FillEasy C Adhesive Feed System

Transcription

1 FillEasy C Adhesive Feed System Customer Product Manual Issued 5/10 This document contains important safety information Be sure to read and follow all safety information in this document and any other related documentation. NORDSON CORPORATION DULUTH, GEORGIA USA

2 Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: Address all correspondence to: Nordson Corporation Attn: Customer Service Lakefield Drive Duluth, GA Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, Bowtie, CanWorks, Century, CF, CleanSleeve, CleanSpray, ColorMax, Color-on-Demand, Control Coat, Coolwave, Cross-Cut, cscan+, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, Emerald, Encore, ESP, e stylized, ETI - stylized, Excel 2000, Fillmaster, FlexiCoat, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli-flow, Horizon, Hot Shot, icontrol, idry, iflow, Isocoil, Isocore, Iso-Flo, itrax, Kinetix, LEAN CELL, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Porous Coat, PicoDot, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Signature, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Sure Wrap, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Ultra, UpTime, u-tah, Vantage, VersaBlue, Versa-Coat, VersaDrum, VersaPail, Versa-Screen, Versa-Spray, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, AquaCure, ATS, Auto-Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro+,Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat, Cobalt, Controlled Fiberization, Control Weave, ContourCoat, CPX, cselect, Cyclo-Kinetic, DispensLink, Drop Cure, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, e.dot+, E-Nordson, Equalizer, EquiBead, FillEasy, Fill Sentry, FlowCoat, Fluxplus, Get Green With Blue, G-Net, G-Site, ion, Iso-Flex, itrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, MonoCure, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI, Pinnacle, Plasmod, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, Quad Cure, Ready Coat, RediCoat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, SureFoam, Sure Mix, SureSeal, Swirl Coat, TAH, ThruWave, TinyCure, Trade Plus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners rights Nordson Corporation All rights reserved

3 Table of Contents i Table of Contents Safety... 1 Safety Alert Symbols... 1 Responsibilities of the Equipment Owner... 2 Safety Information... 2 Instructions, Requirements, and Standards... 2 User Qualifications... 3 Applicable Industry Safety Practices... 3 Intended Use of the Equipment... 3 Instructions and Safety Messages... 4 Installation Practices... 4 Operating Practices... 4 Maintenance and Repair Practices... 5 Equipment Safety Information... 5 Equipment Shutdown... 6 General Safety Warnings and Cautions... 7 Other Safety Precautions First Aid Safety Labels and Tags Description Features Specifications General Pneumatic Electric Dimensions Intended Use System Components Electrical Cabinet Electrical Controls Suction Lance Cone/Tank Lid and Level Sensor Installation Unpacking and Positioning FillEasy C Positioning the Electrical Cabinet Setup Installing the Cone and Level Sensor Assembly Attaching the Cone and Level Sensor Attaching the Transfer Hose to the Cone Connecting the Cooling Air Hose Connect the Suction Lance Connect the Level Sensor to the Control Box Calibrating the Level Sensor Adjusting the Air Throttle Nordson Corporation

4 ii Table of Contents Operation Maintenance Maintenance Schedule External Cleaning Troubleshooting Using the Illustrated Parts Lists Recommended Parts Electrical Enclosure Parts Nordson Corporation

5 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 1 FillEasy C Adhesive Feed System Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as use ) of the product described in this document (hereafter referred to as equipment ). Additional safety information, in the form of task specific safety alert messages, appears as appropriate throughout this document. WARNING! Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property. Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all safety information that follows the signal word. WARNING! Indicates a potentially hazardous situation that, if not avoided, can result in serious personal injury, including death. CAUTION! Indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION! (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property Nordson Corporation

6 2 FillEasy C Adhesive Feed System Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment are met, and for qualifying all potential users. Safety Information Research and evaluate safety information from all applicable sources, including the owner specific safety policy, best industry practices, governing regulations, material manufacturer's product information, and this document. Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information. Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices. If applicable, receive approval from your facility's engineering or safety department, or other similar function within your organization, before installing or operating the equipment for the first time. Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re evaluate safety practices and procedures whenever changes are made to the process or equipment Nordson Corporation

