5-Gallon Pail Unloader. Item # EQUIPMENT MANUAL

Transcription

1 5-Gallon Pail Unloader Item # EQUIPMENT MANUAL

2 1 BACKGROUND PERSONNEL SAFETY MACHINE SAFETY LIST OF COMPONENTS SUPPLIED DESCRIPTION THEORY OF OPERATION MAIN COMPONENTS Control Panel Temperature Range Zone Heating Indicator Melt Unit Ready Lamps Temperature Setting to Fahrenheit or Celsius Temperature Loop Control Pump Control Standby Control Open Sensor LED (Safety feature) Auxiliary Input Connection Platen Temperature Hose 1 & 2 Temperature Head 1 & 2 Temperature Pneumatic Control Panel Platen Silicone Seal Product Pressure Regulator Particle Filter Pail Elevator Gear Motor Control TECHNICAL DATA SPECIFICATIONS DATA Components Weight Dimensions ENERGY REQUIREMENTS Electrical Pneumatic Connections INSTALLATION FLOOR SPACE REQUIREMENTS ASSEMBLY CONNECTIONS OPERATIONS POWERING UP THE PUR UNLOADER Daily Start-up RECOVERING FROM AN E-STOP LOADING A PAIL PURGING REMOVING AN EMPTY PAIL DISPENSING Hand Held Applicator...18

3 8.6.2 Automatic Valve SHUTTING THE SYSTEM DOWN MAINTENANCE CONTROL PANEL ELEVATOR Linear Rails Elevator Platform PRODUCT DELIVERY PATH Platen Silicone Seal Hoses Applicator Dispense Nozzle Connections Pressure Regulator TROUBLESHOOTING TABLE ACCESSORIES REPLACEMENT PARTS WARRANTY...26

4 1 BACKGROUND This 5-Gallon Product Pail Unloader was specifically designed to extrude Henkel or other PUR products. However, this machine is capable of extruding or spraying any Hot Melt adhesive that is in a smooth straight-sided 5 gallon pail. This equipment has been designed for ease of use and longevity. Its unique pail elevator design permits extrusion of the adhesive product without flexing of hoses or cable bundles. In addition, a number of safety devices are built-in to protect the operator during use of the equipment. Further, the unit s small footprint, full enclosure, and easy to use iconic control panel makes it an ideal solution for Hot Melt dispense applications. It is highly recommended that the system be kept sealed as much as possible (for PUR). PUR product is a moisture cure sensitive material, and is best to keep its exposure to air at a minimum. Once a pail is loaded, do not remove it until another is available for replacement or a system purge is required. The product path is from the pail through the heated platen to the hose and to the applicator. Keep this product path sealed at all times for prolonged trouble-free operation. 2 PERSONNEL SAFETY Wear the following protection when working on or around this equipment: Always wear heat resistant gloves rated to 205 C (400 F). Then using heat resistant gloves, allow all system temperatures to stabilize at 193 C (380 F) or below before attempting operation (check your adhesive temperature requirements). Use leather or insulating apron when changing pails or performing maintenance on or around the platen. Always wear eye protection when servicing, operating or dispensing the equipment. Properly ventilate equipment according to appropriate MSDS of the hot melt material used. Do not store combustible materials in the vicinity of equipment. Trained operators may perform only external equipment adjustments. Trained maintenance technicians must perform internal adjustments and service. 3 MACHINE SAFETY This equipment contains potential energy (pneumatic and fluid) that can be dangerous if not properly released prior to maintenance or service operations. 2

5 Prior to any repair, machine modifications or maintenance 1. Close main air supply shut-off valve. 2. Turn main electrical power off, if not troubleshooting electrical problems. When loading or unloading product pails, keep hands and body parts away from pinch points such as: 1. Platen and pail. 2. Elevator and machine panels. 3. Machine access door. 4 LIST OF COMPONENTS SUPPLIED (1) 5-Gallon Pail Unloader (1) Electrical power cord (un-terminated) (1) Equipment manual 5 DESCRIPTION 5.1 Theory of Operation The 5-Gallon Pail Unloader is designed to extrude PUR and other Hot Melt product from metal straight-sided containers. A pail is prepared for loading onto the Unloader. The access door is opened in order to install a pail of product. The pail is positioned onto the elevator platform and the platen is engaged onto the pail. A heated platen melts the product which then flows towards the center of the platen (by design). As the elevator maintains upward pressure on the pail, 3

