Hot Melt Material Applicator Manual P/N 403 022 D 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 1997. 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_403022D
Table of Contents I Table of Contents Section 1 Safety Separate document Section 2 Description 1. Intended Use............................................. 2-1 Area of Use (EMC)...................................... 2-1 Use Limitation........................................ 2-1 Unintended Use Examples............................ 2-1 2. Residual Risks............................................ 2-2 3. Operating Manual......................................... 2-2 4. Series Overview.......................................... 2-3 Explanation of Unit Description........................... 2-3 5. Configuration Code........................................ 2-3 Example............................................... 2-3 Code and Keys......................................... 2-3 6. Unit Components......................................... 2-4 7. Functioning............................................... 2-5 Melting Process and Hot Melt Material Supply.............. 2-5 Motor.................................................. 2-5 Gear Pump............................................ 2-5 Safety Valve (Option).................................... 2-5 Heating and Temperature Control......................... 2-6 Undertemperature Locking Device...................... 2-6 Overtemperature indication / shutdown.................. 2-6 Temperature Setback................................. 2-6 Inert Gas Equipment.................................... 2-7
II Table of Contents Section 2 Description (contd.) 8. Electrical Cabinet......................................... 2-8 Front/Rear Side......................................... 2-8 Main Switch............................................ 2-9 Button Heating On/Off................................... 2-9 Temperature Controller.................................. 2-9 Channel assignment.................................. 2-9 Push button Temperature Setback........................ 2-9 Buttons Motor Start/Stop................................ 2-10 Torque Setting Dial..................................... 2-10 Button Purge.......................................... 2-10 Lighted Symbol Inert Gas Bottle Empty................... 2-10 Lighted Symbol Inert Gas Supply........................ 2-10 Electrical Cabinet Aeration.............................. 2-10 Door Locks............................................ 2-10 9. Protective Panels........................................ 2-11 10. ID Plate................................................. 2-11 Section 3 Installation 1. Transport................................................ 3-1 Lifting (Unpacked Unit).................................. 3-1 2. Unpacking................................................ 3-1 3. Removing................................................ 3-1 4. Storage.................................................. 3-1 5. Disposal................................................. 3-1 6. Setting Up................................................ 3-2 7. Overview................................................. 3-2 8. Exhausting Hot Melt Material Vapors......................... 3-2 9. Electrical Connections..................................... 3-3 Laying Cables.......................................... 3-3 Line Voltage............................................ 3-3 External Motor Release.................................. 3-3
Table of Contents III Section 3 Installation (contd.) 10. Connecting Inert gas...................................... 3-3 11. Installing Heated Hoses.................................... 3-4 Connecting............................................. 3-4 Disconnecting.......................................... 3-4 Relieving Pressure................................... 3-4 Second Open jawed Wrench.......................... 3-4 Section 4 Operation 1. Filling the Tank............................................ 4-1 Maximum Filling Level................................... 4-1 Opening and Closing Tank............................... 4-2 Opening Tank........................................ 4-2 Closing Tank......................................... 4-2 Tank Hood Switch.................................... 4-2 2. Operating Elements....................................... 4-3 3. Setting Temperatures...................................... 4-3 General Values......................................... 4-3 4. Setting Inert Gas Control................................... 4-3 5. Setting Adhesive Output Quantity........................... 4-4 Without Pressure Control Valve........................... 4-4 With Pressure Control Valve (Option)...................... 4-4 6. Initial Startup............................................. 4-5 7. Daily Switch ON/OFF...................................... 4-6 Daily Switch ON........................................ 4-6 Daily Switch OFF (Inert Gas also Off)...................... 4-6 Daily Switch OFF (Inert Gas not Off)....................... 4-6 8. Emergency Switch OFF.................................... 4-6 9. Settings Record Form..................................... 4-7 Section 5 Maintenance 1. Relieving Pressure........................................ 5-1 2. Daily Maintenance........................................ 5-2 3. Regular Maintenance...................................... 5-2 4. External Cleaning......................................... 5-3
IV Table of Contents Section 5 Maintenance (contd.) 5. Inspection for External Damage............................. 5-3 6. Electrical Cabinet Fan Maintenance......................... 5-3 7. Changing Hot Melt Material Type............................ 5-4 Flushing with a Cleaning Agent........................... 5-4 8. Maintenance Record Form................................. 5-5 Section 6 Troubleshooting 1. Temperature Controller.................................... 6-1 2. Helpful Tips.............................................. 6-1 3. Safety Valve.............................................. 6-1 4. Indication Lamps.......................................... 6-2 5. Troubleshooting Tables.................................... 6-3 Only the White Indication Lamp is Lit...................... 6-3 Red Indication Lamp is Lit................................ 6-3 Unit does not Function................................... 6-4 One Channel (Heating Zone) does not Heat................ 6-4 No Hot Melt Material (Motor does not Rotate)............... 6-4 No Hot Melt Material (Motor Rotating)..................... 6-5 Not Enough Hot Melt Material............................ 6-5 Hot Melt Material Pressure Too High...................... 6-5 Hot Melt Material Pressure Too Low....................... 6-5 Hot Melt Material Residues in Tank........................ 6-5 Hot Melt Material Hardens in Tank........................ 6-6 Section 7 Specifications 1. General Data............................................. 7-1 2. Temperature.............................................. 7-1 3. Electrical Data............................................ 7-2 4. Dimensions and Weights................................... 7-2 Section 8 Index............................................................. 8-1
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 Hot melt material applicators of the series may only be used to melt and feed polyurethane hot melt materials (PUR). Any other use is considered as not intended and is carried out at the operator s own risk. Nordson will not be responsible for personal injury or equipment 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. Area of Use (EMC) The units are designed for use in industrial areas (see also included Declaration of Conformity). Use Limitation When used in residential and commercial areas, the units can cause interference in other appliances, e.g. radios. Unintended Use Examples The unit may not be used under the following conditions: In defective condition When unapproved changes or modifications have been made by the customer Without heat protection and protective panels With electrical cabinet door open With tank lid open With tank hood open In an explosive atmosphere When the values stated under Specifications are not complied with. The unit may not be used to melt and process the following materials: Explosive and flammable materials Erosive and corrosive materials Foodstuffs.