7 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 3 User Qualifications Equipment owners are responsible for ensuring that users: receive safety training appropriate to their job function as directed by governing regulations and best industry practices are familiar with the equipment owner's safety and accident prevention policies and procedures receive, equipment and task specific training from another qualified individual NOTE: Nordson can provide equipment specific installation, operation, and maintenance training. Contact your Nordson representative for information possess industry and trade specific skills and a level of experience appropriate to their job function are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in the manner described in this document. The information provided here is not meant to include all possible safety practices, but represents the best safety practices for equipment of similar hazard potential used in similar industries. Intended Use of the Equipment Use the equipment only for the purposes described and within the limits specified in this document. Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non standard auxiliary devices Nordson Corporation

8 4 FillEasy C Adhesive Feed System Instructions and Safety Messages Read and follow the instructions provided in this document and other referenced documents. Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices. Ensure that the equipment is rated for the environment in which it will be used and that the processing characteristics of the material will not create a hazardous environment. Refer to the Material Safety Data Sheet (MSDS) for the material. If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance. Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects. Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources. Properly ground all equipment. Contact your local building code enforcement agency for specific requirements. Ensure that fuses of the correct type and rating are installed in fused equipment. Contact the authority having jurisdiction to determine the requirement for installation permits or inspections. Operating Practices Familiarize yourself with the location and operation of all safety devices and indicators. Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist. Use the personal protective equipment (PPE) specified for each task. Refer to Equipment Safety Information or the material manufacturer's instructions and MSDS for PPE requirements. Do not use equipment that is malfunctioning or shows signs of a potential malfunction Nordson Corporation

9 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 5 Maintenance and Repair Practices Perform scheduled maintenance activities at the intervals described in this document. Relieve system hydraulic and pneumatic pressure before servicing the equipment. De energize the equipment and all auxiliary devices before servicing the equipment. Use only new Nordson authorized refurbished or replacement parts. Read and comply with the manufacturer's instructions and the MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation. Dispose of waste cleaning compounds and residual process materials according to governing regulations. Refer to the applicable MSDS or contact the authority having jurisdiction for information. Keep equipment safety warning labels clean. Replace worn or damaged labels. Equipment Safety Information This equipment safety information is applicable to the following types of Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices 2011 Nordson Corporation

10 6 FillEasy C Adhesive Feed System Equipment Shutdown To safely complete many of the procedures described in this document, the equipment must first be shut down. The level of shut down required varies by the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure. The levels of shut down are: Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal. Refer to the melter specific product manual for instructions on relieving system hydraulic pressure. De energizing the System Isolate the system (melter, hoses, guns, and optional devices) from all power sources before accessing any unprotected high voltage wiring or connection point. 1. Turn off the equipment and all auxiliary devices connected to the equipment (system). 2. To prevent the equipment from being accidentally energized, lock and tag the disconnect switch(es) or circuit breaker(s) that provide input electrical power to the equipment and optional devices. NOTE: Government regulations and industry standards dictate specific requirements for the isolation of hazardous energy sources. Refer to the appropriate regulation or standard. Disabling the Guns NOTE: Adhesive dispensing guns are referred to as applicators in some industries. All electrical or mechanical devices that provide an activation signal to the guns, gun solenoid valve(s), or the melter pump must be disabled before work can be performed on or around a gun that is connected to a pressurized system. 1. Turn off or disconnect the gun triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the gun solenoid valve(s). 3. Reduce the air pressure to the gun solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the gun Nordson Corporation

