Hot Melt Application Head Series PW...

Hot Melt Application Head Series... Manual English NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

Note This manual applies to the entire series. Order number P/N = Order number for Nordson products Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1999. 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, OptiMix, Package of Values, Patternview, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Rhino, S. design stylized, Saturn, SC5, Seal Sentry, 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, Walcom, 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, Coolwave, CPX, Dry Cure, E-Nordson, EasyClean, Eclipse, Equi=Bead, Fill Sentry, Fillmaster, Gluie, Heli-Flow, Ink-Dot, Iso-Flex, Kinetix, Lacquer Cure, Maxima, MicroFin, Minimeter, Multifil, Origin, PermaFlo, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, PurTech, Pulse Spray, Ready Coat, Select Series, Sensomatic, Shaftshield, SheetAire, Spectral, Spectronic, Spectrum, Summit, Sure Brand, Sure Clean, Sure Max, Swirl Coat, Tempus, Tracking Plus, Trade Plus, Universal, Vista, Web Cure, 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_458013I

Table of Contents I Table of Contents Safety............................................................... 1 Description 1. Intended Use............................................... 1 Unintended Use Examples.............................. 1 2. Residual Risks.............................................. 2 3. Note on Manual............................................. 2 4. Functioning................................................. 2 Principle Drawing Adhesive Flow........................... 3 5. ID Plate.................................................... 3 6. Illustrations................................................. 4 Model with Swivel Device.................................. 4 Model with Linear Unit..................................... 5 Installation 1. Unpacking.................................................. 6 2. Transport.................................................. 6 3. Installation................................................. 6 Exhausting Adhesive Vapors............................... 6 4. Storage.................................................... 6 5. Disposal................................................... 6 6. Electrical Connection........................................ 7 Laying Cable............................................. 7 Connecting Application Head............................... 7 Solenoid Valves with Separate Connecting Cable........... 7 7. Pneumatic Connection....................................... 8 Operating with Non-lubricated Control Air.................... 8 Operating with Lubricated Compressed Air................... 8 Connecting Control Air..................................... 9 Control Modules........................................ 9 Swivel Device / Linear Unit.............................. 9

II Table of Contents Installation (contd.) 8. Installing Heated Hoses..................................... 10 Connecting.............................................. 10 Disconnecting........................................... 10 Relieving Pressure.................................... 10 Second Open-jawed Wrench............................ 10 Operation 1. Triggering Solenoid Valve................................... 11 2. Setting Temperatures....................................... 11 3. Important When Using Polyurethane Application Materials (PUR)..................... 11 4. Setting Adhesive Application Quantity......................... 12 Setting Nozzle Stem Stroke............................... 12 5. Positioning Application Head................................ 13 Setting Depth of Submersion.............................. 13 Setting Application Width and Position...................... 13 6. Settings Record Form...................................... 14 Maintenance 1. Relieving Pressure......................................... 15 2. Maintenance Table......................................... 16 3. Visual Inspection for External Damage........................ 16 4. Lubricating Spindles........................................ 16 5. External Cleaning.......................................... 17 6. Replacing Control Module................................... 17 7. Removing Nozzle Insert..................................... 18 8. Purging with Cleaning Agent................................. 19 9. Replacing Seals............................................ 20 Plug Plate............................................... 20 Plug Plate with Seal Design C........................... 20 Plug Plates with Older Seal Designs..................... 21 Piston.................................................. 22 Piston with Seal Design B.............................. 22 Piston with Seal Design A.............................. 23 10. Internal cleaning........................................... 24 Disassembling Mouthpiece................................ 25 Assembling Mouthpiece.................................. 25 11. Maintenance Record Form.................................. 26

Table of Contents III Troubleshooting 1. Troubleshooting Table...................................... 27 Specifications 1. Operating Specifications.................................... 29 2. Electrical Specifications..................................... 29 3. Other Specifications........................................ 29 Processing Materials.............................................................. 30

IV Table of Contents

Hot Melt Application Head Series... 1 Safety WARNING: 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. Description 1. Intended Use Hot melt application heads of the series... hereafter also referred to as application head may be used only to apply polyolefine, EVA and PUR hot melt adhesives. 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 application heads may not be used under the following conditions: In defective condition When changes or modifications have been made by the customer In a potentially explosive atmosphere With unsuitable adhesives When the values stated under Specifications are not complied with. The application heads may not be used to process the following materials: Explosive and flammable materials Erosive and corrosive materials Food products.

