EQUIPMENT Operation Manual

Transcription

1 EQUIPMENT Operation Manual Loctite Hysol BULK 14 System Part Number 98133, 115VAC Model Part Number 98134, 230VAC Model

2 TABLE OF CONTENTS 1. PLEASE OBSERVE THE FOLLOWING Emphasized Sections For Your Safety DESCRIPTION General Description Operating Elements and Connections TECHNICAL DATA Energy Requirements Dimensions INSTALLATION Shipping and Handling Positioning the Melt Unit and Space Requirements Component Installation Hot Melt Supply Hoses Handheld Applicators Automatic Mounted Applicators Mounted Electric Applicators Electrical Wiring Supply Hose Electrical Connections Applicator Electrical Connections Auxiliary Input Connections Front Panel Removal OPERATING THE UNIT ON/OFF Power Switch and Circuit Breaker Front Panel Controls Fahrenheit or Celsius Temperature Readout Setting Tank Temperature Setting Hose #1 & #2 Temperature Setting Valve #1 & #2 Temperature Setting Pump Function Mode Selector Pump Speed Setting Heating Indicators Melt Unit Ready Lights Open Sensor Error LED Auxiliary Input Connection and Control Setting Drastic Reduction of the Tank Temperature Drastic Reduction of Hose or Valve Temperature Cold Temperature Start-Ups Start-Up Instructions Adhesive Pressure Adjustment Setting Temperature Setting Example CARE AND MAINTENANCE Hose Replacement Tank Screen Inspection Replacing Front Panel Removing Tank Cover Bulk-14 & 34 Motor Control Fuses Kit BULK-14 DRIVE COUPLER HUB ASSEMBLY REPLACEMENT Bulk-14 Pump Replacement BULK-14 Pump Rebuild Kit Bulk-12 and 14 Pressure Adjuster Assembly Kit Pressure Adjuster Rebuild Kit

3 6.14 Tank Thermistor Assembly Replacement Bulk TROUBLE SHOOTING (BULK-14) DOCUMENTATION SPARE PARTS AND ACCESSORIES (BULK-14) WARRANTY

4 1. Please Observe the following 1.1 Emphasized Sections Warning! Refers to safety regulations and requires safety measures that protect the operator or other persons from injury or danger to life. Notice Gives recommendations for better handling of the unit during operation or adjustment as well as for service activities. 1.2 For Your Safety For safe and successful operation of the unit, read these instructions completely. If the instructions are not observed, the manufacturer can assume no responsibility. Retain this manual for future reference. Warning! Always wear goggles and heat resistant gloves rated to 400 F (205 C) when operating system. Warning! Observe general safety regulations for the handling of chemicals such as Loctite adhesives and sealants. Observe the manufacturer s instructions as stated in the Material Safety Data Sheet (MSDS). Properly ventilate equipment according to appropriate MSDS for the hot melt adhesive used. Warning! Do not mix hot melt formulations in the melt tank. To change formulations, purge and clean tank with materials recommended by the adhesive manufacturer at the recommended temperature. Warning! In the event of malfunction turn off power to the equipment at the circuit breaker of the melt unit and remove power source to the unit at the nearest main disconnect. Warning! Do not use flammable material. Notice While under warranty, the unit may be repaired only by an authorized Henkel service representative. Notice Henkel Corporation has designed this equipment for safe operation. However, heated thermoplastics and other hot melt materials are dangerous and care must be exercised to ensure operational safety. Handling must be in accordance with hot melt adhesives manufacturer specifications. Notice Dispose of hot melt adhesives properly. Refer to the Materials Safety Data Sheet (MSDS) of the hot melt for recommended disposal methods. 4

5 Notice The following safety features are included in each melt unit: The tank, hose, and applicator head are monitored for over temperature conditions. The affected zone is shut down if an error condition is detected. The circuit breaker is automatically tripped when the tank is sensed to be over temperature. A passive over temperature sensor trips the melt unit circuit breaker before irreparable damage occurs to the unit in the unlikely event that the closed loop electronics should malfunction, resulting in a runaway heating condition in the melt unit. Operation of the pump/motor is inhibited until the melt tank reaches 80% of the selected temperature. This prevents damage to the pump/motor by attempting to operate while the adhesive is too viscous to be pumped. a. Items Supplied Carefully remove the unit from its shipping carton and inspect it for any signs of damage. Any damage should be reported immediately to the carrier. Refer to the list of supplied parts below and compare to the contents. Report any missing parts promptly to the Henkel customer service department at LOCTITE or Operators Manual, P/N mm Hex Key, P/N Trim Potentiometer Tool for temperature range adjustment, P/N

