Hot Melt Material Applicator Manual English NORDSON ENGINEERING GMBH LÜNEBURG GERMANY
Note This manual applies to the entire series. Order number P/N = Order number for Nordson products Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1996. 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, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, icontrol, iflow, Isocoil, Isocore, Iso-Flo, itrax, JR, KB30, Kinetix, Little Squirt, LogiComm, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure-Max, Tela-Therm, Tracking Plus, TRAK, Trends, Tribomatic, Ultra, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, BetterBook, Blue Series, CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Color-on-Demand, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail, E-Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G-Net, G-Site, HDLV, Ink-Dot, ion, Iso-Flex, itrend, KVLP, Lacquer Cure, Lean Cell, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, MiniEdge, Minimeter, Multifil, Myritex, OptiStroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, TrueBlue, Ultrasmart, Universal, Viper, Vista, VersaDrum, VersaPail, WebCure, 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. COV_EN_315915E 2006 Nordson Corporation
Table of Contents I Table of Contents Section 1 Safety Separate document Section 2 Description 1. Intended Use............................................. 2-1 Area of Use (EMC)...................................... 2-1 Use Limitation........................................ 2-1 Unintended Use Examples............................ 2-1 2. Residual Risks............................................ 2-2 3. Operating Manual......................................... 2-2 4. Series Overview.......................................... 2-2 Explanation of Unit Description........................... 2-2 5. Configuration Code........................................ 2-3 6. Unit Components......................................... 2-4 7. Functioning............................................... 2-5 Melting Process and Hot Melt Material Supply.............. 2-5 Motor.................................................. 2-5 Gear Pump............................................ 2-5 Shutoff Valve (Option)................................... 2-5 Mechanical Safety Valve (Standard)....................... 2-6 Pneumatic Safety Valve (Option).......................... 2-6 Weighing Cell.......................................... 2-6 Heating................................................ 2-6 Temperature Control.................................... 2-7 Undertemperature Locking Device...................... 2-7 Overtemperature indication / shutdown.................. 2-7 Temperature Setback................................. 2-7 Tank Hood and Tank Lid................................. 2-8 Tank Hood Switch.................................... 2-8 Inert Gas Equipment.................................... 2-9 Vacuum Pump....................................... 2-9 Air Dryer (Option)....................................... 2-9 Pressure Sensor (Option)................................ 2-9 2006 Nordson Corporation
II Table of Contents Section 2 Description (contd.) 8. Electrical Cabinet........................................ 2-10 Front/Rear Side........................................ 2-10 Opening the Electrical Cabinet........................... 2-11 Pulling the Electrical Cabinet Forward.................... 2-11 Main Switch........................................... 2-12 Control System........................................ 2-12 Channel allocation................................... 2-12 Indicator Light......................................... 2-13 Button Heating On/Off.................................. 2-13 Button Purge.......................................... 2-13 Lighted Symbol Inert Gas Bottle Empty................... 2-13 Lighted Symbol Inert Gas Supply........................ 2-13 Programmable Week Timer (Option)..................... 2-13 Bar Graph (Option)..................................... 2-13 Electrical Cabinet Ventilation............................ 2-13 Tach Generator Connection Socket...................... 2-14 XS 2 Interface......................................... 2-14 9. Protective Panels........................................ 2-15 10. ID Plate................................................. 2-15 Section 3 Installation 1. Transport................................................ 3-1 Lifting (Unpacked Unit).................................. 3-1 2. Unpacking................................................ 3-1 3. Removing................................................ 3-1 4. Storage.................................................. 3-1 5. Disposal................................................. 3-1 6. Setting Up................................................ 3-2 7. Overview................................................. 3-2 8. Mounting Indicator Light.................................... 3-3 9. Exhausting Hot Melt Material Vapors......................... 3-3 10. Electrical Connections..................................... 3-3 Laying Cables.......................................... 3-3 Line Voltage............................................ 3-3 Tach Generator (Accessories)............................ 3-3 XS 2 Interface.......................................... 3-4 2006 Nordson Corporation
