Hot Melt Applicators EP 11 / EP 11 N EP 12 V / EP 12 L / EP 12 RV

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1 Hot Melt Applicators EP 11 / EP 11 N EP 12 V / EP 12 L / EP 12 RV Manual - English - Issued 03/11 NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

2 Note This document is valid for 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 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 All rights reserved. Trademarks AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, Bowtie, CanWorks, Century, CF, CleanSleeve, CleanSpray, Color on Demand, ColorMax, Control Coat, Coolwave, Cross Cut, cscan+, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo Coat, e.dot, EFD, Emerald, Encore, ESP, e stylized, ETI stylized, Excel 2000, Fillmaster, FlexiCoat, Flexi Spray, Flex O Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli flow, Helix, Horizon, Hot Shot, icontrol, idry, iflow, Isocoil, Isocore, Iso Flo, itrax, JR, KB30, Kinetix, LEAN CELL, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist Cure, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, PatternView, PermaFlo, PicoDot, PluraFoam, Porous Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro Flo, ProLink, Pro Meter, Pro Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat, Select Cure, Signature, Slautterback, Smart Coat, Solder Plus, Spectrum, Speed Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure Max, Sure Wrap, Tela Therm, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Ultra, UniScan, UpTime, u TAH, Vantage, Veritec, VersaBlue, Versa Coat, VersaDrum, VersaPail, Versa Screen, Versa Spray, Walcom, Watermark, When you expect more. are registered trademarks - - of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, AquaCure, Artiste, ATS, Auto Flo, AutoScan, Axiom, Best Choice, BetterBook, Blue Series, Bravura, CanNeck, CanPro, Celero, Chameleon, Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat, Cobalt, ContourCoat, Controlled Fiberization, Control Weave, CPX, cselect, Cyclo Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid, DuraCoat, e.dot+, E Nordson, Easy Clean, EasyOn, EasyPW, Eclipse, Equalizer, Equi Bead, Exchange Plus, FillEasy, Fill Sentry, Flow Coat, Fluxplus, G Net, G Site, Get Green With Blue, Gluie, Ink Dot, IntelliJet, ion, Iso Flex, itrend, KVLP, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, MonoCure, Multifil, MultiScan, Myritex, Nano, NexJet, OmniScan, OptiStroke, Origin, Partnership+Plus, PatternJet, PatternPro, PCI, Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PurTech, Quad Cure, Ready Coat, RediCoat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureFoam, SureMix, SureSeal, Swirl Coat, TAH, Tempus, ThruWave, TinyCure, Trade Plus, Trlogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Viper, Vista, WebCure, 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. EP11 / EP Nordson Corporation

3 Table of Contents I Table of Contents Safety Instructions... 1 Introduction... 1 Intended Use... 1 Unintended Use Examples... 1 Residual Risks... 2 Note on Manual... 2 Definition of Term(s)... 2 Applicator... 2 Melter... 2 Control Module... 2 Series Overview... 2 Explanation of Type Designation... 2 Description of Components / Functioning... 3 EP 11 02, L design... 3 EP 12 01, V design... 4 EP 11 N... 5 Material Flow... 6 Nozzle... 6 Shim Plates... 6 Special Aspect of the EP Suction Stem Control Module... 7 Heating... 7 Filter Cartridge... 7 Filter (Option)... 7 ID Plate... 7 Options... 8 Special Features... 8 Installation... 9 Unpacking... 9 Transport... 9 Storage... 9 Disposal... 9 Installing Exhausting Material Vapors Electrical Connection Laying Cable Electrically Connecting Applicator Connecting Solenoid Valves Lubricated or Non lubricated Compressed Air Operating with Non lubricated Compressed Air Operating with Lubricated Compressed Air Pneumatic Connections Connecting Continuous Air and Control Air Connecting EP 12 with Pressure Accumulator Connecting Heated Hose Using Second Open end Wrench Connecting Disconnecting Nordson Corporation EP11 / EP 12

4 II Table of Contents Operation Important When Using Polyurethane Application Materials (PUR) Triggering Solenoid Valves Setting Temperature Setting Control Air Pressure Setting Material Pressure Positioning the Applicator Coating Open pore Substrate Coating Closed pore Substrate Material Application Sample Calculation Settings Record Maintenance Relieving Pressure Regular Maintenance PUR Adhesives Visual Inspection for External Damage External Cleaning Changing Material Purging with Cleaning Agent Disassembling and Cleaning Nozzle Assembling Nozzle Inserting New Shim Plate Changing Control Module Removing Control Module Installing Control Module Cleaning Filter Cartridge Removing Filter Cartridge Replace the Filter Screen Installing Filter Cartridge Nozzle Filter Changing Filter Cartridge Processing Materials Maintenance Record Troubleshooting Introduction Technical Data General Data Air pressure Temperatures Electrical Data Dimensions and Weights EP11 / EP Nordson Corporation

