Hot Melt Applicator MC 405 for Foil Bags

Hot Melt Applicator for Foil Bags Manual English NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

NOTE This manual is for products with the following P/N: 8015767 8022490 8027924 8037680 8018042 8023117 8031127 8050298 8018738 8023592 8032936 8053974 8021214 8023715 8033329 8056231 8021304 8026980 8036830 8022149 8027366 8036855 Order number P/N = Order number for Nordson products Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2001. 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, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, Package of Values, Pattern View, PluraFoam, Porous Coat, PowderGrid, Powderware, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Rhino, S. design stylized, Saturn, SC5, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Watermark, When you expect more. are registered trademarks of Nordson Corporation. ATS, Aerocharge, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, COLORMAX, Control Weave, Controlled Fiberization, CPX, E-Nordson, EasyClean, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink-Dot, Iso-Flex, Kinetix, Maxima, MicroFin, Minimeter, Multifil, OptiMix, PluraMix, Primarc, Prism, Process Sentry, PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, 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_213668G

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 Operating Restrictions................................ 2-1 Unintended Use Examples............................ 2-1 2. Residual Risks............................................ 2-2 3. Definition of Terms........................................ 2-2 4. Note on Manual........................................... 2-2 5. Unit Components......................................... 2-3 6. Functioning............................................... 2-4 Melting Process and Adhesive Feeding.................... 2-4 Gear Pump............................................ 2-4 Motor.................................................. 2-4 Compiling Actual Speed................................. 2-4 Shutoff Valve........................................... 2-5 Mechanical Safety Valve................................. 2-5 Heating................................................ 2-5 Temperature Control.................................... 2-5 Undertemperature Interlock............................ 2-5 Overtemperature Indication / Shutdown................. 2-5 Temperature Setback................................. 2-6 Pressure Sensor........................................ 2-6 Inert Gas Equipment (Option)............................ 2-6 Tank Lid with Pneumatic Cylinder and Plunger.............. 2-7

II Table of Contents Section 2 Description (contd.) 7. Electrical Cabinet......................................... 2-8 Opening Electrical Cabinet............................... 2-9 Pulling Out Electrical Cabinet............................. 2-9 Indicator Beacon....................................... 2-10 Week Timer (Option)................................... 2-10 Control System........................................ 2-10 Mode Switch Raise/Lower Plunger....................... 2-10 Electrical Cabinet Ventilation............................ 2-11 Main Switch........................................... 2-11 Connecting Socket Tach Generator (Interface XS 5)........ 2-11 Interface XS 2......................................... 2-11 8. Protective Panels........................................ 2-12 9. ID Plate................................................. 2-12 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. Attaching Indicator Beacon................................. 3-2 8. Electrical Connections..................................... 3-2 Laying Cable........................................... 3-2 Line Voltage............................................ 3-2 Tach Generator (Accessory).............................. 3-3 Interface XS 2.......................................... 3-3 9. Pneumatic Connection..................................... 3-3 10. Installing Heated Hoses.................................... 3-4 Connecting............................................. 3-4 Disconnecting.......................................... 3-4 Relieving Pressure................................... 3-4 Second Open-jawed Wrench........................... 3-4

Table of Contents III Section 4 Operation 1. Initial Startup............................................. 4-1 2. Filling the Tank............................................ 4-2 3. Setting Temperatures...................................... 4-3 General Values......................................... 4-3 4. Setting Adhesive Quantity.................................. 4-4 Motor/Pump Speeds.................................... 4-4 Manual Mode........................................... 4-4 Automatic Mode........................................ 4-4 5. Switching Unit ON/OFF.................................... 4-5 Unit with Week Timer (Option)............................ 4-5 External Unit Release................................... 4-5 Daily Startup........................................... 4-5 Daily Switchoff.......................................... 4-5 6. Switching Off in an Emergency.............................. 4-5 7. 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 5. Visual Inspection for External Damage....................... 5-3 6. Electrical Cabinet Fan Maintenance......................... 5-3 7. Changing Type of Adhesive................................ 5-4 8. Purging with Cleaning Agent................................ 5-4 9. Cleaning Tank............................................ 5-4 10. Maintenance Record Form................................. 5-6

