Series 3700VMPD Hot Melt Material Applicator

Transcription

1 Series 3700VMPD Hot Melt Material Applicator with DC Pump, L Manifold, and Vista Controller Customer Product Manual Part NORDSON CORPORATION Duluth, Georgia

2 Nordson Corporation welcomes requests for information, comments and inquiries about its products. General information about Nordson can be found on the Internet using the following address: Address all correspondence to: Nordson Corporation Attn: Customer Service Lakefield Drive Duluth, GA 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. Trademarks AccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray, Flow Sentry, Fluidmove, Fluidshooter, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, Package of Values, PluraFoam, Porous Coat, PowderGrid, Powderware, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Ready Cost, Rhino, S. design stylized, Saturn, SC5, SCF, Select Charge, Select Coat, Select Cure, Shur-Lok, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure-Bond, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. ATS, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, CPX, Control Weave, Controlled Fiberization, EasyClean, Ebraid, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink-Dot, Maxima, MicroFin, Minimeter, Multifil, OptiMix, Pattern View, PluraMix, Primarc, Prism, Process Sentry, PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, and 2 Rings (Design) are trademarks of Nordson Corporation. Viton is a registered trademark of DuPont Dow Elastomers.

3 Table of Contents i Table of Contents Section 1 Safety 1. Operate Safely Safety Symbols Qualified Personnel Intended Use Installation and Electrical Connections Operation Less-Obvious Dangers Action in the Event of Unit Malfunction Danger of Burns Maintenance/Repair Cleaning Thermoplastic Hot Melt Material Equipment and Material Disposal Section 2 Description 1. Introduction Functional Operation Startup Mode Operating Mode Standby Mode Overview of the Mechanical Components Tank Pump Manifold Operator Panel Manual MPD-MA-01

4 ii Table of Contents Section 2 Description (contd) 4. Control System Features of the Operator Panel System Status Area FAULT Light READY Light Displays Area Selector Display and Up Key Multipurpose Display and Keys Actual Temperature Display Enter Key System Setup Area Up and Down Keys Right Key TEMPERATURE Area SYSTEM SETTINGS Area CLOCK Area System Controls Area MONITOR/SCAN Key and Light STANDBY Key and Light HEATERS Key and Light CLOCK Key and Light PUMP Key and Light CLEAR FAULTS Key POWER Switch Section 3 Installation 1. Introduction Inspection Installation Guidelines Installation Location Wiring Requirements Hose/Gun Power Requirements Melter Installation Mounting the Melter Installing the Tank Strainer Manual MPD-MA-01

5 Table of Contents iii Section 3 Installation (contd) 5. Hose and Gun Installation Installing Guns Installing Hoses Electrical Installation Opening the Electrical Enclosure Input/Output Board Making the Input/Output Board Connections Connecting Output Contacts (Optional) Connecting Electrical Service Closing the Electrical Enclosure Air Supply Installation System Programming Procedures Programming System Controls Programming SYSTEM SETTINGS Controls Programming TEMPERATURE Controls To Program All Zones to the Same Temperature To Program Setpoint and Standby Temperatures Individually Programming CLOCK Controls To Set the Clock To Set Standby and Heater Times To Change a Standby or Heater Time To Delete a Standby or Heater Time To Delete Times for an Entire Day An Example of How to Use the Seven-Day Clock Feature System Preparation Records of System Settings Record of SETPOINT (Operating) Temperature Settings Record of Standby Temperature Settings Record of Set Times for Heaters On and Heaters Off Record of Set Times for Entering and Exiting Standby Record of Customized System Settings Features Record of Air Pressure Settings Record of System Faults Record of System Warnings Manual MPD-MA-01

6 iv Table of Contents Section 4 MPD 1. Introduction Installation Making the Customer Connections Setup Making Controller Adjustments Establishing the Bead Size Settings for Normal Operation Section 5 Operation 1. Introduction Operating Procedures Turning the Seven-Day Clock On and Off Automatically Starting the Melter Manually Starting the Melter Checking the Adhesive Level and Filling the Tank Placing the Melter In Standby Mode Taking the Melter Out of Standby Mode Automatically Shutting Down the Melter Manually Shutting Down the Melter System Monitoring Procedures Checking the Zone Temperatures Checking the Programmed SYSTEM SETTINGS Features Checking the Warning or Fault Log Running a System Test Procedure for Changing Adhesives Section 6 Maintenance 1. Introduction Maintenance Schedule Maintenance Procedures Relieving Hydraulic Pressure Replacing a Hose Plug or Hose Connector O-Ring Cleaning the System Drain the Tank Clean the Tank Cleaning the Manifold Filter Checking the Speed Reducer Oil Level Manual MPD-MA-01

