===== CONTENTS ===== CHAPTER 1 SAFETY SUMMARY 1-1 INTRODUCTION 3 1-2 SAFETY DURING INSTALLATION 3 1-3 SAFETY DURING OPERATION 3 1-4 PRECAUTIONS DURING OPERATION 4 1-5 SAFETY DURING MAINTENANCE 4 1-6 SAFETY WHEN USING ADHESIVE AND SOLVENT 5 CHAPTER 2 MACHINE FAMILIARIZATION 2-1 INTRODUCTION 6 2-2 SPECIFICATION 7 2-3 FUNCTIONS 7 CHAPTER 3 UNPACKING AND INSTALLATION 3-1 INTRODUCTION 9 3-2 UNPACKING AND INSTALLATION 9 3-3 MACHINE INSPECTION 9 3-4 INSTALLATION OF ROLLER COATER 9 3-5 INSTALLATION OF POWER 10 CHAPTER 4 OPERATION INSTRUCTION 4-1 INTRODUCTION 11 4-2 SAFE PRECAUTIONS 11 4-3 INSTRUCTION OF CONTROL PANEL 11 4-4 PREPARATIONS BEFORE OPERATION 13 4-5 NORMAL OPERATION PROCEDURE 14 4-5-1 PROCEDURE OF TURNING ON MACHINE 14 4-5-2 PROCEDURE OF TURNING OFF MACHINE 14 4-6 ADJUSTMENT 14 CHAPTER 5 TROUBLESHOOTING 5-1 TROUBLESHOOTING WHEN OPERATION 16 CHAPTER 6 MAINTENANCE 6-1 HOW TO MAINTAIN THE MACHINE 19 6-2 HOW TO CLEAN THE ROLLER AND CHANGE HMA 19 CHAPTER 7 DIAGRAMS
1-1 INTRODUCTION CHAPTER 1 SAFETY SUMMARY This chapter is to provide related safe precautions while doing installation, operation and maintenance of Roller Coater (HS7004-BA) to prevent personal and equipment s risk. These safe precautions can be classified as following: 1.1 Safety during installation 1.2 Safety during equipment operation 1.3 Safety during maintenance 1.4 Safety during use of hot melt adhesive and solvent 1-2 SAFETY DURING INSTALLATION 1) A correct and effective grounding line must be installed when installing this roller coater. Without it, any isolation component would still be conductive, resulting in shock hazard. 2) Check whether the power cords and their isolation protection match requirement according to the load of the roller coater and its accessories. 3) Ensure that wire of main power is installed correctly the breaker from outside. 4) Ensure that the roller coater is working under the proper voltage. This roller coater may be burned by using wrong voltage. 1-3 SAFETY DURING OPERATION 1) Avoid operating the roller coater near the volatile or explosive materials and gases. 2) DO not operate the equipment without the covers, panels and safety guards properly installed. 3) Do not operate the machine when the ambient temperature is below 0 or above 50.
1-4 PRECAUTION DURING OPERATION 1) Do not use the equipment as a ladder or stepping tools. 2) Avoid some sharp tools or some impurities damaging the surface of roller while cleaning. 3) Please start the motor after making sure HMA of tank is melted completely. 4) Use only the metal base when attempting to lift or move applicator. Do not use covers, doors, panels, braces or grips of equipment. 5) If accident occurs, like finger or some stuff are rolled by roller, please immediately press the emergency stop switch to stop machine. 6) Do not wear gloves while operation to avoid hand being rolled by roller. 1-5 SAFETY DURING MIANTENANCE The main precautions to be adopted when carrying out maintenance are: 1) Disconnect the electrical power supply before maintenance the equipment. 2) Do not wear rings, watches, bracelets, etc. when carrying out the maintenance. 3) Do not in any way to disassemble or adjust any component of equipment unless another person who can provide immediate assistance is nearby. 4) Only qualified person can do maintenance on the equipment. 5) Do not touch bare connection or component without disconnecting the electrical power supply while power is on. Dangerous voltage exists at several points in the equipment. 6) Disconnect the power supply before removing any protection case or changing any electrical components. 7) If possible, please stand on a rubber insulating mat when carrying out maintenance. Do not work on wet floor or in very damp surrounding. 8) Always wear the protective glasses, clothing and heat-resistant gloves to avoid being burned by hot surface of components or molten glue.
