Drum Melters DG 21 / DG 201

Drum Melters DG 21 / DG 201 Manual P/N 464 839 A - English - NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

Note This manual applies to the entire series. Order number P/N = Order number for Nordson products Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2001. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks AccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat, Cross Cut, Cyclo Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo Coat, EPREG, ETI, Excel 2000, Flex O Coat, FlexiCoat, Flexi Spray, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso Flo, JR, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millenium, Mini Squirt, Moist Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, Package of Values, Pattern View, PluraFoam, Porous Coat, PowderGrid, Powderware, Pro Flo, ProLink, Pro Meter, Pro Stream, PRX, RBX, Rhino, S. design stylized, Saturn, SC5, Select Charge, Select Coat, Select Cure, Slautterback, Smart Coat, Spray Squirt, Spraymelt, Super Squirt, Sure Coat, System Sentry, Tela Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa Coat, Versa Screen, Versa Spray, Watermark, When you expect more. are registered trademarks - - of Nordson Corporation. ATS, Aerocharge, Auto Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, COLORMAX, Control Weave, Controlled Fiberization, CPX, E Nordson, EasyClean, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink Dot, Iso Flex, Kinetix, Maxima, MicroFin, Minimeter, Multifil, OptiMix, PluraMix, Primarc, Prism, Process Sentry, PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, 2 Rings (Design) are trademarks - - of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners' rights. COV_EN_464839A

Table of Contents I Table of Contents Section 1 Safety Section 2 Description Separate document 1. Intended Use... 2 1 Unintended Use - Examples -... 2 1 Electromagnetic Compatibility... 2 2 Area of use... 2 2 Operation restriction... 2 2 Installation... 2 2 2. Residual Risks... 2 2 3. Definition of Terms... 2 2 4. Manual References... 2 3 5. Illustrations and System Components... 2 3 System DG 21... 2 4 System DG 201... 2 5 6. Functioning... 2 6 Conditioning Compressed Air... 2 6 Raising and Lowering Melt Platen... 2 6 Melting Process and Material Flow... 2 7 Level Indications... 2 7 Level indication with variable steps (special feature)... 2 7 Heating and Temperature Control... 2 8 Undertemperature interlock... 2 8 Overtemperature shutdown... 2 8 Pump Drive... 2 8 7. Melt Platen... 2 9 Melting Plates... 2 9

II Table of Contents Section 2 Description (contd.) 8. Electrical Cabinet... 2 10 Main Switch... 2 10 EMERGENCY OFF Button (Special Feature)... 2 10 Temperature Controller... 2 11 Temperature Controller (in Electrical Cabinet)... 2 11 Control System... 2 11 Electrical Cabinet Ventilation... 2 11 Connection Socket Tachometer Generator... 2 11 Interface XS2... 2 11 Door Lock... 2 11 Switches, Buttons and Indication Lamps... 2 12 Special features... 2 14 9. Pneumatic Unit... 2 15 10. Compressed Air Filter / Air Conditioning Unit... 2 16 11. Tandem Drum Melter... 2 17 12. Options Overview and Short Description... 2 18 Coupling EC 20... 2 18 Tach/Automatic Mode... 2 18 Speed Compiler DR 130... 2 18 Automatic Drum Deaeration... 2 18 Week Timer... 2 18 Drum Almost Empty Indication... 2 18 Release Coating... 2 18 Drum Jacket... 2 18 Pallet Model... 2 19 High Capacity Model... 2 19 Indicator Beacon... 2 19 Assembly Handgun Operation... 2 19 Exhaust Hood... 2 19 Drip Pan... 2 19 13. ID Plate... 2 20

Table of Contents III Section 3 Installation 1. Unpacking... 3 1 Lifting (Unpacked) System... 3 1 2. Transport... 3 2 3. Removing... 3 2 4. Storage... 3 2 5. Disposal... 3 2 6. Setting Up... 3 3 7. Exhausting Material Vapors... 3 4 8. Electrical Connections... 3 5 Laying Cables... 3 5 Line Voltage... 3 5 Power Supply... 3 5 Hose Connection Socket(s)... 3 5 Tachometer Generator (Accessory)... 3 5 Interface XS2... 3 6 9. Installing Heated Hoses... 3 7 Connecting... 3 7 Disconnecting... 3 7 Relieving pressure... 3 7 Second open jawed wrench... 3 7 10. Pneumatic Connections... 3 8 Pneumatic... 3 8 Pneumatic Safety Valve (Special Equipment)... 3 9 11. Indicator Beacon (Option)... 3 9

IV Table of Contents Section 4 Operation 1. Two hand Control... 4 1 2. Pneumatic Switch... 4 2 Lower... 4 3 Raising (Aerating Drum)... 4 3 3. Deaerating Drum... 4 3 Deaeration with Ball Valve... 4 4 Deaeration with Rotary Valve... 4 4 Deaeration with Switch/Button... 4 4 4. Lubricating Sealing(s)... 4 4 5. Inserting and Replacing Drum... 4 5 6. Setting Pressure Controller... 4 6 Pressure Controller and Display for Operating Pressure of Cylinder... 4 6 Pressure Controller for Admission Pressure of Cylinder... 4 7 Pressure Controller for Drum Aeration... 4 7 7. Adjusting Switch Rod... 4 8 Position of switch rod... 4 8 Switching functions when lowering... 4 8 Switching functions when raising... 4 8 8. Setting Values and Parameters... 4 9 Speeds... 4 9 Temperatures... 4 9 Recommended values... 4 9 High Capacity Drum Melters... 4 10 9. Switching System ON/OFF... 4 10 System With Week Timer (Option)... 4 10 External System Release... 4 10 Daily Switch ON... 4 11 Daily Switch OFF... 4 11 10. Switching Off in an Emergency... 4 11 11. Initial Startup... 4 12 12. Settings Record Form... 4 14

