Electro-pneumatic Hot Melt Applicator EP 45

Transcription

1 Electro-pneumatic Hot Melt Applicator EP 45 Manual - English - Edition 06/11 NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

2 Note This document applies to the entire series. Order number P/N = Order number for Nordson articles Note This is a Nordson corporation publication which is protected by copyright. Copyright 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. 011 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 000, 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, Optimum, 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, OptiMix, OptiStroke, Origin, Partnership+Plus, PatternJet, PatternPro, PCI, Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet, 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, 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' right.

3 Table of Contents I Table of Contents Safety Instructions... 1 Introduction... 1 Intended Use... 1 Unintended Use - Examples Residual Risks... Note on Manual... Definition of Term(s)... Applicator... Melter... Control Module... Illustrations... 3 EP EP 45 with Recirculation Control Module... 4 Function... 5 ID Plate... 5 Installation... 6 Unpacking... 6 Transport... 6 Installing... 6 Exhausting Material Vapors... 6 Storage... 6 Disposal... 6 Electrical Connection... 7 Laying Cable... 7 Connecting Applicator... 7 Connecting Solenoid Valves... 7 Pneumatic Connection... 8 Compressed Air Filter (Accessory)... 8 Connecting Control Air... 8 Lubricated or Non lubricated Control Air... 9 Operating with Lubricated Control Air... 9 Connecting Heated Hose Using Second Open end Wrench Connecting Disconnecting... 10

4 II Table of Contents Operation Important When Using Polyurethane Application Materials (PUR) Triggering Solenoid Valves Setting Temperature... 1 Maximum Operating Temperature... 1 Setting Control Air Pressure... 1 Maximum Control Air Pressure... 1 Setting Material Application Quantity Setting Nozzle Stem Stroke Positioning Applicator Angle of Incidence Height / Contact Line and Parallelism Open-pore Substrate Closed pore Substrate Operation Settings Record Maintenance Relieving Pressure Daily Maintenance PUR Adhesives Visual Inspection for External Damage External Cleaning of Applicator Applicators with Release Coating Applicators without Release Coating External Cleaning of Nozzle... 0 Nozzle with Release Coating... 0 Nozzle without Release Coating... 0 Regular Maintenance... 0 Changing Type of Material... 1 Purging with Cleaning Agent... 1 Disassembling and Cleaning Nozzle... Assembling Nozzle... 3 Inserting New Shim Plate... 3 Maintenance Record... 4 Repair / Retrofitting... 5 Modifying Applicator for New Control Modules... 5 Replacing Single Control Modules... 5 Retrofitting Control Module... 6 Removing Control Module... 6 Disassembling Control Module... 7 Replacing and Lubricating O-rings... 8 Lubricating O rings... 8 Overview of Parts... 8 Assembling Control Module... 9 Installing Control Module... 9 Troubleshooting Technical Data General Data Cordset... 3 Processing Materials... 33

5 Applicator 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 45 may be used only to apply hot melt adhesives. 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: Polyurethane adhesive (exception: special models that are designed to apply PUR, when requested by the customer) Explosive and flammable materials Erosive and corrosive materials Food products.

6 Applicator 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 Definition of Term(s) This manual applies to the entire series. The position numbers in the illustrations do not correspond to the position numbers in the technical drawings and parts lists. The illustrations show only the essential components of the applicator. Refer to the technical drawings for additional components and details. 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.

7 Applicator 3 Illustrations EP 45 NOTE: EP 45 applicators are available for different application widths up to 1000 mm. As the application width increases, so does the number of control modules needed Fig. 1 1 Body Bracket 3 Hose connection 4 Nozzle stem stroke adjustment 5 Solenoid valve 6 Control air connection 7 Control module 8 Filter block (option) 9 Filter cartridge (option) 10 ID plate EPAH334L140A Nozzle mouthpiece 1 Shim plate 13 Mouthpiece receptacle 14 Electrical equipment cover 15 Cordset

8 4 Applicator Illustrations (contd.) EP 45 with Recirculation Control Module Fig. EP 45 with recirculation control module 1 Recirculation control module Hose connection for material supply 3 Hose connection for material recirculation 4 Nozzle 5 Body 6 Cordset 7 Control module EPAH140M084A0597

