Fill Sentry Automated Fill System Customer Product Manual Part NORDSON CORPORATION www.nordson.com
CAUTION: If this equipment is used with other Nordson equipment, refer to the manuals provided with that equipment for instructions and the safety precautions you should take. Nordson Corporation welcomes requests for information, comments and inquiries about its products. General information about Nordson can be found on the Internet using the following address: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 11475 Lakefield Drive Duluth, GA 30097 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright January 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, Fluidshooter, 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, PluraFoam, Porous Coat, PowderGrid, Powderware, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Ready Cost, Rhino, S. design stylized, Saturn, SC5, SCF, Select Charge, Select Coat, Select Cure, Shur-Lok, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure-Bond, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. ATS, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, CPX, Control Weave, Controlled Fiberization, EasyClean, Ebraid, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink-Dot, Maxima, MicroFin, Minimeter, Multifil, OptiMix, Pattern View, PluraMix, Primarc, Prism, Process Sentry, PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, and 2 Rings (Design) are trademarks of Nordson Corporation. Fill Sentry 2001 Nordson Corporation
Table of Contents i Table of Contents Safety System Overview System Setup Operation Operate Safely............................................... 1-2 Safety Symbols............................................... 1-3 Qualified Personnel........................................... 1-4 Intended Use................................................. 1-4 Installation and Electrical Connections........................... 1-5 Operation.................................................... 1-5 Maintenance/Repair........................................... 1-7 Cleaning..................................................... 1-8 Thermoplastic Hot Melt Material................................ 1-9 Equipment and Material Disposal............................... 1-9 System Description........................................... 2-2 System Components.......................................... 2-3 Section Overview............................................. 3-2 Verifying the Program......................................... 3-4 Adjusting the System Air Pressure.............................. 3-8 Adjusting the Tilt Table......................................... 3-9 Adjusting the Adhesive Demand Cycle Variables................. 3-10 Setting the Fault Limit Value................................... 3-14 Setting the Blow Back Count.................................. 3-16 Testing the System........................................... 3-18 Controls and Indicators........................................ 4-2 Operating Procedures......................................... 4-6 2001 Nordson Corporation
ii Table of Contents Maintenance Troubleshooting Schematics Parts Technical Data Weekly Maintenance Procedures............................... 5-2 Monthly Maintenance Procedures............................... 5-6 Light Tower Fault Light Turns On................................ 6-2 Tank Overfills................................................. 6-7 Light Tower Fault Light Remains Off When the Tank Runs Low...................................... 6-9 System Pneumatic Diagram.................................... 7-2 System Control Schematic..................................... 7-3 System Wiring Diagram........................................ 7-4 How to Order Parts........................................... 8-2 Major System Component Parts................................ 8-2 Installation Kit............................................... 8-16 Recommended Spare Parts................................... 8-17 Accessories................................................. 8-17 General Specifications......................................... 9-2 Vacuum Pump................................................ 9-3 Light Tower assembly......................................... 9-3 Main Control Unit............................................. 9-3 Drop Chute with Sensor....................................... 9-4 Tilt Table..................................................... 9-4 Components Dimensions...................................... 9-4 2001 Nordson Corporation
Safety 1-1 Section 1 Safety Operate Safely................................................... 1-2 Safety Symbols.................................................. 1-3 Qualified Personnel.............................................. 1-4 Intended Use.................................................... 1-4 Installation and Electrical Connections............................ 1-5 Operation....................................................... 1-5 Less-Obvious Dangers.......................................... 1-6 Action in the Event of Unit Malfunction............................. 1-6 Danger of Burns................................................ 1-7 Maintenance/Repair.............................................. 1-7 Cleaning........................................................ 1-8 Thermoplastic Hot Melt Material................................... 1-9 Equipment and Material Disposal................................. 1-9 1999 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-2 Safety Safety Operate Safely Safety instructions contained in this section and throughout this document apply to tasks that may be performed with or on the unit. Warnings related to specific safety concerns are included within the text as appropriate. It is very important that these safety instructions are always followed. Failure to do so could result in personal injury and/or damage to the unit or other equipment. With this in mind, here are some basic safety recommendations: Read and become familiar with this Safety section prior to installing, operating, maintaining, or repairing the unit. Read and follow the warnings which appear within the text and are related to specific tasks. Store this document within easy reach of personnel operating or maintaining the unit. Wear personal protective equipment and clothing such as safety goggles and gloves. Familiarize yourself with and follow all safety instructions prescribed by your company, general accident-prevention regulations, and government safety regulations. A1EN 02 [XX SAFE] 4 Issued 11/94 1999 Nordson Corporation
Safety 1-3 Safety Symbols The following symbols are used to warn against dangers or possible sources of danger. Become familiar with them! Failure to heed a warning could lead to personal injury and/or damage to the unit or other equipment. WARNING: Failure to observe may result in personal injury, death, or equipment damage. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from the line voltage. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown. WARNING: Risk of explosion or fire. Fire, open flames, and smoking prohibited. WARNING: System or material pressurized. Relieve pressure. Failure to observe may result in serious burns. CAUTION: Failure to observe may result in equipment damage. CAUTION: Hot surface. Failure to observe may result in burns. 1999 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-4 Safety Qualified Personnel Qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and/or repair the equipment. It is the responsibility of the company operating the equipment to see that its personnel meet these requirements. Intended Use The unit is designed and intended to be used only for the purpose described in the Description section. Uses not in accordance with that section or as described in this document are considered unintended uses and not in accordance with governing regulations. WARNING: Use of this equipment in ways other than described in this document may result in personal injury, death, or equipment damage. The following actions of the owner or operator of the unit are some, but not all, examples of unintended use which would permit Nordson to claim it is not responsible for personal injury or property damage arising from such unintended use: Unapproved modifications or changes to the unit Failure to comply with the safety instructions Failure to comply with instructions concerning installation, use, operation, maintenance, or repair, or when these tasks are carried out by unqualified personnel Use of inappropriate or incompatible foreign materials or auxiliary equipment Failure to observe workplace safety rules or regulations issued by government authorities or safety councils A1EN 02 [XX SAFE] 4 Issued 11/94 1999 Nordson Corporation
Safety 1-5 Installation and Electrical Connections WARNING: Failure to follow the safety procedures can result in injury or death. All electrical, pneumatic, gas, and hydraulic connections and installations of hot melt equipment may only be carried out by qualified personnel. Be sure to observe installation instructions for components and accessories. Equipment must be properly grounded and fused according to its rated current consumption (see ID plate). Cables which run outside the unit must regularly be checked for wear or damage. Power supply wire gauge and insulation must be sufficient to handle rated current consumption. Cables must never be squeezed or pinched. Do not locate cables or hoses in high traffic areas. Operation The unit should be operated by qualified personnel in accordance with the instructions presented in this document. WARNING: Failure to follow the safety procedures can result in injury or death. Never allow the unit to be operated by personnel under the influence of substances which reduce their reaction times, or who are not able to operate the equipment for physical reasons. Prior to each start-up of the unit, check protection and warning devices and make sure they are fully functional. Do not operate the unit if these devices are not functioning properly. When the removal of safety equipment is required for installation, maintenance, or repair of the unit, it must be re-connected immediately upon completion of the work. Prior to start-up of the unit, check to make sure all safety guards and safety equipment are in place and functioning properly. 1999 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-6 Safety Operation (contd) In a humid environment, only equipment featuring a corresponding class of protection may be operated. Do not operate the unit in an explosive environment. Keep parts of the body or clothing away from rotating parts. Do not wear loose articles of clothing when operating or servicing units with rotating parts. Take off wrist watches, rings, necklaces, or similar pieces of jewelry and pin up or cover long hair before performing any work on or with the unit. To carry out measurements on work pieces, switch off the unit and wait until it comes to a standstill. Never point hand guns or applicator nozzles at yourself or other persons. Less-Obvious Dangers WARNING: An operator or service technician working with the unit should be aware of less-obvious dangers that often cannot be completely minimized at production sites: Exposed surfaces of the unit which cannot be practically safeguarded. They may be hot and take time to cool after the unit has been operating. The possibility that electrical potentials may remain in the unit after the unit was de-energized Hot melt material and vapors Hydraulically or pneumatically operated parts of the unit Parts winding something up or down which are not covered Action in the Event of Unit Malfunction If the unit malfunctions, switch it off immediately. Turn the circuit breaker or main power switch OFF. Have the unit repaired by qualified personnel only. A1EN 02 [XX SAFE] 4 Issued 11/94 1999 Nordson Corporation