6 2. Description 2.1 General Description Loctite Hysol Bulk-14 Hot Melt System is used for melting and pumping hot melt thermoplastic adhesives. The system consists of the melt unit, heated supply hose(s), and applicators. System operation is further enhanced by the use of timers, foot switches, or other controllers. All temperatures in the system are controlled by closed loop electronics using thermistor-based sensors. This equipment is designed for use with standard adhesives and sealants such as EVA s with flashpoints above 232 C (410 F). 2.2 Operating Elements and Connections 1 Melt Unit The Loctite Hysol Bulk-14 Hot Melt System is able to pump a variety of thermoplastic materials, such as packaging or product assembly adhesives, wax, and various potting materials. The melt unit consists of a heated melt tank with a motor-driven, positive-displacement gear pump. The tank has a 14-pound capacity with an integral melt grid. The tank unit is completely electric; it does not require the use of compressed air for operation. The wide-mouth design of the tank lid allows use of virtually any form of adhesive, including granules, flakes, pillows, and blocks. The tank s integral melt grid transfers heat efficiently from the heaters to the thermo-plastic material. Temperatures and controls are set from the front panel of the unit through membrane pushbutton switches. A pressure regulator valve provides fluid pressure regulation by controlling flow through a bypass mechanism. Additional flow control regulation can also be made through adjustment of motor speed. 2 Supply Hose The Loctite Hysol Bulk-14 Hot Melt System supports two hot melt supply hoses. The gear pump has two outlets to channel adhesive flow to the supply hoses. Temperatures for each hose are individually selected using the membrane pushbutton switches on the front panel of the melt unit. Both hoses are electrically and mechanically attached to the melt unit via easy access connectors on the front of the melt unit. 3 Applicator Applicators used with the Loctite Hysol Bulk-14 Hot Melt System are connected electrically and mechanically to the supply hoses. Temperatures for each applicator are individually selected using membrane pushbutton switches on the front panel of the melt unit. Mounted automatic applicator heads will typically be used in conjunction with a controller, timer, or other switching device attached to the auxiliary connectors on the melt unit; pump motor switching is also accomplished automatically via this connection. Handheld applicators are generally used in manual application systems and possess an integral reed relay switch on the handle grip to control the melt unit pump motor. A three position membrane switch on the front panel of the melt unit is used to turn the pump off; allow the pump to be cycled by a pattern controlling device via the auxiliary connector or by a Handheld Applicator; or to allow the pump to run continuously. Selection of the cycle setting results in the motor idling at a crawl speed, rapidly accelerating to the speed selected by the pump speed indicator when activated, then returning to the crawl speed when the application of adhesive ends. The motor crawl feature assures constant adhesive pressure in the supply hose and applicator head, thus assuring a strong stream of adhesive when the applicator is activated.

7 4. Electrical Considerations Electrical power to the Loctite Hysol Bulk-14 Hot Melt System is controlled by a circuit breaker on the right lower side of the front panel. The system is designed to be energized from a 20-amp power source. Hoses, applicator heads and control devices (timers, foot switches, etc.) are designed with multi-pin plugs to easily connect to the melt unit for simplicity or installation. All connections are located at the front of the melt unit to allow for ease of assembly and disassembly. 5. Safety Considerations The following safety features are included in each melt unit: The tank, hose and applicator valve are monitored for over temperature conditions. The affected zone is shut down if an error condition is detected. The manual/magnetic circuit breaker is automatically tripped when the tank is sensed to be over temperature. A passive over temperature sensor trips the melt unit circuit breaker before irreparable damage occurs to the unit in the unlikely event that the closed loop electronics should malfunction, resulting in a runaway heating condition in the melt unit. Operation of the pump/motor is inhibited until the melt tank reaches 80% of the selected temperature. This prevents damage to the pump/motor by attempting to operate while the adhesive it too viscous to be pumped. The pump and motor are protected by a fuse that opens if a stall or overload condition occurs. 6. Maintenance Considerations Loctite Hysol Bulk-14 Hot Melt Systems are designed with simplicity and reliability in mind. Troubleshooting, maintenance and service are quite easy. Front panel diagnostics isolate specific zones which may be experiencing fault conditions. All electrical components are designed for easy access using ordinary hand tools. Modular design minimizes down time in the event of sub-assembly failures. 3. Technical Data 3.1 Energy Requirements Electrical power to the Loctite Hysol Bulk-14 Hot Melt System is controlled by a manual/magnetic circuit breaker located on the lower left side of the melt unit. The system is designed to be energized from a 20-amp power source. 3.2 Dimensions Width: Length: Height: Empty Weight: 11.5 inches inches 24 inches w/lid open 51 pounds 7

8 4. Installation 4.1 Shipping and Handling The Loctite Hysol Bulk-14 Hot Melt System is shipped with the melt unit, supply hose (if ordered), and applicator head (if ordered) disconnected. The supply hose and applicator head are typically packed in separate boxes from the melt unit. The melt unit is shipped on a plywood board placed on a foam pad inside a corrugated box. Padding is also placed around the sides and top of the melt unit to protect it during shipment. Each unit is shipped with a 10-mm hex key for the pressure adjustment; trim potentiometer tool and an operator system manual. The supply hose will be loosely coiled in a box separate from the melt unit. The handheld, mounted automatic heads and other system applicator accessories will also be placed in separate packaging when shipped. Notice Use extreme care when shipping the melt unit due to its size and weight, to avoid damaged. Keep the original packing material for future shipment should it be required. Place system on a pallet and ship via common carrier rather than shipping via parcel services. 4.2 Positioning the Melt Unit and Space Requirements Remove the melt unit from the shipping materials. Position it so servicing is convenient and the control panel is easily accessible. Select a surface that is flat and level to avoid warping the frame and misaligning the pump and motor shaft. Notice Bolt the melt unit securely to a supporting flat surface. Use the bolt holes at the bottom of the unit. Position the unit to allow access to tighten or loosen hose fittings. 4.3 Component Installation Warning! Turn off melt unit circuit breaker and disconnect the power cord prior to installing hoses and/or applicator to the melt unit to avoid accidental system pressurization or electrical shock. Read section 2 & 5 of this manual before installing any components. TOOLS USED FOR INSTALLATION One 5/16 Open End Wrench One 7/16 Open End Wrench Two 1/2 Open End Wrench One 13/16 Open End Wrench Two 11/16 Open End Wrench One 10mm Hex Wrench One 3/16 Hex Wrench One 7/64 Hex Wrench 8

