ection 11 Electrical ystem
11-0 Electrical ystem
Table of Contents i Table of Contents ection 11 Electrical ystem 1. Introduction... 11-1 Electrical Operation... 11-1 Heating Zones... 11-2 2. Electrical pecifications... 11-2 3. Cordset Installation... 11-2 Installing Meltex M-tyle Cordsets... 11-4 Disconnecting Cordsets... 11-5 4. Checking RTD Operation... 11-6 5. Removing and Replacing an RTD... 11-8 6. RTD Resistance Chart... 11-11 7. Thermostat Operation... 11-12 8. Resetting a Thermostat... 11-13 9. Checking Thermostat Operation... 11-13 10. Removing and Replacing a Thermostat... 11-14 11. Checking olenoid Valve Operation... 11-15 12. Electrical ervice Kits and pare Parts... 11-16
ii Table of Contents
Electrical ystem 11-1 ection 11 Electrical ystem WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. Introduction This section describes the eries CF-200 Applicator electrical system for applicators with Meltex 7-wire, M-style (PT100) cordsets. The electrical system includes the following components: cordsets RTDs thermostats heater cartridges extension cords solenoid valves In addition to the electrical components that are part of the eries CF-200 Applicator, the adhesive hose contains connectors and associated wiring that connect electrically to the applicator. (The adhesive hose electrical connectors and wiring and the extension cord supply electrical power to the adhesive manifold and to the heated air manifold and to carry the electrical signals from the RTDs to the controller.) Electrical Operation On Nordson eries CF-200 Applicators, electrical power is supplied to one or more heaters in the adhesive manifold to maintain the adhesive at its application temperature. Electrical power is also supplied to one or more heaters in the heated air manifold to heat its incoming air supply to the application temperature of the adhesive. Electrical wiring and connections are also present in both manifolds to connect the RTD for each heating zone to a controller. (An RTD provides an electrical signal proportional to the temperature in its heating zone.)
11-2 Electrical ystem Electrical Operation (contd.) In each heating zone, a thermostat wired in series with the heater(s) provides additional overtemperature protection. Meltex 7-wire, M-style cordsets also include two wires that provide electrical power to a solenoid valve attached to the CF-200 applicator. The solenoid valve controls the supply of module actuating air to the applicator. Heating Zones A manifold on a eries CF-200 Applicator is divided into one or more heating zones. A heating zone in the adhesive manifold is known as an adhesive heating zone. A heating zone in the heated air manifold is known as an air heating zone. The number of heating zones in a manifold depends on the size of the manifold and the available control channels. The size of an applicator is related to its output requirements and whether or not the applicator is filtered or non-filtered. The heating requirements of a filtered applicator are greater than those of a non-filtered applicator. Also, the heating requirements of the heated air manifold are greater than the heating requirements of the adhesive manifold. Each heating zone includes one RTD, one thermostat, and one or two heater cartridges. These devices are electrically connected to a control channel on the melter controller or on a stand-alone temperature controller. The controller receives the RTD electrical signal, and the controller regulates the electrical power supplied to the zone heater(s) based on the RTD signal. 2. Electrical pecifications Refer to the applicator nameplate stamping information on the applicator reference drawing in ection 8 for the voltage and wattage information for the eries CF-200 Applicator documented by this publication. 3. Cordset Installation A Meltex 7-wire, M-style cordset for an adhesive heating zone has a square 8-pin male plug that connects to an 8-pin female receptacle on an adhesive hose. A Meltex-wire M-style cordset for an air heating zone has a round 7-pin male plug that connects to a 7-pin female connector on an extension cord. 4601008 Fig. 11-1 Meltex 7-Wire, M-tyle Adhesive Manifold Cordset Connector
Electrical ystem 11-3 3. Cordset Installation (contd.) 4601009 Fig. 11-2 Meltex 7-Wire, M-tyle Air Manifold Cordset Connector Table 11-1 lists the extension cords for use with Meltex 7-Wire, M-style cordsets that are available from Nordson. Table 11-1 Extension Cords for Meltex 7-Wire, M-style Cordsets Part Description Length 152 555 For 8-pin, Meltex M-style adhesive manifold cordset (square-round) 152 466 For 8-pin, Meltex M-style adhesive manifold cordset (square-round) 152 558 For 8-pin, Meltex M-style adhesive manifold cordset (square-round) 154 478 For 7-pin, Meltex M-style air manifold cordset (round-round) 154 479 For 7-pin, Meltex M-style air manifold cordset (round-round) 154 480 For 7-pin, Meltex M-style air manifold cordset (round-round) 6.1 m (20 ft) 7.3 m (24 ft) 10.1 m (33 ft) 6.1 m (20 ft) 7.3 m (24 ft) 10.1 m (33 ft) Normally, the electrical configuration, including the number of adhesive hose electrical connectors, extension cords, and applicator cordsets, is determined by a Nordson representative working with the customer. NOTE: The cordset installation procedure in this section describes an installation in which the adhesive heating zone cordsets are connected to the power supplies through adhesive hose receptacles and adhesive manifold extension cords and air heating zone cordsets are connected to the power supplies through air manifold extension cords, which is the recommended configuration.