Table of Contents III Section 3 Installation (contd.) 11. Installing Heated Hoses.................................... 3-5 Connecting............................................. 3-5 Disconnecting.......................................... 3-5 Relieving Pressure................................... 3-5 Second Open jawed Wrench.......................... 3-5 12. Pneumatisches Sicherheitsventil (Option).................... 3-6 Hose Diameter......................................... 3-6 Compressed Air Preparation............................. 3-6 Compressed Air Preparation............................. 3-6 13. Inert Gas Equipment....................................... 3-6 14. Air Dryer (Option)......................................... 3-6 Connecting Hose or Pipeline............................. 3-6 Disposing of Condensate................................ 3-6 15. Adjusting Drum Supporting Ring............................ 3-6 Section 4 Operation 1. Tank Empty Message...................................... 4-1 2. Filling the Tank............................................ 4-1 3. Setting Temperatures...................................... 4-2 General Values......................................... 4-2 4. Setting Hot Melt Material Feed Quantity...................... 4-3 Motor/Pump Speeds.................................... 4-3 Manual Operation....................................... 4-3 Automatic Operation.................................... 4-3 5. Initial Startup............................................. 4-4 6. Daily Switch ON/OFF...................................... 4-5 Daily Switch ON........................................ 4-5 Daily Switch OFF (Inert Gas also Off)...................... 4-5 Daily Switch OFF (Inert Gas not Off)....................... 4-5 7. Emergency Switch OFF.................................... 4-5 8. Settings Record Form..................................... 4-6 Section 5 Maintenance 1. Relieving Pressure........................................ 5-1 2. Daily Maintenance........................................ 5-2 3. Regular Maintenance...................................... 5-2 4. External Cleaning......................................... 5-3 2006 Nordson Corporation
IV Table of Contents Section 5 Maintenance (contd.) 5. Inspection for External Damage............................. 5-3 6. Electrical Cabinet Fan Maintenance......................... 5-3 7. Changing Hot Melt Material Type............................ 5-4 8. Flushing with a Cleaning Agent............................. 5-4 9. Maintenance Record Form................................. 5-5 Section 6 Troubleshooting 1. Control System........................................... 6-1 2. Helpful Tips.............................................. 6-1 3. Indication Lamps and Indicator Light......................... 6-2 4. Troubleshooting Tables.................................... 6-3 Only the White Indication Lamp is Lit...................... 6-3 Red Indication Lamp is Lit................................ 6-4 Unit does not Function................................... 6-5 One Channel (Heating Zone) does not Heat................ 6-5 No Pilot Voltage........................................ 6-5 No Hot Melt Material (Motor does not Rotate)............... 6-6 No Hot Melt Material (Motor Rotating)..................... 6-7 Incorrect Motor Rotation in Automatic Operation............ 6-7 Not Enough Hot Melt Material............................ 6-7 Hot Melt Material Pressure Too High...................... 6-7 Hot Melt Material Pressure Too Low....................... 6-8 Hot Melt Material Residues in Tank........................ 6-8 Hot Melt Material Hardens in Tank........................ 6-8 Section 7 Specifications 1. General Data............................................. 7-1 2. Temperature.............................................. 7-1 3. Electrical Data............................................ 7-2 4. Dimensions and Weights................................... 7-2 5. Other Data............................................... 7-2 Section 8 Index............................................................. 8-1 2006 Nordson Corporation
Section 1 Safety Observe and follow all safety instructions, the general safety instructions included as a separate document, as well as the specific safety instructions in all other related documentation. 2006 Nordson Corporation
1-0 Safety 2006 Nordson Corporation
Section 2 Description 2006 Nordson Corporation
2-0 Description 2006 Nordson Corporation
Description 2-1 Section 2 Description 1. Intended Use Hot melt material applicators of the Series may only be used to melt and feed polyurethane hot melt materials (PUR) from 20-Liter drums and suitable adhesive blocks. Any other use is considered as not intended and is carried out at the operator s own risk. Nordson will not be responsible for personal or equipment damage resulting from unintended use. Intended use also includes the observance of Nordson safety instructions. Nordson recommends collecting detailed information about the materials to be used. Area of Use (EMC) The units are designed for use in industrial areas (see also included Declaration of Conformity). Use Limitation When used in residential and commercial areas, the units can cause interference in other appliances, e.g. radios. Unintended Use Examples The unit may not be used under the following conditions: In defective condition When unapproved changes or modifications have been made by the customer Without heat protection and protective panels With electrical cabinet door open With tank lid open With tank hood open In an explosive atmosphere When the values stated under Specification are not complied with. The unit may not be used to melt and process the following materials: Explosive and inflammable materials Erosive und corrosive materials Foodstuffs 2006 Nordson Corporation
2-2 Description 2. Residual Risks The unit is designed to protect operating personnel from possible risks. However, some residual risks cannot be avoided. Personnel must consider the following: Risk of burns from hot melt material. Risk of burns on the tank lid after the tank hood has been opened Risk of burns when filling the tank Risk of burns from heated accessories such as heated hoses or hot melt application heads. Inhalation of potentially hazardous hot melt material vapors. 3. Operating Manual Representative for all units of the series, this manual describes a unit with one gear pump and one hose connection. NOTE: The position numbers in the illustrations do not correspond to the position numbers in the technical drawings or spare parts lists. 4. Series Overview The series includes the following units. Unit Motors / Pumps Hose connections per pump -1x1 1 1-1x2 1 2-2x1 2 1-2x2 2 2 Explanation of Unit Description The description is illustrated by the example -2x1. -2x1 1 hose connection per pump 2 motors / pumps 20 Liter drums Series description Description Nordson units of the Meltex product line which process polyurethane hot melt material. M = Moisture C = Curing 2006 Nordson Corporation