6 the liquefied product is channeled towards the gear pump around the bottom center of the platen. A static seal prevents the product from flowing out of the pail between the platen and the pail wall. On the control panel, a temperature range is selected that is within the products dispense temperature. Once the application temperature is reached, the equipment is ready to dispense product. When the applicator trigger is actuated, the gear pump turns on and forces the product down the heated hose and towards the dispense applicator. Accessory Connectors Emergency Stop Control Panel Power On/Off Drive Motor Pneumatic Panel Elevator Drive Cylinder Cover Panel Dimensions A B 30 C 24 D 31.5 Safety Door 4

7 5.2 Main Components Control Panel Control and trouble shooting for the entire melt system is accomplished from the melt unit controller front panel. A brief overview of these controls and indicators follow. STANDBY CONTROL PUMP SPEED CONTROL PAIL PURGE/BLOW-OFF ELEVATOR CONTROL TEMP LOOP CONTROL ELEVATOR FUNCTION PUMP CONTROL TEMP RANGE Elevator Control Up arrow (motion) Continuous; solid line Up arrow (motion) Pulse; dashed line Down arrow (motion) Continuous; solid line Down arrow (motion) Pulse; dashed line To make the elevator move, place the Elevator Control selector switch as desired, then press the Elevator function pushbutton Temp Control Sets Temp Range; temperatures of Platen, Hose, and Applicator Purge/Blow-Off Removes air from pail during loading (elevator selector in up position); Injects air into the empty pail for removal (elevator selector in down position). Elevator Function Actuates the ELEVATOR CONTROL function selected Pump Speed In increments of 2% (each bar represents 10%) Temp Range Current range selected Pump Control Turns On/Off the Pump 5

8 Standby Control Places process temperatures set points 40% below nominal for a preset (programmable) time Temperature Range The temperature range indicator is a single 7 segment LED display showing the range currently set for the tank, hose, and head temperatures. A chart indicating the settings for each temperature range is listed as follows: Deg. F (Deg. C) Tank Temperatures Hose and Head Temperatures Range to 195 ºF (49 to 91 ºC) 150 to 225 ºF (66 to 107 ºC) Range to 235 ºF (71 to 113 ºC) 190 to 265 ºF (88 to 129 ºC) Range to 275 ºF (93 to 135 ºC) 230 to 305 ºF (116 to 152 ºC) Range to 315 ºF (116 to 157 ºC) 270 to 345 ºF (132 to 174 ºC) Range to 355 ºF (138 to 179 ºC) 310 to 385 ºF (154 to 196 ºC) Range to 395 ºF (160 to 202 ºC) 350 to 425 ºF (177 to 218 ºC) See section for programming instructions Most manufacturers of hot melt adhesives offer advice for setting the temperatures of the delivery system. In order to reduce degradation of the adhesive, the delivery hose should be at a lower temperature than the applicator and melting tank (or platen) 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 will always be set to the recommended delivery temperature; however certain production conditions may require adjustment of this setting. For the purpose of the following example however, we will assume that conditions are ideal. In this example, the adhesive will have a recommended delivery temperature of 350 F. Volume Low Medium High Requirement: Platen Setting Hose Setting Applicator Setting

9 Zone Heating Indicator The series of Loop Output indicators refer to the platen, hose, and head. 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 Lamps 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 Platen is at the SET temperature. The platen is at temperature when the associated LED is flashing GREEN. The pump WILL operate even if the HOSE or HEAD is NOT at the set temperature. It is therefore recommended that adhesive only be dispensed after all of the LED s have changed from a solid green or flashing AMBER color to a flashing GREEN color Temperature Setting to Fahrenheit or Celsius o o o Use the Loop Select Up/Down button to select Platen. The LED to the left of the device should show green. Press the Loop Select button four times. The Range indicator will start to blink. Pressing the Loop Select button will toggle the display from degrees C and F and vice-versa Temperature Loop Control It will be necessary to turn ON the accessories that are connected to the platen (hoses & applicators). By using the up/down arrow buttons until the LED is on the device that will be used, for example: Hose 1 and Valve 1. By depressing the On/Off button the LED on the output side will illuminate. In similar manner, the devices that are no longer required can be turned off. When the temperature range is selected ( ), these devices will be supplied power to heat-up. LOOP ON/OFF CONTROL PUMP CONTROL The Platen does not require to be turned ON this is an automatic function. 7

