Bulk Melters BM 200 with Piston Pump - EASY Pneumatics -

Bulk Melters BM 200 with Piston Pump - EASY Pneumatics - Manual - English - Issued 05/06 NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

Note After approx. December 2003, 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 2003. 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. 2006 All rights reserved. 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.

Table of Contents I Table of Contents Safety... 1 1 Introduction... 2 1 Intended Use... 2 1 Unintended Use - Examples -... 2 1 Area of Use... 2 2 Residual Risks... 2 2 Note on Manual... 2 3 Configuration Code... 2 4 ID Plate... 2 5 Essential Components... 2 6 Model Variations and Options... 2 7 Pressure Switch... 2 7 Exhaust Hood... 2 7 Changeover System... 2 7 High Drum Jacket for Cardboard Drums... 2 8 Divided Base Plate for Pallet Conveyance... 2 8 Button Purge Mode... 2 8 Electrical Cabinet... 2 9 Button Two hand Control and Pneumatic Switch... 2 10 Control System... 2 10 Key Switch Remote / Local and Indication Lamp Remote.. 2 10 Main Switch... 2 10 Electrical Cabinet Ventilation... 2 10 Electrical Connections... 2 11 Week Timer (Accessory)... 2 12 Door Lock... 2 12 Light Tower (Accessory)... 2 12 Heating Punch... 2 13 Melting Plates... 2 13 Functioning... 2 14 Raising and Lowering Heating Punch... 2 14 Deaerating Drum... 2 14 Aerating Drum... 2 14 Melting Process and Material Flow... 2 15 Deaeration cock... 2 15 Drive... 2 15 Heating and Temperature Control... 2 16 Undertemperature Interlock... 2 16 Overtemperature Indication / Shutdown... 2 16 Temperature Setback... 2 16

II Table of Contents Installation... 3 1 Unpacking... 3 1 Lifting (Unpacked System)... 3 1 Transport... 3 1 Storage... 3 2 Setting Up... 3 2 Removing... 3 3 Disposal... 3 3 Exhausting Material Vapors... 3 4 Electrical Connections... 3 5 Laying Cable... 3 5 Line Voltage... 3 5 Power Supply... 3 5 Hose Receptacle(s)... 3 5 Interface XS2... 3 6 Installing Heated Hoses... 3 7 Laying Hoses... 3 7 Connecting... 3 7 Disconnecting... 3 7 Relieving Pressure... 3 7 Second Open jawed Wrench... 3 7 Pneumatic Connection... 3 8 Preparing for Changeover System... 3 8 Reducing Heating Punch Lifting Speed... 3 8 Accessories... 3 9 Light Tower... 3 9 Week Timer... 3 9 Pressure Switch... 3 9 Transformer... 3 9 Operation... 4 1 Initial Startup... 4 1 Adjusting Switch Rod... 4 2 Setting Values and Parameters - Notes -... 4 3 Material Pressure / Output Quantity... 4 3 Temperatures... 4 3 Recommended Values... 4 3 Inserting and Replacing Drum... 4 4 Raising Heating Punch... 4 4 Lowering Heating Punch... 4 5 Deaerating Pump... 4 5 Switching System ON/OFF... 4 6 Daily Startup... 4 6 Daily Switchoff... 4 6 Switching Off in an Emergency... 4 6 Settings Record... 4 7

Table of Contents III Maintenance... 5 1 Risk of Burns... 5 1 Relieving Pressure... 5 1 Daily Maintenance... 5 2 Regular Maintenance... 5 3 External Cleaning... 5 4 Visual Inspection for External Damage... 5 4 Electrical Cabinet Ventilation... 5 4 Compressed Air Filter... 5 5 Draining Condensate... 5 5 Cleaning Filter Element... 5 5 Pneumatic Pressure Restrictor Valves... 5 6 Function Testing of Pressure Restrictor Valve... 5 6 Cleaning Pressure Restrictor Valve... 5 6 Changing Type of Material... 5 7 Purging with Cleaning Agent... 5 7 Cleaning Melting Plate... 5 7 Maintenance Record Form... 5 8 Troubleshooting... 6 1 Some Tips... 6 1 Troubleshooting with Control System... 6 2 Indication Lamps and Light Tower... 6 2 Troubleshooting Tables... 6 3 Repair... 7 1 General Notes... 7 1 Replacing Sealing Rings... 7 2 Replacing O rings... 7 3 Replacing Melting Plate Temperature Sensor or Thermostat... 7 4 Technical Data... 8 1 General Data... 8 1 Electrical Specifications... 8 1 Material Pressures... 8 2 Temperatures and Thermostats... 8 3 Air Consumption... 8 3 Exhaust Hood... 8 3 Dimensions... 8 4 Weight... 8 4 Processing Materials... 8 5 Lubricating Heating Punch Sealing Rings... 8 5 Inserting Thermostats and Temperature Sensors... 8 5 Lubricating O rings... 8 5 Screw Locking Device... 8 5

IV Table of Contents

Safety 1 1 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.