9 4.4 Hot Melt Supply Hoses Notice The hose should not be flexed when cold to avoid damage. The hoses have a minimum bend radius of eight inches when hot; further flexure will cause permanent damage. Notice Hot melt fittings must be heated before loosening or tightening to prevent damage. New and clean supply hose fittings do not need to be heated. Notice Support the hose during dispensing operations to prevent excessive flexure. Failure to properly support the hose will result in premature failure. Notice Ensure that you have access to the adhesive manifold fittings and electrical connectors being careful not to tilt it beyond the point where adhesive can spill from the melt tank. Never turn the melt unit upside down. Loosely connect the JIC swivel fitting on the hose to the manifold fitting, and then tighten the JIC swivel fitting using an 11/16 open-end wrench. Be certain the JIC fitting is securely seated on the manifold fitting otherwise adhesive will leak once the unit reaches operating temperature. Properly align the keys of the hose electrical connector to the melt unit connector and securely screw these parts together. Figure Handheld Applicators The handheld nozzle should never be pointed towards people when the melt unit is powered. Pressures can develop within the hot melt system causing the adhesive to be projected significant distances. Pointing the handheld applicator nozzle at someone (including yourself!) presents a potential burn hazard. The trigger mechanism of the handheld applicator should never be pulled until the entire system is up to operating temperature. Attempts to retract the trigger before adhesive in the handheld applicator has adequately softened will result in damage to the needle assembly. This damage is not covered under warranty. The backside of the handheld applicator grip contains a yellow lever to control pump motor operation. It is recommended that the front panel of the melt unit be set for cycle operation with pump motor control from the handheld applicator switch. This will prevent unnecessary wear on the motor and pump mechanisms. Hot melt fittings must be heated before loosening or tightening to prevent damage. New and clean supply hose fittings do not need to be heated. 9

10 Applicator # VAC 50/60 Hz MAXIMUM WORKING PRESSURE 500 PSI S/N: MMDDYY-XX-X C D A B E Figure 2 Handheld Applicator to Supply Hose Installation a) Loosely connect the JIC fitting on the supply hose to the handheld applicator, then tighten the JIC fitting using two 11/16 open end wrenches, one on the handheld applicator and one on the hose. A 13/16 open-end wrench is required for the handheld applicator swivel. b) Install the heat shield insulation over the handheld applicator/hose connectors. c) Assemble the two pieces of the handheld applicator swivel shield over the insulation assuring the top collar of the shield fits into the groove machined in the JIC male handheld applicator fitting. d) Insert the two screws into the handheld applicator swivel shield and tighten. e) Properly align the keys of the hose electrical connector to the handheld applicator connector and securely screw these parts together. 4.6 Automatic Mounted Applicators The following points should adhere to: Notice Automatic applicators are mounted to appropriate brackets using supplied hardware. Notice Insulation spacers must be used between the applicator head and the mounting bracket and between the mounting bracket and mounting bolt to assure minimum heat loss and allow the applicator to efficiently reach the desired temperature. Notice Fittings connecting the applicator head to the hose should be kept as short as possible and insulation should be applied over the hose/head fitting connections to further minimize heat loss since this connection is unheated. Hot melt fittings must be heated before loosening or tightening to prevent damage. New and clean supply hose fittings do not need to be heated. 10

11 4.7 Mounted Electric Applicators Mounted electric applicator heads require only electricity to actuate the needle. Both applicator head heating and actuating power is supplied through the melt unit through supply hose, therefore, no external connections are required making installation very simple. This applicator is ideal for installation sites where no compressed air available. Control is accomplished via the auxiliary connector on the melt unit. B C D Figure 3 Mounted Electric Applicator to Supply Hose Installation A /4-20 TAPPED HOLE 3/8 DEEP 2 HOLES BOTH SIDES MOUNTING HARDWARE INCLUDED WITH APPLICATOR CUSTOMER SUPPLIED OR OPTIONAL MOUNTING BRACKET KIT a) Loosely connect the mounting bolts through the insulation washers and mounting bracket into the applicator head as shown in the above illustration. Tighten the bolts using a 7/16 open-end wrench. b) Loosely connect the JIC fitting on the supply hose to the applicator head, and then tighten the JIC fitting using an 11/16 open-end wrench. c) Install the heat shield insulation over the applicator/hose connectors d) Properly align the keys of the hose electrical connector to the applicator connector and securely screw these parts together. 4.8 Mounted Air-Operated Applicators The mounted air applicator requires compressed air supply to actuate the needle(s). The supply of this compressed air is regulated via solenoid valve attached to the mounted air applicator. Both the applicator heating and solenoid actuating power is supplied through the melt unit/supply hose wiring facilitating the installation. Pattern control can be made via the auxiliary connector on the melt unit. NOTES: Mounted applicators are to be mounted to appropriate brackets using supplied hardware. Insulation spacers must be used between the applicator head and the mounting bracket and between the mounting bracket and mounting bolt to assure minimum heat loss and allow the applicator to efficiently reach the desired temperature. Keep all fittings connecting the applicator to the hose as short as possible. Insulate the applicator/hose fitting connections to further minimize heat loss since this connection is unheated. Hot melt fittings must be heated before loosening or tightening to prevent damage. New and clean supply hose fittings do not require heating on initial install. Caution: First check to insure that you have the proper voltage to applicator. The voltage of the applicator should be the same as the melt unit voltage. 11