IV Table of Contents Section 6 Troubleshooting 1. Control System........................................... 6-1 2. Some Tips............................................... 6-1 3. Indication Lamps and Indicator Beacon...................... 6-2 4. Troubleshooting Tables.................................... 6-3 Only the White Indication Lamp is Lit...................... 6-3 Red Indication Lamp is Lit................................ 6-4 Unit not Functioning..................................... 6-5 One Channel (Heating Zone) does not Heat................ 6-5 No Pilot Voltage........................................ 6-5 No Adhesive (Motor does not Rotate)...................... 6-6 No Adhesive (Motor Rotating)............................ 6-7 Incorrect Motor Rotation in Automatic Mode................ 6-7 Not Enough Adhesive................................... 6-7 Adhesive Pressure too High.............................. 6-7 Adhesive Pressure too Low.............................. 6-8 Adhesive Residues in Tank............................... 6-8 Adhesive Hardens in Tank............................... 6-8 Section 7 Specifications 1. General Data............................................. 7-1 2. Temperatures............................................. 7-1 3. Electrical Specifications.................................... 7-2 4. Dimensions and Weights................................... 7-2

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.

1-0 Safety

Section 2 Description

2-0 Description

Description 2-1 Section 2 Description 1. Intended Use The hot melt applicator hereafter referred to as unit may be used only to melt and feed polyurethane hot melt adhesives from aluminum compound foil bags. 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. Area of Use (EMC) The units are designed to be used in industrial areas (Also refer to included Declaration of Conformity). Operating Restrictions When using in residential, business or industrial areas, the equipment may cause interference with other units, e.g. radios. Unintended Use Examples The unit may not be used under the following conditions: In defective condition When changes or modifications have been made by the customer Without heat protection and protective panels With electrical cabinet door open With tank lid open In a potentially explosive atmosphere When the values stated under Specifications are not complied with. The unit may not be used to melt and feed the following materials: Explosive and flammable materials Erosive and corrosive materials Food products.

2-2 Description 2. 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 adhesive Risk of burns on the hot tank lid Risk of burns when filling tank Risk of burns from hot accessories, e.g. heated hoses and hot melt application heads Inhalation of potentially hazardous hot melt adhesive vapors. 3. Definition of Terms In Nordson documents, the safety valve is also referred to as bypass and bypass valve. 4. Note on Manual NOTE: The position numbers in the illustrations do not correspond to the position numbers in the technical drawings and the parts lists.

Description 2-3 5. Unit Components Figure 2-1 shows the essential components of the unit. Details can be found in the technical drawings (Refer to Spare Parts Lists). 15 14 1 13 12 11 10 9 8 7 6 5 4 3 2 002873 Fig. 2-1 1 Electrical cabinet 2 Motor* 3 Actual speed compiler* 4 Coupling 5 Gear pump* 6 Bypass plate with shutoff valve 7 Safety valve* 8 Tank: Grid 9 Tank: High melt section 10 Hose connection fitting 11 Hose connection socket (with plug) 12 Pressure sensor* 13 Inert gas equipment* (Option) 14 Tank lid 15 Pneumatic cylinder 1 Note: There are separate manuals available for components marked with an asterisk (*). Note: 1 On some models, the level is indicated by a rod that runs through the lid and parallel to the pneumatic cylinder. There may be switching cams on the rod to link additional electrical components. Refer to wiring diagram.

2-4 Description 6. Functioning This section describes the functioning of the unit. The functioning of individual unit components is described in the corresponding manual for the component (Refer to Index of Documentation). Melting Process and Adhesive Feeding The PUR foil bag is placed in the tank. The adhesive is melted in the tank. The melted adhesive flows to the gear pump. The gear pump feeds the adhesive to the hose connection fitting. The adhesive is then fed through a heated hose to the hot melt application head or assembly handgun. A pneumatically operated plunger in the tank applies sufficient pressure to empty the PUR foil bag. Gear Pump Also refer to Gear Pump. The size and speed determine the output quantity. NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, ensure that the tank is filled. Motor Motor. The electronically controlled motor drives the gear pump. The speed is indicated in the display. Refer to manual Control System for instructions on setting speed. NOTE: The control system can be set to adjust a setpoint pressure instead of a setpoint speed. NOTE: The motor is not ready for operation until the undertemperature interlock has been released or the unit has nearly reached the set temperature setpoint. Compiling Actual Speed Also refer to Compiling Actual Speed and Control System. A sensor compiles the current motor/pump speed, then the speed is displayed on the control system CS 20.