1 2 Safety

Introduction 2 1 Section 2 Introduction Intended Use Bulk melters of the series BM 200 with Piston Pump - hereafter also referred to as system - may only be used to melt and feed suitable materials. When in doubt, seek permission from Nordson. CAUTION: Only undamaged and suitable drums (Refer to Technical Data) may be used. CAUTION: PUR material may be processed only in models with exhaust hood and manual drum aeration valve! Any other use is considered to be unintended. Nordson will not be liable for personal injury or property damage resulting from unintended use. Intended use includes the observance of Nordson safety instructions. Nordson recommends obtaining detailed information on the materials to be used. Unintended Use - Examples - The systems may not be used under the following conditions: In defective condition With electrical cabinet door open In a potentially explosive atmosphere With unsuitable operating/processing materials When safety valves and pressure restrictor valves are not lead sealed When the values stated under Technical Data are not complied with. The systems may not be used to process the following materials: Explosive and flammable materials Erosive and corrosive materials Food products.

2 2 Introduction Area of Use The system is designed for use in industrial areas. When using in industrial areas and in small businesses, the system may cause interference in other electrical units, e.g. radios. Residual Risks In the design of the unit, every measure was taken to protect personnel from potential danger. However, some residual risks can not be avoided. Personnel should be aware of the following: Risk of burns from hot material Risk of burns from hot system components Risk of burns when conducting maintenance and repair work for which the system must be heated up Risk of burns when attaching and removing heated hoses Material fumes can be hazardous. Avoid inhalation Pinching parts of the body between heating punch and drum.

Introduction 2 3 Note on Manual This manual applies to models with PLC controlled pneumatics (after approx. December 2003) This manual is valid only in conjunction with all documents included in the complete set of documentation (blue binder) When the system has special features, customer specifications and/or supplements or a higher ranking system description may be added to this manual The position numbers in the illustrations do not correspond to the position numbers in the technical drawings and parts lists. Refer to separate document Parts List for details.

2 4 Introduction Configuration Code The configuration code is engraved on the ID plate. NOTE: An X indicates that the function or component was not ordered, meaning that it is unavailable. An S indicates that the model deviates from the configuration code. Such deviations are described in a supplement or a system description. Equipment Box Code Key 1 BM200 Series or unit designation 2 Melting plate Drum aeration valve Exhaust hood A Axial Automatic No B Axial Automatic Yes R Axial Manual No C Axial Manual Yes F Fine blade Automatic No P Fine blade Manual No G Smooth Automatic Yes U Smooth Manual Yes 3 3 Operating voltage 400VAC, 3 Ph Y 4 400VAC, 3 Ph, Delta 5 480VAC, 3 Ph, Delta 4 K Hose connection 16 mm ( 5 / 8 in) installed 8 mm ( 5 / 16 in) included M 20 mm ( 3 / 4 in) L 32 mm (1 1 / 4 in) 5 11 Pump type Gear, PR 6m1 12 Gear, PR 12m1 13 Gear, PR 12m2 14 Gear, PR 25m2 50 Gear, PU 15/85 51 Gear, PU 25/85 52 Gear, PU 35/85 53 Gear, PU 50/85 41 Piston pump, 42:1 42 Piston pump, 24:1 6 L Overtemperature 150 C / 300 F M thermostat 176 C / 350 F H 230 C / 450 F 7 1 Number of hose 1 2 connections 2 Continued...

Introduction 2 5 Options Box Code Key 9 D Pressure controlled 10 P Profibus interface 11 6 Six additional heating channels (three additional receptacles) 12 J High drum jacket (for cardboard drums) 13 W Divided base plate (for pallet conveyance) 14 S Special NOTE: Models with a gear pump are not described in this manual. CAUTION: PUR material may be processed only in models with exhaust hood and manual drum aeration valve! ID Plate BM 3 1 2 ADHESIVE MELTER 4 Serial No: 5 Year Nordson Engineering GmbH Lilienthalstr. 6 D 21337 Lüneburg - Germany www.nordson.com Fig. 2 1 1 Melter designation 2 Order number 3 Configuration code 4 Electrical connection, operating voltage, line voltage frequency, melter fuse protection 5 Serial number

2 6 Introduction Essential Components Components - when they are relevant to installation, operation and maintenance - are described in the appropriate sections of this manual or in separate manuals. 15 14 13 12 1 2 3 4 11 5 6 7 8 9 10 Fig. 2 2 1 Main pressure controller 2 Hose holder 3 Drive (Air motor with piston pump*) 4 Deaeration cock for piston pump 5 Hose connection 6 Drum deaeration valve 7 Drip pan 8 Sensor Drum inserted (mounted on base plate) 9 Drum clamp 10 Heating punch 11 Automatic drum aeration valve mounted on heating punch or Manual drum aeration valve mounted on cross beam Note: There are separate manuals available for components marked with an asterisk (*). 12 Pressure controller with lubricator (for drive) 13 Electrical cabinet 14 Switch rod 15 Hose receptacle

Introduction 2 7 Model Variations and Options Pressure Switch If the material pressure exceeds the threshold value, the pressure switch stops the pump drive by relieving pressure of the air motor via a solenoid valve. Refer to ID plate of the pressure switch for threshold value. NOTE: The pressure switch is mounted onto the deaeration cock of the pump. Exhaust Hood If the bulk melter is used to process polyurethane hot melt adhesives (PUR), fumes are created that should be suctioned off directly at the drum. An exhaust hood is integrated into the bulk melter for this purpose. The exhaust hood must be connected to the customer's exhaust device (Also refer to Installation, Exhausting Material Vapors). Changeover System The changeover system allows uninterrupted operation of two bulk melters. One of the systems is active (feeding material), and the other is in standby mode (system switched on, heating punch heater not yet on). If a drum is almost empty (in this case, in the system on the right), the heating punch heater of the other system is automatically switched on. Now the empty drum can be replaced while the other system is feeding material. Refer to separate manual. Fig. 2 3 Principle drawing

