Hot -melt adhesive extruder EEX100 -F5B2X2TWXMQXS

Transcription

1 Hot -melt adhesive extruder EEX100 -F5B2X2TWXMQX Manual / English -- Nordson Deutschland GmbH D Buchholz--Mendt D GERMANY

2 Note This manual applies to the entire series. erial no /001 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, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, Cleanleeve, Cleanpray, Control Coat, CoolWave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EFD, ETI, Excel 2000, FlexiCoat, Flexi-pray, Flex-O-Coat, Flow entry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot hot, Isocoil, Isocore, Iso-Flo, JR, KB30, Kinetix, Little quirt, Magnastatic, MEG, Meltex, Microcoat, Micromark, Microet, Millenium, Mini quirt, Moist-Cure, Mountaingate, Multican, Nordson, Omnican, OptiMix, Package of Values, Patternview, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-tream, RBX, Rhino, aturn, C5,. design stylized, eal entry, elect Charge, elect Coat, elect Cure, lautterback, mart-coat, older Plus, pectrum, peed-coat, praymelt, pray quirt, uper quirt, ure Coat, Tela-Therm, Tracking Plus, Trends, Tribomatic, Ultrasaver, Unican, UpTime, Veritec, VersaBlue, Versa-Coat, Versa-creen, Versa-pray, Walcom, Watermark, When you expect more. are registered trademarks of Nordson Corporation. AeroDeck, AeroWash, Apogee, AT, Auto-Flo, Autocan, BetterBook, CanNeck,Chameleon, Check Mate, ColorMax, Controlled Fiberization, Control Weave, CPX, Dry Cure, DuraBlue, Dura-Coat, DuraPail, Dura-creen, Easy Clean, Eclipse, EcoDry, e.dot, E-Nordson, Equi=Bead, EP, e tylized, Fillmaster, Fill entry, Gluie, HDLV, icontrol, iflow, Ink-Dot, ion, Iso-Flex, itrend, KVLP, Lacquer Cure, March, Maxima, MicroFin, MicroMax, Minimeter, Multifil, Optitroke, Origin, PatternPro, PluraMix, Powder Pilot, Powercure, Primarc, Printplus, Process entry, Pulse pray, PurTech, Ready Coat, coreguard, elect eries, ensomatic, haftshield, heetaire, pectral, pectronic, peedking, pray Works, ummit, urebead, ure Brand, ure Clean, ure-max, wirl Coat, Tempus, ThruWave, Trade Plus, Trak, Ultrasmart, Universal, Vantage, Viper, Vista, Web Cure, 2 Rings (Design) are trademarks -- T -- 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. Order number EEX100--F5B2X2TWXMQX Issued 04/10 E 2010 Nordson Deutschland GmbH All rights reserved

3 Table of Contents I Table of Contents afety Instruction General Description afety Information Using Hotmelt Temperature Glue Tank Information Leaflet on the Use of PUR--Hotmelts afety Instructions General Instructions Introduction Introduction Intended Use Area of Use (EMC) Operating Restrictions Unintended Use -- Examples Residual Risks Note on Manual eries Overview Explanation of Type Designation ID--Plate oftware Notice Notice on Electrical Engineering Health--Endangering Media Dangerous Points and afety Devices Dangerous Points on the Hotmelt Adhesive Extruder Danger Points in the Vicinity of the Extruder Covers afety equipment on the extruder Important safety notice: Door Lock Lockable main switch Black Main witch (pecial Model) Emergency top Button (Optional for tand--alone Operation) Temperature Control Undertemperature Interlock Under--temperature Indication Overtemperature Indication / hutdown Temperature etbac Electrical afety Valve witch Cabinet Light Tower ( optional ) Control ystem Electrical Cabinet Ventilation Hose connection X1 / X Interface X8 / X9 / X10 / X General Description Functional Diagram E 2010 Nordson Deutschland GmbH EEX100 -F5B2X2TWXMQX P/N

4 II Table of Contents Description of Functional Elements Drive Basic Frame Filling Area Covers crew crew Cylinder Cylinder Feed Cooling Cylinder Feed Cooling in crew Cylinders with Inner Resin Cladding (depending on order) Cylinder feed cooling Basic Functionality of Hot--Melt Processing Extruders Mode of Operation Cooling Heating crew Pressure Regulation Pressure Monitoring Level Monitoring of Hopper Temperature Monitoring Pump station Motor and Gear Pump Manometric switch Pressure sensor Installation Unpacking Transportation Attaching Light Tower (optional) Exhausting Hot Melt Adhesive Vapours Installation and Alignment etup Lifting (Unpacked Unit) Removal torage Disposal Operating conditions Installation: Air humidity: Air temperature: Electrical Connections Notice on the use of ground fault circuit interrupters Laying Cable Line Voltage External control and signal circuits Pilot Voltage / Tach Generator Adjustment to Tachometer Modulation Board Interface Profibus (Option) Electrical installation Assignment of temperature controllers to temperature sensors Connecting Heated Hoses econd Open-jawed Wrench Connecting Disconnecting Relieving Pressure P/N EEX100 -F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

5 Table of Contents III Connector Allocation Installation Assignment: Interface X10 / X Procedure Water installation Important: pecifications Water specifications Operation tart--up Preparations for tart--up etting into operation Electrical connection General control functions External control functions Microprocessor -- temperature control Adjusting the temperatures electing the program level Beginning production Procedure Manual operation Hotmelt delivery via one or several nozzles Desired pressure setting on the extruder (pre--pressure pumps) Procedure Automatic operation Hotmelt application with automatic, speed -- dependent metering Application Mode Intermittent Hotmelt application elector witch Pressure / peed Control election peed Control election Pressure Control Continuous hotmelt application Error messages Dry--run protection witching ystem ON/OFF Daily tart--up Daily witch--off witching Off in an Emergency Maintenance Danger of burns Relieving Pressure Decommissioning Cleaning the crew Cleaning the crew etting into operation Regular Maintenance Maintenance gear pump External Cleaning Inspection for External Damage Over--temperature Thermostat Changing Type of Adhesive Purging with Cleaning Agent Electrical Cabinet Ventilation Maintenance Replacement and Cleaning of Filter Mat Continuous Checks E 2010 Nordson Deutschland GmbH EEX100 -F5B2X2TWXMQX P/N

6 IV Table of Contents For heating elements with ceramic insulation: Bei Heizbändern mit Mikanitisolation: ervice and Maintenance Motor Lubrication Lubricant Recommendations for Threaded Connectors Fault Rectification General Checks Troubleshooting Troubleshooting/Failure Corrective Action ome Tips Troubleshooting with Control ystem Leuchtmelder und Meldeampel Automatik Handbetrieb Troubleshooting tables Red ignal Lamp Flashing Device malfunctioning No adhesive (no motor rotation) Motor superheated No master reference voltage No adhesive (with motor rotation) Incorrect motor speed characteristics in automatic mode Insufficient adhesive One channel (heating zone) does not heat Removing Danger of burns General remarks Removing and Inserting the crew Important Note: Removal Insertion pare Parts Introduction Using the Illustrated Parts List Example Frame for attaching parts Extruder unit Pump unit PN Pressure relief valve Control module D P/N Pneumatic foam Extruder covers Water connection Technical Data Description Connection, tart--up: General Data Electrical Data Temperatures Technical Data P/N EEX100 -F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

7 afety Instruction 1-1 Chapter 1 afety Instruction General Description afety Information The equipment described is intended for use in industrial electrical drive systems. This equipment can endanger life through rotating machinery and high voltages, therefore it is essential that guards for both electrical and mechanical parts are not removed. The following points should be observed for the safety of the personnel: Only qualified personnel familiar with the equipment are permitted to install, operate and maintain the devices. ystem documentation must be available and observed at all times. All non -- qualified personnel are kept at a safe distance from the equipment. The system must be installed in accordance with local regulations. A qualified person is a person who is familiar with all safety notes and established safety practices, with the installation, operation and maintenance of this equipment and the hazards involved. For more detailed definitions see IEC 364. It is recommended that anyone who operates or maintains electrical or mechanical equipment should have a basic knowledge of First Aid. As a minimum, they should know where the First Aid equipment is kept and the identity of the official First Aiders. These safety notes do not represent a complete list of the steps necessary to ensure safe operation of the equipment. If you wish further information, please contact your nearest representative. E 2010 EEX100--F5B2X2TWXMQX P/N

8 1-2 afety Instruction Using Hotmelt Temperature The temperature must not exceed or fall below the specified temperature ranges; continuous temperature monitoring is appropriate. Excessively high temperatures may give rise to odours and impair the quality of the hotmelt. Excessively low temperatures also have negative effects. hould satisfactory results be achieved only at a temperature other than the specified application temperature, please be sure to contact us. Glue Tank Do not leave the glue tank in heated state for a prolonged period without removing the adhesive (thermal damage to the hotmelt). When the machine is to remain out of operation for a prolonged period, the heating should be shut down or the temperature lowered. Glue tanks must be covered, in order to prevent contamination with paper dust, moisture and dirt. We recommend regular cleaning of the melting and application systems. hould you have any doubts or experience any difficulties when using the hotmelt, please call us: We want to help before any damage occurs. Caution - Danger of Injury Protect the operating personnel against burns when handling hotmelts in hot state. Unfortunately, injuries occur when precautionary measures are ignored. Protective gloves are to be worn. Medical advice when hotmelt in hot state has come into contact with the skin: Cool burn immediately with clean and cold water. Do not remove hotmelt residues from the skin. Cover burn with clean and moist compresses and consult a doctor immediately. Hotmelt adhesives also give off fumes at the specified application temperature. This often gives rise to unpleasant smells. In case of temperatures substantially below the specified application temperatures, there is a danger that harmful decomposition products may form. Measures to remove the fumes via appropriate extraction are imperative. P/N EEX100--F5B2X2TWXMQX E 2010

9 afety Instruction 1-3 Information Leaflet on the Use of PUR -Hotmelts When working with PUR--hotmelts, there are some special product characteristics to be taken into account in order to guarantee a smooth and problem--free operation of your melting unit. PUR--hotmelts are characterised by the fact that after the purely physical setting where the material solidifies, a subsequent reaction with humidity occurs which triggers chemical crosslinking. This phenomenon is also caused by processing the material at too high temperatures and / or by thermal strain over too long a period of time. In order to avoid or at least to limit these increases in viscosity, we recommend the following measures: PUR--hotmelts must always and by all means be protected against humidity (ambient air) whether during production, storing or use. Never process PUR--hotmelts at higher temperatures than recommended! Prevent local over--heating. When changing to a different type of adhesive, do check whether the products are compatible. Contact your adhesive supplier for further information. Otherwise there may be a chemical reaction which results in an unmeltable compound! Completely use up the molten material within about 4 hours! Always contact your adhesive supplier / producer and observe strictly the instructions and information given in the material safety data sheet! Our machines are very well apt for the processing of PUR--hotmelts. However, please take into account that there are some special features to be observed when it comes to the use and maintenance of your melting unit: When processing the glue in tank melting units, you need a constant gas injection on the molten material with dry inert gas in order avoid chemical reactions with the ambient air (humidity). All melting units and application equipment (like coating heads, nozzles, hoses, etc. ) have to be cleaned and / or flushed thoroughly in case of a machine standstill / production break or when changing to a different type of adhesive. The remnants of the flushing agent have to be expelled completely from the system before restarting the machine. When processing reactive hotmelts your adhesive supplier or our company shall be glad to advise you. When observing the hints given above, you should have no problems working with PUR--hotmelts. However, we are not in a position to enter into a warranty or give guarantees in case of unprofessional use of this sensitive material or the non--observance of the recommendations given either above or by your adhesive supplier. E 2010 EEX100--F5B2X2TWXMQX P/N