Table of Contents V Section 5 Maintenance 1. Risk of Burns... 5 1 2. Relieving Pressure... 5 1 3. Daily Maintenance... 5 2 4. Regular Maintenance... 5 3 5. External Cleaning... 5 4 6. Inspection for External Damage... 5 4 7. Cleaning or Replacing Air Filter... 5 4 8. Compressed Air Filter / Air Conditioning Unit... 5 5 Draining Condensate... 5 5 Cleaning Filter Element... 5 5 Checking Oil Supply, Filling if Necessary... 5 6 Cleaning Oil Container... 5 6 9. Pneumatic Pressure Restrictor Valve... 5 7 Function Testing of Pressure Restrictor Valve... 5 7 Cleaning Pressure Restrictor Valve... 5 7 10. Changing Type of Material... 5 8 11. Flushing with a Cleaning Agent... 5 8 12. Cleaning Melting Plate... 5 8 13. Maintenance Record Form... 5 9 Section 6 Troubleshooting 1. Helpful Tips... 6 1 2. Troubleshooting Tables... 6 2

VI Table of Contents Section 7 Repair 1. Preparations for Work on Hydraulic System... 7 1 2. Overtemperature Protection... 7 2 Preparations for Replacement... 7 2 Replacing Overtemperature Safety Cut off Fuse... 7 3 Replacing Overtemperature Thermostats... 7 3 Replacing Temperature Sensor... 7 4 3. Replacing Melt Platen Sealing Rings... 7 4 DG 21: One piece Solid Rubber Sealing Rings... 7 4 DG 201: Divided Hose Seals with Strap Retainer... 7 5 Detaching old seal... 7 5 Attaching new seal... 7 6 DG 201: Closed Sealing Rings... 7 6 4. Sealing the Sealing Rings... 7 7 5. Electrical Connection of Cast in Heating Elements... 7 8 Replacing Insulation on Heater Connections... 7 8 Section 8 Specifications 1. General Data... 8 1 2. Noise Emission... 8 1 3. Electrical Data... 8 1 4. Motor/Pump Speeds... 8 2 5. Temperatures, Fuses and Thermostats... 8 2 6. Material Pressures... 8 3 7. Max. Air Pressures... 8 3 8. Weight... 8 3 9. Dimensions... 8 4 10. Processing Materials... 8 5

Section 1 Safety Observe and follow all safety instructions, the general safety instructions included as a separate document, as well as the specific safety instructions in all other related documentation.

1 0 Safety

Section 2 Description

2 0 Description

Description 2 1 Section 2 Description 1. Intended Use Drum melters of the series DG... - hereafter also referred to as system - may only be used to melt and feed suitable materials. When in doubt, seek permission from Nordson. CAUTION: High capacity drum melters may not be used to process polyurethane hot melt adhesives (PUR). CAUTION: Only undamaged and suitable drums (Refer to Specifications) may be used. When cardboard or fiberglass drums are used, the systems must be equipped with a drum jacket (option). Any other use is considered to be unintended and is carried out at the operator's own risk. Nordson will not be liable for personal injury or property damage resulting from unintended use. Intended use also includes the observance of Nordson safety instructions. Nordson recommends collecting detailed information about the materials to be used. Unintended Use - Examples - The systems may not be used under the following conditions: In defective condition With electrical cabinet door open In a potentially explosive atmosphere With unsuitable operating/processing materials When safety valves and pressure restrictor valves are not lead sealed When the values stated under Specifications are not complied with. The systems may not be used to process the following materials: Explosive and flammable materials Erosive and corrosive materials Food products High capacity drum melters may not be used to process polyurethane hot melt adhesives (PUR).

2 2 Description Electromagnetic Compatibility Area of use The system is designed for use in industrial areas. Operation restriction When operated in residential or commercial areas, the systems may cause interference in other electrical units, e.g. radios. Installation Only shielded cables may be connected to the interface XS2. The shield must be connected to ground in compliance with electromagnetic compatibility. 2. Residual Risks In the design of the system, every measure was taken to protect personnel from possible dangers. Nevertheless, some residual risks can not be avoided. Personnel should be aware of the following points: Risk of burns from hot material Risk of burns from hot system components Risk of burns when conducting maintenance and repair work for which the system must be heated up Risk of burns when attaching and removing heated hoses Inhalation of potentially hazardous material fumes The safety valve can malfunction due to hardened or cracked material. 3. Definition of Terms In Nordson documents, the safety valve is also referred to as bypass and bypass valve.

Description 2 3 4. Manual References This manual applies to the entire series. This instruction manual is valid only in conjunction with all documents included in the complete set of documentation (blue binder). When the system has special features, customer specifications and/or supplements may be added to this manual. The position numbers in the illustrations do not correspond to the position numbers in the technical drawings and spare parts lists. The illustrations show only the essential system components. All other components and details can be found in the included technical drawings (Refer to Parts List). There are three different system configurations: Systems with temperature controller(s) and operating elements such as switches and buttons. Also refer to separate manual Temperature Controller. NOTE: When the unit designation contains the suffix PC (e.g. DG 21 PC), the temperature controller PC 6/9/12 is included. Systems with control system. The control system usually includes temperature controllers and operating elements such as switches and buttons. Also refer to separate manual Control System. Systems with PLC and with/without control panel. If the drum melter does not have a control panel, the functions are set elsewhere in the system (e.g. on the hot melt applicator). Also refer to separate manuals. 5. Illustrations and System Components The following illustrations mainly show system components relevant for operation, installation and maintenance. The components are described in this section and in the following sections of this manual or in separate manuals.