10 Pump Control The Cycle\Run LED will remain red until the system (platen) has reached operating temperature; then this LED will turn green (then flashing green) indicating that the pump can be turned on. The pump is typically turned on (Cycle) from Idle automatically when a dispense applicator is triggered (on). Use the On/Off button to turn the Pump on or off manually. On occasion, material may have to be purged without the use of an applicator at the end of a hose. By manually turning this function ON, the pump will come on and allow material to flow (without using an applicator). Exercise extreme care when dispensing melted adhesive-this can cause severe burns. Purging and maintenance functions should be performed by trained, qualified personnel Standby Control This function is useful on occasions when the machine users have to take an extended time away from the machine, such as a lunch break. Placing the machine in standby automatically lowers all set-point temperatures by approximately 40% from nominal. Lowering the temperatures helps to prevent product charring. The lowered temperatures stay at this new setting for a pre-programmed time. After the time expires, the Set-point temperatures go back to the (original) process temperatures. To enter standby mode, just press the STBY button on the control panel as shown in section Use the Set-Temp Increment/Decrement arrows to adjust how long (time) the standby mode is supposed to last (be active). Press STBY button again to return to RUN mode. If this function is used during a lunch break, for example, program the STBY time to end about 10 to 15 minutes earlier than the lunch break will last. In this manner, the machine will be up to temperature by the time the user is back from lunch Open Sensor LED (Safety feature) This LED will be illuminated RED in color when an open circuit condition is sensed. It could happen due to a faulty applicator, a main melt unit malfunction, or even a hose that has failed. The affected zone is automatically de-energized and the green LED loop indicator for that zone ceases to function. This provides a very accurate, simple, and fast turn-around time (for troubleshooting) when there is a system problem Auxiliary Input Connection One auxiliary connection is available for each hose/applicator employed in the system. Different examples of an auxiliary device might be: foot switches, a timer or pattern controller, which would allow you to apply adhesive in different patterns and pressures (such as a swirl pattern when using a swirl tip). The pump or a machine mounted valve can also be turned on remotely through this connector. 8

11 Platen Temperature The platen is the first temperature that you would want to select. The pump platen temperature can be independently set using the following procedure: a. Select the platen as the device you wish to set. This is accomplished by pressing the Loop Select Up arrow button until the green LED to the left of the Platen label is illuminated. LOOP SELECT UP LOOP SELECT DOWN b. Rapidly press the Loop Select Up button four times. This will change the Range Indicator Digit from a fixed to a blinking digit. c. Using either the Set Temp Increment or the Set Temp Decrement button will either increment or decrement the Range Indicator Digit. 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. SET TEMP INCREMENT/ DECREMENT When changing the RANGE, if you go from a higher range to a lower one, the machine will shut-off thinking that an over-temperature condition exists-- temperatures are too high for the selected (new lower) range. To avoid the shut-off, lower the (current) set-points incrementally until you reached the lowest temperature of the range; change 1 range at a time (ex: do not go from range 4 to range 2). 9

12 Hose 1 & 2 Temperature 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 Head 1 & 2 Temperature 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 Pneumatic Control Panel Below the Main Operator Control Panel are 4 air pressure regulators that are required for the PUR Unloader to operate properly. Review the illustration below to familiarize yourself with the location of these regulators. ELEVATOR UP ELEVATOR DOWN BLOW-OFF Elevator Up Elevator Down Blow-Off Adjust the rate of rise of the elevator; 40 PSI typical Adjust the rate of descend of the elevator; 30 PSI typical Empty pail blow-off (during pail removal); 25 PSI typical 10