10 1-4 afety Instruction afety Instructions tatus as per January 1st, 2010 Every person concerned with the transportation, mounting, operation, maintenance and repair of this machine is obliged to have carefully read and understood these operating instructions. General Instructions Work may only be carried out on this machine by duly trained staff and/or by staff who have been correspondingly familiarized with its operation. CAUTION: Improper use may pose risks to life and limb, to the machine itself and any ancillary equipment connected to it, and to the operational efficiency of the machine. The installed equipment may only be used for the purposes determined by the manufacturer or for purposes customary for the type of machine. The machine may only be operated by authorized staff with a suitable professional background and corresponding technical qualifications. A professionally suitable person may, based upon his professional training, expertise and professional experience as well as on his knowledge of the accident prevention and employee protection regulations, assess and execute the tasks he has been charged with, recognizing possible hazards, provided he also fulfils the necessary personal (executive) prerequisites for his work, e.g. capacity to work independently. In order to avoid accidents, operation of the machine is only to be carried out provided that the machine is in perfect working order. No third--party equipment is to be used in conjunction with operating the machine since this would undermine the required level of operational safety. All working methods which impair the machine s operational safety are to be refrained from. The operator is obliged to immediately report any changes affecting machine performance (and impairing operational safety) to the competent supervisory staff. In the event of a disruption which impairs staff safety, the operator is obliged to immediately shut down the machine. The machine may only be restarted once the disruption has been remedied. No safety features may be dismounted, manipulated, or rendered inoperative.the operating company is obliged to ensure that an operational check of the machine s safety devices is carried out both before the first start--up as well as prior to every recommencing of operations thereafter. uch checking procedures must be carried out by staff who have been duly familiarized with the machine s operation. The operating company is obliged to provide the required protective gear for operating staff and is also obliged to ensure that this is used by all staff members. P/N EEX100--F5B2X2TWXMQX E 2010

11 Introduction 2-1 Chapter 2 Introduction Introduction These operating instructions are written so that those who are in charge of operating the machine described read, understand, and observe the instructions given herein in every respect. A complete copy of the technical documentation should always be kept in the vicinity of the machine. WARNING: Particularly important details concerning the deployment of this machine shall be specially referred to in these operating instructions. Non compliant use is strictly prohibited! The operator shall be solely responsible for the consequences of any deviations from the above. Only by reading and knowing these operating instructions can machine defects and mistakes in handling be avoided, thus ensuring trouble--free operation. It is thus very important that these operating instructions are truly known and understood by the people responsible. Careful reading of these operating instructions prior to start--up is strongly recommended by us, since we shall not accept any liability for damages and disruptions of operations which result from non--observance of these operating instructions! We reserve the right to amend descriptions and details given in these operating instructions as may become necessary within the scope of making technical improvements to the machine. E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

12 2-2 Introduction Intended Use Units in the series EEX may only be used for the melting and conveying of thermoplastic adhesives or of thermoplastic raw material for adhesive manufacture. When in doubt seek permission from Nordson. When using reactive, abrasive or chemically aggressive materials, the life time of wear and tear parts (especially pumps) is very much shortened. CAUTION: Use only suitable materials! CAUTION: When using highly viscous adhesives and / or adhesives with fillers, the gear pumps are subject to increased wear and tear. Please talk to us first. We can recommend specially hardened pumps as an alternative with comparatively higher service lives. 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. Area of Use (EMC) The units are designed to be used in industrial areas (Also refer to included Declaration of Conformity). Unintended Use - Examples - Operating Restrictions When using in residential, business or industrial areas, the equipment may cause interference with other units, e.g. radios. The unit may not be used under the following conditions: In defective condition When changes or modifications have been made by the customer Without heat protection and protective panels With electrical cabinet door open With filling hopper lid open In a potentially explosive atmosphere When the values stated under Technical Data are not complied with. The unit may not be used to melt and feed the following materials: Explosive and flammable materials Erosive and corrosive materials Food products. P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

13 Introduction 2-3 Residual Risks In the design of the unit, 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 adhesive Risk of burns in the vianity of the screw cylinder Risk of burns when filling the hopper Risk of burns when conducting maintenance and repair work for which the system must be heated up. Risk of burns from hot accessories, e.g. heated hoses and hot melt application heads Danger of being pulled in by screw! The extruder must not be operated without the filling hopper! Material fumes can be hazardous. Avoid inhalation. Note on Manual NOTE: The position numbers in the illustrations do not correspond to the position numbers in the technical drawings and parts lists. NOTE: The actual machine may differ from the pictures in this manual. E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

14 2-4 Introduction eries Overview The following units are included in the series. Unit Motors / Pump station EEX100--F5B2X2TWXMQX 1 Explanation of Type Designation The unit EEX100--F5B2X2TWXMQX is used as an example. EEX F 5 B 2 X 2TWX MQX with pecial no additionals Hose /Gun connectors with protection frame with casters no protective grid with Week / Day timer with tandby / setback 2 level sensor hooper empty and nearly empty no cooling device Hose connection fittings Ø 13mm Pump station selected 20 l/h max. with quadruple pump station FeCuNi Temperature sensor Extruder type Designation for Nordson Melt Adhesive Extruder. EEX = Extruder ID- Plate Nordson Deutschland GmbH Buchholz - Mendt PHONE: +49 (0) TYPE: EEX100-F5B2X2TWXMQX ERIAL NO.: /001 PERFORMANCE: Watt MAXIMUM VOLTAGE: 3x 400VAC + N + PE YEAR OF CONTRUCTION: 05 /2010 MADE IN GERMANY Fig. 2-1 ID--Plate P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

15 Introduction 2-5 oftware Notice Changes to software provided by Nordson may only be made after consultation with the members of our staff charged with the maintenance of the software. In the event of unauthorized changes being made to our software without our explicit approval, we for our part shall be exempt from any liability for all thus incurred cases of damage or loss, whether these be indirectly or directly connected to such changes. Notice on Electrical Engineering WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. The machine and its accessories must be duly connected in compliance with electrotechnical regulations. Regulations DIN EN1) (Part 1) and DIN/VDE2) 0113(Part1) aretobeobserved. afety features (such as an emergency cutout switch, a limit switch, a key--operated switch, or light barriers, etc.) may neither be removed, bypassed, or impaired in any other way as regards their operational functionality. All safety--switch devices are to be periodically and systematically subjected to an operational check. The control system of the unit may only be handled by duly trained staff who have been familiarized with the unit s operation. Maintenance and repair work may only be carried out if the machine is switched off (power--off condition) and may only be carried out by a skilled electrical worker. A skilled electrical worker is defined as someone who, due to his specialized training, knowledge, and experience and due to his knowledge of the relevant rules and regulations, is able to properly assess the tasks he has been assigned to do and is able to recognize possible hazards. Health- Endangering Media CAUTION: Gases, fumes, or types of dust which pose a hazard to health must be sucked off and possibly decontaminated. Highly inflammable and hazardous waste materials must be immediately removed from the working area. All working processes which involve direct exposure of hot--melt to ambient air set free low--molecular decomposition products which may lead to nuisances caused by obnoxious odours and may, in higher concentrations, lead to mucous membrane irritations. Extraction facilities must thus be installed in the immediate vicinity of the machines. 1) DIN EN = harmonized European standard which has been transposed into German law. 2) D = Deutsches Institut für Normung (German Institute for tandardization) VDE = Verband deutscher Elektrotechniker (Association of German Electrical Engineers) E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

16 2-6 Introduction Dangerous Points and afety Devices The dangerous points on the hotmelt adhesive extruder are protected by corresponding safety devices. WARNING: In the event that a safety device has to be dismantled (e.g. for maintenance or cleaning work), it is imperative that these Operating Instructions are strictly observed The safety device must be correctly re--installed, and its performance checked, after the work has been completed. Dangerous Points on the Hotmelt Adhesive Extruder When the extruder is operational, particular attention must be paid to the following danger points: Danger of burning Danger of being pulled in Fig. 2-2 Dangerous points 1. Danger of burning in the vicinity of the heated screw cylinder. 2. Danger of being pulled in by screw! The extruder must not be operated without the filling hopper! 3. Danger of burning in the vicinity of the pump station. WARNING: Hot! Risk of burns. Wear heat-protective gloves. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

17 Introduction 2-7 Danger Points in the Vicinity of the Extruder WARNING: Danger of accidents caused by operating personnel slipping, tripping or falling! There is a danger of accidents occurring if operating personnel slip, trip or fall because of adhesive granulate lying on the floor or due to electrical and water system cables and pipes. It is therefore necessary to keep the environment of the extruder clean and to lay the electrical and water lines in ducts. Covers The covers may be removed in order to be able to tighten the heating bands or remove the screw. For installation or maintenance purposes, protective covers may be removed. WARNING: Do not operate extruder without the covers in place! afety equipment on the extruder Important safety notice: On principle, our machines are always equipped with overtemperature fuses. As soon as 240 C are being exceeded, the electric heating system is interrupted. The fuses are mounted on each controlled heating circuit -- apart from the worm -- and should be checked / replaced if necessary if the machine does not heat up. NOTE: Upon mounting over--temperature--fuse, they have to be fastened with a torque of max. 1Nm! Door Lock WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. The electrical cabinet can be opened for installation, maintenance and repair. tore 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. E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

18 2-8 Introduction Lockable main switch Fig. 2-3 A lockable main switch is located on the control cabinet or control console of the extruder. The colour identification is a red handle on a yellow background. This switch has the same function as an Emergency top switch. This main switch must be switched off if any work is carried out on the extruder (fitting, repair and maintenance work). Any person working on the interior of the extruder must secure the main switch with a lock (e.g. padlock). In case maintenance work has to be carried out with main switch connected up, safety measures have to be taken acc. to your internal safety procedures. If several persons are working at the same time on the extruder at different activities (e.g. engineer, electrician), each one must use his locking equipment. A maximum of three locking devices can be used. NOTE: The main switch must be set to I/ON when using the week timer. Used to switch on/off the unit. Position 0/OFF = Unit is switched off. Position I/ON = Unit is switched on. Padlocks can be used to protect the main switch from unauthorized access. Black Main witch (pecial Model) ystems with a black main switch are normally supplied with power by a higher-ranking system; the higher-ranking main switch is on that system. The black main switch does not perform the EMERGENCY OFF function. Connected components can still be switched on! Fig. 2-4 Emergency top Button (Optional for tand -Alone Operation) The colour identification of the Emergency top button is a red knob on a yellow background. When the Emergency top button is pressed, the extruder drive is switched off immediately and the heating circuit of the machine is disconnected. In order to re--start the machine after the emergency--off has been activated, the button has to be unlocked. The extruder has then to be re--started. Reset of emergency stop via button Malfunction reset NOTE: Before using the reset function, all interference factors that have lead to the pressing of the Emergency Cut--Out Button have to be checked and eliminated carefully! P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