2-2 Description 2. Residual Risks The unit is designed to protect operating personnel from possible risks. However, some residual risks cannot be avoided. Personnel must consider the following: Risk of burns from hot melt material Risk of burns on the tank lid after the tank hood has been opened Risk of burns when filling the tank Risk of burns from heated accessories such as heated hoses or hot melt application heads Inhalation of potentially hazardous hot melt material vapors. 3. Operating Manual Representative for all units of this series, this manual describes a unit with one gear pump and one hose connection. The position numbers in the illustrations do not correspond to the position numbers in the technical drawings or spare parts lists. The functions Automatic temperature setback when motor has been off for 60 minutes and Piston pump control, described in the separate manual Temperature Controller, are not available on this unit. The safety valve is referred to as bypass or bypass valve in Nordson manuals. It is used as a pressure control valve in this unit.
Description 2-3 4. Series Overview Unit Motors / Pumps Hose connections per pump -1x1 1 1-1x2 1 2 Explanation of Unit Description The description is illustrated by the example -1x2. -1x2 2 hose connections per pump 1 motor / pump Series description / 6 liter tank capacity Description Nordson units of the Meltex product line which process polyurethane hot melt material. M = Moisture C = Curing 5. Configuration Code The configuration code is stamped into the ID plate. The code consists of all positions, whereby a function or component that is not available is replaced with an X (Refer to Example). Example Position 1 2 3 4 5 6 7 8 9 10 11 12 Code M C 6 1 x 1 C F 1 / X Code and Keys The chart shows all possible configurations. Unit des signa natio on tion Con nfigu urat Position Code Key Note 1 M Series or unit designation M = Moisture 2 C Series or unit designation C = Curing 3 6 Series or unit designation 6 = 6 liter tank capacity 4 5 1 One pump 6 x 7 1 One hose connection per pump 2 Two hose connections per pump 8 C Operating voltage 3x400 V AC Temperature sensor Fe-CuNi Fe-CuNi = FE/KO G Operating voltage 3x230 V AC Temperature sensor Fe-CuNi Fe-CuNi = FE/KO V Operating voltage 3x400 V AC Temperature sensor Ni 120 Y Operating voltage 3x230 V AC Temperature sensor Ni 120 9 F Pump PR 12m2 with VX-non-stick coating 10 1 Hose connection 5 / 16 in. = 8 mm 11 / 12 F Safety valve (Pressure control valve) Option
2-4 Description 6. Unit Components Figure 2 1 shows the essential unit components. Details can be found in the technical drawings (Refer to Spare Parts Lists). 2 3 4 1 16 17 15 14 13 12 11 10 9 8 7 25 6 5 24 23 18 20 19 18 22 MCSY339L168B0697 Fig. 2-1 1. Tank hood switch 2. Tank hood 3. Tank hood handle 4. Electrical cabinet 5. Motor 6. Coupling 7. Gear pump 8. Screw on stopper 9. Tank 10. Cable guides 11. Hose connection fitting 12. Protective panels 13. Tank lid handle 14. Tank lid lock 15. Tank lid 16. Tank hood bracket 17. Tank lid detent 18. Inert gas equipment 19. Safety valve plate (option) 20. Safety valve (option) 21. 22. Feet 23. Unit frame 24. Motor cover 25. Heat protection
Description 2-5 7. Functioning The functioning of the unit is described here. The operation of the individual components is described in the manual for the component (refer to Index of Documentation). Melting Process and Hot Melt Material Supply The adhesive is placed in the tank. There it is heated to the processing temperature stated by the manufacturer or to the temperature set by the user. The melted material flows to the gear pump. The gear pump driven by a motor feeds the material to the hose connection fitting. From here the material flows through the heated hose to the hot melt material application head or to the hot melt material handgun. Motor The motor (in this case a torque motor) drives the gear pump (also refer to manual Motor). NOTE: Torque motors function in a special way. They do not run constantly at a set speed; instead their purpose is to supply torque at standstill or at any partial speed. In practice this means that the motor comes to a standstill when the nozzle of an adhesive application head is closed and begins operation again when the nozzle is opened. Because of this, the safety valve that is standard on Nordson adhesive application units is not part of this unit (also refer to Safety Valve [Option] ). NOTE: The motor is first ready for operation when the undertemperature locking device has been released or when the unit has almost reached the set nominal value temperature. NOTE: The motor can also be turned on/off externally (refer to section Installation and Wiring Diagram). Gear Pump The gear pump, which is driven by a motor, feeds the adhesive to the hose connection fitting or to the unit outlet (also refer to manual Gear Pump). NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, make sure the tank is filled. Safety Valve (Option) This unit is equipped with a torque motor. Thus for technical reasons a safety valve is not necessary. On this unit the optional safety valve serves as a pressure control valve for setting and stabilizing the desired adhesive pressure. NOTE: The lead sealing described in the manual Safety Valve is omitted when the safety valve is used as a pressure control valve.