Safety 1-7 Danger of Burns Contact with hot melt materials or hot areas of the unit may produce a severe skin burn. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown. Be extremely careful when using hot melt material. Even solidified material may still be very hot. Always wear protective clothing which safely covers all exposed parts of the body. In case of burns: Immediately cool affected skin areas using cold, clean water. Do not forcefully remove hot melt material from the skin. Immediately seek medical attention. Maintenance/Repair Allow only qualified personnel to perform the procedures described in this document. When performing such tasks, wear protective clothing, and equipment. WARNING: Even when the circuit breaker or main power switch is OFF, the unit is still electrically energized. Complete the following steps prior to maintenance or repair: Disconnect, lock out, and tag external power supply. To ensure the external power supply is disconnected, attempt to operate the unit. If the unit does not energize, proceed with maintenance or repair work. If the unit energizes, repeat the disconnect, lock out, and tag procedure. Re-test the unit. 1999 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-8 Safety Maintenance/Repair (contd) Follow the specific instructions provided in this manual to relieve the system pressure in the entire unit. Secure pneumatically- or hydraulically-operated equipment against uncontrolled movement. Only use parts which do not compromise the safety of the unit. Only use genuine Nordson parts. Always use tools with insulated handles when removing or installing components. Cleaning NOTE: Always refer to the material manufacturer s Material Safety Data Sheet (MSDS) or material information sheet before working with any material. WARNING: Never clean any aluminum part or flush any system using halogenated hydrocarbon fluids. Examples of common halogenated hydrocarbons are: dichloromethylene, 1,1,1-trichloroethylene, and perchloroethylene. Halogenated hydrocarbons may react violently with aluminum parts. WARNING: Fire, open flame, and smoking are prohibited when cleaning fluids are used. Observe all explosion prevention regulations. Cleaning fluids may only be heated using temperature-controlled and explosion-protected heaters. Never use an open flame to clean the unit or components of the unit. Use only cleaning fluids designed or intended to be used with the hot melt material being used in the unit. Never use paint fluids under any circumstances. Note the flash point of the cleaning fluid used. Only use a controlled heating method to heat fluids. Ensure sufficient room ventilation to draw off generated vapors. Avoid prolonged breathing of vapors. A1EN 02 [XX SAFE] 4 Issued 11/94 1999 Nordson Corporation
Safety 1-9 Thermoplastic Hot Melt Material NOTE: Always refer to the material manufacturer s Material Safety Data Sheet (MSDS) or material information sheet before working with any hot melt material. Ensure the work area is adequately ventilated. Do not exceed recommended processing temperatures. Doing so creates a danger to personnel due to decomposition of the material. Equipment and Material Disposal Dispose of equipment and materials used in operation and cleaning according to local regulations. 1999 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4
1-10 Safety A1EN 02 [XX SAFE] 4 Issued 11/94 1999 Nordson Corporation
System Overview 2-1 Section 2 System Overview System Description.............................................. 2-2 How the System Works.......................................... 2-2 System Components............................................. 2-3 Vacuum Pump.................................................. 2-3 Tube Loader................................................... 2-5 Main Control Unit............................................... 2-6 Distribution System............................................. 2-7 Drop Chute with Sensor......................................... 2-8 Melter-Specific Lid Assembly..................................... 2-9 Light Tower Assembly........................................... 2-9 Tilt Table...................................................... 2-10 2001 Nordson Corporation
2-2 System Overview System Overview System Description The system transfers solid adhesives in the form of pellets, pastilles, and mini-slats from a bulk supply to as many as five hot melt systems. It eliminates the need for operators to manually fill the hot melt tanks and prevents the process downtime that occurs when a hot melt tank runs out of adhesive. The system can transfer up to 100 kg/hr (220 lb/hr) of adhesive from a bulk adhesive supply to the tanks. Because the distribution lines for the system run overhead, space requirements for the system are minimal. How the System Works The fill process starts when the level in one of the melters drops below a pre-set level, at which time a sensor located in the melter s tank signals the main control unit (calls for adhesive) to start the vacuum pump. As the vacuum pump cycles, adhesive is drawn up from the bulk supply and transferred in the vacuum air stream through overhead piping and deposited into a tube loader located above the melter. After a pre-set time, the vacuum pump stops and the adhesive discharges into the melter s tank. This process continues until the sensor detects that the tank is once again full. Overhead Piping Bulk Supply Tube Loader Vacuum Pump Melter 5746134A 2001 Nordson Corporation
System Overview 2-3 System Components The system consists of the following standard components: Vacuum pump Tube loader (each melter) Main control unit Distribution system (rigid lines and flexible tubing) Drop chute with sensor Melter-specific lid assembly Light tower assembly (each melter) Tilt table The tube loader, light tower assembly, and drop chute with sensor form a complete fill station. Vacuum Pump The vacuum pump creates the air stream that conveys the adhesive. The main components of the pump are the motor, vacuum turbine, pleated filter, dust collection chamber, and filter blow back assembly (not shown). Motor Vacuum Turbine Pleated Filter Dust Collection Chamber 5746027A 2001 Nordson Corporation
2-4 System Overview Operation When a sensor calls for adhesive, the main control unit turns on the vacuum motor that drives the vacuum turbine. The turbine pulls air into the distribution system through the feed tube serving the fill station calling for adhesive, through the filter, and exhausts the air through vents in the turbine housing. Vacuum Motor Vacuum Turbine Turbine Housing Distribution System Filter 5746031A After a pre-programmed number of vacuum pump cycles, the filter blow back assembly delivers three short blasts of compressed air into the filter in the opposite direction of normal air flow. This action loosens any fines and powder, which fall into the dust collection chamber located below the filter. Filter Blow back Assembly 5746089A 2001 Nordson Corporation
System Overview 2-5 Tube Loader The tube loader separates the adhesive from the air stream and provides a convenient way to control the volume of adhesive being delivered to a tank each time the pump cycles. The main components of the tube loader are the adhesive trap, vacuum valve, separator screen, sequence valve, tube loader body, and flapper valve. Adhesive Trap Vacuum Valve Separator Screen Solenoid Valve Tube Loader Body Flapper Valve 5746082A Operation Whenever the main control unit turns the vacuum pump on, it simultaneously opens the solenoid valve on the tube loader at the station that is calling for adhesive. The solenoid valve then opens the tube loader s vacuum valve, allowing the vacuum to draw air in through the melter s feed tube, which pulls the flapper valve closed. 5746085A 2001 Nordson Corporation
2-6 System Overview When sufficient vacuum exists, adhesive is drawn up through the feed tube, into the overhead adhesive transfer line, through the adhesive trap, and into the top of the tube loader. As adhesive enters the tube loader, it is separated from the air stream by the separator screen. Adhesive powder and fines entering the tube loader pass through the screen and are ultimately deposited on the vacuum filter. When the pump cycle ends, the vacuum is lost and the weight of the adhesive pushes the flapper valve open. The adhesive falls through the flexible tubing and into the melter s tank. 5746086A Main Control Unit The main control unit is used to set up the Fill Sentry system, turn it on and off, and reset faults. The control unit includes the system s input and output circuits, power switch, reset button, 24 VDC power supply, and programmable control relay. For more than two melters, an expansion module is added to the relay. Power Switch Reset Button 5746013A 2001 Nordson Corporation
System Overview 2-7 Distribution System The distribution system consists of a single vacuum line that connects each tube loader to the vacuum pump, individual adhesive transfer lines running from the bulk container to each tube loader, and a flexible drop line from each tube loader down to the drop chute mounted on the hot melt tank. The distribution lines run overhead to minimize space requirements. Adhesive Transfer Lines Vacuum Line Vacuum Pump Bulk Container Tube Loader Flexible Drop Line 5746048A The distribution system contains one feed tube for each fill station. A feed tube is a piece of rigid tubing that serves as the adhesive intake point for each adhesive transfer line. On some systems, the feed tubes are inserted vertically into the top of the tote and held in place by a bracket. Feed tube positions can be adjusted as the adhesive level changes in the bulk container. On some systems, the feed tubes are positioned horizontally at the bottom of a special bulk container. All feed tubes, whether vertical or horizontal, have a series of air inlets that are used to control the level of vacuum and therefore the volume of adhesive in an individual adhesive transfer line. The flexible tubing connecting each feed tube to it s overhead distribution line is used to cover the air inlets. As more air inlet openings are covered, the vacuum level increases. Likewise, as more air inlets are exposed, the vacuum level decreases. An increase in vacuum level causes a proportional increase in the volume of adhesive entering the distribution line. Air Inlets Bracket Feed Tube 5746040A 2001 Nordson Corporation