Description 2-3 5. Configuration Code The configuration code is stamped into the ID plate. NOTE: An X means the function or components were not ordered and are therefore not included. Unit designation Configuration Options Box Code Key 1 M Series or unit description (Moisture) 2 C Series or unit description (Curing) 3 4 Series or unit description 4 4 5 2 6 0 7 8 1 One pump 2 Two pumps 9 x 10 1 One hose connection per pump 2 Two hose connections per pump 11 C Operating voltage 400 V AC Temperature sensor Fe-CuNi (FE/KO) G Operating voltage 230 V AC Temperature sensor Fe-CuNi (FE/KO) V Operating voltage 400 V AC Temperature sensor Ni 120 Y Operating voltage 230 V AC Temperature sensor Ni 120 12 A Pump 1 Type: PR 2m1 VX-coating C Pump 1 Type: PR 4m1 VX-coating D Pump 1 Type: PR 6m1 VX-coating E Pump 1 Type: PR 12m1 VX-coating F Pump 1 Type: PR 12m2 VX-coating G Pump 1 Type: PR 25m2 VX-coating 13 A Pump 2 Type: PR 2m1 VX-coating C Pump 2 Type: PR 4m1 VX-coating D Pump 2 Type: PR 6m1 VX-coating E Pump 2 Type: PR 12m1 VX-coating F Pump 2 Type: PR 12m2 VX-coating G Pump 2 Type: PR 25m2 VX-coating 14 1 Hose connection 5 / 16 in. = 8 mm 2 Hose connection 5 / 8 in. = 16 mm 3 Hose connection 1 / 2 in. = 13 mm (only in connection with temperature sensor Fe-CuNi (FE/KO) 15 / 16 B Bar graph 17 F Shutoff valve on one pump G Shutoff valve on two pumps 18 P Pneumatic safety valve on one pump Q Pneumatic safety valve on two pumps 19 M Pressure display on one pump N Pressure display on two pumps 20 T Programmable week timer 21 U Tank lid heating 22 V Protective panels with VX-coating 23 D Air dryer 24 A One additional head/hose connection B Two additional head/hose connections C Three additional head/hose connections 25 X 26 X 27 S Special version 2006 Nordson Corporation
2-4 Description 6. Unit Components Figure 2-1 shows the main unit components. Details can be found in the technical drawings (Refer to Spare Parts Lists). 1 2 3 4 5 6 7 8 9 10 11 27 12 13 26 Ä 14 15 25 16 24 23 22 21 20 19 18 17 MCSY191L176B1098 Fig. 2-1 Side view 1. Indicator light 2. Electrical cabinet 3. Tank hood switch 4. Tank lid 5. Tank hood 6. Tank lid heating (Option) 7. Overpressure valve (0.5 bar) 8. Protective panel 9. Heated jacket 10. Drum supporting ring 11. Low melt zone 12. Hose connection socket 13. Pressure sensor (option) 14. Hose connection fitting 15. Weighing cell 16. Transport rollers 17. High melt zone 18. Cable guides 19. Hot melt material drain flange 20. Safety valve (35 bar) 21. Gear pump 22. Coupling 23. Inert gas equipment 24. Air dryer (option) (not visible) 25. Motor (not shown) 26. Compressed air filter (only with the option air dryer ) 27. Heat protection 2006 Nordson Corporation
Description 2-5 7. Functioning The functioning of the unit is described here. The operation of the individual components is described in the manual for the component (refer to Index of Documentation). Melting Process and Hot Melt Material Supply The drum or adhesive block is placed in the tank. Here it is only heated until it has melted and flows into the high melt zone. In the high melt zone the material is heated to the processing temperature prescribed by the hot melt material supplier. The melted material flows to the gear pump. The gear pump driven by a motor feeds the material to the hose connection fitting. From here the material flows through the heated hose to the hot melt material application head or hot melt handgun. Motor See also manual Motor. The electronically controlled motor drives the gear pump. The motor speed is indicated in a display. To set speed see manual Control System. NOTE: The motor is first ready for operation when the undertemperature locking device has been released or when the unit has almost reached the set nominal value temperature. NOTE: Avoid a permanent motor/pump speed of less than 5 RPM and more than 80 RPM to prevent excessive wear. Gear Pump See also manual Gear Pump. The gear pump is driven by a motor and feeds the hot melt material to the hose connection fitting. The size and speed of the gear pump determine the material feed quantity. NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, make sure the tank is filled. NOTE: Avoid a permanent motor/pump speed of less than 5 RPM and more than 80 RPM to prevent excessive wear. Shutoff Valve (Option) 2 1 XXSY036S050A0595 Fig. 2-2 The shutoff valve is located in the safety valve plate which is between the tank and gear pump. It serves to block the flow of hot melt material when the gear pump is to be replaced. It is activated with a hex spanner. Position 1: shutoff valve open Position 2: shutoff valve closed. 2006 Nordson Corporation
2-6 Description Mechanical Safety Valve (Standard) See also manual Safety Valve. The mechanical safety valve limits the hot melt material pressure produced by the gear pump and holds it constant. It is factory set and lead sealed. When the factory set pressure is exceeded, the safety valve opens and the hot melt material circulates inside the safety valve plate. Pneumatic Safety Valve (Option) See also manual Safety Valve. The pneumatic safety valve has the same safety function as the mechanical safety valve. In addition, it offers the possibility to set the hot melt material pressure to a certain value or to control it dependant on the parent machine speed. Weighing Cell CAUTION: Do not place objects on the unit. This could cause the weighing cell to indicate an incorrect weight. See also manual Weighing Cell. The weighing cell is used to monitor the tank filling level. The lowest tank filling level is displayed by the indicator lamp (yellow). It must be adjusted by the customer. NOTE: Nordson recommends setting the lowest tank illing level so that the yellow lamp of the indicator lamp lights when the hot melt material just reaches the melt grate in the low melt zone (see arrow in Fig.). To do so, place a weight (approx. 