Melter MC 20 / MC 21 with Foil Bag

Transcription

1 Melter MC 20 / MC 21 with Foil Bag Manual English Issued 05/06 NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

2 Note This document applies to the entire series, beginning with serial number LU03K 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, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, icontrol, iflow, Isocoil, Isocore, Iso-Flo, itrax, JR, KB30, Kinetix, Little Squirt, LogiComm, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure-Max, Tela-Therm, Tracking Plus, TRAK, Trends, Tribomatic, Ultra, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, BetterBook, Blue Series, CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Color-on-Demand, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail, E-Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G-Net, G-Site, HDLV, Ink-Dot, ion, Iso-Flex, itrend, KVLP, Lacquer Cure, Lean Cell, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, MiniEdge, Minimeter, Multifil, Myritex, OptiStroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, TrueBlue, Ultrasmart, Universal, Viper, Vista, VersaDrum, VersaPail, 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.

3 Table of Contents I Table of Contents Safety Introduction Intended Use Area of Use (EMC) Operating Restrictions Unintended Use Examples Residual Risks Note on Manual Series Overview Explanation of Type Designation ID Plate Configuration Code Special Model Bookbinding Functioning Melting Process and Adhesive Feeding Temperature Control Undertemperature Interlock Overtemperature Indication / Shutdown Temperature Setback Channel Allocation Symbols Essential Components Tank Lid and Pneumatic Cylinder with Punch Air Conditioning Unit with Pressure Controller Hinged Tank (Only MC 21) Motor and Gear Pump Bypass Plate with Safety Valve Protective Panels Exhaust Hood Proportional Pressure Control Valve Pressure Sensor Electrical Cabinet Light Tower Acoustic Signal Transmitter (Special Feature) Control System Mode Switch Manual / Auto and Button Raise / Lower Punch Key Switch Remote / Local and Indication Lamp Remote Main Switch Week Timer (in Electrical Cabinet) Electrical Cabinet Ventilation Hose Receptacles Cable Harness Interface XS Interface Profibus (Option) Interface Key-to-line Mode Pattern Control System Door Lock

4 II Table of Contents Installation Unpacking Transport Lifting (Unpacked Unit) Removal Storage Disposal Setup Attaching Light Tower Exhausting Adhesive Vapors Electrical Connections Laying Cable Line Voltage Pilot Voltage / Tach Generator Interface XS Interface Profibus (Option) Pneumatic Connection Pneumatic Safety Valve (Option) Connecting Heated Hoses Second Open-jawed Wrench Connecting Disconnecting Relieving Pressure Operation Initial Startup Setting Values and Parameters Notes Speed, Pressure Pneumatic Safety Valve (Option) Temperatures Recommended Values Filling the Tank Setting Changing Time Switching System ON/OFF Daily Startup Daily Switchoff Switching Off in an Emergency Settings Record Maintenance Relieving Pressure Regular Maintenance External Cleaning Visual Inspection for External Damage Tank Cleaning Tank by Hand High Melt Section (Reservoir) Overtemperature Thermostat Check the air relief hole Changing Type of Adhesive Purging with Cleaning Agent Electrical Cabinet Ventilation Maintenance Maintenance Record

5 Table of Contents III Troubleshooting Some Tips Troubleshooting with Control System Indication Lamps and Light Tower Red Indication Lamp is Lit Only the White Indication Lamp is Lit Troubleshooting Tables Unit not Functioning One Channel (Heating Zone) does not Heat No Adhesive (Motor Rotating) No Adhesive (Motor does not Rotate) No Pilot Voltage Motor Overheated Incorrect Motor Rotation in Automatic Mode Not Enough Adhesive Adhesive Pressure too High Adhesive Pressure too Low Adhesive Residues in Tank Adhesive Hardens in Tank Punch Does Not Move Up Technical Data General Data Electrical Data Temperatures Dimensions and Weights Exhaust hood Flow Chart A-1

6 IV Table of Contents

7 Safety 1-1 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.

8 1-2 Safety

9 Introduction 2-1 Section 2 Introduction Intended Use Melters in the series MC 20 / MC 21 may be used only to melt and feed polyurethane hot melt adhesives (PUR) from foil bags. 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. Area of Use (EMC) The units are designed to be used in industrial areas (Also refer to included Declaration of Conformity). Operating Restrictions When using in residential, business or industrial areas, the equipment may cause interference with other units, e.g. radios. Unintended Use Examples The unit may not be used under the following conditions: In defective condition When changes or modifications have been made by the customer Without heat protection and protective panels With electrical cabinet door open With tank lid open In a potentially explosive atmosphere When the values stated under Technical Data are not complied with.