12 1. (A) Loosely connect the mounting bolts through the insulation washers and mounting bracket into the applicator head (see illustration). Tighten the bolts using a 7/16 open-end wrench. 2. (B) Loosely connect the JIC fitting on the supply hose to the applicator head, and then tighten the JIC fitting using an 11/16 open-end wrench. Ensure you have a tight connection to avoid leaks. 3. (C) Install the heat shield insulation supplied over the applicator/hose connector, secure with tie wraps. 4. (D) Place the compression nuts and sleeves over the two aluminum tubes and insert between the applicator head and air solenoid valve. Tighten the compression nuts using two ½ open end wrenches until snug. 5. (E) Properly align the keys of the four-pin solenoid connector with its mating connector on the applicator head and rotate the locking nut fully to make connection. 6. (F) Properly align the keys of the nine-pin hose electrical connector with its mating applicator connector head and rotate the locking nut fully to make connection. See 4-way solenoid installation instructions for valve connections (included with solenoid valve). VALVE SHOWN FOR REFERENCE ONLY REGULATED AIR IN D F E HOSE SOLENOID C B AIR APPLICATOR 115 VAC ITEM # SN XXXXXXX A MOUNTING HARDWARE INCLUDED WITH APPLICATOR CUSTOMER SUPPLIED OR OPTIONAL MOUNTING BRACKET KIT 1/4-20 HOLES Figure 4 Mounted Air Applicator to Supply Hose Installation 4.9 Electrical Wiring The Loctite series hot melt units use single phase, 100 to 130 VAC, or 200 to 240 VAC, 50 to 60 Hz power sources, each with earth ground for safety. The 115 VAC melt units come equipped with a 20 amp molded plug for convenient connection to a 115 VAC, 20-amp receptacle. The 230 VAC melt units come equipped with a 20 amp molded plug for convenient connection to a 230 VAC, 20-amp receptacle. Figure 5 Melt Unit Electrical Connection 12

13 4.10 Supply Hose Electrical Connections Electrical power to heat supply hoses is provided via the melt unit. Supply hoses are equipped with a multi-pin, molded connector that is attached to the bottom plate of the control panel for ease of installation Applicator Electrical Connections Electrical power to heat and actuate all handheld and mounted automatic applicators is supplied by the melt unit via the supply hoses. The applicators are equipped with multi-pin, molded connectors designed to mate to hose connectors for ease of installation Auxiliary Input Connections The auxiliary input connection is used when employing automatic applicators and/or for controlling the flow of atomizing air in spray applications. Controllers supplied by Henkel Corporation are available with terminated cables to simplify connection to the melt system. Cables with one end un-terminated, PN for single channel external interface or P/N for dual channel external interface) is available to allow connection of a customersupplied controller into the melt system. Figure 6 Auxiliary Connector Pin Designator 13

14 4.13 Front Panel Removal The Loctite Bulk hot melt unit is designed for ease of use and reliability. Under normal circumstances, the front panel should not need to be removed. If a new version of software is released, the following procedure can be used to remove the front panel. Figure 7 Front Panel Side view a) Slide the front end of the melt unit towards the edge of the worktable far enough to access the supply hose electrical connectors being careful not to tilt it so far that adhesive spills from the melt tank. Never turn the melt unit upside down. b) Disconnect the supply hose electrical connector panel from the melt unit. c) Remove the two hex head screws to the left and right of the hose electrical connectors using a 5/16 wrench, supporting the panel in position to prevent its movement. d) Slowly slide the control panel down and away from the melt unit taking care not to strain the cables interconnecting the melt unit and the control panel. The control panel can be laid on a flat surface in front of the melt unit or held in a horizontal position. e) At this point, the front panel is accessible for replacement or updates. f) To reinstall, rotate the control panel until it rests against the melt unit, with the top of the control panel approximately 1/2 below the top of the melt unit opening. Make sure that no cables are obstructing the control panel from seating properly. g) Slide the control panel up so that it seats properly into the melt unit. h) Insert and tighten the two hex head screws using a 5/16 wrench. i) Reconnect the supply hose electrical connector(s) into the melt unit and reposition the melt unit to its proper position. 14

15 5. Operating the Unit 5.1 ON/OFF Power Switch and Circuit Breaker This section covers the operating controls and indicators from the Loctite Bulk Hot Melt System. Please read carefully before attempting to operate system. The On/Off power switch is located at the lower left side of the melt unit. It is a manual circuit breaker and also a magnetic breaker, which opens the circuit when the current exceeds 20 amps (at 115VAC or 230VAC) or when over-temperature conditions are sensed at the melt tank. Fig. 8 Circuit Breaker 5.2 Front Panel Controls Control and trouble shooting for the entire melt system is accomplished from the melt unit front panel. A brief overview of these controls and indicators are shown on the following pages. Set Temp Display (or Standby Timer) Standby Toggle Pump ON/OFF Loop Output Indicators Loop Select UP Set Temp Increment/Decrement Pump Speed Indicator Pump Speed Increment/Decrement Pump Status LED Loop Select DOWN Standby Status LED Loop Select On/Off Range Indicator Digit Pump Function Toggle Pump Function LED s Over Temp Error LED Actual Temp Display Open Sensor Error LED Figure 9 Front Panel Controls 15