Description 2-5 Shutoff Valve Fig. 2-2 2 1 XXSY036S050A0595 The shutoff valve is located in the bypass plate between the tank and the gear pump. It is used to stop the adhesive flow when the gear pump is to be replaced. The shutoff valve is operated with a hexagon wrench. Position 1: Shutoff valve open Position 2: Shutoff valve closed. Mechanical Safety Valve Also refer to Safety Valve. The mechanical safety valve limits the adhesive pressure generated by the gear pump. It is factory set and lead sealed. When the factory-set pressure is exceeded, the safety valve opens, allowing the adhesive to circulate within the bypass plate. Heating The system is heated with cast-in heating elements and heater cartridges. Temperature Control Also refer to Control System. The temperature is measured by sensors and is electronically controlled by the control system. Undertemperature Interlock The undertemperature interlock prevents the unit or system from being started up when the adhesive is too cold until the temperature setpoint minus undertemperature value has been exceeded. However, every time initial heating occurs, the locking device 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 hot melt 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: 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 unit remains ready for operation. Contd...

2-6 Description Temperature Control (contd.) 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 Specifications for shutdown value. NOTE: Depending on the type of adhesive used, the overtemperature thermostat on the high melt section may need to be adapted to the maximum processing temperature of the adhesive (This may mean replacing it). Refer to section Specifications for information on thermostats. 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 remedied by qualified personnel. Temperature Setback Serves to protect the adhesive and save energy during interruptions in production or work stoppages. Setback value and setback period are adjustable. Pressure Sensor Also refer to Pressure Sensor and Control System. The pressure sensor compiles the material pressure at the hose connection fitting. This material pressure is indicated on the control system. Inert Gas Equipment (Option) When processing certain materials, e.g. polyurethane hot melt adhesive (PUR), thermoplastic polyester or polyamide resin, the inert gas prevents an undesired reaction with the atmosphere. It displaces the air in the tank and protects the material. NOTE: Units built in 2003 and later (serial number LU03...) no longer have the option inert gas equipment. Material feeding from the original PUR material package (foil bag) prevents exposure to the atmosphere, assuming the plunger remains pressurized even when the unit is switched off. CAUTION: Use only suitable inert gas. Information on the gas to be used can be obtained from the material safety data sheet or from the manufacturer of the material in the tank.. The tank is automatically pressurized with inert gas during operation as set on the control system (inert gas supply interval and inert gas supply time). Also refer to Inert Gas Equipment and Control System under Operating the Motor Part.

Description 2-7 Tank Lid with Pneumatic Cylinder and Plunger The tank lid is fastened to the unit frame with a hinge, allowing it to be swiveled out with the pneumatic cylinder and the plunger. Reed contacts on the pneumatic cylinder detect the plunger position, thus indicating the level. The lid can not be opened until the plunger has triggered the upper Reed contact, releasing the electromagnetic lock. An electromechanical safety switch prevents the plunger from moving up or down when the lid is open. The lower Reed contact triggers the empty indication; the height is factory-set to complete emptying of compound foil bags (3 mm), but it can be modified. CAUTION: When processing material that reacts with the atmosphere (humidity): Ensure that the plunger is pressurized even when the unit is off to prevent the material from being exposed to the atmosphere.

2-8 Description 7. Electrical Cabinet WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from the line voltage. 1 2 M1 1 1 2 2 3 3 4 4 1 2 C F 4 6 7 3 5 3 8 002874 Fig. 2-3 Electrical cabinet 1 Indicator beacon 2 Week timer (option)* 3 Lock 4 Control system CS 20* 5 Mode switch Raise/lower plunger 6 Air filter 7 Main switch 8 Fan Note: There are separate manuals available for components marked with an asterisk (*).

Description 2-9 Opening Electrical Cabinet WARNING: Allow only qualified and authorized personnel to open the electrical cabinet. The key is included in the delivery. WARNING: Disconnect unit from power supply before opening 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. 2-4 Principle drawing Pulling Out Electrical Cabinet The electrical cabinet can be pulled out for installation, maintenance and repair. First unlock with the key. WARNING: Ensure that cables do not touch rotating or hot parts after the electrical cabinet is pushed back. Do not pinch cables. MCSY196L070A0796 Fig. 2-5 Principle drawing