10 2-2 Introduction The unit may not be used to melt and feed the following materials: Explosive and flammable materials Erosive and corrosive materials Food products. Residual Risks In the design of the unit, every measure was taken to protect personnel from potential danger. However, some residual risks can not be avoided. Personnel should be aware of the following: Risk of burns from hot adhesive Risk of burns on the hot tank lid Risk of burns when filling tank Risk of burns from hot accessories, e.g. heated hoses and hot melt application heads Material fumes can be hazardous. Avoid inhalation. Note on Manual A unit with one gear pump and one hose connection is described here, but the description is valid for all MC 20 / MC 21 models. NOTE: The position numbers in the illustrations do not correspond to the position numbers in the technical drawings and parts lists.

11 Introduction 2-3 Series Overview The following units are included in the series. Unit Motors/pumps Hose connections per pump MC 20/21-1x1 1 1 MC 20/21-1x2 1 2 MC 20/21-2x1 2 1 Explanation of Type Designation The unit MC 20-2x1 is used as an example. MC 20-2x1 1 hose connection per pump 2 motors/pumps Tank volume for 20 liter foil bag Designation for Nordson units in the Meltex product line that process polyurethane hot melt adhesive. M = Moisture C = Curing ID Plate Fig. 2-1 Information Description Unit Code Unit designation and configuration code P/N Article number Ser. Serial number U Operating voltage Volt I Fuse protection Ampère f Line voltage frequency Hertz P Power consumption of unit Watt P max Maximum power consumption of unit and connected accessories Watt

12 2-4 Introduction Configuration Code The configuration code is engraved on the ID plate. NOTE: An X indicates that the function or component was not ordered, meaning that it is unavailable. An S indicates that the model deviates from the configuration code. Such deviations are described in a supplement that is then added to this manual. Series Equipment Options Box Code Key 1 M Series or unit designation 2 C MC21: Model with hinged tank One pump 2 Two pumps 7 x 8 1 One hose connection per pump 2 Two hose connections per pump 9 A Operating voltage 400 V AC 3 phase Y B Operating voltage 400 V AC 3 phase delta C Operating voltage 480 V AC 3 phase delta 10 1 Pump 1 Type: PR 6 (0,90 ccm/rev) 2 Pump 1 Type: PR 12 (1,80 ccm/rev) 3 Pump 1 Type: PR 12m2 (3,60 ccm/rev) 4 Pump 1 Type: PR 25m2 (7,74 ccm/rev) 11 1 Pump 2 Type: PR 6 (0,90 ccm/rev) 2 Pump 2 Type: PR 12 (1,80 ccm/rev) 3 Pump 2 Type: PR 12m2 (3,60 ccm/rev) 4 Pump 2 Type: PR 25m2 (7,74 ccm/rev) 12 / 13 A Profibus 14 B Connections for six additional heating zones (distributed onto three connecting receptacles) 15 C Pneumatic safety valve Special Model Bookbinding In addition to configured units, there is a special model available for the bookbinding industry; it is equipped with additional components. Also refer to supplementary documents on the Bookbinding System as well as manuals for the additional components.

13 Introduction 2-5 Functioning Melting Process and Adhesive Feeding The opened foil bag is placed in the tank. There is a heated grid (1, low melt section) in the tank. The adhesive is melted there and fills a reservoir (3, high melt section, approx. 3 liters). The adhesive flows from the reservoir to the gear pump (12). The gear pump feeds the adhesive to the hose connection (7). A pneumatically operated punch in the tank applies sufficient pressure to the foil bag on the grid. The pressure is automatically switched on and off according to whether adhesive is dispensed or not. The low melt and high melt sections are heated separately. This way only a small amount (approx. 3 liters) of adhesive is heated to processing temperature. This adhesive supply ensures continuous adhesive dispensing, even when the foil bag is changed Fig. 2-2 Principle drawing 1 Low melt section (grid) 2 High melt section (reservoir) 3 Motor 4 Coupling 5 Bypass plate 6 Safety valve 7 Hose connection 8 Heated hose (accessory) 9 Suction bore 10 Pressure bore 11 Bypass hole 12 Gear pump