17 kg, 37.4 lbs) on the tank lid. The potential free relay outputs Tank full and Fill tank can be used for example to activate signalling units and/or to control an automatic tank filling (XS 2 Interface). The switching points of the relay outputs can be adjusted. Fig. 2-3 MCSY201S060A0796 Lowest tank filling level Heating Heating is carried out by cast in heating elements, heating cartridges and a heated jacket. Low melt zone High melt zone Tank (warm tank) Tank lid heating (Option) Cast in heating elements Cast in heating elements Heated jacket Heating cartridges NOTE: The heated jacket (Channel 11) and tank lid heating (Channel 12) are switched on/off by the tank hood switch. The heating time can be set on the control system with the parameter T1 (Refer to manual Control System). Parameter Function Setting range Factory setting T1 Heating time Off / 1 to 180 minutes 30 minutes 2006 Nordson Corporation
Description 2-7 Temperature Control See also manual Control System. The temperature is measured by sensors and electronically controlled by the Control System. Undertemperature Locking Device The undertemperature locking device prevents the unit or system from starting up when the hot melt material is too cold. It is activated until the nominal temperature value minus undertemperature value has been exceeded. On initial heating of the unit, the locking device is first released when the actual temperature is 3 C below the nominal value temperature. The undertemperature locking device locks the motors, solenoid valves and, in some cases, other components of the hot melt material application system. Refer to the Wiring Diagram to determine which components are locked. Overtemperature indication / shutdown The independently operating overtemperature shutdown mechanisms protect the unit and adhesive from overheating. For overtemperature shutdown, the heating and motor are switched off. The red indication lamp collective fault lights up. Overtemperature indication through temperature controller: Switches relay output collective fault when setpoint temperature value plus overtemperature value has been reached and the red indication lamp lights up. The unit remains ready for operation. Overtemperature shutdown through temperature controller: The overtemperature shutdown value is set automatically 30 C above the highest temperature setpoint value. Overtemperature shutdown through thermostat(s): Serves as an emergency switch OFF in case the overtemperature shutdown of the temperature controller does not function properly. Refer to section Specification for shutdown value. NOTE: Depending on the hot melt material used, the overtemperature thermostats Low melt zone and High melt zone must be adjusted to the max. processing temperature of the hot melt material (i.e. replaced). However, the switchoff value of the thermostats may not exceed the max. operating temperature of the unit! For thermostats see section Specifications. WARNING: When the overtemperature shutdown is triggered, there is either a fault in settings or unit malfunction. Switch off the unit and have the fault eliminated by qualified personnel. Temperature Setback Serves to protect the hot melt material and save energy during interruptions in production or work stoppages. Setback value and setback period are adjustable. 2006 Nordson Corporation
2-8 Description Tank Hood and Tank Lid WARNING: Hot. Risk of burns on the tank lid after opening the tank hood. Wear heat protective gloves. WARNING: Do not operate the unit when the tank lid is open. Hot melt material vapors which may contain hazardous substances can escape. Tank Hood Switch The tank hood switch (Fig. 2-4) activates the following functions on opening and closing: Tank hood switch Tank hood is opened Tank lid heating (Option) and heated jacket are switched off. Tank is relieved of inert gas pressure (quick deaeration). Unlock / Lock Tank hood is closed Tank lid heating (option) and heated jacket are switched on and heat only for the time set on the control system (parameter T1 ). Vacuum pump pumps out air for the time set on the control system (parameter C2 ). Vacuum pump switches off. Tank is supplied with inert gas for the time set on the control system (parameter C1 ). Inert gas supply carried out at regular intervals as set on the control system (parameter Con and CoF ). Unlock / Lock T1 C1 Parameter Function Setting range Factory setting Heating time (Tank lid heating and heated jacket) Inert gas supply on (after expiration of C2 ) Off / 1 to 180 minutes 30 minutes 2 to 240 seconds 30 seconds C2 Vacuum pump on Off / 2 to 240 seconds 30 seconds Con CoF Inert gas supply on (Intermittent gas supply) Inert gas supply off (Intermittent gas supply) Note: When Con = Off, the parameter CoF is not displayed. Off / 2 to 120 seconds 5 seconds 2 to 120 minutes 30 minutes MCSY211S210A0896 Fig. 2-4 2006 Nordson Corporation
Description 2-9 Inert Gas Equipment See also manual Inert Gas Equipment and manual Control System under Operation of the Motor Section. CAUTION: Use only suitable inert gas. Refer to the Material Safety Data Sheet of the material or contact the material supplier. When processing certain materials, for example polyurethane hot melt materials (PUR), thermoplastic polyester or polyamid resin, the inert gas prevents an undesired reaction with the atmosphere. It purges the air in the tank and protects the material. The tank is supplied with pressure reduced inert gas. A 2,5 bar (36.25 psi) safety valve limits the inert gas inlet pressure. The tank is protected by a 0.4 bar (5.8 psi) overpressure valve against too high pressure. The inert gas supply is carried out: Automatically during operation as set on the Control System (inert gas injection interval and duration of injection). Automatically after the