19 Introduction 2-9 Temperature Control Also refer to manual Control ystem. The temperature is measured by sensors and is electronically controlled by the control system. NOTE: To avoid damaging the machine by starting up when too cold, the heating zone temperatures must first be checked and compared with the nominal temperatures set. After longer downtimes, the extruder heat--through time must expire after the set nominal temperatures have been reached (minimum 10 minutes after temperature release, adhesive -dependent). Also refer to manual Control ystem. Undertemperature Interlock The undertemperature interlock prevents the unit or system from being started up before the adhesive has exceeded the temperature setpoint minus undertemperature value. However, every time initial heating occurs, the interlock is not released until the actual temperature is 10 C(5.4 F) below the temperature setpoint. Under -temperature Indication The undertemperature interlock locks the motors, solenoid valves and, in some cases, other components of the hot melt application system. Refer to the wiring diagram to determine which components are locked. Overtemperature Indication / hutdown The independently operating overtemperature shutdown mechanisms protect the unit and adhesive from overheating. For overtemperature shutdown, the heating and motor are switched off. The red indication lamp Collective fault lights up. A distinction is made between excess temperature signalling and excess temperature switch -off. Overtemperature indication through temperature controller: When the temperature setpoint plus overtemperature value has been reached, the relay output Collective fault is switched and the red indication lamp Collective fault lights. The unit remains ready for operation. Excess temperature switch--off is by thermostat(s) or an excess temperature fuse as a hardware safeguard; and where hardware protection is not possible by an electronic (software) excess temperature safeguard: Functions as an emergency OFF in the event that the excess temperature switch--off of the temperature controller is not working properly. WARNING: When the overtemperature shutdown is triggered, there is either a fault in settings or unit malfunction. witch off the unit and have the fault remedied by qualified personnel. E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

20 2-10 Introduction Electrical afety Valve Temperature etbac erves to protect the adhesive and save energy during interruptions in production or work stoppages. etback value and setback period are adjustable. WARNING: Danger of bursting! The extruder must not be operated without the safety valve! The extruder is equipped with a safety valve that measures the melt pressure at the screw tip. The pressure sensor is located at the end of the screw cylinder in the cylinder itself or in a separate, screwed--on component (e.g. screw--on flange) and is connected to the warning and switch--off system of the extruder drive. Important note: If the extruder is not started up as described in Chapter 4 (tart--up), the pressure sensor will be unable to operate. The maximum permissible mass pressure ( bar, depending on sensor equipment) and the heat--through time for the extruder can be found in the Technical Data. If the pressure sensor is defective, it may only be replaced by an intact pressure sensor of the same type and pressure measuring range. A stopping plug must not be used to replace the defective pressure sensor. WARNING: The pressure sensor must not be damaged during fitting or cleaning work on the screw cylinder. witch Cabinet Light Tower ( optional ) Red flashing light Yellow Collective fault ystem is heating up / tandby min one drive is enabled Green ready for operation ( Manual mode ) flashing light nearly empty NOTE: The level indication lamp on the electrical cabinet lights up when the granulate level in the hopper falls below the level sensor. This occurs when there is less than five liters of granulate in the hopper. The hopper must be refilled to prevent an interruption in operation. The lamp goes off as soon as the hopper is refilled. WARNING: Risk of injury from rotation auger. Neve reach into the hooper when the motor is running. Fig. 2-5 P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

21 ZONE OLLWERT / W IRWERT / X Introduction 2-11 Control ystem F WATCHDOG C On the control system FP 13, values and parameters are set, and operating modes and faults are displayed. Electrical Cabinet Ventilation Electrical cabinet ventilation (fan with filter) reduces the temperature inside of the electrical cabinet. The filters must be serviced regularly. Refer to Maintenance. Hose connection X1 / X2 They are used for the connection of two heating zones each (heated hose and application head). Depending on the design of the unit one or more hose connections are wired. Interface X8 / X9 / X10 / X100 erves as a connection between the system and external devices. NOTE: Only use screened cables. Connect screening in accordance with EMC to ground. NOTE: Inductive loads (like solenoid valves) to be connected to the machine have to be equipped with a protective device (e.g. free--wheel diode) that renders the induced voltage arising upon shutting down an inductive load inoperative (contact manufacturer if necessary). E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

22 2-12 Introduction General Description The extruder is used for the continual processing of thermoplastic adhesive granulate. The raw material is fed to the screw through the hopper. It is passed through the screw and melted in the heated screw cylinder Fig. 2-6 The actual machine may differ from the pictures in this manual. 1 Basic frame 2 Drive motor 3 Bearing plate 4 Delivery screw 5 haft cylinder 6 Temperature sensor 7 Heating cuff 8 Brace frame 9 Pressure sensor 10 Manometric switch 11 Electrical cover 12 Pump connecting block 13 Gear pump 14 Coupling 15 Motor pump station 16 Filling hooper 17 Tank lid 18 Level sensor 19 Fixation base 20 Mobile wheels 21 Electric switch cabinet 22 Pressure relief valve P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

23 Introduction 2-13 General Description (cont.) Fig. 2-7 Electric switch cabinet 23 Operating box 24 External cabinet ventilation 25 Operator panel FP13 26 Lamp --Undertemperature-- 27 Enable lamp ( ystem Ready ) 28 Lamp --Overtemperature-- 29 Luminous button --Malfunction reset-- 30 Zone description plate 31 peed indicator pump 32 Motor potentiometer pump 1 33 witch pump 1 34 witch Extruder (Manu / 0 / Auto) 35 witch nozzle 1 36 Emergency off 37 Main switch 38 Interface plug X10 External Enabelings 39 Interface plug X 8 ( 4 -pole ) External conductance 40 Interface plug X 9 ( 7 -pole ) Potential free contact 41 Interface plug X11 Voltage supply 42 Interface plug X6 Control unit Analaog 43 Interface plug X7 Control unit Digital 44 Hose connection X1 -X5 Hose / Head ID--Plate 46 Power supply E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

24 2-14 Introduction Functional Diagram TI 1 = Cooling water cylinder zone TIC 2 = Cylinder zone 1 TIC 3 = Cylinder zone 2 TIC 4 = Cylinder zone 3 TIC 5 = Pump station TIC 6 = Hose 1 TIC 7 = Nozzle 1 TIC 8 = Hose 2 TIC 9 = Nozzle 2 TIC10 = Hose 3 TIC11 = Nozzle 3 TIC12 = Hose 4 TIC13 = Nozzle 4 TIC14 = Hose 5 TIC15 = Nozzle 5 PIC 1 = Output pressure extruder P 1 = Manometric switch extruder P 2 = Manometric switch Pumpe 1 P 3 = Manometric switch Pumpe 2 P 4 = Manometric switch Pumpe 3 P 5 = Manometric switch Pumpe 4 M 1.1 = Motor extruder M 1.2 = Motor fan extruder M 2.1 = Motor pump 1 M 2.2 = Motor fan pump 1 M 3.1 = Motor pump 2 M 3.2 = Motor fan pump 2 M 4.1 = Motor pump 3 M 4.2 = Motor fan pump 3 M 5.1 = Motor pump 4 M 2.2 = Motor fan pump 4 OT 1-4 = Pump connecting block EV 1 = Pressure relief valve EV 2 = Valve nozzle 1 EV 3 = Valve nozzle 2 EV 4 = Valve nozzle 3 EV 5 = Valve nozzle 4 EV 6 = Valve nozzle 5 LI 1 = Level hopper nearly empty LI 1 = Level hopper empty LEGENDE: TI TIC LI PIC PI EV OT P M = Temperature sensor = Temperature control circuit = Fill level sensor = Pressure control circuit = Pressure control = Electrical valve = Overtemperature fuse = Manometric switch = Motor Fig. 2-8 Functional diagram. P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

25 Introduction 2-15 Description of Functional Elements Drive The electro--mechanically--actuated drive is a rpm--controlled three--phase drive consisting of a three--phase geared motor and frequency converter. Basic Frame The basic frame serves to hold the components. Filling Area The filling area consists of a water--cooled filling piece (depending on order) and a filling hopper. The adhesive is supplied via the filling hopper. The hopper has a non--stick coating. WARNING: Danger of being pulled in by screw! The extruder must not be operated without the filling hopper! Do not reach into the filling aperture! Keep all types of metal components away from the filling area. Danger of damage to the extruder screw. Covers WARNING: Do not operate extruder without the covers in place! The covers may be removed in order to be able to tighten the heating bands or remove the screw. For installation or maintenance purposes, protective covers may be removed. crew WARNING: Note rotation direction of screw. Incorrect rotation direction can cause damage! Air or water--cooling can be used as required for the screw. The coolant is supplied to the screw via a revolving seal and a coolant pipe. The screw cooling must be set according to the process engineering conditions, while complying with the maximum permissible medium temperatures. (Maximum temperature setting for this extruder is 250 C, higher values depend on application specification). E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

26 2-16 Introduction crew Cylinder Depending on the order, the inner bore of the screw cylinder is nitrided, specially nitrided or made of bimetal. In certain sections, it can be equipped with a resin bushing. These designs are important for the processing of abrasive and/or corrosive adhesives. The screw cylinder is equipped with adjustable heating zones and, optionally, with air--cooling. Heating is implemented via electrical resistance heating cuffs. Cylinder Feed Cooling The cylinder feed cooling affects the output, which can differ according to product and adhesive. The cooling intensity is controlled electronically. Heating cuffs Cooling water supply Cooling water return Fig. 2-9 crew with heating cuffs P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

27 Introduction 2-17 Cylinder Feed Cooling in crew Cylinders with Inner Resin Cladding (depending on order) The screw cylinder can be supplied with an inner resin cladding as a special design. The extruder is then equipped with a multi--part screw cylinder. The feed section and another component of the screw cylinder are sheathed internally with a wear--resistant resin cladding. This resin is very sensitive to knocks (danger of dislodgment) and temperature change shocks (danger of shattering!). To avoid damage in this area, the following rules must be complied with: 1. The screw must be fitted into and removed from the screw cylinder very carefully (see Chapter 6). 2. Always start up the cylinder feed cooling before switching on the cylinder heating, as the heating--up of the Cylinder should be a slow and continuous process. Therefore: 3. Only start cylinder feed cooling when the temperature in this area is still below 40 C! At higher temperatures, there is a danger that the feed section with the resin bushing may burst when cold water is passed through. 4. Never switch on the cylinder feed cooling after start--up or during production. In these cases, the temperature always exceeds 40 Cin the feed part and therefore there is an increased danger of shattering. 5. Always maintain a steady and constant flow of coolant water for the cylinder feed cooling. Interrupting the water flow causes the temperature in the feed part to rise, leading to renewed danger of shattering. 6. Only use treated water as per the water specifications. Ensure that the tool connection piece is correctly aligned to the screw cylinder when mounting the pump station on the extruder, i.e. the sealing surfaces of the connection piece must be parallel to the cylinder end. The precise centering position must also be ensured (height and lateral offset). E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