14 2-6 Introduction Temperature Control Also refer to manual Control System. The temperature is measured by sensors and is electronically controlled by the control system. Undertemperature Interlock The undertemperature interlock prevents the unit or system from being started up before the adhesive has exceeded the temperature setpoint minus undertemperature value. However, every time initial heating occurs, the interlock is not released until the actual temperature is 3 C (5.4 F) below the temperature setpoint. The undertemperature interlock locks the motors, solenoid valves and, in some cases, other components of the hot melt 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: When the temperature setpoint plus overtemperature value has been reached, the relay output Collective fault is switched and the red indication lamp Collective fault lights. The unit remains ready for operation. Overtemperature shutdown by temperature controller: The overtemperature shutdown value is set automatically 30 C (54 F) higher than the highest temperature setpoint value. Overtemperature shutdown by thermostat(s): Serves as an emergency switch OFF in case the overtemperature shutdown of the temperature controller does not function properly. Refer to section Technical Data for shutdown value. 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 remedied by qualified personnel.

15 Introduction 2-7 Temperature Setback Serves to protect the adhesive and save energy during interruptions in production or work stoppages. Setback value and setback period are adjustable. Channel Allocation Symbols Fig Low melt section 2 High melt section 3 Heated hose (accessory) 4 Application head or assembly handgun (accessory) 5 Additional temperature channel

16 2-8 Introduction Essential Components Fig. 2-4 The actual model can deviate from the illustration. 1 Pneumatic cylinder with punch 6 Exhaust hood 2 Air conditioning unit with pressure 7 Protective cover controller 8 Electrical cabinet 3 Compressed air connection 9 Hose connection 4 Tank lid 5 Proportional pressure control valve B 10 Gear motor 11 Coupling 12 Gear pump* 13 Bypass plate with safety valve* 14 Tank Note: There are separate manuals available for components marked with an asterisk (*). Note: The components marked with a B are available only in conjunction with the special model Bookbinding.

17 Introduction 2-9 Tank Lid and Pneumatic Cylinder with Punch 1 The tank lid is fastened with a hinge, allowing it to be swiveled out with the pneumatic cylinder. Reed contacts (1) on the pneumatic cylinder detect the position of the pneumatically operated punch and thus the level in the foil bag. The signals from the Reed contacts are processed by a PLC. The lid can not be opened until the punch has triggered the upper Reed contact. The lower Reed contact triggers the empty indication; the height is factory-set to complete emptying of common foil bags, but it can be modified. The middle Reed contact serves to trigger the Almost empty indication. When the punch has reached its lowest position (foil bag empty), it is automatically moved up. The foil bag can then be changed. 1 Air Conditioning Unit with Pressure Controller The pressure controller (1) is used to set pneumatic pressure to be applied to the pneumatic cylinder. The setting must be modified according to the processed material and the output quantity (2 to 6 bar / 29 to 87 psi). 2 Pressure Switch A pressure switch (2) switches off the main contactor when the inlet pressure falls below 2 bar. Hinged Tank (Only MC 21) The tank is hinged and can be folded back to clean the high melt section and the grid.

18 2-10 Introduction Motor and Gear Pump The electronically controlled motor drives the gear pump. This speed is indicated on the control system CS 20. Refer to manual Control System for instructions on setting speed. NOTE: With the special model for the bookbinding industry, the speed is not regulated to a preset value; the pressure at the material outlet is regulated. This way the required material pressure is available as soon as a connected application head is triggered (opened). Refer to manual Control System for instructions on setting pressure. CAUTION: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, ensure that the tank is filled. CAUTION: To prevent excessive wear, the motor/pump speed should not continuously fall below 5 min -1 (rpm) or continuously exceed 80 min -1 (rpm). Bypass Plate with Safety Valve The mechanical safety valve limits the adhesive pressure generated by the gear pump and keeps it constant. When the set pressure is exceeded, the safety valve opens, allowing the adhesive to circulate within the bypass plate. The pneumatic safety valve (1, option) serves to adjust the adhesive pressure by means of control air. The pneumatic control pressure ist set manually e.g. at a separate control unit (2, accessory). 1 2 Protective Panels WARNING: Do not operate without protective panels. The protective panels can be detached for installation, maintenance and repair.

19 Introduction 2-11 Exhaust Hood 1 The fumes created when polyurethane hot melt adhesives (PUR) are processed should be suctioned off directly at the tank. An exhaust hood (1) is integrated for this purpose. The exhaust hood must be connected to the customer s exhaust device (Also refer to Installation, Exhausting Adhesive Vapors). Proportional Pressure Control Valve 1 2 NOTE: The proportional valve is a standard component only with the special model Bookbinding. The proportional valve (1) supplies a pneumatic outlet pressure based on the speed of the book binding machine. This outlet pressure serves as the control pressure for an application head (EP 48-V); it keeps the application weight steady. The assembly contains a pressure controller (2) to adjust the inlet pressure. Pressure Sensor 1 NOTE: The pressure sensor (1) is a standard component only with the special model Bookbinding. When the pressure sensor is added to other MC 20 units, it simply enables the pressure to be monitored by an external unit. The pressure sensor directly at the material outlet enables pressure-controlled operation of the MC 20. The frequency converter, which controls the motor speed, is parameterized a certain way for this purpose. This pressure is set and indicated on the control system CS 20. Refer to manual Control System. Also refer to manual Pressure Control for Applicators MX/MC.