2-10 Description Indicator Beacon (1, Fig. 2-3) White Red Yellow Yellow blinks Green Blue Unit switched on Collective fault Tank empty (Special model) Tank half-empty Unit ready for operation (Special model) Plunger in highest position Also refer to section 6 Troubleshooting and manual Control System for information on Collective fault. The motor/pump does not stop automatically when the empty indication occurs, because when the indication is transmitted, there is still a reserve of approx. 400 g in the high melt section. This is sufficient for uninterrupted feeding during adhesive package replacement. Week Timer (Option) (2, Fig. 2-3) Refer to manual Week Timer. Used to automatically switch on/off the unit. The week timer is located in the electrical cabinet. NOTE: The main switch must be set to I/ON when using a week timer. Control System (4, Fig. 2-3) Refer to manual Control System for operation. Mode Switch Raise/Lower Plunger (5, Fig. 2-3) The plunger is controlled with this switch. The lamp Control voltage on must be lit. In the position Raise The plunger moves to the highest position The tank lid is unlocked when the upper Reed switch is passed. In the position Lower The (closed) tank lid is locked; the audible click indicates that the electromagnetic lock has locked correctly The plunger moves to working position as soon as the tank lid has been closed.

Description 2-11 Electrical Cabinet Ventilation (6, 8 Fig. 2-3) Serves to cool the electrical cabinet. The filters must be serviced regularly (Refer to section 5, Maintenance). Main Switch (7, Fig. 2-3) Used to switch on/off the unit. Position 0/OFF = Unit is switched off. Position I/ON = Unit is switched on. Padlocks can be used to protect the main switch from unauthorized access. NOTE: The main switch must be set to I/ON when using the week timer. Connecting Socket Tach Generator (Interface XS 5) (Back of electrical cabinet, not shown) Used to connect a tach generator (accessory). The appropriate tach generator can be purchased from Nordson. If the tach generator is included in delivery, refer to manual Tach Generator. WARNING: The pilot voltage may not exceed 160 V DC. Failure to observe will result in damage to succeeding components. NOTE: The pilot voltage must be adjusted (Refer to manual Control System). Interface XS 2 (Back of electrical cabinet, not shown) Serves as a connection between the unit and the customer s equipment. Refer to section Wiring Diagram for connecting arrangement.

2-12 Description 8. Protective Panels WARNING: Do not operate without protective panels. The side protective panels can be removed and the back panel folded down for installation, maintenance, etc. First unlock the panel fasteners with the included square wrench. The bottom section of the back cover can be unscrewed and removed. MCSY199L059A0796 Fig. 2-6 9. ID Plate 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. 2-7 Information Description Unit Code Unit designation and configuration code P/N Article number Ser. Serial number U Operating voltage Volt I Fuse protection Ampère f Line voltage frequency Hertz P Power consumption of unit Watt P max Maximum power consumption of unit and connected accessories Watt

Section 3 Installation

3-0 Installation

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 Refer to section Specifications for weight. Use only suitable transport devices. Screw the unit onto a special pallet (with rubber feet that reduce vibrations) using angle brackets (Fig. 3-1). Pack with sturdy materials. Use padding material to fill hollow spaces between unit and packaging. Protect the unit from humidity, dust, jolts and vibrations. Observe additional transport instructions for units with weighing cells (Refer to manual Weighing Cell). MCSY204S050A0796 Fig. 3-1 Principle drawing Lifting (Unpacked Unit) Refer to section Specifications for weight. Lift only at the unit frame using suitable lifting equipment or a forklift. 2. Unpacking Unpack carefully. Then check for any damage caused during shipping. Save special pallet and angle brackets for later use. Reuse packaging materials or dispose of properly according to local regulations. 3. Removing Run the unit until empty, separate all connections from the unit, and allow the unit to cool down. 4. Storage Do not store unit outside! Protect from humidity, dust and extreme temperature fluctuations (formation of condensation). 5. Disposal Properly dispose of unit according to local regulations.

3-2 Installation 6. Setting Up Set up only in an environment that corresponds to the stated Degree of Protection (Refer to section Specifications). Do not set up in a potentially explosive atmosphere! Protect from vibration. Remove transport protection (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. Attaching Indicator Beacon The indicator beacon must be screwed onto the electrical cabinet (It was removed for transport). 8. Electrical Connections WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Laying Cable Ensure that cables do not touch rotating and/or hot unit components. 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 cross-section of the power cable must correspond to the rated current. Refer to ID plate for rated current. The mains terminals are located in the electrical cabinet. Refer to wiring diagram for connecting arrangement.