2 Hot Melt Application Head Series... 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 on the hot application head: from hot adhesive, when replacing filter cartridge and when making adjustments. Inhalation of potentially hazardous hot melt adhesive vapors. 3. Note on Manual The position numbers in the illustrations do not correspond to the position numbers in the technical drawings and the parts lists. The illustrations show only the essential components. All other components and details can be found in the included technical drawings (Refer to Parts List ). 4. Functioning The application heads... are intended to coat foils that are then adhered to profiles of varying shapes and materials (Profile Wrapping). Polyolefine, EVA and PUR hot melt adhesives can be processed. The application width can be steplessly adjusted between 5 mm and the maximum application width during operation. NOTE: The number in the type designation indicates the maximum application width in mm. NOTE: Some models have a set minimum application width. Refer to separate technical drawing for application pattern. A swivel device or linear unit ( 1000 and higher) with web guide for guiding the substrate is integrated. When work is interrupted for longer periods of time, the application slit (nozzle) can be closed almost all the way with the application width adjuster (not on models with minimum application width). This also causes almost all of the adhesive residue that would otherwise harden in the application head to be pressed out of the application head. The nonstick coating on the parts coming into contact with adhesive makes external cleaning easier. Electrical heater cartridges are used to heat the unit. The temperature is continuously measured by a temperature sensor and controlled by an electronic temperature controller located in the electrical cabinet of a feeding unit or in a separate electrical cabinet.

R Hot Melt Application Head Series... 3 Principle Drawing Adhesive Flow 1 2 3 5 4 Control air Hot melt adhesive 002884 Fig. 1 1 Control rod 2 Filter cartridge 3 Hose connection 4 Clamping device 5 Piston rod 5. ID Plate Nordson Engineering GmbH D 21337 Lüneburg Germany Type of application head Nordson order number Serial number Operating voltage Power consumption V = Volt W = Watt V W CFSY084S0501095 Fig. 2

4 Hot Melt Application Head Series... 6. Illustrations Model with Swivel Device Because the unit is continuously being modified and improved, there are several models in the series... Thus illustrations in this manual can deviate from the actual unit. When appropriate, consult the included Technical Drawing. Figure 3 shows the essential components of the application head using a 350 as an example. More detailed illustrations can be found in the enclosed technical drawings. 1 2 3 4 10 11 12 13 14 9 8 7 6 5 002963 Fig. 3 Application head 350 with swivel device and web guide 1 Control rod 2 Clamping device 3 Handwheel Piston adjustment 4 Handwheel Position adjustment 5 Pneumatic cylinder with stop 6 Piston rod 7 Mouthpiece with application slit (nozzle) 8 Reservoir 9 Swivel device 10 Filter cartridge* 11 Hose connection 12 Connections Heater 13 Solenoid valve Control modules 14 Solenoid valve Swivel device Note: There are separate manuals available for components marked with an asterisk (*). Note: The handwheels Piston adjustment and Position adjustment can also be attached to the other side of the application head. On models with only one hose connection, the connection is always on the piston side of the application head.