7 Table of Contents v Section 6 Maintenance (contd) 4. Flushing the System Preparing to Flush the System To Flush the System with Hot Melt Material To Flush the System with a Flushing Material To Flush the System with Type R Fluid Flushing the Reverse-Flush Filter Flushing Hoses and Guns To Restore the Melter to Normal Operation Section 7 Vista Controller 1. Introduction Overview of the Control System Control Assembly Melter-Specific Boards Input/Output Board Troubleshooting Tables Electrical Safety During Troubleshooting Opening and Closing the Electrical Enclosure Opening Closing Internal, Hose, or Gun Zone Not Heating Settings Changed or Lost Melter Not Powering On Control System Indicating a Warning or Fault Troubleshooting Procedures Checking the POWER Switch Checking the Voltage Plug and Contactor Board Harness Checking a Heater or Heater Circuit Checking a Thermostat Troubleshooting Under-Temperature Conditions Manual MPD-MA-01

8 vi Table of Contents Section 7 Vista Controller (contd) Troubleshooting Overtemperature Conditions Troubleshooting an RTD or RTD Circuit Troubleshooting the I/O Board Repair Procedures Replacing a Fuse Replacing a Control Assembly Board Preparation for Removal Power Board Removal Power Board Installation Control Board Removal Control Board Installation Display Board Removal Display Board Installation System Restoration Replacing the Operator Panel Operator Panel Removal Operator Panel Installation Replacing the Control Assembly Control Assembly Removal Control Assembly Installation Replacing a Melter-Specific Board I/O Board Replacement Replacing an RTD or a Thermostat RTD or Thermostat Removal RTD or Thermostat Installation Manual MPD-MA-01

9 Table of Contents vii Section 8 Hydraulics 1. Introduction Troubleshooting Tables Adhesive Not Applying Properly Pump or Motor Not Working Troubleshooting Procedures Motor Chain and Sprocket Check Manifold Blockage Check Pump Procedures Preparing for Repairs Removing the Pump Disassembling the Pump Cleaning the Pump Components Reassembling the Pump Checking the Bearing and the Seal Reinstalling the Pump Motor and Speed Reducer Procedures Replacing the Motor Replacing the Speed Reducer Speed Reducer Removal Speed Reducer Installation Section 9 Tank and Manifold 1. Introduction Overview of the Tank Tank and Manifold Replacement Preparing to Replace the Tank or Manifold Disassembling the Tank and Manifold Reassembling the Tank and Manifold Restoring the Melter to Normal Operation Valve Replacement Procedures Replacing the Pressure Relief Valve Replacing the Drain Valve Replacing the Manifold Pressure Control Valve Manual MPD-MA-01

10 viii Table of Contents Section 10 Schematics 1. Introduction Use of Wiring Diagrams Section 11 Parts 1. Introduction Using the Illustrated Parts List Control Assembly Parts List Melter-Specific Parts List Pump Assembly Parts List Service Kits UpTime Packs Recommended Spare Parts for DC Pumps Air Pressure Regulator and Filter Assembly Parts List Melter Assembly Parts List Melter Assembly Service Kits Ground Stud Assembly Parts List Manifold Assembly Parts List Manifold Filter Parts List Manifold Assembly Service Kits Manifold Filter Service Kits Manifold Assembly UpTime Packs Pressure Control Valve Parts List Recommended Spare Parts Hose/Gun Test Plugs Line Filter Section 12 Specifications 1. Introduction Procedure for Calculating Hose/Gun Capacity Power Data Tables Section 13 Glossary 1. Glossary Manual MPD-MA-01