11 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 7 General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual. Equipment types are designated in Table 1 as follows: HM = Hot melt (melters, hoses, guns, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and guns) Equipment Type Table 1 General Safety Warnings and Cautions Warning or Caution HM WARNING! Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent based material through a compatible Nordson melter, read and comply with the material's MSDS. Ensure that the material's processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with MSDS requirements can cause personal injury, including death. HM WARNING! Reactive material! Never clean any aluminum component or flush Nordson equipment with halogenated hydrocarbon fluids. Nordson melters and guns contain aluminum components that may react violently with halogenated hydrocarbons. The use of halogenated hydrocarbon compounds in Nordson equipment can cause personal injury, including death. HM, CA WARNING! System pressurized! Relieve system hydraulic pressure before breaking any hydraulic connection or seal. Failure to relieve the system hydraulic pressure can result in the uncontrolled release of hot melt or cold adhesive, causing personal injury. Continued Nordson Corporation

12 8 FillEasy C Adhesive Feed System Equipment Type General Safety Warnings and Cautions (contd) Table 1 General Safety Warnings and Cautions (contd) Warning or Caution HM WARNING! Molten material! Wear eye or face protection, clothing that protects exposed skin, and heat protective gloves when servicing equipment that contains molten hot melt. Even when solidified, hot melt can still cause burns. Failure to wear appropriate personal protective equipment can result in personal injury. HM, PC WARNING! Equipment starts automatically! Remote triggering devices are used to control automatic hot melt guns. Before working on or near an operating gun, disable the gun's triggering device and remove the air supply to the gun's solenoid valve(s). Failure to disable the gun's triggering device and remove the supply of air to the solenoid valve(s) can result in personal injury. HM, CA, PC WARNING! Risk of electrocution! Even when switched off and electrically isolated at the disconnect switch or circuit breaker, the equipment may still be connected to energized auxiliary devices. De energize and electrically isolate all auxiliary devices before servicing the equipment. Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injury, including death. HM, CA, PC WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and should not be used with solvent based adhesives that can create an explosive atmosphere when processed. Refer to the MSDS for the adhesive to determine its processing characteristics and limitations. The use of incompatible solvent based adhesives or the improper processing of solvent based adhesives can result in personal injury, including death. HM, CA, PC WARNING! Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others and can damage to the equipment Nordson Corporation

13 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 9 Equipment Type Warning or Caution HM CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of guns, hoses, and certain components of the melter. If contact can not be avoided, wear heat protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. HM CAUTION! Some Nordson melters are specifically designed to process polyurethane reactive (PUR) hot melt. Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipment and cause premature reaction of the hot melt. If you are unsure of the equipment's ability to process PUR, contact your Nordson representative for assistance. HM, CA CAUTION! Before using any cleaning or flushing compound on or in the equipment, read and comply with the manufacturer's instructions and the MSDS supplied with the compound. Some cleaning compounds can react unpredictably with hot melt or cold adhesive, resulting in damage to the equipment. HM CAUTION! Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment. Before using the equipment, confirm that the hot melt is compatible with Type R fluid Nordson Corporation

14 10 FillEasy C Adhesive Feed System Other Safety Precautions Do not use an open flame to heat hot melt system components. Check high pressure hoses daily for signs of excessive wear, damage, or leaks. Never point a dispensing handgun at yourself or others. Suspend dispensing handguns by their proper suspension point. First Aid If molten hot melt comes in contact with your skin: 1. Do NOT attempt to remove the molten hot melt from your skin. 2. Immediately soak the affected area in clean, cold water until the hot melt has cooled. 3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medical personnel providing treatment Nordson Corporation

15 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 11 Safety Labels and Tags Figure 1 illustrates the location of the product safety labels and tags affixed to the equipment. Table 2 provides an illustration of the hazard identification symbols that appear on each safety label and tag, the meaning of the symbol, or the exact wording of any safety message. Figure 1 Safety labels and tags WARNING! Table 2 Safety Labels and Tags Item Part Description 1. WARNING! 2011 Nordson Corporation