16 5.3 Tank Temperature Range Indicator The temperature range indicator is a single 7 segment LED display showing the range currently set for the tank, hose, and valve temperatures. A chart indicating the settings for each temperature range is listed as follows: RANGE Tank Temperatures Hose and Valve Temperatures Deg F (bold) / Deg C Deg F (bold) / Deg C Range to to to to 107 Range to to to to 129 Range to to to to 152 Range to to to to 174 Range to to to to 196 Range to to to to Fahrenheit or Celsius Temperature Readout Setting To set temperature unit of measure for display follow the procedure: 1. Use the loop select Up/Down to select tank. The LED to the left of the device should show green. 2. Press the Loop Select button up four times. The range indicator will start to blink. 3. Pressing the Loop Select on/off, button will toggle the display from C to F or F to C showing temperatures in the actual temperature display. The higher display temperature readout will be in Fahrenheit, the lower temperature reading will be in Celsius. 5.5 Tank Temperature Setting The tank is the first temperature that you would want to select. The tank temperature can be independently set using the following procedure: 1. Select the tank as the device you wish to set. This is accomplished by either pressing the Loop Select Up or the Loop Select Down buttons until the green LED to the left of the TANK label is illuminated. 2. Rapidly press the Loop Select Up button four times. This will change the Range Indicator Digit from a solid state to a blinking state. 3. Using either the Set Temp Increment or the Set Temp Decrement button will either increment or decrement the Range Indicator Digit. 4. After the Range Indicator Digit has been incremented/decremented, you can now use the Set Temp Increment/Decrement buttons to change the desired temperature. If the Range that you selected in the first part of this procedure is not the range that you desire, you must repeat step #1 until you are at the range you want. 5.6 Hose #1 & #2 Temperature Setting 1. Select Hose 1(2) as the device you wish to set. This is accomplished by either pressing the Loop Select Up or the Loop Select Down buttons until the green LED to the left of the HOSE 1(2) label is illuminated. 2. Use either the Set Temp Increment or Set Temp Decrement buttons to increment/decrement the desired temperature. 16

17 5.7 Valve #1 & #2 Temperature Setting 1. Select Head 1(2) as the device you wish to set. This is accomplished by either pressing the Loop Select Up or the Loop Select Down buttons until the green LED to the left of the HEAD 1(2) label is illuminated. 2. Use either the Set Temp Increment or Set Temp Decrement buttons to increment/decrement the desired temperature. 5.8 Pump Function Mode Selector These three LED s indicate pump Cycle, Crawl, or Run, and are controlled by the Pump Function Toggle button. Cycle: The pump is cycled on/off when the pump-switch on a handheld or foot switch is activated. The same condition happens when an automatic pattern control device is used. Crawl: The pump is normally on, turning at a slow fixed velocity. The crawl function keeps a constant pressure from the pump, through the hose, and to the handheld or automatic mounted applicator. This ensures that when the handheld/footswitch/automatic device is activated, the adhesive will be dispensed on demand with be no lag time. Note: Pump speed is not adjustable when in crawl mode. Run: The pump is always on. 5.9 Pump Speed Setting When selecting cycle, crawl, or run, and the pump is activated for the purpose of dispensing adhesive; the speed of the pump will be whatever is displayed on the pump speed indicator s row of ten green contiguous LED s. The speed of the pump is adjusted by using the Pump Speed Increment or Pump Speed Decrement buttons. There is also an On/Off switch, which is above the pump status indicator. In all three of the above cases when the pump is activated for the purpose of dispensing adhesive, the speed of the pump will be whatever is displayed on the pump speed indicator s row of ten green contiguous LED s. The speed of the pump is adjusted by using the Pump Speed Increment and Pump Speed Decrement buttons. There is also an On/Off switch, which is above the pump status indicator Heating Indicators The series of Loop Output indicators refer to the tank, hose, and valve. The LED s will flash amber while warming up. Once the desired temperature has been reached, each LED Loop Indicator output will turn to a green color. Note that all three LED s should be a flashing green color before dispensing adhesive Melt Unit Ready Lights When the Melt Unit is ready to operate, all three LED indicators as observed on the Loop Output Indicator row of LED s will flash green. Note that the pump will not operate until the Tank is at temperature. The tank is at temperature when the associated LED is flashing green. The pump WILL operate even if the HOSE or Valve is NOT at temperature. Dispense the adhesive only after all of the LED s have changed from a flashing amber color to a flashing green color Open Sensor Error LED This LED will be illuminated red in color when an open circuit condition is sensed. It could happen due to a faulty applicator, a melt unit malfunction, or a hose that has failed. The affected zone is automatically de-energized which provides a very accurate, simple, and fast turn-around time when there is a system problem. For example, if the failure occurred in the Valve area, a new applicator could quickly and easily be replaced. 17

18 5.13 Auxiliary Input Connection and Control Setting One auxiliary connection is available for each hose/applicator employed. Different examples of an auxiliary device might be: foot switches, a timer or controller, or an external kit, which would allow you to apply adhesive in different patterns and pressures (such as a swirl pattern when using a swirl tip). Auxiliary input selection is accomplished on a per channel basis and can only be accessed when the control is in a Standby Mode. First press the Standby Toggle at the top center of the control panel. The system will go into standby and allow the changes to the auxiliary mode. Next, using the Loop Selection up or down button, select the channel to which you chose to activate or de-activate. When the channel is selected, just press the Loop Select on/off button and make the desired selection. After the selection is completed, just press the Standby Toggle button again and the change is complete Standby Timer Setting Setting the standby timer will reduce the tank temperature for a selected amount of time. When the standby time is complete, the tank settings automatically resume to previous set temperatures. 1. Press the Standby toggle. 2. Press temperature increment/decrement to increase or decrease time. Set time will appear in the set temperature display. You must enter a minimum of five minutes for standby time Drastic Reduction of the Tank Temperature Drastic reductions in temperature of the tank will cause the melt tank circuit breaker to trip. This is a safety feature to protect the unit from damage. This condition can occur if the operator tries to adjust the TANK temperature from Range-5 to a Range-2. If this function is invoked, the system thinks there is an over-temp condition. To prevent this thermal runaway condition from doing damage, the breaker trips, and all power is cut off. This situation may be easily remedied by allowing the tank temperature to cool down before resetting the circuit breaker Drastic Reduction of Hose or Valve Temperature Drastic reductions in temperature of the hose or valve once they are at operating temperature may result in a sensed over-temperature condition for that zone. An audible alarm will be sounded and the OVER TEMP LED on the front panel will be illuminated and heating for that zone will be disrupted Cold Temperature Start-Ups 1. Attempting to start-up the melt system at ambient temperatures below 42 F (6 C) with the melt unit set at Range-4 or higher may result in an open circuit condition being sensed by the melt unit. This condition will prevent that open zone from heating. 2. This condition is remedied by adjusting the temperature range for the open zone to a lower setting. This setting may be adjusted back up to the desired higher setting once the tank, hose, and head have warmed to a temperature above 42 F. 18