9) Do not use any tool that is with flaming or a sharp tip to clean melting tank to avoid damaging the Teflon coating on surface of tank. 10) Please stop operating roller coater immediately when the hot melt glue is leaking out. And inform the qualified people to maintain. 1-6 SAFETY WHEN USING HOT MELT ADHESIVE AND SOLVENT A. HOT MELT ADHESIVE 1) The surface of hot melt adhesive would be solidified immediately at normal temperature. However, molten adhesive inside is still high temperature. 2) Always wear protective glasses, clothing and heat-resistant gloves when load hot melt adhesive into tank or operate machine close by. B. SOLVENT 1) Do not use an open flame or uncontrolled heating devices to heat solvents. 2) Do not use solvent that has high volatility to avoid burning and exploding at high temperature. And this kind of solvent may result poison air at high temperature. 3) Make sure the working area is ventilation enough before use solvents. 4) Do not work under using cleaning solvent for a long time to avoid breathing too much poison air that caused by high temperature. NOTICE: If skin is touched by molten hot melt adhesive, 1) Do not try to remove the molten adhesive on the skin. 2) Immerse the affected area into cold water until the adhesive is cooled down. 3) Do not try to remove the cooing adhesive from the skin. 4) Wrap the wound with clean and wet clothing. If the condition of injury is very serious, please keep the patient s body temperature in normal temperature, and send the patient to the hospital immediately.
CHAPTER 2 MACHINE FAILIARIZATION FIGURE 2.1 APPEARANCE OF HS7003B-BA 2-1 INTRODUCTION This chapter is to introduce the general characteristics, structure of this roller coater and how to operate this roller coater. The figures (2.1 &2.2) of machine s appearance, hydraulic system and electronic system are also included in this chapter. FIGURE 2.2 HYDRAULIC & ELECTRONIC SYSTEM
2-2 SPECIFICATION ITEM HS7004-BA POWER REQUIREMENT ψ220vac/50hz POWER 3.0KW WEIGHT 60KG DIMENSION 610*310*330 ROLLER WIDTH 410MM TANK CAPACITY 4.3L MAX. VISCOSITY MELTING RATE 20,000CPS 3KG/h 2-3 FUCTIONS 1) HEATING SYSTEM Heaters in the bottom of tank and inside the roller provide heating for HMA. Mechanic temperature controller would automatically control temperature accordingly. Please start the motor after HMA being melted completely for protection. It will take about 30 minutes to melt HMA completely. The tank of this roller coater uses power-heating system. Heaters and RTD are in the bottom of tank and inside the roller. Temperature of heating system is detected by RTD, and then transfer signal to the PID, at last PID will decide whether heat or not accordingly. When the power is turned on, the temperature control system will firstly check the electro-circuit, checking the SSR and RTD are normal or not. Subsequently run the PID of heating area. On first time to start the motor everyday, please make sure HMA in tank is melted completely. It will take about 30 minutes to melt HMA completely.
2) PID TEMPERATURE CONTROLLER This PID controller includes many functions, like digits display, alert, adjustment, etc. Especially for temperature adjustment, because that temperature is measured by RTD then transfer signal to PID. PID controller will decide whether heater or not accordingly. 3) ELECTRONIC TEMPERATURE CONTROLLER The temperature detected by the thermal couple is transited into electronic signal, and then transferred to the comparison device of the temperature controller. The device compares the voltage detected by the thermal couple, with the setting voltage. And then send out ON/OFF signal to SSR in order to control the power switch of the heater. 4) DRIVING SYSTEM The motor could be started after temperature is reaching setting value. Motor will drive the gears of rollers through chain after starting. The lower roller is dipped in tank, and the HMA could be rolled up by rolling. Put the material on roller, and then HMA could evenly be coated on the surface of material. SPECIFICATION OF MOTOR: VOLTAGE POWER FREQUENCY 220VAC 200W 50HZ
CHAPTER 3 UNPACKING AND INSTALLATION 3-1 INTRODUCTION This chapter is to introduce how to take out this roller coater from case and how to install this roller coater and related accessories properly. 3-2 UNPACKING AND INSTALLATION This roller coater has been assembled before delivery. Please pay attention on the process of taking this roller coater out from case, please put hands under bottom of machine then take it out. It is forbidden that take this machine out by holding other components of this machine. 3-3 MACHINE INSPECTION After tacking out the roller coater, the following items are suggested to check. 1) Check the surface and control panel of this roller coater are damaged, scratched, eroded or rugged. 2) Open the protective cover, checking whether the electrical wires in control box are loosened or not. 3) Check all the connected components if they are assembled together or not. 3-4 INSTALLATION OF ROLLER COATER Place the roller coater on the flat and proper position that near production line, and make sure the control panel is easy to operate. There must be enough space for operators to work. 1) Place the machine on a flat surface, and fix the machine by four screws fixed on the double edge of machine. 2) Do not install the machine where the ambient temperature is below 0 or above 50.