Hot Melt Application Head Series... 5 Model with Linear Unit Figure 4 shows the essential components of an application head using a 1300 as an example. More detailed illustrations can be found in the enclosed technical drawings. 1 2 3 4 1300 13 12 11 10 9 8 7 6 5 4 002787 Fig. 4 Example: Application head 1300 with linear unit and web guide 1 Assembly Application head 4 Handwheels Piston adjustment 2 Edge band guide 5 Clamping device 3 Linear unit 6 Limit stop 7 Control rod 8 Piston rod 9 Anti-twist device 10 Filter cartridges * 11 Hose connections 12 Connections Heater 13 Reservoirs Note: There are separate manuals available for components marked with an asterisk (*).

6 Hot Melt Application Head Series... 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. Unpacking Unpack carefully. Then check for any damage caused during shipping. Reuse packaging materials or dispose of properly according to local regulations. 2. Transport NOTE: The application head is a high precision, valuable part. Handle very carefully! Protect the mouthpiece from damage. 3. Installation Install the application head in the appropriate place in the coating machine. Observe the following: Do not operate in a potentially explosive atmosphere Protect from humidity, vibrations, dust and drafts Ensure access to parts relevant for maintenance and operation Position correctly: Control modules must be on top Protect mouthpiece from damage. Exhausting Adhesive Vapors Ensure that adhesive vapors do not exceed the prescribed limits. Exhaust adhesive vapors when necessary. Provide sufficient ventilation of the location where the unit is installed. 4. Storage Do not store outside! Protect from humidity and dust. Do not lay unit on the mouthpiece. Protect the mouthpiece from damage. 5. Disposal When your Nordson product has exhausted its purpose and/or is no longer needed, dispose of it properly according to local regulations.

Hot Melt Application Head Series... 7 6. Electrical Connection WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Laying Cable WARNING: 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! Connecting Application Head WARNING: Only operate with the voltage shown on the ID plate. Link the heater connections to the corresponding outlets of the higher-ranking system components (electrical cabinet of a feeding unit or separate electrical cabinet), depending on system and quantity of heated hose: Via the sockets/connecting lines for heated hoses Via separate connecting cables. Use safety clips when available to secure the plug connection. Solenoid Valves with Separate Connecting Cable With application heads..., the solenoid valves are usually triggered via separate cable, not via sockets / connecting lines for heated hoses. WARNING: Operate solenoid valves only with the voltage shown on the ID plate. CAUTION: Trigger control module solenoid valve(s) only when the application head is heated to operating temperature! If the adhesive is too cold, control module seals may be damaged.

8 Hot Melt Application Head Series... 7. Pneumatic Connection The application head may only be connected to pressure-controlled and conditioned compressed air. The quality of the compressed air must be at least class 2 as stipulated by ISO 8573 1. This means: Max. particle size 1 m Max. particle density 1 mg/m 3 Max. pressure dewpoint 40 C / 40 F Max. oil concentration 0.1mg/m 3. Operating with Non-lubricated Control Air When control modules / application heads are connected to a compressed air system in which the compressed air has previously been lubricated, simply ceasing to lubricate the air is not sufficient. The oil remaining in the compressed air supply will reach the solenoid valves and the control modules and wash out the lubricant/oil from these parts, substantially decreasing the lifetime of the units. To operate with non-lubricated control air, ensure that The system has been converted to absolutely non-lubricated operation No oil from a possible defective compressor can penetrate the compressed air supply. NOTE: Nordson will assume no warranty/liability for damage resulting from unpermitted, temporary lubrication. Operating with Lubricated Compressed Air The application heads / control modules can also be operated with lubricated compressed air. NOTE: Once the air has been lubricated, it must always be lubricated; the lubricated compressed air will wash out the lubricant on the solenoid valves and the control modules. Nordson recommends: Oil P/N Klüber Unisilkon TK002/50 316 578

Hot Melt Application Head Series... 9 Connecting Control Air Control air pressures are adjusted on external compressed air control valves. The pressure control valves are not part of the application head. Control Modules 1. Connect an adjustable air supply to the air connection of the solenoid valve Control module (13, Fig. 3). 2. Set control air pressure to 4 to 6 bar (0.4 to 0.6 MPa / 58 to 87 psi). The exact pressure must be determined for each application. Swivel Device / Linear Unit WARNING: Risk of squash! When EMERGENCY OFF occurs, ensure that the air supply is stopped with the customer s EMERGENCY OFF chain. 1. Connect an adjustable air supply to the air connection of the solenoid valve Swivel device (14, Fig. 3) or Linear unit. 2. Set control air pressure to 4 to 6 bar (0.4 to 0.6 MPa / 58 to 87 psi). The exact pressure must be determined for each application.