2 8 Introduction High Drum Jacket for Cardboard Drums CAUTION: Do not use metal drums with this model! The drum jacket is designed only for cardboard drums! NOTE: Models for cardboard drums have only the lower sealing ring on the heating punch (configuration code: box 12 = J). Divided Base Plate for Pallet Conveyance The bulk melter is set up on a divided base plate. This enables a drum to be moved under the punch on a pallet. CAUTION: Risk of damage! Do not operate equipment until it is screwed securely to the floor. Otherwise the descending punch would lift the system off of the floor. Button Purge Mode Some special models have a button for Purge mode on the electrical cabinet (usually on the back) The pump drive is activated as long as the button is pressed (prerequisites: System ready and Heating punch in drum).

Introduction 2 9 Electrical Cabinet 9 10 1 2 1 3 4 5 11 12 6 7 8 Fig. 2 4 1 Button Two hand control 2 Pneumatic switch 3 Control system* 4 Indication lamp Remote (only with option Profibus) 5 Key switch Remote / local (only with option Profibus) 6 Main switch 7 Electrical cabinet ventilation 8 Base Note: There are separate manuals available for components marked with an asterisk (*). 9 Light tower 10 Electrical connections 11 Door lock 12 Week timer* (accessory)

2 10 Introduction Button Two hand Control and Pneumatic Switch Used to manually control the heating punch when the drum is being changed. WARNING: The two hand control may only be operated by one person using both hands! The pneumatic switch lights up green when the drum is inserted. Control System On the control system, values and parameters are set, and operating modes and faults are displayed. Refer to manual for the Control System used. Key Switch Remote / Local and Indication Lamp Remote When set to Remote, the system is not controlled by the internal control system but via the interface Profibus (Option). Main Switch The main switch is used to switch the system on and off. Position 0/OFF = System is switched off. Position I/ON = System is switched on. Padlocks can be used to protect the main switch from unauthorized access. Black Main Switch (Special Model) Systems with a black main switch are normally supplied with power by a higher ranking system; the higher ranking main switch is on that system. The black main switch does not perform the EMERGENCY OFF function. Connected components can still be switched on! Electrical Cabinet Ventilation Air Filter / Fan with Filter Electrical cabinet ventilation reduces the temperature inside of the electrical cabinet. It must be serviced regularly. Refer to Maintenance.

Introduction 2 11 Electrical Connections Also refer to section Installation and to the wiring diagram. 1 2 4 Fig. 2 5 1 Additional receptacles (with option Additional temperature channels) 2 Interface Profibus (Option) 3-4 Interface XS2 Additional Receptacles Depending on the model, up to three additional receptacles are available. Two heating zones (usually for hose and application head) can be controlled via each receptacle. NOTE: The hose receptacles on the terminal box (Pos. 15, Abb. 2 2) are for hoses that are connected to the heating punch of the bulk melter. Interface PROFIBUS (Option) The PROFIBUS interface enables Remote operation by a higher ranking control unit. Refer to separate manual. Interface XS2 Serves as a connection between the system and external devices.

2 12 Introduction Week Timer (Accessory) The week timer is used to automatically switch the system on and off. The main switch must be set to I/ON (switched on) when using the week timer. Refer to separate manual. Door Lock The electrical cabinet can be opened for installation, maintenance and repair. Store the included key such that it is accessible only to qualified and authorized personnel. The system may not be operated when the electrical cabinet is open. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from the line voltage. Light Tower (Accessory) The light tower shows the system operating modes. Refer to section Troubleshooting and manual Control System. White Green Yellow Red Switched on Ready for operation Drum almost empty (flashing light) and drum empty (light on) Collective fault

Introduction 2 13 Heating Punch The heating punch consists of the heating plate, the melting plate and sealing rings. NOTE: Models for cardboard drums have only the lower sealing ring on the heating punch (configuration code: box 12 = J). 1 2 3 Fig. 2 6 1 Heating plate 2 Sealing rings 3 Melting plate (if present) Melting Plates Depending on what the bulk melter is used for, one of these melting plates is used. The melting plates are all release coated. Smooth melting plate Fine blade melting plate Axial melting plate Fig. 2 7

2 14 Introduction Functioning Raising and Lowering Heating Punch A pneumatic cylinder controls raising and lowering of the heating punch. When lowering the heating punch, a two hand control must be operated for safety reasons until the heating punch is in the drum. The air pressure in the pneumatic cylinders is limited to 7.5 bar (0.75 MPa / 109 psi) by a pressure restrictor valve. Deaerating Drum The drum deaeration valve must be opened manually so that air can escape (drum is deaerated) when the heating punch is lowered into the drum. Aerating Drum Air must be introduced into the drum (drum is aerated) to prevent a vacuum from forming when the heating punch is raised. Depending on the model, this is done with an automatic drum aeration valve or must be prepared manually by screwing in an aeration pipe. The air pressure in the drum is limited to 1 bar (0.1 MPA / 14.5 psi) by a pressure restrictor valve. Air Heating punch Heating punch Compressed air Drum Drum Fig. 2 8 Deaerating Aerating