2-6 Description Heating and Temperature Control The melting zone is heated with cast in heating elements. They provide optimal heat conduction and energy utilization. The temperature is measured by sensors and regulated electronically by the temperature controller. Undertemperature Locking Device The undertemperature locking device prevents the unit or system from starting up when the hot melt material is too cold. It is activated until the nominal temperature value minus undertemperature value has been exceeded. On initial heating of the unit, the locking device is first released when the actual temperature is 3 C below the nominal value temperature. The undertemperature locking device locks the motors, solenoid valves and, in some cases, other components of the hot melt material application system. Refer to the wiring diagram to determine which components are locked. Overtemperature indication / shutdown The independently operating overtemperature shutdown mechanisms protect the unit and adhesive from overheating. For overtemperature shutdown, the heating and motor are switched off. The red indication lamp collective fault lights up. Overtemperature indication through temperature controller: Switches relay output collective fault when setpoint temperature value plus overtemperature value has been reached and the red indication lamp lights up. The unit remains ready for operation. Overtemperature shutdown through temperature controller: The overtemperature shutdown value is set automatically 30 C above the highest temperature setpoint value. Overtemperature shutdown through thermostat(s): Serves as an emergency switch OFF in case the overtemperature shutdown of the temperature controller does not function properly. Refer to section Specification for shutdown value. NOTE: Depending on the adhesive used, the overtemperature thermostats of the tank and possibly of the optional can receptacle may need to be adapted to the maximum processing temperature of the adhesive (This may mean that the overtemperature thermostats have need to be replaced). However, the switchoff value of the thermostat may not exceed the max. operating temperature of the unit! For thermostats see section Specifications. WARNING: When the overtemperature shutdown is triggered, there is either a fault in settings or unit malfunction. Switch off the unit and have the fault eliminated by qualified personnel. Temperature Setback Serves to protect the hot melt material and save energy during interruptions in production or work stoppages. Setback value and setback period are adjustable.
Description 2-7 Inert Gas Equipment See also manual Inert Gas Equipment and manual Temperature Controllers. CAUTION: Use only suitable inert gas. Refer to the Material Safety Data Sheet of the material or contact the material supplier. The inert gas prevents the material in the tank from reacting with humidity. It displaces the air in the tank and thus protects the material from an undesired reaction which may cause the material to harden sooner than it should. Inert gases are e.g. nitrogen (N) and carbon dioxide (CO 2 ). The advantage of carbon dioxide is that it is heavier than air and literally floats on top of the material in the tank. NOTE: A diaphragm compressed air dryer, including preceding high performance compressed air filter, for conditioning compressed air such that it can be used as inert gas, can be purchased from Nordson. The inert gas supply is carried out: Automatically during operation as set on the Control System (inert gas injection interval and duration of injection). Automatically after the tank hood is closed. The duration of injection can be set on a timer relay. Manually by pressing the Purge button as an additional Inert gas flush, e.g. when the tank has been filled. An empty gas bottle is indicated by the lighted symbol Inert gas bottle empty. CAUTION: When the main switch is set to 0/OFF, the inert gas equipment is turned off and the tank is deaerated. This can lead to hardening of the adhesive in the tank (Also refer to Daily Shutdown).
