Automatic Mlelter Feeder

Transcription

1 Automatic Mlelter Feeder Series 2300 Part NORDSON CORPORATION. AMHERIST, OHIO. USA

2 No&on Corporation welcomes requests for information, comments and inquiries about its products. Address all correspondence to No&on Corporation 475 Lakefield Drive Duluth, GA 3055-l 5 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 989. No part of this document may be photocopied, reproduced, or translated tot another language without the prior wntten consent of Nordson Corporation. The information contained in this publication is subject to change without notice Trademarks AquaGuard, Blue Box, Control Coat, Equi=Bead. FloMelt, FoamMelt, FoamMix, Helix, Hot Shot, Hot Stitch, Meltex, MicroSet, MultiScan, No&on, the Nordson logo, OmniScan, Porous Coat, Posi-Stop, RBX, Sure-Bond, UniScan, UpTime, and Versa-Spray are registered trademarks of Nordson Corporation. BetterBook%, CF, Controlled Fiberization, Easy-Screen, Fibermelt. flo-tracker, PrintGuard, and Package of Values are trademarks of Nordson Corporation. P/N Issued l/96 Q 996 Nordson Corporatlon All rlghfs reserved

3 TABLE OF CONTENTS SECTION I - SAFETY SUMMARY Introduction Explanation of Terms and Symbols I Safety During Installation Safety During Servicing Safety When Using Hot Melt Adhesives and Solvents Hot Melt Adhesivles Heat Solvents SECTION II SECTION III EQUIPMENT FAMILIARIZATION Introduction.... Functional Descriptil~n.... Specifications PREPARATION FOR USE Introduction.... Unpacking and Inspection.... Physical Setup.... Level Control Sensitivity Adjustment.... Operation... Parent Machine Interlock Installation l! SECTION IV MAINTENANCE Introduction Preventive Maintenanlce Periodic Inspection/Cleanup Hopper Cleanout/Material Changeover Corrective Maintenance Equipment Troubleshooting Applicator Tank Does Not Fill Applicator Tank Overfills Grid Heater Overheats Disassembling the Control Enclosure Reassembling the Control Enclosure /30 SECTION V - DIAGRAMS AND TABLES SECTION VI - ILLUSTRATED PARTS LIST mIssued /89@Nordson Corporation 989

4 LIST OF FIGURES Figure Page Series 2300 Automatic Melter Feeder Automatic Melter Feeder Dimensions Position of Rechner Sensor. e Key Parts Used In Installation and Setup of PM Position of PM Light (Top View) /20 6 Automatic Melter Feeder Electrical Wiring Diagram Automatic Melter Feeder Electrical Schematic Automatic Melter Feeder Assembly (Front View) Automatic Melter Feeder Assembly (Side View) Automatic Melter Feeder Control Assembly ( of 2) Automatic Melter Feeder Control Assembly (2 of 2) Automatic Melter Feeder Heater Control Assembly mIssued /89@Nordson Corporation 989

5 46-77-l SECTION I SAFETY SUMHARY INTRODUCTION This section of the manual contains safety guidelines for the use of Nordson@ equipment. They are repeated throughout the manual where they apply, along with some specific warnings and cautions which are not included here. The guidelines cover installation, operation, and servicing. The safety information contained in this section applies to anyone working with Nordson equipment, including operations and service personnel. A WARNING: Failure to follow these recommendations may result in personal injury from burns or electrocution and/or equipment and property damage. EXPLANATION OF TERMS AND SYMBOLS The following safety symbols and signal words are used throughout this publication to alert the reader to personal safety hazards, or to identify conditions that may result in equipment or property damage. A A r A WARNING: General warning. Failure to observe may result in personal injury or death. WARNING: Risk of electrical shock. Failure to observe may resu:lt in personal injury or death. CAUTION: GeneraIL caution. Failure to observe may result in minor personal injury or damage to property. NOTE: Important information. Failure to observe may result in equipment damage. SAFETY DURING INSTALLATION DO NOT operate Nordson equipment under the following conditions: 46-77mIssued /89m@Nordson Corporation 989. At a pressure higher than the rated maximum working pressure of any component in the system. 2. Near volatile or otherwise explosive gases or materials. 3. Without the covers, panel and safety guards properly installed. 4. At atmospheric temperatures below 20 F (-6OC) or above 20 F (50 C).