19 5.18 Start-Up Instructions Warning! Fire, explosion, personal injury, property and equipment damage can result if the materials used in or around any hot melt supply equipment do not meet all the following requirements: I. Minimum flash point of the material should be at least 50 F (10 C) above the highest operating temperature of the melt system. II. III. IV. Liquid and vapors should be non-toxic and non-flammable at operating temperatures of the melt system. Any materials mixed in the melt system (i.e. purging compounds and adhesives, or different adhesives) should not react violently to produce heat, flames, toxic gases, cross-linking or disabling of the adhesives ability to melt at its designed temperature. Materials used in the melt system must not corrode, abrade or otherwise detrimentally affect the system. 1. Become familiar with the melt unit controls in its entirety by reading the manual. 2. Fill the melt tank with adhesive material to a level no higher than 1.5 inches (4 cm) from the top. Certain product assembly materials will degrade over time due to oxidation. It is best not to put more material in the tank than will be used in one day. Set the tank temperature as low as feasible for each specific application to avoid charring. 3. Turn the melt unit on, selecting the desired temperature setting for the melt tank, supply hose, and applicator head. Refer to the temperature chart in Section 5.20 of this manual for guidance of setting desired temperatures. Lower temperature settings will increase the material s pot life. The hot melt system employs staged heating upon start-up to reduce current loads and prevent adhesive degradation in the hose and applicator head as the melt unit achieves its desired temperature. The melt unit heats to approximately 80% of desired temperature before heating the supply hose and applicator. All three elements of the melt system achieve desired temperature at approximately the same time utilizing this method of heating. 4. Select the desired operating mode using the pump function toggle selector. 5. Select the desired pump operating speed. 6. Set adhesive pressure via the pressure regulator valve Adhesive Pressure Adjustment Setting The melt unit adhesive pressure regulator valve is located on the right side of the pump and is adjusted using a 10- mm hex wrench. Pressure adjustments should be attempted only when the melt unit is at operating temperature. To increase flow, turn the pressure regulator valve clockwise. To decrease flow, turn the pressure regulator valve counter-clockwise. Figure 10 Pressure Regulator Valve 19

20 5.20 Temperature Setting Example To reduce degradation of the adhesive, the delivery hose should be at a lower temperature than the applicator and melting tank at a lower temperature than the delivery hose. When volume requirements vary, the temperature settings for the melting tank and delivery hose may also vary. The applicator should always be set to the recommended delivery temperature, however certain conditions may require adjustment of this setting. In this example, the adhesive will have a recommended delivery temperature of 350 F. Volume Requirement:Low Medium High Tank Setting ( F) Hose Setting ( F) Applicator Setting ( F)

21 6 Care and Maintenance All electrical and mechanical components of the Loctite Hysol Bulk-14 Hot Melt System should be visually inspected for damage/wear prior to powering up the system each day. This inspection should include, but may not be limited to, the following areas event of sub-assembly failures: Inspect the melt tank for foreign materials and/or charring of the adhesive. Wipe off all excess adhesives from all surfaces with purging compound. Check the hoses, applicator, and nozzles for wear and assure integrity of all electrical connections. Verify the hose is being properly supported so it is not over-stressed during use. The minimum bend radius is 8 inches (21 cm) when hot. Look for leaks under the melt unit and at all mechanical connections. Problems noted should be remedied prior to powering up the unit. The system should be purged with a flushing agent when char build-up occurs or if the hot melt formulation is changed. Warning! Hot melt materials can cause severe burns resulting in disfigurement or blindness. Take the following precautions before beginning any maintenance action: 1. Wear eye protection goggles, gloves, and protective clothing. 2. De-pressurize the supply hoses and applicator by shutting off the pump motor and firing the applicator either manually or automatically into a disposal receptacle until no more adhesive is expelled through the applicator. 3. Allow the melt unit to cool down before beginning any maintenance. 4. Always disconnect hose/applicator electrical connectors before disconnecting mechanical fittings. Notice The part of the system being serviced should be heated to a temperature high enough to soften the adhesive prior to dismantling, assembly or adjustment to prevent damage to mechanical components (i.e. hose/valve fittings, pressure adjusters, tank lid, etc.). Assure that power to the melt system is turned off prior to attaching any electrical connector to avoid arcing or possible component failure. 6.1 Hose Replacement Notice Liquefied hot melt adhesive in the melt unit tank affords a potential burn hazard when attempting to replace supply hoses. Be certain that all material in the tank has cooled before attempting this maintenance action. 1. Turn off the melt unit circuit breaker and allow the adhesive in the tank to completely solidify. 2. Turn on the melt unit circuit breaker for five minutes to allow fittings to warm or heat fittings. 3. Turn off the melt unit circuit breaker and disconnect the melt unit s electrical power. 4. Disconnect the supply hose electrical connector. 5. Tilt the melt unit backward far enough to access the adhesive manifold fittings. Loosen the supply hose JIC fitting and remove the hose from the melt unit. 6. Install a new hose as specified in section