2-8 Description 8. Electrical Cabinet WARNING: Risk of electric shock. Failure to observe can result in personal injury, death and/or equipment damage. Front/Rear Side 1 2 3 4 5 6 7 8 14 9 10 11 12 13 16 15 MCPA039L151A0397 Fig. 2-2 1. Main switch 2. Temperature controller 3. Air filter 4. Push button Heater off 5. Push button Heater on 6. Lighted symbol Inert gas injection 7. Push button Purge (Inert gas flush) 8. lluminated symbol Inert gas bottle empty 9. Torque setting dial 10. Push button Motor Start 11. Push button Motor Stop 12. Push button Temperature setback 13. Door locks 14. Electrical cabinet fan with filter 15. Dummy plate 16. Connection socket heated hose
Description 2-9 Main Switch (1, Fig. 2-2) Serves to switch the unit On/Off. Position 0/OFF = unit is switched off. Position I/ON = unit is switched on. The main switch can be secured with padlocks against unauthorized switching. CAUTION: When the main switch is set to 0/OFF, the inert gas equipment is turned off and the tank is deaerated. This could cause hardening of the adhesive in the tank (Refer also to Daily Shutdown). NOTE: The heater or the load current circuit must also be turned on. This is done by pressing the push button Heating on. Button Heating On/Off (4 and 5, Fig. 2-2) The buttons switch the heating (load current circuit) on or off. Temperature Controller (2, Fig. 2-2) For operation see manual Temperature Controllers. Channel assignment Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8 Channel 9 Tank (melt zone) Heated hose Application head Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned Push button Temperature Setback (12, Fig. 2-2) Serves to turn on/off the temperature setback. The temperature setback function protects the adhesive and saves energy during breaks. The setback temperature and time can be set (Refer to manual Temperature Controllers).
2-10 Description Buttons Motor Start/Stop (10 and 11, Fig. 2-2) Used to turn on/off the motor. Bu the motor can not be turned on until the unit is ready for operation or until the green lamp in the temperature controller lights up. NOTE: The motor can also be turned on/off externally (Refer to Installation, External Motor Release and Wiring Diagram). NOTE: Do not operate Nordson gear pumps without adhesive. Ensure that the tank is filled before turning on the motor. Torque Setting Dial (9, Fig. 2-2) Serves to set the torque or the adhesive output quantity within the range of 0 to 100 %. The selected setting should be locked in to avoid accidental resetting. Button Purge (7, Fig. 2-2) Pressing the button activates an additional Inert gas flush, e.g. after the tank has been filled. Lighted Symbol Inert Gas Bottle Empty (8, Fig. 2-2) Lights when the inert gas bottle is empty. Lighted Symbol Inert Gas Supply (6, Fig. 2-2) Lights each time inert gas is injected. Electrical Cabinet Aeration (3 and 14, Fig. 2-2) Serves to aerate the electrical cabinet, which reduces the inside temperature. The filter must be cleaned or replaced regularly (Refer to Section 5 Maintenance). Door Locks (13, Fig. 2-2) The electrical cabinet can be opened with the aid of the included key. Store the key such that it is accessible only to qualified and authorized personnel. WARNING: Allow only qualified and authorized personnel to open the electrical cabinet. WARNING: Disconnect equipment from the line voltage.
Description 2-11 9. Protective Panels WARNING: Do not operate unit without protective panels. The protective panels may be removed for installation, maintenance, etc. The panel locks (panel fasteners) are unlocked with the included square wrench. MCSY333S050A0397 Fig. 2-3 10. ID Plate The ID plate contains the following information: Code Nordson Engineering GmbH D 21337 Lüneburg Germany R P/N Ser. U I A f V 50/60 Hz P W Pmax W XXSY015L034A0395 Fig. 2-4 Information Description Unit Code Unit description and configuration code P/N Article number Ser. Serial number U Operating voltage Volt I Fuse rating Ampere f Frequency of line voltage Hertz P Power consumption of the unit Watt P max Power consumption of the unit and connected accessories Watt
2-12 Description
Section 3 Installation
3-0 Installation
Installation 3-1 Section 3 Installation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. Transport See Section Specifications for weight. Only use suitable methods of transport. Protect the unit from humidity, excessive dust, impacts and vibrations. Lifting (Unpacked Unit) See section Specifications for weight. Lift at the unit frame using suitable lifting equipment or a forklift. 2. Unpacking Unpack the unit carefully and check for damage caused during transport. Recycle packing materials or dispose of properly according to local regulations. 3. Removing Empty unit completely and rinse thoroughly with cleaning agent (Refer to Maintenance). Then disconnect all connections to the unit and allow the unit to cool. 4. Storage Do not store the unit in the open! Protect the unit from humidity, excessive dust and great fluctuations in temperature (forming of condensation). 5. Disposal Ensure proper disposal of the unit according to local regulations.
3-2 Installation 6. Setting Up Set up the unit only in surroundings which correspond to its Degree of Protection (see section Specifications). Do not set up in explosive surroundings! Protect the unit against vibrations. Remove transport protection devices (if any). Provide enough space for unit to be easily accessible (Fig. 3-1). MCSY332S070A0397 Fig. 3-1 7. Overview NOTE: The overview does not replace the following description. Exhaust hot melt material vapors if necessary (can only escape when the tank lid is open) Electrical connections Connect inert gas Install heated hose MCSY336L110B0697 Fig. 3-2 8. Exhausting Hot Melt Material Vapors Make sure that hot melt material vapors do not exceed the prescribed limits. Exhaust the vapors if necessary. Provide sufficient ventilation in the area where the machine is set up.