2 4 Description System DG 21 1 21 2 3 4 5 20 6 7 8 9 10 19 18 11 17 12 16 13 15 14 001552 Fig. 2 1 1 Motor* 2 Hose connection socket 3 Switch rod 4 Hose holder 5 Pneumatic cylinder 6 Drum aerating valve 7 Hose connection fitting 8 Drum pressure pad 9 Drum deaerating valve 10 Melt platen 11 Drum clamp 12 Transport rolls 13 Reservoir 14 Safety valve* 15 Switch (drum inserted) 16 Gear pump* 17 Coupling 18 Electrical cabinet 19 Initiator drum empty indication 20 Pneumatic unit 21 Compressed air filter or air conditioning unit Note: There are separate manuals available for all components marked with an asterisk (*).

Description 2 5 System DG 201 16 17 18 1 15 2 14 3 4 5 13 6 12 11 7 8 10 9 001553 Fig. 2 2 1 Initiator drum empty indication 2 Pneumatic unit 3 Electrical cabinet 4 Pneumatic cylinder 5 Hose connection fitting 6 Drum aerating valve 7 Melt platen 8 Drum clamp 9 Reservoir 10 Switch (drum inserted) 11 Drum deaerating valve 12 Gear pump with safety valve* 13 Coupling 14 Motor* 15 Hose holder 16 Hose connection socket 17 Switch rod 18 Compressed air filter or air conditioning unit Note: There are separate manuals available for all components marked with an asterisk (*).

2 6 Description 6. Functioning The functioning of individual components is described in separate manuals (Refer to Index of Documentation). Conditioning Compressed Air The compressed air is conditioned by a compressed air filter or an air conditioning unit. It ensures low maintenance and minimal wear operation of the pneumatically driven components by dehydrating and cleaning the compressed air. It also compensates for pressure fluctuations. For additional information, refer to Installation and Maintenance. Raising and Lowering Melt Platen A pneumatic switch controls raising and lowering of the melt platen, and pneumatic cylinders move the melt platen. When lowering the melt platen, a two hand control must be operated for safety reasons until the melt platen is in the drum. When the melt platen sealing ring is completely inside of the drum, the drum must be deaerated. When the drum is deaerated, the air that is under the melt platen escapes. When the melt platen is raised out of the drum, the drum must be aerated below the melt platen to support raising. Air Melt platen Melt platen Compressed air Drum Drum Deaerating Aerating DGBM031L092A0599 Fig. 2 3 Principle drawing

Description 2 7 Melting Process and Material Flow The material is melted only directly below the melting plate. Depending on what the system is used for, the melt platen can be equipped with different melting plates (Refer to Melting Plates). The melted material is conveyed to the hose connection fitting by a pump. From there it flows through a heated hose to an application head or to an assembly handgun - or possibly to an applicator to fill it. A safety valve limits the material pressure generated by the pump and keeps it stable. Fig. 2 4 Principle drawing Level Indications A visual and acoustic signal indicates that the drum is empty. The drum empty indication is switched off automatically when the melt platen is raised. The indication is triggered by an initiator (19, Fig. 2 1 and 1, Fig. 2 2) on the lifting device when the trigger reaches the height of the initiator. The height of the trigger (a screw) can be adjusted to accommodate different melting plates and drums. Level indication with variable steps (special feature) To enable the indications full, half full and empty, the system includes several initiators. The initiators are attached to a rod and can be easily adjusted. The initiators are adjusted either by the customer or at the factory to suit customer specifications.

2 8 Description Heating and Temperature Control The melt platen is heated with cast in heating elements, providing optimum thermal conductivity and utilization of energy. The temperature is measured and electronically controlled by one or more temperature sensor(s). Undertemperature interlock The undertemperature interlock prevents the system from being started up while the material is too cold; the temperature setpoint minus the undertemperature value must be exceeded. WARNING: If the motor is switched on, it automatically starts up (again) when the undertemperature value is exceeded. Overtemperature shutdown Overtemperature shutdown (fuse or thermostat) protects the system and adhesive from overheating. NOTE: When polyurethane adhesives (PUR) are processed, the overtemperature thermostat or fuse may need to be adapted to the adhesive processing temperature. This may mean that it has to be replaced. Refer to Specifications. WARNING: When overtemperature shutdown is triggered, there is either a fault in settings or system malfunction. Switch off the system and have the fault eliminated by qualified personnel. For details and other functions, refer to separate manual for temperature controller or control system. Pump Drive NOTE: Special systems can accommodate two electrical motors. The electronically controlled electric motor drives a gear pump. The motor /pump speed can be set either with a speed dial (Refer to Electrical Cabinet), with a control system (Refer to separate manual Control System) or with pilot voltage.