11 Introduction O-1 General Hot Melt Material Processing Instructions NOTE: Before processing hot melt material, carefully read the material manufacturer s Material Safety Data Sheet (MSDS) or material information sheet. Nordson supplies only general processing instructions and is not liable for hazards associated with or damage caused by the use of hot melt material. Storage Store the material in dry areas at room temperature. Keep it in covered, dust-protected containers. Preparations for Material Application/Coating Keep the substrate at room temperature, dry, and free of dust and grease. Perform tests to determine the suitable hot melt material, optimum operating conditions, and preliminary treatment of the substrate for the application. Some substrates contain plasticizers and other ingredients which dissipate over time. In some cases, surfaces are treated with waxes, anti-stick oils, etc. Without adequate pretreatment, the hot melt bond in these applications may be defective at the time of dispensing. Processing Temperature The application temperature of the hot melt material at the nozzle is crucial for effective bonds. Refer to the material manufacturer s MSDS or material information sheet. Avoid unnecessary thermal stress. If the work is interrupted, reduce the melting temperature. Avoid heating the hot melt material above the prescribed processing temperature. Higher temperatures may cause charring of the hot melt material. This results in downtime. In addition, material may generate dangerous vapors at excessively high temperatures. Remove these vapors by using appropriate exhaust systems Nordson Corporation Issued 9/94 O1EN 07 [XX PROC] 1

12 O-2 Introduction Danger of Burns Be careful when using hot melt materials. These materials are solid at room temperature. For proper application, they may be heated to temperatures of up to 230 C (450 F). Refer to the safety instructions in the Safety section. Mixing Hot Melt Materials Avoid mixing different hot melt materials. Refer to Changing the Hot Melt Material in the Maintenance section. Disposal of Hot Melt Material Refer to the supplier s MSDS or material information sheet. O1EN 07 [XX PROC] 1 Issued 9/ Nordson Corporation

13 Section 1 Safety 2001 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4

14 1-0 Safety A1EN 02 [XX SAFE] 4 Issued 11/ Nordson Corporation

15 Safety 1-1 Section 1 Safety 1. Operate Safely Safety instructions contained in this section and throughout this document apply to tasks that may be performed with or on the unit. Warnings related to specific safety concerns are included within the text as appropriate. It is very important that these safety instructions are always followed. Failure to do so could result in personal injury and/or damage to the unit or other equipment. With this in mind, here are some basic safety recommendations: Read and become familiar with this Safety section prior to installing, operating, maintaining, or repairing the unit. Read and follow the warnings which appear within the text and are related to specific tasks. Store this document within easy reach of personnel operating or maintaining the unit. Wear personal protective equipment and clothing such as safety goggles and gloves. Familiarize yourself with and follow all safety instructions prescribed by your company, general accident-prevention regulations, and government safety regulations Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4

16 1-2 Safety 2. Safety Symbols The following symbols are used to warn against dangers or possible sources of danger. Become familiar with them! Failure to heed a warning could lead to personal injury and/or damage to the unit or other equipment. WARNING: Failure to observe may result in personal injury, death, or equipment damage. WARNING: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from the line voltage. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown. WARNING: Risk of explosion or fire. Fire, open flames, and smoking prohibited. WARNING: System or material pressurized. Relieve pressure. Failure to observe may result in serious burns. CAUTION: Failure to observe may result in equipment damage. CAUTION: Hot surface. Failure to observe may result in burns. 3. Qualified Personnel Qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and/or repair the equipment. It is the responsibility of the company operating the equipment to see that its personnel meet these requirements. A1EN 02 [XX SAFE] 4 Issued 11/ Nordson Corporation

17 Safety Intended Use The unit is designed and intended to be used only for the purpose described in the Description section. Uses not in accordance with that section or as described in this document are considered unintended uses and not in accordance with governing regulations. WARNING: Use of this equipment in ways other than described in this document may result in personal injury, death, or equipment damage. The following actions of the owner or operator of the unit are some, but not all, examples of unintended use which would permit Nordson to claim it is not responsible for personal injury or property damage arising from such unintended use: Unapproved modifications or changes to the unit Failure to comply with the safety instructions Failure to comply with instructions concerning installation, use, operation, maintenance, or repair, or when these tasks are carried out by unqualified personnel Use of inappropriate or incompatible foreign materials or auxiliary equipment Failure to observe workplace safety rules or regulations issued by government authorities or safety councils 2001 Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4