3) If this roller coater is installed outside factory or the well-ventilated area, please try to avoid the HMA being touched by ventilation air, due to the coating will be influenced. 4) This roller coater is not a fully hermetic and water-proof equipment, please do not spray water near machine. It will cause machine get short, damaged and eroded by these water. 3-5 INSTALLATION OF POWER SUPPLY The power rate of this roller coater is 220VAC and single phase, please note the following items while installation. 1) Do not attempt to amend the roller coater to work at other voltage. Otherwise the roller coater will get damaged. 2) Make sure the external power supply is disconnected before checking electrical components. NOTE: After finishing the above steps, please do not turn on the power immediately. Kindly read the next chapter then turn on the power.
CHAPTER 4 OPERATION INSTRUCTION 4-1 INTRODUCTION This chapter is to introduce the control panel, precautions before operation and operation steps of this roller coater and how to change HMA. 4-2 SAFE PRECAUTIONS 1) Always wear the protective glasses, clothing and heat-resistant gloves to avoid being burned by hot surface of components or molten glue. 2) Do not touch the rollers while roller coater is running to avoid being burnt by components or surface of high temperature. 4-3 INSTRUCTION OF CONTROL PANEL This control panel includes PID temperature controller, main power switch, switch for start and stop motor, switch for emergency stop, fuses, etc. The more details would be introduced by following sections. Please do read this instruction to avoid roller coater getting damaged by operation. 7 6 4 1 2 3 5 8 FIGURE 4.1 CONTROL PANEL
1) PID TEMPERATURE CONTROLLER SV: Setting Temperature PV: Present Temperature Press buttons to adjust setting temperature. No DISPLAY Specification 1 PV Displaying Present Temperature of tank 2 SV Displaying Setting Value 3 AL Indicator for Alarm: ON/OFF 4 OUT Indicator for output: ON/OFF 5 AT Indicator for Auto Tune: ON/OFF 6 SET Select/confirm Key 7 Decrease Key 8 Increase Key 9 AT(key) Auto Tune Key 2) ELECTRONIC TEMPERATURE CONTROLLER Temperature setting is by turning the knob. (5 per graduation) The indicator on right-side will show green light while heating. The indicator on right-side will show red light while temperature is reached. 3) START SWITCH When AL1 is on, the red light will also be on. Please make sure HMA inside tank is melted completely before starting motor. Use the toggle switch to start motor, and also use it to stop motor. 4) INCHING SWITCH If the material is rolled by roller, use this inching switch to reverse roller. And take out the material from roller immediately.
5) MAIN POWER SWITCH Switch to ON position, and this green light will be on. It meaning the power is turned on. 6) EMERGENCY STOP Press this RED BUTTON would stop motor instantly. 7) INVERTER Turn the knob on control panel of inverter to adjust speed of motor. 8) FUSE The fuse would avoid electronic components being burnt. 4-4 PREPARATIONS BEFORE OPERATION 1) Load clean and dry HMA into melting tank. And close tank lid to avoid some impurities falling into melting tank. FIGURE 4.2 MELTING TANK NOTE: Please disconnect the external power supply before loading HMA into tank. Otherwise there is still some voltage at wire head.