28 2-18 Introduction Cylinder feed cooling The cylinder feed cooling affects the output, which can differ according to product and adhesive. The cooling intensity is controlled electronically. A decision must be made before starting up the extruder whether the feed zone should be operated HOT or COLD. This is dependent on the raw material to be processed. If operation should be HOT, the temperature in the cooling zone must be raised. The temperature in the feed zone is dependent on the creep heat from the cylinder zone TI 1 and from the friction heat produced by the screw. Zone description,, page 2.15). If the feed cooling is required for the product, cooling must always be switched on before switching on the cylinder heating. It is essential that the temperature in the feed zone is a maximum of 40 C. The stop valve must be opened and the necessary water volume must be set with the manual control valve (see Technical Data). The flow and volume can be read off from the water meter. The temperature in the feed zone will now increase slightly during the heating up process. After production has started, the temperature increases again depend on the product and frictional heat of the screw. During operation, the temperature will stabilize and remain relatively constant as long as speed, water volume and water supply temperature remain constant. If the temperature increases in the cooling zone (over--temperature warning), check immediately why the temperature has increased and if there is a lack of water, which can be seen from the water meter, correct immediately. If the cause cannot be rectified directly or if there is no water flow at all and the temperature has increased by another 20 C, the system must be shut down and the fault rectified. The applicable installation instructions for screw cylinders with flange connection can be found in the relevant installation diagram. In all cases, the fixing screws on the flange connection must be tightened in a controlled manner with a torque wrench (see diagram specification). If the situation is unclear or data is missing, please contact Fa. Nordson. Ensure that the tool connection piece is correctly aligned to the screw cylinder when mounting the pump station on the extruder, i.e. the sealing surfaces of the connection piece must be parallel to the cylinder end. The precise centering position must also be ensured (height and lateral offset). P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

29 Introduction 2-19 Basic Functionality of Hot- Melt Processing Extruders Fig chnittdarstellung 1. Hopper placed above screw feeding 2. crew cylinder with flange 3. Motor with back--pressure bearing for driving the extruder screw 4. Extruder screw 5. Heating cuffs 6. Cylinder Feed Cooling 7. Level monitoring 8. Pressure sensor 9. Manometric switch 10. Temperature sensor 11. Inspection opening E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

30 2-20 Introduction Mode of Operation The hopper is filled with a sufficient supply of hot--melt granules that ripple down to the screw feeding. uitable free--flowing properties have to be presupposed. The gear motor starts to rotate the screw. By means of the screw channels, the granules are being moved towards the pump station (respectively the hose connection flange). The high motor performance has a considerable share in the heat generation of the extruder. Cooling In order to maintain free--flowing properties and to prevent an unwanted reaction of the hot--melt before processing, the cylinder situated under the granule hopper (feeding area) is constantly being cooled down (cooling liquid: water). One hose connection each is destined to ensure water supply and drain respectively. Flow direction has no effect on the cooling properties. Heating The whole length of the cylinder is mantled by heating cuffs (electrical resistance heating). The real values of each heating zone can be adjusted and read at the temperature controllers. Temperature is being measured by sensors (PT100 or Fe/Ko). crew The screw geometry causes a defined compression. Heating energy and frictional heat both combine to the melting of the granule. For this reason, the screw is being sub -divided into 3 different sections: 1. Transportation zone 2. Compression zone 3. Pumping zone A correct and homogenous melting is ensured by a concerted action of heating energy and frictional heat. The frictional heat also depends on the speed (rpm) of the screw. That s why parameters often state an optimum speed. P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

31 Introduction 2-21 This is being ascertained at the first factory staging by using the hot--melt supplied by the customer. For this reason, the hot--melt always has to be the type finally used in production. Delivery is made with the parameters that ensure the optimum speed for the continuous rating guaranteed for the extruder. Based on the multiplicity of available extruder adhesives, an adhesive--specific temperature profile of the glue used in the system is being defined as a rule. Our extruders always fulfil current safety rules. The operator is additionally protected by the integration of important control functions. These comprise purely functional as well as system protective measures. Pressure Regulation The extruder is equipped with two independent pressure regulating and controlling systems. Electronic Pressure Regulation In automatic mode, this control continually reads the adhesive pressure in the compression zone of the cylinder and adjusts the screw speed in accordance with the digitally set operation pressure (= set pressure). In case the actual value ecxeeds the set pressure, an electronic safety cut--out shuts down the motor in manual as well as in automatic mode. Pressure sensor with limit switch function The pressure sensor fulfilling the function of a limit switch continuously controls the adhesive pressure and shuts down the extruder motor once the set limit value has been reached. Pressure Monitoring 1. Hazard pressure freely adjustable threshold value / message only 2. Alarm pressure first system limit value / machine shut--down. 3. Over--pressure second system limit value by means of a further limit indicator / machine shut--down. E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

32 2-22 Introduction Level Monitoring of Hopper 1. Hopper empty triggers protection against running dry 2. Hopper almost empty hazard message 3. Hopper full hazard message (optional) Temperature Monitoring 1. Under -temperature system is locked until melting temperature has been reached / system protection until melted adhesive can be conveyed in a homogenous condition. 2. Over -temperature 1 freely adjustable hazard warning, usually without action taken. Message only. 3. Over -temperature 2 freely adjustable, electronic control of limit values with adjustable time lag for shutting down the system. 4. Over-temperature 3 system limit value. Lay-out depending on system when option pump station is chosen. Value read by means of thermo elements (hardware). Triggering leads to the destruction of the thermo elements (standard values 180 C, 240 C, 280 C). P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

33 Introduction 2-23 Pump station The gear pump station meters out exact quantities of glue and feeds them into the hoses and coating heads. The pumps are driven by separately controlled A.C. drives. The extruder itself feeds into the pump station and maintains a constant primary pressure. When operating in automated mode, this primary pressure allows to feed variable quantities into the nozzles. A pressure -- regulated system guarantees a constant supply of the pumps Fig Motor Pump station 2. Coupling 3. Gear pump 4. Pump connecting block 5. Pressure relief valve 6. Collecting tray 7. Hose connection 8. Electrical cover 9. Manometric switch 10. ensor hoop guard 11. Inspection opening 12. upport bracket Motor and Gear Pump The electronically controlled motor drives the gear pump. CAUTION: Never let gear pumps run dry. CAUTION: The long--term rpm of motors / pumps should not to be lower than 5 min--1 and not higher than 80 min--1 in order to avoid excessive wear and tear. Manometric switch Pressure sensor In case an overpressure of 90 bars is exceeded, a manometric switch (10) shuts down the extruder drive. The pressure sensor is placed directly at the material exit and allows a pressure--regulated operation of the unit. ee manual on pressure sensor. E 2010Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

34 2-24 Introduction P/N EEX100--F5B2X2TWXMQX E 2010Nordson Deutschland GmbH

35 Installation 3-1 ection 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 Immediately on arrival of the hotmelt adhesive extruder, a check is to be carried out to see whether the applicator has been delivered in perfect working order. Damages incurred in transit must be confirmed in writing by the shipping agent and immediately reported to Fa. Nordson. ave special pallet and angle brackets for later use. Reuse packaging materials or dispose of properly according to local regulations. Transportation The Extruder must be transported in a horizontal position! 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. WARNING: After each transport, check and tighten motor, coupling and gear pump if necessary Attaching Light Tower (optional) The light tower must be screwed onto the electrical cabinet (It was removed for transport). Exhausting Hot Melt Adhesive Vapours Make sure that hot melt adhesive vapours do not exceed the prescribed limits. Exhaust the vapours if necessary. Provide sufficient ventilation in the area where the machine is set up. E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

36 3-2 Installation Installation and Alignment The installation and alignment of the extruder is non--critical. The dimensions of the extruder can be found in the dimensions sheet. The position and nominal values for the water inlets and outlets can also be found in the dimensions sheet. The extruder is normally delivered with the screw inserted. The basic frame is sufficiently rigid torsionally. Damage within the system is almost entirely impossible. Each extruder is set up ready for production, aligned and pre--calibrated at the factory before delivery. A horizontal installation area is a pre--requisite. etup et up only in an environment that corresponds to the stated Degree of Protection (Refer to section Technical Data). Do not set up in a potentially explosive atmosphere! Protect from vibration. Remove transport protection (if present). Check all plug and screw connections for tightness. Leave enough free space around the unit. Lifting (Unpacked Unit) Refer to the Technical Data for weight. Lift only at the unit frame using suitable lifting equipment or a forklift. Removal 1. Run the unit until empty. 2. In case of a long--term shut--down clean the unit with cleaning agent (see chapter maintenance). 3. eparate all connections from the unit and allow it to cool down. torage Do not store unit outside! Protect from humidity, dust and extreme temperature fluctuations (formation of condensation). Disposal Properly dispose of unit according to local regulations. P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

37 Installation 3-3 Operating conditions Machine installation requirements: Installation: Up to maximum 1000 m above sea level, in rooms that are as dustfree and dry as possible. Dripping, spray or hose water must not be present in the vicinity of the extruder. Air humidity: Formation of condensed water must be avoided, otherwise special measures must be implemented. Air temperature: +15 Cto+40 C E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

38 3-4 Installation Electrical Connections WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Notice on the use of ground fault circuit interrupters NOTE: In some countries respectively for some applications there are regulations which prescribe the use of ground fault circuit interrupters. In this case please adhere to the following: The ground fault circuit interrupter must be inserted between the mains power supply and the machine. You may only use ground fault circuit interrupters which respond to pulsed currents or to all currents (> 30 ma). Laying Cable WARNING: Only lay temperature--resistant cables within the hot area of the installation. Ensure that cables do not touch rotating and/or hot unit components. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! Line Voltage 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 cross-section of the power cable must correspond to the rated current. Refer to ID plate for rated current. The mains terminals are located in the electrical cabinet. Refer to wiring diagram for connecting arrangement. External control and signal circuits WARNING: Connect the external control and signal circuits with appropriate cables in conformity with NEC Class I. To avoid short circuits, lay the cables in such a manner that they do not come into contact with printed--circuit boards. P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

39 Installation 3-5 Pilot Voltage / Tach Generator For key-to-line mode, pilot voltage must be connected to X8. The pilot voltage can be supplied e.g. by a tach generator (accessory) driven by the parent machine. WARNING: The pilot voltage may not exceed (0--10) V DC. Failure to observe will result in damage to succeeding components. CAUTION: Master reference voltages >12 V DC without adaptation card can destroy the input assemblies. NOTE: ome models with two pump drives have separate pilot voltage inputs for both pump drives. Adjustment to Tachometer Modulation Board NOTE: Only use screened cables. Connect screening in accordance with EMC to ground. NOTE: Inductive loads (like solenoid valves) to be connected to the machine have to be equipped with a protective device (e.g. free--wheel diode) that renders the induced voltage arising upon shutting down an inductive load inoperative (contact manufacturer if necessary). Interface Profibus (Option) The PROFIBU interface enables remote operation by a higher--ranking control unit. Refer to separate manual. E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