6 With hoses enclosed in any material that interferes with heat dissipation. This includes electrical conduit, insulation of any type or tight metal covers. 6. With large areas of hose in contact with a cold floor, cold supports or other such surfaces. Cold points along the hose restrict the flow of adhesive inside the hose and can create potential problems during operations. 7. In drafty areas with the applicator guns unshielded from the draft. Rapid heat dissipation due to air movement across the guns may cause operational problems. 8. (If a handgun is used) with the handgun trigger left unlocked while the gun is unattended. In Addition:. Use only the metal base when attempting to lift or move an applicator. DO NOT use equipment covers, doors, panels or hose connectors as braces or grips. 2. NEVER use Nordson equipment as a ladder or stepping stool. 3. Route all hoses to prevent damage from kinking, abrasion and other physical damage. DO NOT allow a hose to be installed with a bend radius of less than 6 inches (50 mm). 4. NEVER point an applicator handgun at yourself or anyone else. SAFETY DURING SERVICING. DO NOT perform internal service or adjustment on any equipment unless another person capable of rendering first aid and resuscitation is present. 2. Only qualified personnel should service Nordson equipment. 3. To avoid personal injury, never touch exposed connections and components while power in ON. Dangerous voltages exist at several points in the equipment wIssued /89@Nordson Corporation 989

7 Disconnect, lock out and tag external electrical power before removing protective panels or replacing electrical components. 5. Remove all jewelry (rings, watches, etc.) before servicing equipment. 6. If possible, stand on a rubber mat when servicing Nordson equipment. DO NOT work on equipment if standing water is present. Avoid working in a highhumidity atmosphere. Cover exposed terminals and work areas with rubber sheeting to avoid accidental contact while the power is ON. 7. Always wear safety glasses, protective gloves (Nordson P/N ) or equivalent and long-sleeved protective clothing to prevent injury from hot applicator parts, splashed hot melt adhesive and hot gun surfaces. 8. To prevent serious injury from molten adhesive under pressure, always relieve system hydraulic pressure (by triggering the gun, for example) before opening any hydraulic fitting or connection. 9. NEVER use an open torch, drill or broach when cleaning a nozzle. 0. NEVER operate equipment with a known leak in the system. SAFETY WHEN USING HOT MELT ADHESIVES AND SOLVENTS Hot Melt Adhesives. Use extreme care when working with molten material. They solidify rapidly at high temperatures and present a hazard. Severe burns can occur if the molten materials come in contact with the skin. Even when first solidified, they are still hot. 2. Always wear protective clothing and eye protection when handling molten material or working near equipment containing hot melt adhesives under pressure. 3. IF MOLTEN MATERIAL COMES IN CONTACT WITH THE SKIN DO NOT try to remove molten material from the skin mIssued /89@Nordson Corporation 989

8 Immediately immerse the affected area in cold, clean water. Keep the affected areas immersed until the material has cooled. DO NOT try to remove the cooled material from the skin. Cover the affected area with a clean, wet compress. In cases of severe burns, look for signs of shock. If shock is suspected, have patient lie down, use a blanket to preserve body heat and elevate the feet several inches. Call a physician immediately. Heat Solvents. DO NOT use an open flame or uncontrolled heating device to heat solvents (for example, a small pan on an unregulated hot plate). 2. Avoid fire hazard by using a controlled heating device to heat solvents (for example, a small deep fat fryer or thermostatically controlled hot plate). 3. DO NOT USE PAlNT-TYPE SOLVENTS UNDER ANY CIRCUX- STANCES! These solvents are volatile and may be a fire and/or toxic-vapor hazard even at room temperature. 4. Always be sure the work area is adequately ventilated. Avoid prolonged or repeated breathing of solvent vapors. 5. Halogenated Hydrocarbon Solvents are dangerous when used to clean aluminum components in a pressurized fluid system. No zlvailable stabilizers prevent halogenated hydrocarbon solvents from reacting under all conditions with aluminum components in a pressurized fluid pumping system. 6. NEVER clean any aluminum component or flush any system using halogenated hydrocarbon solvents. use Type R (P/N ) solvents or contact your solver t or hot melt supplier for a non-halogenated hydrocarbon solvent for cleaning and flushing. Halogenated fluids include the following solvents: 46-77mIssued /89WNordson Corporation 985

9 Fluorinated Solvents: Dichlorofluoromethane Trichlorofluoromethane Chlorinated Solvents Carbon Tetrachloride Chloroform Dichloromethane Ethylene Dichloride Methylene Chloride Monochlorobenzene Monochlorotoluene Orthodichlorobenzene Perchloroethylene Trichloroethylene Brominated Solvents Ethylene Dibromide 8 Methyl Bromide Methylene Chlorolbromide Iodinated Solvents: Ethyl Iodide Methyl Iodide N-butyl Iodide Propyl Iodide 46-77mIssued /89WNordson Corporation 989

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11 SECTION II EQUIPMENT FAMILLARIZATION INTRODUCTION The Nordson Automatic Melter Feeder is an accessory unit for use with Nordson Series 2300 hot melt applicators. Automatic Melter Feeder features include:. Storage of up to 50 lbs. of non-blocking* granular or pelletized hot melt material; melted material is fed on demand directly into the applicator tank Melt rate of up to 40 Ibs. per hour.. Thermostatically controlled aluminum heating grid for protection against overheating of the grid.. Manual or automatic operation. Rugged construction.. Easy serviceability. *Resists sticking together at low temperatures mIssued /96GNordson Corporation 989