18 1-4 Safety 5. Installation and Electrical Connections WARNING: Failure to follow the safety procedures can result in injury or death. All electrical, pneumatic, gas, and hydraulic connections and installations of hot melt equipment may only be carried out by qualified personnel. Be sure to observe installation instructions for components and accessories. Equipment must be properly grounded and fused according to its rated current consumption (see ID plate). Cables which run outside the unit must regularly be checked for wear or damage. Power supply wire gauge and insulation must be sufficient to handle rated current consumption. Cables must never be squeezed or pinched. Do not locate cables or hoses in high traffic areas. 6. Operation The unit should be operated by qualified personnel in accordance with the instructions presented in this document. WARNING: Failure to follow the safety procedures can result in injury or death. Never allow the unit to be operated by personnel under the influence of substances which reduce their reaction times, or who are not able to operate the equipment for physical reasons. Prior to each start-up of the unit, check protection and warning devices and make sure they are fully functional. Do not operate the unit if these devices are not functioning properly. When the removal of safety equipment is required for installation, maintenance, or repair of the unit, it must be re-connected immediately upon completion of the work. Prior to start-up of the unit, check to make sure all safety guards and safety equipment are in place and functioning properly. A1EN 02 [XX SAFE] 4 Issued 11/ Nordson Corporation

19 Safety 1-5 In a humid environment, only equipment featuring a corresponding class of protection may be operated. Do not operate the unit in an explosive environment. Keep parts of the body or clothing away from rotating parts. Do not wear loose articles of clothing when operating or servicing units with rotating parts. Take off wrist watches, rings, necklaces, or similar pieces of jewelry and pin up or cover long hair before performing any work on or with the unit. To carry out measurements on work pieces, switch off the unit and wait until it comes to a standstill. Never point hand guns or applicator nozzles at yourself or other persons. Less-Obvious Dangers WARNING: An operator or service technician working with the unit should be aware of less-obvious dangers that often cannot be completely minimized at production sites: Exposed surfaces of the unit which cannot be practically safeguarded. They may be hot and take time to cool after the unit has been operating. The possibility that electrical potentials may remain in the unit after the unit was de-energized Hot melt material and vapors Hydraulically or pneumatically operated parts of the unit Parts winding something up or down which are not covered Action in the Event of Unit Malfunction If the unit malfunctions, switch it off immediately. Turn the circuit breaker or main power switch OFF. Have the unit repaired by qualified personnel only Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4

20 1-6 Safety Danger of Burns Contact with hot melt materials or hot areas of the unit may produce a severe skin burn. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and/or heat-protective gloves depending on the symbols shown. Be extremely careful when using hot melt material. Even solidified material may still be very hot. Always wear protective clothing which safely covers all exposed parts of the body. In case of burns: Immediately cool affected skin areas using cold, clean water. Do not forcefully remove hot melt material from the skin. Immediately seek medical attention. 7. Maintenance/Repair Allow only qualified personnel to perform the procedures described in this document. When performing such tasks, wear protective clothing, and equipment. WARNING: Even when the circuit breaker or main power switch is OFF, the unit is still electrically energized. Complete the following steps prior to maintenance or repair: Disconnect, lock out, and tag external power supply. To ensure the external power supply is disconnected, attempt to operate the unit. If the unit does not energize, proceed with maintenance or repair work. If the unit energizes, repeat the disconnect, lock out, and tag procedure. Re-test the unit. A1EN 02 [XX SAFE] 4 Issued 11/ Nordson Corporation

21 Safety 1-7 Follow the specific instructions provided in this manual to relieve the system pressure in the entire unit. Secure pneumatically- or hydraulically-operated equipment against uncontrolled movement. Only use parts which do not compromise the safety of the unit. Only use genuine Nordson parts. Always use tools with insulated handles when removing or installing components. 8. Cleaning NOTE: Always refer to the material manufacturer s Material Safety Data Sheet (MSDS) or material information sheet before working with any material. WARNING: Never clean any aluminum part or flush any system using halogenated hydrocarbon fluids. Examples of common halogenated hydrocarbons are: dichloromethylene, 1,1,1-trichloroethylene, and perchloroethylene. Halogenated hydrocarbons may react violently with aluminum parts. WARNING: Fire, open flame, and smoking are prohibited when cleaning fluids are used. Observe all explosion prevention regulations. Cleaning fluids may only be heated using temperature-controlled and explosion-protected heaters. Never use an open flame to clean the unit or components of the unit. Use only cleaning fluids designed or intended to be used with the hot melt material being used in the unit. Never use paint fluids under any circumstances. Note the flash point of the cleaning fluid used. Only use a controlled heating method to heat fluids. Ensure sufficient room ventilation to draw off generated vapors. Avoid prolonged breathing of vapors Nordson Corporation Issued 11/94 A1EN 02 [XX SAFE] 4