11-4 Electrical ystem Installing Meltex M-tyle Cordsets To connect Meltex 7-Wire, M-style cordsets on a eries CF-200 Applicator, use the following procedure: 1. If the system is in operation, relieve the hydraulic pressure in the hot melt system (refer to Relieving Hydraulic Pressure in ection 7). 2. Disconnect and lock out the electrical power to the hot melt system. 3. Connect the plug at the melter end of the adhesive hose to a receptacle at the melter. 4. Locate each adhesive manifold extension cord, and plug each one into a melter receptacle. (Adhesive zone extension cords have a square receptacle at one end and a round plug at the other end.) 1 2 3 5 4 6 4204083 Fig. 11-3 Typical Low-Wattage T-type Cordset Connection 1. Adhesive manifold 2. Adhesive heating zone cordset and plug 3. Adhesive hose receptacle 4. Adhesive hose 5. Hose cord and plug 6. Melter controller receptacles 5. At the applicator, plug an adhesive manifold cordset (square connector) into the receptacle at the applicator end of the adhesive hose. 6. For each remaining adhesive manifold cordset, plug the cordset into the square receptacle on an adhesive manifold extension cord. 7. Locate all air manifold extension cords. (Air manifold extension cords have round 7-pin connectors at both ends.) 8. Connect each air manifold extension cord plug to a receptacle on the melter.
Electrical ystem 11-5 Installing Meltex M-tyle Cordsets (contd.) 1. Connect each air manifold cordset (round connector) to an air manifold extension cord receptacle. 1 2 3 4 5 6 Fig. 11-4 Typical Air Heating Zone Cordset Connection 1. Adhesive manifold 4. Extension cord 2. Air heating zone cordset and plug 5. Extension cord plug 3. Extension cord receptacle 6. Control channel receptacle 4204018 2. elect one of the following steps as appropriate: If the cordsets were connected as part of the initial installation of the eries CF-200 Applicator, return to the applicator installation procedures in ection 3 of this publication and complete the installation. If the cordsets were connected as part of another procedure, return to that procedure. If the hot melt system is to be returned to normal operation, apply electrical power, then return the system to normal operation (refer to tarting the Applicator in ection 4). Disconnecting Cordsets To disconnect the cordsets on a eries CF-200 Applicator, use the following procedure: 1. If the system is in operation, relieve the hydraulic pressure in the hot melt system (refer to Relieving Hydraulic Pressure in ection 7). 2. Disconnect and lock out electrical power to the hot melt system. 3. For each cordset on the applicator, disconnect the cordset plug from the adhesive hose or extension cord receptacle to which it is connected.