12 Figure - Series 2300 Automatic Melter Feeder =Issued /96mONordson Corporation 989

13 FUNCTIONAL DESCRIPTION The Automatic Melter Feeder shown in Figure does not show a hot melt applicator. The hinged cover at the top of the melter feeder unit is raised and material loaded into the hopper. The level of material in the hopper can be checked through the glass inspection port. As the material heats and becomes molten, it flows directly into the holding tank in the applicator unit beneath the melter feeder. The Parent Machine Interlock (PMI) board prevents the melter feeder grid heaters from cycling ON until hot melt material in the applicator tank reaches the applicator setpoint. The PMI, acting essentially as a time delay, begins timing when the tank temperature control channel reaches the setpoint. This time delay is adjustable and is set by the operator. The level sensor controls the flow of hot melt from the melter feeder into the applicator tank. The FILL light on the control panel indicates that the melter feeder unit is in operation and that the grid heaters are ON. A MANUAL FILL switch located on the melter feeder control box panel allows the operator to bypass the PM Board and level sensor circuits, and manually feed hot melt material to the applicator unit as desired. To manually fill the applicator tank, press the melter feeder MANUAL FILL switch. When the material in the applicator tank reaches the desired level release the switch. NOTE: There is a time delay from when the MANUAL FILL switch is pressed and when material begins to flow from the hopper into the applicator tank. The delay also occurs from when the MANUAL FILL switch is released and when material stops flowing from the hopper into the tank. A Be careful not tlo allow hot melt material to overflow when manually filling the tank. Overflowing the tank could create a fire haz,ard. To check the amount of hot melt in the applicator tank, lift the lid and observe the level of material in the tank =Issued /964Nordson Corporation 989

14 SERIES 2300 AUTOMATIC MELTER FEEDER SPECIFICATIONS Hopper Adhesive Capacity: Form: 50 lbs. (68 kg). Non-blocking granules or pellets are recommended, but the unit is capable of melting solid particles up to one square inch (6.45 sq. cm.) in any dimension. Melt Rate: Up to 40 lbs ( 8.4 kg) per hour, depending the adhesive. on Operating Temperature Range: F ( C); optional thermostats for F and F operation. Electrical Dimensions: Requirements: 230 VAC, Phase, 60 Hertz. Height with door open: 68 in. ( cm) NOTE: Due to possible technological and/or quality improvements, equipment specifications are subject to change without notice Figure 2 - Series 2300 Automatic Melter Feeder Dimensions mIssued /96=ONordson Corporation 989

15 SECTION PREPARATION III FOR USE INTRODUCTION This chapter is divided into four major sections. They are: = Unpacking and Inspection. Physical Setup. Level control Sensitivity Adjustment Procedure Operation. Parent Machine Interlock Installation NOTE: Refer to the specific applicator manual for your particular unit during the Physical Setup and Startup procedures in the section. UNPACKING AND INSPECTION Use normal care when unpacking the Automatic Melter Feeder. Do not leave packing materials in the hopper. After the Automatic Melter Feeder has been removed.from its shipping container and all packing materials removed: AUTOMATIC MELTER FEEDER SHIP WITH LIST m Refer to the ship with list (below) to determine if all of the required parts have been included: Part No. Description Q~Y Screw, Hex Head, 5/6-8 x 0.50 in Lockwasher, Split, 0.3 in Nut, Hex Head, Reg., 0.3 l Washer, Flat, 0.34 ID x Heater Enclosure 04 Pump Enclosure Sensor Bracket Capacitive Sensor, 2M Parent Machine Interlock Board 46-77=Issued /96GNordson Corporation 989

16 Inspect the melter feeder surfaces for evidenr.c> of dents, scratclics or other physical damage.. Check for loose connections in the melter feetl~~r cant rol box arid heater box. PHYS I CAL SETUP -.-. Remove the two 2300 appl i cator loach i ng i ( >>( ( II r-i ): screws and lift the lid from the applicator IIIII t top panel. 2. Remove the four screws (20) which secure the I~I( I ttal feeder hood (27) to the melter feeder heater yt-iti f larige, then remove the hood. 3. Position the melter feeder hood and chute ( i! OII the applicator top panel over the tank openirlg. 4. Position the Model 2300 unit on the melter ft~~~<lt~r base (). 5. Remove the tape from the hood and c-tiut<x,tss~~ml)ly <jr~cl secure the hood to the heater grid f lange IIS I rig the securing screws removed in step Install and tighten the four hex head scrci+ s (&i that secure the applicator to the melter fet~clt~r ~),Is(x A This step may require tilting the appl ic itotunit with the mounting cover plate arili tiood attached. Be careful not to dam,dgr tt( melter feeder or applicator unit. 7. Remove the Rechner sensor condui t (E ig. 8) i I 0 t h( control box (32) by removing the nut loca t (x( I IAS I (I(> the control box. To install the Rechner ~~~IIs~~ t- thread the c.oaxial cable through the bottom 0 the conduit, through the opening in the bottom of :Ilt, control box % then through the conduit nut anal ltrg into the controller. Secure the conduit to tlrf enclosure with the condui t locknut. NOTE : It is impossible to thread the coaxial cable through the conduit without disnssembl I rug the condui t from the control box. 4tj-77mIssued /89@Nordson Corporation 989