Installation 3-3 9. Electrical Connections WARNING: Risk of electrical shock. Failure to observe can result in personal injury, death or equipment damage. Laying Cables Make sure that cables do not come into contact with any rotating and/or heated unit components. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! The unit is equipped with cable guides for laying cables (1, Fig. 3-3). 1 1 1 MCSY334S065B0779 Fig. 3-3 Line Voltage WARNING: The unit may only be operated with the line voltage indicated on the ID plate. NOTE: Permissible tolerances regarding the rated line voltage are +5% / 10%. The mains connection cable must have a cross section matching the rated power consumption. See ID plate for rated current. The mains terminals are located in the electrical cabinet. See Wiring Diagram for connection allocation. External Motor Release The motor can also be turned on/off externally. The contacts External motor release were bridged by the factory. To use the external motor release, the bridge must be removed and replaced by the customer s external switching device (Refer to Wiring Diagram). Terminal strip XL2 (Contact 1 and 2 bridged by factory) Contacts 1 and 2 switched externally Contacts 1 and 3 switched externally The motor can be turned off externally. But to turn the motor back on, it must be turned on externally, then the button Motor Start must be pressed. The buttons Motor Start and Motor Stop no longer have a function 10. Connecting Inert gas See manual Inert Gas Equipment.
3-4 Installation 11. Installing Heated Hoses WARNING: Hot! Risk of burns. Wear heat protective gloves. Connecting 1 2 3 If cold hot melt 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 unit. For more than one hose: every hose connection fitting is allocated to a corresponding connection socket. Do not mistakenly exchange! NOTE: For units with recirculation hoses: do not mistake recirculation hoses for feed hoses. 2. Heat the unit and hose to approx. 80 C (176 F). Fig. 3-4 Principle drawing MXHH001S050A0295 3. Screw the hose onto the unit. NOTE: Close unused hose connection fittings with Nordson screw caps. Disconnecting WARNING: System and hot melt material pressurized. Relieve pressure before disconnecting heated hoses. Failure to observe can result in serious burns. Relieving Pressure 1. Set motor speed to 0 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 hot melt material flows out. 4. Re-use the hot melt 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
Section 4 Operation
4-0 Operation
Operation 4-1 Section 4 Operation WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. Filling the Tank WARNING: Hot! Risk of burns. Wear safety goggles and heat protective gloves. Risk of burns from the tank lid when the tank hood has been opened. Hot adhesive can splash out of the tank when it is being filled. Insert the adhesive carefully. Before filling the tank, make sure the tank and hot melt material are clean and free of foreign substances. Foreign substances can damage the unit and accessories. Also ensure that the inert gas inlet hole and the tank deaeration hole are not plugged with adhesive. NOTE: Do not completely empty the tank. If there is too little adhesive in the tank, the adhesive can overheat. This can cause adhesive residue and hardening, resulting in malfunctioning. MCTK017S050A0397 Fig. 4-1 Maximum Filling Level Ensure that the melted adhesive can not reach the inert gas inlet hole and the tank deaeration hole.
4-2 Operation Opening and Closing Tank WARNING: Hot! Risk of burns on the tank lid after opening the tank hood. Wear heat protective gloves. WARNING: Do not operate the unit when the tank lid is open. Hot melt material vapors which may contain hazardous substances can escape. 1 WARNING: The tank lid may not be opened until the quick dearation procedure is audibly completed CAUTION: Do not operate unit when tank hood is open. When the hood is open the tank is relieved of inert gas pressure, and no inert gas pressurization occurs. This can result in the adhesive hardening in the tank. Opening Tank 1. Open the tank hood (1) (Also refer to Tank Hood Switch). 2. Open the tank lid lock (3). 3. Pull the tank lid open with the aid of the tank lid handle (2) until the tank lid detent (5) locks into place. 2 3 4 Closing Tank 1. Hold on to the tank lid with the aid of the tank lid handle (2). Pull the tank lid detent (5) back and close the tank lid. 2. Lock the tank lid lock (3). 3. Close the tank hood (1) (Also refer to the Tank Hood Switch). Tank Hood Switch The tank hood switch (4) activates the following functions on opening and closing the tank hood (1): 5 Tank hood is opened Tank is relieved of inert gas pressure (quick deaeration). Tank hood is closed Inert gas is applied to the tank for the period set on the timer relay. Inert gas supply carried out at regular intervals as set on the temperature controller. 6 MCSY335S220B0697 Timer relay Function Setting range Factory settings K6 Inert gas supply 0.5 to 10 minutes 30 seconds Fig. 4-2
Operation 4-3 2. Operating Elements All of the operating elements are described in Section 2, Description. 3. Setting Temperatures Refer to manual Temperature Controllers. NOTE: Processing temperature is also referred to in the description of the Control System as nominal value temperature. NOTE: The temperature setting is determined by the processing temperature prescribed by the hot melt material supplier. Do not exceed the maximum operating temperature of the unit or heated system components. Nordson assumes no guarantee and/or liability for damage caused by incorrect temperature settings. NOTE: Depending on the adhesive used, the overtemperature thermostats of the tank and possibly of the optional can receptacle may need to be adapted to the maximum processing temperature of the adhesive (This may mean that the overtemperature thermostats have need to be replaced). The switchoff value of the thermostat may not exceed the max. operating temperature of the unit! For thermostats see section Specifications. General Values Heating zone / Temperature / Time The values in the table are general values for temperature settings. Setting Tank 10 C (50 F) below prescribed processing temperature Undertemperature value 10 C (50 F) below set processing temperature Overtemperature value 10 to 30 C (50 86 F) above set processing temperature Setback temperature Setback period As required As required Application head (Accessories) Prescribed processing temperature(s) Heated hose (Accessories) Prescribed processing temperature 4. Setting Inert Gas Control Refer to manual Temperature controllers.