11-6 Electrical ystem 4. Checking RTD Operation Use the following procedure to check RTD operation: 1. With the applicator at normal operating temperature, relieve hydraulic pressure (refer to Relieving Hydraulic Pressure in ection 7). 2. Disconnect and lock out power. 3. Use an ohmmeter to check the RTD resistance between pins 6 and 7 at the cordset connector. ee Figure 11-9 for the correct resistance for the applicator temperature. 4110419 Fig. 11-5 RTD Resistance Check at the Cordset
Electrical ystem 11-7 4. Checking RTD Operation (contd.) 4. If the RTD resistance between pins 6 and 7 is normal, the RTD is operating correctly. If the RTD resistance between pins 6 and 7 indicates an open circuit, loosen the applicator wiring cover screws and remove the cover. 1 1 4204021 Fig. 11-6 Adhesive Manifold ervice Cover (Typical) 1. Location of service cover screws 5. Check for loose RTD wires or wire nuts. If loose wiring or connections are found, perform the following steps: a. Repair loose wiring and connections. b. Check the RTD resistance between pins 6 and 7 with an ohmmeter. If the resistance is normal, the RTD is now operating correctly. If the resistance check indicates an open circuit, go to step 6. 6. Disconnect the wires to the RTD electrical leads. 7. Connect an ohmmeter across the RTD leads to measure the resistance at the normal operating temperature. 8. Compare the measured resistance to the value on the RTD resistance versus temperature chart in this section (see Figure 11-9). If the measured resistance is within the resistance range for the operating temperature, reconnect the RTD wiring, replace the wiring cover, and return to the troubleshooting guide.
11-8 Electrical ystem 4. Checking RTD Operation (contd.) If the measured resistance is not within the resistance range for the operating temperature, replace the RTD (refer to Removing and Replacing an RTD in this section). 5. Removing and Replacing an RTD To remove and replace an RTD on a CF-200 applicator: 1. Relieve the hydraulic pressure (refer to Relieving Hydraulic Pressure in ection 7). 2. Unplug all applicator cordsets from the receptacles on the adhesive hoses. 3. Remove the screws that secure the cover to the manifold. 1 1 Fig. 11-7 Adhesive Manifold ervice Cover (Typical) 1. Location of service cover screws 4204021
Electrical ystem 11-9 5. Removing and Replacing an RTD (contd.) 4. Disconnect the RTD leads from the input leads. (ee the wiring diagram on the applicator reference drawing in ection 8 for detailed wiring information, if necessary). NOTE: ome eries CF-200 Applicators use cordsets with continuous RTD leads (no wire nuts). On applicators with continuous RTD leads, cut the leads when replacing the RTD. 1 Fig. 11-8 Typical RTD Leads 1. Air heating zone RTD leads 4204029 5. Remove the RTD from its mounting hole in the manifold. CAUTION: Attempting to remove an RTD that is lodged in the mounting hole by pulling on its electrical leads could cause the leads to break off, making it even more difficult to remove the RTD. Dislodge the RTD before pulling on its electrical leads. During assembly of the applicator, Nordson applies a heat-sink compound on the RTD to improve its heat sensing ability. After a period of time, this compound hardens and can cause the RTD to become lodged in the mounting hole.
11-10 Electrical ystem 5. Removing and Replacing an RTD (contd.) If the RTD is lodged in the mounting hole, use one of the following methods to loosen and remove it from the mounting hole: On some newer CF-200 applicators, there is an access hole in the manifold body directly behind the RTD mounting hole in which a rod can be inserted and used to gently push or tap the RTD to loosen it. On CF-200 applicators without the access hole previously described, dislodge the RTD by placing a small punch against the center of the RTD and carefully tapping on the punch with a hammer to loosen the seal between the RTD and the manifold body. After it is dislodged, carefully pull the RTD out using its electrical leads. CAUTION: triking the manifold body with the hammer or punch when attempting to dislodge the RTD from the mounting hole can damage the manifold body. To avoid damage, place the punch in the center of the RTD and strike the punch squarely with the hammer without using excessive force. 6. Insert the replacement RTD into the mounting hole. NOTE: Applying a heat sink compound to the RTD before inserting it into the mounting hole improves the heat sensing ability of the RTD. 7. Connect the electrical leads from the cordset to the RTD leads. NOTE: Electrically, the RTD is not polarity sensitive. Consequently, either cordset lead can be connected to either RTD lead. 8. Replace the manifold cover and secure it with the cover screws. 9. Connect each applicator cordset plug to the adhesive hose receptacle from which it was disconnected. 10. Restore the system to normal operation (refer to the melter technical manual).