20 2-12 Introduction Electrical Cabinet Fig. 2-5 The actual model can deviate from the illustration. 1 Light tower 6 Key switch Remote / local and 2 Button Raise punch indication lamp Remote (only with the option Profibus) 3 Mode switch Manual / auto 7 Main switch 4 Button Lower punch 8 Hose receptacles 5 Control system CS 20* 9 Electrical cabinet ventilation 10 Cable harness B 11 Interface XS 2 12 Interface Key-to-line mode 13 Interface Profibus (option)* 14 Pattern control system B* Note: There are separate manuals available for components marked with an asterisk (*). Note: The components marked with a B are available only in conjunction with the special model Bookbinding.

21 Introduction 2-13 Light Tower White Red Yellow (flashing) Yellow Green Unit switched on Collective fault Foil bag almost empty (middle Reed contact on pneumatic cylinder) Foil bag empty (lower Reed contact on pneumatic cylinder) Unit ready for operation Also refer to section 6 Troubleshooting and manual Control System for information on Collective fault. NOTE: Automatic motor/pump standstill does not occur after the indication Foil bag empty until an adjustable time Changing time has expired. When the empty indication occurs, the amount of adhesive in the reservoir should be sufficient to ensure uninterrupted feeding while the bag is being changed. Refer to Operation, Filling the Tank, Setting Changing Time. Acoustic Signal Transmitter (Special Feature) Generates an acoustic signal when Drum empty occurs. Control System On the control system, values and parameters are set, and operating modes and faults are displayed. Refer to separate manual. Mode Switch Manual / Auto and Button Raise / Lower Punch WARNING: Risk of squash from moving punch when tank lid is swiveled out! Do not lower punch onto protective cover or edge of tank. Position Manual. The punch can be controlled manually with the button Raise/lower punch, e.g. to clean the punch plate. Position Auto: The punch is controlled automatically, depending on the operating mode of the unit.

22 2-14 Introduction Key Switch Remote / Local and Indication Lamp Remote When set to Remote, the system is not controlled by the internal control system but via the interface Profibus (Option). Main Switch NOTE: The main switch must be set to I/ON when using the week timer. Used to switch on/off the unit. Position 0/OFF = Unit is switched off. Position I/ON = Unit is switched on. Padlocks can be used to protect the main switch from unauthorized access. Black Main Switch (Special Model) Systems with a black main switch are normally supplied with power by a higher-ranking system; the higher-ranking main switch is on that system. The black main switch does not perform the EMERGENCY OFF function. Connected components can still be switched on! 1 Week Timer (in Electrical Cabinet) The week timer (1) is used to automatically switch the system on and off. The main switch must be set to I/ON (switched on) when using the week timer. Refer to separate manual. Electrical Cabinet Ventilation Electrical cabinet ventilation (fan with filter) reduces the temperature inside of the electrical cabinet. The filters must be serviced regularly. Refer to Maintenance. Hose Receptacles Used for electrical connection of two heating zones each (heated hose and application head). Depending on the design, one or more hose receptacles are connected. Refer to wiring diagram.

23 Introduction 2-15 Cable Harness NOTE: The cable harness is a standard component only with the special model Bookbinding. The cable harness is used to connect the application head EP48-V. The heating zones Application head and Filter are controlled via the cable harness. Interface XS 2 Serves as a connection between the system and external devices. Interface Profibus (Option) The PROFIBUS interface (2) enables Remote operation by a higher-ranking control unit. Refer to separate manual. Interface Key-to-line Mode NOTE: Key-to-line mode is also referred to as Automatic mode in Nordson literature. In key-to-line mode the motor/pump speed is regulated synchronously to the speed of the parent machine. The pilot voltage can be supplied e.g. by a tach generator (accessory) driven by the parent machine. Refer to Installation. Pattern Control System NOTE: The pattern control system is a standard component only with the special model Bookbinding. The pattern control system Eclipse is used to trigger application heads dependent on the product position. Refer to separate manual. Door Lock WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. The electrical cabinet can be opened for installation, maintenance and repair. Store the included key such that it is accessible only to qualified and authorized personnel. The system may not be operated when the electrical cabinet is open.