9 Applicator 5 Function The applicators in the series EP 45 are used for continuous and intermittent coating of open-pore and closed-pore substrates with hot melt adhesives. The exchangeable surface nozzles or mouthpieces are available in standard application widths up to 500 mm, or up to 1000 mm as special models. The material flows from the melter through the heated hose, then into the applicator. From there it passes through distribution channels and into the nozzle. The application widths and patterns can be modified to suit the needs of the specific application by inserting shim plates / masks (1, Fig. 1). The control module and body are separate from one another. This enables temperatures of 00 C / 39 F or 60 C / 500 F (high temperature or T version) to be maintained over longer periods of time. Electrical heater cartridges are used to heat the unit. The temperature is continuously measured by a temperature sensor and regulated by an electronic temperature controller located in the electrical cabinet of the melter. Recirculation control modules (Refer to Fig. ) enable the material pressure in the applicator to be maintained at a constant value. When the control modules close and no material is applied, the recirculation control modules open, allowing the material to flow back into the melter tank. ID Plate Applicator type Serial number Nordson order number Year Voltage, Current, Frequency Fig. 3

10 6 Applicator 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 damage caused during transport. 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. Installing Install the applicator in the appropriate place in the production machine. Observe the following: Do not operate in a potentially explosive atmosphere Protect from humidity, vibrations, dust and drafts Ensure access to parts relevant for maintenance and operation Protect the nozzle from damage. 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. Storage Disposal Do not store outside! Protect from humidity and dust. Do not lay unit on the nozzle. Protect the nozzle from damage. When your Nordson product has exhausted its purpose and/or is no longer needed, dispose of it properly according to local regulations.

11 Applicator 7 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 components. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! Connecting Applicator WARNING: Operate the applicator only at the operating voltage shown on the ID plate. The unit is connected electrically by inserting the plugs into the corresponding receptacles on the melter or a terminal box. Secure the voltage plug with the clamp if necessary. 1. Connect the cable with the plug (1) to the heated hose receptacle.. Use safety clips () - when available - to secure the plug connection. 1 Fig. 4 Connecting Solenoid Valves NOTE: Observe the voltage stated on the ID plate of the solenoid valve. Trigger the solenoid valve only when the applicator is heated to operating temperature! If the material is too cold, control module seals may be damaged. Depending on the specific design of the melter, 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.

12 8 Applicator Pneumatic Connection The applicator may only be connected to pressure-controlled and conditioned compressed air. NOTE: The control air must either be lubricated or may not be lubricated at all. Please carefully follow the instructions in the chapter Lubricated or Non-lubricated Control Air. Compressed Air Filter (Accessory) Safe operation and service life of pneumatically driven applicators essentially depend on conditioning of the compressed air. Dust or condensation will increase the wear on sliding surfaces and sealing elements, thereby causing damage. Thus the compressed air should be conditioned with a compressed air filter with water separator. The air conditioning unit cleans and dries the compressed air. NOTE: The filter mesh size may not exceed 40 µm. Connecting Control Air 1 1. Connect the control air hose to the air connection (1).. Also supply control air to the recirculation control modules (Refer to Fig. ), when present. NOTE: Ensure that control air is on at all times. Among other functions, it keeps the nozzle closed when EMERGENCY OFF occurs or when the system comes to a standstill. This prevents material from dripping out of the nozzle. Fig. 5

13 Applicator 9 Lubricated or Non lubricated Control Air Applicators in the series EP 45 built in 1997 or later can be operated with either lubricated or non lubricated compressed air. To accommodate this, the control modules are modified in the following way: Control module cylinder has a special interior coating O-rings (on the piston) with increased Shore hardness. 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. The new control modules can be identified by a circumferential groove (arrow, Fig. 6). Fig. 6 When control modules / applicators of the new design are 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. To operate with non lubricated control air, ensure that: The system has been converted to absolutely non lubricated operation No oil from a possibly defective compressor can penetrate the compressed air supply. Control air is on at all times. It keeps the control modules closed when EMERGENCY OFF occurs or when the system comes to a standstill. This prevents material from dripping out of the nozzle. NOTE: Nordson will assume no warranty or liability for damage caused by unpermitted, temporary lubrication. Operating with Lubricated Control Air The applicators / control modules of the new design 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. Only the following oil may be used: Oil P/N Klüber Unisilkon TK 00/

14 10 Applicator 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 hose connection on the unit from turning. Fig. 7 Connecting 1 3 If cold material can be found in the hose connection, these components (1, ) must be heated until the material softens (approx. 80 C, 176 F). 1. First only connect the hose (3) electrically.. Heat the system and hose to approx. 80 C (176 F). 3. Screw on heated hose. Fig. 8 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).. 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.