40 3-6 Installation Electrical installation The technicians must familiarize themselves with the circuit documentation before starting installation work. The operator is responsible for correct dimensioning and implementation of the electrical system. All power cables must be laid separately from the signal lines within the cable ducts or cableways. Power cables and signal lines are appropriately marked. The cables in the control cabinet must be correctly connected, using the connection terminals, to the cable support rails to safeguard against tensile loads. The individual wires must be laid according to their target designations. Ensure that the terminal connections are tight and secure. WARNING: All drives are set up for clockwise rotary fields. The extruder screw must rotate to the left when seen in the working direction. All heating elements on the extruder must be retightened after the initial start--up. Retightening of ceramic heating bands must be carried out with extreme care. Electrical safety valves must be recalibrated according to process engineering specifications before the initial start--up (see Technical Data for maximum permissible mass pressure). If test runs have already been implemented in the factory with the original customer adhesives, the last two points are not required. Assignment of temperature controllers to temperature sensors The assignment of temperature controllers to temperature sensors must be checked (e.g. after repairs). The applicable controller must be set to 60 C for this test. WARNING: Before carrying out this test, ensure that the heating is disconnected (switch off the automatic heating circuit breakers). Remove the temperature sensor from the corresponding bore on the screw cylinder as per the controller numbering. Heat the sensor tip, e.g. with a lighter, but not with any fluid. An increase in temperature should be displayed by the display of the controller connected to this temperature sensor. All other zones should be checked as described above. witch the automatic circuit breakers back on when tests are complete. The connecting sockets and plugs of the heating bands and corresponding temperature sensors must be numbered for tools and tool connections. The correct allocation of heating band connections to the temperature controllers must be checked carefully. To do this, insert each plug in turn in the heating bands of the zone being checked. A power consumption must be noted on the ammeter of the corresponding temperature controller. P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

41 Installation 3-7 Connecting Heated Hoses WARNING: Hot! Risk of burns. Wear heat-protective gloves. econd Open-jawed Wrench Use a second open-jawed wrench when connecting and disconnecting the heated hose. This prevents the unit s hose connection from turning. Attach connecting cable extruder / hose Fig Connecting Fig Disconnecting If cold material can be found in the hose connection, these components (1, 2) must be heated until the material softens (approx. 80 _C, 176 _F). 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. crew on heated hose. NOTE: Close unused hose connections with Nordson port plugs. WARNING: ystem and material pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. Relieving Pressure 1. et motor speed to 0 min-1 (rpm); switch off motor(s). 2. Place a container under the nozzle(s) of the application head/assembly handgun. 3. Activate the application head / assembly handgun electrically or manually. Repeat this procedure until no more material flows out. 4. Re-use the material or dispose of properly according to local regulations. E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

42 3-8 Installation Connector Allocation A synchronisation of the applicator with other machines is effected via the X8 plug. To do so, apply an external control voltage ( d.c. Voltage ) to the X8 plug. Fig ocket An external desired value may be coupled through X8 as reference voltage for dosing the hotmelt in accordance with the machine speed. Direct current -- dependent on machine speed: Pin 1 +VDC 1 adjustable from 0 Volt through 200 Volt Factory alignment ( 0-10 ) Volt Pin 2 0VDC Pin 3 not connected Pin 4 PE Ground Fig Plug Fig P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

43 Installation 3-9 Installation X9 Enable socket for the internal enable signal in automatic operation Fig The X9 socket is used to supply three different internal output signals of the applicator. A potential -- free contact switches between Pins 3 and 4 to signal that the melt adhesive applicator is ready for production. The temperature state signals are present on pins 1, 2 and 5, 6. Assignment: Plug connector Pin Pin Pin ocked connector Undertemperature signal ystem ready Overtemperature signal Plug connector ocket connector Fig E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

44 3-10 Installation Interface X10 / X 100 erves as a connection between the system and external devices. For valid allocation please refer to wiring diagram. NOTE: Only use screened cables. Connect screening in accordance with EMC to ground. NOTE: Inductive loads (like solenoid valves) to be connected to the machine have to be equipped with a protective device (e.g. free--wheel diode) that renders the induced voltage arising upon shutting down an inductive load inoperative (contact manufacturer if necessary). Procedure Plug X10/X100for external control functions on automated production The above layout shows the standard allocation. In case of deviations, please refer to the information and data contained in the electrical diagramm (documentation see chapter 8 ). In case of modifications the plug is named X10/X100. P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

45 Installation 3-11 Water installation The extruder is equipped (depending on the order) with various cooling systems: Cylinder cooling Cylinder feed cooling crew cooling WARNING: Water must not come into contact with the heating cuff (heating elements, plugs and cable connections). This must be avoided in particular with the water supplies to/from the cylinder feed cooling! The cooling water must include an anticorrosive. The water of the cooling systems has to have an operational pressure range of bars and a feeding temperature of 18 C maximum. The maximum deviation permitted for the cylinder feed cooling is +/ bars. As to flow rate refer to the Technical Data Important: All water return lines must have unpressurized outlets, using stop valves is not permitted. When using separate tempering units for cylinder feed cooling or screw cooling, these connections must remain in place. Heating cuffs Cooling water supply Cooling water return E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

46 3-12 Installation pecifications Water specifications Water used for the cooling system must meet the following specifications: Raw water Treated water Total hardness max. 12 dh Total hardness max. 5 dh Permanent hardness max. 5 dh Permanent hardness max. 5 dh ph value 8--9,5 ph--value 8--9,5 Fe max. 0,04 mg/l The water must be free of algae and particulates and must not contain any gaseous components such as chlorine, ozone, etc. or opacifiers. If particulates are present in the water, we recommend that a filter is inserted in the Water supply line. Raw water can be used for gear oil cooling. Treated water must be used for the filling aperture cooling, cylinder feed cooling and screw cooling. The cooling water must include an anticorrosive. P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

47 Operation 4-1 Chapter 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. WARNING: After each transport, check and tighten motor, coupling and gear pump if necessary tart -up NOTE: Before pressing the main switch and actuating the control functions, the documentation has to be read carefully and the safety instructions have to be strictly adhered to! NOTE: pecial care is to be taken in the manual operation mode as this is a non--locked working status. Only specially authorised staff may use the Ultra Foam Mix manual operation mode. Preparations for tart- up The electrical installation must be checked in accordance with the provided electrical documentation. The following points are of extreme importance: Check the effectiveness of the Emergency top and safety cutouts, e.g. electrical safety valves. Adjust the limit values for warnings or switch--off as per process requirements. The maximum permissible mass pressure for the extruder and the heat--through time of the extruder (without screen changer and tool) can be found in the Technical Data. The rotation direction of the screw must be checked. Electrically connect the hotmelt hoses and dispenser heads. These components must be at operating temperature to lay the hoses and fit the heads. WARNING: The cold connection points between pump station, hoses and dispenser heads cannot yet be connected together. If test runs have already been implemented in the factory with the original customer adhesives, the last two points are not required. E 2010 EEX100--F5B2X2TWXMQX P/N

48 4-2 Operation etting into operation WARNING: The extruder may only be operated with the filling hopper and electrical safety valve, in place! Open feed for cylinder feed cooling. The current cooling temperature can be read off the operator unit FP 13, Zone 1. Filling melt adhesive / hotmelt into the filling hopper. Check that the pumps and nozzle switches are set at 0. Turn the speed potentiometer to 0. witch on main switch. Check the heating zones at FP 13 and set them if necessary. Wait until the temperature release occurs. WARNING: chläuche dürfen erst nach Aufheizung aufgebogen und verlegt werden. - Electrical connection - General control functions External control functions Provide a protective ground for the line and protect it after the overall drawing of current ( refer to the nameplate ). Tension fluctuations may be accepted up to + / -- 5%. The cable and plug connection will be provided at the customer s in accordance with the local regulations. The wiring diagrams are contained in the control cabinet as well as in the last section of the operating instructions ( Chapter 8 ). tandard design : self - contained unit Please note the wiring diagram for the drivers / pumps and nozzles. The standard electric wiring in the factory is such that the pump and the nozzle can be separately switched (solenoid valve control via hotmelt hose). Automatic start of the hotmelt applicator together with the start of the mother machine: ince most melting units are connected to production machines, the start/stop signals for the extruder, pumps and nozzles are activated by the production machine. In this case potential--free contacts can be applied to the socket X10 / X 100. (see circuit diagram for contact assignment), Observe the switch--on sequence. P/N EEX100--F5B2X2TWXMQX E 2010

49 Operation 4-3 Activating nozzles equipped with solenoids : The same X10 / X100 socket also provides the contacts for the control of the solenoids on the nozzles. Please note the voltage for the magnet coil. All applicators are of standard design for controlling 24 V d.c. valves. The hotmelt hose is used for a standard control. Hotmelt dosage in accordance with the machine -speed variations : For a varying continuous material speed of the mother machine, a tacho -- generator may be mounted ( connection to the X8 tachometer socket on the control panel ) to adapt the speed of the gear pump to the varying production speeds. Refer to the electrical diagram X8 socket. Microprocessor - temperature control ZONE OLLWERT / W IRWERT / X F WATCHDOG C [ E ] [ A ] [ B ] [ C ] [ D ] Fig. 4-1 Adjusting the temperatures Use the [A]and [B]keys to select channel 1. Use the [C]and [D]keys to set the desired temperature ( the desired temperature flashes in the display ). Use the [E]key to save the adjusted setpoint ( the setpoint is displayed permanently ). Use the [B]key to select channel 2 and to enter the setpoint for this channel correspondingly. Use the [E] key to save. Proceed as follows to select an other temperature program. E 2010 EEX100--F5B2X2TWXMQX P/N

50 4-4 Operation electing the program level Press the [A]keys until the P is shown on the panel display. ( The setpoint display shows the currently active program level ). ZONE OLLWERT / W IRWERT / X F WATCHDOG C [ A ] Fig. 4-2 Use the [C]+ [D]keys to set the desired program level ( ). ZONE OLLWERT / W IRWERT / X F WATCHDOG C [ C ] [ D ] Fig. 4-3 Use the [E]key to activate the set program level. Move into control zone by activating key [B] The valid temperature parameters can now be entered in the newly activated program level. CAUTION: Important Free channels which have no temperature sensor connected to them must be set below 20 C ( ) in the setpoint and saved with the [E] key. (Deactivates the under -- temperature blocking ) P/N EEX100--F5B2X2TWXMQX E 2010

51 Operation 4-5 Beginning production Collective malfunction signal First check whether the set temperature setpoints have been reached. These setpoints have been reached, when the enable lamp ( green ) in the middle lights up on the control panel front and the red undertemperature lamp is extinguished ZONE OLLWERT / W IRWERT / X F Overtemperature red WATCHDOG C ystem ready green Undertemperature red Fig. 4-4 Procedure Manual operation Hotmelt delivery via one or several nozzles Turn the speed potentiometer to 0. Turn the Extruder switch on and set it to MANUAL position. Turnthe Pump switchonandsetitto MANUAL position. Turn the NOZZLE switch on and set it to MANUAL position. Turn up the speed potentiometer until the desired speed is reached and the required hotmelt volume is being pumped. The extruder operates pressure--controlled (Works setting 5 bar) The pumps are only started when the extruder has reached the required preset pressure. E 2010 EEX100--F5B2X2TWXMQX P/N