2-8 System Overview The vertical feed tubes are equipped with a metal strip at the intake end to prevent clogging. The other end of each feed tube is connected to the flexible drop tubing that connects the feed tube to it s overhead distribution line. Installations that require the use of horizontal feed tubes generally require the fabrication of an adapter to mate the feed tubes to the bottom of the bulk adhesive supply. As with vertical feed tubes, the air-to-adhesive ratio is adjusted by moving the flexible tubing to cover or expose air inlet openings. Whereas vertical feed tubes draw adhesive up from their open end, horizontal feed tubes are gravity fed with adhesive through a rectangular opening in the side of the tube. The volume of adhesive entering a horizontal feed tube is controlled by sliding the feed tube in or out of the adapter to expose more or less of the rectangular opening. Drop Chute with Sensor The drop chute is mounted to a modified lid assembly for each melter and holds the level sensor in position inside the melter s tank. The sensor is connected directly to a control module inside the light tower junction box. When the sensor initiates a fill request, adhesive is discharged from the tube loader into the drop chute, which directs the adhesive into the tank. A lid on the top of each drop chute can be removed for manual filling of the tank. Lid Drop Chute Level Sensor 5746029A 2001 Nordson Corporation
System Overview 2-9 Melter-Specific Lid Assembly In order to fit the drop chute to different melter models, the original melter lid assembly is removed and a new melter-specific replacement lid assembly is installed. 5746141A Light Tower Assembly The system includes one light tower assembly for each fill station. The light tower at each fill station indicates when the station is on (green), when it is calling for adhesive (blue), and when a fault has occurred (red). The light tower is mounted on a junction box equipped with a station power (on/off) switch and a control module for adjusting the sensitivity of the fill station s level sensor. Red Blue Green Station Power On/Off Switch Control Module 5746038A 2001 Nordson Corporation
2-10 System Overview Tilt Table As the level of adhesive in the tote decreases, the distribution of adhesive across the tote tends to become uneven, with less adhesive on the feed tube side. To ensure a continuous supply of adhesive to the feed tubes, the tilt table automatically inclines when the tote is approximately one-half full, which causes the remaining adhesive to flow around and cover the feed tube inlets. To further improve the flow of adhesive to the feed tubes, the tilt table is equipped with a vibrator that turns on each time the vacuum pump operates. To prevent the introduction of foreign material into the adhesive supply, a protective tarp is provided to cover the tote. The tarp fits snugly over the tote and has an opening for the feed tubes. Protective Tarp Tilt Table Tote 5746030A 2001 Nordson Corporation
System Setup 3-1 Section 3 System Setup Section Overview................................................ 3-2 Why Setup?.................................................... 3-2 Verifying the Program............................................ 3-4 Adjusting the System Air Pressure................................ 3-8 Adjusting the Tilt Table........................................... 3-9 Adjusting the Adhesive Demand Cycle Variables.................. 3-10 Setting the Fault Limit Value..................................... 3-14 Setting the Blow Back Count.................................... 3-16 Testing the System.............................................. 3-18 2001 Nordson Corporation
3-2 System Setup System Setup Section Overview This section provides the setup procedures necessary for the system to operate correctly. When the system was installed, Nordson personnel completed each of the procedures described in this section and no further setup or adjustment of the system should be necessary. However, under certain circumstances, one or more of the setup procedures may have to be repeated. The setup procedures are: Verifying the Program Adjusting the System Air Pressure Adjusting the Tilt Table Adjusting the Adhesive Demand Cycle Variables Setting the Fault Limit Value Setting the Blow Back Count Testing the System This section does not describe the installation of system components. Why Setup? The circumstances that may require one or more setup procedure to be repeated can vary widely. Therefore, the procedures are presented here in the same sequence and at the same level of detail as used by Nordson service personnel during a typical installation. Typical circumstances that may lead to the repeat of a setup procedure are outlined in the following table. This symbol designates abbreviated procedures or key procedure information intended for use by an experienced system user. 2001 Nordson Corporation
System Setup 3-3 Circumstance program was inadvertently changed or corrupted change in system performance change in process workflow or manpower change in adhesive after routine plant-level maintenance or following a long-term system shutdown when conducting system troubleshooting when directed by Nordson Service Procedure Reload the program. Adjust the adhesive demand cycle variables: level sensor calibration air-to-adhesive ratio pump cycle time Adjust the fault limit value. Adjust the blow back count. Test the system. as directed in Section 6, Troubleshooting as directed NOTE: Changing the adhesive is considered a routine operating procedure as opposed to a system setup procedure. For information on changing the adhesive, refer to Section 4, Operation, Changing the Adhesive Type. 2001 Nordson Corporation
3-4 System Setup Verifying the Program The main control unit was installed with the most current version of the operating program loaded in the programmable relay. Before completing any other system setup procedure, check the program to confirm that it is intact and that it holds the correct settings, and set the current date and time. If the program is corrupt, reload it using a program card. To check the program: 1. Confirm that the system power switch and breaker are OFF. 2. Unplug the vacuum pump power cord. 3. Plug in the system power cord. 4. Turn the system breaker and power switch ON. The power supply LED turns on and the main screen indicates RUN. If the LED turns on but the main screen does not appear, the program may not be loaded or is corrupt. Refer to To reload the program, in this section. 5746078A NOTE: Station no. 1 may immediately call for adhesive when the system is turned on. 2001 Nordson Corporation
System Setup 3-5 Reload the Program Turn system power OFF Plug in program card Turn system power ON System mode to STOP Enter password Select CARD-EASY System mode to RUN Turn system power OFF Remove program card To reload the program: 1. Turn the system power OFF. 2. Plug a spare program card (chip) into the face of the programmable relay. NOTE: Blank and pre-loaded program cards are available from Nordson. To make a spare card from an empty card, refer to To make a spare program card, in this section. 3. Turn the system power ON. 4. Load the program as follows: a. Press x 2, x 2, OK,. The main screen indicates STOP. b. Press x 2. The password screen appears. c. Using the or keys, toggle to the first character position, and then use the or keys to set the first digit of the password. d. Repeat step 4c to set each remaining digit of the password. e. Press x 3. The programming screen appears. f. Select CARD, and then press. The card screen appears. g. Select CARD-EASY, and then press. The REPLACE? prompt appears. 5746078A 2001 Nordson Corporation
3-6 System Setup To reload the program: (contd) h. Press, and then x 3. The program is reloaded and the main screen appears. i. Repeat step 4a to set the main screen back to RUN. 5. Turn the system power OFF. 6. Remove the spare program card. 7. Turn the system power ON. Make a Spare Program Card Turn system power OFF Plug in program card Turn system power ON System mode to STOP Enter password Select EASY-CARD System mode to RUN Turn system power OFF Remove program card To make a spare program card: 1. Turn the system power OFF. 2. Plug a spare program card (chip) into the face of the programmable relay. 3. Turn the system power ON. 4. Load the program as follows: a. Press x 2, x 2, OK,. The main screen indicates STOP. b. Press x 2. The password screen appears. c. Using or keys, toggle to the first character position, and then use or keys to set the first digit of the password. d. Repeat step 4c to set each remaining digit of the password. e. Press x 3. The programming screen appears. 2001 Nordson Corporation
System Setup 3-7 f. Select CARD, and then press. The card screen appears. g. Select EASY-CARD, and then press. The REPLACE? prompt appears. h. Press, and then x 3. The program is copied to the spare card, and then the main screen appears. 5. Turn the system power OFF. 6. Remove the program card. 7. Turn the system power ON. To set the date and time: 1. On the programmable relay, press. The main menu appears with the PASSWORD option flashing. 2. Select SET CLOCK, and then press. The set clock screen appears. When WINTER TIME is shown, the clock s mode is set to daylight savings time. When SUMMER TIME is shown, the clock s mode is not set for daylight savings time. To change the clock mode, go to step 3, otherwise, go to step 4. 2001 Nordson Corporation
3-8 System Setup To set the date and time: (contd) 3. Select the current mode setting, and then use or to set the desired mode. 4. Select SET CLOCK, and then press. The clock screen appears. 5. Use or to select the first digit of the time displayed. 6. Use or to change the value of the digit selected. 7. If necessary, continue to change any other digits by repeating steps 5 and 6. 8. Press, and then. Adjusting the System Air Pressure Adjust the air pressure at the regulator for each of the following components: Blow back system: 550 687 kpa (80 100 psi) Solenoid valve (on each tube loader): 410 690 kpa (60 100 psi) Tilt table: 550 687 kpa (80 100psi) 2001 Nordson Corporation
System Setup 3-9 Adjusting the Tilt Table The tilt table is designed to sense the weight of the adhesive and begins to tilt the tote when approximately one-half of the adhesive remains. For this reason, the table must be adjusted each time the adhesive type is changed. The tilt table s speed and range of motion is determined by adjusting the table s air inlet pressure. NOTE: Adjust the tilt table when the tote containing the new type of adhesive is one-half full. WARNING: Pinch-point hazard. Keep arms and legs clear of the tilt table when operating. Confirm all personnel are clear of the tilt table when it is operating. Adjust the Tilt Table Use one-half-full tote Move control lever horizontal Set pressure to 80 psi Move control lever down and observe tilt table Move control lever up Increase or decrease pressure to achieve smooth, continuous tilt motion To adjust the tilt table: 1. Confirm the control handle is horizontal (table stop). 2. Set the tilt table pressure regulator to 351 kpa (80 psi). 3. Move the control handle down (table tilt). If the pressure is set correctly, the table should tilt completely in one smooth and continuous motion, otherwise, go to step 6. 4. Move the control handle up (table down). The table returns to its starting position. 5. Move the control handle to the horizontal position (stop). The table is now correctly adjusted. 6. Do one of the following: If the table tilted in a rapid, jerking motion, move the control handle up (table down). Lower the air pressure by 34 kpa (5 psi), and then continue with step 3. If the table failed to move or tilted only partially, move the control handle up (table down). Raise the air pressure by 34 kpa (5 psi), and then continue with step 3. 2001 Nordson Corporation