17 Install the PM Board to the unit referring to the PARENT MACHINE INTERLOCK INSTALLATION PROCEDURES in this manual. Remove the button plug from the 2300 base under the electrical housing. Push the end of the PMJ conduit (Fig. 8) through the opening and secure it with,i locknut (39) from the conduit connector. Referring to Fig. 7 - Automatic Melter Feeder Electrical Schematic, attach wires 7 and 4B to the PM Board. 0. Remove and discard the original pump cover.. Remove the button plug on the 2300 unit located under the pump cover and install the bracket over the hole. Remove the bottom locknut from the Rechner sensor and insert the sensor through the bracket, locknut and cover until the white portion is no longer visible (Fig. 3). Tighten the bottom locknut to secure the sensor to the bracket. IF ANY WHITE PORTION OF THE SENSOR IS VISIBLE ABOVE THE UNIT COVER, THE SENSOR WILL NOT OPERATE CORRECTLY. Adjust by loosening both the locknuts and sliding the sensor as required. Then secure it iin place by tightening the locknuts. 2. Replace the discarded pump cover with the modified cover that has been supplied with the melter feeder. 3. Attach the pump tower plate to the pump tower with four screws. Coil the excess sensor cable and store it in the control box so the cable does not touch any of the metal enclosure. NOTE: Failure to ensure that the cable does not touch the enclosure may result in personal injury and/or equipment damage. 4. Run electrical power to the melter feeder and the Model 2300 applicator. NOTE: Refer to your applicator manual for the procedures required to complete the installation and setup of the unit in addition to Figure 6 - Automatic Melter Feeder Electrical Wiring Diagram mIssued /89@Nordson Corporation 989

18 Refer to LEVEL CONTROL SENSITIVITY ADJUSTMENT PROCEDURE before filling with adhesive. 6. Refer to FUNCTIONAL DESCRIPTION for proper unit filling instructions. BRACKET TOP COVER WHITE ---I Figure 3 - Position of Rechner Sensor LEVEL CONTROL SENSITIVITY ADJUSTHENT PROCEDURE. Locate the level control potentiometer and red indicator LED on the lower panel of the level controller inside the electrical control box. A WARNING: This equipment contains energized electrical components with potentials that!i could be fatal. Only qualified personnel should operate this equipment 46-77mIssued /89=0Nordson Corporation 989

19 While checking through the modified 2300 Melter Feeder lid door, press and hold in the Manual Fill button to activate the heated grid. Observe the flow of adhesive from grid into the hood and applicator tank. a WARNING: Wear safety glasses, safety gloves, and protective clothing to prevent insjury from hot applicator parts, splashed hot melt adhesive material and hot gun surfaces. NOTE: The FILL indicator LED should remain lit while the button is held in. Allow enough adhesive to fill the applicator tank until the level of adhesive is inch (25.4 mm) below the sensor probe, or approximately 2 inches below the metal cover on the 2300 unit, then release the Manual Fill button. Use a small screwdriver to locate the sensitivity scale mid-range by turning the level control pot at least 5 turns in one direction, and 7 or 8 turns in the other direction. NOTE: This procedure must be followed because there are no stops or "clicks" when the adjustment pot reaches the end of the range. Turning the pot at least 5 turns in any one direction assures that the end of the range is reached. NOTE: DO NOT touch the sensor cable inside the control unit. Touching the cable may activate or deactivate the heated grid. 0. From this point, turn the pot until the red indicator LED goes on and all indicator LEDs go off. NOTE: With the level control sensitivity properly adjusted, the Melter Feeder fill sequence will begin and remain on until the adhesive level is within inch (2.54 cm) of the sensor. NOTE: If adhesive builds up on the sensor, it may be necessary to increase the level control sensitivity or to clean the sensor lens mIssued /89@Nordson Corporation 989

20 OPERATION m Follow the daily startup instructions for the applic;itr)rgiven in the applicator operations manual; then turn thcl Automatic Melter Feeder power ON. m Add material to the melter feeder hopper as requircci. m Turn the melter feeder OFF at the circuit breaker on the control panel; power the applicator unit down according to instructions in the applicator operations manual. PARENT MACHINE INTERLOCK INSTALLATION Description of Parent Machine Interlock Installation of PM A Parent Machine Interlock performs two basic functions: it provides a way for an operator to tell when the adhesive in the tank has reached applicati-on temperature (an indicator light turns off) and, once this temperature is reached, it energizes a contact which may be used to operate a normally open or a normally closed switch on a parent machine. If, for example, a system user wants to ensure that a packaging line does not run unless the adhesive is fully melted, a PMI can be used to achieve this purpose.. Disconnect and lock out input electrical power. A s WARNlNG: Disconnect and lock out external power to the applicator before opening the electrical enclosure. The input terminal board and the input terminals on the main circuit breaker are still electrically energized if external power is not disconrlected, even though the circuit breaker on the front of the applicator is turned off. WARNING: DO NOT touch the black heat sinks extending from the green circuit board when power to the unit is on. They are electrically energized and therefore present a shock hazard. 2. Remove the electrical control cabinet enclosure by unscrewing the captive screw on top of the cabinet mIssued /89@Nordson Corporation 989