4-4 Operation 5. Setting Adhesive Output Quantity The amount of adhesive necessary (application weight) depends on the customer s hot melt material deposit and must be determined through experimentation. Without Pressure Control Valve The adhesive output quantity or the torque is set with the torque controller (9, Fig 2 2) within a range of 0 to 100 %. The selected setting should be locked in to avoid accidental resetting. NOTE: Torque motors function in a special way. They do not run constantly at a set speed; instead their purpose is to supply torque at standstill or at any partial speed. In practice this means that the motor comes to a standstill when the nozzle of an adhesive application head is closed and begins operation again when the nozzle is opened. With Pressure Control Valve (Option) On units that are equipped with the optional safety valve used on this unit as a pressure control valve a more even adhesive output quantity can be set. The pressure control valve (20, Fig 2 1) is located between the tank and the gear pump. Setting range 0 to 7.0 MPa 0 to 70 bar 0 to 1015 psi Factory setting 3.5 MPa 35 bar 508 psi Turning to the right Turning to the left Increases adhesive pressure / output quantity Decreases adhesive pressure / output quantity 1. Set torque controller to the necessary value. 2. Set the pressure control valve such that the motor speed remains nearly stable when the application head nozzle is closed. 3. Alternately set the torque controller and the pressure control valve in order to set the adhesive output quantity as evenly as possible. 4. Lock torque controller.
Operation 4-5 6. Initial Startup After the unit has been properly installed, initial startup can take place. NOTE: The unit was subjected to extensive functional tests prior to shipment. In doing so, the tank was filled with a special test material. Residues of this material may still be present in the unit. To remove these residues, melt and feed several kilograms of hot melt material before starting production. NOTE: The temperature setting is determined by the processing temperature prescribed by the hot melt material supplier. Do not exceed the maximum operating temperature of the unit or heated system components. Nordson assumes no guarantee and/or liability for damage caused by incorrect temperature settings. NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, make sure the tank is filled. NOTE: Before executing the following steps, the user must be familiar with the operation of the temperature controller. 1. Ensure that the tank is pressurized with inert gas. 2. Set main switch to position I/ON. 3. Activate button Heating on. 4. Fill the tank. 5. Close tank lid and tank hood. 6. Carry out all settings on the temperature controller. 7. Set timer relay (see under Opening and Closing Tank). 8. Wait until the unit is ready for operation (green lamp on temperature controller is lit). 9. Switch on the motor. 10. Set adhesive output quantity or torque.
4-6 Operation 7. Daily Switch ON/OFF Daily Switch ON/OFF has the same meaning as the terms starting and stopping. Daily Switch ON NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, make sure the tank is filled. 1. Ensure that the tank is pressurized with inert gas. 2. Set main switch to position I/ON. 3. Activate button Heating on. 4. Fill hot melt material if necessary. 5. Wait until the unit is ready for operation. 6. Switch on the motor. 7. Set adhesive output quantity or torque. Daily Switch OFF (Inert Gas also Off) 1. Switch off the motor. 2. Set main switch to position 0/OFF. 3. Secure main switch with padlocks if necessary to prevent unauthorized operation. CAUTION: When the main switch is set to 0/Off, the inert gas equipment is turned off and the tank is deaerated. This could cause hardening of the adhesive in the tank. Daily Switch OFF (Inert Gas not Off) 1. Switch off the motor. 2. Activate button Heating off. 8. Emergency Switch OFF WARNING: Switch off the unit immediately in any emergency situation. 1. Set main switch to 0/OFF. 2. After standstill and before switching the unit on again, have the malfunction eliminated by qualified personnel.