3-10 System Setup Adjusting the Adhesive Demand Cycle Variables Correct cycling of the system depends on the adjustment of three variables for each fill station: Level sensor calibration The adjustment of the level sensor control module to increase or decrease the detection range of the sensor. Air-to-adhesive ratio The volume of air per unit volume of adhesive entering the distribution system. As the volume of air entering the system decreases, the volume of adhesive entering the system increases. Pump cycle time The amount of time the vacuum pump runs each time adhesive is delivered to a melter. The greater the run-time of the pump, the greater the amount of adhesive delivered to the melter. These variables define a melter s adhesive demand cycle. A demand cycle is the complete adhesive delivery sequence that begins when a blue light turns on and ends when the light turns off. Two additional variables fault limit and blow back count indirectly affect the operation of the system and are described later in this section. Other than the level sensor calibration, each of these variables was established and recorded by Nordson when the system was installed. The variables were recorded in Section 4, Using the System Settings Log. Under normal circumstances, it is not be necessary to re-establish these variables. TIP: If the melter cannot be operated under production conditions, you can simulate adhesive draw-down using the melter s drain valve. To calibrate a level sensor: 1. Disconnect the vacuum pump pigtail from the power cord. 2. With the melter running at production volume, manually fill the tank of station no.1 to 2.5 cm (1 in.) below the level sensor. 3. Turn the station power ON. NOTE: The blue light may come on immediately after the station is turned on. 4. Adjust the level sensor control module sensitivity (left or right) until the yellow LED turns on (adhesive detected). 5. Turn the sensitivity adjustment one-half turn past the position where the LED came on. 2001 Nordson Corporation
System Setup 3-11 Adjust the Air-to-Adhesive Ratio and Pump Cycle Time Begin with all air inlets open Observe trap for two pump cycles Increase adhesive delivery rate by closing inlets or increasing pump cycle time Decrease adhesive delivery rate by opening inlets or decreasing pump cycle time REMINDER: A demand cycle is the complete adhesive delivery sequence that begins with the blue light turning on and ends with the blue light turning off. To adjust the air-to-adhesive ratio and pump cycle time: 1. Turn the system power OFF and allow the adhesive tank level to drop. 2. Expose all six air inlets on the feed tube. 3. Turn the system power ON. The demand cycle begins and adhesive is conveyed from the tote to the fill station. 4. Observe the adhesive trap for two consecutive demand cycles. You should notice that: as the pump cycles, adhesive collects in the trap and near the top of the tube loader, and when the pump stops, the adhesive near the top of the tube loader drops back into the trap, partially filling it. NOTE: Because the adhesive transfer lines are initially empty, the first demand cycle will require more cycles of the pump than subsequent demand cycles. 5. Respond as shown in the following table: NOTE: The procedure for changing the pump cycle time is provided on the next page. REMINDER: Systems using horizontal feed tubes also require the adjustment of the adhesive slot size. Discuss this adjustment with Nordson service. If the adhesive level in the trap is... Adjust the air inlet openings by... Change the pump cycle time by... 1 / 3 to 2 / 3 filled Doing nothing Doing nothing 2 / 3 + filled Not Applicable Reducing time < 1 / 3 filled Covering 1 inlet Increasing time NOTE: If the tube loader becomes clogged with adhesive, reduce the pump cycle time. 2001 Nordson Corporation
3-12 System Setup To adjust the air-to-adhesive ratio and pump cycle time:(contd) 6. After the second demand cycle ends, observe the level of adhesive in the tank and re-adjust the control module sensitivity as shown in the following table: If the blue light is... On On Off and the adhesive level is... 2.5 cm (1 in.) below sensor <2.5 cm (1 in.) below sensor >2.5 cm (1 in.) below sensor adjust the sensitivity... Doing nothing Clockwise Counter clockwise NOTE: The number of pump cycles required to complete a demand cycle depends on the size of a melter s tank, the melter s adhesive usage rate, and the elapsed time before the control system is able to poll the melter s level sensor. A longer-than-normal demand cycle for one melter may result in a longer demand cycle for the next sequential melter. Under optimum conditions, a demand cycle ends after one vacuum pump cycle. To change the vacuum pump cycle time: 1. On the programmable relay, press x 2. The main menu appears with the PASSWORD option flashing. 5746003 2. Press to select PARAMETER, and then press OK. The T1 (pump cycle time) screen appears with T1 flashing. 5746017 3. Pressing select the melter you are changing the adhesive for. T1 corresponds to station no.1, T2 corresponds to station no. 2, and so on. NOTE: Ignore all T screens except for T1 through T5. 5746018 2001 Nordson Corporation
System Setup 3-13 4. Press or to select the first (or next) digit of the current pump cycle time. 5746019 5. Use or to change the value of the digit selected in step 4. Refer to Using the System Settings Log located at the end of Section 4 to determine the correct pump cycle time for the new melter adhesive configuration. 5746020 NOTE: The factory default pump cycle time is 5 seconds. 6. If necessary, continue changing the remaining digits of the pump cycle time by repeating steps 4 and 5. 7. Press OK. The new pump cycle value is entered and the display returns to the flashing T1. 8. Repeat steps 3 through 7 to change the pump cycle time for each remaining fill station. 2001 Nordson Corporation
3-14 System Setup Setting the Fault Limit Value The fault limit value is the number of times the system will attempt to satisfy a level sensor that is calling for adhesive before a system fault occurs. When a fault occurs, the system ignores the demanding sensor and turns on the red fault light. In practical terms, the fault limit value determines the amount of time an operator has to correct any condition that prevents a level sensor from being satisfied. For example, with the fault limit set to 4 the default value an operator would have about 2 minutes before a fault would occur. The time delay is calculated as follows: Program cycle time ~25 seconds Pump cycle time (default) Total cycle time Fault limit x 4 + ~5 seconds ~30 seconds Total time delay before a fault occurs = 120 seconds The fault limit value is changed using the programmable relay. The maximum fault limit value that can be entered is 9999. When determining the fault limit value, consider the following factors: At the time the fault count (delay) begins, the tank is already drawn down by one demand volume. During the fault delay and before the red light goes on, the tank is being drawn down without being refilled. The tank s volume should not be drawn-down below one-half full before the fault occurs. Quickly refilling the tank with bulk adhesive when the tank is below one-half full may cold-shock the adhesive. Based on the historical or calculated production volume of the melter, the operator should determine how much time remains before the tank runs dry. 2001 Nordson Corporation
System Setup 3-15 To change the fault limit: 1. On the programmable relay, press x 2. The main menu appears with the PASSWORD option flashing. 5746003 2. Press to select PARAMETER, and then press OK. The T1 screen appears with T1 flashing. 5746017 3. Press until the C1 (fault limit) screen appears. 5746021 4. Press to change C1, if required, to the correct melter number where C1 corresponds to station no.1, C2 corresponds to station no. 2, and so on. 5746022 5. Press or to select the first (or next) digit of the current fault limit. 5746023 6. Use or to change the value of the first digit selected in step 5. Refer to Using the System Settings Log, located at the end of Section 4, to determine the correct fault limit for the new melter-adhesive configuration. 5746024 NOTE: The factory default setting for the fault limit is 4. 2001 Nordson Corporation
3-16 System Setup To change the fault limit: (contd) 7. If necessary, continue changing the remaining digits of the fault limit by repeating steps 5 and 6. 8. Press OK. The new fault limit value is entered and the display returns to the flashing C1. 9. Repeat steps 2 through 6 to change the fault limit for each remaining melter. 10. Press OK, and then to return to the date/time screen. 5746010 Setting the Blow Back Count The blow back count is the number of times the vacuum pump will cycle before the filter blow back assembly delivers three short blasts of air into the filter to dislodge fines and residual powder. When using adhesives that cause a rapid buildup of adhesive powder on the filter cartridge, the blow back count may have to be increased. The blow back count is adjusted using the programmable relay. To adjust the blow back count: 1. On the programmable relay, press x 2. The main menu appears with the PASSWORD option flashing. 5746003 2. Press to select PARAMETER, and then press OK. The T1 screen appears with T1 flashing. 5746017 3. Press until the C7 (blow back count) screen appears. 5746021 2001 Nordson Corporation
System Setup 3-17 4. Press or to select the first digit of the blow back count. 5746022 5. Use or to change the blow back count. 5746023 6. If necessary, continue changing any remaining digits of the blow back count by repeating steps 4 and 5. 7. Press OK x 2 and then press to return to the date/time screen. 2001 Nordson Corporation
3-18 System Setup Testing the System After completing any setup procedure, test the system under actual or simulated production conditions. Check the following: Operation of the lights: all of the lights operate. Cycle time consistency: the demand cycle for each station occurs at a regular interval and requires the same number of pump cycles to satisfy the level sensor. Trap operation: adhesive moves through and collects evenly in the trap after each pump cycle. Adhesive pickup: adhesive flows smoothly and completely around the intake of each feed tube without forming clumps or voids in the adhesive. Separator screen: look for adhesive shavings or foreign debris. Filter/blow back operation: check that the blow back system operates after the pre-programmed number of vacuum pump cycles is reached. Tilt table operation: confirm the table begins tilting when the tote is one-half full. 2001 Nordson Corporation
Operation 4-1 Section 4 Operation Controls and Indicators........................................... 4-2 System Power Supply and Breaker................................ 4-3 System Power Switch............................................ 4-3 Reset Button................................................... 4-4 Station Power Switch............................................ 4-4 Light Tower..................................................... 4-5 Programmable Relay............................................ 4-5 Tilt Table Control Handle......................................... 4-6 Operating Procedures............................................ 4-6 Starting the System Normally..................................... 4-7 Responding to a System Fault.................................... 4-7 Shutting the System Down....................................... 4-8 Starting the System After a Shutdown.............................. 4-9 Changing the Adhesive Type.................................... 4-11 Using the System Settings Log................................... 4-18 2001 Nordson Corporation