Introduction 2 15 Melting Process and Material Flow 1 2 The material is melted only directly below the melting plate (4). A piston pump (3) conveys the melted material to the hose connection (2). From there it flows through a heated hose (1) to either an application head or an assembly handgun. 5 3 Deaeration cock The deaeration cock (5) is used to deaerate the pomp upon intial startup and every time the drum is being replaced. 4 Drive 1 2 3 An air motor (2) which is controlled by its own pressure controller (1, with lubricator) drives the piston pump (3). Control pressure (P) and transmission ratio of the piston pump determine the material pressure and thus the output quatity: [bar] [MPa] [psi] P 24:1 42:1 P 24:1 42:1 P 24:1 42:1 1 24 42 0,1 2,4 4,2 14,5 348 609 3 72 126 0,3 7,2 12,6 43,5 1044 1827 6 144 252 0,6 14,4 25,2 87 2088 3654 WARNING: Ensure that the subsequent system components are designed to accommodate the material pressure!

2 16 Introduction Heating and Temperature Control The heating punch is heated by cast in heating element, the pump is heated by heating bands. Temperatures are measured by sensors and electronically controlled. Undertemperature Interlock The undertemperature interlock prevents the unit or system from being started up when the material is still too cold until the temperature setpoint minus undertemperature value has been exceeded. However, every time initial heating occurs, the interlock is not released until the actual temperature is 3 C (5.4 F) below the temperature setpoint. The undertemperature interlock locks the motors, solenoid valves and, in some cases, other components of the application system. Refer to the wiring diagram to determine which components are locked. Overtemperature Indication / Shutdown The independently operating overtemperature shutdown mechanisms protect the system and the material 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: When the temperature setpoint plus overtemperature value has been reached, the relay output Collective fault is switched and the red indication lamp Collective fault lights. The system remains ready for operation. Overtemperature shutdown by temperature controller: The overtemperature shutdown value is set automatically 30 C (54 F) higher than the highest temperature setpoint value. Overtemperature shutdown by thermostat(s): Serves as an emergency switch OFF in case the overtemperature shutdown of the temperature controller does not function properly. Refer to section Technical Data for shutdown value. WARNING: When the overtemperature shutdown is triggered, there is either a fault in settings or system malfunction. Switch off the system and have the fault remedied by qualified personnel. Temperature Setback Serves to protect the material and save energy during interruptions in production or work stoppages. Setback value and setback period are adjustable.

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. Unpacking Unpack carefully and check for damage caused during transport. Save pallet and fastening and packing material for later use, or dispose of properly according to local regulations. Lifting (Unpacked System) Refer to Technical Data for weight. Lift only with a suitable floor conveyor (lift truck or fork lift). Transport For systems with divided base plate: CAUTION: Risk of damage! Do not move system without attaching transport protection to the base plate. Refer to Technical Data for weight. Use only suitable transport devices. If possible, use the pallet on which the system was delivered, and fasten the system to the pallet. Protect from damage, moisture and dust with suitable packing material. Avoid jolts and vibrations.

3 2 Installation Storage Do not store system outside! Protect from humidity, dust and extreme temperature fluctuations (formation of condensation). Setting Up For systems with divided base plate: CAUTION: Risk of damage! Do not operate equipment until it is screwed securely to the floor. Otherwise the descending punch would lift the system off of the floor. Set up only in an environment that corresponds to the stated Degree of Protection (Refer to Technical Data). Do not set up in a potentially explosive atmosphere! Protect from vibration. Remove transport protection (if present). Ensure that there is sufficient free space around the system, especially above it. Refer to Technical Data for dimensions. Fig. 3 1

Installation 3 3 Removing 1. Convey all material out of system and remove drum. 2. When system will not be used for longer periods of time, purge with cleaning agent if necessary (Refer to Maintenance). 3. Wipe off sealing ring and clean melting plate (Refer to Maintenance). 4. Disconnect all lines to the system, and allow system to cool. Disposal When your Nordson product has exhausted its purpose and/or is no longer needed, dispose of it properly according to local regulations.

3 4 Installation Exhausting Material Vapors Ensure that material vapors do not exceed the prescribed limits. Always observe the safety data sheet (MSDS) for the material to be processed. If necessary, exhaust material vapors and/or provide sufficient ventilation of the location of the system. On systems with exhaust hoods, material vapors are suctioned directly at the drum. NOTE: The exhaust hood must be connected to the customer's exhaust device. Refer to Technical Data. Customer's Fig. 3 2 System without exhaust hood System with integrated exhaust hood

Installation 3 5 Electrical Connections WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Laying Cable WARNING: Use only temperature resistant cable in the heating part of the system. Ensure that cables do not touch rotating and/or hot parts. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! Line Voltage WARNING: Operate only with the line voltage stated on the ID plate. NOTE: Permitted deviation from the rated line voltage is +5% / 10%. NOTE: The power connection cable must have a cross section matching the power consumption P max. (Refer to ID Plate). Power Supply The mains terminals are located in the electrical cabinet. Refer to Wiring Diagram for connecting arrangement. Hose Receptacle(s) For electrical connection values, refer to Technical Data.

