ITW Dynatec c. 2006 Page 1 Revised 4/20/07 Description GEMINI TM DYNACONTROL TM HOSES Automatic & Manual Versions FOR DYNAMELT & DYNAMINI TM ADHESIVE APPLICATION SYSTEMS Adhesive supply hoses are electrically-heated, flexible conduits designed for the transfer of hotmelt material from an adhesive supply unit (ASU) to an applicator (head or handgun). Hoses are heated by resistance heaters which are wrapped around the hose core and covered with a hightemperature insulation. Hose temperature is regulated by the ASU s controller. A sensor located in the hose provides temperature information to the controller. GEMINI* DYNACONTROL hoses are 1000 psi (69 bar) hoses used to deliver hot-melt material from a Dynamelt or Dynamini ASU to an ITW Dynatec applicator (either a dispensing head or a hand-held applicator). These hoses provide through wiring for power, sensor and chassis ground in the applicator. All DynaControl hoses feature PT-100 RTD sensors. Gemini hoses are equipped with an extra heater and RTD sensor and a switch assembly which allows switching the hose s operation between the two. This provides a backup to eliminate downtime and allows time to plan for eventual hose replacment. On the Gemini Automatic hose, the switch is done automatically. On the Gemini Manual hose, the operator initiates the switch. Gemini hoses are water-resistant, made so by their seamless flexible sleeving, sealed end cuffs and liquid-tight electrical conduit and fittings. Specifications Standard Option (Dynamelt M only) Hose Size... #6 Hose #8 Hose End Couplings... #6 Hose #8 Hose female swivel at both ends female swivel at both ends All Dynacontrol Hoses Sensor... 100 Ohm Platinum RTD (coefficient = 0.00385 Ohm/ Ohm/ C) Wiring... Uses 1000 VAC 500 F (260 C) nickel-plated copper multi-strand,tfe insulated. Per MIL-W-22759/10. Flex Hose... Smooth innercore of extruded TFE (nominal thickness 0.030) with type 304 stainless steel wire braid reinforcement. Maximum Operating Temperature... * Patent Pending 425 F (218 C) continuous cont.
Page 2 ITW Dynatec c. 2006 Specifications, cont. Maximum Operating Pressure... 1000 PSI (69 bar) at 425 F (218 C) Minimum Burst Pressure... 7500 PSI (510 bar) at 425 F (218 C) Maintenance... None required in this application. Spare Parts... No user-replaceable parts. Hose Tag Information... MANUFACTURER PART NUMBER LENGTH INSIDE DIAMETER DATE OF MANUFACTURE SERIAL NUMBER Installation Instructions Before installing any hose to an ASU, make sure the ASU s power switch is OFF. DANGER HIGH VOLTAGE ITW Dynatec systems use electrical power that can be life threatening. Disconnect and lock out input power to the application system before connecting, disconnecting or troubleshooting any hose(s). Refer to Chapter 3 of the adhesive application unit s manual for hose installation location, instructions and an illustration specific to your ASU. Gemini hoses connect to the ASU with both an adhesive port connection on the filter outlet manifold and a 15-pin electrical connector. The opposite end of the hose connects to the applicator (head or handgun) with both an adhesive inlet connection and a 9-pin electrical connector. Refer to the Hose Installation Diagram on page 3 as a general guide. Observe the following cautions when connecting and routing adhesive hoses. CAUTION: When tightening hose swivel fittings, hold the hose and cuff to prevent the hose from rotating. CAUTION: If the hose is cold and contains adhesive, it may be damaged if bent. To avoid this, turn on power to the hoses and wait until the ASU s readout indicates that they are at operating temperature before routing them around surrounding machinery. CAUTION: Do not allow hose to be covered by machinery or by any type of solid conduit, pipe, tubing, etc. CAUTION: Maintain a minimum of 1/2 clearance between adjacent hoses.
ITW Dynatec c. 2006 Page 3 ASU Filter Outlet Manifold Electrical Connection Adhesive Port Connection Adhesive Inlet Connection Applicator Head Electrical Connection Electrical Connection Hand-held Applicator Hose Installation Diagram: ASU to Automatic or Hand Applicator To Disconnect Hose from ASU or Applicator Never attempt to disconnect a hose from its adhesive port without first assuring that all system pressure has been relieved. WARNING: HIGH PRESSURE, HOT ADHESIVE When disconnecting a hose or hose cap, hot adhesive can escape from both the manifold and from the end of the hose under high pressure. Wear a face shield, gloves and protective clothing. Stand clear until all pressure is relieved. Before disconnecting a hose, turn the ASU s pump/motor OFF. Then activate the applicator to relieve adhesive pressure in the system. To Check Temperature Sensor Resistance When temperature sensor resistance is being verified, refer to the Resistance Table in Chapter 7 of the ASU s manual. The temperature sensor in Gemini Dynacontrol hoses is a 100 Ohm platinum RTD. The temperature coefficient is 0.00385 Ohms/ Ohm/ C. Refer to the ASU service manual for system wattage limitations. Hose Troubleshooting Tip Hose problems can be isolated by electrically connecting the hose to an alternate socket on the ASU. If the malfunction goes with the hose, the problem will usually be in the hose that was moved. If the malfunction does not move with the hose, the problem is probably in the ASU.