Operation 4-7 9. Settings Record Form Make a copy of the form before filling it out. Production information: Hot melt material: Supplier Processing temperature Viscosity Cleaning agent: Supplier Flash point Leading channel: Tank (factory-set) Processing temperatures (nominal value temperatures): Tank Heated hose (Accessories) 1) 2) Application head (Accessories) 1) 2) Air heater (Accessories) 1) 2) Motor torque: Timer relay: Inert gas control: Feeding time Interval Air pressure at application head (Accessories): Control air 1) 2) Spray air 1) 2) Notes: Name Date
4-8 Operation
Section 5 Maintenance
5-0 Maintenance
Maintenance 5-1 Section 5 Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. NOTE: Maintenance is an important preventative measure for maintaining operational safety and extending the lifetime of the unit. It should not be neglected under any circumstances. 1. Relieving Pressure WARNING: System and hot melt material under pressure. Before removing heated hoses, application heads or hot melt handguns, relieve system pressure. Failure to observe can result in serious burns. WARNING: Hot! Risk of burns. Wear heat-protective gloves. 1. Set motor speed to 0 RPM; switch off motor(s). 2. Place a reservoir under the nozzle(s) of the application head/hot melt handgun. 3. Trigger the solenoid valve(s) electrically or manually; or, pull the trigger of the hot melt handgun. Repeat this procedure until no more hot melt material flows out. 4. Re use hot melt material or dispose of properly according to local regulations.
5-2 Maintenance 2. Daily Maintenance Some of the maintenance activities described under Regular Maintenance may have to be carried out daily. Unit part Activity Interval Refer to Entire unit External cleaning Daily Page 5-3 Inspection for external damage Daily Page 5-3 Tank Visual inspection for impurities in Before every tank filling the tank Visual inspection of holes for inert gas supply, air exhaust, etc. to check whether they are clogged with adhesive; clean if necessary 3. Regular Maintenance The stated intervals are general guidelines based on experience. Depending on the location of the unit, production conditions and operating time of the unit, other maintenance intervals may prove necessary. Unit part Activity Interval Refer to Electrical cabinet fan Check filter, clean or replace if Depending on dust Page 5-3 necessary accumulation; daily if necessary Power cable Inspection for damage Every time the unit is serviced Air hoses Inspection for damage Every time the unit is serviced Gear pump Refer to separate manual Motor / gear box Refer to separate manual Tank Refer to separate manual Safety valve Refer to separate manual (Pressure control valve) Inert gas equipment Refer to separate manual Air dryer with compressed air filter (Special equipment) Refer to separate manuals
Maintenance 5-3 4. External Cleaning External cleaning prevents pollution created by production from causing unit malfunctions. CAUTION: Observe the unit s Degree of Protection when cleaning (see Specifications). CAUTION: Do not damage or remove warning signs. Damaged or removed warning signs must be replaced by new ones. Only remove hot melt material residues with a cleaning agent recommended by the hot melt material supplier. Pre heat with an air heater if necessary. Vacuum up dust, fluffs etc. or remove them with a soft cloth. 5. Inspection for External Damage WARNING: When damaged parts pose a risk to the operational safety of the unit and/or safety of personnel, switch off the unit and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. 6. Electrical Cabinet Fan Maintenance The electrical cabinet fan is maintenance free. The filter may have to be cleaned or replaced depending on dust emission. A dirty filter can be recognized by its dark color. Clean the filter by tapping out the dirt.
5-4 Maintenance 7. Changing Hot Melt Material Type Remove the old material from the unit by operating until empty or draining from the unit. NOTE: Before changing the material type, determine whether the old and new hot melt materials can be mixed. If mixing is possible: Residues of the old material can be flushed out using the new material. If mixing is not possible: Thoroughly flush the unit with a cleaning agent recommended by the hot melt material supplier. NOTE: Ensure proper disposal of the old hot melt material according to local regulations. Flushing with a Cleaning Agent CAUTION: Only use a cleaning agent recommended by the hot melt material supplier. Observe the Material Safety Data Sheet of the cleaning agent. Residues of the cleaning agent can be flushed out of the unit by the new hot melt material before production begins. NOTE: Ensure proper disposal of the cleaning agent according to local regulations.
Maintenance 5-5 8. Maintenance Record Form Copy the form before filling out. Gear pump Unit part Date / Name Date / Name Date / Name Motor / gear box Electrical cabinet fan Tank Safety valve (Pressure control valve) Inert gas equipment Air dryer (Special equipment)
5-6 Maintenance
Section 6 Troubleshooting
6-0 Troubleshooting
Troubleshooting 6-1 Section 6 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. WARNING: Some troubleshooting activities may have to be carried out when the unit is energized. Observe all safety regulations concerning energized parts (active parts). Failure to observe can result in electric shock. 1. Temperature Controller The temperature controller offers the following troubleshooting aids which are described in the manual Temperature Controllers: Indication lamps Diagnosis program Automatic fault display LEDs on the modules and boards 2. Helpful Tips Before beginning with systematic troubleshooting activities, check the following points: Are all parameters correctly set? Do all plug connections have sufficient contact? Have fuses been activated? Are external, inductive loads (e.g. solenoid valves) equipped with freewheeling diodes? The freewheeling diodes must be directly allocated to the inductive load, e.g. through luminous sealings. 3. Safety Valve The safety valve mentioned in some of the charts is an option and is used in this unit as a pressure control valve.