22 1-8 Safety 9. Thermoplastic Hot Melt Material NOTE: Always refer to the material manufacturer s Material Safety Data Sheet (MSDS) or material information sheet before working with any hot melt material. Ensure the work area is adequately ventilated. Do not exceed recommended processing temperatures. Doing so creates a danger to personnel due to decomposition of the material. 10. Equipment and Material Disposal Dispose of equipment and materials used in operation and cleaning according to local regulations. A1EN 02 [XX SAFE] 4 Issued 11/ Nordson Corporation

23 Section 2 Description Manual MPD-MA-01

24 2-0 Description Manual MPD-MA-01

25 Description 2-1 Section 2 Description 1. Introduction The Series 3700VMPD melter is the main component of the hot melt system. The melter liquefies the adhesive, maintains it at the setpoint (operating) temperatures, and pumps it through hoses to dispensing guns. The guns apply the adhesive to the surface of the product or package. The guns may be automatically operated, by an air supply or an electric gun driver, or hand-operated. Most automatic gun systems also use a timer, pattern controller, or programmable logic controller (PLC) to trigger the guns. Figure 2-1 shows a typical Series 3700VMPD hot melt system Fig VMPD Series Hot Melt System 1. Melter 3. Hose 2. Control panel 4. Air-operated gun A The tank, hoses, and guns are electrically heated: the tank by a cast-in heater element, the hoses by a spirally wound heating element, and the guns by a cartridge heater. The temperatures of the tank, hoses, and guns are individually monitored and controlled using a temperature-sensing device called a resistance temperature detector (RTD). Manual MPD-MA-01

26 2-2 Description 1. Introduction (contd) Series 3700VMPD melters can be used to melt and pump almost any thermoplastic adhesive or similar material that can be liquefied and extruded at temperatures below 218 C (425 F). The melters are not intended for use with polyurethane-reactive (PUR) adhesives because these adhesives require unique systems designed to prevent curing of the adhesive inside the dispensing equipment. Series 3700VMPD melters should be used only as described in this manual. 2. Functional Operation The melter has three basic modes of operation: startup, operating, and standby. Each heated component (each hose, each gun, and the tank) is referred to as a zone. Startup Mode During a sequential startup, when the clock timer or an operator turns the system on the tank and hoses begin to heat. After the temperatures of the tank and hoses are all within 19.5 C (35 F) of their setpoint temperatures, the guns begin to heat. When the tank, hoses, and guns are within 3 C (5 F) of their setpoint temperatures, a time delay begins. The time delay, which you can adjust, provides additional time for the material in the tank to melt. At the end of the time delay, the green READY light turns on, indicating that the system is ready for operation. The capability to heat all zones simultaneously is also available. Operating Mode When a gun is triggered, the pump draws in the melted adhesive and pushes it through a manifold, filter, and hose to a dispensing gun. The gun applies the adhesive to the product or package surface. Figure 2-2 shows the path that melted adhesive follows as it flows through the system. Standby Mode When you place the melter in the standby mode, the control system disables the pump and reduces the temperature of all heating zones to the standby temperature setpoints you have selected. You can use the standby mode to keep the adhesive warm when normal operation must be interrupted for a while. The lower temperature reduces char formation and conserves energy. Manual MPD-MA-01

27 Description Fig Typical motor 2. Tank 3. Gear pump 4. Pressure relief valve Adhesive Flow Path of a Typical Gear Pump System 5. Manifold 6. Filter 7. Gun 8. Hose 9. Drain valve 10. Pressure control valve A Manual MPD-MA-01