52 4-6 Operation Desired pressure setting on the extruder (pre- pressure pumps) 3 4 The pre--pressure for the pumps is set with the potentiometer (Pos. 2 / 9R4) on the switch cabinet. The standard pressure is 5 bar which equals the potentiometer setting Maximum pressure is 25 bar which equals the potentiometer setting The actual pressure can be read off the pressure measuring transducer (Pos. 3 / 12A1) Procedure Automatic operation If the nozzle application is in connection with a production machine, tart / top Pump and Open / Close Nozzle should be via a potential -- free contact between the two machine parts ( connection socket X10). ( Condition : The above - mentioned tacho - adjustment has been performed ) The extruder switch in the switch cabinet must be adjusted at the Auto setting when the filling hopper is filled with heated adhesive. Turn the Pump switch on and set it to Auto position. Turn the Nozzle switch on and set it to Auto position. Turn the speed potentiometer to maxwert. Turn the speed potentiometer (Pos.2 / 9R4) to a level until the desired hotmelt rate is delivered. Convey the required amount of hotmelt via the external guide voltage, connector X8 ( V). The dosage itself must be determined at constant speed conditions. The reduction of speed subsequently lowers the application rate to a pump standstill when the machine is stopped. Under production conditions, the signals for external tart / top Pumps and Open / Close Nozzle are provided via a potential -- free contact between the two machines ( refer to the electric diagram of the X10 / X100 socked ). Hotmelt application with automatic, speed - dependent metering. In this case the gear pump rotation is adapted to the machine speed. This adjustment is only possible if a tacho -- generator which provides a control voltage for the motor control system of the applicator is attached to the pump drive.( Control voltage 0--10V ) WARNING: If the adjustments for a speed -- dependent adhesive rate have not been done in the factory in consultation with the customer, an appropriate test and / or balance between the tacho control voltage and the motor control system must be performed. This measure is described at the end of this chapter ( refer to tacho -- adjustment ). P/N EEX100--F5B2X2TWXMQX E 2010

53 Operation 4-7 Application Mode Intermittent Hotmelt application An application only for individual zones requires the use of a programming unit, providing the control commands for opening and closing the nozzles from the control unit via the melt unit control panel and the hotmelt hose to the solenoid valves mounted to the nozzles. ignal receivers may be detectors mounted to an appropriate place on the production machine, such as photocells, inductive proximity switches etc. For varying machine speeds, an additional so called displacement sensor must be provided. A wide range of control units is available for that Put in the bridge X (1) for intermittent application. Hotmelt is intermittent conveyed while the extruder, the pumps and the nozzles are being controlled. IN E 2010 EEX100--F5B2X2TWXMQX P/N

54 4-8 Operation elector witch Pressure / peed Control election peed Control For speed control, press bridge XD (2). The extruder operates only in speed controlled mode (e. g. for cleaning of worm or when feeding into a tank melting unit). XD Use only without gear pump station or with pump block open. peed can be adjusted via Lenze Keypad (frequency parameter C37; Jog value 1, max. 50 Hz). election Pressure Control For pressure control, pull out bridge XD (2). Reestablish the standard settings as described above. WARNING: When switching from speed to pressure control, the jog value 1 has to be adjusted to 5 Hz. Continuous hotmelt application Remove the bridge X(1) for continous application. Hotmelt is continuously conveyed while the extruder, the pumps and the nozzles are being controlled. OUT Error messages Group alarms of the drive controls, pressure sensors, excess temperature safeguards and dry--run protection are displayed by the Fault Reset momentary--contact control switch (77 / 8H1). After the fault has been remedied, the group alarms must be acknowledged by actuating the momentary--contact control switch. Dry- run protection If the flow of material is interrupted during production, then the extruder is turned off after a preset time. (Pressure / Time) P/N EEX100--F5B2X2TWXMQX E 2010

55 Operation 4-9 witching ystem ON/OFF NOTE: Before initial startup, read and observe the instructions in Initial tart--up. tart up only as described under Initial tart--up. NOTE: The main switch must be set to I/ON (switched on) when using the week timer. Refer to separate manual. NOTE: When external system release via interface plug X10 is used, the main switch must be set to I/ON (switched on). Daily tart- up NOTE: Gear pumps may not be operated without hot melt material. Before switching on the motor, ensure that the tank is filled. 1. etmainswitchtoi/on. 2. Wait until the unit is ready for operation. 3. witch on motor Daily witch- off 1. witch off motor. 2. etmainswitchto0/off. 3. If necessary, secure main switch with padlock against unauthorized access. 4. Make daily inspection. witching Off in an Emergency WARNING: witch off the unit immediately in any emergency situation. 1. etmainswitchto0/off. 2. After standstill and before switching the unit on again, have the malfunction remedied by qualified personnel. Black Main witch (pecial Model) ystems with a black main switch are normally supplied with power by a higher--ranking system; the higher--ranking main switch is on that system. The black main switch does not perform the EMERGENCY OFF function. Connected components can still be live! E 2010 EEX100--F5B2X2TWXMQX P/N

56 4-10 Operation P/N EEX100--F5B2X2TWXMQX E 2010

57 Maintenance 5-1 Chapter 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 operational safety and extending the lifetime of the unit. It should not be neglected under any circumstances. Danger of burns ome maintenance work can only be done when the machine is heated--up. WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. Relieving Pressure WARNING: ystem and material pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. 1. et motor speed to 0 min-1 (rpm); switch off motor(s). 2. Place a container under the nozzle(s) of the application head/assembly handgun. 3. Activate the application head / assembly handgun electrically or manually. Repeat this procedure until no more material flows out. 4. Re-use the material or dispose of properly according to local regulations. E 2010 EEX100--F5B2X2TWXMQX P/N

58 5-2 Maintenance Decommissioning 1. Open shut--off valve on filling hopper, remove granulate and operate extruder until empty. In general, the feed area of the screw should also be run till empty to facilitate restarting. If the motor current consumption decreases, reduce screw rpm to 20 min -- 1 and empty screw for a maximum of 1 minute. witch off all heating zones via the main switch or reduce the temperature of the heating zones as per the process requirements. 2. Close water supplies. Cleaning the crew If the extruder needs cleaning for process reasons, the following procedure must be followed before the final switch--off: 3. Reduce the screw cylinder temperature to the processing temperature of the cleaning granulate. 4. top the extruder drive. (low down extruder drive so that the screw continues to turn slowly.) Attention! Danger of burns from hot components and escaping hot adhesive! Wear protective gloves, clothing and shoes! Danger of inhaling toxic substances! There is a possibility that toxic vapours escape from the screw cylinder during maintenance or cleaning work at the end of the screw cylinder. 5. Disassemble lid of inspection opening. Operate screw with suitable cleaning granulate as recommende by the adhesive manufacturer until empty. The granulate feed must be dosed and the screw should be operated at a low rpm. Do not exceed the maximum current consumption value of the screw drive motor. P/N EEX100--F5B2X2TWXMQX E 2010

59 Maintenance Insert granules slowly, best manually. Take care that the screw is always visible, meaning that it may not be covered completely with granules. Otherwise the extruder may get stuck! Therefore always make pauses between filling in of the cleaning granules, e. g. observe filling cycles that allow about 30 cm of the screw to be free from granules! 7. After cleaning has been finished, the cleaning granules have to be driven out of the extruder completely. 8. top extruder drive an clean inspection opening manually using cloth and / or soft metallic brushes (copper / brass). It is very important that NO cleaning granules get into the pumps and / or the hoses! (The granules are very hard and, if processed properly, do not melt so that they might damage e. g. the pumps!) Usually, the screw needs not be pulled out. In case you have to, please follow instructions of - section 7- for dismounting of screw. Clean screw (wooden or PTFE spatula or soft brushes). Cleaning the crew The cylinder bore must be thoroughly cleaned with a round wire brush. The bore must then be cleaned with a cloth soaked in petroleum. CAUTION: Do not use metallic tools. Do not use wire brushes. Use soft cloth if necessary. Finally, the screw must be cleaned with a soft cloth and finegrain polishing paste until the metal is bright. If the screw is to be stored for longer periods, it should be coated with Vaseline or sprayed with a protective coating. WARNING: Make sure that no impurities or remnants of the cleaning material are left in the cylinder when the screw is being re--inserted. Mount screw as described in - section 7--. etting into operation Refill hopper with fresh, dry granules. Disconnect the hoses and let the extruder run slowly (<5RPM) in RPM mode until set pressure is reached. top the extruder and switch to pressure control mode. tart the extruder in pressure control mode and start the outer pumps with 5 RPM until clean, bubble--free adhesive leaks out of the connections. top the extruder and re--connect the hoses. After this has been finished, the extruder may be brought back into normal operating condition. E 2010 EEX100--F5B2X2TWXMQX P/N

60 5-4 Maintenance Regular Maintenance The maintenance intervals are general guidelines based on experience. Depending on operating environment, production conditions and hours of operation, other scheduled maintenance tasks may prove necessary. Unit part Activity Interval Entire Extruder External cleaning Daily Inspection for external damage Daily Geared motor Change of lubricant Respect manufacturerer s recommendations. Filling hopper Visual inspection for pollution in hopper; clean if necessary Before filling every time Gear pump Check pump packing for leakages Hours of operation 500 h. Electrical Cabinet Clean fan screens, clean or replace filter Daily, if dust accumulation is Ventilation severe Pressure sensor Refer to separate manual Maintenance gear pump Gear pump maintenance is limited to the tightening of the seat screw for the packing gland. (1). This has to take place whenever adhesive leaks between the shaft and the seat. A quarter turn of the screw is mostly sufficient. Unscrew the safety plate (2, 3), readjust the packing gland, readjust the safety plate and fasten. The safety plate prevents the gland from loosening through vibration. If no further tightening is possible the pump has to be replaced. External Cleaning External cleaning prevents impurities created by production from causing unit malfunctions. CAUTION: Observe manufacturer s instructions when using cleaning agent. CAUTION: Do not damage or remove warning signs. Damaged or removed warning signs must be replaced by new ones 1. Only remove adhesive remnants with cleaning agents recommended by the adhesive manufacturer. If necessary heat cold Ultra Foam Mix until adhesive is liquid. 2. Thoroughly remove warm adhesive with a cleaning agent and / or soft cloth. 3. Vacuum off dust, fluffs etc. or remove them with a soft cloth. P/N EEX100--F5B2X2TWXMQX E 2010

61 Maintenance 5-5 Inspection for External Damage WARNING: When damaged parts pose a risk to the operational safety of the unit and / or safety of personnel, switch off the unit and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. Over- temperature Thermostat Changing Type of Adhesive Purging with Cleaning Agent The over--temperature thermostats (1) serve as an automatic switchoff in case the over--temperature shutdown of the temperature controller does not function properly. NOTE: Depending on the type of adhesive used, the overtemperature thermostats of the tank may need to be adapted to the maximum processing temperature of the adhesive (This may mean replacing it). Refer to Technical Data. Remove the old adhesive by running until empty or by draining the unit. NOTE: Before changing the type of adhesive, determine whether the new adhesive may be mixed with the old adhesive. Maybemixed:Remaining old adhesive can be flushed out using the new adhesive. May not be mixed: Thoroughly purge the unit with a cleaning agent recommended by the adhesive supplier. NOTE: Properly dispose of the old adhesive according to local regulations. CAUTION: Use only a cleaning agent recommended by the adhesive manufacturer. Observe the Material afety Data heet for the cleaning agent. Before starting production again, flush out cleaning agent residue using the new adhesive. NOTE: Properly dispose of cleaning agent according to local regulations. E 2010 EEX100--F5B2X2TWXMQX P/N