Description 2 9 7. Melt Platen The melt platen consists of a heating plate, a melting plate and a sealing ring. Depending on the model, there are one or two sealing rings. NOTE: Before initial startup and every time the drum is replaced, lubricate the melt platen sealing ring(s) (Refer to Specifications for lubricant). Remove material residue before lubricating. 2 1 2 3 Fig. 2 5 Principle drawing 1 Heating plate (example) 2 Sealing ring 3 Melting plate (example) Melting Plates Depending on what the drum melter is used for, one of these melting plates is used. The melting plates are all release coated. Smooth melting plate Fine lamella melting plate Axial melting plate DGTK040L065A0399 Fig. 2 6 Principle drawing

2 10 Description 8. Electrical Cabinet The electrical cabinet contains all of the essential operating elements of the system, described briefly here. 1 1 9 9 10 10 Fig. 2 7 Principle drawing 1 Temperature controller* or control system* 2 Indication lamp undertemperature 3 Indication lamp overtemperature 4 Indication lamp drum empty 5 Button temperature setback 6 Motor switch 7 Button test 8 Speed dial 9 Main switch 10 Interface XS2 11 Indication lamp unit ON Note: There are separate manuals available for all components marked with an asterisk (*). Main Switch (9) The main switch is used to switch the system on and off. Position 0/OFF = System is switched off. Position I/ON = System is switched on. The main switch can be secured with padlocks to prevent unauthorized persons from switching on the system. EMERGENCY OFF Button (Special Feature) (Not shown) The EMERGENCY OFF button is used to switch off the unit in an emergency. The EMERGENCY OFF button must be unlocked before the unit is switched on again.

Description 2 11 Temperature Controller (1) Refer to manual for temperature controller. Temperature Controller (in Electrical Cabinet) (Not shown) Refer to manual for temperature controller FR 461/462. This temperature controller is used for overtemperature switchoff (melting plate) or with high capacity drum melters (medium temperature sensor). Control System (Not shown) Instead of temperature controller, switches (not: main switch) and buttons. If included, refer to manual Control System. Electrical Cabinet Ventilation (Not shown) The electrical cabinet ventilation system reduces the temperature inside of the electrical cabinet. The filters must be serviced regularly. Refer to Maintenance. There is no electrical cabinet ventilation on systems with heat exchangers (special feature). Connection Socket Tachometer Generator (Not shown) The connecting socket is used to connect a tachometer generator (accessory) or pilot voltage for adapting the system's electric motor to the speed of the parent machine. Refer to Installation and manual Tachometer Generator. Interface XS2 (10) Serves as a connection between the system and external devices. Refer to Wiring Diagram. Door Lock (Not shown) The electrical cabinet may be opened for installation, maintenance and repair. Store the included key such that it is accessible only to qualified and authorized personnel. The system may not be operated when the electrical cabinet is open. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from the line voltage.

2 12 Description Switches, Buttons and Indication Lamps The various operating elements depend on the model of the unit. When a control system or control panel is used, they are usually not part of the system. Speed dial (8) Position 10 is the highest speed permitted. Refer to manual Motor. NOTE: The function of the speed dial depends on the position of the manual/tach (auto) switch. Digital speed dial (not shown) Used to set the pump speed and thus the output quantity. Display Speed (not shown) Shows the speed of the gear pump as a factor of the output quantity. Motor switch (6) When the melting plate has reached the set temperature (the undertemperature interlock has released), the motor can be switched on with the motor switch. Button Test (7) WARNING: When the Test button is pressed, hot material can come out of the application head nozzle or the hose connection fitting. When the Test button is pressed, electrically triggered parts such as the drive and solenoid valve are switched on; triggering via the XS2 interface is not necessary. Indication lamp Unit ON (11) Lit when the main switch is turned on.

Description 2 13 Indication lamp Undertemperature (2) As long as the control lamp is lit, the drive is blocked because the pump temperature has not exceeded the undertemperature value set on the temperature controller or because it has fallen below the undertemperature value during operation. Indication lamp Undertemperature (2) NOTE: Only DG 21 PC (Multichannel temperature controller) As long as the control lamp is lit, the drive is blocked because the temperature in one of the active heating zones has not exceeded the undertemperature value set on the temperature controller or because it has fallen below the undertemperature value during operation. Indication lamp Overtemperature (3) Lights up when the actual temperature in one of the active heating zones has exceeded the overtemperature value set on the temperature controller. The heater is then automatically switched off via a timer relay. When the processing temperature has fallen again, the system must be reset. This is done by turning the main switch off then back on again, or on some models via an illuminated push button. Illuminated push button Motor on When the undertemperature lock has been released (indication lamp Undertemperature goes off), the motor can be switched on by pressing the button. Lit when the motor is running. Illuminated push button Motor stop Used to manually stop the motor. Indication lamp Drum empty or Replace drum (4) Lights up when the melting plate on the melt platen reaches the bottom of the drum or is nearly there. Goes off when the melt platen is lifted.

2 14 Description Indication lamp Drum almost empty (not shown) Refer to Level indication with variable steps (special feature). Illuminated push button Acknowledge drum replacement Lights up when the drum is empty and needs to be replaced. When the drum has been replaced, press the illuminated push button to signal readiness to the connected system components. Button Temperature setback (5) NOTE: Only on DG 21 PC (multichannel temperature controller) Serves to protect the material and to save energy during interruptions in operation or work breaks. Press the button to activate the function. To switch the system on again before the set time has expired, press the button again. For more information on the function Temperature setback and setpoints, refer to manual for the temperature controller. Special features Manual/tach switch or manual/auto switch Position manual: The motor/pump speed (output quantity) is set to the required value directly on the speed dial. Position tach (auto): The motor/pump speed is set synchronous to a parent machine, depending on the setting of the speed dial. Indication lamp General fault indication and reset button When the system is equipped with a single channel temperature controller, a customized general fault indication for the hose and application head controllers can be delivered/retrofitted. The temperature controller has been set at the factory and is ready for operation. Reset A general fault is indicated by a red control lamp with a warning triangle on it. The potential free fault indication is on the terminal strip and available for customer use (Refer to wiring diagram). The fault indication is terminated by pressing the reset button. NOTE: To prevent undesired fault indications, temperature controllers not in use should be set to 0 C.