Page 4 ITW Dynatec c. 2006 The Gemini Advantage The hoses of Dynatec s Gemini adhesive hose line are designed with built-in heater and sensor backups to aid the user in the event of a failure in these two components. Troubleshooting Heaters and RTD Sensors in Gemini Automatic Hoses With the automatic Gemini hose, there is no need for the operator to troubleshoot the hose. The hose will switch between good and bad heater and the good and bad sensor automatically. Note: both heaters and sensors will switch when one or the other becomes faulty. Troubleshooting Heaters and RTD Sensors in Gemini Manual Hoses Follow this procedure to determine if the failure of a hose is due to a faulty heater or RTD sensor before switching between the two heaters and sensors in the Gemini switch assembly. 1. Disconenct hose from ASU or applicator following the instructions outlined on the previous page. WARNING: HIGH PRESSURE, HOT ADHESIVE When disconnecting a hose or hose cap, hot adhesive can escape from both the manifold and from the end of the hose under high pressure. Wear a face shield, gloves and protective clothing. Stand clear until all pressure is relieved. 2. Make sure that incoming line power to the ASU and that the unit s Main Power Switch are turned OFF. DANGER HIGH VOLTAGE Disconnect and lock out input power to the application system before proceeding with these instructions. 3. Test resistance using the pins within the hose connection: a. To determine RTD sensor failure: The resistance value (Ohms) of your temperature sensor depends on the temperature of the sensor at the time it is being tested. At 25 C(77 F), the resistance of a DCL PT 100 (Platinum) sensor should be 110 Ohms at 25 C(77 F). With an ohmmeter, contact pins 9 and 10 and measure resistance. A tolerance range of ± 5% is allowed. b. To determine heater failure: With an ohmmeter, contact pins 11 and 12 and measure resistance. Heater circuit resistance is listed on the red hose warranty tag attached to the adhesive supply unit end of the power cord. A tolerance range of ± 10% is allowed.
ITW Dynatec c. 2006 Page 5 Using the Gemini Automatic Hose s Switch Assembly Note: The illustrations on this page are not for users of the Gemini Automatic hose. The switch box of the Gemini Automatic hose should never be opened. Opening it will void your Dynatec hose warranty. 1. When either a heater or a RTD sensor becomes faulty on a Gemini Automatic hose, the hose will automatically switch to the good heater and sensor. No action is required by the operator. 2. When the hose makes the switch to fresh components, the light will turn ON in the hoses switch box. The light will stay ON or blink for the life of the hose. Using the Gemini Manual Hose s Switch Assembly Once it has been determined that either the heater or the RTD sensor is faulty in a Gemini Manual hose, use the appropriate switch within the Gemini switch enclosure to toggle between the hose s two heaters or sensors. Procedure: 1. Loosen the four screws in the corners of the Gemini switch box. Remove switch box cover. 2. Locate the switch of the faulty component (heater or sensor). 3. Toggle the switch from circuit #1 position to circuit #2 position. See illustration below, right for closeup of circuit positions. Note: Switches are always in position #1 when hose is shipped from ITW Dynatec s factory. Position #2 is the backup circuit. 4. Re-intall switch box cover. cover switchplate Record switch actuation date here 5. On the switch box cover label, record the date of circuit #2 actuation in the space provided for H2 or S2. heater switch sensor switch Gemini Manual Hose Circuit Positions Gemini Manual Hose Switch Assembly in diagram above, both heater and sensor are in Circuit #1 (left) position. in diagram above, both heater and sensor are in Circuit #2 (backup) position.
Page 6 ITW Dynatec c. 2006 Troubleshooting Hoses DO NOT PULL HOSE TO MOVE UNIT (Pull forces greater than 20lbs can permanently damage the hose.) PUSH DON T PULL USE TWO WRENCHES TO ADJUST FITTINGS DON T BEND OR CRIMP HOSE USE 45 HOSE FITTING (PN# N07831) OR 90 HOSE FITTING (PN# N07830) HOSE BALANCER KIT 084F440 DO NOT HANG HOSE WITHOUT SUPPORT DO NOT CLAMP, SQUEEZE OR TIE HOSE USE HOSE SUPPORT WITH HOSE BALANCER KIT USEHOSESUPPORTS (5-pack is PN 113342) DO NOT SQUEEZE OR PRESS HOSES TOGETHER ALLOW 1/2 MINIMUM SPACE BETWEEN HOSES } 1/2 DO NOT FLEX GLUE FILLED HOSE WHEN COLD! The minimum bend radius should be as follows: Hose Core Hose Radius.313 = #6 8in.406 = #8 14in.625 = #12 16in.875 = #16 20in 1.375 = #24 30in ALLOW GLUE FILLED HOSES TO HEAT UP BEFORE FLEXING! NOTE: Hose failure due to above listed Wrong practices will void hose warranty.