4-2 Operation Operation Controls and Indicators The following controls and indicators are used to operate the system under normal conditions: System Power Supply and Breaker System Power Switch Reset Button Station Power Switch Light Tower Programmable Relay Tilt Table Control Handle The relative position of each control and indicator is illustrated in the following diagram. A detailed description of each control and indicator follows the diagram. System Power Switch Reset Button Light Tower System Power Switch Programmable Relay System Power Supply and Breaker Tilt Table Control Handle 5746139A 2001 Nordson Corporation
Operation 4-3 System Power Supply and Breaker The power supply provides direct current to the system and contains the system circuit breaker. The circuit breaker is used to disconnect the system from the plant power. When the circuit breaker is in the ON position, the power light and programmable relay turn on. Power Light 5746012A System Power Switch The system power switch is located on the front of the main control unit. The switch supplies control power to the system. When the switch is turned on, the programmable relay immediately checks the status of each fill station in priority order. Power Switch 5746013A 2001 Nordson Corporation
4-4 Operation Reset Button The reset button is located on the front of the main control unit and to the right of the system power switch. The button is used to return a faulting fill station back into the system s control cycle. Fill stations that are operating normally (not faulting) are unaffected by the use of the reset button. Reset Button 5746013A Station Power Switch Each fill station connected to the system is equipped with a station power switch. The switch is located on the front of each light tower assembly. The station power switch is used to manually start or stop the transfer of adhesive to the melter. Station Power Switch 5746011A 2001 Nordson Corporation
Operation 4-5 Light Tower Each fill station connected to the system is equipped with a three-color light tower that extends from the top of the light tower junction box. The lights indicate when the fill station is on (green), when it is calling for adhesive (blue), and when a fault has occurred (red). Red Light Tower Blue Green 5746008 Programmable Relay The programmable relay is mounted inside the main control unit. The relay monitors the status of all level sensors, controls both the number and duration of adhesive demand cycles for each melter, and activates the different light tower indications. When the adhesive type is changed, the programmable relay s LCD and control buttons are used to change the fault limit and adhesive demand cycle time. LCD Control Buttons 5746009A 2001 Nordson Corporation
4-6 Operation Tilt Table Control Handle The tilt table control handle is located on the left side of the table assembly. When the handle is moved to position 4, the table tilts. When the handle is moved to position 2, it lowers. Position N is the neutral position where no air enters or exits the tilting mechanism. Position 4 Position 2 Position N 5746140A Operating Procedures The system operating procedures are: Starting the System Normally Responding to a System Fault Shutting the System Down Starting the System After a Shutdown Changing the Adhesive Type After the system is installed by Nordson personnel, it is fully operational and ready to use. No further setup or adjustment of the system should be necessary to transfer adhesive to the melters. The system is designed to run automatically and requires minimal operator attendance. The system is also energy efficient and can be left on continuously, even when the melters are shut down. 2001 Nordson Corporation
Operation 4-7 Starting the System Normally The transfer of adhesive to individual fill stations is stopped and started using the power switch on each station. Each fill station operates independently from the other stations; one can be turned off while the others remain on. To start the system normally: 1. Turn the station power switch at each melter ON. The green power light turns on. If the melter needs adhesive, the blue light at that location will also turn on. 2. When the vacuum pump cycles to fill the first demanding melter, listen for the solenoid valve to open and then observe adhesive entering the adhesive trap. After several vacuum pump cycles, the trap should remain partially filled with adhesive. Responding to a System Fault Normally, the fault light indicates that the tote supplying the melter is running low on adhesive or the feed tube for the faulting melter is not correctly positioned in the tote. Respond to a fault by correcting the condition and clearing the fault light. NOTE: The fault light turns on after the last pump cycle before the fault limit is reached. For example, if the fault limit is set to 6, the fault light will turn on at the end of the 5th pump cycle. To clear the fault light: 1. Check and refill the tote or correct the position of the faulting station s feed tube. 2. Press the reset button. The red fault light will turn off and the blue light will turn on. If no other station is being filled, the adhesive demand cycle for that station will begin. 3. Confirm normal operation of the system. If the melter faults again, refer to Section 6, Troubleshooting, to determine the cause of the fault and correct the condition. 2001 Nordson Corporation
4-8 Operation Shutting the System Down You can temporarily shut the system down at an individual fill station for example, to clean or repair it or you can shut the system down as a whole if you are no longer running the production line. TIP: When shutting down an individual station, remove the station s feed tube from the tote to ensure that no adhesive is inadvertently transferred to the melter. To shut down an individual unit: Turn the station power switch OFF. The green power light turns off. To shut down the entire system: 1. Remove the feed tubes from the tote and place them where they will not be a hazard. 2. Allow the system to operate normally until the trap above each station is clear of adhesive. 3. Turn the system power OFF. 4. Turn the system breaker OFF. CAUTION: Do not allow adhesive to remain in the adhesive transfer lines, trap, or portions of flexible tubing if the system is to remain shutdown for more than three days during which the ambient plant temperature will remain at or above 22 C (72 F). Adhesive remaining in the system under these conditions may consolidate, causing blockages in the system. 2001 Nordson Corporation
Operation 4-9 Starting the System After a Shutdown A complete shutdown condition exists when power to the system has been shut off at the power supply, the system power switch, each station power switch, and the adhesive transfer lines have been purged. To restart the system, inspect it to ensure that the correct operating conditions exist and turn the power on. After restarting the system, confirm that it is operating correctly. REMINDER: If your system uses more than one tote, be sure to inspect each tote. To confirm that the correct conditions exist: 1. Inspect the tote and ensure it is correctly positioned on the tilt table and contains the correct type of adhesive. Refer to Changing the Adhesive, in this section, for information on changing adhesives. 2. Remove the protective tarp from the tote and confirm that each feed tube is inserted into its bracket and that the feed tubes are buried deeply in the adhesive without covering the air inlet openings. Bracket Air Inlet Openings Feed Tube Adhesive 5746006A 3. Confirm that the correct number of air inlet openings are exposed on each feed tube. Refer to Using the System Settings Log, located at the end of this section, to determine the number of inlets that should be exposed based on the station s number and the adhesive being used. 4. Replace the protective tarp. 2001 Nordson Corporation
4-10 Operation TIP: When re-starting the system after a shutdown a long delay can be avoided as the system attempts to automatically fill each melter by manually pre-filling each melter s hopper. To apply power to the system: 1. Turn the system breaker ON. The power light illuminates and the current date and time appear on the programmable relay. 2. Turn the system power switch ON. 3. Turn each station power switch ON. If station no.1 requires adhesive, the blue light at that location turns on and the solenoid valve can be heard opening. NOTE: Each station is assigned a filling order priority, with station no.1 having the highest priority. The programmable relay will satisfy station no.1 s level sensor before cycling to station no. 2 and so on. To confirm correct operation of the system: As the vacuum pump cycles to fill each melter, listen for the solenoid valve to open and observe the adhesive entering the adhesive trap. After several adhesive demand cycles, the trap should remain partially filled with adhesive. NOTE: You can also determine if the sequence valve is operating correctly by observing the LED on the valve body turning on. Adhesive Trap Sequence Valve 5746084A 2001 Nordson Corporation
Operation 4-11 Changing the Adhesive Type To change the type of adhesive being transferred by the system, complete, in the order shown, whichever of the following tasks are appropriate for your system. A detailed procedure is provided for each task. TIP: Refer to Section 2, System Overview, and Section 3, System Setup, for information on how the demand cycle variables, fault limit value, and blow back count affect the operation of the system. 1. Purge the system. 2. Change the vacuum pump cycle time. 3. Adjust the air-to-adhesive ratio. 4. Set the fault limit value. 5. Set the blow back count. 6. Calibrate the level sensor. 7. Replace adhesive supply. 8. Adjust the tilt table. 9. Pre-fill the melter tanks. 10. Restart the system. In some instances, an adhesive changeover will not require the completion of tasks 2 8. Because the adhesives are set up to run on the system during the system installation, they may share common and predictable system settings. The appropriate settings required to transfer each type of adhesive through the system were recorded by Nordson in Using the System Settings Log, located at the end of this section. If the variables listed in the log for the new adhesive match those of the current adhesive, they do not need to be changed. Also, unless the physical characteristics of the new adhesive are significantly different than the current adhesive, the level sensor should be able to reliably detect the new adhesive and the tilt table should not need adjustment. NOTE: These procedures are presented as if all melters are using the same adhesive tote. 2001 Nordson Corporation
4-12 Operation To purge the system: 1. Remove the feed tubes from the tote and place them where they will not be a hazard. 2. Allow the system to operate normally until the trap above each station is clear of adhesive and the tank is empty. 3. Turn the system power OFF. To change the vacuum pump cycle time: 1. On the programmable relay, press x 2. The main menu appears with the PASSWORD option flashing. 5746003 2. Press to select PARAMETER, and then press OK. The T1 screen appears with T1 flashing. 5746017 3. Press to select the melter you are changing the adhesive for. T1 corresponds to station no.1, T2 corresponds to station no. 2, and so on. NOTE: Ignore all T screens except for T1 through T5. 5746018 2001 Nordson Corporation