24 2-16 Introduction

25 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. Unpacking Unpack carefully. Then check for any damage caused during shipping. Save special pallet and angle brackets for later use. Reuse packaging materials or dispose of properly according to local regulations. Transport Refer to Technical Data for weight. Use only suitable transport devices If possible, use the pallet on which the system was delivered, and fasten the system to the pallet Protect from damage, moisture and dust with suitable packing material Avoid jolts and vibrations. Lifting (Unpacked Unit) Refer to the Technical Data for weight. Lift only at the unit frame using suitable lifting equipment or a forklift. Removal Run the unit until empty, separate all connections from the unit, and allow the unit to cool down.

26 3-2 Installation Storage Do not store unit outside! Protect from humidity, dust and extreme temperature fluctuations (formation of condensation). Disposal Properly dispose of unit according to local regulations. Setup Set up only in an environment that corresponds to the stated Degree of Protection (Refer to section Technical Data). Do not set up in a potentially explosive atmosphere! Protect from vibration Remove transport protection (if present) Check all plug and screw connections for tightness Leave enough free space around the unit. Attaching Light Tower The light tower must be screwed onto the electrical cabinet (It was removed for transport). Exhausting Adhesive Vapors 1 Ensure that adhesive vapors do not exceed the prescribed limits. Always observe the safety data sheet (MSDS) for the material to be processed. NOTE: The exhaust hood must be connected to the customer s exhaust device. Refer to Technical Data.

27 Installation 3-3 Electrical Connections WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Laying Cable 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! Line Voltage WARNING: Operate only with the line voltage stated on the ID plate. NOTE: Permitted deviation from the rated line voltage is +5% / 10%. NOTE: The cross-section of the power cable must correspond to the rated current. Refer to ID plate for rated current. The mains terminals are located in the electrical cabinet. Refer to wiring diagram for connecting arrangement. Pilot Voltage / Tach Generator For key-to-line mode, pilot voltage must be connected to XS5. The pilot voltage can be supplied e.g. by a tach generator (accessory) driven by the parent machine. CAUTION: The pilot voltage may not exceed 160 V DC. Failure to observe will result in damage to succeeding components. NOTE: Some models with two pump drives have separate pilot voltage inputs for both pump drives.

28 3-4 Installation Interface XS 2 Serves as a connection between the unit and external devices. The actual connecting arrangement is described in the wiring diagram. NOTE: Use only shielded cables/lines. Connect the shield to ground in compliance with electromagnetic compatibility regulations. NOTE: Inductive loads (e.g. solenoid valves) connected to the unit must be equipped with a protective device (e.g. recovery diode) that disables the inductive voltage generated when an inductive load is switched off. Interface Profibus (Option) The PROFIBUS interface enables Remote operation by a higher-ranking control unit. Refer to separate manual. Pneumatic Connection 1 2 Connect dry, clean and non-lubricated compressed air (1). Set air pressure for pneumatic cylinder to approx. 2 bar (0.2 MPa / 29 psi) on the pressure controller (2). The setting must be modified according to the processed material and the output quantity (max. 6 bar / 87 psi). Pressure Switch A pressure switch switches off the main contactor when the inlet pressure falls below 2 bar. Pneumatic Safety Valve (Option) The pneumatic safety valve (1, option) serves to adjust the adhesive pressure by means of control air. The pneumatic control pressure ist set manually e.g. at a separate control unit (2, accessory). Refer to separate manual. 1 2

29 Installation 3-5 Connecting Heated Hoses WARNING: Hot! Risk of burns. Wear heat-protective gloves. Second Open-jawed Wrench Use a second open-jawed wrench when connecting and disconnecting the heated hose. This prevents the unit s hose connection from turning. 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. For more than one hose: Every hose connection is allocated to a corresponding receptacle. Do not mistakenly exchange! 2. Heat the system and hose to approx. 80 C (176 F). 3. Screw on heated hose. NOTE: Close unused hose connections with Nordson port plugs. Disconnecting WARNING: System and material pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. Relieving Pressure 1. Set motor speed to 0 min-1 (rpm); switch off motor(s). 2. Place a container under the nozzle(s) of the application head/assembly handgun. 3. Activate the application head / assembly handgun electrically or manually. Repeat this procedure until no more material flows out. 4. Properly dispose of adhesive according to local regulations.