5 Applicators 1 Safety Instructions WARNING: Observe and follow all safety instructions, the general safety instructions included as a separate document, as well as the specific safety instructions in all other related documentation. WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Introduction Intended Use Hot melt applicators in the series EP 11 and EP 12 may be used only for surface application of hot melt adhesives. The maximum material pressure may not exceed 70 bar (7 MPa / 1015 psi). Any other use is considered to be unintended. Nordson will not be liable for personal injury or property damage resulting from unintended use. Intended use includes the observance of Nordson safety instructions. Nordson recommends obtaining detailed information on the materials to be used. Unintended Use Examples The applicator may not be used under the following conditions: In defective condition When changes or modifications have been made by the customer In a potentially explosive atmosphere When unsuitable materials are used When values stated under Technical Data are not complied with. The applicator may not be used to process the following materials: Explosive and flammable materials Erosive and corrosive materials Food products Nordson Corporation EP11 / EP 12

6 2 Applicators Residual Risks In the design of the unit, every measure was taken to protect personnel from potential danger. However, some residual risks cannot be avoided. Personnel should be aware of the following: Risk of burns on the hot applicator: from hot material and when making adjustments Material fumes can be hazardous. Avoid inhalation. Note on Manual Because the unit is continuously being modified and improved, there are several models of the applicator. Thus illustrations in this manual may deviate from the actual design The illustrations show only the essential components of the applicator. Refer to the technical drawing for additional components and details. Definition of Term(s) Applicator The term application head is also used in Nordson literature. Melter General term for tank melters and bulk melters. Control Module The term module is also used in Nordson literature. Series Overview Explanation of Type Designation The table shows the various models of the application heads in the series EP 11 and EP 12. EP 11 / EP 11 N One suction stem control module per application zone EP 12 V standard model Two suction stem control modules per application zone, V design EP 12 Lspecial model Two suction stem control modules per application zone, L design EP 12 RV special model Two suction stem control modules per application zone, V design, includes recirculation control module EP11 / EP Nordson Corporation

7 Applicators 3 Description of Components / Functioning EP 11 02, L design Fig. 1 1 Suction stem control module * 2 Solenoid valve 3 Solenoid valve plug 4 Cordset 5 Control air connection 6 Mounting bracket 7 Body 8 Nozzle 9 Hose connection 10 Filter cartridge Note: There are separate manuals available for components marked with an asterisk (*) Nordson Corporation EP11 / EP 12

8 4 Applicators Description of Components / Functioning (contd.) EP 12 01, V design Fig. 2 1 Filter cartridge 2 Solenoid valve 3 Solenoid valve plug 4 Control air connection 5 Suction stem control module * 6 Hose connection 7 Mounting bracket 8 Body 9 Nozzle 10 Cordset Note: There are separate manuals available for components marked with an asterisk (*). EP11 / EP Nordson Corporation

9 Applicators 5 EP 11 N Fig. 3 1 Solenoid valve plug 2 Solenoid valve 3 Control air connection 4 Suction stem control module * 5 Mounting bracket 6 Body 7 Nozzle 7 8 Hose connection 9 Filter cartridge 10 Cordset Note: There are separate manuals available for components marked with an asterisk (*) Nordson Corporation EP11 / EP 12

10 6 Applicators Description of Components / Functioning (contd.) Material Flow The melter pumps the material through a heated hose to the applicator. In the applicator the material flows through the filter cartridge(s) and the material channels to the nozzle. Control modules open and close the material supply to the nozzle. The nozzle applies the material to the substrate in a contact coating process. The application pattern is determined by grooves in the mouthpiece or by a shim plate. The shim plate is located between the nozzle mouthpiece and the mouthpiece receptacle. The application pattern also depends on the speed at which the substrate moves, the quantity of material and the material temperature. In addition, the quality of the application is influenced by the distance and the angle between the nozzle and the substrate. Nozzle Shim Plates The applicator nozzle touches the substrate, causing it to naturally wear. It may need to be refaced. Refer to section Maintenance. A specific application pattern is achieved by inserting shim plates of certain sizes and designs between the mouthpiece and the mouthpiece receptacle. Fig. 4 Special Aspect of the EP 12 The V design of the EP 12 allows two control modules to be assigned for each application zone. The material paths are the same length. The control modules perform alternating applications, meaning that extremely brief pauses between applications are possible. EP11 / EP Nordson Corporation