Electrical ystem 11-11 6. RTD Resistance Chart The chart in this section shows how the resistance of a platinum RTD varies with respect to temperature. Platinum RTDs are supplied with eries CF-200 Applicators with Meltex 7-wire, M-style cordsets. RTD resistance varies with changes in temperature (the higher the temperature, the higher the resistance). Use this chart when testing RTD performance. REITANCE IN OHM TEMPERATURE IN o C 0 20 40 60 80 100 120 140 160 180 200 220 240 205 200 195 PLATINUM RTD 190 185 180 175 170 165 160 155 150 145 140 135 130 125 120 115 110 105 100 32 68 104 140 176 212 248 284 320 356 392 428 464 TEMPERATURE IN o F 4110319 Fig. 11-9 Platinum RTD Resistance as a Function of Temperature
11-12 Electrical ystem 7. Thermostat Operation In each adhesive heating zone on Nordson eries CF-200 Applicators with Meltex 7-Wire, M-style cordsets, a thermostat is connected in series with the heater(s). The thermostat provides additional overtemperature protection. 4110399 Fig. 11-10 Adhesive Manifold Thermostat 1. Reset button NOTE: When an adhesive manifold thermostat opens because of high temperature, it must be manually reset before the applicator can be returned to normal operation. (Refer to Resetting a Thermostat in this section.) NOTE: The setpoint temperature for the thermostat used with Meltex, 7-wire, M-style cordsets is 260 _C (500 _F). Normally, the controller maintains the temperature in a heating zone based on the resistance of the RTD. However, if the RTD fails, the thermostat acts as a backup, preventing the temperature in that heating zone from rising above the setpoint. During normal operation, when the applicator temperature is below the setpoint, the thermostat should be closed, allowing power to reach the heaters. If the applicator does not heat properly and the applicator temperature has not been above the setpoint temperature, a thermostat may have failed. If the applicator temperature rises above the thermostat setpoint, the thermostat has failed. The hot melt system should be shut down and the thermostats checked and replaced as necessary.
Electrical ystem 11-13 8. Resetting a Thermostat Perform the following procedure to reset a thermostat on a eries CF-200 Applicator with Meltex 7-Wire, M-style cordsets: 1. With the applicator at the normal operating temperature, relieve the hydraulic pressure (refer to Relieving Hydraulic Pressure in ection 7). 2. Disconnect and lock out the system power. 3. Remove the manifold cover (see Figure 11-6), and locate the wiring for the thermostat and the heater(s) (see the wiring diagram on the applicator reference drawing in ection 8). 4. Locate the thermostat to be reset, and press the reset button located on the thermostat. 5. Replace the manifold cover. 6. Return the hot melt system to normal operation. 9. Checking Thermostat Operation Perform the following procedure to determine whether or not a thermostat has failed in the open position: 1. With the applicator at the normal operating temperature, relieve the hydraulic pressure (refer to Relieving Hydraulic Pressure in ection 7). 2. Disconnect and lock out the system power. 3. With the applicator at or below the normal operating temperature, locate the cordset to which the thermostat is connected. Unplug the cordset from the adhesive hose or the extension cord receptacle. NOTE: When the temperature is at or below the recommended application temperature of the adhesive, the thermostat should be closed. 4. Use an ohmmeter to check the resistance between pins 2 and 3 on the cordset connector. Perform one of the following tests based on the results of the resistance test. If the measured resistance does not indicate an open circuit, the thermostat is operating correctly at the normal operating temperature. Return to the procedure that referenced this test. If the measured resistance indicates an open circuit, the thermostat may have failed. Proceed to the next step in this troubleshooting procedure.