30 3-6 Installation

31 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. Initial Startup After the unit has been properly installed, initial startup can take place. Some of the individual steps are described in detail in the subsequent text. 1. Set main switch to I/ON. 2. Set values and parameters on the control system. 3. Fill the tank. 4. Wait until the unit is ready for operation (green lamp lit). 5. Switch on motor. 6. Set motor/pump speed (or pressure) as needed for the desired adhesive quantity.

32 4-2 Operation Setting Values and Parameters Notes Values and parameters except air pressures for the pneumatics are set on the control system. For additional information, refer to manual for control system used. Speed, Pressure With the special model for the bookbinding industry, the speed is not regulated to a preset value; the pressure at the material outlet is regulated. In automatic mode, the speed and thus the output quantity is determined by a pilot voltage. The pilot voltage is supplied e.g. by a tach generator driven by the parent machine. Pneumatic Safety Valve (Option) The pneumatic safety valve serves to adjust the adhesive pressure by means of control air. The pneumatic control pressure ist set manually e.g. at a separate control unit. Temperatures CAUTION: The temperature setting is determined by the processing temperature prescribed by the adhesive supplier. The maximum operating temperature for the product described here and heated components may not be exceeded. Nordson will grant no warranty and assume no liability for damage resulting from incorrect temperature settings. Recommended Values The values stated in the tables are general values determined by experience; deviation may prove necessary. Heating zone / temperature / time Setting Low melt section Approx. 5 to 10 C (9 to 18 F) above softening temperature High melt section (reservoir and pump) 10 C (18 F) below prescribed processing temperature Undertemperature value 15 C (27 F) (deviation from setpoint) Overtemperature value 15 to 30 C (27 to 54 F) (deviation from setpoint) Temperature setback value (standby) As needed Setback period As needed Application head (accessory) Prescribed processing temperature Heated hose (accessory) Prescribed processing temperature

33 Operation 4-3 Filling the Tank NOTE: Automatic motor/pump standstill does not occur after the indication Foil bag empty until an adjustable time Changing time has expired. When the empty indication occurs, the amount of adhesive in the reservoir should be sufficient to ensure uninterrupted feeding while the bag is being changed. WARNING: Hot! Risk of burns. Wear safety goggles and heat-protective gloves. Hot adhesive can splash out of the tank. 1. Open tank lid (swivel out). 2. Cut a round opening of 200 to 220 mm diameter in the middle of the end of the foil bag, then place the bag in the tank with the open end down. NOTE: The size and centering of the opening are essential to proper emptying. Nordson recommends using the stencil P/N to cut the hole. 3. Close tank lid (swivel in). The punch is lowered automatically. Setting Changing Time 1 After the indication Foil bag empty (light tower: yellow), the changing time begins. If the foil bag is not changed before this time expires, the motor/pump automatically comes to a standstill. The changing time can be set on the timer relay 231K5 (1) in the electrical cabinet.

34 4-4 Operation Switching System ON/OFF NOTE: Before initial startup, read and observe the instructions in Initial Startup. Start up only as described under Initial Startup. NOTE: The main switch must be set to I/ON (switched on) when using the week timer. Refer to separate manual. NOTE: When external system release via interface XS2 is used, the main switch must be set to I/ON (switched on). Daily Startup NOTE: Nordson gear pumps may not be operated without hot melt material. Before switching on the motor, ensure that the tank is filled. 1. Set main switch to I/ON. 2. Wait until the unit is ready for operation. 3. Switch on motor. Daily Switchoff 1. Switch off motor. 2. Set main switch to 0/OFF. 3. If necessary, secure main switch with padlock against unauthorized access. Switching Off in an Emergency 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 remedied by qualified personnel. Black Main Switch (Special Model) Systems with a black main switch are normally supplied with power by a higher-ranking system; the higher-ranking main switch is on that system. The black main switch does not perform the EMERGENCY OFF function. Connected components can still be switched on!

35 Operation 4-5 Settings Record Production information: Adhesive: Cleaning agent: Reference channel: Manufacturer Processing temperature Viscosity Manufacturer Flash point High melt section (reservoir and pump) (factory set) Processing temperatures (Setpoint temperatures): Low melt section (grid) High melt section (reservoir and pump) Heated hose (accessory) 1) 2) 3) 4) Application head (accessory) 1) 2) 3) 4) Motor/pump speed, with models for the bookbinding industry: Setpoint pressure Motor/pump Air pressure: bar MPa psi Operating pressure Notes: Name Date

36 4-6 Operation

37 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 preventive measure for maintaining operating safety and extending the lifetime of the unit. It should not be neglected under any circumstances. WARNING: Hot! Risk of burns. Wear appropriate protective clothing/equipment. Some maintenance work can only be done when the system is heated up. Relieving Pressure WARNING: System and adhesive pressurized. Relieve system of pressure before disconnecting heated hoses, application heads and assembly handguns. Failure to observe can result in serious burns. 1. Set motor speed to 0 min -1 (rpm); switch off motor(s). 2. Place a container under the nozzle(s) of the application head / 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 adhesive flows out. 4. Properly dispose of adhesive according to local regulations.