15 Applicator 11 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 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. WARNING: Operate only at the operating voltage shown on the ID plate. CAUTION: Trigger the solenoid valves only when the applicator is heated to operating temperature! Seals in the application control module and the recirculation control module can become damaged if the material is too cold.

16 1 Applicator Setting Temperature The procedure for setting the temperatures is described in the temperature controller manual. Temperature controllers are not part of the applicator. They can be located e.g. in the electrical cabinet of the melter or in a separate electrical cabinet. Maximum Operating Temperature 00 C / 39 F; 60 C / 500 F with high temperature version NOTE: The maximum operating temperature may not be exceeded. Nordson will grant no warranty and assume no liability for damage resulting from incorrect temperature settings. Setting Control Air Pressure The control air pressure for the control module is set for each application on an external air pressure control valve. The air pressure control valve is not part of the applicator. NOTE: Ensure that the applicator is supplied with control air at all times. The control air keeps the control modules closed when EMERGENCY OFF occurs or when the system comes to a standstill. This prevents material from dripping out of the nozzle. Maximum Control Air Pressure 6 bar / 0.6 MPa / 87 psi NOTE: The maximum control air pressure may not be exceeded. Nordson will assume no warranty or liability for damage caused by an incorrect pressure setting.

17 Applicator 13 Setting Material Application Quantity The material quantity needed depends on the desired grammage and on the substrate speed. It is usually preselected using the pump speed dials. The optimum setting must be determined by trial and error. The speed dials are located e.g. in the electrical cabinet of a melter or in a separate electrical cabinet. Depending on the model of the material application system, pump speed control can also occur with a tach generator or an electronic pressure controller. Setting Nozzle Stem Stroke All control modules are equipped with a nozzle stem stroke adjustment. It is used for fine adjustment of the material application quantity or the material flow quantity. WARNING: Hazard! The stem stroke adjustment knob has no upper setting limit. If compressed air is connected, never completely turn up the adjustment knob / adjustment screw; it may jump out. CAUTION: The nozzle stem stroke may be adjusted only when the applicator is heated! Failure to observe can cause damage to seals. Figure 9 shows: Latching nozzle stem stroke adjustment (1) Stem stroke adjustment with adjustment screw () and locknut (3) Max mm Max in. 1 The non adjustable nozzle stem stroke limiter (4). NOTE: The stem stroke adjustment knob has no upper setting limit; starting from the bottom, it may only be turned a maximum of ¼ revolutions upward. This corresponds to a nozzle stem stroke of maximum 1. mm. Failure to observe can result in - among other things - increased wear and malfunctioning. Experience has shown that a stroke adjustment of max. 0.5 to 0.6 mm (which corresponds to 1 turn) has proven to be sufficient. 3 Nozzle stem stroke Counterclockwise (+) = Increase increase Clockwise (-) = decrease Decrease Flow rate Max mm Max in. 4 XXAH157S130A0797 Fig. 9

18 14 Applicator Positioning Applicator Since the optimum angle of incidence of the applicator is a factor of various customerćspecific parameters, the angle can not be determined precisely beforehand. However, it must be at or about 90. NOTE: The ideal application position should always first be determined by trial and error! Angle of Incidence At an angle less than 90, a material bead is formed on the nozzle. When this occurs, coating is not uniform. At an angle greater than 90, hot melt adhesive runs under the nozzle and onto the substrate. This results in uneven, flaky application CTSY096L045A1195 Fig. 10 Angle of incidence, principle drawing (applicator shown symbolically) 1 Applicator Nozzle 3 Application roll 4 Substrate

19 Applicator 15 Positioning Applicator (contd.) Height / Contact Line and Parallelism 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 of material to open pore substrate Application of material to closed pore substrate Open-pored substrate Closed-pored substrate CTSY097L045B0997 Fig. 11 Parallelism (principle drawing, applicator shown symbolically) Open-pore Substrate The contact line (5) should be below the line at which the substrate (4) runs onto the roll (3) when coating an open pore substrate (e.g. nonwoven). The applicator nozzle () always has contact to the substrate (Refer to Fig. 11). Closed pore Substrate The contact line (4) should be at the line at which the substrate (4) runs onto the roll (3) when coating a closed pore substrate. The nozzle always has contact to the substrate (Refer to Fig. 11).