11 Applicators 7 Suction Stem Control Module Suction stem control modules precisely open and close the material supply to the nozzle by pneumatically raising or lowering the nozzle stems. The material is suctioned back into the control module by the upward movement. This ensures that the material is cut off properly. A compression spring ensures that the control module outlet is closed when pressure drops, preventing material from being applied. Heating The applicator is heated with electrical heater cartridges. The temperature is continuously measured by temperature sensors and is controlled with electronic temperature controllers. The temperature controllers are not part of the applicator. Filter Cartridge Filter (Option) The material flows from the inside of the filter cartridge to the outside. Thus dirt particles remain in the filter cartridge. The applicator can be equipped with one or more filter(s) (10, Fig. 1) instead of (a) filter cartridge(s). This depends on the installation position of the applicator and on the material quantity to be filtered. ID Plate Applicator type Nordson order number Serial number Operating voltage Power consumption oper. temp. max. V = Volt W = Watt Maximum operating temperature 2011 Nordson Corporation EP11 / EP 12

12 8 Applicators Options Option Recirculation control module (EP 11) Body in L model (EP 12) Electrical Pressure Sensor (EP 12) Brief Description Recirculation control modules cause the material to circulate in the applicator, or they return the material to the applicator tank. The substrate can be passed along the applicator at a 90 angle. (Also refer to Fig.1.) The electrical pressure sensor measures the material pressure in the applicator. Special Features Special feature Recirculation control module (EP 12) Applicator without filter cartridge (EP 11) Nozzle with nozzle tips (EP 11) Brief Description Recirculation control modules cause the material to circulate in the applicator, or they return the material to the melter tank. Some applications may require that the filter cartridge be omitted. The material must then be filtered in a preceding unit. Nozzle tips allow material bead application. The nozzles are cleaned with a nozzle cleaning set (P/N ), a drill and/or a bath. EP11 / EP Nordson Corporation

13 Applicators 9 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. Unpacking Unpack carefully. Then check for any damage caused during shipping. Reuse packaging materials or dispose of properly according to local regulations. Transport The applicator is a high precision, valuable part. Handle very carefully! Protect the nozzle from damage. Storage Do not store outside! Protect from humidity and dust. Do not lay unit on the nozzle. Protect the nozzle from damage. Disposal When your Nordson product has exhausted its purpose and/or is no longer needed, dispose of it properly according to local regulations Nordson Corporation EP11 / EP 12

14 10 Applicators Installing When installing the applicator, the following points should be observed in order to avoid unnecessary effort later. Protect from humidity, vibrations, dust and drafts Ensure access to parts relevant for maintenance and operation Install/attach the applicator to/in the parent machine with the mounting bracket. To achieve optimum material application, during assembly ensure that the distance and, when appropriate, the angle between the nozzle and the substrate can be varied. When installing the unit, ensure that cables, air hoses, and heated hoses can not be bent, pinched, torn off or otherwise damaged. Exhausting Material Vapors Ensure that material vapors do not exceed the prescribed limits. Exhaust material vapors when necessary. Provide sufficient ventilation of the location where the unit is installed. Electrical Connection WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Laying Cable WARNING: Ensure that cables do not touch rotating and/or hot unit components. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! Electrically Connecting Applicator Connecting Solenoid Valves The unit is connected electrically by inserting the plugs into the corresponding receptacles of the melter or a terminal box. Secure the voltage plug with the clamp if necessary. The solenoid valves on the control modules are controlled either by an external power supply, e.g. control unit, or through the valve control lines of the heated hose. Secure the voltage plug with the clamp if necessary. NOTE: Observe the voltage stated on the ID plate of the solenoid valve. EP11 / EP Nordson Corporation

15 Applicators 11 Lubricated or Non lubricated Compressed Air CAUTION: Control modules EP 10 D may be operated only with dry, controlled and non lubricated compressed air. NOTE: The control module EP 10 can be operated with either lubricated or non lubricated compressed air. Operating with Non lubricated Compressed Air When an applicator is connected to a compressed air system in which the compressed air has previously been lubricated, simply ceasing to lubricate the air is not sufficient. The oil remaining in the compressed air supply will reach the solenoid valves and the control modules and wash out the original lubricant/oil from these parts, substantially decreasing the service life of the units. NOTE: It must be ensured that the compressed air supply to the application heads has been converted to absolutely non lubricated operation. NOTE: It must be ensured that no oil from a possibly defective compressor may be permitted to penetrate the compressed air supply. NOTE: Nordson will assume no warranty/liability for damage resulting from unpermitted, temporary lubrication. Operating with Lubricated Compressed Air The control module EP 10 can also be operated with lubricated compressed air. NOTE: Once the air has been lubricated, it must always be lubricated; the lubricated compressed air will wash out the original lubricant on the solenoid valves and the control modules. Use only resin free, low viscosity silicon oil. Nordson recommends: Oil P/N Klüber Unisilkon TK 002/ Nordson Corporation EP11 / EP 12