Installation 3-3 Tach Generator (Accessory) Connection is made via the connecting socket. Refer to wiring diagram for connecting arrangement. The appropriate tach generator can be purchased from Nordson. If the tach generator is included in delivery, refer to manual Tach Generator. WARNING: When connecting to Nordson units in the Meltex series, the pilot voltage may not exceed 160 V DC. Failure to observe will result in damage to succeeding components. NOTE: The pilot voltage produced by the tach generator must be adjusted (Refer to control system). Interface XS 2 Serves as a connection between the unit and external devices. Refer to wiring diagram for connecting arrangement. NOTE: Use only shielded cables/lines. Connect the shield to ground in compliance with electromagnetic compatibility regulations. NOTE: Inductive loads (e.g. solenoid valves) connected to the unit must be equipped with a protective device (e.g. recovery diode) that disables the inductive voltage generated when an inductive load is switched off. 9. Pneumatic Connection 1 Connect dry and non-lubricated compressed air (1). Set air pressure for pneumatic cylinder to 1 bar (0,1 MPa / 14,5 psi) on the customer s pressure controller. The setting must be modified according to the processed material and the output quantity (max. 2 bar / 29 psi).

3-4 Installation 10. Installing Heated Hoses WARNING: Hot! Risk of burns. Wear heat-protective gloves. Connecting 1 2 3 If there is cold adhesive in the hose connection fitting (1) and/or hose connection (2), these components must be heated until the hot melt material softens. 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 unit and hose. Fig. 3-3 Principle drawing MXHH001S050A0295 3. Screw the heated hose onto the unit. NOTE: Close unused hose connection fittings with Nordson screw caps. Disconnecting WARNING: System and adhesive pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. Relieving Pressure 1. Set motor speed to 0 min -1 (rpm); switch off motor(s). 2. Place a reservoir under the nozzle(s) of the application head / assembly handgun. 3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger of the assembly handgun. Repeat this procedure until no more adhesive flows out. 4. Reuse adhesive 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 hose connection fitting from turning. MXHH002S033A0295 Fig. 3-4 Principle drawing

Section 4 Operation

4-0 Operation

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. 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. Material residue may still be present in the unit. To remove the residue, melt and feed several kilograms of adhesive before starting production. NOTE: 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. NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, ensure that the tank is filled. NOTE: To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min- 1 (rpm) or continuously exceed 80 min -1 (rpm). NOTE: The operator must make himself familiar with the manual Control System before carrying out the following steps. 1. Set main switch to I/ON. 2. Fill the tank. 3. Set mode switch Raise/lower plunger to Lower; the tank lid is locked and the plunger moves down to working position. 4. Make all adjustments on the control system. 5. Wait until the unit is ready for operation (green lamp lit). 6. Pre-select motor. 7. Switch on motor. 8. Set motor/pump speed as needed for the desired adhesive quantity.

4-2 Operation 2. Filling the Tank ACHTUNG: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. Hot adhesive can squirt out of the tank. Carefully place foil bag in tank. WARNING: Do not operate unit with open tank. When the tank is open, hot adhesive vapors can escape; vapors may contain potentially hazardous substances. Before filling the tank, ensure that tank and adhesive are clean and free of foreign substances. Foreign substances can result in damage to the unit or accessories. NOTE: Never use a damaged adhesive package. CAUTION: When processing material that reacts with the atmosphere (humidity): Use only foil bags with a diameter no more than 5 mm less than the tank diameter. Then the foil bag can serve as a seal when squeezed together. If necessary contact Nordson to obtain an insert that reduces the size of the tank. 1. Raise plunger (with mode switch on electrical cabinet). 2. Fold tank lid back. 3. Cut an X in the bottom of the foil bag. Each cut should be approx. 30 mm long so that the opening more or less corresponds to the hole diameter of the grid. 4. Then carefully place the foil bag in the tank with the open end down. 5. Close tank lid. 6. Lower plunger (with mode switch on electrical cabinet). NOTE: Cease operation before the tank is completely empty. If there is too little adhesive in the tank, the adhesive can overheat. This can cause adhesive residue and crust to form, causing malfunctions. NOTE: Properly dispose of empty foil bags according to local regulations.

Operation 4-3 3. Setting Temperatures Temperature settings as well as all other control system functions are described in detail in the manual Control System. NOTE: The processing temperature is also called temperature setpoint in the description of the control system. NOTE: 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. NOTE: Depending on the type of adhesive used, the overtemperature thermostat on the high melt section may need to be adapted to the maximum processing temperature of the adhesive (This may mean replacing it). However, the shutdown value of the thermostats may not exceed the max. operating temperature of the unit! Refer to section Specifications for information on thermostats. General Values Heating zone / temperature / time The values stated in the tables are general values determined by experience. Setting High melt section 10 C below prescribed processing temperature Undertemperature value 10 C below set processing temperature Overtemperature value 10 to 30 C above set processing temperature Temperature setback value (standby) Setback period As needed As needed Application head (accessory) Prescribed processing temperature(s) Heated hose (accessory) Prescribed processing temperature