tank hood is closed. The inert gas supply time can be set on the control system. Manually by pressing the Purge button as an additional Inert gas flush, e.g. when the tank has been filled. When the inert gas pressure is too low, the illuminated symbol Inert gas bottle empty lights up. In addition, a potential free contact for connection of external indication devices is available (XS 2 Interface). Vacuum Pump The vacuum pump automatically exhausts the air in the tank after the tank hood has been closed. The exhaust time can be set on the control system. The coarse filter (in the lid) and the fine filter (in the air line) should be cleaned yearly. Air Dryer (Option) Also refer to manual Membrane Compressed Air Dryer and manual High Power Compressed Air Filter. The membrane compressed air dryer in conjunction with the preceding high power compressed air filter conditions compressed air such that it can be used as inert gas to prevent the material in the tank from reacting to humidity. Pressure Sensor (Option) Refer to manual Pressure Sensor and manual Control System. The pressure sensor compiles the material pressure at the hose connection fitting. This material pressure is displayed on the control system. 2006 Nordson Corporation
2-10 Description 8. Electrical Cabinet WARNING: Risk of electric shock. Failure to observe can result in personal injury, death and/or equipment damage. WARNING: Disconnect equipment from the line voltage. Front/Rear Side 1 2 3 16 17 18 1 2 3 4 5 6 7 8 9101112 4 1 2 3 4 5 6 7 8 9 10 1112 15 M1 min 1 bar psi 1 1 2 2 3 3 4 4 1 2 C F 19 7 20 R 14 13 12 11 10 9 8 21 Front side Rear side MCSY197L139B1198 Fig. 2-5 1. Main switch 2. Control System (with option bar graph) 3. Indicator light 4. Bar grapf (Option) 5. 6. 7. Door locks 8. Programmable week timer (Option) 9. Lighted symbol Inert gas bottle empty 10. Button Purge (Inert gas flush) 11. Lighted symbol Inert gas supply 12. Button Heating on 13. Button Heating off 14. Electrical cabinet fan with filter 15. Air filter 16. XS 2 Interface 17. Connection socket Tach generator 18. Connection socket Tank lid heating (Option) 19. Connection socket heated jacket (warm tank) 20. Connection socket Low melt zone heating 21. Connection socket High melt zone heating 2006 Nordson Corporation
Description 2-11 Opening the Electrical Cabinet WARNING: Only allow qualified and authorized personnel to open the electrical cabinet. The key is provided with the unit. WARNING: Disconnect unit from line voltage before opening the electrical cabinet. 1 234 56 7 8 9101112 1234 56 7 8 9101112 1 1 2 2 3 3 4 4 1 2 M1 min 1 bar psi C F R MCSY195L060A0796 Fig. 2-6 Pulling the Electrical Cabinet Forward The electrical cabinet can be pulled forward for installation, maintenance and repair work. To do so, unlock with the key provided with the unit. WARNING: Make sure cables do not come into contact with rotating and heated parts after returnig the electrical cabinet to its normal position. Do not pinch cables. MCSY196L070A0796 Fig. 2-7 2006 Nordson Corporation
2-12 Description Main Switch (1, Fig. 2-5) Serves to switch the unit On/Off. Position 0/OFF = unit is switched off. Position I/ON = unit is switched on. The main switch can be secured with padlocks against unauthorized switching. NOTE: The heating must be switched on separately (Button 12, Fig. 2-5). NOTE: When using a programmable week timer (Option), the main switch must always be in position I/ON. CAUTION: The inert gas equipment is also switched off in position 0/OFF. The material can harden in the tank. Control System (2, Fig. 2-5) For operation see manual Control System. Channel allocation Channel 1 Channel 2 Low melt zone High melt zone Channel 3 Heated hose 1 Channel 4 Application head 1 Channel 5 Heated hose 2 Only with -1x2-2x1 Channel 6 Application head 2-2x2 Channel 7 Heated hose 3 Only with -2x2 Channel 8 Application head 3 Channel 9 Heated hose 4 Channel 10 Application head 4 Channel 11 Channel 12 Heated jacket (warm tank) Tank lid heating (Option) NOTE: Channels 11 and 12 are switched on/off by the tank hood switch (see also in this Section under Tank Hood Switch). Tank hood open Tank hood closed Channels 11 / 12 heating switched off (measuring mode) Channels 11 / 12 heating switched on (control mode) The heating time can be set on the control system in the electrical cabinet 2006 Nordson Corporation
Description 2-13 Indicator Light (3, Fig. 2-5) Indicates except for the yellow lamp the same operating modes as the indication lamps of the Control System (see also Section Troubleshooting and manual Control System). White Red Yellow Green Unit switched on Collective fault Lowest tank filling level as set by the customer Unit ready for operation Button Heating On/Off (12, 13, Fig. 2-5) The buttons switch the heating (load current circuit) on or off. Button Purge (10, Fig. 2-5) Pressing the button activates an additional Inert gas flush, e.g. when the tank has been filled. Lighted Symbol Inert Gas Bottle Empty (9, Fig. 2-5) Lights when the inert gas bottle is empty. Lighted Symbol Inert Gas Supply (11, Fig. 2-5) Lights each time inert gas is supplied. Programmable Week Timer (Option) (8, Fig. 2-5) See manual Programmable Week Timer. The programmable week timer is located in the right electrical cabinet door. It switches the load current circuit (heating) on / off and takes over the function of the buttons Heating on and Heating off. NOTE: When using a programmable week timer (Option), the main switch must always be in position I/ON. Bar Graph (Option) (4, Fig. 2-5) Also refer to manual Control System. The bar graph simultaneously shows the range that the temperature is in for all channels that are switched on. Electrical Cabinet Ventilation (14, 15 Fig. 2-5) Serves to keep the electrical cabinet cool. The filters must be cleaned regularly (see Section Maintenance). 2006 Nordson Corporation