62 5-6 Maintenance Electrical Cabinet Ventilation Maintenance Continuous Checks The electrical cabinet fan is maintenance-free. The filter must be cleaned or replaced, depending on dust accumulation. A dirty filter can be recognized by its dark color. It is cleaned by shaking the filter out. Replacement and Cleaning of Filter Mat Remove cover to replace filter mat. Wash filter mat in water of up to 40 C, with a mild detergent added if necessary. It is also possible to beat, vacuum or to blow with compressed air. In case of greasy substances: Wash filter mat in benzine, trichorethylene or warm water with grease solvent added. Do not wring nor use sharp jet. Check safety equipment functionality. The control cabinet door must be closed. Check water flow in all water cooling systems. Check connections for possible leaks. Check oil level in gears. Check whether all cable connections are tightly connected to the terminals and whether all fuses are securely held by the clips. Heat caused by poor contacts can damage both the fuses and the clips. WARNING: Important: If terminal blocks are not tightly connected there is grave danger of overheating which may result in cable fire! Check the fit of thermo--elements. Check the electrical conductance of all heating zones. The insulation resistance should lie above 1000 Ohm/Volt. Check the symmetrical power input under load conditions in the 3 phases of the thyristor board. Use an ammeter. The values of the 3 phases should not differ by more than 10 %. Check heating and thyristor contactors for correct condition and function. Worn contacts must be replaced as soon as possible to avoid subsequent damage. Check the condition of all patch cords for nozzles or tools. Ensure that the earthing terminals have a resistance lower than 0.1 Ohm to the steel of the tool. P/N EEX100--F5B2X2TWXMQX E 2010

63 Maintenance 5-7 For heating elements with ceramic insulation: During the initial heating procedure check and retighten, where necessary, the clamping screws at regular intervals until the operating temperature has been reached. Any tightening required must be carried out with particular care. Too high a pre--stress can lead to the ceramic stones being damaged. The aluminium cooling elements located between the heating elements must also be checked for correct fit and retightened if necessary. Fig. 5-5 Heating cuffs NOTE: When mounting the Heating cuffs, they are to be fastened with a tightening torque of 1,5Nm! WARNING: Danger of burns from hot components! Wear protective gloves, clothing and shoes! Bei Heizbändern mit Mikanitisolation: Während des ersten Aufheizvorganges die pannschrauben auf festen itz überprüfen und ggf. nachziehen. Die gleichmäßige und feste Auflage sollte immer wieder geprüft werden. Vorhandene Alukühlkörper müssen ebenfalls nach der ersten Inbetriebnahme auf festen itz überprüft werden und ggf. nachgezogen werden. E 2010 EEX100--F5B2X2TWXMQX P/N

64 5-8 Maintenance ervice and Maintenance WARNING: All service and maintenance work may only be carried out while the machine is in a power--off condition! Please only use the lubricants recommended in the manufacturer s directions and observe the specified maintenance breaks. Please also observe the attached rules and regulations of the suppliers. The timely and conscientious maintenance of the machine not only ensures its trouble--free operation, it also avoids costly repairs.the gear oil used for topping up must be at room temperature, however, at least 15 C Fig. 5-1 Item. 1 2 Operating hours Maintenance Maintenance part Lubrication point Manufacturer Quantity Lubricant pursuant to DIN Filling quantity per lubrication point approx. 3 cm Liter 3 a. r. E R! a. r. P/N EEX100--F5B2X2TWXMQX E 2010

65 Maintenance 5-9 Motor Lubrication The extruder drive motor is equipped either with permanently lubricated bearings or with semi--lubricated bearings that should be replaced following defects or large motor overhauls (see manufacturer documentation). Lubricant Recommendations for Threaded Connectors All threaded connectors exposed to high temperatures must be correctly treated with suitable lubricants. The correct selection of solid lubricants facilitates easy tightening of all connections and loosening in assembly work. All connections, screws and nuts must be cleaned before applying the recommended Molykote Paste HC Plus. This paste must be applied extremely thinly with a hard brush. The Molykote lubricant film must be applied without any gaps to thread flanks and roots, and head/nut contact surfaces. Fault Rectification Faults during production should not arise if these operating instructions are observed carefully, the system operated correctly and the required maintenance work implemented as necessary. General Checks Check all connections, tighten terminals where necessary. Mains connection should only be implemented with a clockwise rotary field, check using a rotary field indicator. Permissible mains voltage deviation at 400 V: +6% / --10%. Check on--state of all circuit breakers and automatic circuit breakers. Check condition of controller and fault signals. Check all fuses for throughput. WARNING: Do not replace special semi--conductor fuses with normal fuses. Check motor connections in terminal box. E 2010 EEX100--F5B2X2TWXMQX P/N

66 5-10 Maintenance P/N EEX100--F5B2X2TWXMQX E 2010

67 Troubleshooting 6-1 Chapter 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: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Troubleshooting activities may sometimes have to be carried out when the unit is energized. Observe all safety instructions and regulations concerning energized unit components (active parts). Failure to observe may result in an electric shock. Troubleshooting/Failure Corrective Action Provided these operating instructions are conscientiously adhered to, provided the machine is properly and expertly operated, and provided the specified maintenance work is carried out, operational disruptions are not to be expected. WARNING: hould unforeseeable disruptions nevertheless occur, the technical safety instructions must be strictly observed in resolving them. After a disruption has occurred, the extruder may only be restarted if the reason for the disruption has been established and the disruption or fault has been remedied. In cases of uncertainty, Nordson is to be consulted. In so doing, please give exact information about the disruptive effects, e.g. details on the respective status of signal lamps and readings. Furthermore, the complete serial number or constructor s number is to be stated. Acknowledgement of malfunction signals with Fault reset button ( necessary for further operation of machine ) Nordson Deutschland GmbH Industriepark Nord 23, Buchholz -Mendt / Germany Phone , Fax E 2010 EEX100--F5B2X2TWXMQX P/N

68 6-2 Troubleshooting ome Tips Before systematic troubleshooting is begun, the following should be checked: Are all parameters set correctly? Has the interface X10 / X 100 been wired correctly? For automatic mode: setpoints are supplied by profibus? Do all plug connections have sufficient contact? Have fuses been activated? Could the fault have been caused by an external PLC? Have external inductive loads (e.g. solenoid valves) been equipped with free--wheel diodes? These diodes have to be grouped directly together with the inductive load, e. g. by means of luminous sealings. Troubleshooting with Control ystem The control system offers the following troubleshooting aids, described in the manual Control ystem: Indication lamps and light tower Diagnosis program in the temperature section Automatic fault display in the temperature section ervice display Error in the motor section LEDs on the modules and boards. Leuchtmelder und Meldeampel Die Leuchtmelder und die Meldeampel melden bis auf die gelbe Lampe der Meldeampel die gleichen Betriebszustände wie das Kontrollsystem: Automatik Rot Dauerlicht = Der rote Leuchtmelder zeigt eine törung an / das Gerät ist in tandby geschaltet. iehe Tabelle Roter Leuchtmelder leuchtet. Gelb Dauerlicht: = Anlage in Betrieb Grün Dauerlicht= Betriebsbereit. Der grüne Leuchtmelder leuchtet erst, wenn alle Kanäle ihre ollwerttemperatur erreicht haben. Handbetrieb Rot Dauerlicht = Der rote Leuchtmelder zeigt eine törung an / das Gerät ist in tandby geschaltet. Gelb Dauerlicht: = Motor / Pumpen in Betrieb Luce verde continua = Betriebsbereit. Der grüne Leuchtmelder leuchtet erst, wenn alle Kanäle ihre ollwerttemperatur erreicht haben. P/N EEX100--F5B2X2TWXMQX E 2010

69 Troubleshooting 6-3 Troubleshooting tables The troubleshooting tables are an orientation aid for qualified personnel; however, they cannot replace targeted troubleshooting using for example circuit diagrams or measuring devices. They do not cover all possible malfunctions, but only those which could presumably occur.) Red ignal Lamp Flashing Problem Possible Cause Corrective Action Under -temperatue Refill filling hopper Wait until temperature has been during operation reached. Ambient temperature too high hort circuit temperature sensor Interruption temperature sensor Main contactor defective or fallen off Alarm message speed Ambient temperature too high Lower ambient temperature through ventilating or cooling Filter of switch cabinet ventilation dirty Clean or exchange Fan of switch cabinet defective Exchange! Exchange!cable break!temperature sensor defective Pneumatic input pressure falls under 2 bars!pollution -- blockage of: adhesive channels, hose -- coating head -- nozzle Exchange!Control sensor, replace if necessary Check pneumatic connection!starting from application system Remove hot--melt hose, deliver, watch pressure. Device malfunctioning Possible Cause No line voltage Master switch not switched on Main switch defective Master fuse triggered Fuse control voltage triggered Corrective Action Establish line voltage supply. witch on master switch Replace main switch Check whether there is a short--circuit in device or in equipment. Check whether there is a short--circuit in device or in equipment. E 2010 EEX100--F5B2X2TWXMQX P/N

70 6-4 Troubleshooting No adhesive (no motor rotation) Motor superheated Possible Cause Device not yet ready for operation (insufficient temperature during heat--up phase) Device temporarily inoperable (insufficient temperature during operation). / Adhesive was refilled. Motor not switched on Motor not preset Motor start--up protection activated peed not set Automatic mode selected, however, manual mode required No external Release Motor via X10 / X100 interface Automatic mode selected and no master reference voltage available No voltage supply for motor Central module of motor block defect or misaligned Control panel circuit board of motor block defect or misaligned Corrective Action Remedy cause. Remove motor contamination Wait until device is heated--up and green signal lamp illuminates Wait until device is heated--up and green signal lamp illuminates witch on Preset motor and switch on subsequently witch motor(s) on again et speed witch to manual mode Bridge or switch contacts of X 10 / X100 interface. Enable master reference voltage supply or use internal master reference voltage. Determine defect metrologically Align or replace Align or replace Motor superheated Possible Cause Ambient temperature too high Cooling air suction grid soiled Pump blocked by contaminant Pump too tight Adhesive too cold Corrective Action Lower ambient temperature by aerating or cooling Clean Replace pump Replace pump et temperature according No master reference voltage Possible Cause Master machine not operating Tachogenerator (equipment) defective Faulty polarization of master reference voltage Corrective Action Activate master machine Replace Reverse polarity P/N EEX100--F5B2X2TWXMQX E 2010

71 Troubleshooting 6-5 No adhesive (with motor rotation) Filling hopper empty Possible Cause Adhesive inlet hole to the pump or suction hole of pump blocked No pump rotation because of loosened coupling screws Corrective Action Refill filling hopper Unfasten pump and clean inlet hole or suction hole Tighten Incorrect motor speed characteristics in automatic mode Possible Cause Incorrect setting of parameters Fluctuation of master reference voltage despite constant machine speed Corrective Action Reset parameters lip of drive unit (i.e. V--belt) Remove slip Insufficient adhesive Possible Cause Adhesive inlet hole to the pump or suction hole of pump partially blocked Worn pump block of gear pump Processing temperature too low Extruder s operating pressure (pre--pressure) too low Corrective Action Unfasten pump and clean inlet hole or suction hole Replace pump Adjust temperature settings --et the operating pressure with the potentiometer (9R4) --Check the extruder temperature --If necessary clean the extruder screw One channel (heating zone) does not heat Possible Cause Channel switched off Channel/heating zone defective Corrective Action witch on Remove sensor break / defect E 2010 EEX100--F5B2X2TWXMQX P/N