4-4 Operation 4. Setting Adhesive Quantity Adhesive output quantity settings as well as all other control system functions are described in detail in the manual Control System. NOTE: The setting for the pneumatic punch pressure must be modified according to the processed material and the output quantity (max. 2 bar / 29 psi). Motor/Pump Speeds The speed measured at the gear box output shaft is referred to as the motor/pump speed. The actual motor speed is significantly higher. NOTE: To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min- 1 (rpm) or continuously exceed 80 min -1 (rpm). Manual Mode The speed is equal to the set value and does not change. It also can not be controlled synchronously to a parent machine. Automatic Mode If the function Pressure control is activated on the control system, the speed is automatically determined by the preset setpoint pressure. In speed-controlled operation, the speed is controlled synchronously to the parent machine. Parameters can be set. NOTE: Automatic mode is only possible if pilot voltage is available. NOTE: The pilot voltage must be adjusted (Refer to manual Control System).

Operation 4-5 5. Switching Unit ON/OFF NOTE: Before the unit is switched on for the first time, read and observe Initial Startup. The unit is switched on/off with the main switch. Position 0/OFF = Unit is switched off. Position I/ON = Unit is switched on. Padlocks can be used to protect the main switch from unauthorized access. Unit With Week Timer (Option) External Unit Release Daily Startup The week timer is used to automatically switch the unit on and off. The main switch must be set to I/ON (switched on) when using the week timer. The external unit release feature is used to externally switch the unit on/off via the interface XS 2. When external unit release is used, the main switch must be set to I/ON (switched on). Also refer to Installation, Interface XS 2. NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, make sure the tank is filled. NOTE: To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min- 1 (rpm) or continuously exceed 80 min -1 (rpm). 1. Set main switch to I/ON. 2. Fill tank if necessary. 3. Wait until the unit is ready for operation. 4. Preselect motor(s). 5. Switch on motor(s). Daily Switchoff 1. Switch off motor(s). 2. Set main switch to 0/OFF. 3. If necessary, secure main switch with padlock against unauthorized access. CAUTION: When processing material that reacts with the atmosphere (humidity): Ensure that the plunger is pressurized even when the unit is off to prevent the material from being exposed to the atmosphere. 6. Switching Off in an Emergency WARNING: Immediately switch off the unit in any emergency situation. 1. Set main switch to 0/OFF or when available press EMERGENCY OFF button (special feature). 2. After standstill and before switching the unit on again, have the malfunction remedied by qualified personnel.

4-6 Operation 7. Settings Record Form Production information: Adhesive: Cleaning agent: Leading channel: Manufacturer Processing temperature Viscosity Manufacturer Flash point High melt section (factory-set) Processing temperatures (setpoint temperatures): Tank Heated hose (accessory) Application head (accessory) Heated hose (accessory) Application head (accessory) Parameters on control system (if optional inert gas equipment present) Con Inert gas supply on (interval gas supply) CoF Inert gas supply off (interval gas supply) Motor/pump speeds: Motor/pump Air pressures at application head (accessories): Control air Spray air Notes: Name Date

Section 5 Maintenance

5-0 Maintenance

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. 1. Relieving Pressure WARNING: System and adhesive pressurized. Relieve system of pressure before disconnecting heated hoses, application heads and hot melt handguns. Failure to observe can result in serious burns. WARNING: Hot! Risk of burns. Wear heat-protective gloves. 1. Set motor speed to 0 min -1 (rpm); switch off motor(s). 2. Place a reservoir under the nozzle(s) of the application head / assembly handgun. 3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger of the assembly handgun. Repeat this procedure until no more adhesive flows out. 4. Reuse adhesive or dispose of properly according to local regulations.