28 2-4 Description 3. Overview of the Mechanical Components The major mechanical components of a Series 3700VMPD melter are the tank, the pump, and the manifold. Tank 1 The tank holds a large supply of adhesive and melts it before it is pumped to the hoses and guns. Series 3700 melters have a tank only. The term tank is used to mean the tank strainer, and the melting fins collectively including the location of the tank heater connectors. See Figure Refer to the Technical Data section for the tank storage capacity and other key information about the tank. Fig. 2-3 Key Parts of the Tank 1. Tank 2. Tank strainer 3. Melting fins 4. Heater connectors A Pump The pump delivers the melted adhesive from the tank through the manifold and hoses to the guns. The key parts of a DC gear pump are the gear pump, the pump drive, the speed reducer, and the DC motor. Figure 2-4 shows the key parts of the pump. Refer to the Technical Data section for the pump delivery rate and other key information about the pump Fig. 2-4 Key Parts of the DC Gear Pump 1. Pump drive 3. DC motor 2. Speed reducer 4. Gear pump A Manual MPD-MA-01

29 Description 2-5 Manifold The manifold directs the flow of adhesive from the pump through the manifold filter to the hoses. The manifold has the following components: a reverse-flush manifold filter a pressure relief valve two drain valves ports for up to six hoses Figure 2-5 shows key parts of the manifold A Fig. 2-5 Key Parts of the Manifold 1. Pressure relief valve 2. Air-piloted pressure control valve 3. Drain valve 4. Hose ports 5. Reverse-flush filter Manual MPD-MA-01

30 2-6 Description Operator Panel The operator panel provides the controls and indicators you need to program, operate, and monitor your hot melt system. The key functions of the operator panel are described in the next part of this section, Control System. 4. Control System The control system regulates all temperature settings and controls how the melter functions. The operator panel allows you to program the system to meet changing needs: Heated zones are controlled individually, giving you more flexibility in setting up your system. With the seven-day clock feature, you can tailor operations for a week at a time, with different schedules for each day of the week. The control system is designed so that a brownout or power failure will not cause a loss of your programmed settings. Manual MPD-MA-01

31 Description 2-7 Features of the Operator Panel The operator panel provides the controls, indicators, and messages needed to operate the system. It is divided into four functional areas: System Status Displays System Setup System Controls Fig. 2-6 Operator Panel 1. System Status area 2. Displays area 3. System Setup area 4. System Controls area Manual MPD-MA-01

32 2-8 Description System Status Area The System Status area of the operator panel gives you a quick summary of the status of your system. The FAULT and READY lights let you know if the system is prepared for operation Fig. 2-7 System Status Area 1. FAULT light 2. READY light FAULT Light The red FAULT light turns on to indicate: an overtemperature condition in a zone an open or short RTD in any zone a fault-code between F1-F9 READY Light The green READY light turns on to indicate: all zones are +/- 3 C (+/- 5 F) of the setpoint temperatures system-ready time delay has elapsed no faults exist Manual MPD-MA-01

33 Description 2-9 Displays Area The Displays area of the operator panel gives you detailed information about the status of your system. When you are running the system, it shows the status of each heating zone. When you are customizing the system, it shows your current system setup Fig Displays Area 1. Selector display 2. Multipurpose display 3. Actual temperature display 4 4. Enter key 5. Up and Down keys 6. Up key Manual MPD-MA-01

34 2-10 Description Selector Display and Up Key The Selector display allows you to access information about the status of your system during operation and system setup. The display shows the selected zone number when used with TEMPERATURE and when scanning day when used with CLOCK feature number when used with SYSTEM SETTINGS The Up key, which is located below the Selector display, changes the value of a setting. Multipurpose Display and Keys During normal operation, the Multipurpose display shows the setpoint temperature for a selected zone. This allows you to compare the actual temperature of the displayed zone with its targeted temperature. Actual Temperature Display The Actual Temperature display shows the actual temperature of the heated zone. When the scan mode is enabled, each zone is displayed in sequence. When the scan mode is disabled, only the temperature for the selected zone is displayed. Enter Key The Enter key saves the number shown in the Multipurpose display. Manual MPD-MA-01

35 Description 2-11 System Setup Area 4 3 The System Setup area of the operator panel allows you to customize the system to your needs. From this area you can control the temperature at which each zone operates (TEMPERATURE) how the melter operates (SYSTEM SETTINGS) when the system operates (CLOCK) To customize system controls, use the keys in the System Setup area in conjunction with the keys in the Displays area. 5 Fig. 2-9 System Setup Area 1. Up and Down keys 2. Right key 3. TEMPERATURE area 4. SYSTEM SETTINGS area 5. CLOCK area Up and Down Keys The Up and Down keys select features within the System Setup area, allowing you to tailor the system to your needs. You can select the following features using the Up and Down keys: SETPOINT temperature STANDBY temperature SYSTEM SETTINGS SET TIME ENTER STANDBY EXIT STANDBY HEATERS ON HEATERS OFF Right Key The Right key selects features within the System Setup area, allowing you to tailor the system to your needs. You can select the following features using the Right key: INTERNAL zone HOSE zone GUN zone INTERVAL 1 INTERVAL 2 Manual MPD-MA-01