6-2 Troubleshooting 4. Indication Lamps The indication lamps show the following operating modes: Red (15) = Collective fault indication. The red lamp indicates that the temperature controller has recognized a fault. See troubleshooting table Red indication lamp is lit. White (14) = Switched ON. After switching on and during the heating phase, at first only the white indication lamp is lit (normal condition). A fault has first occurred when the temperature does not increase (observe temperature display) and when the green indication lamp is not lit after the heating phase has ended (1 hour and longer). See troubleshooting table Only the white indication lamp is lit. Green (13) = Ready for operation. The green indication lamp lights when all channels have reached their nominal value temperatures. 15 1 2 3 14 13 C F XXCO082L065B0199 Fig. 6-1 (For position numbers see also manual Temperature Controller)
Troubleshooting 6-3 5. Troubleshooting Tables The troubleshooting tables serve as an orientation for qualified personnel. They cannot, however, replace targeted troubleshooting with the help of wiring diagrams and measuring instruments. They also do not include all possible problems, only those which most typically occur. Only the White Indication Lamp is Lit Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Activate diagnosis program of the temperature controller Nominal value temperatures of one or more heating zones are not reached Fuse(s) defective (There are also fuses located on the modules and the boards) Turn on or replace Manual Temperature Controller Manual Temperature Controller Wiring diagram Broken or loose cable Replace or tighten Overtemperature thermostat (on the Replace Spare parts list tank) defective Temperature sensor(s) defective Replace Solid state relay defective Replace Heater(s) defective Replace (Heaters in tank and heated hose can not be replaced) Temperature setback is switched on Switch off or wait until the setback period has expired Manual Temperature Controller Red Indication Lamp is Lit Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Overtemperature message from temperature controller (Display 3: Hi blinking) Undertemperature emergency switchoff from temperature controller (Displays 1, 2 and 3: blinking) Undertemperature during operation (Display 3: Lo blinking) Ambient temperature too high (Displays 1, 2 and 3: AM bie nt blinking) Temperature sensor short circuit (Display 3: S blinking) Temperature sensor interruption (Display 3: E blinking) Manual Temperature Controller, Service message Error Adhesive was filled up Wait until temperature has been reached again Manual Temperature Controller, Service message Error Ambient temperature is too high Lower ambient temperature by aerating or cooling Electrical cabinet ventilation filter dirty Clean or replace Section 5 Electrical cabinet fan defective Replace Replace Replace
6-4 Troubleshooting Unit does not Function Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to No line voltage Connect line voltage supply Section 3 Main switch not turned on Turn on main switch Section 2 Main switch defective Replace main switch Main fuse activated Turn on main fuse Main fuse activated again Check for short circuit in the unit or Wiring diagram accessories Fuse Control voltage (UN / UL) activated Check for short circuit in the unit or accessories Overtemperature thermostat triggered Temperature set too high Correct temperature setting and wait for unit to cool off Adhesive manufacturers data sheet Wrong overtemperature thermostat Replace Section 7 installed Temperature controller defective Replace One Channel (Heating Zone) does not Heat Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Channel is turned off Turn on Manual Channel switched to measuring mode Switch to control mode Temperature Controller Channel / heating zone defective Activate diagnosis program of the temperature section No Hot Melt Material (Motor does not Rotate) Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Wait until unit is heated up and green indication lamp is lit Unit not yet ready for operation (Undertemperature during heating phase) Unit not ready for operation (Undertemperature during operation) Adhesive was filled up Wait until unit is heated up and green indication lamp is lit Troubleshooting table Only the white indication lamp is lit Motor not turned on Turn on Manual Undertemperature during operation Temperature re Controller Speed not set Set speed Temperature setback turned on Turn off or wait until the setback time has expired Motor defective Replace Motor is not supplied with voltage Determine error through measuring Wiring diagram Fuses defective Replace Torque controller defective Replace
Troubleshooting 6-5 No Hot Melt Material (Motor Rotating) Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Tank empty Fill tank Section 3 Adhesive feed port to the pump or Unscrew pump and feed port or clean Manual Gear Pump suction hole to pump blocked suction hole Pump does not turn Coupling screws loose Tighten Not Enough Hot Melt Material Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Adhesive feed port to the pump or Unscrew pump and feed port or clean Manual Gear Pump suction hole to pump partially blocked suction hole Safety valve defective Clean or replace Manual Safety Valve Processing temperature set too low Correct temperature setting Adhesive manufacturers data sheet Pump block of gear pump worn Replace pump Manual Gear Pump Hot Melt Material Pressure Too High Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Safety valve dirty (and thus blocked) Disassemble and clean or replace Manual Safety Valve Safety valve defective Replace Hot Melt Material Pressure Too Low Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Safety valve dirty (and thus blocked) Disassemble and clean or replace Manual Safety Valve Safety valve defective Replace Hot Melt Material Residues in Tank Possible Cause Possible Fault / Troubleshooting Corrective Action Refer to Tank setpoint temperature too high Correct temperature setting Adhesive manufacturer data sheet