3 6 Installation Interface XS2 The interface serves as a connection between the system and external devices. The functions are described in detail in the manual Control System CS 20 for Bulk Melters, section Central Module with Digital Input/Output. NOTE: It is essential to bridge Pin 9 with Pin 1 (24 V DC ) before initial startup. Also refer to plug connection diagram Interface XS2 for BM 20 (wiring diagram). NOTE: To conform with a European standard regarding electro magnetic compatibility, only shielded cable may be connected. The shield must be connected to ground in compliance with the standard (PE connection in plug connector). NOTE: Inductive loads (e.g. solenoid valves) connected to the system must be equipped with a protective device (e.g. recovery diode) that disables the inductive voltage generated when an inductive load is switched off. Pin Input Output Function 1 24 V DC Internal switching voltage for activating inputs 2, 3, 4, 5, 7 and 9. The switching voltage must be connected to the appropriate input. 2 24 V DC Unit release (main contactor) 3 24 V DC Release Drives 4 24 V DC Switch on/off Temperature setback 5 24 V DC Release Motor for application 1 6 - Not assigned 7 24 V DC Release Motor for application 2 (no automatic speed change of piston lifting) 8 Not assigned 9 Internal link 10 Internal link 11 Not assigned 12 Internal link 13 16 Not assigned 17 24 V DC external External potential for outputs 18, 19, 20, 21, 24 and 26 24 V DC +/ 10 % 18 24 V DC, max. 2 A Indication Ready for operation 19 24 V DC, max. 2 A Indication Collective fault 20 24 V DC, max. 2 A Indication Drum almost empty 21 24 V DC, max. 2 A Indication Drum empty 22 Internal link 23 Not assigned 24 24 V DC, max. 2 A Valve control application 1 25 Not assigned 26 24 V DC, max. 2 A Valve control application 2 27 32 Not assigned PE Shield NOTE: Refer to Wiring Diagram for electrical connection.

Installation 3 7 Installing Heated Hoses WARNING: Hot! Risk of burns. Wear heat protective gloves. Laying Hoses Guide hose through the hose guide. The hose connection is in the piston pump. Connecting 1 2 3 If cold material can be found in the hose connection (1) and/or hose fitting (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 is allocated to a corresponding receptacle. Do not mistakenly exchange! 2. Heat the system and hose to approx. 80 C (176 F). 3. Screw the heated hose onto the unit. NOTE: Close unused hose connections with Nordson port plugs. Disconnecting WARNING: System and material pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. Relieving Pressure 1. Use the pressure controller (12, Fig. 2 2) to set the pump stroke frequency to 0. 2. Place a container under the nozzle(s) of the application head/assembly handgun. 3. Activate the application head / assembly handgun electrically or manually. Repeat this procedure until no more material flows out. 4. Re use the material or dispose of properly according to local regulations. Second Open jawed Wrench Use a second open jawed wrench when connecting and disconnecting the heated hose. This prevents the unit's hose connection from turning.

3 8 Installation Pneumatic Connection 1 Connect dry, clean and non lubricated compressed air (2). Set air pressure for pneumatic cylinder to approx. 5 bar (0.5 MPa / 72.5 psi) on the pressure controller (1). The setting can be modified according to the material processed (max. 7.5 bar / 0.75 Mpa / 109 psi). The air pressure in the pneumatic cylinders is limited to 7.5 bar (0.75 MPa / 109 psi) by a pressure restrictor valve. NOTE: The control pressure for the air motor is set on the customer's pressure controller. 2 Preparing for Changeover System The DIP switches S 8.1 and S 8.2 of the CS 20 control system's temperature control panel board must be set to OFF (no leading channel) in changeover systems. Refer to separate manual for control system. Reducing Heating Punch Lifting Speed 1 2 NOTE: The lifting speed need only be reduced if the heating punch often lifts the drum as it moves up. 1. Remove protective plate (1) from pneumatics. 2. Turn throttle screw (2) clockwise slightly with a screwdriver. The correct setting must be determined by trial and error. 3. Attach protective plate again.

Installation 3 9 Accessories The following components can also be installed later as accessories: Light Tower The light tower must be screwed onto the electrical cabinet. It must be connected to terminal XLWT according to the Wiring Diagram. Week Timer The week timer must be installed in the electrical cabinet. To do this, remove clamp XLWZ and install the week timer in its place. Wire according to Wiring Diagram. Pressure Switch The deaeration cock of the piston pump is threaded for screwing in a pressure switch. Transformer Systems designed for operating voltage of 400VAC, 3 Ph Y can be operated at 200 or 240 VAC with the transformer.

3 10 Installation

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. Initial Startup NOTE: Some of the following tasks are described in detail in the subsequent text. 1. Ensure that the switch rod is set to the drum height. 2. Ensure that lubricator and oil reservoir are filled (refer to manual Air motor with piston pump). 3. Set pneumatic switch to 0. 4. Set main switch to I/ON. 5. Control system: Set values and parameters. 6. Set week timer, if present. 7. Insert drum. 8. Set pressure controller for air motor according to desired output quantity. 9. Deaerate pump. 10. Optimize settings and record in settings record form. NOTE: All system functions were tested before the system left the factory. Special test material was used. There may be residue from this material on the melting plate, in the pump, etc. To remove such residue, melt and feed several kilograms of material before starting production.