36 2-12 Description TEMPERATURE Area The TEMPERATURE area of System Setup allows you to program the setpoint and standby temperatures for three types of heated zones: internal, hose, or gun. When used in the TEMPERATURE area, The Up and Down keys select SETPOINT or STANDBY. The Right key selects the zone type (internal, hose, or gun) for programming temperatures (standby or setpoint). SYSTEM SETTINGS Area From the SYSTEM SETTINGS area, you can customize or check the settings of the following system features: password enable system-ready time delay overtemperature setpoint Celsius or Fahrenheit units global temperature bands individual temperature bands sequential startup or simultaneous startup display heater proportioning warning or power notification ready or pump notification auto-energize heaters time with heaters on fault log display Manual MPD-MA-01

37 Description 2-13 CLOCK Area From the CLOCK area you can program the system to turn heaters on or off or to place the system in standby or operating mode at a time that you select. The clock stores two sets of times, referred to as intervals. Each interval stores four settings as shown in Table 2-1. Table 2-1 Interval Settings INTERVAL 1 INTERVAL 2 Standby Settings Heater Settings Enter Exit On Off Enter Exit On Off System Controls Area The System Controls area of the operator panel allows you to control basic system operations and override programmed controls. The lights in this area tell you whether a feature is on or off. Using the keys and switches in this area, you can Monitor the status of a particular zone, or scan each zone to check its status. Take the system into or out of standby. Turn the heaters on or off. Turn the clock feature on or off. (This is useful when you do not want the system to startup automatically.) Turn the pump on or off. Run a system test to determine whether a fault that the system has detected was corrected. Turn main power to the melter on or off. Fig System Controls Area 1. MONITOR/SCAN key and light 2. STANDBY key and light 3. HEATERS key and light 4. CLOCK key and light 5. PUMP key and light 6. CLEAR FAULTS key 7. POWER switch Manual MPD-MA-01

38 2-14 Description MONITOR/SCAN Key and Light Pressing the MONITOR/SCAN key places the system in the monitor or scan mode. In the scan mode, The system scans each heated zone, displaying each zone s temperature in sequence. If the system-ready time delay feature is active, the system shows the number of minutes remaining until the system is ready for operation. The MONITOR/SCAN light turns on and stays on. In the monitor mode, The system displays the temperature of only the zone currently selected. If the system-ready time delay feature is active and is currently selected for monitoring, the system shows the number of minutes remaining until the system is ready for operation. The MONITOR/SCAN light stays on. Manual MPD-MA-01

39 Description 2-15 STANDBY Key and Light Pressing the STANDBY key when the HEATERS light is on takes the system into or out of the standby mode. When the standby feature is active, The STANDBY light turns on. The READY light turns off. The pump turns off. Temperatures in all zones drop until the temperature of each zone reaches the preselected standby temperature. The HEATERS light remains on. If the HEATERS light is not on, you cannot place the system in the standby mode. When the standby feature is disabled, The STANDBY light turns off. The heaters turn on and all enabled zones begin heating. After all zones have reached their preselected setpoint temperature, the READY light turns on. HEATERS Key and Light Pressing the HEATERS key turns power to the heaters on and off. The heaters must be turned on for the melter to operate. The HEATERS light turns on when this feature is active. NOTE: If the system is set for auto-energize heaters, the heaters are automatically enabled and the HEATERS light turns on when the POWER switch is turned on. Manual MPD-MA-01