11-14 Electrical ystem 9. Checking Thermostat Operation (contd.) 5. Remove the manifold cover (see Figure 11-6) and locate the wiring for the thermostat and the heater. Inspect the wiring and wire nuts for looseness or damage. If loose or damaged connections or damaged wiring is found, tighten the connections or repair the damaged wiring. 6. Use an ohmmeter to test the electrical continuity of the thermostat by placing the ohmmeter probes on thermostat wiring connectors. Perform one of the following steps based on the result of the continuity test. If the measured resistance indicates a short circuit, the thermostat is operating correctly. Replace the manifold cover, connect the cordset to the receptacle from which it was unplugged, and return to the procedure that referenced this test. If the measured resistance indicates an open circuit, the thermostat is open. Go to tep 7. 7. Attempt to reset the thermostat by pressing the reset button located on the thermostat. 8. Perform the electrical continuity test described in tep 6, and perform one of the following steps based on the results of the continuity test. If the measured resistance indicates a short circuit, the thermostat is operating correctly. Replace the manifold cover, connect the cordset to the receptacle from which it was unplugged, and return to the procedure that referenced this test. If the measured resistance indicates an open circuit, the thermostat is open. Replace the thermostat (refer to Removing and Replacing a Thermostat in this section). 10. Removing and Replacing a Thermostat Use the following procedure to remove and replace a thermostat: 1. With the applicator at the normal operating temperature, relieve the hydraulic pressure (refer to Relieving Hydraulic Pressure in ection 7). 2. Disconnect and lock out the system power. 3. Remove the manifold cover (see Figure 11-6), and locate the thermostat and heater wiring.
Electrical ystem 11-15 10. Removing and Replacing a Thermostat (contd.) 4. Loosen the wire nuts connecting the wiring to the thermostat, remove the thermostat screws, and remove the thermostat from the manifold. 5. Place the new thermostat in the mount, secure it with the thermostat screws, and connect the thermostat wiring to the cordset and heater wiring with the wire nuts. (ee the wiring diagram on the applicator reference drawing in ection 8.) 6. Replace the manifold cover. 7. Plug the cordset into the adhesive hose or extension cordset receptacle. 8. Return the hot melt system to normal operation. 11. Checking olenoid Valve Operation Use the following procedure to check the operation of the solenoid valve: 1. Relieve the hydraulic pressure (refer to Relieving Hydraulic Pressure in ection 7). 2. Disconnect and lock out power to the hot melt system. 3. Unplug the adhesive cordset that supplies electrical power to the solenoid valve. 4. Use an ohmmeter to check the resistance between pins 4 and 5 on the cordset. 5. A short circuit or low resistance indicates that the solenoid is operating correctly. Return to the procedure that referenced the solenoid valve check. An open circuit indicates loose wiring, a poor connection, or a damaged solenoid. Proceed to step 6. 6. Remove the manifold service cover and check the cordset wiring to the solenoid for damaged wiring or loose connections. (ee the wiring diagram on the applicator reference drawing in ection 8 to locate the manifold service cover and the service cover screws.) Perform one of the following steps: If damaged wiring or a loose connection is found, proceed to tep7. If cordset wiring damage or a loose connection is not found, refer to the solenoid documentation for troubleshooting information.
11-16 Electrical ystem 11. Checking olenoid Valve Operation (contd.) 7. Repair damaged wiring or loose connections and test the electrical continuity at cordset pins 4 and 5. Perform one of the following steps: If the solenoid operation is normal, replace the service cover, connect the cordset, and return the system to normal operation. Refer to the solenoid valve documentation for troubleshooting information. 12. Electrical ervice Kits and pare Parts Table 11-2 CF-200 Electrical ervice Kits and pare Parts Part Description Note 860 265 ensor with 90-inch leads, RTD, Platinum, 100-ohm 140 305 ensor with 10-inch leads, RTD, Platinum, 100-ohm Heater A NOTE A: Refer to the applicator parts list in ection 8 for the heater part numbers.