Description 2 15 9. Pneumatic Unit The pneumatic unit contains all pneumatic operating elements of the system as described in the section Operation. Factory set and lead sealed pressure restrictor valves prevent unpermissible excessive pressurization of subsequent pneumatic components. When the values set at the factory are exceeded, the compressed air is audibly discharged. NOTE: The lead seals on the pressure restrictor valves may not be broken. Repairs may be made only by the manufacturer. 6 Front view Side view Fig. 2 8 1 Pressure controller Admission pressure cylinder 2 Pressure controller Drum aeration 3 Pressure controller Operating pressure cylinder 4 Pneumatic switch* 5 Pressure display Operating pressure cylinder 6 Compressed air filter or air conditioning unit 7 Two hand control Note: * Different models (Refer to section Operation)

2 16 Description 10. Compressed Air Filter / Air Conditioning Unit The compressed air for the pneumatically driven components is conditioned with a compressed air filter or an air conditioning unit. The compressed air filter dehydrates and cleans the compressed air. The air conditioning unit also has a lubricator. The lubricated air is used for the pneumatic cylinder. Fig. 2 9 Air conditioning unit 1 Water separator with condensate bowl 2 Oil container 3-4 - 5 Lubricator 6 Inspection window 7 Condensate drain valve 8-9 Oil filling hole 10 Filter element 11 Baffle plate 12 Metering screw 13 Air inlet 14 Air outlet, lubricated 15 Oil syphon tube 16 Air outlet, non lubricated

Description 2 17 11. Tandem Drum Melter Tandem drum melters enable continuous operation. There is always one system active (material feeding) and one in standby mode (System is switched on, but melt platen heater is not on yet). If a drum has been emptied to a certain level (in this case, in the system on the right), the melt platen heater of the other system is automatically switched on. Now the empty drum can be replaced while the other system is feeding material. Heated hose ÁÁÁ ÁÁÁ ÁÁ Manifold Fig. 2 10 Principle drawing

2 18 Description 12. Options Overview and Short Description Options - when they are relevant to installation, operation and maintenance - are described in the appropriate sections of this manual or in separate manuals. Coupling EC 20 Electromagnetic coupling. NOTE: This option is not available for the system DG 201. Tach/Automatic Mode The motor speed is regulated synchronous to the speed of the parent machine (only when a tach generator is connected). Speed Compiler DR 130 A non contact sensor scans a toothed wheel rim attached to the gear output shaft. The pulses thus generated are evaluated by a succeeding electronic device and shown in the speed display as the actual speed. Automatic Drum Deaeration Refer to section Operation / Deaerating Drum / Deaeration with Switch. Week Timer The week timer is used to automatically switch on and off the system. It is located in the electrical cabinet. The main switch must be set to I/ON to be able to use the week timer. Refer to manual Week Timer. Drum Almost Empty Indication Refer to Level Indications. Release Coating The release coating prevents the material being processed from sticking, making cleaning easier and protecting from corrosion. The melting plate on the melt platen is standardly release coated. Drum Jacket The drum jacket supports cardboard and fiber glass drums. When such drums are used, the system must be equipped with a drum jacket (Also refer to Intended Use). NOTE: This option is not available for the system DG 21.

Description 2 19 Pallet Model A Euro pallet (800 x 1200 mm) with a drum on it can be transported directly into the system with these models. NOTE: This option is not available for the system DG 21. High Capacity Model High capacity drum melters have a higher melting capacity. CAUTION: High capacity drum melters may not be used to melt polyurethane adhesives (PUR). NOTE: This option is not available for the system DG 21. Indicator Beacon The indicator beacon shows the operating states of the systems. This option also includes an acoustic drum empty indication. Yellow Red Green White Drum almost empty and drum empty General fault Ready Switched on Assembly Handgun Operation When the system is operated with assembly handgun(s) the motor - which must first be switched on - does not start up until the assembly handgun is triggered. With control system CS 20: When the system is operated with two assembly handguns, the motor speed and thus the output quantity are automatically increased. CAUTION: Application heads may not be connected to systems with the option Assembly handgun mode. Failure to observe will result in short circuit. Exhaust Hood Material vapors are suctioned out directly at the drum. To do this, the exhaust hood must be connected to the customer's exhaust device (Also refer to Installation, Exhausting Material Vapors). Drip Pan A drip pan on a track can be slid under a lifted melt platen.

2 20 Description 13. ID Plate 002433 Fig. 2 11 Fig. 2 12 002386 Information Description Unit Typ System designation Code (System designation and) configuration code - P/N Order number (part number) - Ser. Serial number - U Operating voltage Volt I Fuse rating Ampère f Line voltage frequency Hertz P Power consumption of system Watt P max Power consumption of system and connected accessories Watt

Section 3 Installation

3 0 Installation

Installation 3 1 Section 3 Installation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. Unpacking Unpack carefully and check for transport damage. Save pallet and fastening and packing material for later use, or dispose of properly according to local regulations. Lifting (Unpacked) System Refer to Specifications for weight. Lift only with a suitable floor conveyor (lift truck of fork lift). Fig. 3 1 Lifting system. Example: With a fork lift

3 2 Installation 2. Transport Refer to Specifications for weight. Use only suitable methods of transport. If possible, use the pallet on which the system was delivered, and fasten the system to the pallet. Protect from damage, moisture and dust with suitable packing material. Avoid jolts and vibrations. 3. Removing Convey all material out of system and remove drum. When system will not be used for longer periods of time, rinse with cleaning agent if necessary (Refer to Maintenance). Wipe off sealing ring and clean melting plate (Refer to Maintenance). Disconnect all lines to the system, and allow system to cool. 4. Storage Do not store system outside! Protect from humidity, dust and excessive temperature fluctuations (formation of condensation). 5. Disposal When your Nordson product has exhausted its purpose and/or is no longer needed, please dispose of it properly according to local regulations.