10 Hot Melt Application Head Series... 8. 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. 2. Heat application head and hose until the adhesive softens. 3. Screw the hose onto the unit. MXHH001S050B0997 Fig. 5 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(s) of the unit feeding the material to 0 min -1 (rpm); switch off motor(s). 2. Place a reservoir under the application slit of the application head. 3. Activate the solenoid valve electrically or manually. 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. 6

Hot Melt Application Head Series... 11 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. Triggering Solenoid Valve Trigger the solenoid valve Control modules only when the application head is heated to operating temperature! If the adhesive is too cold, control module seals may be damaged. 2. Setting Temperatures The procedure for setting the temperatures is described in the temperature controller manual. Temperature controllers are not part of the application head. They can be located e.g. in the electrical cabinet of the feeding unit or in a separate electrical cabinet. 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. CAUTION: The maximum operating temperature (200C / 392 F) may not be exceeded. Nordson will assume no warranty or liability for damage resulting from incorrect temperature settings. 3. Important When Using Polyurethane Application Materials (PUR) It is imperative that the following guidelines are followed when processing polyurethane application materials (PUR): Wear respiratory protection when the maximum permissible concentration of hazardous substances is exceeded. During production interruptions and work breaks, reduce temperature and close application slit using the handwheels Piston adjustment and Position adjustment as far as possible. Cover remaining opening with special grease (Refer to Processing Materials). Before prolonged standstill of the application system, purge with a suitable cleaning agent. Use only a cleaning agent recommended by the material manufacturer. Close open material connections.

12 Hot Melt Application Head Series... 4. Setting Adhesive Application Quantity The adhesive application quantity depends on the desired adhesive application weight and on the substrate speed. It is usually preselected using the pump speed dials. The optimum setting must be determined by trial and error. The speed dials are located e.g. in the electrical cabinet of the adhesive feeding unit or in a separate electrical cabinet. Depending on the model of the hot melt adhesive application system, pump speed control can also occur with a tach generator or an electronic coating weight control. Setting Nozzle Stem Stroke Some control modules are equipped with a nozzle stem adjustment. It is used for fine adjustment of the adhesive application quantity or the adhesive flow quantity. As the control module closes, the nozzle stem presses a small amount of material out of the surface nozzle. When an application requires only a small quantity of adhesive, a lower stem stroke should be set to keep the material quantity as low as possible. Figure 7 shows the nozzle stem stroke adjustment with adjusting screw (1) and retaining nut (2). WARNING: Hazard! The stem stroke adjustment knob has no upper setting limit. If compressed air is connected, never turn the adjusting screw all the way up; it may jump out. Max. + 2.8 mm Max. + 1.175 in. 1 2 WARNING: The stem stroke may only be adjusted when the application head is heated up! Failure to observe may cause damage to seals. 002868 Fig. 7 Nozzle stem stroke Counterclockwise (+) = increase Flow quantity Increase Clockwise ( ) = decrease Decrease