16 12 FillEasy C Adhesive Feed System Description The FillEasy C Adhesive Feed System transports granulated adhesive from a storage bin, through a transfer hose, and into the melter tank when the level sensor detects a low level. Figure 2 shows the components of a FillEasy C system Figure 2 FillEasy C system components 1. Control cabinet 2. Suction lance 3. Transfer hose (4 m) 4. Cone 5. Level sensor 6. Adhesive storage bin 7. Supply air hose 2011 Nordson Corporation

17 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 13 Features Automatically maintains adhesive in the melter at a preset level. Ensures uninterrupted production and saves operator time. Simple design reduces maintenance requirements. Can be installed on ProBlue 7, 10 and 15 hot melt systems. Easy to install. Unique design features ensure consistent transfer of adhesive: Vibrator on suction lance design minimizes bridging in the adhesive container Cone shape allows an even dispersion of adhesive in the tank Eliminates missed beads and poor bonding due to tank running dry. Specifications General Parameter Specification Melter ProBlue 4, 7, 10 and 15 Bravura B4, B6, B9 and B14 Adhesive Pellets, pastilles, chicklets Maximum adhesive transfer rate 227 (500) kg/hr (lb/hr) Operating air pressure bar (psi) (dry, non lubricated) Minimum 4 bar (0.4 MPa or 58 psi) Maximum 6 bar (0.6 MPa or 87 psi) Pneumatic Parameter Air consumption 4 bar (0.4 MPa 58 psi) 6 bar (0.6 MPa or 87 psi) Air connection Specification 24 scfm (686 Nl/min) 30 scfm (857 Nl/min) 2 scfm (57 Nl/min) max. cooling 10 mm OD (0.393 in.) 2011 Nordson Corporation

18 14 FillEasy C Adhesive Feed System Electric Parameter Voltage Frequency Fuse rating Specification VAC 10% 1 w/neutral 50/60 Hz 1A Dimensions Parameter Weight kg (lb) 20.0 (44.1) Specification Control cabinet W x H x D mm (in.) 212 x 232 x 130 (8.35 x 9.13 x 5.12) Feeding lance L x W mm (in.) 615 x 105 (24.21 x 4.14) Transfer hose m (ft) 4 (14.1) Cone height mm (in.) 340 (12.6) Screen mesh size mm (in.) 0.5 x 0.5 (0.02 x 0.02) Storage bin capacity kg (lb) 60 (132) Intended Use FillEasy C cannot be used in any way other than specified in this manual. Carefully observe the instructions in the Safety section prior to use Nordson Corporation

19 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 15 System Components Electrical Cabinet The front panel of the electrical cabinet displays three LEDs that have different colored lights that indicate the unit status: Power ON LED (white light) indicates that the system is switched on. The start/stop and running LEDs (blue light) indicate adhesive delivery. When the melter sends a low level signal, FillEasy C begins transferring adhesive from the storage bin, through the transfer hose and into the melter tank. Alarm LED (red light) indicates when the system exceeds the user defined fill limit and the system stops filling. Press the Buzzer button to reset and resume normal activity Power ON/OFF 2. Control box lock 3. Start/Stop Figure 3 Electrical cabinet front view 4. Cooling air On/Off 5. Reset 6. Buzzer 7. Power ON 8. Running 9. Error 2011 Nordson Corporation

20 16 FillEasy C Adhesive Feed System Electrical Cabinet (contd) The bottom of the electrical cabinet contains fittings for connecting to the pneumatic tubing. Power supply cable and sensor cable are pre wired Figure 4 Electrical cabinet bottom view 1. Air supply input 4-6 bar 10 mm OD x 8 mm ID 2. Air supply for cone cooling 8mm OD x 6mm ID 3. Power supply VAC 50/60Hz 4. Level sensor 5. Air supply for venturi pump and vibrator 10 mm OD x 8 mm ID 2011 Nordson Corporation