16 12 Applicators Pneumatic Connections Connecting Continuous Air and Control Air 1. Connect customer's air supply to the inlet of the air conditioning unit. Maximum air pressure: 10 bar 1 MPa 145 psi 2. Connect suction stem control modules to the customer's air supply (or air conditioning unit). 3. Set control air pressure: Approx. 5 to 6 bar Approx. 0.5 to 0.6 MPa Approx to 87 psi NOTE: The exact pressure must be determined for each application. Connecting EP 12 with Pressure Accumulator Applicators EP 12 can be equipped with a pressure accumulator. The pressure accumulator must be connected to the customer's air supply. Refer to the separate manual Air Manifold Bar with Pressure Accumulator for additional information. NOTE: The exact pressure must be determined for each application. EP11 / EP Nordson Corporation

17 Applicators 13 Connecting Heated Hose WARNING: Hot! Risk of burns. Wear heat protective gloves. Using Second Open end Wrench Use a second open end wrench when connecting and disconnecting the heated hose. This prevents the unit's hose connection from turning. Fig. 5 Connecting If cold material can be found in the hose connection, these components (1, 2) must be heated until the material softens (approx. 80 C, 176 F). 1. First connect the hose (3) electrically to the unit. 2. Heat the system and hose to approx. 80 C (176 F). 3. Screw on heated hose. Fig. 6 Disconnecting WARNING: System and material pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. WARNING: Hot! Risk of burns. Wear safety goggles and heat protective gloves. 1. Set the motor speed of the melter to 0 rpm; switch off motor(s). 2. Place a container under the nozzle(s) of the applicator / assembly handgun. 3. Activate the solenoid valve(s) electrically or manually; or pull the trigger of the assembly handgun. Repeat this procedure until no more material flows out. 4. Properly dispose of material according to local regulations Nordson Corporation EP11 / EP 12

18 14 Applicators 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. Important When Using Polyurethane Application Materials (PUR) Triggering Solenoid Valves Setting Temperature It is imperative that the following guidelines are followed when processing polyurethane application materials (PUR): Wear respiratory protection when the maximum permissible concentration of hazardous substances is exceeded. Before prolonged standstill of the application system, purge with a suitable cleaning agent. Use only a cleaning agent recommended by the material manufacturer. Close open material connections airtight. When the system is to cease operation for only a short time, it suffices to coat the application slot generously with grease. CAUTION: Use only special high temperature grease. Refer to page 33, Processing Materials! Any other grease may cause the PUR material to cross link. CAUTION: Trigger the solenoid valves only when the applicator is heated to operating temperature! Seals in the application control module and the retrosuction control module can become damaged if the material is too cold. NOTE: When setting the temperature, the temperature prescribed by the material manufacturer is decisive. The maximum operating temperature of the product described here may not be exceeded. The applicator temperature required is set on the melter (maximum 200 C / 392 F). Nordson will grant no warranty and assume no liability for damage resulting from incorrect temperature settings. EP11 / EP Nordson Corporation

19 Applicators 15 Setting Control Air Pressure The control air pressure is set to suit each application on an air conditioning unit. The air conditioning unit with pressure control valve is not part of the applicator. NOTE: It is important to observe the instructions on lubricating or not lubricating the control air (page 11) and in the separate manuals for the control modules! Set control air pressure: 5 to 6 bar 0.5 to 0.6 MPa 72.5 to 87 psi The exact pressure must be determined for each application. NOTE: The maximum control air pressure may not be exceeded. Nordson will assume no warranty or liability for damage resulting from incorrect pressure settings. Setting Material Pressure The material pressure is generated by the melter pumps. CAUTION: The maximum material pressure may not be exceeded: 70 bar 7 MPa psi 2011 Nordson Corporation EP11 / EP 12

20 16 Applicators Positioning the Applicator Fig. 7 The optimum angle of incidence of the applicator is a factor of various customer specific parameters and can not be determined precisely beforehand. Good application and material cutoff is achieved when the applicator is positioned almost completely vertical to the substrate. The angle can be adjusted within a range of approx. 80 to 100 If the angle of incidence of the applicator to the substrate is too great, a bead of material forms as soon as the material is cut off (Also refer to Fig. 7). This soon leads to irregular material application and a scaly application pattern. NOTE: The optimum position of the applicator depends on several factors of the customer's specific application. Thus trial and error is the only way to determine the best position. The fundamental differences are: Application to open pore substrate (fleece) Application to closed pore substrate: Coating Open pore Substrate The applicator nozzle should be positioned between two rolls, as shown in Fig. 8. The coating is applied to the tensed substrate. The substrate should not be diverted from a straight path by more than approx. 1 mm when the applicator touches it Fig. 8 EP11 / EP Nordson Corporation

21 Applicators 17 Coating Closed pore Substrate The applicator nozzle should be positioned close to the coating roll, as shown in Fig. 9. However, coating is not performed against the roll but against the tensed substrate. The substrate should not be diverted from a straight path by more than approx. 1 mm when the applicator touches it Fig Nordson Corporation EP11 / EP 12