21 Locate the two-part terminal block at the bottom of the PM circuit board (see Fig. 4). While holdirlg on to the receptacle part of this terminal block, carefully pull on the plug part of the terminal block until the two parts separate. To obtain working room, unplug the white plugs along the top of the main circuit board (there will he t\$,cj of these on a Model 2302, four on a 2304, and flue on a 2305).. Remove the two screws that secure the main circuit board to the base of the applicator. Tilt the top part of the circuit board away from the applicator until it inclines at approximately a forty-five degree angle. DO NOT try to remove the board from the applicator completely because it is still connected by wires at several points. Carefully attach the PM board to the main circuit board by inserting the four pins into the pin connectors on the main board. (See Fig. 4 for approximate locations of pins.) Make sure that all_ pins are securely in place. The pins connect thr PM board to the main board both physically and electrically. 8. Take the light connected to terminals and 2 of the plug and insert it into the top slot on the main circuit board (see Fig. 4 and 5). Secure it in place by wedging the rubber collar around the light into place (it may be helpful to use a screwciriver for this purpose). 9. Using the plug that was removed from the PM boar-d in step 3, connect the leads in either order (the PM is not polarity sensitive) to terminals 3 and 4 on the plug if a normally closed switch is to be controlled; connect them to terminals 4 and 5 ii a normally open switch is to be controlled. (See Fig. 4 for terminal numbers.) NOTE: The contacts are rated for 250 volts, 5 amperes 46-77mIssued /89@Nordson Corporation 989

22 rtime ADJUSTMENT PMI BOARD,/- PIN-CONNECTOR LOCATIONS (48-, J8-2, J8-3, QOQOQOQOQ ACTIVE/INACTIVE SWITCH TWO PART TERMINAL BLOCK Figure 4 - Key Parts Used in Installation and Setup of PHI 0. Reconnect the plug of the two-part terminal block to its receptacle at the bottom of the PM board. NOTE: Make sure that the PM board is still securely connected to the main circuit board at all four pin lvocations. The pins connect the PM board to the main board electrically as well as physically.. Return the main circuit board to an upright position and secure it to the base of the applicator with the two screws removed in step Reconnect the white plugs to their receptacles along the top of the main circuit board. Connect the L'Lug labeled to the connector labeled J on the circuit board, plug NG. 2 to connector 52, and so forth, until all plugs are connected mIssued /89@Nordson Corporation 989

23 46-77-U/20 3. Move the active/inactive switch on the PM (see Fig. 4) to the left if it is desired to have the Pr\lf inactive after the initial startup sequence; move the switch to the right if it is desired to have the PM active after the initial startup sequence. For a detailed description of how the PM operates in both the active and inactive modes, see your applicator owners manual. 4. Set the adjusting screw on the PM board (see Fig. 4) to obtain the desired delay cycle. Fully counterclockwise is 2 minutes, the maximum delay possible. Straight up and down is about 7 minutes. LAMP (P/N ) CIRCUIT BOARD Figure 5 - Position of PM Light (Top View) 46-77mIssued /89@Nordson Corporation 989

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25 SECTION IV MAINTENANCE INTRODUCTION Your Nordson Automatic Hot Melter Feeder was designed and constructed to serve reliably in the most demanding circumstances. Even so, it would be wise to develop and follow a preventive maintenance program. In this way, it is possible to maintain the highest quality performance and keep equipment malfunction to a minimum. This section covers both PREVENTIVE and CORRECTIVE MAINTENANCE procedures. PREVENTIVE MAINTENANCE includes: CORRECTIVE MAINTENANCE includes:. Periodic inspection/cleanup. 9 Hopper cleanout/material changeover. Equipment troubleshooting. Removal and replacement of assemblies. 9 Disassembly, repair of components and reassembly. A The Automatic Melter Feeder contains energized electrical components with potentials that could be fatal. Dis- ci connect and lock out input electrical power before performing maintenance on this equipment. Only qualified personnel shall operate this equipment. A Wear safety glasses, safety gloves (P/N ) and protective clothing to prevent injury from hot automatic melter feeder and applicator parts. A Never heat any component with a torch or other open flame. If it becomes necessary to heat components for maintenance or repair, use an electric oven with forced air circulation or a flameless electric heat gun. A Halogenated hydrocarbon solvents are dangerous when used to clean components in a pressurized fluid system. See the Safety Summary? Section 40-, for further details. Use of halogenated hydrocarbon solvents in this system could result in an explosion mIssued /89@Nordson Corporation 989