21 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 17 Electrical Controls Figure 5 shows the control relay station Figure 5 Layout of the electrical section 1. PLC control for low level, fault, delay and timer duration 2. Solenoid valve (fill solenoid) 3. Air throttle (bleed air valve) 2011 Nordson Corporation

22 18 FillEasy C Adhesive Feed System Suction Lance See Figure 6.The suction lance sucks adhesive from the storage bin. The suction lance is comprised of the following components: Venturi pump to suck in and transport the adhesive. Vibrator to keep the adhesive in loose condition. 1 2 Figure 6 Suction lance components 1. Venturi pump 2. Vibrator 2011 Nordson Corporation

23 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 19 Cone/Tank Lid and Level Sensor See Figure 7. A transfer hose (not shown) transports adhesive from the storage bin of the FillEasy C to the melter tank. The cone and level sensor assembly attaches the transfer hose to a melter tank lid that is precut to the dimensions of the cone. The new tank lid must be retrofitted to the melter before the cone is attached. The cone contains a mesh screen to prevent fine adhesive powder from being emitted into the ambient air. The air supply to the cone provides a cooling effect that prevents the adhesive from sticking to it Figure 7 Material transfer components 1. Cone 2. Lid assembly 3. Level sensor 2011 Nordson Corporation

24 20 FillEasy C Adhesive Feed System Cone/Tank Lid and Level Sensor(contd) The level sensor detects the adhesive level in the melter tank. When the adhesive falls below the set point the level sensor sends a signal to the FillEasy C control cabinet. Installation WARNING! Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Unpacking and Positioning FillEasy C CAUTION! Do not store outside! Protect from humidity and dust. 1. Exercise normal care to prevent equipment damage during unpacking. 2. Inspect for any damage that may have occurred during shipping. Report any damage to the Nordson representative. 3. Position the FillEasy C close to the production line with the following guidelines: Provide sufficient space for cleaning and maintenance above and on all sides of the FillEasy C. Ensure sufficient access to transfer hose for maintenance. Ensure that the cables, air hoses, and the transfer hose are not bent, pinched, torn off, or damaged Nordson Corporation

25 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 21 Positioning the Electrical Cabinet See Figure 8. Mount the electrical cabinet to the stand using four (4) M6 screws and the brackets through mounting holes on the back of the electrical cabinet. Figure 8 Control box mounting Setup This section provides instructions to install the cone, connect level sensor sensor signal return wire to different melters, calibrate the level sensor, and adjust the air throttle. Installing the Cone and Level Sensor Assembly CAUTION! Do not twist or bend the sensor signal wire from the sensor to the level sensor relay box Nordson Corporation

26 22 FillEasy C Adhesive Feed System Attaching the Cone and Level Sensor 1. Insert the screen mesh into the cone. 2. See Figure 9. Place the cone on the modified tank lid and secure with the two brackets provided. Figure 9 Cone and level sensor mounting 2011 Nordson Corporation

27 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 23 Attaching the Transfer Hose to the Cone 1. Attach the transfer hose to the cone. 2. See Figure 10. Secure the cone to the lid using the clamp (see drawing on left). Figure 10 Attach the transfer hose to the cone 3. Calibrate the level sensor. Refer to Calibrating the Level Sensor given later Nordson Corporation

28 24 FillEasy C Adhesive Feed System Connecting the Cooling Air Hose 1. See Figure 11. Connect one end of the6 mm OD polyethylene tubing to the inlet on the cone, and the other end into the control box. Figure 11 Cooling hose connections 2. Secure the air hose to the transfer hose using the tie wraps provided Nordson Corporation

29 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 25 Connect the Suction Lance See Figure 12. Connect one end of the 10 mm OD air tubing to the air inlet on the suction lance. Connect the other end of the air tubing to the control box. Figure 12 Suction lance air connections 2011 Nordson Corporation