22 18 Applicators Material Application Sample Calculation Application weight (grammage) m Application width b Substrate speed v Material quantity M = m b v Nordson recommends following the sample calculation before starting up the applicator and making a note of the application-specific values for application weight and width, substrate speed and pump output capacity. These values can be used to calculate the pump speed and material quantity. The results of the calculations are also entered in the table. This ensures that all values can be reproduced at any time. NOTE: The material quantity for intermittent application is calculated the same as for continuous material application. Application weight (grammage) m = 20 g/m 2 Application width of each material track b = 10 mm = 0.01 m Substrate speed v = 500 m/min Material quantity M = m b v = 20 g/m m 500 m/min = g/min Output capacity of pump D = 2.4 g/revolution Pump speed n = M D = g/min 2.4 g/revolution 42 rev/min Customer specific values: Output capacity of pump D Pump speed n = M D EP11 / EP Nordson Corporation

23 Applicators 19 Settings Record Production information: Material: Cleaning agent: Basic settings Basic temperature settings Manufacturer Processing temperature Viscosity Manufacturer Flash point Application weight Application width Substrate speed Material quantity Material pressure Output capacity Body Heated hose Motor/pump speeds: Motor/pump 1) 2) 3) 4) 5) 6) Notes: Name Date 2011 Nordson Corporation EP11 / EP 12

24 20 Applicators Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. NOTE: Maintenance is an important preventive measure to maintain operating safety and to extend the service life of the unit. It should not be neglected under any circumstances. Relieving Pressure WARNING: System and material pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. WARNING: Hot! Risk of burns. Wear heat protective gloves. 1. Set motor speed of the unit feeding the material to 0 min 1 ; switch off motor(s). 2. Place a container under the nozzle(s) of the applicator. 3. Activate the solenoid valves electrically or manually. Repeat this procedure until no more material flows out. 4. Properly dispose of material according to local regulations. EP11 / EP Nordson Corporation

25 Applicators 21 Regular Maintenance Unit part Activity Interval Refer to Entire applicator Inspect for damage Daily Page 22 External Cleaning Daily Page 22 Purge with cleaning agent Daily when using PUR Page 24 adhesives Control modules Check for leakage Daily - Nozzle Cleaning Regularly, or when the Page 24 application pattern deteriorates Replace shim plate When damaged Page 25 Have it refaced When damaged Cordset Inspect for damage Every time the applicator is - Air hoses serviced - Control modules Check detection holes Daily - Replace When damaged Page 26 Filter cartridge (option) Clean filter cartridge and replace filter screen Depending on degree of material pollution. Page 27 Page 28 Nozzle Filter (Option) Recommendation: Every 100 hours of operation Page 31 Pressure sensor (option) Check performance Calibrate Every year; more often if conditions of use require Separate manual Check the separating membrane for damage and for sensor is removed, more Every time the pressure hardened or charred material often if necessary 2011 Nordson Corporation EP11 / EP 12

26 22 Applicators PUR Adhesives CAUTION: Reduce temperature when production is to cease for longer than 30 minutes. Visual Inspection for External Damage CAUTION: When damaged parts pose a risk to the operational safety of the applicator and/or safety of personnel, switch off the applicator or application system and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. External Cleaning External cleaning prevents impurities created during production from causing the unit to malfunction. Always follow manufacturer's instructions when using cleaning agents! 1. Electrically heat the cold applicator until the material is liquid. 2. Thoroughly remove the warm material with a cleaning agent and/or a soft cloth. 3. Remove dust, fluffs, etc. with a vacuum cleaner or a soft, lint free cloth. CAUTION: Do not damage or remove warning labels. Damaged or removed warning labels must be replaced by new ones. Changing Material NOTE: Before changing the type of material, determine whether the old and new material may be mixed. May be mixed: Remaining old material can be flushed out using the new material. May not be mixed: Thoroughly purge the unit with a cleaning agent recommended by the material supplier. NOTE: Properly dispose of the material and cleaning agent according to local regulations. EP11 / EP Nordson Corporation

27 Applicators 23 Purging with Cleaning Agent CAUTION: Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. NOTE: When PUR adhesive is used, it must be prevented from reacting to the thermal load in the applicator. The applicator must be purged every day when work is completed. Rinse out cleaning agent just before beginning production again. 1. Maintain operating temperature. 2. Place a container under the nozzle. 3. Relieve pressure (Refer to page 20). 4. Detach the heated hose from the applicator (Refer to page 13 ) to prevent impurities from the melter and hose from being forced into the applicator during purging. 5. Purge the melter and heated hose (Refer to separate manuals). 6. Attach the heated hose to the applicator again. 7. Purge the applicator until the material has been flushed out completely. NOTE: When PUR adhesive is used, do not proceed until right before production is to begin again. 8. Purge applicator (and, when appropriate, melter and hose) with the material currently in use to flush out the cleaning agent. NOTE: Properly dispose of cleaning agent according to local regulations Nordson Corporation EP11 / EP 12