2-14 Description Tach Generator Connection Socket (17, Fig. 2-5) Serves to connect a tach generator (Accessories). The tach generator is available from Nordson. If part of the shipment, refer also to manual Tach Generator. WARNING: When connecting to Nordson units of the Meltex product line, the pilot voltage may not exceed 160 V DC. Failure to observe can result in damage to electronic components. NOTE: The pilot voltage must be aligned (see manual Control System). XS 2 Interface (16, Fig. 2-5) Serves as a connection between the unit and customer s external devices. For connection allocation see Sections Installation and Wiring Diagram. 2006 Nordson Corporation
Description 2-15 9. Protective Panels WARNING: Do not operate the unit without protective panels. For installation, maintenance, etc. the side panels can be removed and the rear panel tilted outward. The panel fasteners can be unlocked with the square spanner supplied with the unit. The lower part of the rear cover can also be removed. MCSY199L059A0796 Fig. 2-8 10. ID Plate The ID plate contains the following information: Code Nordson Engineering GmbH D 21337 Lüneburg Germany R P/N Ser. U I A f V 50/60 Hz P W Pmax W XXSY015L034A0395 Fig. 2-9 Information Description Unit Code Unit description and configuration code P/N Article number Ser. Serial number U Operating voltage Volt I Fuse rating Ampere f Frequency of line voltage Hertz P Power consumption of the unit Watt P max Maximum power consumption of the unit and connected accessories Watt 2006 Nordson Corporation
2-16 Description 2006 Nordson Corporation
Section 3 Installation 2006 Nordson Corporation
3-0 Installation 2006 Nordson Corporation
Installation 3-1 Section 3 Installation 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. Transport See Section Specifications for weight. Only use suitable methods of transport. Mount the unit to a special pallet (with rubber vibration absorbers) using angle brackets (Fig. 3-1). Pack with sturdy materials; fill the spaces between the unit and packing with suitable filling material. Protect the unit from humidity, excessive dust, impacts and vibrations. Observe additional transport instructions for units with weighing cells (see Manual Weighing Cell). MCSY204S050A0796 Fig. 3-1 Lifting (Unpacked Unit) See Section Specifications for weight. Lift at the unit frame using suitable lifting equipment or a forklift. 2. Unpacking Unpack the unit carefully and check for damage caused during transport. Save the special pallet and angle brackets for later use. Recycle packing materials or dispose of properly according to local regulations. 3. Removing Operate the unit until empty, separate all connections from the unit and allow the unit to cool down. 4. Storage Do not store the unit in the open! Protect the unit from humidity, excessive dust and great fluctuations in temperature (forming of condensation). 5. Disposal Ensure proper disposal of the unit according to local regulations. 2006 Nordson Corporation
3-2 Installation 6. Setting Up Set up the unit only in surroundings which correspond to its Degree of Protection (see Section Specifications). Do not set up in explosive surroundings! Protect the unit against vibrations. Remove transport protections (if present). Check all plug and screw connections for tightness. Leave enough free space around the unit (Fig. 3-2). MC SERIES MCSY194L059A0796 Fig. 3-2 Principle drawing 7. Overview NOTE: The overview does not replace the following description. Electrical connections Exhaust hot melt material vapors if necessary (can only escape when the tank lid is open) Mount indicator lamp Adjust drum supporting ring if necessary Install heated hose Connect condensate diverter if necessary Connect inert gas Exhaust material vapors and inert gas after automatic tank quick deaeration if necessary MCSY203L100B1198 Fig. 3-3 Principle drawing 2006 Nordson Corporation
Installation 3-3 8. Mounting Indicator Light The indicator light must be mounted to the electrical cabinet (it was removed for transport). 9. Exhausting Hot Melt Material Vapors Make sure that hot melt material vapors do not exceed the prescribed limits. Exhaust the vapors if necessary. Provide sufficient ventilation in the area where the machine is set up. Connect a hose to the tank quick deaeration and exhaust the hot melt material vapor/inert gas mixture. 10. Electrical Connections WARNING: Risk of electrical shock. Failure to observe can result in personal injury, death or equipment damage. Laying Cables Make sure that cables do not come into contact with any rotating and/or heated unit components. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! Line Voltage WARNING: The unit may only be operated with the line voltage indicated on the ID plate. NOTE: Permissible tolerances regarding the rated line voltage are +5% / 10%. NOTE: The mains connection cable must have a cross section matching the rated power consumption. See ID plate for rated current. The mains terminals are located in the electrical cabinet. See Wiring Diagram for connection allocation. Tach Generator (Accessories) The tach generator is connected at the connection socket (17, Fig. 2-5). See Wiring Diagram for connection allocation. The tach generator is available from Nordson. If it is a part of the shipment, refer also to the Manual Tach Generator. WARNING: When connecting Nordson units of the Meltex product line, the pilot voltage may not exceed 160 V DC. Failure to observe can result in damage to electronic components. NOTE: The pilot voltage produced by the tach generator must be aligned (see Control System). 2006 Nordson Corporation