26 In addition, remember the following tips and recommendations: Standard test equipment and procedures shall be used.. The system indicator light (SL) remaining OFF at power up does not necessarily indicate a complete electrical failure. Verify 230 VAC input power to the automatic melter feeder. Open the control and heater enclosures to visually inspect for exposed wire shorted to ground, to another wire, or to a terminal. Do not use a battery-type test light to check continuity of heaters. This type of test light will not indicate continuity. Remove and lock out electrical power when testing for continuity or resistance values. Isolate the component from the circuit before checking resistance. The heaters are wired in series. Therefore, if one unit fails, the entire heater grid will remain cold. Typical individual heater resistance values are: Part No Description ~-- Voltage ~ Cold Resistance Grid Heater 48 VAC ohms 46-77mIssued /89WNordson Corporation 989

27 PREVENTIVE MAINTENANCE Periodic inspection/cleanup: Keep sensor clean of hot melt material buildup. 9 Keep the unit clean at all times. Keep the hot melt adhesive material supply clean and free from contaminants. 9 Inspect the unit periodically for loose electrical and mechanical connections. A 2 Always disconnect and lock out input electrical power before opening the control or heater enclosures. Hopper cleanout/material changeover:. Follow material changeover and system cleaning instructions provided in the applicator operations manual. Open the hopper clean-out door -- located just below the hopper glass inspection port -- and remove all unmelted material from the hopper. A Wear safety glasses, safety gloves (P/N ) and protective clothing to prevent injury from hot melter feeder and applicator parts. Fill the hopper with only new non-blocking pellet or granular hot melt material; restore the system to normal operations. CORRECTIVE MAINTENANCE Generally, replacement of broken wires, missing fasteners and similar items is not considered part of corrective maintenance. Unless failure caused by these items presents an immediate hazard to personnel or equipment, they should be noted and eliminated during the preventive maintenance cleaning and inspection procedures. Equipment Troubleshooting The flow charts on the following pages provides orderly "road maps" for finding and diagnosing several possible situations. Use the illustrated parts lists, electrical schematic and the wiring diagram as aids when using the troubleshooting flow charts mIssued /89@Nordson Corporation 989

28 APPLICATOR TANK DOES NOT FILL. Main switch ON. Control panel SYSTEM light not Ohi. -Go to step 2. Control panel SYSTEM light ON. -Go to step Disconnect and lock out power to unit; check continuity line and load on each side of circuit breaker. Continuity OPEN. -Replace Continuity good. -Replace circuit breaker, restore system to normal operation. SYSTEM light bulb, restore system to normal operation. 3. Power to unit ON, press MANUAL FILL switch. Adhesive flow light ON. Adhesive flow -Restore system to normal operation Adhesive flow, light OFF. -Replace step 4. bulb, go to No adhesive flow. -Go to step mIssued Corporation 989

29 APPLICATOR TANK DOES NOT FILL (Continued) 4. Check sensor for buildup of material. Ground circuit faulty. *Clean off buildup, restore system to normal operation. No buildup. 'Go to step Run level control sensor adjustment procedure. Level control LED operates properly. *Restore system to normal operation. Level control procedure not OK. OReplace level control, restore system to normal operation. 6. Recheck PM Board installation Grid heats, adhesive flows. No afdhesive flows. *Restore system to normal PM Board. c 46-77wIssued /89WNordson Corporation 989

30 APPLICATOR TANK DOES NOT FILL (Continued) 7. (a) Power to unit OFF. (b) Remove MANUAL FILL wire 4 or 6. (c) Check continuity. Continuity good. 'Go to step 8. Continuity OPEN. or partial. -Replace switch, go to step Check grid heater resistance; TB2, terminal to terminal to 37.5 ohms. -Go to step 9. Less than 32.0 ohms..- Check resistance of each heater, replace faulty heater, restore system to normal operation. 9. Check overheatthermostat: disconnect wire 5, check continuity across thermostat. Continuity good. -Go to step 0. Continuity OPEN. -Reset thermostat, restore system to normal operation mIssued /89@Nordson Corporation 989

31 APPLICATOR TANK DOES NOT FILL (Continued) 0. Wire 5 disconnected, check continuity across control relay terminals 3 and 5. Continuity good. Continuity open. *Replace relay, restore system to normal operation. Go to step.. Check relay coil: (a) Disconnect wire 0 or 20. (b) Check resistance across relay terminals and 2. Resistance = zero or infinite. -Replace relay, restore system to normal operation. Cold resistance 080 to 320 to step Check for obstructions between relay contacts No to step 3. found. aclean contacts or replace relay; restore system to normal operation. 3. Check temperature control continuity (read between COMM and NC). Continuity good. -Check for broken or loose wires, tighten/replace as necessary; restore system to normal operation. Continuity open. -Replace temperature control restore system to normal operation mIssued /89@Nordson Corporation 989