Hot Melt Application Head Series... 13 5. Positioning Application Head 15 To keep tensile forces to the web guide rolls at a minimum, the substrate should be guided at a right angle to the nozzle. During coating, the nozzle must be submerged several millimeters into the substrate. This is done by pneumatically swiveling the web guide or by guiding the head on the linear unit to the web guide. WARNING: Risk of squash! Do not handle application head when the web guide is swiveling in and out or the linear unit is moving. Swiveling is controlled by an external control unit. 002869 The optimum depth depends, among other factors, on the substrate and the web tension; it must be determined by trial and error. Fig. 8 Setting Depth of Submersion CAUTION: Adjust the stops such that the web guide does not touch the mouthpiece, even when swiveled in. Set limit stops to achieve the desired insertion depth. Set the proximity switches on the pneumatic cylinder such that they switch when position Swiveled in has been reached. On some models the upper web guide roll can be adjusted parallel by several millimeters to optimize the web path. Setting Application Width and Position CAUTION: Adjust application width and position only when the application head is heated. Otherwise cold material will damage the application head. A A B When the handwheel Piston adjustment is turned, the piston moves in the nozzle and the application width changes. When the handwheel Position adjustment is turned, the nozzle moves over the piston and the application width also changes. When both handwheels are turned, the position of the adhesive path on the substrate can be moved. The best way to determine the direction of rotation of the handwheels is to try them out before initial startup. B 002139 Fig. 9 Principle drawing

14 Hot Melt Application Head Series... 6. Settings Record Form Production information Adhesive Cleaning agent / rinsing material Basic settings Temperatures Manufacturer Softening temperature Max. processing temperature Viscosity Manufacturer Max. heating temperature Flash point Control air pressure Stem stroke (rotations) Application width Setpoint Undertemperature Overtemperature Notes Form filled out by: Name Date

Hot Melt Application Head Series... 15 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 operational lifetime of the unit. It should not be neglected under any circumstances. 1. Relieving Pressure WARNING: System and adhesive pressurized. Before disconnecting heated hoses and replacing filter cartridges, relieve system pressure. Failure to observe can result in serious burns. WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. 1. Set motor speed(s) of feeding unit to 0 min -1 (rpm); switch off motor(s). 2. Place a reservoir under the application slit of the application head. 3. Activate the solenoid valve electrically or manually. Repeat this procedure until no more adhesive flows out. 4. Reuse adhesive or dispose of properly according to local regulations.

16 Hot Melt Application Head Series... 2. Maintenance Table The maintenance intervals are general guidelines based on experience. Depending on the location of the unit, the production conditions and the operating time, other maintenance intervals may prove necessary. Unit part Activity Interval Refer to Purge with cleaning agent When changing adhesive, if the Page 19 adhesives used can not be mixed Complete application system Before prolonged production interruptions, if PUR adhesive is processed Observe adhesive manufacturer s instructions Complete application Visual inspection Daily Page 16 head External cleaning Daily Page 17 Mouthpiece External cleaning Daily Page 17 Internal cleaning When dirty Page 24 Seals Replace When damaged Page 20 Control module Check inspection hole* Weekly Replace When leaking Page 17 Spindles Lubricate As needed Page 16 Filter cartridge Refer to separate manual NOTE: * The inspection hole is the hole in the control module casing through which the nozzle stem can be seen. 3. 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. 4. Lubricating Spindles Use only temperature-resistant grease to lubricate the spindles on the piston and position adjustment. Nordson recommends special high temperature grease (Refer to Processing Materials).

Hot Melt Application Head Series... 17 5. External Cleaning External cleaning prevents impurities created during production from causing the unit to malfunction. CAUTION: Do not damage or remove warning signs. Damaged or removed warning signs must be replaced by new ones. CAUTION: Never use hard tools. Use extreme care when handling the mouthpiece. WARNING: Hot! Risk of burns. Wear heat-protective gloves. Remove adhesive residue only 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. 1. Remove hot melt adhesive residue from the mouthpiece promptly with a soft cloth. 2. Remove tough and hardened residue with a wooden or PTFE spatula if necessary. 6. Replacing Control Module WARNING: Hot! Risk of burns. Wear heat-protective gloves. CAUTION: To prevent damage to seals and nozzle stem, replace control modules only when application head is heated. Fig. 10 Principle drawing EPAH305S050A1297 1. Heat application head until adhesive is soft. 2. Set to maximum application width. 3. Relieve pressure. 4. Disconnect compressed air hoses. 5. Release fastening screws and replace control module. 6. Screw new control module into place. 7. Reconnect compressed air. NOTE: The stem stroke adjustment (when present) usually does not require adjustment.