20 16 Applicator Operation Switch on melter Set stem stroke Switch on control unit Connect compressed air supply: 1 to 6 bar 0.1 to 0.6 MPa 14.5 to 87 psi Switch on production machine Fig. 1 EPAH14L147A0997

21 Applicator 17 Settings Record Production information: Material: Cleaning agent: Manufacturer Processing temperature Viscosity Manufacturer Flash point Basic settings Control air pressure Stem stroke (rotations) Temperatures Applicator Undertemperature Overtemperature Notes: Name Date

22 18 Applicator 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. 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 the motor speed of the unit feeding the material to 0 min 1 ; switch off the motor(s).. 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. Fig. 13 Principle drawing, material pressure relief

23 Applicator 19 Daily Maintenance Unit part Activity Interval Refer to Entire applicator Visual inspection Daily Page 19 External cleaning Entire nozzle (mouthpiece receptacle, shim plate and mouthpiece) External cleaning Page 19 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 of Applicator External cleaning prevents impurities created during production from causing the unit to malfunction. CAUTION: Do not damage or remove warning labels. Damaged or removed warning labels must be replaced by new ones. CAUTION: Never use hard tools. Handle the nozzle with extreme care. Remove material residue only with a cleaning agent recommended by the material supplier. Heat with an air heater if necessary. Remove dust, flakes etc. with a vacuum cleaner or a soft cloth. Applicators with Release Coating CAUTION: Do not use hard or metallic tools to clean. Do not use wire brushes! This could damage the release coating. Use only soft aids (wooden or PTFE spatula or soft brush). Applicators without Release Coating If the applicator is not release coated, charred adhesive residue can be removed by polishing the mouthpiece and mouthpiece receptacle along the entire length of the applicator with 1000 grain wet emery paper and cutting oil.

24 0 Applicator External Cleaning of Nozzle CAUTION: Clean the nozzle very carefully, and never use hard or metallic tools. A damaged nozzle will result in uneven material application, and it will need to be repaired. WARNING: Hot! Risk of burns. Wear heat protective gloves. 1. Remove material residue from the nozzle promptly with a soft cloth, before it chars.. Remove tough and hardened residue with a wooden or PTFE spatula if necessary. Nozzle with Release Coating Refer to page 19, Applicator with Release Coating. Nozzle without Release Coating Refer to page 19, Applicator without Release Coating. Regular Maintenance The maintenance intervals are general guidelines based on experience. Depending on operating environment, production conditions and hours of operation, other maintenance intervals may prove necessary. Unit part Activity Interval Refer to Applicator Purge with cleaning agent When material is changed or when dirty Daily when using PUR adhesives Page 1 Nozzle Disassemble and clean When dirty Page 0 Control module Check detection hole * Replace Replace O-rings Weekly When leaking When leaking Page Filter (option) Separate manual NOTE: * The detection hole is the hole in the control module casing through which the nozzle stem can be seen.

25 Applicator 1 Changing Type of 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. 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. Heat the applicator until the material softens (approx. 80 C / 176 F) and relieve pressure.. Place a container under the applicator. 3. Unscrew plug (1) Collect material. 5. Purge with cleaning agent 6. Screw plug in again. Fig. 14 NOTE: Properly dispose of cleaning agent according to local regulations. Fig. 15

26 Applicator Disassembling and Cleaning Nozzle 1. Heat applicator until material is soft.. Detach and disassemble nozzle (Refer to Fig. 16). 3. Insert forcing screws to separate the mouthpiece and mouthpiece receptacle from one another. 4. Use suitable tools to remove charred material from holes and channels. 5. If necessary, polish body and mouthpiece sealing surfaces with 1000 grain wet emery paper and cutting oil (metal working oil). 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. 3 mm 3 mm 3 mm Fig. 16

27 Applicator 3 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.. Assemble the nozzle as shown in Fig 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.5 Nm. Use a torque wrench. NOTE: Contact Nordson for information on special models with different screws. Inserting New Shim Plate Fig. 17 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 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.