ITW Dynatec c. 2006 Page 7 Gemini Automatic Hose Configuration and Block Diagram DANGER HIGH VOLTAGE Within the Gemini Automatic Hose s switch box is electrical power that can be life threatening. DO NOT OPEN THE GEMINI AUTOMATIC HOSE SWITCH BOX! Opening the Gemini Automatic Switch Box voids your Dynatec hose warranty! No Gemini Automatic Hose schematics are published in this manual. DO NOT attempt to troubleshoot within the Gemini Automatic Hose s Switch Box. Connector Configuration: Gemini Automatic Hoses Primary Heater Secondary Heater Selector Relays Monitoring Heater Defect? Primary RTD + RTD Defect? Secondary RTD Fault Indication Block Diagram: Gemini Automatic Hoses
Page 8 ITW Dynatec c. 2006 Gemini Manual Hose Schematics 15-pin connector ASU end of hose 9-pin connector Applicator end of hose Pin Connectors for Gemini Manual Hoses Gemini Manual Switch Assembly Terminals
ITW Dynatec c. 2006 Page 9 Gemini Manual Hose Schematics Schematic 101082-GM: Gemini Manual Hose, DynaControl
Page 10 ITW Dynatec c. 2006 Schematic 112633-GM: Gemini Manual Hose, DynaControl 2-Heater Hoses Used on longer hoses (over 45 feet) and on the #8 8ft. hose Schematic 100951-GM: Gemini Manual Hose, Upgrade, Nor Hoses
ITW Dynatec c. 2006 Page 11 Typical Gemini DynaControl Hoses The following hose charts give part numbers (PN), size, length, voltage, resistance and wattage of the most commonly-used Gemini DynaControl hoses. Note: Most hoses are available in either a Gemini Manual (GM) or a Gemini Automatic (GA) version. Part numbers are expressed as XXXXXX-GM (for manual version) or XXXXXX-GA (for automatic version). 120VAC Dynamini ASU Hoses, #6 (0.313 ID) Hose PN Heater Wire Resistance (Min./ Max.) Voltage (AC) Nominal Hose Power, Watts 102437-GM/GA 1.2 4 115-134 Ohms 120v 112 102438-GM/GA 1.8 6 76.1-88.8 Ohms 120v 168 102439-GM/GA 2.4 8 58.1-67.8 Ohms 120v 224 102440-GM/GA 3.1 10 47.3-55.2 Ohms 120v 280 102441-GM/GA 3.7 12 38.3-44.7 Ohms 120v 336 109483-GM/GA 4.9 16 29.8-34.8 Ohms 120v 448 111805-GM/GA 6 20 22.6-26.4 Ohms 120v 560 200VAC Dynamelt S & Dynamini ASU Hoses, #6 (0.313 ID) Hose PN Heater Wire Resistance (Min./ Max.) Voltage (AC) Nominal Hose Power, Watts 109896-GM/GA 1.2 4 316-369 Ohms 200v 112 109897-GM/GA 1.8 6 213-249 Ohms 200v 168 109898-GM/GA 2.4 8 150-176 Ohms 200v 224 109899-GM/GA 3.1 10 129-151 Ohms 200v 280 109900-GM/GA 3.7 12 109-127 Ohms 200v 336 109901-GM/GA 4.9 16 76.2-88.9 Ohms 200v 448 109903-GM/GA 6 20 64.3-75.1 Ohms 200v 560 109904-GM/GA 7.3 24 54.3-63.4 Ohms 200v 672
Page 12 ITW Dynatec c. 2006 240VAC Standard Dynamini, Dynamelt S & M Series ASU Hoses, #6 (0.313 ID) Hose PN Heater Wire Resistance (Min./ Max.) Voltage (AC) Nominal Hose Power, Watts 101083-GM/GA 1.2 4 466-544 Ohms 240v 112 101084-GM/GA 1.8 6 279-326 Ohms 240v 168 101085-GM/GA 2.4 8 236-275 Ohms 240v 224 101086-GM/GA 3.1 10 189-221 Ohms 240v 280 101087-GM/GA 3.7 12 155-181 Ohms 240v 336 101088-GM/GA 4.9 16 118-137 Ohms 240v 448 102138-GM/GA 6 20 95.6-112 Ohms 240v 560 101089-GM/GA 7.3 24 77.3-90.2 Ohms 240v 672 200/240VAC, Hoses, #6 (0.313 ID) (Optional for Dynamelt M Series ASUs only) Hose PN Heater Wire Resistance (Min./ Max.) Voltage (AC) Nominal Hose Power, Watts (Min./ Max.) 105187-GM/GA 9.1 30 56.2-65.6 Ohms 240v 840 106216-GM/GA 11 36 51.9-60.5 Ohms 240v 1008 105601-GM/GA 12 40 45.4-53.0 Ohms 240v 1120 240VAC Optional Dynamelt M Series ASU Hoses, #8 (0.406 ID) Also requires a PN 103949 Fitting (8 JIC) Hose PN Heater Wire Resistance (Min./ Max.) Voltage (AC) Nominal Hose Power, Watts 103316-GM/GA 1.2 4 301-351 Ohms 240v 168 103317-GM/GA 1.8 6 206-241 Ohms 240v 252 103318-GM/GA 2.4 8 154-181 Ohms 240v 336 103319-GM/GA 3.1 10 126-147 Ohms 240v 420 103320-GM/GA 3.7 12 103-121 Ohms 240v 504 103321-GM/GA 5.5 18 67.9-79.3 Ohms 240v 756 103322-GM/GA 7.3 24 52.8-61.6 Ohms 240v 1008 106030-GM/GA 9.1 30 40.0-46.6 Ohms 240v 1260 106031-GM/GA 11 36 33.2-38.8 Ohms 240v 1512 106176-GM/GA 12 40 30.8-35.9 Ohms 240v 1680
ITW Dynatec c. 2006 Page 13 120VAC Spray (Swirl) Hoses for Dynamini ASUs, #6 (0.313 ID) Hose PN Heater Wire Resistance (Min./ Max.) Voltage (AC) Nominal Hose Power, Watts (Min./ Max.) 102442-GM/GA 2.4 8 58.1-67.8 Ohms 120v 224 102443-GM/GA 3.1 10 47.3-55.2 Ohms 120v 280 102444-GM/GA 3.7 12 38.3-44.7 Ohms 120v 336 111549-GM/GA 4.9 16 29.8-34.8 Ohms 120v 448 112911-GM/GA 6 20 22.6-26.4 120v 560 240VAC Spray (Swirl) Hoses for Standard Dynamini, Dynamelt S & M Series ASUs, #6 (0.313 ID) Hose PN Heater Wire Resistance (Min./ Max.) Voltage (AC) Nominal Hose Power, Watts (Min./ Max.) 102173-GM/GA 2.4 8 236-275 Ohms 240v 224 102174-GM/GA 3.1 10 189-221 Ohms 240v 280 102175-GM/GA 3.7 12 155-181 Ohms 240v 336 102176-GM/GA 4.9 16 118-137 Ohms 240v 448 102177-GM/GA 6 20 95.6-112 Ohms 240v 560 102178-GM/GA 7.3 24 77.3-90.2 Ohms 240v 672 Abrasion Resistant DCL Hoses, 0.313 ID (#6) Part Number for 120v Bead Applicator Part Number for 120v Spray Applicator Part Number for 200/240v Bead Applicator Part Number for 200/240v Spray Applicator 1.8 6 104633-GM/GA n.a. 104561-GM/GA n.a 2.4 8 104634-GM/GA 104637-GM/GA 104562-GM/GA 104640-GM/GA 3.1 10 104635-GM/GA 104638-GM/GA 104563-GM/GA 104641-GM/GA 3.7 12 104636-GM/GA 104639-GM/GA 104564-GM/GA 104642-GM/GA 4.9 16 n.a. n.a. 104565-GM/GA 104643-GM/GA 6 20 112912-GM/GA 112913-GM/GA 104566-GM/GA 104644-GM/GA 7.3 24 n.a. n.a. 104567-GM/GA 104645-GM/GA
Page 14 ITW Dynatec c. 2006 Spray (Swirl) Air Regulator Kit An air control kit, consisting of a regulator and a choice of three solenoid valves (see chart below) is available for swirl applications. To order, specify both regulator and solenoid valve part numbers. Description Voltage Part Number Regulator 084M008 Select one of the following solenoid valves: Pneumatic, 3 way 120 030A014 Pneumatic, 3 way 240 030A013 Pneumatic, 3 way 24 030A016 Hanger Strap Kit PN 113342 In applications where a hose is routed through or over a machine, straps may be used to suspend it to prevent the hose from laying on the ground or on machinery. Nylon hanger straps are recommended, set at an interval of every four feet. The strap kit consists of five hanger straps.