28 24 Applicators Disassembling and Cleaning Nozzle The application nozzle must be regularly disassembled (mouthpiece, shim plate and mouthpiece receptacle) and cleaned. Material residue affects the quality of the application. It must be removed. NOTE: When using cleaning agents, observe the manufacturer's information! Carefully read the Material Safety Data Sheet for the cleaning agent used. NOTE: Nordson will assume no warranty or liability for damage resulting from incorrect cleaning Heat applicator until material is soft. 2. Release fixing screws (8) and detach nozzle from body. 3. Release screws (2) and, with the aid of the screws and the forcing thread (3), pry the mouthpiece (4) off of the mouthpiece receptacle (7). NOTE: Alignment pins (6) determine the position of the mouthpiece in relation to the mouthpiece receptacle Knock alignment pins out of the hole with a punch and hammer. 5. Use suitable tools (drill, reamer) to remove charred material from holes and channels. 6. Use a cleaning agent to dissolve material residue that could not be removed mechanically. NOTE: Properly dispose of cleaning agent, material residue and cutting oil according to local regulations. CAUTION: Only use a cleaning agent recommended by the material supplier. Observe Manufacturer Safety Data Sheet (MSDS) for the cleaning agent. EP11 / EP Nordson Corporation

29 Applicators 25 Assembling Nozzle 1. Apply high-temperature grease (Refer to page 33 Processing Materials). To the O rings To the screw threads Under the screw heads. 2. Use pins to join mouthpiece receptacle (7), shim plate (5) and mouthpiece (4), then screw together. Do this by hammering in the alignment pins (6) until the tops of the pins are even with the top of the mouthpiece. 3. Put Quadrings (1) back into place if necessary. 4. Screw application nozzle back onto the body with the fixing screws (8). NOTE: Tighten fixing screws size M4, property class 70 in three steps, with a total of 2.5 Nm. Use a torque wrench. NOTE: Contact Nordson for information on special models with different screws. Inserting New Shim Plate Fig. 10 Reface 1. Disassemble the application nozzle. Refer to page Fit new shim plate between mouthpiece and mouthpiece receptacle. The shim plate is held in place by two cylinder pins. 3. Screw nozzle halves together. NOTE: The shim plate protrudes 1 to 2 mm out of the nozzle. 4. The shim plate must be ground until it is even with the mouthpiece and the mouthpiece receptacle. 5. Assemble the nozzle. See instructions above Nordson Corporation EP11 / EP 12

30 26 Applicators Changing Control Module WARNING: Hot! Risk of burns. Wear heat protective gloves. CAUTION: If some but not all of the control modules on an applicator are replaced, the applicator must continue to be operated with lubricated compressed air. Observe the instructions in the section Installation on lubricating or not lubricating compressed air. Nordson recommends keeping a supply of control modules to prevent production stoppage. CAUTION: The control module is a high precision, valuable part. Handle very carefully! Removing Control Module 1. Disconnect air hoses. 2. Heat the applicator until the material is soft. 3. Release the four screws (M4) and extract the control modules from the warm applicator. Installing Control Module Fig. 11 ÏÏ NOTE: Required tool: Torque wrench. 1. Apply high-temperature grease (Refer to page 33, Processing Materials) To the O-rings, To the screw threads Under the screw heads. 2. Insert the new control module carefully, taking care not to tilt it. NOTE: When the control module is slid into the body, the two O rings cause some resistance that must be overcome. When the part with the detection holes is on the body, the control module has been slid in far enough. 3. Screw in the four screws (M4) by hand. Do not tighten! 4. Tighten the screws crosswise in three steps of 0.9 Nm each. Use a torque wrench. 5. Ensure that the compressed air supply has been converted to absolutely non lubricated operation. 6. Re connect air and electrical connection. NOTE: Observe the voltage stated on the ID plate of the solenoid valve. EP11 / EP Nordson Corporation

31 Applicators 27 Cleaning Filter Cartridge NOTE: Remove filter cartridge only when the applicator is hot and not under pressure. Install only in a hot applicator. WARNING: Hot! Risk of burns. Wear safety goggles and heat protective gloves. WARNING: System and material pressurized. Relieve system of pressure before replacing a filter cartridge. Failure to observe can result in serious burns. 1 2 Removing Filter Cartridge 1. Place a container under the filter bore. NOTE: Use a second open end wrench when screwing in and out the pressure relief screw (1, Fig. 12). This prevents the filter cartridge (2, Fig. 12) from turning. 2. Screw pressure relief screw out of the filter cartridge until material flows out. 3. Turn the filter cartridge all the way counterclockwise. 4. Simultaneously press the filter cartridge in and turn counterclockwise again (bayonet fastener): then extract it. Use an open end or ring wrench (size 17), if necessary. Fig. 12 NOTE: If the filter cartridge is stuck in the filter bore, grasp the filter cartridge with a pliers and extract. 5. Purge the filter bore by allowing the pump to run briefly with material. This rinses out particles of dirt that may still be in the filter bore. 6. Properly dispose of material according to local regulations Nordson Corporation EP11 / EP 12