Installation 3 3 6. Setting Up Set up only in an environment that conforms to the system's stated Degree of Protection (Refer to Specifications). Do not set up in a potentially explosive environment. Protect from vibration. Remove transport protection (if present). Ensure that there is sufficient free space around the system, especially above it. Refer to Specifications for dimensions. Fig. 3 2 Principle drawing

3 4 Installation 7. Exhausting Material Vapors Ensure that material vapors do not exceed the prescribed limits. Always observe the safety data sheet for the material to be processed. If necessary, exhaust material vapors and/or provide sufficient ventilation of the location of the system. NOTE: The exhaust hood must be connected to the customer's exhaust device. Customer's Fig. 3 3 Principle drawing

Installation 3 5 8. Electrical Connections WARNING: Risk of electrical shock. Failure to observe can result in personal injury, death or equipment damage. Laying Cables WARNING: Use only temperature resistant cable in the heating part of the system. Ensure that cables do not touch rotating and/or hot parts. Do not pinch cable, and check regularly for damage. Immediately replace damaged cable! Line Voltage WARNING: Operate only with the line voltage stated on the ID plate. NOTE: Permitted deviation from the rated line voltage is +5% / -10%. NOTE: The power connection cable must have a cross section matching the power consumption P max. (Refer to ID Plate). Power Supply The mains terminals are located in the electrical cabinet. For connecting arrangement, refer to Wiring Diagram. On special models, power supply may be through a plug connection. Hose Connection Socket(s) For electrical connection values, refer to Specifications. CAUTION: Application heads may not be connected to systems with the option Assembly handgun mode. Failure to observe will result in short circuit. Tachometer Generator (Accessory) The tachometer generator is connected at the electrical cabinet. Also refer to Wiring Diagram and manual Tacho Generator. CAUTION: The pilot voltage produced by the tachometer generator may not exceed 160 V DC. Failure to observe will result in damage to the succeeding components. NOTE: The pilot voltage produced by the tachometer generator must be aligned.

3 6 Installation Interface XS2 The interface serves as a connection between the system and external devices. Refer to wiring diagram for connecting arrangement. NOTE: To conform with a European standard regarding electromagnetic compatibility, only shielded cable may be connected. The cable must be connected to ground in compliance with the standard. NOTE: Inductive loads (e.g. solenoid valves) connected to the system must be equipped with a protective device (e.g. recovery diode) that disables the inductive voltage generated when an inductive load is switched off.

Installation 3 7 9. Installing Heated Hoses WARNING: Hot! Risk of burns. Wear heat protective gloves. Connecting 1 2 3 If cold material can be found in the hose connection fitting (1) and/or hose connection (2), these components must be heated until the material softens (approx. 80 C, 176 F). 1. First connect the hose (3) electrically to the system. For more than one hose: every hose connection fitting is allocated to a corresponding connection socket. Do not mistakenly exchange! 2. Heat the system and hose to approx. 80 C (176 F). 3. Screw the hose onto the system. NOTE: Close unused hose connection fittings with Nordson screw caps. MXHH001S050B0997 Fig. 3 4 Principle drawing Disconnecting WARNING: System and material pressurized. Relieve pressure before disconnecting heated hoses. Failure to observe can result in serious burns. Relieving pressure 1. Set motor speed to 0 min 1 (rpm); switch off motor(s). 2. Place a reservoir under the nozzle(s) of the application head/hot melt handgun. 3. Activate the solenoid valve(s) electrically or manually; or, pull the trigger of the hot melt handgun. Repeat this procedure until no more material flows out. 4. Re use the material or dispose of properly according to local regulations. Second open jawed wrench Using a second open jawed wrench prevents the hose connection fitting on the unit from turning. MXHH002S033A0295 Fig. 3 5 Principle drawing

3 8 Installation 10. Pneumatic Connections The compressed air for the pneumatically driven components is conditioned with a compressed air filter or an air conditioning unit. Refer to Specifications for connection values. Pneumatic 1 Before the air hose is connected to the compressed air filter (1), verify: 1. The pneumatic switch must be set to idle/stop. NOTE: Connect only dry, clean and non lubricated compressed air. Fig. 3 6 Compressed air filter Before connecting the air hose to the air conditioning unit, verify: 1. The pneumatic switch must be set to idle/stop. 2. The oil container (2) on the lubricator (5) must be filled with oil, and the metering screw (12) must be open approx. 1/2 revolution. Then connect the air hose to the air inlet (13) on the air conditioning unit. Fig. 3 7 Air conditioning unit If an adhesive that crosslinks with moisture (e.g. PUR) is to be processed, the drum should be aerated with a suitable inert gas instead of with air. On some models the inert gas is supplied via a special pressure controller. 1. Connect inert gas suitable for the adhesive to be used to the pressure controller inlet (As indicated by arrow). 2. Set a pressure of 0.5 bar on the pressure controller. NOTE: There is no pressure controller for aerating the drum on PUR drum melters with inert gas pressure controllers. Fig. 3 8 Pressure controller for inert gas

Installation 3 9 Pneumatic Safety Valve (Special Equipment) Depending on the model of the safety valve, the pneumatic connection is either on a compressed air connection or a control unit for pneumatic safety valves. For additional information, refer to manual Pneumatic Safety Valve and/or to manual Control Unit for Pneumatic Safety Valves. 11. Indicator Beacon (Option) The indictor beacon must be screwed onto the electrical cabinet. It was removed to prevent transport damage.