4 2 Operation Adjusting Switch Rod 1 2 3 4 Set the switch rod (2) such that it activates switch 4 when the sealing ring (3) is completely submerged in the drum. To do this, release hexagonal socket screw (1). NOTE: Models for cardboard drums have only the lower sealing ring on the heating punch (configuration code: box 12 = J). Setting the switch rod adjusts the system to the drum height used. The switch rod activates the switches (4, 5 and 6) one after the other and thus triggers the following switching functions: 5 6 Switching Functions when Lowering Switches from two hand lowering mode to normal lowering mode when the sealing ring (3) is completely submerged in the drum (switch 4). Triggers the drum almost empty indication (switch 5). Triggers the drum empty indication (switch 6). Switching Functions when Raising Switches off the automatic drum aeration (switch 4).

Operation 4 3 Setting Values and Parameters - Notes - Many values and parameters are set at the control system. For additional information, refer to control system used. Material Pressure / Output Quantity An air motor (2) which is controlled by its own pressure controller (1, with lubricator) drives the piston pump (3). Control pressure (P) and transmission ratio of the piston pump determine the material pressure and thus the output quatity: [bar] [MPa] [psi] P 24:1 42:1 P 24:1 42:1 P 24:1 42:1 1 24 42 0,1 2,4 4,2 14,5 348 609 1 2 3 3 72 126 0,3 7,2 12,6 43,5 1044 1827 6 144 252 0,6 14,4 25,2 87 2088 3654 WARNING: Ensure that the subsequent system components are designed to accommodate the material pressure! Temperatures CAUTION: The temperature setting is determined by the processing temperature prescribed by the adhesive supplier. The maximum operating temperature for the product and heated components described here may not be exceeded. Nordson will grant no warranty and assume no liability for damage resulting from incorrect temperature settings. Recommended Values The values stated in the tables are general values determined by experience; deviation may prove necessary. Heating zone / temperature / time Setting Heating punch, pump 10 C (18 F) below prescribed processing temperature Undertemperature value 10 C (18 F) (deviation from setpoint) Overtemperature value 10 to 30 C (18 to 54 F) (deviation from setpoint) Temperature setback value (standby) As needed Setback period As needed Application head (accessory) Prescribed processing temperature Heated hose (accessory) Prescribed processing temperature

4 4 Operation Inserting and Replacing Drum CAUTION: Place only undamaged, suitable drums in the system; otherwise the heating punch sealing ring will be damaged. Always keep the base plate of the system clean so that the drum is positioned straight. WARNING: Risk of burns! Hot material can splash out when the heating punch exits the drum. Hot material may flow out of the deaeration valve. Wear suitable protective clothing! NOTE: Some of the following tasks are described in detail in the subsequent text. 1. Raise heating punch. 2. Set pneumatic switch to 0/Stop. 3. Insert or replace drum. The pneumatic switch lights up green when the drum is inserted. 4. Lubricate sealing ring. Refer to Processing Materials in the section Technical Data. 5. Lower heating punch. 6. Deaerate pump. 7. Properly dispose of empty drum according to local regulations. Raising Heating Punch a b c 1 2 3 If the heating punch is inside of the drum, the drum must be aerated to support raising. Aerating means that compressed air is forced under the heating punch. 1. Aeration must be done manually for models without automatic aeration valve: a. Screw out rod with star grip (1). b. In place of the rod, screw in the aeration pipe (2, stored in the holder on the electrical cabinet). c. Attach aeration connection (3, stored on the cross beam) to aeration pipe. 2. Set pneumatic switch to Raise. Automatic drum aeration begins when the pneumatic switch is moved to Raise and ceases when the punch leaves the drum. In case the heating punch lifts the drum: Quick fix: Set pneumatic switch to 0 and press two hand control to increase air pressure in drum. Long term solution: Reduce heating punch lifting speed (Refer to Installation). The air pressure in the drum is limited to 1 bar (0.1 MPA / 14.5 psi) by a pressure restrictor valve.

Operation 4 5 Lowering Heating Punch 1 2 The drum must always be deaerated when the heating punch is moved into the drum. When the drum is deaerated, the air that is under the heating punch escapes. 1. Set pneumatic switch to Lower. 2. Place the drip pan (2) in front of the deaearation valve (1). 3. Open deaeration valve (1): Screw out rod with star grip. 4. Press both buttons on the two hand control at the same time (within 0.5 seconds) until the heating punch is inside of the drum. The downward movement continues on its own. 5. Close deaeration valve when material flows out free of bubbles. 6. Deaerating pump. 7. Properly dispose of material according to local regulations. Deaerating Pump 1 2 The piston pump must be deaerated upon initial startup and every time the drum is changed. It is equipped with a deaeration cock for this purpose. 1. Place reservoir (2) under deaeration cock (1). The deaeration valve is located on the back of the piston pump. 2. Open deaeration cock (1). 3. Set motor/pump to medium output quantity, then switch on. NOTE: Do do this, some models use a Purge button which is located on the side or the back of the electrical cabinet. 4. Wait until material flows out free of air. 5. Close deaeration cock (1). 6. Properly dispose of material according to local regulations.