30 26 FillEasy C Adhesive Feed System Connect the Level Sensor to the Control Box 1. See Figure 13. Route the sensor wire through the bottom of the control box. Figure 13 Route the sensor wire through the bottom of the control box 2. See Figure 14. Secure the eyelet of the sensor wire to the sensor relay labeled 17/B1 inside the control box. Figure 14 Sensor relay 2011 Nordson Corporation

31 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 27 Calibrating the Level Sensor CAUTION! Do not calibrate the level sensor unless the cone interior and elbow, cooling tube and mesh screen are clean and free from debris. Failure to clean will contibute to build up after calibration has been set. Calibrate the level sensor at start up or or after a system failure. 1. With the melter tank 3 / 4 full of adhesive, raise the level sensor until the sensor box (labeled 17/B1) LED changes from yellow to green. Do not immerse the level sensor into the adhesive. 2. After the LED changes color, raise the level sensor height an additional 1 / 2 turn. 3. Fill the tank with adhesive to a level that is 6 mm ( 1 / 4 in.) from the top of the tank. The LED on the sensor box will change from yellow to green. 4. Raise the level sensor until the LED on the sensor box turns yellow. 5. When the LED changes color, lower the level sensor an additional 1 / 2 turn. 6. Tighten the nut on the lid to secure the position of the level sensor. The level sensor is now calibrated Nordson Corporation

32 28 FillEasy C Adhesive Feed System Adjusting the Air Throttle The air supply cools the cone and prevents the adhesive from sticking or coagulating. The continuous air supplied to the air throttle can be adjusted to regulate the volume of air to the cone. Do not let the temperature of the cone exceed 40 C (104 F). Set the lowest air volume required to achieve the cone temperature by following these steps. NOTE: Measure the cone temperature just above the collar so that it reaches the appropriate temperature. NOTE: The amount of air flow is dependent upon the tank temperature and upon the softening point of the adhesive. The higher the softening temperature of adhesive, the greater the volume of air flow will be required. 1. See Figure 15. Turn the adjustment screw to the right (clockwise) until air does not flow. 2. Turn the adjustment screw 1 / 4 turn to the left (counterclockwise) to open. CAUTION! Ensure that the fill chute is kept cooler than the softening point of the adhesive. Failure to do so will create adhesive buildup on the screen and the sensor. 1 Figure 15 Adjust the air throttle 1. Air throttle 2011 Nordson Corporation

33 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 29 Operation When installed and functioning properly, the following sequence of events will occur: 1. The sensor detects a low adhesive level. 2. The level sensor relay box LED changes from green to yellow. 3. The blue Start/Stop LED begins to blink. 4. The PLC relay times out, and its LED goes from blinking to constant. 5. The blue Running LED starts blinking and activates the fill solenoid and the blue fill light. 6. When the level sensor detects full, all relays turn off. 7. The level sensor relay box LED changes from yellow to green. 8. If the PLC running relay times out before the sensor detects a full tank, all 4 relay LEDs will turn on, the FAULT light will be lit, and the FILL light will be off Nordson Corporation

34 30 FillEasy C Adhesive Feed System Maintenance Maintenance is an important preventive measure for maintaining operating safety and extending the operational lifetime of the unit. It should not be neglected under any circumstances. WARNING! Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING! When damaged parts pose a risk to the operational safety of the unit and/or safety of personnel, switch off the unit and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. Maintenance Schedule Depending on the location of the unit, the production conditions and the operating time, other maintenance intervals may prove necessary. Unit Activity Interval FillEasy C System Inspect for damage Daily External cleaning Daily Inspect compressed air setting Daily Transfer hose Inspect for damage, replace if necessary Weekly Level sensor Inspect for impurities Weekly Inspect level monitoring setting Daily Cone Clean Weekly Clean screen mesh, replace if necessary Daily External Cleaning External cleaning prevents impurities from causing the unit to malfunction. Remove dust, fluffs, etc. with a vacuum cleaner or a soft cloth Nordson Corporation