18 Hot Melt Application Head Series... 7. Removing Nozzle Insert NOTE: The nozzle insert is the part in which the nozzle stem of the control module blocks or releases the material flow. Older application head models use a body with integrated nozzle receptacle instead. Control module models to be used with a separate nozzle insert can be recognized by the rounded nozzle stem tip. 1. Remove control module (Refer to Replacing Control Module). 1 2. Extract nozzle insert (2) from control module hole. Do this by inserting included tool (1), turning 45 and extracting. 3. Always replace the O-ring on the nozzle insert. 2 002623 Fig. 11

Hot Melt Application Head Series... 19 8. Purging with Cleaning Agent CAUTION: Use only a cleaning agent recommended by the adhesive manufacturer. Observe Manufacturer Safety Data Sheet (MSDS) for the cleaning agent. WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. 1. Empty the feeding unit and fill with cleaning agent. 2. Heat up heated system components. Comply with maximum heating temperature of cleaning agent. 3. Place a suitable reservoir under the application slit. 4. Set the speed and pressure of the feeding unit to the lowest values. 5. Activate the solenoid valve electrically or manually. 6. Switch on feeding unit. 7. Continue to convey the cleaning agent until the cleaning agent flowing out of the unit no longer contains adhesive residue. NOTE: Properly dispose of cleaning agent according to local regulations. NOTE: Before starting production again, flush out cleaning agent residue using the new hot melt adhesive.

20 Hot Melt Application Head Series... 9. Replacing Seals The seals must be replaced when adhesive is emitted outside of the set width. WARNING: Risk of squash! Ensure that the swivel device / linear unit can not be triggered. Stop control air supply to prevent triggering. WARNING: Hot! Risk of burns. Wear heat-protective gloves. NOTE: When a seal is replaced, the inside of the mouthpiece should always be cleaned (Refer to Internal Cleaning). Plug Plate NOTE: Only models with only one piston (up to application width 800 mm) have a plug plate. Plug Plate with Seal Design C 1 1 2 3 4 5 003046 Fig. 12 Plug plate, seal design C (assembly P/N 206215) 1 End plate P/N 206256 2 Sealing socket P/N 206255 3 O-ring P/N 250263 4 Sealing plate P/N 206257 5 Sealing cord P/N 252430 1. Heat application head until adhesive is soft. NOTE: Hardened reactive adhesives (PUR) can not be softened. 2. Relieve pressure (Refer to Relieving Pressure). 3. Remove end plate (1). 4. Disassemble mouthpiece (Refer to Internal Cleaning, Disassembling Mouthpiece).

Hot Melt Application Head Series... 21 5. Detach parts 2 and 5. 6. For best results, the assembly P/N 206215 should be completely replaced. Parts 2 and 5 are already built into the assembly. Otherwise: a. Pry open sealing socket (2) (e.g. with a retaining ring pliers) to be able to extract the sealing plate. b. Remove old sealing cord. c. Lay new sealing cord in groove and press lightly into place (smooth vice jaws!). d. Replace O-ring. e. Pry open sealing socket and put plate back into place. f. Insert assembled parts 2 to 5 in mouthpiece. 7. Replace piston seals if necessary (Refer to Piston). 8. Assemble mouthpiece. 9. Screw on end plate. Plug Plates with Older Seal Designs Plug plates with older seal designs can be recognized by the grasping thread. NOTE: For best results, the plug plate should be replaced with the assembly P/N 206215 (plug plate with seal design C) for better sealing instead of simply replacing the seal. 1 A B 5 2 6 3 7 4 003047 Fig. 13 Plug Plates, Seal Designs A and B 1 Grasping thread 2 Plug plate P/N 455391 3 Not shown: Sealing socket P/N 459429 4 Not shown: Sliding seal P/N 455440 5 Plug plate P/N 464234 6 Sealing socket P/N 459429 7 Flat seal P/N 789731