Operation 4-13 4. Press or to select the first (or next) digit of the current pump cycle time. 5746019 5. Use or to change the value of the digit selected in step 4. Refer to the Using the System Settings Log, located at the end of this section, to determine the correct pump cycle time for the new melter adhesive configuration. 5746020 NOTE: The factory default pump cycle time is 5 seconds. 6. If necessary, continue changing the remaining digits of the pump cycle time by repeating step 4 and 5. 7. Press OK. The new pump cycle time is entered and the display returns to the flashing T1. 8. Repeat step 3 through 7 to change the pump cycle time for each remaining fill station. To adjust the air-to-adhesive ratio: 1. Refer to the Using the System Settings Log, located at the end of this section, to determine the number of air inlet openings that should be exposed for each melter adhesive combination. 2. Move the flexible tubing up or down on the feed tube to cover or uncover the correct number of air inlets. 2001 Nordson Corporation
4-14 Operation To set the fault limit: 1. On the programmable relay, press x 2 The main menu appears with the PASSWORD option flashing. 5746003 2. Press to select PARAMETER, and then press OK. The T1 screen appears with T1 flashing. 5746017 3. Press until the C1 screen appears. 5746021 4. Press to select the melter. C1 corresponds to station no.1, C2 corresponds to station no. 2, and so on. 5746022 5. Press or to select the first (or next) digit of the current fault limit. 5746023 6. Use or to change the value of the first digit selected in step 5. Refer to Using the System Settings Log, located at the end of this section, to determine the correct fault limit for the new melter-adhesive configuration. 5746024 NOTE: The factory default setting for the fault limit is 4. 7. If necessary, continue changing the remaining digits of the fault limit by repeating steps 5 and 6. 2001 Nordson Corporation
Operation 4-15 8. Press OK. The new fault limit value is entered and the display returns to the flashing C1. 9. Repeat steps 2 through 6 to change the fault limit for each remaining melter. 10. Press OK, and then to return to the date/time screen. 5746010 To change the blow back count: 1. On the programmable relay, press x 2 The main menu appears with the PASSWORD option flashing. 5746003 2. Press to select PARAMETER, and then press OK. The T1 screen appears with T1 flashing. 5746017 3. Press until the C7 (blow back count) screen appears. 5746021 4. Press or to select the first digit of the blow back count. 5746021 2001 Nordson Corporation
4-16 Operation To change the blow back count:(contd) 5. Use or to change the blow back count. 5746023 6. If necessary, continue changing any remaining digits of the blow back count by repeating steps 4 and 5. 7. Press x 2 then press to return to the date/time screen. To calibrate each level sensor: Refer to To calibrate a level sensor, in Section 3. WARNING: Pinch-point hazard. Ensure arms and legs are clear of the tilt table before operating. Confirm all personnel are clear of the tilt table when lowering. To adjust the tilt-table: 1. Confirm that the control handle is horizontal (table stop). 2. Set the tilt table pressure regulator to 551 kpa (80 psi). 3. Move the control handle down (table tilt). If the pressure is set correctly, the table should tilt completely in one smooth and continuous motion, otherwise, go to step 6. 4. Move the control handle up (table down). The table returns to its starting position. 2001 Nordson Corporation
Operation 4-17 5. Move the control handle to the horizontal position (stop). The table is now correctly adjusted. 6. Do one of the following: If the table tilted in a rapid, jerking motion, move the control handle up (table down). Lower the air pressure by 34 kpa (5 psi) and then continue with step 3. If the table failed to move or tilted only partially,move the control handle up (table down). Raise the air pressure by 34 kpa (5 psi) and then continue with step 3. To pre-fill each melter s tank: NOTE: Refer to the instructions that came with each melter for information on adding adhesive to an empty tank. Remove the lid of each drop chute and carefully pour in adhesive until the level is 2.5 cm (1 in.) below the sensor. To restart the system: 1. Replace the feed tubes and protective tarp. 2. Turn the system power switch ON. The system resets, and then begins checks and fills each station in priority order. 3. Confirm the system is operating correctly. Refer to To confirm correct operation of the system, in Section 4. 2001 Nordson Corporation
4-18 Operation Using the System Settings Log When Nordson installed the system, the pump cycle time, fault limit, blow back count, and air inlet settings required to transfer each type of adhesive to each fill station were determined. This information was recorded in the following log. Refer to Changing the Adhesive Type, in this section, for information on changing these settings. System name/number: Settings last changed: Station No.1 Adhesive type Vacuum pump cycle time (seconds) Fault limit Blow Back Count Air inlet openings exposed Station No.2 Adhesive type Vacuum pump cycle time (seconds) Fault limit Blow Back Count Air inlet openings exposed Station No.3 Adhesive type Vacuum pump cycle time (seconds) Fault limit Blow Back Count Air inlet openings exposed Station No.4 Adhesive type Vacuum pump cycle time (seconds) Fault limit Blow Back Count Air inlet openings exposed Station No.5 Adhesive type Vacuum pump cycle time (seconds) Fault limit Blow Back Count Air inlet openings exposed 2001 Nordson Corporation
Maintenance 5-1 Section 5 Maintenance Weekly Maintenance Procedures.................................. 5-2 Cleaning the Level Sensor........................................ 5-2 Cleaning the Filter............................................... 5-3 Cleaning the Flapper Valve....................................... 5-5 Monthly Maintenance Procedures................................. 5-6 Cleaning the Separator Screen.................................... 5-6 Cleaning the Vacuum Valve....................................... 5-7 Replacing the Filter.............................................. 5-9 2001 Nordson Corporation
5-2 Maintenance Maintenance Weekly Maintenance Procedures The maintenance procedures that should be performed on a weekly basis are: Cleaning the Level Sensor Cleaning the Filter Cleaning the Flapper Valve Cleaning the Level Sensor Condensation from melted adhesive collects on the surface of the sensor in the form of an oily residue. If the residue is allowed to accumulate, the sensor may falsely indicate that the tank is full. Clean the Level Sensor To clean the level sensor: 1. Turn the station power OFF. Turn station power OFF Remove the sensor through the access hole in the drop-chute Clean the sensor Reassemble the sensor Turn station power ON The green light on the light tower turns off. 2. Remove the screw and washer that hold the removable plate on to the drop chute. 3. Lift the plate to remove the bottom slot of the plate from the opening in the drop chute. 4. Remove the sensor assembly by rotating the top of the plate outward and then pulling the sensor assembly out through the access hole. 5746046A 2001 Nordson Corporation
Maintenance 5-3 To clean the level sensor: 5. Use a citrus-type cleaning agent to clean the sensor. 6. Reinstall the sensor assembly. 7. Turn the fill station power ON. The green light on the tower turns on. Cleaning the Filter As adhesive fines and powder accumulate on the filter, the level of vacuum available to the system will decrease. The type of adhesive in use and the adhesive usage rate determine the rate at which the fines and powder accumulate. Often, the amount of powder mixed with an adhesive is adjusted seasonally by the adhesive manufacturer to improve the flow characteristics of the adhesive. Since each manufacturing situation is different and the amount of powder accumulation cannot be easily predicted, Nordson recommends that the filter be cleaned weekly. CAUTION: Airborne dust may be harmful. Wear appropriate personal protective equipment when handling the filter or touching the adhesive powder. Refer to the Material Safety Data Sheet for the adhesive in use. Clean the Filter Turn system power OFF Remove the dust collector Remove the filter Blow air from the inside to the outside of the filter Re-assemble Turn system power ON To clean the filter: 1. Turn the system power OFF. 2. Loosen the three latches on the dust collection chamber and remove the chamber. To dump the contents of the dust collection chamber into a container that is not near the pump, also disconnect the vacuum line from the chamber. Vacuum Line Latches Dust Collection Chamber 5746042A 2001 Nordson Corporation
5-4 Maintenance To clean the filter: (contd) 3. Empty the chamber into a suitable container, and then clean the inside of the chamber with a damp cloth. 4. Remove the filter. 5746043A 5. Inspect the filter cartridge. If the filter is damaged or badly clogged, replace it with a new one. Otherwise, blow off the filter under an exhaust hood. 6. Re-assemble the filter assembly. 7. Turn the system power ON. 2001 Nordson Corporation
Maintenance 5-5 Cleaning the Flapper Valve During normal operation of the system, adhesive powder will accumulate on the face of flapper valve. If an excessive amount of powder accumulates, the valve may stick in the closed position preventing adhesive from falling into the drop chute. Clean the Flapper Turn station power OFF Remove the flapper valve enclosure Clean the valve Lubricate the valve Replace the enclosure Turn station power ON To clean the flapper valve: 1. Turn the system power OFF. The green light on the light tower turns off. 2. Remove the flapper valve enclosure. 5746035A 3. Use a citrus-type cleaning agent to clean the flapper valve. 4. Use a spray-type, silicone-based lubricant to lubricate the face of the valve. 5. Re-assemble the flapper valve enclosure and tighten the two screws. 6. Turn the fill station power ON. The green light on the light tower turns on. 2001 Nordson Corporation
5-6 Maintenance Monthly Maintenance Procedures The maintenance procedures that should be performed on a monthly basis are: Cleaning the Separator Screen Cleaning the Vacuum Valve Replacing the Filter Cleaning the Separator Screen Over time, adhesive powder and foreign material, introduced into the system from the bulk adhesive source, may accumulate on the separator screen within each tube loader. This condition can reduce the rate of adhesive transfer to the effected tube loader. Clean the Separator Screen To clean the separator screen: 1. Turn the fill station power OFF. Turn station power OFF Remove the screen from the top of the tube loader Clean the screen Lubricate the screen Replace the screen Turn station power ON The green light on the light tower turns on. 2. Loosen the screw at the top of the tube loader and pull the flexible-hose adapter up and out of the tube loader. ÂÂÂ ÂÂÂ 5746036A 2001 Nordson Corporation