2) Turn on the external power supply. 3) Turn on the main switch on control panel, and refer to 4-3 to make setting on PID temperature controller. 4) Prepare some materials, like leather, cloth, etc. for trial coating. 5) Start motor after temperature reaching setting value, and make sure HMA inside tank being melted completely. 4-5 NORMAL OPERATION PROCEDURE 4-5-1 PROCEDURE OF TURNING ON MACHINE 1) Turn on the external power supply. 2) Turn on the main power switch on control panel. 3) Check HMA inside tank is at least 30% in tank. (80% full of tank is suggested.) FIGURE 4.3 CAPACITY OF MELTING TANK 4) Check the temperature on PID controller whether it is reaching setting value. (SV=PV) 5) When setting value is reaching, checking HMA inside tank is melted completely, and then the motor can be started. 4-5-2 PROCEDURE OF TURNING OFF MACHINE 1) Turn off main power switch on control panel. 2) Disconnect the external power supply. 4-6 ADJUSTMENT 4-6-1 ADJUSTMENT OF COATING THICKNESS Turn the black knob behind the roller coater to adjust coating thickness. (Clockwise turning is for more glue amount; anti-clockwise turning is for less glue amount)
4-6-2 ADJUSTMENT OF MOTOR SPEED FIGURE 4.3 GLUE AMOUNT ADJUSTER Turn the knob on control panel of inverter to adjust speed of motor. (Clockwise turning is for high speed; anti-clockwise turning is for low speed) FIGURE 4.4 INVERTER
CHAPTER 5 TROUBLESOOTING 5-1 TROUBLESHOOTING WHEN OPERATION PROBLEM POSSIBLE CAUSE TROUBLESHOOING 1. The surface of 1. Please stop motor and clean roller is not the roller immediately when There is clean. (It may some impurities are some HMA some sticking on the surface of on surface impurities or roller. of roller cloth on the surface) Uneven coating The end of material still with HMA after coating 1. Some impurities are possible to stick between blade and roller, affecting glue coating. 2. Probably HMA inside tank is not enough. 1. Temperature of roller is not hot enough. (Different HMA has different melting temperature) 2. HMA is not suitable for coating. (Viscosity of HMA is too high) 1. Clean the roller and change HMA. 2. Check if HMA inside tank is enough. 1. Re-adjust temperature of roller. 2. Change other suitable HMA.
HMA inside melting tank is easy to be charred or yellowish Materials rolled into melting tank while coating 1. Temperature of roller is too high. 2. Length of coating is too long, causing much air to be brought into melting tank. 3. HMA is poor in the ability of anti-oxidizatio n. 1. Temperature of roller is not enough. 2. Materials are too thin and soft to be coated. 1. Properly adjust temperature of roller. 2. Please stop running motor without coating. 3. Change HMA that has better anti-oxidization. 1. Adjust temperature of roller. 2. Select other kind of applicator to coat HMA on these soft or thin materials.
Roller or melting tank is not heating Indicator to start motor is on, but motor cannot be started 1. Heaters are 1. Replace a new heater. damaged or power2. Replace a new PID temperature is failure. controller. 2. PID temperature 3. Replace a new fuse (15A) controller is 4. Replace a new RTD. damaged. 5. Connect the power cords or 3. Fuse of main replace new power cord. power supply is 6. Replace a new mechanic damaged. temperature controller. 4. RTD is damaged. 5. Power cords are damaged or short. 6. The mechanic temperature controller to avoid tank overheating is damaged. 1. Fuse is broken. 2. Bearing of roller is damaged. 3. Power cords are damaged. 1. Replace a new fuse. 2. Replace a new bearing. 3. Connect the power cord or replace new power cord. Edges of 1. Screws of side 1. Tighten those screws. lower plate are loose. 2. Replace a new O-ring. roller are 2. O-ring is leaking damaged. HMA out
CHAPTER 6 MAINTENANCE 6-1 HOW TO MAINTAIN THE MACHINE 1) Please keep surface of machine clean. Do not use volatile solvent to clean, such as gasoline, toluene, etc. 2) HMA inside melting tank will get charred and aged after a period of heating, please change HMA regularly for ensuring coating quality. 3) Please do not run the motor while doing maintenance to avoid hands being rolled by roller. 4) Once cloth or any impurity fall into melting tank during operation, please clean it out. Those stuff will affect glue coating. 5) Always wear the protective glasses, clothing and heat-resistant gloves to avoid being burned by hot surface of components or molten glue. 6) Regularly smear some lubricant on chain and gear. 6-2 HOW TO CLEAN THE ROLLER AND CHANGE HMA 6-2-1 THE WAY TO CHANGE HMA 1) This melting tank coated by Teflon, so the surface is non-adhesive and easy to clean. 2) Heat roller and tank at the same time, and ensure HMA is melted completely. Then raise the back of machine around 15 degree to make HMA flow to front of tank, subsequently turn off power to cool down HMA. 3) When temperature of HMA is down to 50~60, take out the HMA from tank by hands. 4) Please heat the rest of HMA, and then use cloth to clean it. 5) Surface of melting tank coated by Teflon, please do not scratch it by any sharp tools. It may cause bad separation effect.