5-2 Maintenance 2. Daily Maintenance Maintenance activities described under Regular Maintenance may need to be performed daily. Unit part Activity Interval Refer to Entire unit External cleaning Daily Page 5-3 Visual inspection for external Daily Page 5-3 damage Tank Visual inspection for pollution in Before filling tank every time tank Visual inspection of inert gas supply holes to check for blockage; clean if necessary 3. Regular Maintenance The maintenance intervals are general guidelines based on experience. Depending on the location of the unit, production conditions and operating time of the unit, other maintenance intervals may prove necessary. Unit part Activity Interval Refer to Electrical cabinet fans Check filter, clean or replace if Depending on dust Page 5-3 necessary accumulation; daily if necessary Power cable Inspect for damage Every time the unit is serviced Air hoses Inspect for damage Every time the unit is serviced Tank Clean When very dirty Page 5-4 Gear pump Refer to separate manual Motor / gear box Refer to separate manual Safety valve Refer to separate manual Inert gas equipment (option) Refer to separate manual

Maintenance 5-3 4. External Cleaning External cleaning prevents impurities created during production from causing the unit to malfunction. CAUTION: Observe the unit s Degree of Protection when cleaning (Refer to Specifications). CAUTION: Do not damage or remove warning signs. Damaged or removed warning signs must be replaced by new ones. Only remove hot melt adhesive residue with a cleaning agent recommended by the adhesive supplier. Heat with an air heater if necessary. Remove dust, flakes etc. with a vacuum cleaner or a soft cloth. 5. Visual Inspection for External Damage WARNING: When damaged parts pose a risk to the operational safety of the unit and/or safety of personnel, switch off the unit and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. 6. Electrical Cabinet Fan Maintenance The electrical cabinet fan is maintenance-free. The filter 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.

5-4 Maintenance 7. Changing Type of Adhesive Remove the old adhesive by running until empty or by draining the unit. NOTE: Before changing the type of adhesive, determine whether the new adhesive may be mixed with the old adhesive. May be mixed: Remaining old adhesive can be flushed out using the new adhesive. May not be mixed: Thoroughly purge the unit with a cleaning agent recommended by the adhesive supplier. NOTE: Properly dispose of the old adhesive according to local regulations. 8. Purging with Cleaning Agent CAUTION: Use only a cleaning agent recommended by the adhesive manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. Before starting production again, flush out cleaning agent residue using the new hot melt adhesive. NOTE: Properly dispose of cleaning agent according to local regulations. 9. Cleaning Tank The tank must be cleaned mechanically when it is extremely polluted. NOTE: Low melt, grid and high melt are release-coated. Thus metallic tools may not be used to remove adhesive. This could damage the release coating. Use wooden or plastic spatulas, or if necessary soft brushes (never use wire brushes). Impurities result from particles of dirt that enter the tank during filling and from adhesive residue. The tank must be cleaned before the type of adhesive is changed or when adhesive residue has formed. With the, the low melt section and grid can be detached from the high melt section by releasing the quick snap clamp. NOTE: If a cold, unfilled tank is to be cleaned, e.g. in the morning before production begins, the tank must first be heated to the softening temperature of the adhesive. Then proceed with step 3.

Maintenance 5-5 1. Convey all adhesive out of the unit. 2. Switch off motor/pump. 3. Raise plunger. 4. Switch off unit and wait until it has cooled off enough that it can be comfortably touched with protective gloves (adhesive softening temperature). WARNING: Hot! Risk of burns. Wear heat-protective gloves. Fig. 5-1 1 2 MCTK031S067A0198 5. Fold tank lid back. 6. Release quick snap clamps (1). 7. Using the screwed in T-handles, lift the tank out of the unit and place it to the side. 8. Carefully lift off grid and lay it aside. 9. Depending on the level of pollution, clean tank, grid and high melt section using one of the methods described above. 10. Check Viton sealing rings (2) for damage; replace if necessary. 11. Re-assemble in reverse order. NOTE: Properly dispose of cleaning agents and adhesive residue according to local regulations.

5-6 Maintenance 10. Maintenance Record Form Gear pump Unit part Date / name Date / name Date / name Motor / gear box Electrical cabinet fans Tank Safety valve Inert gas equipment (option)

Section 6 Troubleshooting

6-0 Troubleshooting

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 unit is energized. Observe all safety instructions and regulations concerning energized unit components (active parts). Failure to observe may result in an electric shock. 1. Control System The control system offers the following troubleshooting aids, described in the manual Control System: Indication lamps and indicator beacon Diagnosis program in the temperature section Automatic fault display in the temperature section Service display Error in the motor section LEDs on the modules and boards. 2. Some Tips Before beginning with systematic troubleshooting activities, check the following points: Is the optional week timer programmed correctly? Are all parameters set correctly? Is the XS 2 interface connected correctly? For automatic mode: Is pilot voltage present? Do all plug connections have sufficient contact? Have 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 3. Indication Lamps and Indicator Beacon With the exception of the yellow light on the indicator beacon, the lamps and the indicator beacon indicate the same modes as the control system: Red = Collective fault. The red lamp indicates that the control system has recognized a fault. Refer to troubleshooting table Red indication lamp is lit. White = Switched ON. After switching on and during the heating 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 heating phase has ended (1 hour and longer). Refer to troubleshooting table Only the white indication lamp is lit. Green = Ready for operation. The green indication lamp lights when all channels have reached their setpoint temperatures. Yellow = Plunger down (tank empty). 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 MXCO054L067A1295 Fig. 6-1 (Refer to manual Control System for position numbers)