3 10 Installation

Section 4 Operation

4 0 Operation

Operation 4 1 Section 4 Operation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. NOTE: The system should not be started up until the user has read the manual and is familiar with the system. Also refer to Initial Startup. 1. Two hand Control WARNING: Before operating the two hand control, ensure that no one can be injured when the melt platen is lowered. Do not handle drum! Noncompliance can result in burns, crushing and severed limbs. The two hand control may only be operated by one person using both hands! It is used to lower the melt platen when it is outside of the drum. When the melt platen enters the drum, the system automatically switches to regular lowering mode. Fig. 4 1 Symbol Two hand control 1. Set pneumatic switch (Refer to Pneumatic Switch) to Lower. 2. Press both buttons on the two hand control at the same time (within 0.5 seconds) until the melt platen is inside of the drum.

4 2 Operation 2. Pneumatic Switch The modes described in the tables to lower and raise the melt platen are set with the pneumatic switch. The systems will be / are equipped with the following switches. 1 0 2 WARNING: Before operating the pneumatic switch, ensure that no on can be injured by moving parts of the system. Position Mode Notes 0 Idle / stop - 3 1 0 2 1 Lower - 2 Raise - 3 Raise and aerate - 4 Lower and deaerate Option 4 3 NOTE: The labeling of the mode switch shown in Fig. 4 2 was replaced with numerals here for technical reasons. Fig. 4 2 0 Position Mode Notes Raise and aerate - 0 Idle / stop - 001534 Lower - Fig. 4 3 Position Mode Notes Raise and aerate - Lower and deaerate Option Lower - 001292 Idle / stop - Fig. 4 4

Operation 4 3 Lower NOTE: The melt platen can only be lowered when there is a drum in the system and the drum clamp is closed. 1. Lubricate sealing ring(s) (For lubricant, refer to Specifications). 2. Set pneumatic switch to Lower. 3. Operate two hand control (Refer to Two hand Control). 4. Deaerate drum when the melt platen sealing ring(s) is/are completely immersed in the drum (Refer to Deaerating Drum). Raising (Aerating Drum) Melt platen Compressed air WARNING: Risk of burns! When the melt platen leaves the drum, hot material can come out and/or drip from the melt platen. Wear suitable protective clothing! The melt platen is raised. If the melt platen is inside of the drum, the drum must be aerated to support raising. Aerating means that compressed air (0.5 bar / 0.05 MPa / 7.25 psi) is forced under the melt platen. Fig. 4 5 Drum Principle drawing DGBM039S032A0799 Drum aeration begins automatically when the pneumatic switch is set to Raise and aerate. It does not stop until the pneumatic switch is set to Idle/stop. 3. Deaerating Drum WARNING: Risk of burns! Hot material may flow out of the deaeration valve. Wear appropriate protective equipment. Air Melt platen The drum must always be deaerated when the melt platen is moved into the drum. Deaeration allows the air under the melt platen in the drum to escape. Drum DGBM040A032A0799 Fig. 4 6 Principle drawing

4 4 Operation 3. Deaerating Drum (contd.) Deaeration with Ball Valve 1. Place a reservoir (1) in front of the deaeration valve (2). 2. Open deaeration valve (2) when the sealing ring(s) on the melt platen (3) is/are completely immersed in the drum. Only when system is warm! 1 2 3. Close deaeration valve (2), when material flows out free of air bubbles. 4. Dispose of material properly according to local regulations. 3 Fig. 4 7 DGBM041S050A0799 Deaeration with Rotary Valve The drum is deaerated by turning the square bolt to the left with an open jawed wrench. Deaeration with Switch/Button If the pneumatic switch is set to Lower and deaerate (option), the deaeration valve is automatically opened as the melt platen descends. On special models there may be a separate button (special feature) on the side of the electrical cabinet to operate the deaeration valve. 4. Lubricating Sealing(s) Lubricate the sealing ring(s) before initial startup and every time the drum is replaced. Remove material residue before lubricating. Refer to Specifications for lubricant.

Operation 4 5 5. Inserting and Replacing Drum NOTE: Place only undamaged, suitable drums in the system; otherwise the melt platen sealing ring(s) will be damaged. Always keep the base plate of the system clean so that the drum is positioned straight. If necessary, move the switch rod to the height of the drum (Refer to Adjusting Switch Rod). WARNING: Risk of burns! Hot material can drip from the melting plate. Wear appropriate protective equipment. 1. Lift melt platen and aerate while it is still in the drum. 2. Set pneumatic switch to 0/Stop. 3. Insert or replace drum. 4. With DG 21 / DG 21 PC: Adapt drum pressure pad to the height of the drum. 5. Close drum clamp. The drum clamp must be adjusted for each drum. This is done with the threaded rods (1) in the clamps. The user must determine the correct setting of the drum clamp by trial and error: The drum may not be damaged; it must stand firmly and not fall over or be able to be lifted out of the drum melter. Fig. 4 8 Drum clamp 6. Lubricate sealing ring(s). 7. Lower melt platen. 8. Deaerate drum when the melt platen sealing ring(s) is/are immersed in the drum. 9. Dispose of material properly according to local regulations.