22 6.2 Tank Screen Inspection Tank Screen Replacement P/N A U shaped screen is located in the bottom of the melt tank to prevent contaminants from damaging the adhesive pump assembly. This screen should be inspected and cleaned on a regular basis. It is easiest to do this when the melt tank is at operating temperature and close to being empty of adhesive. 1. Grasp the screen from the bottom of the melt tank using needle nose pliers. Be very careful not to let any contaminants on the screen fall back into the melt tank. 2. Clean all debris from the screen using purging compound. 3. Inspect the screen for damage and replace if necessary. 4. Reposition new or clean screen into the bottom of the melt tank assuring it fits snugly between the grids and over the top of the sump hole outlet to the gear pump. 6.3 Front Panel Fuse Replacement Fuse Kit Replacement P/N Before you attempt to change or check the fuses, remove all power from melt unit. All hoses and other control connected to the unit should be removed from the unit until the cause of the blown fuse is removed. The fuse blown should be a good indicator as to where to look for the problem. 1. First remove the control from the melt unit (see manual for details). Note removal of the connector is not required. 2. The fuses are located on the connector panels and are inserted into small pin holders. 3. After locating fuses use a digital voltmeter (DVM) to locate blown fuse. 4. Use a needle nose pliers to carefully grip and remove the damaged fuse. 5. Replace with new fuse by inserting the fuse firmly back into pin holder. 6. Re-install control panel back into the melt unit and reconnect power to unit. 7. Reconnect the items to the unit and restore power. Figure 11 Input/Output Power Board 22

23 6.4 Replacing Front Panel Part No Control Panel Assembly, 115 VAC Part No Control Panel Assembly, 230 VAC INSTALLATION INSTRUCTIONS: 1. Disconnect power from unit. 2. Disconnect hose if connected. See hose replacement. 3. Disconnect any accessories connected to the auxiliary bypass connector. 4. Using 3/32 in. hex wrench, remove screws from front panel shield. 5. Using a 5/16 in. socket wrench, remove screws and washers from underneath front panel. 6. Pull front panel from tank. Disconnect the 9-pin and 12 pin and ground wire connections. 6.5 Removing Tank Cover INSTALLATION INSTRUCTIONS: 1. Disconnect power from unit. 2. Using 3/32 in. hex wrench, remove screws from front panel shield and remove. 3. Remove Front Panel. See Replacing Front Panel. 4. Using a screwdriver, remove screws from cover. Pull cover from tank. 23

24 6.6 Bulk-14 & 34 Motor Control Fuses Kit Part No INSTALLATION INSTRUCTIONS: FOR THE BULK-14 POUND UNIT 1. REMOVE TWO SCREWS FROM THE BOTTOM OF THE CONTROL PANEL AND ALLOW PANEL TO REST. OR FOR THE BULK-34 POUND UNIT 1. REMOVE 2 SCREWS FROM THE UPPER CORNERS AND ALLOW PANEL TO BE LIFTED OUT. DISCONNECT GROUND WIRE AND CONNECTORS AND PLACE PANEL IN A SAFE PLACE. 2. REMOVE FROM UNDER THE LIP OF THE FRAME, THE FOUR (4) SCREWS USED TO SECURE THE ENCLOSURE TO THE FRAME. 3. LIFT ENCLOSURE FROM FRAME AND SET ASIDE. 4. EXAMINE THE FUSES IN THE MOTOR CONTROL, AND CHECK WITH A METER IF REQUIRED, TO DETERMINE WHICH FUSES ARE BAD. 5. REPLACE FUSE AND RE-ASSEMBLE COVER AND CONTROL PANEL. NOTE: BE SURE THAT ALL GROUND WIRES ARE RE-CONNECTED. 24

25 6.7 BULK-14 DRIVE COUPLER HUB ASSEMBLY REPLACEMENT Part No INSTALLATION INSTRUCTIONS: 1. Remove power. 2. Ensure that unit is at room temperature. 3. Rotate unit to lay on its side. 4. Using a 5/16 wrench, remove the four screws from motor and allow motor to fall away from bracket. Note: DO NOT allow motor to pull on cord. 5. Using a 1/8 allen hex key, back out the set screws from both sections of the coupling, pump side and motor side, and remove the sections. 6. Take the new coupler and slide it onto the pump shaft. 7. Bring the motor back up into position and slide the shaft into the coupler. Hold into position and reinstall the four screws. 8. Snug up the four screws on the motor, then using your fingers, rotate the coupler on the two (2) shafts. If the coupler will not rotate, or rotates hard, tap (do not hit) the motor to allow the coupler to rotate. This will ensure proper alignment of the two (2) shafts. 9. When alignment is complete, tighten the four (4) screws on the motor and align the set screws on the two (2) shafts to allow the screws to lock on the flats on the shafts. If required, the motor shaft will turn. When aligned, tighten both set screws. 10. Rotate unit back to its normal position and reconnect power. Drive Coupler Pump Side Hub Woodruff Key Coupler Pivot Bearing Spring Dowel Pin Drive Coupler Motor Side Hub Cup Point Socket Set Screw 25

26 6.8 Bulk-14 Pump Replacement Part No. Installation Instructions: Note: Disconnect power from unit. Note: The pump must be Hot to properly disassemble and replace pump. Use heat gun to heat the pump before removal. Take care to ensure your safety. Gloves, safety glasses and protective clothing should be worn, when handling heated parts. Note: When replacing o-ring seals, lubricate with Krytox lubricant. 1. Turn melt unit on its side to gain access to the pump. 2. Using a ¼ hex wrench, remove the 2 bolts from the pump. 3. The pump needs to be lifted up to release the alignment pins from the tank approx 1/10 and then moved away from the motor. 4. The drive coupler will disengage as the pump is removed. 5. Use care to insure that the 3 balls and springs on the coupler are kept intact. If either are lost a replacement coupler will be required. 6. After the pump has been removed, remove the 2 o-rings from the tank and clean the surface of the tank with the material supplied. 7. Replace the o-rings with the new ones supplied being sure to apply the lube provided with the pump. 8. Remove the drive coupler from the pump shaft using a 1/8 hex wrench and install onto the shaft of the new pump. Use care to insure that the setscrew is aligned with the flat on the pump shaft but not tight at this point. 9. Put the pump back into position on the tank using caution not to disturb the 2 o-rings on the tank. Rotate the pump shaft to align the 2 halves of the coupler (check to see that all 3 balls and springs are in place) and allow the pump to move into place. 10. When the pump is in place it will drop to the tank as the pins align with the holes on the tank. 11. Using the 2 bolts removed first bring them down snug then tight. 12. Slide the coupler into position and tighten the setscrew to lock on to the shaft. 13. Check coupler alignment. 14. If coupler is misaligned, use a 5/16 wrench and loosen the 4 screws on the motor just enough to allow the motor to be pushed into position. 15. Retighten the screws on the motor. 16. Turn tank back to normal position and resume operation. 26