28 4 Applicator Maintenance Record Applicator Unit part Activity Date Name Date Name Purge with cleaning agent Nozzle Disassemble and clean Control module Check detection hole Filter (option) Clean and replace filter screen

29 Applicator 5 Repair / Retrofitting WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Modifying Applicator for New Control Modules Applicators in the series EP 45 built in 1997 or later can be operated with either lubricated or non lubricated compressed air. If older applicators are to be retrofitted for operation with non-lubricated compressed air, the control modules have to be replaced. If an old applicator is to be retrofitted with new control modules to enable operation with non-lubricated compressed air, the following measures must be performed: Replace the control module with a control module of the new design Replace the solenoid valve Change the compressed air supply to absolutely oil-free operation Set the nozzle stem stroke (Refer to page 13, Setting Nozzle Stem Stroke). Replacing Single Control Modules If some but not all of the control modules on an applicator are replaced with control modules of the new design, the applicator must continue to be operated with lubricated compressed air. The following oils may be used: Oil P/N Klüber Unisilkon TK 00/ Klüber Unisilkon TK00/

30 6 Applicator Retrofitting Control Module If a control module is to be retrofitted to enable operation with non-lubricated compressed air, the following measures must be performed: Remove control module (See below, Removing Control Module and page 9, Installing Control Module). Disassemble control module (Refer to page 7) Replace the cylinder (Refer to page 8, Overview of Parts) Replace and oil the O-rings on the piston (Refer to page 8, Overview of Parts and Lubricating O-rings) Replace all solenoid valves Change the compressed air supply to absolutely oil-free operation Set the nozzle stem stroke (Refer to page 13, Setting Nozzle Stem Stroke). Removing Control Module WARNING: Hot! Risk of burns. Wear heat protective gloves. 1. Disconnect compressed air hoses.. Heat the applicator until the material is soft. 3. Release fixing screws and detach control module. Fig. 18

31 Applicator 7 Disassembling Control Module WARNING: Hot! Risk of burns. Wear heat protective gloves NOTE: When reassembling, only use parts of the same control module, or replace with new Nordson parts. Do not combine parts from different control modules. NOTE: Disassembly of the socket block (9) is not described here. Special tools, knowledge and skills are needed for disassembly. When the socket block leaks, the entire control module should be replaced. NOTE: Nordson will assume no warranty/liability when control modules fail due to incorrect assembly or parts. 1. Disconnect compressed air hoses.. Heat the applicator to approx. 100 C so that the fixing screws (3) do not break when removed. The applicator can cool off again when the fixing screws (3) have been removed. 3. When the cylinder (4) is to be replaced, first unscrew the nozzle stem stroke adjustment (1) and then release the fixing screws (3). When the cylinder (4) is not to be replaced, just release the fixing screws (3). 4. Remember the position of the small air outlet bore before detaching the cylinder (4). Fig. 19 NOTE: Do not draw the piston (7) out of the socket block (9). Failure to observe can cause leakage in the socket block if hardened material residue sticks to the piston (7) nozzle stem.

32 8 Applicator Replacing and Lubricating O-rings 1. Carefully press the piston (7, Fig. 19) down to prevent the nozzle stem from pulling out of the socket block (9, Fig. 19).. Remove the O rings (5 and 6, Fig. 19). 3. Use your fingers to place the new O-rings (5 and 6, Fig. 19) on the piston (7, Fig. 19). Do not use anything else. 4. Lubricate the O rings. Lubricating O rings Before putting the cylinder (4) over the piston again, all of the O rings (5 and 6, Fig. 19) have to be replaced and thoroughly lubricated with the following oil. Oil P/N Klüber Unisilkon TK00/ Overview of Parts Control module Cylinder O-ring * Illustration P/N Component of the following applicators P/N Designation P/N * EP x.5 17 x * Refer to included spare parts list * The O rings are marked with a white dot