22 Hot Melt Application Head Series... Piston 1. Release clamping screw (3) on clamping device and slide clamping device over the nut (2) on the piston spindle. 2. Release stop (1) and slide over the nut (2) on the piston spindle. 3. Unscrew anti-twist device (4). 4. Disassemble mouthpiece (Refer to Internal Cleaning, Disassembling Mouthpiece). 5. Crank piston rod all the way off of the spindle and extract it from the body. 6. Depending on the piston design, proceed as follows: 1 2 3 4 002958 Fig. 14 Piston with Seal Design B 1. Release screw (5) and pull piston off of piston rod. 2. Clamp piston in a vice and unscrew cap nut (8). The sealing socket (6, O/N 464226) and flat seal (9, P/N 789731) can now be checked and, if necessary, replaced. Re-assembly is in reverse order. 5 6 7 8 9 002959 Fig. 15 Piston with Seal Design B (Assembly P/N 464235)

Hot Melt Application Head Series... 23 Piston with Seal Design A 1. Knock out alignment pin (10, Fig. 16). 2. Unscrew nut (5) from the piston rod. 3. Place piston rod back into the body and crank in such that the included disassembly tool (11) can be screwed onto the body as shown. Do this by putting the top part of the mouthpiece in place but not screwing it on. 4. Insert M6 screw (13) into the piston rod. 5 6 7 8 9 10 5. Crank in piston rod such that wiper rings (6), sealing socket (7) and slide receptacle (14) are pulled off. Now the individual pieces can be removed, checked and replaced, if necessary. NOTE: The piston with seal design A does not have a separate assembly number. For order numbers of individual parts, refer to technical drawings and parts lists for application head. Re-assembly is in reverse order. Observe the following: Position of wiper rings: Chamfer (12) facing away from the sealing socket. 11 12 13 To prevent the slide from bending: Screw on anti-twist device (4, Fig. 14) as soon as the piston rod is screwed in far enough Application heads with plug plate: Adjust stop (1, Fig. 14) on piston rod such that the slide (8) and the clamped in plate (2, Fig. 13) in the plug plate just have contact when the piston rod is cranked in all the way, thereby closing the application slit. 14 Fig. 16 Piston with Seal Design A 002960

24 Hot Melt Application Head Series... 10. Internal cleaning The inside of the mouthpiece must be cleaned when adhesive residue reduces the quality of the application pattern. WARNING: Risk of squash! Ensure that the swivel device can not be triggered. To do this, block the control air supply to the swivel device. WARNING: Hot! Risk of burns. Wear heat-protective gloves. CAUTION: Use only a cleaning agent recommended by the adhesive manufacturer. Observe Manufacturer Safety Data Sheet (MSDS) for the cleaning agent. 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).

Hot Melt Application Head Series... 25 Disassembling Mouthpiece 1. Relieve pressure. Refer to Relieving Pressure. 1 2 3 2. Detach plug plate. Refer to Replacing Seals, Plug Plate). NOTE: With plug plates with seal design C, only the end plate is removed. 3. Release control rod (2) on clamping device (3) and slide slightly into the control air strip (1). 4. Remove reservoir (4). 5. Release accessible screws in top section of mouthpiece (6). 6. Screw in included assembly guide pins. 7. Insert M10 screws into the forcing thread of the top section of the mouthpiece (6) to separate the top section from the bottom section. 6 5 4 002138 Fig. 17 8. Remove adhesive residue from the holes and the channels as well as from the sealing surfaces. 9. Use a cleaning agent to dissolve adhesive residue that could not be removed mechanically. NOTE: Properly dispose of cleaning agent and adhesive residue according to local regulations. Assembling Mouthpiece 1. Put top section of mouthpiece in place; use a rubber hammer if necessary. 2. Tighten screws to 60 Nm. 3. Unscrew included assembly guide pins.