4 6 Operation Switching System ON/OFF NOTE: Before initial startup, read and observe the instructions in Initial Startup. Start up only as described under Initial Startup. NOTE: The main switch must be set to I/ON (switched on) when using the week timer (accessory). Additional information on the week timer can be found in the manual Week Timer. NOTE: When external system release via interface XS2 is used, the main switch must be set to I/ON (switched on). Daily Startup 1. Set main switch to I/ON. 2. Set pneumatic switch to Lower. 3. Wait until system is ready. 4. Switch on motor. Daily Switchoff 1. Set main switch to 0/OFF and protect from unauthorized access with padlocks if necessary. 2. Set pneumatic switch to Stop. 3. Perform daily maintenance. Switching Off in an Emergency WARNING: Immediately switch off the system in any emergency situation. 1. Set main switch to 0/OFF or - when available - press EMERGENCY OFF button (special feature). 2. Set pneumatic switch to 0/Stop. 3. After standstill and before switching the system back on, have the fault remedied by qualified personnel. Black Main Switch (Special Model) Systems with a black main switch are normally supplied with power by a higher ranking system; the higher ranking main switch is on that system. The black main switch does not perform the EMERGENCY OFF function. Connected components can still be switched on!

Operation 4 7 Settings Record Production information: Application material Cleaning agent: Leading channel: Manufacturer Processing temperature Viscosity Manufacturer Flash point Factory set Processing temperatures (Setpoint temperatures): Heating punch Heated hose (accessory) 1) 2) 3) 4) Application head (accessory) 1) 2) 3) 4) Air pressure: bar MPa psi Operating pressure Air motor Notes: Name Date

4 8 Operation

Maintenance 5 1 Section 5 Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. NOTE: Maintenance is an important preventive measure for maintaining operating safety and extending the lifetime of the unit. It should not be neglected under any circumstances. Risk of Burns WARNING: Hot! Risk of burns. Wear appropriate protective clothing/equipment. Some maintenance work can only be done when the system is heated up. Relieving Pressure WARNING: System and material pressurized. Relieve system of pressure before disconnecting heated hoses, application heads and assembly handguns. Failure to observe can result in serious burns. 1. Use the pressure controller (12, Fig. 2 2) to set the pump stroke frequency to 0. 2. Place a container under the nozzle(s) of the application head/assembly handgun. 3. Activate the application head / assembly handgun electrically or manually. Repeat this procedure until no more material flows out. 4. Re use the material or dispose of properly according to local regulations.

5 2 Maintenance Daily Maintenance The maintenance intervals are general guidelines based on experience. Depending on the location of the system, production conditions and operating time of the system, other maintenance intervals may prove necessary. Unit part Activity Interval Refer to Entire system External cleaning Daily Page 5 3 Inspect for external damage Page 5 4 Power cable Inspect for damage - Air hoses Inspect for damage - Displays and lamps Function check (test) Manual Control System Electrical cabinet ventilation Melting plate Sensor Drum inserted Base plate Lubricator Oil reservoir Clean fan screens, clean or replace filter Check melting plate for charred material, clean if necessary Check sensor for material residue or other impurities, clean if necessary Check base plate for material residue or other impurities, clean if necessary Check oil level; add oil if necessary (Refer to Processing Materials in section Technical Data) Check oil level; add oil if necessary (Refer to Processing Materials in section Technical Data) Daily, if dust accumulation is severe Every time the drum is changed Page 5 4 Page 5 7 Section Description Daily - Daily - Manual Air Motor with Piston Pump

Maintenance 5 3 Regular Maintenance The maintenance intervals are general guidelines based on experience. Depending on the location of the system, production conditions and operating time of the system, other maintenance intervals may prove necessary. Unit part Activity Interval Refer to Compressed air filter Drain condensate Weekly Page 5 5 Clean filter element Every three months Pneumatic pressure restrictor valve Air motor Piston pump Clean condensate collector When cleaning filter element Function test Every six months Page 5 6 Cleaning When not functioning correctly Refer to separate manual

5 4 Maintenance External Cleaning External cleaning prevents pollution created by production from causing system malfunctions. CAUTION: Observe the unit's Degree of Protection when cleaning (Refer to section Technical Data). CAUTION: Do not damage or remove warning signs. Damaged or removed warning signs must be replaced by new ones. Remove material residue only with a cleaning agent recommended by the material supplier. Heat with an air heater if necessary. Remove dust, flakes etc. with a vacuum cleaner or a soft cloth. Visual Inspection for External Damage WARNING: When damaged parts endanger the operating safety and/or the safety of personnel, switch off the system and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. Electrical Cabinet Ventilation ÂÂÂ ÂÂÂ ÂÂÂ ÂÂÂ The electrical cabinet fans require no maintenance. The filters must be cleaned or replaced, depending on dust accumulation. A dirty filter can be recognized by its dark color. It is cleaned by shaking the filter out.