13 5.2.3 Platen Review the call-outs below and become familiar with the platen and associated components and hardware. DRIVE MOTOR SHAFT FRAME TIE RODS (3) BLOW-OFF VALVE PRESSURE REGULATOR HOSE 1 OUTLET PORT HOSE 2 OUTLET PORT Silicone Seal This seal is an integral part of the platen. A flexible silicone seal is attached to the platen to maintain an air-tight seal against moisture and prevent product curing. Observe care when a new pail is being installed and make sure that the pail is centered. PLATEN SEAL TEFLON WIPER The silicone static seal needs to be kept in good service condition. Always inspect the seal s condition when a pail is replaced. Look for hardened materials pieces or other foreign matter and remove from the surface. There should only be clean and debris-free product on the seal. High temperature silicone grease can be lightly applied to the outer surface of the seal to prolong the life and to enhance a moisture free seal. 11

14 Product Pressure Regulator The regulator is used to adjust for product pressure. Increasing the pressure will increase the delivery force of the product. Use the motor speed in conjunction with the pressure regulator to achieve a balance between product output volume and pressure of the product coming out of the nozzle. PUMP PRESSURE REGULATOR Particle Filter The particle filter is designed to capture solids and keep them from getting into the gear pump assembly and subsequently into the product path. Be sure to have the system in a maintenance mode (have the machine warm and DO NOT cycle the pump) before removing the filter. The filter is easily removed with a wrench. The filter can then be replaced with a new one or cleaned and re-installed. When the machine is powered for the first time, inspect the filter after 30 days. Devise a maintenance schedule based on the filter s condition at the time of the inspection. PARTICLE FILTER Pail Elevator The elevator is powered by a 5 diameter pneumatic cylinder capable of developing up to 1,500 pounds of force at 80 PSI. However, only a small amount of air consumption is needed to cycle the elevator. In the event of a power failure, the elevator will be held into position by a series of 3-way pneumatic valves. If the pail is full (heavy load) and there is no shop air, slowly and gradually the elevator could descend. 12

15 5.2.5 Gear Motor Control The Gear Motor is brush-less and the speed is fully variable. The motor can be adjusted from 6 Hz to 60 Hz; or from 10 to 100% of the nominal (60Hz) frequency. The Pump Speed Indicator (with up/down arrows) on the control panel provides this adjustment. Each time the button is depressed (lets say up) the frequency increases by 2%; with 5 depressions, 1 LED indicator will illuminate 10%). The same goes for decreasing the motor speed. By changing the speed of the motor, more or less product volume can be delivered in the same amount of time. It is best to run the machine at an optimum pressure. Do not run the motor faster than it has to for the particular application. Perform trials into a waste bucket until the best delivery results are obtained. Other factors that influence product output is the temperature of the product (viscosity), pump pressure, pump speed, hose length, and the nozzle tip. If too much demand is placed for product output, the motor may stall (cannot keep up with demand). Ensure that pump pressure is not too high or other factors mentioned above will restrict the flow. The pump motor then will attempt to extrude the product and could stall (and stop) by trying to push the (heavy, cold) product through (a long hose, or a small orifice). If the motor stops; it is protected by the motor control board and in most all cases be restarted after the overload condition is resolved. VARIABLE SPEED MOTOR PUMP SPEED CONTROL 13

16 6 TECHNICAL DATA 6.1 Specifications Data Components Platen Gear Motor Pump 2300 Watts/with baked on Teflon coat, silicone seal ¾ HP, frequency variable Flow rate 100 lb/hr (using package grade EVA) Weight 375 lbs Dimensions 6.2 Energy Requirements Electrical 30W x 22D x 52 ¼H Supply Voltage Amperage 220 VAC, 1 Phase 30 Amp maximum Pneumatic Air Supply / Pneumatic Quality PSI Filtered 20 μm, oil free, non-condensing Connections Inlet Pneumatic Electrical 1/4 NPT single-phase power wires 7 INSTALLATION 7.1 Floor Space Requirements Allow for machine size plus hose length. In addition, consider overhead space in the event the process may be more favorable to a hose hanging over the work area rather than having the hose lying on the floor. Optional hose support kit is strongly recommended (especially with longer hoses): Item #