6-2-2 THE WAY TO CLEAN THE ROLLER 1) Once cloth or any impurity fall into melting tank during operation, please clean it out. Those stuff will affect glue coating. 2) Start the motor with lower speed, and turn the knob behind machine to increase glue amount. 3) After finishing above steps, impurities will be rolled out by roller running. And please stop machine and remove impurities by tools. 6-2-3 MAINTENANCE OF DRIVING SYSTEM It s very important to maintain driving system of this machine. Because this part is close to melting tank, although this part protected by cover, it is still possible to be stuck by HMA. Driving system will be affected by HMA being solidified on chain or gear. Even cause motor or inverter to get damaged. If any HMA on chain, please cleans it right away by tools. Besides, it is necessary to smear lubricant on chain and gear, and check if any HMA leakage occurs from tank.
CHAPTER 7 DIAGRAMS 7.1 TOTAL ASSEMBLY DRAWING OF HS7004-BA
No. SERIAL NUMBER ITEM QUANTITY 1 7004K04 MACHINE BASE 1 2 Y090 EMERGENCY STOP SWITCH 1 3 Y090-1 INCHING SWITCH 1 4 F4A F5A F10A FUSE 1 1 1 5 NW3001 WIRE ASSEMBLY OF INVERTER 1 6 EPR1VR-1 INDICATOR OF MOTOR START (RED) 1 7 EA02-4 TOGGLE SWITCH 1 8 EPR2VG INDICATOR OF POWER (GREEN) 1 9 MC2P20A NO FUSE BREAKER 1 10 M2V200W-325Y MOTOR (AC) 1 11 7002B17A CHAIN GEAR OF MOTOR 1 12 7002C06 ADJUSTABLE ROD 1 13 7002B19-1 SEAL 2 14 7002B20-1 BUSHING (RIGHT, CLOCKWISE TIGHTENING) 1 15 7002B21-1 SHAFT (RIGHT, CLOCKWISE TIGHTENING) 1 16 SPB253316 BEARING 2 17 7002B12 FIXED ROD 1 18 7004B04 HEATER 1 19 7002B14 CHAIN GEAR 1 20 PID-48-301 TEMPERATURE CONTROLLER (PID) 1 21 7002D22 COVER 1 22 7002D21 COVER 1 23 L03 L03-1 L03-2 CHAIN 0.5 1 1 24 7002C04 KNOB 1 25 E2V-2 FAN 1 26 ET2V-2C COVER OF FAN 1 27 7002T09-2 FIXED BASE OF TANK (LEFT) 1 28 EHJ-RM ALLIGATOR CLIP 1 29 7004B01 ROLLER 1 30 7004C03 SCRAPING BOARD (COPPER) 1 31 7004C01 SCRAPING BOARD 1 32 7004C02 ADJUSTABLE ROD 1 33 7002B20 BUSHING (LEFT, ANTI-CLOCKWISE TIGHTENING) 1 34 7002B22 SUPPORTTING RING 1 35 7002B21 SHAFT (LEFT, ANTI-CLOCKWISE TIGHTENING) 1 36 7002B23 FIXED STAND 2
No. SERIAL NUMBER ITEM QUANTITY 37 MB1415FDU BEARING WITHOUT OIL 2 38 7002D07 COVER 1 39 1103B04 BAKELITE 2 40 7002D06 STRIPPING PIN 17 41 7002C07-2 SENSOR-BlOCK 1 42 HTR05-D SENSOR 1 43 7004K02 HEAT-INSULATION BOARD 1 44 7004T04 TANK 1 45 7004T03 SUPPORTING BOARD 1 46 7004K03 LID OF TANK 1 47 7002T08-2 FIXED BASE OF TANK (RIGHT) 1 48 N2-2P5-M INVERTER 1 49 7004K05 COVER 1 50 7002T13 SUPPORTER 4 51 B6P TERMINAL BLOCK 2 52 YST-15 SHORT PIN 3 53 CPD20 FIXED BASE OF POWER CORD 1 54 HT2V50W19-8.5 HEATER 4 55 TF2-2CB TEMPERATURE CONTROLLER (ELECTRONIC) 1 56 7002C02-2 SUPPORTINIG BOARD 1 58 7002C02-1 SUPPORTINIG BOARD 1 59 OP25V O-RING 2 60 OB25 BACK-RING 2
7.2 CIRCUIT DRAWING OF HS7004-BA
7.3 ELECTRONIC COMPONENTS CONFIGURATION OF HS7004-BA