38 5-2 Maintenance Regular Maintenance The maintenance intervals are general guidelines based on experience. Depending on operating environment, production conditions and hours of operation, other scheduled maintenance tasks may prove necessary. Unit part Activity Interval Refer to Entire unit External cleaning Daily Page 5-2 Inspect for external damage Daily Page 5-2 Condensate collector of air conditioning unit Tank Punch plate Electrical cabinet ventilation Gear pump Safety valve Pressure sensor Empty As needed Visual inspection for pollution in tank; clean if necessary Check deaeration holes for blockage; unclog if necessary Clean fan screens, clean or replace filter Refer to separate manual Refer to separate manual Refer to separate manual Before filling every time Before filling every time Page 5-4 Daily, if dust accumulation is severe Page 5-3 External Cleaning External cleaning prevents impurities created during production from causing the unit to malfunction. CAUTION: Observe the unit s Degree of Protection when cleaning (Refer to Technical Data). CAUTION: Do not damage or remove warning labels. Damaged or removed warning labels must be replaced by new ones. Only remove hot melt adhesive residue with a cleaning agent recommended by the adhesive supplier. Heat with an air heater if necessary. Remove dust, flakes etc. with a vacuum cleaner or a soft cloth. Visual Inspection for External Damage WARNING: When damaged parts pose a risk to the operational safety of the unit and/or safety of personnel, switch off the unit and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts.

39 Maintenance 5-3 Tank Cleaning Tank by Hand Cold material can usually be peeled off of the sides of the tank. If necessary, first heat tank to material softening temperature. NOTE: The inside of the tank is release coated. Do not use metallic tools to clean. Do not use wire brushes! This could damage the release coating. High Melt Section (Reservoir) MC 20 Before the high melt section (3) can be cleaned, the low melt section (2) must be detached: WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage Disconnect the system from the power supply. 2. Close tank lid (swivel in). 3. On low melt section (2): Detach electrical connections to heater cartridges and overtemperature thermostats. 4. Release all screws (4) and lift off upper tank section (1) by the eyelets (on the pneumatic cylinder) with a suitable lifting device. Secure the low melt section to prevent it from falling. When reassembling, tighten screws with 25 Nm / MC 21 The tank is hinged and can be be folded back to clean the high melt section and the grid. 1. Remove the protective cover. 2. Open the tank lid (swivel out). 3. Release the four clamps (1). 4. Fold back the top section of the tank. Keep in mind that the tank is heavy!

40 5-4 Maintenance Overtemperature Thermostat 1 The overtemperature thermostats (1) serve as an automatic switchoff in case the overtemperature shutdown of the temperature controller does not function properly. NOTE: Depending on the type of adhesive used, the overtemperature thermostats of the tank may need to be adapted to the maximum processing temperature of the adhesive (This may mean replacing it). Refer to Technical Data. Check the air relief hole 1 1. Slide the protective panels aside. 2. Swivel out the tank lid. 3. Use a wooden or plastic pick to pierce the air relief holes (1). NOTE: Do not use metallic tools to clean. This could damage the release coating.

41 Maintenance 5-5 Changing Type of Adhesive Remove the old adhesive by running until empty or by draining the unit. NOTE: Before changing the type of adhesive, determine whether the new adhesive may be mixed with the old adhesive. May be mixed: Remaining old adhesive can be flushed out using the new adhesive. May not be mixed: Thoroughly purge the unit with a cleaning agent recommended by the adhesive supplier. NOTE: Properly dispose of the old adhesive according to local regulations. Purging with Cleaning Agent CAUTION: Use only a cleaning agent recommended by the adhesive manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. Use only cleaning agents in foil bags. Before starting production again, flush out cleaning agent residue using the new adhesive. NOTE: Properly dispose of cleaning agent according to local regulations. Electrical Cabinet Ventilation Maintenance ÂÂ ÂÂ ÂÂÂ ÂÂ ÂÂ The electrical cabinet fan is maintenance-free. The filter must be cleaned or replaced, depending on dust accumulation. A dirty filter can be recognized by its dark color. It is cleaned by shaking the filter out.