40 2-16 Description CLOCK Key and Light Pressing the CLOCK key turns the seven-day clock on and off. When the clock is on, the system is controlled by the settings for ENTER STANDBY, EXIT STANDBY, HEATERS ON, and HEATERS OFF. The CLOCK light turns on when this feature is active. NOTE: If the clock feature is enabled when the POWER switch is turned off, it will automatically be enabled when the switch is turned back on. The CLOCK light will turn on to show that the clock feature is enabled. PUMP Key and Light Pressing the PUMP key turns the pump on and off. The PUMP light turns on when this feature is active. CLEAR FAULTS Key Pressing the CLEAR FAULTS key runs a system test. The test lasts five seconds and verifies that the problem causing a system fault was corrected. If the problem was corrected, the FAULT light in the System Status area of the operator panel will turn off once the test is completed. If the problem was not corrected, the FAULT light will stay on. POWER Switch Pressing the POWER switch turns power to the melter on or off. Manual MPD-MA-01

41 Section 3 Installation

42 3-0 Installation

43 Installation 3-1 Section 3 Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This section of the manual describes how to install the melter, hoses, and guns, and how to set up and customize the melter for your operation. 2. Inspection Exercise normal care to prevent equipment damage during unpacking. After unpacking the equipment, inspect it for any damage that may have occurred during shipping. Look for dents and scratches and make sure all fasteners are tight. Report any damage to your Nordson representative. 3. Installation Guidelines The following general guidelines are provided to help you obtain the best performance from your melter. Additional guidelines are provided throughout this section as appropriate. Installation Location Carefully select the installation location for the melter, hoses, and guns. Make sure the mounting surface is level and can support the weight of a full melter. For the weight of a full melter, refer to the Technical Data section. Allow enough room to open the tank lid, open the electrical enclosure, remove the filter assembly, lift off the pump cover, make the electrical connections, and drain the manifold filter. For melter dimensions and recommended clearances, refer to the Technical Data section.

44 3-2 Installation Installation Location (contd) Position the melter so the drain valve projects over the edge of the mounting surface. Allow enough room for installers to route the hoses properly. Make sure an operator can reach all controls. Allow enough clearance for maintenance personnel to service and repair the melter. Wiring Requirements Observe the following wiring requirements when choosing a location for your melter. Allow enough room to route your electrical wiring to the melter. You can use the access holes in the base of the melter for either rear access or bottom access. Make connections with the minimum length of wire needed. A long wire can act as an antenna for electrical noise. Hose/Gun Power Requirements The power requirements of your hoses and guns must be determined to make sure that you do not overload the melter. If your Nordson representative has not already checked to see that your melter can support all of the hoses and guns you plan to install, you need to calculate your hose/gun power requirements now. You also need to check your calculations if you change your system configuration or add new hoses or guns. To determine your hose/gun power requirements, refer to the procedure for calculating hose/gun capacity in the Technical Data section. If you need help, contact your Nordson representative.

45 Installation Melter Installation Use these procedures to mount the melter and install the tank strainer. Mounting the Melter Follow this procedure to mount your melter. 1. Remove the bolts that secure the melter to the shipping pallet. Save the bolts for later use. 2. If your local language is different from what is on the melter, find the packet of adhesive-backed, local-language warning tags that was shipped with it. Overlay the non-english language part of the tags already on this melter with the tags from the packet in your own language. Carefully follow the instructions in the packet for the correct placement of the tags. WARNING: Risk of personal injury or equipment damage. Use an appropriate lifting device and exercise caution when lifting the melter. 3. Using a suitable lifting device that is capable of lifting the melter, position the melter on the mounting surface. To determine the weight of your melter, refer to the Technical Data section. 4. Check to see that the melter is level. Provide shims as needed. 5. Using the melter base as a guide, drill four holes in the mounting surface for 8 mm ( 5 / 16 in.) mounting bolts. 6. See Figure 3-1. Secure the melter to the mounting surface with the bolts you removed in step A Fig. 3-1 Securing the Melter to the Mounting Surface

46 3-4 Installation Installing the Tank Strainer The tank strainer prevents unmelted adhesive from blocking the pump intake. Follow this procedure to install the tank strainer on your melters. 1. Locate the tank strainers that was shipped with your melter. 2. See Figure 3-2. Determine which tank strainer to use for your adhesive: the small or the large. Use the large strainer if your solid adhesive is in pellet or small-pillow form. Use the small strainer if your solid adhesive is in brick or large-pillow form Fig. 3-2 Small Strainer (left) and Large Strainer (right) 3. Remove all wrapping from the strainer. Small pieces of wrapping can cause blockage in the pump. 4. Open the tank lid and place the strainer on the fins in the bottom of the tank. Position the cutout in the strainer around the pump. 5. Close the tank lid.