27 6.9 BULK-14 Pump Rebuild Kit Part No PLEASE NOTE The pump must be HOT to properly disassemble and reassemble. Take extra care to ensure your safety. Gloves, safety glasses, and protective clothing should be used. INSTALLATION INSTRUCTIONS: 1. Heat melt unit and pump as much adhesive as possible out of unit. Unplug unit from electrical service. 2. Supporting one side, tilt unit to access the underside. 3. Loosen pump and motor set screws from coupler assembly. 4. Loosen or remove the motor mounting bolts (10-32 x 1/2 ). 5. Remove the (2) 5/16-18 x 3 bolts from pump, lift pump from tank, remove o-rings from between tank and pump. 6. Remove (2) screws 1/4-20 x 1 to remove retainer, seal housing, thrust washer, and shaft seal (pay attention to orientation for reinsertion). 7. Clean parts with solution and replace pump shaft seal and thrust washer. 8. Remove #2-026 o-ring, clean o-ring groove with solution, replace and lubricate. 9. Remove (3) 1/4-20 x 2 screws from pump; pry plates apart without damaging mating surfaces. 10. Remove (2) #2-034 o-rings from between plates, clean plates with solution, replace o-rings and lubricate. 11. Clean all remaining adhesive from between plates and reassemble. 1/4-20 x 1 Seal, Pump Shaft Washer, Thrust 1/4-20 x 2 O-Ring O-Ring O-Ring O-Ring O-Ring

28 6.10 Bulk-12 and 14 Pressure Adjuster Assembly Kit Part No INSTALLATION INSTRUCTIONS: 1. Allow unit to cool down to a warm level. 2. Using a 1 size wrench (for 12 & 14# units) or a 1 1/4 size wrench (for 34# units), remove the pressure adjuster from the bottom by turning in a counter clockwise direction. 3. Remove the assembly and place on the side. 4. Using a pick or small screwdriver, remove the items left inside. 5. Using the cleaning solution and cleaning pad, clean the area before replacing the unit and apply lubricant supplied to the thread and o-ring seal area. 6. Taking the unit supplied, with spring and needle, re-install the assembly into the unit and tighten. Needle, Pressure Adj. Spring Seal O-Ring O-Ring

29 6.11 Pressure Adjuster Rebuild Kit Part No INSTALLATION INSTRUCTIONS: 1. USING A 1" END WRENCH, REMOVE THE PRESSURE ADJUSTER FROM TANK. THIS IS BEST DONE WHEN THE UNIT IS WARM, BUT NOT HOT! 2. BE SURE THAT ALL PARTS ARE REMOVED FROM THE TANK. 3. USING A 3/32 ALLEN KEY, REMOVE THE SET SCREW FROM THE ADJUSTING KNOB AND UNSCREW THE KNOB FROM THE SHAFT. 4. USING A PAIR OF PLIERS, GRASP THEUNTHREADED END OF THE PRESSURE ADJUSTER SHAFT AND REMOVE BY TURNING IN A COUNTER CLOCKWISE DIRECTION UNTIL THREADS ARE DISENGAGED FROM BODY. 5. USING A SMALL SCREWDRIVER OR AN AWL, REMOVE THE SEAL FROM THE BODY AND ALSO THE O-RING # USING THE CLEANING SOLUTION PROVIDED AND THE CLEANING PAD, CLEAR ALL THE SURFACES OF THE BODY, ESPECIALLY THE SEAL SURFACES. 7. USING THE LUBRICANT PROVIDED, APPLY TO INSIDE OF BODY (SMALL OPENING) FROM THE SEAL END. APPLY A SMALL AMOUNT TO THE ORINGS, TO THE THREADS ON THE SHAFT AND TO THE UNTHREADED PORTION OF THE SHAFT. 8. PRIOR TO ASSEMBLY, LUBRICATE O-RINGS AND SEAL (SUPPLIED), REPLACE O-RING # OVER THE BODY, REPLACE SEAL INTO THE BODY WITH OPEN SIDE OF THE SEAL FACING OUTWARD AND THE O-RING # TO THE SHAFT. 9. INSERT PRESSURE ADJUSTER SHAFT INTO BODY USING CARE NOT TO PUT THE THREADS OF THE SHAFT INTO CONTACT WITH THE SEAL. 10. SCREW THE SHAFT INTO THE BODY UNTIL IT STOPS AND REPLACE THE KNOB AND SET SCREW USING CARE TO ENSURE THE SET SCREW IS TIGHTENED ONTO THE FLAT OF THE SHAFT. 11. REINSTALL THE ASSEMBLY BACK INTO THE TANK USING THE NEW SPRING PROVIDED AND ENSURE THAT THE ASSEMBLY IS TIGHT. Needle, Pressure Adj. Spring Seal O-Ring O-Ring