Maintenance 5-7 To clean the separator screen: (contd) 3. Remove the separator screen. 4. Use a citrus-type cleaning agent to clean the screen. 5. Use a spray-type, silicon-based lubricant to lubricate the screen. 6. Re-assemble the tube loader. 7. Turn the fill station power ON. The green light on the tower turns on. Cleaning the Vacuum Valve Because the vacuum valve is directly exposed to the vacuum air stream that carries the adhesive, adhesive powder carried in the air stream may accumulate on the valve s internal components. Over time, the accumulation may affect the operation of the valve. Clean the Vacuum Valve Turn station power OFF Open the bypass valve Remove the vacuum valve Clean the seals and moving parts Lubricate the valve Close the bypass valve Align the gasket Close the bypass valve Turn station power ON To clean the vacuum valve: 1. Turn the fill station power OFF. The green light on the tower turns OFF. 2. Open the solenoid by-pass valve. 5746049A 2001 Nordson Corporation
5-8 Maintenance To clean the vacuum valve: (contd) 3. Remove the four screws that hold the top and bottom sections of the vacuum valve together, and then separate the sections. 5746044A 4. Close the solenoid bypass valve. 5. Use a citrus-type cleaner to clean the following areas: plunger actuator rod seal actuator rod gasket Plunger Actuator Rod and Seal Gasket 5746041A 2001 Nordson Corporation
Maintenance 5-9 To clean the vacuum valve: 6. Apply a spray-type, silicon-based lubricant to the cleaned areas. 7. Align the four holes in the gasket with the matching holes in the mounting plate, and then open the solenoid bypass valve. The plunger moves down and holds the gasket in place. 8. Re-assemble the valve sections. 9. Turn the fill station power ON. The green light on the tower turns ON. Replacing the Filter Once a month, or more often if required, replace the vacuum pump filter. Refer to Cleaning the Filter, in this section. 2001 Nordson Corporation
Troubleshooting 6-1 Section 6 Troubleshooting Light Tower Fault Light Turns On.................................. 6-2 Tank Overfills.................................................... 6-7 Light Tower Fault Light Remains Off When the Tank Runs Low......................................... 6-9 2001 Nordson Corporation
6-2 Troubleshooting Troubleshooting Light Tower Fault Light Turns On Check the level of adhesive in the tote. Is the tote empty? Yes Refill or replace the tote. No Check the adhesive around the feed tubes for voids or clumping. Go to A 5746125A 2001 Nordson Corporation
Troubleshooting 6-3 A Any voids or clumps in the adhesive? Yes Redistribute the adhesive and confirm that the vibrator (if installed) operates each time the vacuum pump cycles. No Check the feed tube and connecting flexible tubing for blockage. Is the feed tube or flexible tubing blocked? Yes Remove the blockage. No Reset the faulting fill station, and then, using your hand, check the vacuum level at the feed tube inlet. Is the suction strong? Yes The pump cycle time or fault limit values may be set too low for your process requirements. Try increasing the pump cycle time or fault limit value. No Go to B 5746126A 2001 Nordson Corporation
6-4 Troubleshooting B Determine if any changes have recently been made to the adhesive or hot melt system. For example, was a larger tank added or were the demand cycle variables changed? Where there recent changes to the system? Yes Go to C No Refer to the following table for further troubleshooting suggestions. 5746127A Possible Problem Too many air inlet openings are covered on the feed tube, causing an excessive amount of adhesive to be drawn into the distribution system. Too many air inlet openings are exposed. The vacuum level is insufficient to fill the tube loader completely. The pump cycle time is set too low, causing a buildup of adhesive in the feed tube and flexible lines connected to the overhead rigid piping. Recommended Action Open one or more air inlets. Cover one or more additional air inlets. Clear any blockage and increase the pump cycle time. 2001 Nordson Corporation
Troubleshooting 6-5 C Determine if the vacuum pump filter is excessively dirty. Is the filter excessively dirty? Yes Clean the filter. Refer to Cleaning the Filter in Section 5, Maintenance. No Check to see if the flapper valve in the tube loader is stuck. For tube loader disassembly instructions, refer to Cleaning the Flapper Valve in Section 5 Maintenance. Is the valve stuck? Yes Clean the valve. Refer to Cleaning the Flapper Valve in Section 5, Maintenance. No Go to D 5746128A 2001 Nordson Corporation
6-6 Troubleshooting D Check for a plugged separator screen in the tube loader. For tube loader disassembly instructions, refer to Cleaning the Separator Screen in Section 5, Maintenance. Is the separator screen plugged? Yes Clean the separator screen. Refer to Cleaning the Separator Screen in Section 5, Maintenance. No The vacuum valve may not be working properly. Refer to the following table for further troubleshooting suggestions. 5746129A Possible Problem The vacuum valve is sticking in the closed (or almost closed) position, causing a loss of vacuum. Inadequate or complete loss of air supply to the solenoid valve. The solenoid valve is not receiving a signal to open from the main control unit. There is a leak in one of the distribution lines. Recommended Action Manually operate the vacuum valve by opening the solenoid by-pass valve using a flat-tip screwdriver. Clean the vacuum valve if it fails to open. Refer to Cleaning the Vacuum Valve in Section 5, Maintenance. Verify that compressed air at 550 690 kpa (80 100 psi) is being supplied to the solenoid valve. Check that the LED on the sequence valve turns on whenever the blue light on the light tower turns on. If the LED does not turn on, one of the following problems may exist: the electrical connector to the solenoid valve is not connected, the electrical connection is loose, the solenoid valve is defective, or the programmable relay is defective. Check the lines for leaks and make repairs as necessary. 2001 Nordson Corporation
Troubleshooting 6-7 Tank Overfills TIP: If you suspect that the bulb in the blue light is burned out, check the yellow LED on the sensor control module in the light tower junction box. The blue light should turn on when the yellow LED is on. Is the blue light on at the overfilling station? No The vacuum valve is probably stuck (or is frequently sticking) in the open position allowing adhesive being conveyed to other stations to enter the tube loader. Yes The sensitivity of the sensor may be set to low. Go to B Clean the vacuum valve and place the station back into operation. Refer to Cleaning the Vacuum Valve in Section 5, Maintenance. Is the tank still overfilling? No Resume normal operation. Yes Verify that the solenoid valve on the tube loader is closing properly. Go to A 5746130A 2001 Nordson Corporation
6-8 Troubleshooting A Is the solenoid valve closing properly? No Repair or replace the solenoid valve. Yes Increase the sensitivity of the level sensor and then place the system back into operation. Refer to To Calibrate a Level Sensor in Section 3, System Setup. B Is the tank still still overfilling? No Resume normal operation. Yes Refer to the following table for additional troubleshooting suggestions. 5746131A Possible Problem The level sensor is defective and cannot be correctly adjusted. The programmable relay is defective. Recommended Action Replace the sensor. If the problem persists, replace the sensor control module in the light tower junction box. Replace the programmable relay. 2001 Nordson Corporation
Troubleshooting 6-9 Light Tower Fault Light Remains Off When the Tank Runs Low TIP: If you suspect that the bulb in the red light is burned out, check the programmable relay. If the message is ERROR: Loader JAMMED or EMPTY, the red light should be on. Is the station s green light on? No The fill station is not on. Turn the station power ON. Yes Is the blue light on? Yes No There is a problem in the level sensor circuit. The fill station is calling for adhesive but the vacuum pump is not turning on. Refer to the following table for additional troubleshooting suggestions. Go to A 5746132A Possible Problem The vacuum pump is unplugged. The vacuum pump motor is not working. The vacuum pump is not receiving a run signal from the main control unit. Recommended Action Plug the vacuum pump pigtail into the power cord. Replace the motor brushes. If the motor still does not work, replace the motor. Check for loose wires. If no loose wires are found, replace the programmable relay. 2001 Nordson Corporation
6-10 Troubleshooting A There is problem in the level sensor circuit. Unplug the vacuum pump. Clean the level sensor. Refer to Cleaning the Level Sensor in Section 5, Maintenance. After cleaning the sensor, does the blue light turn on? No Yes Reconnect the vacuum pump and resume operation. Refer to the following table for additional troubleshooting suggestions. 5746133A Possible Problem A wire is loose in the level sensor circuit. The sensitivity of the level sensor is set too high, causing the adhesive level to drop too far before a fill request is sent. The level sensor or level sensor control module is defective. Recommended Action Check for a loose connection in the level sensor wiring. Increase the sensitivity of the level sensor. Refer to To Calibrate a Level Sensor in Section 3, System Setup. Replace the level sensor. If the problem persists, replace the level sensor control module. 2001 Nordson Corporation
Schematics 7-1 Section 7 Schematics System Pneumatic Diagram....................................... 7-2 System Control Schematic........................................ 7-3 System Wiring Diagram........................................... 7-4 2001 Nordson Corporation
7-2 Schematics System Pneumatic Diagram SYSTEM AIR, CENTRAL CONTROLLER SYSTEM AIR VACUUM PUMP VACUUM FLOW HOT MELT BLOW BACK M TUBE LOADER #1 HOT MELT UNIT #1 SYSTEM AIR HOT MELT VACUUM FLOW SYSTEM AIR TUBE LOADER #2 HOT MELT UNIT #2 HOT MELT TOTE VACUUM FLOW HOT MELT SYSTEM AIR TUBE LOADER #3 HOT MELT UNIT #3 VACUUM FLOW HOT MELT SYSTEM AIR TUBE LOADER #4 HOT MELT UNIT #4 VACUUM FLOW HOT MELT TUBE LOADER #5 HOT MELT UNIT #5 5746112A 2001 Nordson Corporation
Schematics 7-3 2001 Nordson Corporation 5746136A System Control Schematic
Schematics 7-4 2001 Nordson Corporation 5746137A System Wiring Diagram
Schematics 7-5 System Wiring Diagram (contd) 2001 Nordson Corporation
7-6 Schematics 2001 Nordson Corporation
Parts 8-1 Section 8 Parts How to Order Parts............................................... 8-2 Major System Components Parts.................................. 8-2 Main Control Unit, 1 2 Station.................................... 8-3 Main Control Unit, 3 5 Station.................................... 8-4 Vacuum Pump.................................................. 8-5 Tube Loader.................................................... 8-6 Light Tower..................................................... 8-7 Drop Chute..................................................... 8-8 Melter Specific Lid Assembly (Models 3830/3930.................... 8-9 Melter Specific Lid Assembly (Models 3860/3890, & 3960)........... 8-10 Melter Specific Lid Assembly (Model KB).......................... 8-11 Melter Specific Lid Assembly (Model 6000)........................ 8-12 Melter Specific Lid Assembly (Model 3400, 3500, & 3700)........... 8-13 Melter Specific Lid Assembly (Model 2300)........................ 8-15 Installation Kit................................................... 8-16 Recommended Spare Parts...................................... 8-17 Accessories..................................................... 8-17 2001 Nordson Corporation