72 6-6 Troubleshooting P/N EEX100--F5B2X2TWXMQX E 2010

73 Removing 7-1 Chapter 7 Removing WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Danger of burns WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. ome maintenance work can only be done when the machine is heated--up. WARNING: ystem and material pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. General remarks In order to disassemble certain machine parts, the adhesive in the melter has to be soft. This means that the equipment has to be heated until the necessary temperatures have been reached. In some cases you may also use a heat gun. Only use original spare parts (see spare parts list). Please also read instruction manuals of the spares as included in the delivery. Removing and Inserting the crew Important Note: The screw and screw cylinder are coated with a corrosion protection agent for shipping and must be cleaned with petroleum before commissioning (does not apply to systems which come with adhesive test). WARNING: The screw may only be removed and inserted when the machine is warm and switched off! E 2010 EEX100--F5B2X2TWXMQX P/N

74 7-2 Removing Removal The clean screw can be removed without any ejection equipment (e.g. for alignment). The emptied screw must be removed with ejection equipment (e.g. for cleaning work). To do this, proceed as follows: 1. Unfasten cover of pump station 2. Detach heated hose 3. Disassemble lid of inspection opening. 4. To unfasten the extruder screw loosen screw Pos. 1 and remove washer (2) and retaining ring (3) Insert ejection tool into the orifice of the pressure bearing 6. lowly push screw to the front or pull it out carefully using the ejection tool. P/N EEX100--F5B2X2TWXMQX E 2010

75 Removing 7-3 Finally, the screw must be cleaned with a soft cloth and finegrain polishing paste until the metal is bright. If the screw is to be stored for longer periods, it should be coated with Vaseline or sprayed with a protective coating. WARNING: When removing/inserting the screw, ensure that the screw shaft does not damage the sealing surfaces of the screw cylinder (do not tilt). WARNING: Hot! Risk of burns in the vicinity of the heated screw cylinder. Remove material residues on the screw with a copper spatula and brass brush. Do not use hard or sharp--edged tools. Wear heat-protective clothing, safety goggles, and heat-protective gloves. Insertion Both screw and screw cylinder must be at room temperature before insertion. They can then be heated up together. 1. Before inserting the screw into the screw cylinder, clean the screw shaft and grease with roller bearing grease. 2. Insert the screw into the screw cylinder and push it through to the screw drive shaft. WARNING: Insert the screw into the screw cylinder very carefully to avoid damage to the screw, the screw drive shaft and the sealing surfaces of the screw cylinder. 3. The screw must be pushed without force into the screw cylinder. WARNING: Danger of injury through shearing when inserting the screw into the screw cylinder! Fingers and hands can be injured through inattention! Wear heat--resistant protective gloves! 4. Refit covers E 2010 EEX100--F5B2X2TWXMQX P/N

76 7-4 Removing P/N EEX100--F5B2X2TWXMQX E 2010

77 pare Parts 8-1 Chapter 8 pare Parts Introduction To order parts, call the Nordson Customer ervice Center or your local Nordson representative. Use this five-column parts list, and the accompanying illustration, to describe and locate parts correctly. Nordson Deutschland GmbH Industriepark Nord 23, Buchholz -Mendt / Germany Phone , Fax Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code N (not shown) indicates that a listed part is not illustrated. A dash ( ) is used when the part number applies to all parts in the illustration. The number in the Part column is the Nordson part number. A series of dashesinthiscolumn(------)means the part cannot be ordered separately. The Description column gives the part name, as well as its dimensions and other characteristics when appropriate. Indentions show the relationships between assemblies, subassemblies, and parts. Example Item Part no Designation Quantity Part Assembly ubassembly 1 If you order item 1 you will get the single spare part as described. If you order item 2, you will get the complete assembly group. If you order item 3, you will get the subassembly. E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

78 8-2 pare Parts Frame for attaching parts Fig. 8-1 P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

79 pare Parts 8-3 Frame for attaching parts Item Part Description Quantity Basic frame Bearing plate Mounting plate Motor Machine screw DIN 912 M12 x N Brace frame Washer DIN 125 A Machine screw DIN 912 M10 x N Axial cylinder toller bearing DIN Machine screw DIN912 M16 x N Circlip DIN x 2, Machine screw DIN 912 M16 x N Mobile wheels Fixed wheels Hexagonal nut IO 4032 M10--D--N Hexagonal screw IO 4014 M10 x 50 x 26--N ocket Feather Key DIN 6885 A16 x 10 x Washer DIN 125 A 8, Machine screw DIN 912 M8 x N ensor hoop guard Brace frame Insulating plate Machine screw DIN 912 M10 x N Washer DIN 125 A 13 4 E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

80 8-4 pare Parts Extruder unit Fig. 8-2 P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

81 pare Parts 8-5 Extruder unit Item Part Description Quantity haft cylinder Ø55 x 26 D Worm Ø35 x 26 D Feather key 12 x 8 x 63 M Retaining ring Washer DIN 125 A 10, Machine screw DIN 912 M10 x N Filling hopper Ø Lid Ø Handle Machine screw DIN 912 M8 x N Heating cuff Ø Temperature sensor FeCuNi M14 x 1,5 x 3000mm Locking screw DIN 910 G 2 Zoll Machine screw DIN 912 M8 x N Washer DIN 125 A 8, Machine screw DIN 912 M12 x Washer DIN 125 A Machine screw DIN 912 M16 x N Locking screw M18 x Level sensor 2 E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

82 8-6 pare Parts Pump unit PN Fig. 8-3 P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

83 pare Parts 8-7 Pump unit Item Part Description Quantity Pump connecting block Motor support panel Heating catridge 8x100 / 400W Extension Gear pump PU m Coupling Electrical screwing Manometric switch Temperature sensor FeCuNi M14x1,5x Pressure sensor 100bar Overtemperature protection with insulating plate Machine screw DIN 912 M3 x N Locking plug Ø PTFE--O--ring Ø 80 x PTFE--O--ring Ø 72 x 2, Locking plug DIN 908 Ø crew rod M16 x Washer DIN 125 A Hexagonal screw IO 4032 M Motor Machine screw DIN 912 M6 x Washer DIN 125 A Machine screw DIN 912 M10 x ealing disk PTFE --O--ring Ø 44 x Electrical cover Electrical cover Extension Insulating cover pump unit part Insulating cover pump unit part Knurled nut Machine screw DIN 7984 M8 x , Washer DIN 125 A8, Machine screw DIN 912 M8 x N Washer DIN 125 A6, Washer DIN 9012 A3, Machine screw DIN 912 M3 x N PTFE --O--ring Ø 32 x 2, Terminal block Hexagonal screw IO 4032 M Hose connection 3/8 NPT -- 3/4 UNF Pressure relief valve Ring cable lug Insulating plate Machine screw DIN 912 M4 x N Casing Machine screw DIN 912 M4 x Locking screw DIN 906 1/4 NPT Drawer 1 E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

84 8-8 pare Parts Pressure relief valve Fig. 8-1 Item Part Description Quantity Lid for pressure relief valve Control module D Ø5 x * O--ring PTFE Ø44x3, * O--ring PTFE Ø35x2, Drip play Machine crew DIN 912 M5 x N Elbow union 1/ ealing ring Alu 1/ crewing G1/ Plug joint 1/ Double nipple 1/ Washer DIN 125 A8, Machine screw DIN 912 M8 x N Ermeto pipe Ø6 x 1; 40lg Ermeto pipe Ø6 x 1; 50lg screw joint 6--1_8 1 NOTE: Parts marked with an asterisk (*) are wearing parts and are excluded from our guarantee. P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

85 pare Parts 8-9 Control module D P/N E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

86 8-10 pare Parts Control module D P/N Item Part Description Quantity Air cylinder Pressure spring * O--ring Viton 16 x 2, * O--ring Viton 17 x 2, * O--ring Viton 18 x 2, * O--ring PTFE 22 x 2, * Pressure disk 12 x 5,2 x Circlip DIN 472 Ø Machine screw DIN 912 M 4 x Hexagonal nut IO 4032 M5--D--N Retaining ring DIN 6798 Ø 5, Control piston * ealing Ekonol--tepseal Ø 5mm * O--ring Fluoraz 6,07 x 1, Base module Needle Ø 5mm x 83 mm lg * Tapered pressure disk Needle seat * O--RingPTFE Ø12x2, The positions marked with (+) is possible to order as Renovation kit NOTE: Parts marked with an asterisk (*) are wearing parts and are excluded from our guarantee. P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

87 pare Parts 8-11 Pneumatic foam Fig. 8-2 Item Part Description Quantity Pressure relief valve olenoid valve Dejamming module Valve plug Mounting angle Plug joint Coupler plug 1/ Plug joint 1/ ound absorber 1/ Machine screw DIN 912 M6 x N Washer DIN 125 A E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

88 8-12 pare Parts Extruder covers P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

89 pare Parts 8-13 Extruder covers Item Part Description Quantity Covering hood extruder unit Angle bracket Angle bracket Countersunk screw DIN 7991 M6 x N Cover plate Rivet Ø 4 x 6 5 E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

90 8-14 pare Parts Water connection Cooling water supply Cooling water return Item Part Description Quantity Twin nipple 1/ Angled hose connection 1/2 x 3/4 2 P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

91 Technical Data 9-1 Chapter 9 Technical Data Description Connection, tart- up: General Data The electrical connection to the control cabinet is implemented with the connection cable provided. The water cooling connection is firmly installed; check for possible leaks. The hot melt hose can be connected after the heating procedure is complete. During operation, ensure that the feed area of the screw is always kept covered with adhesive granulate to avoid any running dry. As the temperature control system for the feed area maintains optimal temperatures, all that is required is sufficient cooling water volumes (temperature ca. 15 C) through the cooling aggregate. Adhesive pressure limitation 100 bar Noise emission 70 dba Motor type A.C. motor peed setting range 0to100min -1 To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min -1 (rpm) or continuously exceed 80 min -1 (rpm). Degree of protection IP 32 Electrical Data CAUTION: The unit is designed for only one operating voltage. Operate only at the operating voltage shown on the ID plate. Temperatures Min. ambient temperature Max. ambient temperature Min. operating temperature 10 C 40 C 50 C NOTE: Depending on the type of adhesive used, the overtemperature thermostats of the components may need to be adapted to the maximum processing temperature of the adhesive (This may mean replacing it). E 2010 Nordson Deutschland GmbH EEX100--F5B2X2TWXMQX P/N

92 9-2 Technical Data Dimension ~1252,20 ~1483 ~ 1635,39 ~1900 ~ 2566 ~960 ~ 960 Technical Data Type: upply voltage: Connected load: EEX100 -F5B2X2TWXMQX 3x400VAC + N +PE Heating 35 kw Amount of glue: Coolant: Dimension: Weight: Drive: 100 kg/h Water 20 C ca.0,5 L/min 2566 x 960 x 1636 mm see waybill Three--phase AC Extruder 11 kw Pump station 4 x 0,55 kw P/N EEX100--F5B2X2TWXMQX E 2010 Nordson Deutschland GmbH

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