32 28 Applicators Replace the Filter Screen WARNING: Hot! Risk of burns. Wear heat protective gloves Fig Pressure relief screw 2 O ring 3 Filter screw 4 O ring 5 Filter screen with spring 1. Heat the filter cartridge until material is liquid. 2. Turn the unit consisting of pressure relief screw, filter screen and spring counterclockwise out of the filter screw, then replace. NOTE: Nordson recommends keeping a supply of replacement filter cartridges to avoid interruptions in production. Installing Filter Cartridge 1. Heat applicator until material is liquid. 2. Apply high temperature grease to the O ring. Refer to page 33, Processing Materials. 3. Slide the filter cartridge into the filter bore. NOTE: Air penetrates the filter bore when the filter cartridge is replaced. The applicator is deaerated with the aid of the pressure relief screw. 4. Unscrew the pressure relief screw somewhat. 5. Allow the pump to run briefly until material flows out. This also forces out the air. 6. Turn in the pressure relief screw clockwise all the way when the material flows out free of bubbles. EP11 / EP Nordson Corporation

33 Applicators 29 Nozzle Filter Changing Filter Cartridge NOTE: Remove filter cartridge only when the nozzle filter is hot and not under pressure. Install only when nozzle filter is hot. WARNING: Hot! Risk of burns. Wear heat protective gloves. WARNING: System and material pressurized. Relieve system of pressure before replacing filter cartridge. Failure to observe can result in serious burns. Refer to page 20, Relieve pressure. Removing Filter Cartridge 1. Place a container under the filter bore. For filter cartridges with air relief valve go to step Insert screw into center tapped hole (Fig. 14). Fig Unscrew the filter cartridge counterclockwise with an open end wrench or ring wrench (Fig. 15). CAUTION: As soon as the thread is disengaged, cease turning. Otherwise part of the filter cartridge may remain in the bore. Fig Use suitable pliers to carefully extract filter cartridge (Fig. 16). 5. Purge the filter bore by allowing the pump to run briefly with material. This rinses out particles of dirt that may still be in the filter bore. 6. Properly dispose of material according to local regulations. Fig Nordson Corporation EP11 / EP 12

34 30 Applicators Fig. 17 Installing Filter Cartridge 1. Heat the nozzle filter via the applicator or with a hot air fan until the material is liquid. 2. Apply high temperature grease to all threads and O rings. Refer to page 33, Processing Materials. 3. Slide the filter cartridge into the filter bore. 4. Screw filter cartridge in clockwise with an open end or ring wrench (do not overtighten). 5. Feed material by allowing the pump to run until the material comes out of the applicator free of bubbles. 6. Properly dispose of material according to local regulations. EP11 / EP Nordson Corporation

35 Applicators 31 Disassembling and Cleaning Filter Cartridge Disassemble the filter cartridge only when hot. If the filter cartridge is not disassembled immediately after removal, it must be heated (e.g. with an air heater). WARNING: Hot! Risk of burns. Wear heat protective gloves. NOTE: Only use a cleaning agent recommended by the material supplier. Observe the Material Safety Data Sheet for the cleaning agent. NOTE: Always replace the filter screen (4). 1. Disassemble the filter cartridge when hot. 2. Replace the filter screen. 3. Clean all other parts. 4. Check all O rings; replace if necessary. 5. Apply high temperature grease to all threads and O rings. Refer to page 33, Processing Materials for information on the high-temperature grease. 6. Properly dispose of cleaning agent according to local regulations Fig Center tapped hole 2 Filter screw 3 O ring 4 Filter screen 5 Screw plug 6 Filter sheath 7 Air relief valve 8 Nut 2011 Nordson Corporation EP11 / EP 12

36 32 Applicators Attaching/Removing Filter Casing 1. When the filter casing (4, Fig. 19) has been removed, the O ring (5, Fig. 19) must always be replaced. 2. To screw on, apply high temperature grease to all threads and O rings. Refer to page 33, Processing Materials for information on the high-temperature grease Fig Filter cartridge 2 Cylinder screw 3 Hose connection 4 Filter casing 5 O ring EP11 / EP Nordson Corporation

37 Applicators 33 Processing Materials Designation Order number Use High temperature grease Can 10 g P/N Tube 250 g P/N Cartridge 400 g P/N Apply to O rings and threads NOTE: The grease should not be mixed with other lubricants. Oily/greasy parts must be cleaned before application Nordson Corporation EP11 / EP 12