32 APPLICATOR TANK OVERFILLS. Check sensor for material buildup -Clean sensor, recalibrate and repeat. If fails again then replace material control, restore to normal operation. LED and procedure OK -Restore system to normal operation. GRID OVERHEATS. (a) Remove power to unit. (b) Press RESET button (resets overheat thermostat). (c) Disconnect wire 5 from control relay box. (d) Check continuity across L relay terminals 3 and 5. Continuity good. -Replace relay, restore system to normal operation. Continuity open. -Go to step Check for dead short in heater circuit: (a) Disconnect wire 9 from TB2. (b) Check resistance across TB2, terminals Resistance = 32.0 to 37.!j ohms. -Replace Resistance less and 0. than 32.0 ohms. -Check 6 operation. temperature control, restore system to normal operation. resistance of each heater, replace faulty heater, restore system to normal 46-77mIssued /89@Nordson Corporation 989

33 /30 Disassembling the Control Enclosure --_ The temperature control and overheat thermostat are each attached to the inside of the control enclosure with two screws. Remove the probe from the grid. NOTE : To ensure proper operation of the heater temperature control, take care not to kink or sharply bend the capillary tube when removing or ins tall ing tke probe. Carefully remove the probe from its conduit and into the control enclosure. It may be necessary to loosen or remove the conduit f i tt ings. Reassembling the Control Enclosure -_-- -~---.- Route the probe from the control enclosure, through the conduit and into the heater enclosure. It may be necessaq to loosen or remove the conduit fittings. NOTE : To ensure proper operation of the heater temperature control, take care not to kink or sharply bend the capillary tube when removing or instal ling the probe. Install the temperature control or overheat thermostat in the control enclosure using the screws removed in the disassembly procedure. 9 Tighten all conduit fittings, close the enclosure doors and restore the system to normal operation mIssued /89GNordson Corporation 989

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35 r SECTION c' DIAGRAMS AND TAlIILES CONTROL BOX COVER I i i 4Lf3!oB I w CONTROL BOX PANEL m-e----- LC I BA I 02 SO 6A I I I m---- 3A CONDUIT,CONTROL BOX TO PUMP ENCLOSURE - c CONDUIT,CONTROL BOX TO HEATER _ PARENT MACHINE INTERLOCLi * SHOWN FOR REF ONLY 20 0 PMI I Hl H? H3 H4 t-i 5 L ---m-w--- GRID HEATER BOX J NOTE WIRE NOS Y3T USED ,AND 8 LAST N:) USrD 20 Figure 6 - Automatic Melter Feeder Electrical \diring Diagram 46-77mIssued /85WNordson Corporation 585

36 GRID HEATERS r v 20-7 LE VCL CONTROL O E%EAT THERMOSTAT -J-c--- -_I 6 ICR RELAY I s2 -I 6 d MAN FILL P.B. SWITCH GNDO+ Figure 7 - Automatic Melter Feeder Electrical Schematic ELECTRICAL PARTS LIST (Figures 6 and 7) Symbol Part No. Description ~ Qw ~- LC Rechner Controller CR Control Relay LF Line Filter TBl Terminal Block, 8-Station TB Terminal Block, lo-station Sl Breaker, 2-Pole SL Light, SYSTEM (White) FL Light, FILL (Amber) s Push Button Switch, Normally Open PM Parent Machine Interlock TCl Temperature Control OT Thermostat (Overheat) Kl Grid Heater 5 LP Capacitive Sensor 46-77mIssued /89@Nordson Corporation 989

37 SECTION VI ILLUSTRATED PARTS LISTS INTRODUCTION The Illustrated Parts Lists detail and illustrate the assemblies and components of the Automatic Melter Feeder. Those configurations defined in the Equipment Familiarization section of this manual are detailed in the following lists. COLUMN IDENTIFICATION FIGURE ITEM COLUMN The Figure Item column indicates the callout number in the associated figure. A hyphen (-) in this column denotes that no callout has been made for that part. PART NUMBER COLUMN The Part Number column indicates the Nordson part number for the physical part or assembly. A hyphen (-) in this column indicates a nonsaleable part or a nonsaleable subassembly of a saleable assembly. DESCRIPTION COLUMN The Description column provides the component name and, when possible, additional data such as size, temperature, voltage, etc. REQ'D COLUMN The Req'd column specifies the quantity of the part required per unit or assembly. A hyphen (-) in this column indicates that no specific quantity is required. The term "Ref" in this column indicates the part or assembly has been included for reference only mIssued /89mcjNordson Corporation 989

38 o- RECHNER CONDUIT SENSOR CONDUIT Figure 8 - Automatic Melter Feeder Assembly (Front View) 46-77mIssued /89m@Nordson Corporation 989

39 0 03 I Figure 9 - Automa ic Melter Feeder Assembly (Side View) 4(-T- / f:;suc~(f /89mONords0~ Corporation 989