3-4 Installation XS 2 Interface Serves as a connection between the unit and the customer s external devices. In special versions of the unit, the connection allocation may differ from the one described here. Refer to the Wiring Diagram for the actual connection allocation of such units. NOTE: Use only shielded cables/lines. Connect the shielding to ground according to EMC requirements. NOTE: Inductive loads (e.g. solenoid valves) connected to the unit must be equipped with a protective device (e.g. recovery diode) that deactivates the resulting induction voltage when an inductive load is turned off. Standard connection allocation XS 2 Interface (see also Wiring Diagram) Pin Function Notes Input Output Potential free 1 24 V DC 1 / 2, 5, 10, 11 factory bridged 2 Motor 1 on / off 1 / 2 factory bridged 3 Valve control 1 3 / 4 factory bridged 4 24 V DC 5 Motor 2 on / off 1 / 5 factory bridged 6 Valve control 2 6 / 7 factory bridged 7 24 V DC 8 Temperature setback External on/off 9 Not allocated 10 Release Unit (Main contactor activated) 1 / 10 factory bridged 11 Release All motors 1 / 11 factory bridged 12 External supply voltage for outputs pins 13, 14 and 32 13 Message Ready for operation Supplied by external voltage at pin 12 14 Message Collective fault Supplied by external voltage at pin 12 15 External supply voltage for output pin 16 16 Release Control unit (ES...) Supplied by external voltage at pin 15 17 Not allocated 18 Valve control 3 18 / 19 factory bridged 19 24 V DC 20 Not allocated 21 Valve control 4 21 / 22 factory bridged 22 24 V DC 23 Not allocated 24 Not allocated 25 External supply voltage for output pin 26 26 Weighing cell indication Full Supplied by external voltage at pin 25 27 External supply voltage for output pin 28 28 Weighing cell indication Fill Supplied by external voltage at pin 27 29 Weighing cell 24 V DC + 30 Weighing cell 0 V DC 31 Weighing cell Analog output 0-10 V DC 32 Indication Inert gas empty Supplied by external voltage at pin 12 2006 Nordson Corporation
Installation 3-5 11. Installing Heated Hoses WARNING: Hot! Risk of burns. Wear heat protective gloves. Connecting 1 2 3 If cold hot melt material can be found in the hose connection fitting (1) and/or hose connection (2), these components must be heated until the material softens (approx. 80 C, 176 F). 1. First connect the hose (3) electrically to the unit. For more than one hose: every hose connection fitting is allocated to a corresponding connection socket. Do not mistakenly exchange! NOTE: For units with recirculation hoses: do not mistake recirculation hoses for feed hoses. 2. Heat the unit and hose to approx. 80 C (176 F). Fig. 3-4 Principle drawing MXHH001S050A0295 3. Screw the hose onto the unit. NOTE: Close unused hose connection fittings with Nordson screw caps. Disconnecting WARNING: System and hot melt material pressurized. Relieve pressure before disconnecting heated hoses. Failure to observe can result in serious burns. Relieving Pressure 1. Set motor speed to 0 RPM; switch off motor(s). 2. Place a reservoir under the nozzle(s) of the application head/hot melt handgun. 3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger of the hot melt handgun. Repeat this procedure until no more hot melt material flows out. 4. Re use the hot melt material or dispose of properly according to local regulations. Second Open jawed Wrench Using a second open jawed wrench prevents the hose connection fitting on the unit from turning. MXHH002S033A0295 Fig. 3-5 Principle drawing 2006 Nordson Corporation
3-6 Installation 12. Pneumatisches Sicherheitsventil (Option) The pneumatic connection is made by means of a quick action screw joint located on the unit frame (one per safety valve). Hose Diameter Inner diameter Outer diameter 6 mm 8 mm Compressed Air Preparation Compressed Air Preparation Pressurization of the safety valve should only be carried out with filtered, dehydrated and unlubricated compressed air. Max. operating air pressure 130.5 psi / 0.9 MPa / 9 bar The pneumatic safety valve is equipped with a pressure relief valve which prevents a pressurization of more than 9 bar (130.5 psi) (when approx. 9 bar (130.5 psi) is exceeded, the compressed air is blown off). 13. Inert Gas Equipment See manual Inert Gas Equipment. 14. Air Dryer (Option) The compressed air filter of the air dryer must be equipped with a hose or a pipeline for diverting condensate. Connecting Hose or Pipeline Connect a hose (inside diameter 13 mm) or a pipeline (outer diameter R 1 / 8 ) to the condensate diverter. Ensure that flow of collected condensate is unrestricted. Disposing of Condensate When disposing of the condensate, the amount of dirt should be considered. Observe valid local regulations. 15. Adjusting Drum Supporting Ring See manual Tank. 2006 Nordson Corporation
Section 4 Operation 2006 Nordson Corporation
4-0 Operation 2006 Nordson Corporation
Operation 4-1 Section 4 Operation 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. Tank Empty Message An empty tank or the lowest hot melt material level is indicated by the yellow lamp on the indicator light. Risk of overfilling! Do not fill the tank until the yellow lamp is lit. 2. Filling the Tank WARNING: Hot! Risk of burns. Wera safety goggles and heat protective gloves. Hot melt material may spray out of the tank. Insert the drum or adhesive block carefully. WARNING: The tank lid MUST be closed securely with BOTH clamp levers for operation! Unlock / Lock Unlock / Lock WARNING: Before filling the tank, check every time that the inert gas supply hole and the air exhaust hole are not clogged with adhesive. The material can harden in the tank if the supply hole is clogged. The pressure in the tank can rise too high if the exhaust hole is blocked. NOTE: Close the tank hood after filling the tank. The tank hood switch activates certain functions on opening and closing of the hood (see Section Description, Tank Hood Switch). Before filling the tank, make sure the tank and hot melt material are clean and free of foreign substances. Foreign substances can damage the unit and accessories. Punch a hole in the bottom of the drum with an awl if necessary. This prevents formation of a vacuum in the drum which could hinder the hot melt material from flowing out of the drum. NOTE: Do not operate the tank until completely empty. If there is too little hot melt material in the tank, the material can overheat. This can lead to formation of hot melt residues and deposits which can cause unit malfunctions. MCSY206S050A0796 Fig. 4-1 Filling the tank 2006 Nordson Corporation