Troubleshooting 6-3 4. Troubleshooting Tables The troubleshooting tables serve as an orientation for qualified personnel. They cannot, however, replace targeted troubleshooting with the help of wiring diagrams and measuring instruments. They also do not include all possible problems, only those which most typically occur. Only the White Indication Lamp is Lit Possible cause Possible fault / Troubleshooting Corrective action Refer to Temperature setpoint(s) of one or more heating zones are not reached Release Unit not bridged or not activated Activate diagnosis program of the temperature section Fuse(s) defective (fuses are also located on the modules and boards) Bridge or activate the corresponding contacts of the XS 2 interface Switch on or replace Section 3 Wiring diagram Manual Control System Manual Control System Wiring diagram Cable loose or broken Fix or replace Overtemperature thermostat (on the tank) defective Replace Spare parts list Temperature sensor(s) defective Replace Spare parts list Solid-State-Relay defective Replace Spare parts list Heater(s) defective Replace (Heaters in the tank and heated hose can not be replaced) Temperature setback switched on Switch off or wait until the setback period has expired Automatic temperature setback after motor standstill activated Stop temperature setback Manual Control System

6-4 Troubleshooting Red Indication Lamp is Lit Possible cause Possible fault / Troubleshooting Corrective action Refer to Overtemperature indication from control system (Display 5: Hi blinking) Overtemperature shutdown by control system (displays 3, 4 and 5: blinking) Overtemperature shutdown by tank thermostats Motor switched off due to overheating (thermistor located in the motor) Undertemperature during operation (Display 5: Lo blinking) Ambient temperature too high (Displays 3, 4 and 5: AM bie nt blinking) Temperature sensor short-circuit (Display 5: S blinking) Temperature sensor interruption (Display 5: E blinking) Manual Control System, Service Display Error Adhesive was refilled Wait until the temperature has been reached Manual Control System, Service Display Error Ambient temperature too high Decrease ambient temperature by cooling or airing out Filter of the electrical cabinet fan dirty Clean or replace Section 5 Electrical cabinet fan defective Replace Replace Replace Main contactor defective or dropped Manual Control System, Service Display Error Speed alarm Display 30: r_d Manual Control System, Service Display Error, Parameter r_d, Display Overview Coupling fault (only for optional Coupling monitoring) Display 30: CLU Overpressure (with special function Pressure monitoring) Display 30: Phi Underpressure (with special function Pressure monitoring) Display 30: Plo Safety valve has opened Display 30: bpo (special function) Manual Control System, Service Display Error, Display Overview, Digital Module Manual Control System, Service Display Error, Parameter Phi, Digital Module Manual Control System, Service Display Error, Parameter Plo, Digital Module Manual Control System, Display Overview, Digital Module Other faults Manual Control System, Service Display in Motor Section, Service Display Error

Troubleshooting 6-5 Unit not Functioning Possible cause Possible fault / Troubleshooting Corrective action Refer to No line voltage Connect line voltage Section 3 Main switch not switched on Switch on main switch Section 2 Main switch defective Replace main switch Week timer programmed incorrectly Program correctly Manual Week Timer Week timer defective Replace timer Main fuse activated Switch on main fuse Main fuse activated again Fuse Control voltage (UN / UL) activated Check for short circuit in unit or accessories Check for short circuit in unit or accessories Wiring diagram 24 V DC power supply defective Replace One Channel (Heating Zone) does not Heat Possible cause Possible fault / Troubleshooting Corrective action Refer to Channel is switched off Switch on Manual Control System Channel is switched to measuring mode Switch to control mode Channel/Heating zone defective Activate diagnosis program of the temperature section No Pilot Voltage Possible cause Possible fault / Troubleshooting Corrective action Refer to Parent machine not operating Start up parent machine Tach generator (Accessories) defective Replace Pilot voltage falsely poled Reverse polarity DIP-Switch of the central module incorrectly set or analog board of the central module not aligned properly Check switch positions and align the board if necessary Manual Control System, Central Module Central module defective Replace central module Manual Control System, Central Module, Service Display Uin