Maintenance 5 5 Compressed Air Filter The compressed air filter dehydrates and cleans the compressed air. Draining Condensate Drain condensate before it reaches a level approx. 10 mm below the filter disk. To do this, open the condensate drain valve (7). 10 mm 7 Cleaning Filter Element 1 2 3 4 5 Under normal conditions, clean filter element (5) approx. every three months. Clean sooner if compressed air filter outlet pressure falls. 1. Stop compressed air supply and release residual pressure by opening the condensate drain valve (7). 2. Unscrew condensate collector (6). 3. Unscrew filter element (5) by turning to the left. 4. Rinse filter element (5) with suitable cleaning agent. Then blow out from the inside. The condensate collector (6) may not come into contact with the cleaning agent! 5. Clean condensate collector (6) if necessary. Use only water! 6. Reassemble compressed air filter. 6 7

5 6 Maintenance Pneumatic Pressure Restrictor Valves 1 The factory set, lead sealed pressure restrictor valves prevent unpermissibly high pressurization of subsequent pneumatic components. When the values set at the factory are exceeded, the compressed air is audibly discharged. NOTE: There are pressure restrictor valves on the drum aeration valve (11, Fig. 2 2) in the pneumatic box (1). Function Testing of Pressure Restrictor Valve Functioning of the pressure restrictor valve should be checked approx. every six months. Do this by turning the knurled screw until the compressed air is audibly released. When functioning is not correct, the pressure restrictor valve should be cleaned. If it is still not working as it should, it must be replaced. NOTE: A defective pressure restrictor valve may be replaced only with an original spare valve. Repairs to the pressure restrictor valve may be made only by the manufacturer! Cleaning Pressure Restrictor Valve Pollution that has penetrated seat surfaces and conical nipples can be removed by unscrewing the entire top piece - without changing the minimum operating pressure. Use a sickle wrench to unscrew. ÂÂ Function test Unscrewing top Fig. 5 3 Note: The illustration shows the old model with locking wire instead of a lead sealing disk.

Maintenance 5 7 Changing Type of Material CAUTION: PUR material may be processed only in models with exhaust hood and manual drum aeration valve! NOTE: Before changing the material type, determine whether the old and new material can be mixed. May be mixed: Remaining old material can be flushed out using the new material. May not be mixed: Purge thoroughly and clean melting plate with a cleaning agent recommended by the material manufacturer (Refer to Cleaning Melting Plate). NOTE: Properly dispose of the old material according to local regulations. Purging with Cleaning Agent CAUTION: Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. Before starting production again, flush out residue of the cleaning agent using the new material. NOTE: Properly dispose of cleaning agent according to local regulations. Cleaning Melting Plate The melting plate is standardly release coated. This makes it easy to clean. Cooled material can usually be pulled off of the melting plate; if necessary, first heat to 60 C / 140 F. CAUTION: Do not use hard or metallic tools to clean. Do not use wire brushes! This could damage the release coating. Use only soft aids (wooden or PTFE spatula or soft brush).

5 8 Maintenance Maintenance Record Form Unit part Date / name Date / name Date / name Electrical cabinet ventilation Compressed air filter Pneumatic pressure restrictor valve Air motor Piston pump

Troubleshooting 6 1 Section 6 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. WARNING: Troubleshooting activities may sometimes have to be carried out when the system is energized. Observe all safety instructions and regulations concerning energized unit components (active parts). Failure to observe may result in an electric shock. Some Tips Before systematic troubleshooting is begun, the following should be checked: Are all parameters set correctly? Is the XS 2 interface connected correctly? Do all plug connections have sufficient contact? Have circuit breakers/fuses been activated? Could the fault have been caused by an external PLC? Are external, inductive loads (e.g. solenoid valves) equipped with recovery diodes? The recovery diodes must be directly allocated to the inductive load, e.g. through luminous sealings.

6 2 Troubleshooting Troubleshooting with Control System The control system offers the following troubleshooting aids, described in the manual Control System: Indication lamps and light tower Diagnosis program in the temperature section Automatic fault display in the temperature section LEDs on the modules and boards. Indication Lamps and Light Tower With the exception of the yellow light on the light tower, the indication lamps and the light tower indicate the same modes as the control system: Red = Collective fault. The red lamp indicates that the control system has recognized a fault. White = Switched ON. After switching on and during the heatup phase, at first only the white indication lamp is lit (normal condition). A fault has only occurred when the temperature does not increase (observe temperature display) and when the green indication lamp is not lit after the heatup phase has ended (1 hour and longer). Green = Ready for operation. The green indication lamp lights when all channels have reached their setpoint temperatures. Yellow = Lower tank level, as set by customer. 17 Red 1 2 3 4 5 6 7 8 9 10 11 12 18 White 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 2 3 3 4 4 1 2 M1 min-1 bar psi C F 19 Green Fig. 6 4 (Refer to manual Control System for position numbers)

Troubleshooting 6 3 Troubleshooting Tables The troubleshooting tables serve as an orientation for qualified personnel. They cannot, however, replace targeted fault location with the help of wiring diagrams and measuring instruments. They also do not include all possible problems, only those which most typically occur. Problem Possible Cause Corrective Action System has no Main switch is set to 0 Set main switch to 1 electrical function Fuses are defective Check fuses in electrical cabinet No line voltage supplied Check whether there is line voltage at the line voltage terminals in the electrical cabinet Week timer programmed incorrectly Program differently System has no There is no compressed air Connect compressed air pneumatic Pressure controller set incorrectly Set pressure controller to max. 7.5 bar function (0.75 MPa / 109 psi). System does not reach Ready Only the white indication lamp is lit Temperatures not set correctly on temperature controller Fuses for individual channels defective Temperature setback switched on Automatic temperature setback after motor standstill activated Channel is switched off Channel is switched to measuring mode Channel/Heating zone defective Check temperature settings for all channels Check fuses for individual channels Switch off or wait until the setback period has expired Stop temperature setback Switch on Switch to control mode Activate diagnosis program of the temperature section Continued...