35 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 31 Troubleshooting WARNING! Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. This section contains troubleshooting procedures. These procedures cover only the most common problems that may be encountered. If the problems cannot be solved with the information given here, contact the local Nordson representative. Problem Possible Cause Corrective Action 1. Melter is underfilled Air pressure too low Check air pressure (4-6 bar psi). 2. Overflow protection is activated Transfer hose is blocked or bent Search for blockage and remove it Unbend the transfer hose. Adhesive bridging in container Check and replace vibrator. Air pressure set too low. Level sensor dirty or defective Clean or replace. 3. Melter does not receive overflow signal Level sensor is calibrated incorrectly Improper installation of level sensor signal return wire Timer relay 03KA1 is set incorrectly Timer relay 03KA3 is set incorrectly Incorrect level sensor adjustment Level sensor signal return wire not installed correctly 4. Adhesive dirty Oil or water in Venturi pump with the adhesive Set the level sensor. Refer to Calibrating the Level Sensor. Install the sensor signal return wire, refer to Connecting the Level Sensor Sensor Signal Return Wire to Different Melters given earlier. Reset timer relay. Refer to Setting the Timer Relays. Reset the level sensor. Refer to Calibrating the Level Sensor. Check that the air supply is dry, non lubricated, and compressed. Debris in container Add adhesive. 5. Cone overheats Cone clogged Cone and sensors should be less than 37 C (100 F) Nordson Corporation

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37 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 33 Using the Illustrated Parts Lists To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use these five column parts lists, and the accompanying illustrations, to describe and locate parts correctly. The following chart provides guidance for reading the parts lists. The number in the Item column corresponds to the circled item number in the parts list illustration. A dash in this column indicates that the item is an assembly. The number in the Part column is the Nordson part number you can use to order the part. A series of dashes indicates that the part is not saleable. In this case, you must order either the assembly in which the part is used or a service kit that includes the part. The Description column describes the part and sometimes includes dimensions or specifications. The Note column contains letters that refer to notes at the bottom of the parts list. These notes provide important information about the part. The Quantity column tells you how many of the part is used to manufacture the assembly shown in the parts list illustration. A dash or AR in this column indicates that the amount of the item required in the assembly is not quantifiable. Item Part Description Quantity Note Assembly A Part of assembly A 2 A 2 Part of item Part of item 2 AR NS Part of item 3 2 NOTE A: Important information about item 1 AR: As Required NS: Not Shown 2011 Nordson Corporation

38 34 FillEasy C Adhesive Feed System Recommended Parts Refer to Figure 16. Item Part Description Cone assy, big Cone assy, small FillEasy C lid assy, P FillEasy C lid assy, P7/P FillEasy C lid assy, P FillEasy C lid assy, B FillEasy C lid assy, B FillEasy C lid assy, B FillEasy C lid assy, B Capacitive sensor Control cabinet NS Cone mesh screen, big NS Cone mesh screen, small NS Filter-regulator NS Vibrator ball NS Venturi pump 2011 Nordson Corporation

39 PPA Safety 5/08 Symbols changed, changed factory authorized to Nordson authorized on page 5. PPA Safety 7/30/09 added note regarding applicators vs guns. FillEasy C Adhesive Feed System 35 Figure 16 FillEasy C lid components 2011 Nordson Corporation

40 36 FillEasy C Adhesive Feed System Electrical Enclosure Parts Part Description LOAD SWITCH, FE C MICRO BREAKER, FE C POWER SWITCH, FE C PLC, FE C RELAY, FE C RELAY BASE, FE C BUZZER, FE C WHITE INDICATOR, 220V, FE C RED INDICATOR, 24V, FE C YELLOW INDICATOR, 25V, FE C BLUE INDICATOR, 26V, FE C GREEN BUTTON HEAD BLUE BUTTON HEAD BLUE LED BASE GREEN LED BASE 2011 Nordson Corporation

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