38 34 Applicators Maintenance Record Applicator Unit part Activity Date Name Date Name External inspection and cleaning Control module Nozzle Cleaning Replace nozzle Replace shim plate Filter cartridge Replace EP11 / EP Nordson Corporation

39 Applicators 35 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. Introduction Troubleshooting tables are intended as an orientation for qualified personnel. They cannot, however, replace targeted troubleshooting with the aid of wiring diagrams and measuring instruments. They also do not include all possible problems, only those which most typically occur. The following problems are not included in the troubleshooting tables: Faults in installation Faults in operation Defective cables Loose plug and screw connections. In the column Corrective action, the remark that defective parts should be replaced is generally not included Nordson Corporation EP11 / EP 12

40 36 Applicators Problem Possible Cause Corrective Action Refer to No material Melter tank is empty Fill Separate manual Melter motor and/or pump is Switch on Melter not switched on Melter pump is not working Check Separate manual for pump or melter Applicator does not heat Applicator does not reach the set temperature Solenoid valves do not switch Applicator has not yet reached operating temperature Applicator cold or not warm enough Wait until temperature has been reached; adjust temperature setting if necessary Refer to Applicator does not heat Separate manual Temperature controller Control air not connected Connect Page 12 Nozzle clogged Clean nozzle Page 24 Nozzle stem is stuck Replace control module(s) Separate manual for control module Filter cartridge or nozzle filter clogged Clean Page 27 Page 31 Temperature not set Adjust Page 14 Voltage plug not connected Connect Page 10 Fuses in melter defective Disconnect unit from line - - voltage, check fuses and replace if necessary Heater cartridge(s) in Replace heater cartridge(s) - - applicator defective One or more heater Replace - - cartridges defective Ambient temperature too Increase ambient - - low temperature Control unit not switched on Switch on Separate manual Control Unit Valve connecting cable not plugged in or loose Check that plug connections are tight - - Page 10 Continued... EP11 / EP Nordson Corporation

41 Applicators 37 Problem Possible Cause Corrective Action Refer to Note: Material thickening can not be prevented; it can only be minimized. Thickened material at beginning of application pattern Application pattern not exact Pause time too long The open time* is too long The open time* is too short Stem stroke too high Recirculation pressure too high Pause time too long Temperature not set precisely on melter Temperature of applicator not set precisely Material quantity/pressure not set precisely Distance between application nozzle and substrate incorrect Control unit for solenoid valves not programmed correctly Check stem stroke between piston and socket block; it must be at least mm Check application pressure and adjust recirculation pressure Application must be performed with recirculation Correct setting Separate manual Control Module Separate manual Melter Page 14 Page 15 Correct distance Page 16 Correct programming Separate manual Control Unit Nozzle polluted on outside Clean Page 22 Nozzle polluted on inside Disassemble and clean Page 24 Nozzle damaged Replace nozzle Page 24 Application quantity and Check settings; adjust if - - substrate processing speed not attuned to one another necessary Material unsuitable Ask manufacturer Data sheet of material manufacturer Muffler in control module Replace muffler - - clogged Application temperature too high Set temperature lower Separate manual Temperature controller Material unsuitable Ask manufacturer Data sheet from material manufacturer Application temperature too low Set temperature higher Separate manual Temperature controller Material unsuitable Ask manufacturer Data sheet from material manufacturer NOTE: * The open time is the time from when the material leaves the nozzle until it hardens on the substrate Nordson Corporation EP11 / EP 12

42 38 Applicators Technical Data General Data Available control modules EP 10 EP 10 D Type of heating Possible temperature sensors Electrical resistance heating elements FeKo thermal Pt 100 Ni 120 element Max. closing pressure without compressed air Max. closing pressure with compressed air Max. locking pressure without compressed air Max. locking pressure with compressed air 30 bar 3 MPa 435 psi 70 bar 7 MPa psi 100 bar 10 MPa psi 100 bar 10 MPa psi Max. processable viscosity mpas cp Max. application width Max. application width per control module Min. control module spacing 400 mm 40 mm 30 mm Air pressure Control air 5 to 6 bar 0.5 to 0.6 MPa 72.5 to 87 psi Temperatures Max. ambient temperature 40 C 104 F Max. operating temperature 200 C 392 F EP11 / EP Nordson Corporation

43 Applicators 39 Electrical Data WARNING: Operate the applicator only at the operating voltage shown on the ID plate. Operating voltage 230 V DC Operating voltage frequency 50/60 Hz FeKo, Pt 100 Ni 120 Power consumption P max 1200 W 600 W Degree of protection IP 30 Voltage for solenoid valve 24 V DC 230 V DC Dimensions and Weights Dimensions (L x W x H) Weight Refer to technical drawing See consignment note 2011 Nordson Corporation EP11 / EP 12

44 40 Applicators EP11 / EP Nordson Corporation

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