40 AUTOMATIC MELTER FEEDER PARTS LIST Item No. Part No. Description Req d Automatic Melter Feeder w/rechner Sensor Ref Hopper Base Screw, Hex Head, 5/ 6-8 x 0.50 in Washer, Flat, 0.34 ID x Lockwasher, Split, 0.25 in m Screw, Hex Head, 5/6-8 x 3.50 in Lockwasher, Split, 0.3 in m m m m m m m Nut, Hex Head, Reg, Melter Feeder Support Screw, Hex Head, 5/ 6-8 x 0.75 in. Screw, Pan Head, lo-32 x 0.50 in. Melter Feeder Chute Hopper Cover Plastic Handle Screw, Fil Head, lo-24 x 2 in. Screw, Pan Head, lo-24 x 0.50 in. Screw, Pan Head, 8-32 x 0.50 in Glass, Inspection Ring, Inspection Port Port m m Screw, Skt Head, l/4-20 x 0.63 in. Screw, Hex Head, lo-32 x 0.63 in. Hopper Insulator Grid Melter Screw, Pan Head, lo-32 x 0.88 in. Plate, Heater Retainer Sealant, Rubber Plate, Warning, Hood, Melter Feeder m Heater Assy, 0.38 X 7.25,48 V Spacer, Column Insulator, Electric Enclosure m Hopper w/cleanout Door Control, Melter Feeder, (Figure 9) Rivet, Pop, 3/32 x 0.03 in. m Information Not Used Plate Screw, Fil Head, l/4-20 x 0.75 in. Not Used Not Used Connector, Conduit Connector, Not Used Not Used Hot Straight Conduit 46-77mIssued /96mONordson Corporation ft

41 AUTOMATIC MELTER FEEDER PARTS LIST (Continued) Item No. Part No. Description Req'd 02 Enclosure, Heater (Ship With Item) 04 m Enclosure, Pump (Ship With Item) Bracket, Sensor (Ship With Item) Sensor, Capacitive, 2M (Ship With Item) Parent Machine Interlock Board (Ship With Item) 46-77mIssued /89@Nordson Corporation 989

42 Figure 0 - Automatic Melter Feeder Control Assembly ( of 2) mIssued /89QNordson Corporation 989

43 W d Figure 0 - Automatic Melter Feeder Control Assembly (2 of 2) 46-77aIssued /89@Nordson Corporation 989

44 MELTER FEEDER CONTROL ASSEMBLY PARTS LIST Item No. Part No. Description Req'd 006 Control Assembly, Melter Feeder Ref r ii Harness, Melter Feeder Filter, Line, Power Lockwasher, Split, 8 Screw, Pan Head, 8-32 x 0.38 in. w Screw, Pan Head, 6-32 x 0.3 in. 9 Relay, SPST, 20/240 'VAC Screw, Pan Head, M4 x 20. Lockwasher, Split, 6 9 Bracket, Level Control. Control Enclosure, Painted Latch, Cabinet a Screw, Fil Head, l/4-.28 x 0.63 in. m Level Controller. Screw? Pan Head, 6-32 x 0.25 in. 9 Spacer, Relay Cover. Screw, Standoff Terminal Lug, Flat Spacer, Standoff, 0.38 x.75 in.. Screw, Fil Head, 5-40 x 0.25 in. Temperature Sensing Switch, 50'F. Panel w/inserts, Control Enclosure 9 Screw, Pan Head, lo-32 x 0.38 in. Lockwasher, Ext, 0 9 Thermostat, Tank, Adj., F 9 Screw, Pan Head, 6-32 x 0.9 in. 9 Conduit Connector Strip Marker, 8-Station Power Input Strip Marker, 8-Station w Conduit, Liquid Tight, 0.50 Bulk Spacer, Standoff Connector, Conduit, 45 x 0.50 in. Lockwasher, Split, M l+zn 9 Nut, Hex, M4 m Gasket, Cabinet, 6 x 4 in. Rectangular Indicator Lamp, Amber. Switch, Pushbutton 9 Nut, Dress Rectangular Indicator Lamp, White. Breaker, 2-Pole Front Panel, Control E:nclosure 9 Relay Cover Stud, Self-Clinching, lo-32 w Lockwasher, Split, Nut, Hex Head, Machine, lo Terminal Lug, Ground Ground Tag Wire Assy, Ground, Probe ft 2 3 ; 3.8 ft 46-77mIssued /89@Nordson Corporation 989

45 This Page Intentionallly Left Blank 46-77mIssued Corporation 989

46 HEATER ASSEMBLY ENCLOSURE PARTS LIST Item No. Part No. Description Req'd 02 Heater Control Assembly Ref Grid Heater Enclosure Assembly Conduit Connector. Conduit. Heater Enclosure Wire Group. Ground Tag. Lockwasher, Split, 0 Nut, Hex Head, Machine,, lo-32 Washer, Flat. Terminal Lug, Ground Button Plug 2.2 ft 46-77mIssued /89@Nordson Corporation 989

47 \ _ h-! r Figure - Automatic Melter Feedl?r Heater Control Assembly 0 b 6-77mIssued /89@Nordson Corporation 989

48