17 7.2 Assembly A. The machine comes fully assembled. It should be necessary only to remove from the crate and position on the allocated floor space. B. Mount a handle for the dispense applicator to be held when not in use. This will provide a safe location for the applicator when it is HOT. 7.3 Connections An electrical power drop off into the Main Control Panel is required. Single phase power, 220 volts AC, 30 amps. There is one pneumatic (inlet) connection required. The air source port is a female ¼ NPT fitting. Connect an air source of 80 PSI, dry, filtered air. 8 OPERATIONS Observe caution when operating the machine. Wear proper safety equipment when handling adhesive product. 8.1 Powering Up the PUR Unloader Ensure that the main circuit breakers are ON. Turn the main power switch to ON. The display indicators on the Control Panel will illuminate. All functions STOP if the pail load/unload access door is open (the control panel will illuminate) Daily Start-up A. Ensure all utilities are connected and available. B. Set (inlet) pneumatic pressure to 80 PSI. Turn on the air supply to the station. C. On the side of the Control Panel, turn the rotary ON/OFF power switch to ON. 15

18 8.2 Recovering from an E-Stop Once an E-Stop occurs, all machine motion stops. Ensure that it is safe to resume dispense operations and then un-twist the E-stop knob. If power has been off for some time, it will be necessary to wait until the process temperatures are reached before beginning a dispense operation. 8.3 Loading a Pail Wear proper safety gear when installing or removing pails from the machine. Use only metal straight-sided pails with no ribs. Once a pail is loaded DO NOT remove it until there is a new pail to immediately replace it or purge material available for a system purge. Try to maintain the system sealed from moisture at all times. WARNING When raising or lowering the elevator, keep hands and body away from the platen and pail lip. DO NOT by-pass the door safety switch. A. Remove the lid from the pail. B. Open the access door on the machine and position the pail against the 2 stops on the elevator platform. Close the door; safety switch on door must be closed. C. Adjust the temperatures on the Control Panel as required for the material. D. Place the Elevator Control selector knob to Up and Pulse. Press and release in small increments the Up/Down Elevator Function pushbutton until the pail makes contact with the platen. Look through the clear Lexan at the top of the access door. As the pail gets closer to the platen, if you notice that the edge of the pail and the platen are not aligned, open the access door or lower the elevator and adjust the centering stops on the elevator platform. 16

19 E. Place the Elevator Control selector knob to UP and Continuous, and then press the Elevator Function Up/Down button once. Simultaneously, press the PURGE pushbutton to evacuate air from the pail as the elevator moves up. The elevator will ascend continuously and stop ascending once it comes into contact with the product in the pail. F. Wait until the temperatures are reached for all dispense components before beginning a dispense. G. Adjust the pressure regulator and Gear motor speed if required. 8.4 Purging Purging is required (typically) when a new pail is loaded. Purging removes any air that may have become trapped in the product path. It is most important that all air is removed from the material or it may dispense irregularities and cause internal product curing. The Purge function will only work when the elevator position selector is in the UP position. A. During the Pail Loading procedure press the Purge/Blow-Off pushbutton on the top right corner of the control panel. This will actuate a valve and allow air to be released from the top of the pail as it nears the product in the pail. B. Most of the air from loading the pail should be removed during pail loading and using the Purge pushbutton (step A). If the previous pail was emptied and air bursts were observed at the applicator then (there is air in the system): hold the dispense applicator over an empty pail (to capture waste). C. Use the trigger on the applicator until a continuous stream of product is coming out without any burping or voids. This will remove the remaining air from the product path. D. If Purging is done to prepare the machine for extended shut-down and there is plenty of product left in the pail (that may want to be saved): a. Have purge/clean material on hand before commencing. b. The product pail cover should have been saved. Apply silicon or synthetic grease on the cover s seal. c. Perform the pail removal/unloading procedure. d. Use an air gun or hose and blow nitrogen onto the top of the (removed) PUR pail to remove all/most of the air from the top of the pail and then quickly place the cover on the pail and seal. e. Purge the machine with the purge/clean material until clear purge product comes out of the machine. Leave the purge material pail on the machine and shut the system down. 17