33 Applicator 9 Assembling Control Module If the stem stroke adjustment (1) was detached from the cylinder (4), screw it back on. Replace the sealing rings (). Order number P/N Replace the O ring (8). 3. Verify that the O rings (5 and 6) have been lubricated with the prescribed oil (Refer to page 8, Lubricating O Rings). 4. Carefully draw the cylinder (4) over the piston (7). Ensure that the small air outlet bore is in the same place as is was before the cylinder was removed. 5. Apply mounting paste to the threads of the fixing screws (3), if possible. This is intended to prevent the thread from sticking. Mounting paste: Never Seez, order number: P/N Tighten the fixing screws (3) evenly crosswise. 7. Restore compressed air connections. 8. If the the nozzle stem stroke was adjusted, set it (Refer to page13, Setting Nozzle Stem Stroke). Fig. 0 Installing Control Module 3 mm 1. Heat the applicator until the material is soft.. Apply mounting paste to the threads of the fixing screws, if possible. This is intended to prevent the thread from sticking. Mounting paste: Never Seez, order number: P/N Replace the O ring(s); order number P/N Insert the new control module in the applicator and tighten screws alternately or crosswise. Fig. 1

34 30 Applicator Troubleshooting NOTE: The following table is based on the assumption that all other system components function correctly. Problem Possible Cause Corrective Action Refer to No material Applicator has not yet reached Wait until temperature has been Page 11 operating temperature reached; check temperature setting if necessary Not enough material in melter Fill Melter pump is not working Check Control air not connected Connect Page 8 Nozzle clogged Clean nozzle Page Filter (option) clogged Clean filter and replace filter screen Nozzle stem is stuck Replace control module Page 3 ff No material: Applicator is cold Material application is not exact The open time is too long Temperature not set correctly on Correct temperature setting Page 11 temperature controller Plug has no contact Secure plug Page 7 Heater cartridge(s) defective Replace heater cartridge(s) Nozzle partially blocked or damaged Applicator does not have even contact with the substrate Production parameters not attuned to one another Unscrew (warm) mouthpiece and clean or replace Check positioning, adjust if necessary Check parameters, change if necessary Material unsuitable Consult material manufacturer Data sheet Application temperature too high Set temperature lower Page 11 The open time is too short Material unsuitable Consult material manufacturer Data sheet Application temperature too low Set temperature higher Page 11 Material unsuitable Consult material manufacturer Data sheet

35 Applicator 31 Technical Data NOTE: The technical data only apply to standard applicators. General Data Product Applicator Product name EP 45 (Options: release coating, high temperature (T version), various application widths up to 1000 mm) Operating voltage Refer to ID plate Power consumption Refer to ID plate Control module type Models:standard, zero cavity Filter Models:none, 0.1 mm, 0. mm, 0.4 mm Shim plates / masks Models:0.3 / 0.4 / 0.5 / 0.6 / 0.7 / 0.8 / 0.9 / 1.0 mm Temperature sensor Fe CuNi (FE/KO), Pt 100, Ni 10 Solenoid valve Models:MV 4 U 4 V DC, MV 40 1U 40 V AC, MV 110 1U 110 V AC Degree of protection IP 30 Max. control air pressure 6 bar / 0.6 MPa / 87 psi Hose connection Model: Inside hose diameter 8 mm, 13 mm, 0 mm, 3 mm Max. operating temperature Max. ambient temperature for solenoid valves Weight 00 C / 39 F; 60 C / 500 F with high temperature version a. 55 C / 131 F approx g

36 3 Applicator Cordset 8 green/yellow Ground conductor blue 3 brown Heater 4 black 5 black Solenoid valve Pin insert HAN 7D KWU 6 red 7 blue Thermo lead + Thermo lead - Fig. Power cable for temperature sensor Fe CuNi (FE/KO) 8 green/yellow Ground conductor blue 3 brown Heater 4 black 5 black Solenoid valve Pin insert HAN 7D KWU Fig. 3 Power cable for temperature sensor Pt red (black) 7 white (black) Temperature sensor Pt Black Heater Black 3 Temperature sensor Ni 10 5 Green/yellow Ground conductor Fig. 4 Power cable with temperature sensor Ni 10

37 Applicator 33 Processing Materials Designation Order number Use High temperature grease Can 10 g P/N Tube 50 g P/N Cartridge 400 g P/N 4038 Apply to O-rings and threads NOTE: The grease should not be mixed with other lubricants. Oily/greasy parts must be cleaned before application.

38 34 Applicator