4 6 Operation 6. Setting Pressure Controller 6 Front view Side view Fig. 4 9 1. Pressure controller Admission pressure cylinder 2. Pressure controller Drum aeration 3. Pressure controller Operating pressure cylinder 4. Pneumatic switch 5. Pressure display Operating pressure cylinder 6. Compressed air filter or air conditioning unit 7. Two hand control Pressure Controller and Display for Operating Pressure of Cylinder (3 and 5) Operating pressure is applied to the pneumatic cylinder when the melt platen is lowered and when it has been raised out of the drum. Depending on the material to be processed, the pressure controller may need to be set to a different value. The optimum setting may need to be determined by trial and error. Max. pressure 0.55 MPa 5.5 bar 79.8 psi

Operation 4 7 Pressure Controller for Admission Pressure of Cylinder (1) NOTE: The pressure controller has been factory set. Consult Nordson before adjusting! Admission pressure (reduced operating pressure) is applied to the pneumatic cylinder when the melt platen is moved out of the drum. When the melt platen leaves the drum, the system automatically switches to full operating pressure (Also refer to Adjusting Switch Rod). Max. pressure (limited by pressure restrictor valve) 0.2 MPa 2.0 bar 29.0 psi Pressure Controller for Drum Aeration (2) NOTE: The pressure controller has been factory set. Consult Nordson before adjusting! The adjusting screw can be found under the hexagon cap (can be screwed off) on the axle of the pressure controller. Aeration - compressed air is forced under the melt platen to support raising of melt platen - occurs when the melt platen is moved out of the drum (Refer to Aerating Drum). Max. pressure (limited by pressure restrictor valve) 0.05 MPa 0.5 bar 7.5 psi

4 8 Operation 7. Adjusting Switch Rod The system is adapted to the drum height by adjusting the switch rod. 1 2 3 4 5 Position of switch rod Set the switch rod (3) such that it activates the switch (5) when the sealing ring (4) is at the top of the drum. To do this, release the nuts (1 and 2). Switching functions when lowering Switches from two hand lowering to normal lowering when the melt platen sealing ring (4) is at the top of the drum. The illustration shows a melt platen with one sealing ring (4). When the melt platen has two sealing rings, the setting is determined by the top sealing ring. Switching functions when raising Switches pressurization of pneumatic cylinder from admission pressure to operating pressure when the melt platen moves out of the drum. Fig. 4 10 Principle drawing

Operation 4 9 8. Setting Values and Parameters Speeds Also refer to separate manual Temperature Controller or Control System. NOTE: Avoid a permanent motor/pump speed of less than 5 min 1 (rpm) and more than 80 min 1 (rpm) to prevent excessive wear. Temperatures NOTE: When setting the temperature, the processing temperature prescribed by the material manufacturer is decisive. The maximum operating temperature for the product described here and the system components may not be exceeded. Nordson will assume no warranty and no liability for damage resulting from incorrect temperature settings. Heating range / temperature / sensor Melting plate Pump Medium temperature sensor (for high capacity drum melters) Recommended values The values listed in the tables show general values based on experience; they may not always be exactly applicable. Setting value Prescribed processing temperature Prescribed processing temperature Prescribed processing temperature Undertemperature value 10 C below set setpoint of each temperature controller/channel Overtemperature value 10 to 30 C above set setpoint of melting plate temperature controller/channel Application head (accessory) Heated hose (accessory) NOTE: If the temperature controller FR461/FR462 is used, it is located in the electrical cabinet. Prescribed processing temperature Prescribed processing temperature

4 10 Operation High Capacity Drum Melters These units are equipped with a medium temperature sensor in the hose connection behind the pump. During pumping, the medium temperature sensor measures the current adhesive temperature, which is in turn used to regulate the melting plate temperature. This enables a higher melting capacity and thus a higher output quantity. When the pump is not operated, the temperature controller automatically switches to the melting plate temperature sensor to prevent the adhesive from overheating. WARNING: High capacity drum melters may not be used to melt polyurethane hot melt adhesives (PUR). The temperature controller for this function is located in the electrical cabinet (Refer to separate manual for temperature controller FR461/FR462). 9. Switching System ON/OFF NOTE: Before initial startup, read and observe the instructions in Initial Startup. Start up only as described under Initial Startup. The unit is switched on and off with the main switch. Position 0/OFF = System is switched off. Position I/ON = System is switched on. The main switch can be secured with padlocks tp prevent unauthorized persons from switching on the unit. System With Week Timer (Option) The week timer is used to automatically switch the system on and off. NOTE: The main switch must be set to I/ON when using the week timer. External System Release The external system release feature is used to externally switch the unit on/off via the interface XS2. NOTE: When external system release is used, the main switch must be set to I/ON (switched on).

Operation 4 11 Daily Switch ON NOTE: Do not operate Nordson pumps without material. Before switching on motor, ensure that a drum that is not empty is in the system and that the melt platen has contact with the material. NOTE: Avoid a permanent motor/pump speed of less than 5 min 1 (rpm) and more than 80 min 1 (rpm) to prevent excessive wear. 1. Set main switch to I/ON. 2. Wait until system is ready. 3. Replace drum when empty. 4. Move melt platen into drum (if it is not already in the drum). 5. With control system CS20: Pre select motor(s). 6. Switch on the motor(s). Daily Switch OFF 1. Switch off the motor(s). 2. Set main switch to 0/OFF and protect with padlocks if necessary. 3. Set pneumatic switch to Stop. 4. Conduct daily maintenance. NOTE: The melt platen need not be moved out of the drum. 10. Switching Off in an Emergency WARNING: Immediately switch off the system in any emergency situation. 1. Set main switch to 0/OFF or - when available - press EMERGENCY OFF button (special feature). 2. Set pneumatic switch to Stop. 3. After standstill and before switching the system on again, have the fault remedied by qualified personnel.