20 8.5 Removing an Empty Pail Wear proper safety gear when installing or removing pails from the machine. DO NOT remove a pail until there is a new pail readily available for loading. DO NOT open the pail access door until the elevator has come completely down. A. Place the Elevator Control selector knob to the Pulse Down position. B. Press and pulse the Elevator Up/Down pushbutton while pulsing the Blow-Off pushbutton until the pail is lowered completely and is not in contact with the platen. 8.6 Dispensing Hand Held Applicator A. Most applications will use a manual applicator. This device has a pump start switch opposite the trigger switch, which needs to be actuated for dispensing. B. Press and hold the applicator trigger switch for dispensing to take place. Release the trigger to stop the adhesive flow. When starting the machine for the first time each day, it is a good idea to dispense into a waste cup to check that the dispense setup (volume/pressure) is what is desired. Make adjustments if necessary see sections and Automatic Valve A. These valve types are fixed mounted valves for automatic dispensing. The valves are available with electrical control and can be triggered with a footswitch, or can be integrated to a customer control system for remote triggering. B. A pneumatic version of the automatic valve is also available for applications that require fast cycle times; and are also suited better with higher viscosities products. The valves are also required when dispensing at higher pressures. 8.7 Shutting the System Down The nature of the PUR material is such that it necessitates that the system (material path) be kept sealed at all times. Whether overnight, weekend or extended shutdown, it is best to cover the nozzle with a high temperature grease to prevent moisture from reacting with the PUR material in the valve. The grease should be wiped off when ready 18

21 to start production, and the machine should power up as usual with no expected dispense problems so long as the system has remained sealed. The one area that could experience a problem (most likely due to clogging) is the dispense nozzle. Hardened material at the nozzle tip can be removed with a small pick or small drill bit. Care should be observed not to enlarge the nozzle hole-size when clearing the clog. In event that the machine does not dispense after a start-up, see the Trouble-shooting section of this manual or refer to section MAINTENANCE 9.1 Control Panel The control panel should be kept free of dirt and adhesive in order to provide clear, workable and visible panel indicators and functional buttons. 9.2 Elevator Linear Rails The rails are lubricated for life and require no maintenance. It is a good practice however, to inspect for security, or product splatter build-up (4 month interval to start). 19

22 Do not allow the machine to operate with a loose rail Elevator Platform Maintain the area where the pail is located clean and free of product. If product hardens and gradually builds on the platform, installing and keeping new pails level may become difficult to accomplish. Most PUR takes several hours to fully cure. When product (larger) spills occur, it is best to allow the material to get semi-harden (soft, consistency of clay). In this manner, the product can be removed as solid piece(s); small leaks can be wiped off. 9.3 Product Delivery Path Platen DO NOT allow the machine to remain off with PUR material on the platen sitting idle for weeks without use. If it is expected that the machine will be shut down for longer than 2 weeks; purge the machine with purge/cleaning product before the shut down. DO NOT attempt to clean the bottom of the platen. The best course is to try to maintain the platen sealed (with a pail) once it has been exposed to PUR material. DO clean spills on top of the platen immediately to keep the surface clean and serviceable. The surface is baked on Teflon and should make clean-ups easier; but do not allow PUR material to sit too long on the platen Silicone Seal The seal is designed for many hours of trouble-free operation. If used properly, the seal is expected to last for the life of the platen. Clean or peel material on the seal immediately to prevent build-up and maintain a good seal Hoses Inspect hoses for fraying and damage weekly. Hoses can easily become damaged if they are on the floor in a high foot-traffic area. Keep a clear work area for the hose to prevent damage. The following points should be kept in mind concerning hot melt supply hoses: To avoid damage the hose should not be flexed when cold. The hoses have a minimum bend diameter of sixteen inches when hot. Also, flexure or kinking will cause permanent damage. 20