42 5-6 Maintenance Maintenance Record Tank Unit part Date / name Date / name Date / name Electrical cabinet ventilation Condensate collector Gear pump Safety valve Pressure sensor

43 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: Troubleshooting activities may sometimes have to be carried out when the unit is energized. Observe all safety instructions and regulations concerning energized unit components (active parts). Failure to observe may result in an electric shock. Some Tips Before systematic troubleshooting is begun, the following should be checked: Are all parameters set correctly? Is the XS 2 interface connected correctly? For automatic mode: Is pilot voltage present? Do all plug connections have sufficient contact? Have fuses been activated? Could the fault have been caused by an external PLC? Are external, inductive loads (e.g. solenoid valves) equipped with recovery diodes? The recovery diodes must be directly allocated to the inductive load, e.g. through luminous sealings. Troubleshooting with Control System The control system offers the following troubleshooting aids, described in the manual Control System: Indication lamps and light tower Diagnosis program in the temperature section Automatic fault display in the temperature section Service display Error in the motor section LEDs on the modules and boards.

44 6-2 Troubleshooting Indication Lamps and Light Tower With the exception of the yellow light on the light tower, the indication lamps and the light tower indicate the same modes as the control system: Red = Collective fault. The red lamp indicates that the control system has recognized a fault. Refer to table Red indication lamp is lit. White = Switched ON. After switching on and during the heatup phase, at first only the white indication lamp is lit (normal condition). A fault has only occurred when the temperature does not increase (observe temperature display) and when the green indication lamp is not lit after the heatup phase has ended (1 hour and longer). Refer to table Only the white indication lamp is lit. Green = Ready for operation. The green indication lamp lights when all channels have reached their setpoint temperatures. Yellow: Flashing = Low tank level, as set by customer Lit = Lower tank level, as set by customer. 17 Red White M1 min 1 bar psi C F 19 Green Fig. 6-6 (Refer to manual Control System for position numbers)

45 Troubleshooting 6-3 Red Indication Lamp is Lit Problem Possible Cause Corrective Action Refer to Overtemperature indication from control system (Display 5: Hi blinking) Overtemperature shutdown by control system (displays 3, 4 and 5: blinking) Overtemperature shutdown by tank thermostats Motor switched off due to overheating (thermistor located in the motor) Undertemperature during operation (Display 5: Lo blinking) Ambient temperature too high (Displays 3, 4 and 5: AM bie nt blinking) Temperature sensor short-circuit (Display 5: S blinking) Temperature sensor interruption (Display 5: E blinking) Main contactor defective or dropped Manual Control System, Service Display Error Adhesive was refilled Wait until the temperature has been reached Manual Control System, Service Display Error Ambient temperature too high Filter of the electrical cabinet fan dirty Decrease ambient temperature by cooling or airing out Clean or replace Section 5 Electrical cabinet fan Replace defective Replace Replace Manual Control System, Service Display Error Pneumatic inlet pressure falls below 2 bar Check pneumatic connection Section 3 Continued...

46 6-4 Troubleshooting Problem Speed alarm Display 30: r_d Overpressure (with special function Pressure monitoring) Display 30: Phi Underpressure (with special function Pressure monitoring) Display 30: Plo Safety valve has opened Display 30: bpo (special function) Possible Cause Corrective Action Refer to Manual Control System, Service Display Error, Parameter r_d, Display Overview Manual Control System, Service Display Error, Parameter Phi, Digital Module Manual Control System, Service Display Error, Parameter Plo, Digital Module Manual Control System, Display Overview, Digital Module Other faults Manual Control System, Service Display in Motor Section, Service Display Error

47 Troubleshooting 6-5 Only the White Indication Lamp is Lit Problem Possible Cause Corrective Action Refer to Release unit not bridged or Wiring diagram not activated Temperature setpoint(s) of one or more heating zones are not reached Activate diagnosis program of the temperature section Fuse(s) defective (fuses are also located on the modules and boards) Bridge or activate the corresponding contacts of the XS 2 interface Switch on or replace Manual Control System Manual Control System Wiring diagram Cable loose or broken Fix or replace Overtemperature thermostat Replace Spare parts list (on the tank) defective Temperature sensor(s) Replace Spare parts list defective Solid-State-Relay defective Replace Spare parts list Heater(s) defective Replace (heaters in the tank and heated hose can not be replaced) Temperature setback switched on Automatic temperature setback after motor standstill activated Switch off or wait until the setback period has expired Stop temperature setback Manual Control System Manual Control System