4-2 Operation 3. Setting Temperatures The setting of temperatures as well as all other functions of the Control System are described in detail in the manual Control System. NOTE: Processing temperature is also referred to in the description of the Control System as nominal value temperature. NOTE: The temperature setting is determined by the processing temperature prescribed by the hot melt material supplier. Do not exceed the maximum operating temperature of the unit or heated system components. Nordson assumes no guarantee and/or liability for damage caused by incorrect temperature settings. NOTE: Depending on the hot melt material used, the overtemperature thermostats Low melt zone and High melt zone may have to be adjusted to the max. processing temperature of the hot melt material (i.e. replaced). The switchoff value of the thermostat may not exceed the max. operating temperature of the unit! For thermostats see Section Specifications. General Values The values in the table are general values for temperature settings. Heating zone / Temperature / Time Setting Low melt zone 20 C (68 F) below prescribed processing temperature High melt zone 10 C (50 F) below prescribed processing temperature Heated jacket (Warming tank) approx. 180 C (356 F) Tank lid heating (Option) approx. 180 C (356 F) Undertemperature value 10 C (50 F) below set processing temperature Overtemperature value 10 to 30 C (50 86 F) above set processing temperature Setback temperature Setback period As required As required Application head (Accessories) Prescribed processing temperature(s) Heated hose (Accessories) Prescribed processing temperature 2006 Nordson Corporation
Operation 4-3 4. Setting Hot Melt Material Feed Quantity Setting the hot melt material feed quantity, as well as all other functions of the Control System, are described in detail in the manual Control System. Motor/Pump Speeds The motor/pump speed described here is the speed measured on the output shaft. The actual motor speed is much higher. NOTE: Avoid a permanent motor/pump speed of less than 5 RPM and more than 80 RPM to prevent excessive wear. Manual Operation The motor/pump speed corresponds to a set value and does not change. It can also not be controlled synchronous to a parent machine. Automatic Operation The motor/pump speed is controlled synchronous to parent machine speed. Parameters can be set. NOTE: Automatic operation is only possible if pilot voltage is present. NOTE: The pilot voltage must be aligned (see manual Control System). 2006 Nordson Corporation
4-4 Operation 5. Initial Startup After the unit has been properly installed, initial startup can take place. NOTE: The unit was subjected to extensive functional tests prior to shipment. In doing so, the tank was filled with a special test material. Residues of this material may still be present in the unit. To remove these residues, melt and feed several kilograms of hot melt material before starting production. NOTE: The temperature setting is determined by the processing temperature prescribed by the hot melt material supplier. Do not exceed the maximum operating temperature of the unit or heated system components. Nordson assumes no guarantee and/or liability for damage caused by incorrect temperature settings. NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, make sure the tank is filled. NOTE: Avoid a permanent motor/pump speed of less than 5 RPM and more than 80 RPM to prevent excessive wear. NOTE: The operator must make himself familiar with manual Control System before carrying out the following steps. 1. Set main switch to position I/ON. 2. Activate button Heating on. 3. Align weighing cell (see operating manual Weighing Cell and Section Description under Weighing Cell. 4. Fill the tank. 5. Close tank lid and tank hood. 6. Carry out all settings on the Control System. 7. Wait until the unit is ready for operation (green lamp is lit) 8. Pre select the motor. 9. Switch on the motor. 10. Set motor/pump speed according to the desired material amount. 2006 Nordson Corporation
Operation 4-5 6. Daily Switch ON/OFF Daily Switch ON/OFF has the same meaning as the terms starting and stopping. Daily Switch ON NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, make sure the tank is filled. NOTE: Avoid a permanent motor/pump speed of less than 5 RPM and more than 80 RPM to prevent excessive wear. 1. Set main switch to position I/ON. 2. Activate button Heating on. 3. Fill hot melt material if necessary. 4. Wait unil the unit is ready for operation. 5. Pre select motor(s). 6. Switch on the motor. Daily Switch OFF (Inert Gas also Off) 1. Switch off the motor. 2. Set main switch to position 0/OFF. 3. Secure main switch with padlocks if necessary to prevent unauthorized operation. Daily Switch OFF (Inert Gas not Off) 1. Switch off the motor. 2. Activate button Control voltage off. 7. Emergency Switch OFF WARNING: Switch off the unit immediately in any emergency situation. 1. Set main switch to 0/OFF. 2. After standstill and before switching the unit on again, have the malfunction eliminated by qualified personnel. 2006 Nordson Corporation
4-6 Operation 8. Settings Record Form Make a copy of the form before filling it out. Production information: Hot melt material: Supplier Processing temperature Viscosity Cleaning agent: Supplier Flash point Leading channel: High melt zone (factory set) Processing temperatures (nominal value temperatures): Low melt zone High melt zone Tank (Heated jacket) Tank lid heating Heated hose (Accessories) 1) 2) 3) 4) Application head (Accessories) 1) 2) 3) 4) Air heater (Accessories) 1) 2) 3) 4) Parameters on the control system T1 Heating time (tank lid heating and heated jacket) C1 Inert gas supply on (after expiration of C2 ) C2 Vacuum pump on Con Inert gas supply on (Intermittent gas supply) CoF Inert gas supply off (Intermittent gas supply) Motor/Pump speed: Motor/Pump 1) 2) Air pressure at application head (Accessories): Control air 1) 2) 3) 4) Spray air 1) 2) 3) 4) Notes: Name Date 2006 Nordson Corporation