a round connector and must be connected through an extension cable. In all cases, the capabilities of the melter or standalone controller must be considered. NOTE: Nordson melters have multiple electrical connectors for hose/applicator pairs (two electrical channels are accommodated by each electrical connector), and in all cases there is a maximum wattage allowed per electrical channel as well as a maximum wattage allowed for the combined channels. Refer to the melter manual for additional details or contact your Nordson representative for assistance. WARNING! Risk of personal injury or death. Allow only qualified personnel to perform electrical installation, troubleshooting, or repair procedures. Before performing any electrical procedure, review Safety and disconnect and lock out electrical power to the system.

36 30 AltaSpray Plus Applicators Figure 2: Connecting a single cordset through a hose. Applicator cordset 2. Hose 3. Hose cordset 4. Melter electrical receptacle Figure 3: Connecting a single cordset through an adapter cable and an extension cable. Applicator cordset 2. Adapter cable 3. Extension cable 4. Melter electrical receptacle

37 AltaSpray Plus Applicators 3 Connect Cordsets (contd) Figure 4: Connecting two cordsets: one through a hose and one through an adapter and extension cable. First applicator cordset 2. Adapter cable 3. Extension cable 4. Melter electrical receptacle 5. Second applicator cordset 6. Hose 7. Hose cordset Figure 5: Connecting two cordsets: one through an extension cable and one through a splitter cable. First applicator cordset 2. Extension cable 3. Melter electrical receptacle 4. Second applicator cordset 5. Extension cable 6. Splitter cable

38 32 AltaSpray Plus Applicators Figure 6: Connecting two cordsets: each through an adapter cable and an extension cable. First applicator cordset 2. First adapter cable 3. First extension cable 4. Melter electrical receptacle 5. Second applicator cordset 6. Second adapter cable 7. Second extension cable

39 AltaSpray Plus Applicators 33 Applicator Flushing Flushing the applicator removes cleaning solution, adhesive, and other contaminants from the equipment. The applicator should be flushed before initial use and anytime you change the adhesive in the hot melt system. This helps prevent clogging of the filter or nozzles and makes the applicator work more efficiently. Prepare for Applicator Flushing. Determine whether you need to flush the applicator with adhesive or with cleaning fluid and then with adhesive. Refer to Table 3. Table 3 Applicator Flushing Situations Situation Flushing Materials to Use Initial startup Adhesive only Changing adhesive in the system a. Cleaning solution compatible with both the old and new adhesives b. New adhesive (to remove the cleaning solution) 2. Heat the system to application temperature. Refer to the melter manual as needed. 3. Stop the melter pump(s). 4. Place drain pans under the applicator drain valves, the hose connections, and the modules. WARNING! Risk of burns. Failure to relieve system pressure can cause hot adhesive to spray from a connecting point. Relieve system pressure before loosening or removing a hose, module, or any other part of the hot melt system. Wear heat protective clothing, safety goggles (ANSI Z87. or equivalent), and safety gloves. 5. Relieve system pressure. Refer to Relieving System Pressure under Maintenance. 6. Flush the applicator by performing the following procedures with each flushing material to be used: Flush the Hose Flush the Filter Flush the Manifold Flush the Modules

40 34 AltaSpray Plus Applicators Flush the Hose Follow this procedure to flush the hose. Refer to the melter manual as needed for instructions on starting and stopping the melter pump(s).. Disconnect the hose from the applicator and direct the end of the hose into a waste container. 2. Start the melter pump(s). 3. When the adhesive flowing from the hose is free of any solvent or contaminants, stop the melter pump(s). 4. Wipe any adhesive from the hose connector. 5. Reconnect the hose to the applicator. Flush the Filter Refer to Flushing a Filter under Maintenance to flush the filter. Return here to continue. Flush the Manifold Follow this procedure to flush the manifold. Refer to the melter manual as needed for instructions on starting and stopping the melter pump(s).. Set the pattern air pressure so that there is just enough pressure to prevent adhesive from entering the air ports on the heated air manifold. 2. Remove the modules from the manifold. Refer to the module removal procedure under Repair as needed. 3. Place a drain pan under the manifold. 4. Start the melter pump(s). 5. Allow some adhesive to drain from the manifold. When the adhesive flowing from the manifold is free of any contaminants, stop the melter pump(s). 6. Wipe any adhesive from the manifold. 7. Reinstall the modules on the manifold. Refer to the module removal procedure under Repair as needed.