23 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. Support the hose during gluing operations to prevent excessive flexure. Failure to properly support the hose will result in premature failure. Optional hose support is available item # Applicator Dispense Nozzle The handgun nozzle should never be pointed towards people when the melt unit is powered. Pressures can develop within the hot melt system causing the glue to be projected to significant distances. Pointing the handgun at someone (including yourself) presents a dangerous burn hazard. The trigger mechanism of the handgun should never be pulled until the entire system is up to operating temperature. Attempts to retract the trigger before glue in the handgun has adequately softened will result in damage to the needle assembly. This damage is not covered under warranty. The backside of the handgun grip contains a yellow lever to control pump motor operation. It is recommended that the front panel of the melt unit be set for idle operation with pump motor control from the handgun 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. During normal use, the nozzle should not require maintenance. When the system is shut down for the day, apply a high temperature synthetic or silicone grease at the nozzle tip. If the system is shut down for extended periods of time, the tip of the nozzle may become clogged. The best way to clear the nozzle from cured material is using a small pick. In some instances it may be necessary to use a small or fine drill bit to clear the tip Connections There are a number of connections that should be inspected for security and damag at least weekly. The inspection schedule can be adjusted once a history of the machine s performance is well established. Inspect the aluminum pneumatic lines that attach to the platen for kinks or leaks. Inspect the Gear motor couplings (top and bottom). Inspect the hose connection at the platen. Ensure the security of the (3) tie rods from the platen to the top frame mounts. 21

24 9.3.6 Pressure Regulator This component does not require regular maintenance; though it is a good idea to keep the adjustment knob clean and free of product waste so that it remains serviceable. Do not increase pressure needlessly. If the pressure is set to maximum the pump may stall. The system is designed to extrude product and if the demand is greater than it can provide, the motor will stop. The user must consider hose length, nozzle orifice and pump speed when setting the pressure it is best starting with lower settings and working up as the application requires it. If the motor stops it is protected from damage by motor control board. It can be restarted after the sensing mechanism resets itself this may take a minute or two. Always start dispensing with the lowest setting (pump speed, pressure regulator) and begin increasing these settings until the dispense application is met. 22

25 9.4 Troubleshooting Table PROBLEM PROBABLE CAUSE SOLUTION Adhesive does not come out of the Clogged tip Use a small pick to remove cured nozzle material at the tip. A small drill bit can be used to clear the nozzle tip as an alternative. Unit does not reach temperature Adhesive not molten Loose connector Failed heater element Wait for proper temperature to be reached. Check the Control Panel for a RED indicator of a failed element. Tighten the connector or replaced the failed component. Not enough or too much material is coming out of the applicator Low or high pump regulator pressure Gear motor is not turning at the proper speed. Adjust the regulator pressure as required. Adjust the speed using the Main Control Panel. Elevator does not move Power does not stay on the machine Motor stops rotating Dispensing faster than the unit can melt the material. Air source Elevator air regulator Door interlock safety switch is open Machine does not have air supply Temperatures exceed allowable range Motor stall. Too much product output demand. Lower the dispense rate or volume and re-check operation. Check air source to machine. Adjust regulator to proper pressure to move the platform. The door must be closed for any motion to take place on the machine. Ensure that the required air is being sourced to the machine. Over-temperature condition. Allow the machine to cool down and then attempt to power the system again. Increase dispense nozzle orifice size, lower pump speed, lower pump pressure, lower the product viscosity, reduce hose length. 23

26 9.5 Accessories Applicators Hand Held Description Bottom Inlet Hand Held Top Inlet Mounted (electric 24VDC coil) Mounted (electric 230 VAC coil) Mounted (pneumatic, 24 VDC coil) Mounted (pneumatic, 230 VAC coil) Item # Hoses (extrusion) Description 6 Feet 8 Feet 10 Feet 12 Feet 16 Feet 18 Feet Item # Hoses (spray) Description 6 Feet 8 Feet 10 Feet 12 Feet 16 Feet 18 Feet Item # Nozzles ½.060 Description diameter ½.080 diameter diameter diameter diameter diameter Item # Swirl Nozzles (spray) Swirl.060 Description Assembly diameter.080 diameter Spray (fan cap) assembly Spray Nozzle.040 diameter Spray Nozzle.050 diameter Item # Other Accessories Hose Description Cradle Tension Balancer Foot Switch Spray Controller Item # Please visit to view the complete assortment of Hot Melt nozzles and accessories. 24