26 Hot Melt Application Head Series... 11. Maintenance Record Form Unit part Activity Date Name Date Name Application head Purge with cleaning agent Mouthpiece Disassemble and clean Control module Check inspection hole Filter cartridge Clean and replace filter screen Spindles Lubricate

Hot Melt Application Head Series... 27 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. Troubleshooting Table When troubleshooting, other components of the application system may need to be considered. The troubleshooting table serves as an aid to qualified personnel. It can not however replace targeted troubleshooting using e.g the wiring diagram and measuring instruments. They also do not include all possible problems, only those which most typically occur. Problem Possible Cause Corrective Action Refer to No adhesive Application head has not yet reached operating temperature Wait until temperature has been reached, check temperature setting if necessary Page 11 Not enough adhesive in feeding unit Fill Pump of the feeding unit not working Check Control air not connected Connect Page 9 Mouthpiece blocked Filter cartridge clogged Clean inside of mouthpiece, disassemble if necessary Clean filter cartridge and replace filter screen Page 24 Separate manual Nozzle stem is stuck Replace control module Page 17 Continued on next page

28 Hot Melt Application Head Series... 1. Troubleshooting Table (contd.) Problem Possible Cause Corrective Action Refer to No adhesive: application head is cold Temperature not set correctly on temperature controller Plug has no contact Set correct temperature Page 11 Secure plug connection with clip if available Heater cartridge defective Replace heater cartridge Adhesive application is not exact Mouthpiece partially blocked or damaged Mouthpiece does not have even contact with the substrate Clean inside of mouthpiece, disassemble if necessary Check positioning, adjust if necessary Page 24 Page 13 Production parameters not attuned to one another Adjust parameters, change if necessary Adhesive unsuitable Consult adhesive manufacturer Data sheet The open time is too long The open time is too short Application temperature too high Set temperature lower Page 11 Adhesive unsuitable Consult adhesive manufacturer Data sheet Application temperature too low Set temperature higher Page 11 Adhesive unsuitable Consult adhesive manufacturer Data sheet

Hot Melt Application Head Series... 29 Specifications 1. Operating Specifications Maximum operating temperature 200 C 392 F Operating air pressure Control modules 4 to 6 bar 0,4 to 0,6 MPa 58 to 87 psi Swivel device Maximum adhesive pressure at inlet When application head is open 35 bar 3,5 MPa 507 psi (triggered) When application head is closed 50 bar 5 MPa 725 psi Adhesive viscosity that can be 5000 mpas to 100000 mpas processed Maximum flow quantity (application 1000 g/min per 100 mm application width weight) at: Adhesive pressure = 35 bar / 3.5 MPa / 507.5 psi Adhesive viscosity = 50 000 mpas Application width Heating time Noise emission Note: Ensure that the system component feeding the material (e.g. hot melt applicator series MC) has sufficient feed capacity to achieve the desired grammage (adhesive per surface). 5 to x mm (x depending on type designation) Note: Some models have a set minimum application width. Refer to separate technical drawing for application pattern Approx. 45 min < 85 db(a) 2. Electrical Specifications Operating voltage (heater) Refer to ID plate Power consumption Refer to ID plate Operating voltage (solenoid valve) Refer to ID plates on solenoid valves Power consumption (solenoid valve) Refer to ID plates on solenoid valves Possible temperature sensors Fe-CuNi (FE/KO), Ni 120 or Pt 100 3. Other Specifications Weight 350: approx. 90 kg, refer to transport documents for other types Dimensions Refer to technical drawing Degree of protection IP 50

30 Hot Melt Application Head Series... Processing Materials High temperature grease Tube 250 g P/N 783959 Cartridge 400 g P/N 402238 Caution: Do not mix this lubricant with other lubricants! If necessary, first clean grease off of parts.