8-2 Parts Parts How to Order Parts To order parts, call one of the following: The Nordson customer service center One of the Nordson international offices Your local Nordson representative Major System Components Parts A parts list for each major system component is provided on the page indicated below the illustration of the component. pp. 8-3 & 8-4 pp. 8-5 pp. 8-6 pp. 8-9 through 8-15 pp. 8-7 pp. 8-8 5746135A 2001 Nordson Corporation
Parts 8-3 Main Control Unit, 1 2 Station 3 2 AP1 GS1 CB2 5 6 1 4 5746118A Item Part Description Quantity 341 937 Controller, central, 1 2 station 344 091 Wiring diagram, system 344 089 Schematic, system 1000621 Reference drawing, central controller, 1 2 ST 1 1000574 Power supply, 24 VDC, 5 A, 115 VAC input 1 2 1000575 Relay, programmable 1 1000577 Software, programmable 1 3 1000620 Switch, contactor 2 4 1000622 Circuit breaker 1 5 - - - - - - Socket, relay 1 6 221 696 Relay, 24 VDC 1 2001 Nordson Corporation
8-4 Parts Main Control Unit, 3 5 Station 3 2 5 GS1 6 1 4 5746119A Item Part Description Quantity 1000852 Controller, central, 3 5 station 1000831 Reference drawing, central controller 344 091 Wiring diagram, system 344 089 Schematic, system 1 1000 574 Power supply, 24 VDC, 5 A, 115 VAC input 1 2 1000575 Relay, programmable 1 1000577 Software, programmable 1 3 1000620 Switch, contactor 2 4 1000622 Circuit breaker 1 5 1000871 Relay, expansion, 3 5 station 1 - - - - - - Socket, relay 1 6 221 696 Relay, 24 VDC 1 2001 Nordson Corporation
Parts 8-5 Vacuum Pump 1 (inside) 2 8 6 7 5 3 4 5746116A Item Part Description Quantity 341 935 Vacuum pump, with stand 1 1 341 948 Relay, 24 VDC coil 1 2 341 949 Circuit breaker, 15A 1 3 341 950 Filter cartridge 1 4 341 951 Knob, filter 1 5 341 952 Gasket, U-channel 1 6 1001 387 Motor, VAC pump, with brush, 120 VAC 1 7 341 954 Gasket, motor 1 8 341 955 Valve, solenoid, 24 VDC, 2-way, with light 1 1001 750 Replacement 7 / 8 motor brushes, 4-pack, kit 1 2001 Nordson Corporation
8-6 Parts Tube Loader 3 7 6 1 10 4 ÂÂ ÂÂ ÂÂ 11 8 2 5 9 5746115A Item Part Description Quantity 341 934 Tube loader, with VAC valve 1 1 341 940 Piston, cup, loader 1 2 341 941 Valve, solenoid, 24 VDC, 3-way, with light 1 3 341 942 O-Ring, 1.984 ID x 0.139 wide 1 4 341 943 O-Ring, 2.234 ID x 0.139 wide 1 5 341 944 Cylinder, air, 3 / 4 bore 1 6 341 945 Tube, inlet, 1 3 / 4 OD 1 7 341 946 Tube, outlet, 1 3 / 4 OD 1 8 - - - - - - Mounting bracket 1 9 - - - - - - Flapper valve assembly 1 10 - - - - - - Vacuum valve assembly 1 11 1002880 Perforated screen, cylinder 1 341 934 Reference drawing, tube loader 2001 Nordson Corporation
Parts 8-7 Light Tower 5 6 1 3 4 2 5746117A Item Part Description Quantity 388 221 Enclosure, warning 338 222 Reference drawing, warning, enclosure 344 091 Wiring diagram, system 344 089 Schematic, system 1 - - - - - - Enclosure, warning, machined 1 2 130 677 Switch, power, SPST 1 3 - - - - - - Panel, warning, machined 1 338 226 Harness, wiring, wiring light, VAC feed 1 4 339 719 Controller, with ferrules, 24 VDC 1 5 1009276 Light tower, green, blue, red 1 221 696 Relay, 24 VDC 1 6 1009278 Bulb, LED, clear 3 2001 Nordson Corporation
8-8 Parts Drop Chute 1 5 7 6 3 4 2 5746114A Item Part Description Quantity 336 923 Hood, assembly, with 2m cable 336 922 Reference drawing, hood, assembly 1 901 582 Knob, 1.12 Dia. x 0.88 high, 8-32 MTG 1 2 816 586 Sensor, Rechner 1 3 339 714 Sensor, bracket, bottom 1 4 339 713 Sensor, bracket, top 1 5 336 918 Cover, tower, Fill Sentry 1 6 336 920 Hood, weldment 1 7 338 718 Panel, access, sensor 1 2001 Nordson Corporation
Parts 8-9 Melter Specific Lid Assembly (Models 3830/3930 4 8 6 7 3 5 1 2 9 10 5746113A Item Part Description Quantity 341 922 Lid assy., 3830/3930, VAC feed 341 923 Reference drawing, 3830/3930, lid kit, VAC feed 1 1 341 925 Lid, inner, 3830/3930, VAC feed 1 2 102 710 Spacer, 0.315 ID x 0.625 OD 12 3 341 924 Lid, outer 3830/3930, VAC feed 1 4 982 336 Screw, flat-head, M5 x 20 4 5 106 433 Spacer, 0.218 x 0.375 2 6 983 551 Washer, 0.25 ID x 0.50 OD 2 7 982 320 Screw, pan-head, rec, M5 x 16 2 8 901 582 Handle, plastic 1 9 981 060 Screw, CH x HD, M6 x 50 1 10 983 110 Washer, lock, M, SPT, M6 1 2001 Nordson Corporation
8-10 Parts Melter Specific Lid Assembly (Models 3860/3890, & 3960) 9 4 8 3 5 10 7 11 6 2 1 5746120A Item Part Description Quantity 341 927 Lid assy., 3860/3890/3960, VAC feed 341 928 Reference, drawing, 3860 lid kit, VAC feed 1 341 930 Lid, inner, 3860, VAC feed 1 2 102 710 Spacer, 0.315 ID x 0.625 OD 12 3 341 929 Lid, outer, 3860, VAC feed 1 4 982 336 Screw, flat-head, M5 x 20 3 5 106 433 Spacer 0.218 x 0.375 2 6 983 551 Washer, 0.25 ID x 0.50 OD 2 7 982 320 SCR, pan-head, M5 x 16 2 8 901 576 Handle, plastic 1 9 982 255 Screw, CH x HD, M6 x 50 2 10 983 409 Washer, lock, M, SPT, M6 2 11 984 703 Nut, hex, M6 1 2001 Nordson Corporation
Parts 8-11 Melter Specific Lid Assembly (Model KB) 1 2 3 4 5746121A Item Part Description Quantity 344 090 Lid assy., KB 344 093 Reference drawing, lid adapter assy., KB 1 1 344 092 Lid, hopper, KB 1 2 982 725 Screw, pan-head, rec, M5 x 10 4 3 344 094 Lid, inner, KB 1 4 344 085 Lid, adapter, 6000/KB 1 2001 Nordson Corporation
8-12 Parts Melter Specific Lid Assembly (Model 6000) 2 3 5 4 2 2 6 7 8 1 9 5746122A Item Part Description Quantity 344 088 Lid assy., 6000 344 087 Reference drawing, lid adapter. assy., 6000/KB 1 344 086 Lid, hopper 6000 1 2 982 255 Screw, chez HD, SLT, M6 x 50 6 3 982 725 Screw, pan-head, rec., M5 x 10 4 4 901 576 Handle, plastic 1 5 344 084 Lid, inner, 6000 1 6 344 085 Lid, adapter, 6000/KB 1 7 984 703 Nut, hex, M6, STL 4 8 983 401 Washer, lock, M, SPT, M5, STL 4 9 275 970 Spacer, 0.375 OD x 0.250 ID x 1.250 4 2001 Nordson Corporation
Parts 8-13 Melter Specific Lid Assembly (Model 3400, 3500, & 3700) 8 6 5 9 10 11 1 7 6 2 5 4 3 5746123A 2001 Nordson Corporation
8-14 Parts Item Part Description Quantity Common Parts: 101 899A Reference drawing., MTG, 3000 hood support 1 118 160 Mounting, 3400 hood support 1 2 184 464 Bracket, RH, H/F mount SPRT, PTD 1 3 130 078 Gasket, mounting, 3400, H/F 1 4 184 463 Bracket, LH, H/F mount SPRT, PTD 1 5 983 418 Washer, flat-head, M, oversized, 5, STL 12 6 983 401 Washer, lock, M, SPT, M5, STL 12 7 984 706 Nut, hex, M5, STL 4 8 984 723 Nut, hex, cap, M5, STL 8 111 982 Bracket, RH, 3700, H/F mount SPRT 1 111 933 Bracket, LH, 3700, H/F mount SPRT 1 3400-Specific Parts: 9 118 209 Cover, 3400 H/F mount SUPT 1 118 171 Cover, 3400 H/F mount SUPT, unpainted 1 3500-Specific Parts: 10 118 210 Cover, 3500, H/F, mount, PTD 1 118 169 Cover, 3500, H/F, mount, SUPT, unpainted 1 3700-Specific Parts: 11 124 448 Cover, 3700, H/F, mount SUPDT, PTD 1 124 449 Cover, 3700, H/F, mount, SUPDT, unpainted 1 2001 Nordson Corporation
Parts 8-15 Melter Specific Lid Assembly (Model 2300) 1 2 3 4 5 6 5746124A 2001 Nordson Corporation
8-16 Parts Item Part Description Quantity 1000 954 Mounting assy., 2300 124 521 Reference drawing, adapter, hood assy., 2300 1 984 723 Nut, hex, cap, M5, STL 8 2 983 401 Washer, lock, M, SPT, M5, STL 8 3 983 408 Washer, flat-head, M, narrow, M5, STL 11 4 982 298 SCR, hex, cap, M5 x 50 1 5 124 522 Adapter, 2300, H/F, A 1 6 101 855 Grommet, 0.44 x 26.47 LG 1 Installation Kit Item Part Description Quantity 320 632 Label, wire, 1 12 x 3, vinyl 1 939 694 Strap, cable,.06 4.00, natural 90 972 183 Elbow, male, 3 / 8 tube x 1 / 4 NPT 2 296 093 Cable, unshielded, 3-conductor 175 ft 900 511 Tubing, polyethylene, 0.375 x 0.062 10 ft 972 663 Adapter, 1 / 4 NPT female x 1 / 4 BSP male 1 982 135 Screw, hex, cap, M6 x 30, Zn 36 983 410 Washer, flat-head, M, narrow, M6, STL, Zn 36 984 092 Nut, hex, lock, torque, M6 class 10 36 303 010 Solenoid, 24 VDC, QDR 1 165 769 Regulator kit with gauge 2 2001 Nordson Corporation
Parts 8-17 Recommended Spare Parts Item Part Description Quantity 341 940 Piston, cup, tube loader 1 341 941 Valve, solenoid, 24 VDC, 3-way, with light 1 341 944 Cylinder, air 3 / 4 bore 1 1002880 Perforated screen cylinder 1 1001387 Motor, VAC pump with brush, 120 VAC 1 341 948 Relay, 24 VDC, coil, motor 1 341 950 Filter cartridge 1 341 955 BB valve/solenoid 24 VDC, 2-way, with light 1 1001750 Replacement 7 / 8 MTR brushes, 4-pack 1 1001245 Bulb, 24 VDC, Lamp 10 Accessories Item Part Description Quantity 341 933 Stand, Gaylord tilter, with vibrator 1002857 Sound enclosure, 4-brush, 7 / 8 HP 175 907 Vertical feed tube 344 082 Ring holder, vertical feed tube 344 083 Protective tarp 175 915 Vertical feed tube with vibrator 2001 Nordson Corporation
8-18 Parts 2001 Nordson Corporation
Technical Data 9-1 Section 9 Technical Data General Specifications............................................ 9-2 Vacuum Pump.................................................... 9-3 Light Tower Assembly............................................ 9-3 Main Control Unit................................................. 9-3 Tube Loader...................................................... 9-3 Drop Chute with Sensor........................................... 9-4 Tilt Table......................................................... 9-4 Component Dimensions.......................................... 9-4 Main Control Unit......................................... 9-4 Pump Stand............................................. 9-5 Tube Loader............................................. 9-6 Light Tower.............................................. 9-7 Tilt Table................................................ 9-8 2001 Nordson Corporation
9-2 Technical Data Technical Data General Specifications Item Specification Number of fill stations 1 to 5 Adhesive transfer rate Adhesive forms transferred 55 90 kg/hr (120 200 lb/hr) for each fill station NOTE: The maximum possible rate depends upon the number of fill stations and the type of adhesive in use. Pellets, mini-slats, and pastilles Maximum size of adhesive Maximum allowable distance between the tube loader and the bulk container Maximum allowable distance of pump from tube loader Compatibility with hot melt systems Electrical service Compressed air Maximum noise level The span between any two points on the adhesive s surface cannot exceed 13 mm (0.5 inch) 30 m (100 ft) horizontal and 3.6 m (12 ft) vertical 30 m (100 ft) horizontal and 3.6 m (12 ft) vertical Most Nordson and Slautterback hot melt systems 120 VAC, 1 60 hz, 15 A 1510 Cu cm/sec (3.2 3.9 scfm) @ 80 100 psi 85 db 2001 Nordson Corporation
Technical Data 9-3 Vacuum Pump Item Specification Vacuum motor Power requirements 7 / 8 Hp 110V,1, 60 hz, 15 A Filter size 5 microns Filter area 50 in. 2 Minimum air pressure to blow back system Blowback air consumption 550 kpa (80 psi/100 psi maximum) 1510 Cu cm/sec (3.2 3.9 scfm) @ 80 100 psi Light Tower Assembly Item Specification Light stack red light (fault: fill request not satisfied) blue light (fill station demanding adhesive) green light (fill station power on) Lamp voltage 24 VDC Main Control Unit Item Specification Type of controller Display Power supply output Programmable relay 4 line by 12 character LCD 24 VDC/5 A Enclosure rating NEMA 12 Tube Loader Item Specification Capacity Operating voltage Minimum air pressure Approximately 0.5 kg (1 lb) 24 VDC supplied from main control unit 410 690 kpa (60 100 psi) 2001 Nordson Corporation
9-4 Technical Data Drop Chute with Sensor Item Specification Type of level sensor Operating voltage Capacitance 24 VDC Tilt Table Item Actuator Electrical service Minimum air pressure Specification Pneumatic with optional electric vibrator 24 VDC from main control unit 550 kpa (80 psi) Component Dimensions Main Control Unit 178 mm (7 in.) 246 mm (9.6 in.) 400 mm (15.7 in.) 347 mm (13.6 in.) 400 mm (15.7 in.) (Back) 5746145A 2001 Nordson Corporation