27 10 REPLACEMENT PARTS Description Part Number Particle Filter, 100 mesh Purge Valve Assembly Seal, Primary silicone Wiper, Teflon Mother Board Motor Drive Board Fuse Kit, 10 pack Visit and look in Hot Melt equipment pages, or contact your local Henkel sales representative to request a quote for specific Loctite components. 25

28 11 WARRANTY Henkel expressly warrants that all products referred to in this Instruction Manual for Henkel PUR Hot Melt Dispenser (hereafter called Products ) shall be free from defects in materials and workmanship. Liability for Henkel shall be limited, as its option, to replacing those Products which are shown to be defective in either materials or workmanship or to credit the purchaser the amount of the purchase price thereof (plus freight and insurance charges paid therefor by the user). The purchaser s sole and exclusive remedy for breach of warranty shall be such replacement or credit. A claim of defect in materials or workmanship in any Products shall be allowed only when it is submitted in writing within one month after discovery of the defect or after the time the defect should reasonably have been discovered and in any event, within (12) months after the delivery of the Products to the purchaser. This warranty does not apply to perishable items, such as ( heaters, fuses, filters, lights, etc.). No such claim shall be allowed in respect of products which have been neglected or improperly stored, transported, handled, installed, connected, operated, used or maintained. In the event of unauthorized modification of the Products including, where products, parts or attachments for use in connection with the Products are available from Henkel, the use of products, parts or attachments which are not manufactured by Henkel, no claim shall be allowed. No Products shall be returned to Henkel for any reason without prior written approval from Henkel. Products shall be returned freight prepaid, in accordance with instructions from Henkel. NO WARRANTY IS EXTENDED TO ANY EQUIPMENT WHICH HAS BEEN ALTERED, MISUSED, NEGLECTED, OR DAMAGED BY ACCIDENT. EXCEPT FOR THE EXPRESS WARRANTY CONTAINED IN THIS SECTION, HENKEL MAKES NO WARRANTY OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THE PRODUCTS. ALL WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND OTHER WARRANTIES OF WHATEVER KIND (INCLUDING AGAINST PATENT OR TRADEMARK INFRINGEMENT) ARE HEREBY DISCLAIMED BY HENKEL AND WAIVED BY THE PURCHASER. THIS SECTION SETS FORTH EXCLUSIVELY ALL OF LIABILITY FOR HENKEL TO THE PURCHASER IN CONTRACT, IN TORT OR OTHERWISE IN THE EVENT OF DEFECTIVE PRODUCTS. WITHOUT LIMITATION OF THE FOREGOING, TO THE FULLEST EXTENT POSSIBLE UNDER APPLICABLE LAWS, HENKEL EXPRESSLY DISCLAIMS ANY LIABILITY WHATSOEVER FOR ANY DAMAGES INCURRED DIRECTLY OR INDIRECTLY IN CONNECTION WITH THE SALE OR USE OF, OR OTHERWISE IN CONNECTION WITH, THE PRODUCTS, INCLUDING, WITHOUT LIMITATION, LOSS OF PROFITS AND SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER CAUSED BY NEGLIGENCE FROM HENKEL OR OTHERWISE. 26

29 Loctite Industrial Henkel Corporation 1001 Trout Brook Crossing Rocky Hill, CT Henkel Corporation Automotive / Metals HQ Stephenson Hwy. Madison Heights, MI Henkel Canada Corporation 2225 Meadowpine Boulevard Mississauga, Ontrario L5N 7P2 Henkel Ltda. Brazil Av. Prof. Vernon Krieble, Itapevi Sao Paulo, Brazil Henkel Capital, S.A. de C.V. Calzada de la Viga, s/n, Fracc. Los Laureles Loc. Tulpetlac, C.P Ecatepac de Morelos, Edo de Mexico, Mexico Loctite is a registered trademark of Henkel Corporation, U.S.A Copyright Henkel Corporation. All rights reserved. Data in this operation manual is subject to change without notice. Manual P/N: , Rev A, Date: 03/