41 AltaSpray Plus Applicators 35 Flush the Modules Follow this procedure to flush the modules. Refer to the melter manual as needed for instructions on starting and stopping the melter pump(s).. Ensure that nozzles are removed from the modules. 2. Set the pattern air pressure to bar (2-5 psi). 3. Turn on the module actuating air. 4. Start the melter pump(s). 5. When the adhesive flowing from the modules is free of any contaminants, stop the melter pump(s) and turn off the module actuating air. 6. Wipe any adhesive from the modules. Nozzle Installation Install nozzles before placing the applicator into operation. Refer to Repair for nozzle installation and removal procedures. Applicator Testing Perform tests as needed to ensure that the applicator output meets the requirements of your application. When testing, proceed systematically by changing only one production variable (such as the system pressure) at a time. If changing the variable does not produce the desired result, return it to its original state and try changing a different variable. Proceed in this manner until the desired applicator performance is achieved. Contact your Nordson representative for assistance as needed.

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43 AltaSpray Plus Applicators 37 Operation This section provides procedures for operating the applicator. Before you operate the applicator for the first time, make sure you have completed the installation procedures under Installation flushed the applicator by completing the applicator flushing procedure under Installation optimized the applicator output for your application as described in Applicator Testing under Installation Before you perform any operating procedures, review Safety. Startup NOTE: Because the melter supplies the adhesive and the electrical power to the applicator, the procedures for starting and stopping the applicator vary depending on the type of melter you are using. Refer to the melter manual for complete startup and shutdown procedures.. Start the melter and heat the system to application temperature. 2. Turn on the pattern air. 3. Turn on the module actuating air. 4. Start the melter pump(s). 5. Start the production line. NOTE: Pneumatic and hydraulic pressure ranges are provided under Technical Data.

44 38 AltaSpray Plus Applicators Shutdown NOTE: Because the melter supplies the adhesive and the electrical power to the applicator, the procedures for starting and stopping the applicator vary depending on the type of melter you are using. Refer to the melter manual for complete startup and shutdown procedures.. Stop the production line. 2. Stop the melter pump(s). 3. Shut off the module actuating air. 4. Shut off the pattern air. 5. Relieve system pressure. Refer to Relieving System Pressure under Maintenance. 6. Shut down the melter. Adhesive Pattern Adjustment Use the following techniques to modify the adhesive pattern: adjust the adhesive add on weight (melter pump speed) adjust the electronic control device (timer or pattern controller) adjust the pattern air pressure adjust the pattern air temperature (if applicable) adjust the adhesive application temperature change the type of adhesive used change the nozzle type or size adjust the applicator height If you experience problems obtaining the desired adhesive pattern, refer to Pattern Control Problems under Troubleshooting.

45 AltaSpray Plus Applicators 39 Maintenance This section contains a list of recommended maintenance activities and a recommended schedule for performing those activities. Attempting any other maintenance procedures can result in equipment damage, improper system operation, or personal injury. Before you perform any maintenance procedures, review Safety. Required Tools and Supplies To perform maintenance or repairs, you will need: a set of metric socket wrenches a set of metric Allen (hex) wrenches a set of metric T handle hex keys a set of metric open ended wrenches flat blade and Phillips head screwdrivers drain pans and large waste containers other tools and supplies as noted You will also need a sufficient inventory of spare parts and supplies. Each maintenance and repair procedure in this manual is preceded by a list of the parts and supplies you will need. Refer to Parts for the part numbers of parts and supplies.