Hot Melt Applicators Series EP 48 V (UL Models)

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1 Hot Melt Applicators Series EP 48 V (UL Models) Manual - English - Edition 05/14 NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

2 Note This document applies to products with the following P/Ns: 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 All rights reserved. - Translation of Original - Trademarks AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, Bowtie, Build A Part, CanWorks, Century, CF, CleanSleeve, CleanSpray, Color on Demand, ColorMax, Control Coat, Coolwave, Cross Cut, cscan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo Coat, e.dot, EFD, Emerald, Encore, ESP, e stylized, ETI stylized, Excel 2000, Fibrijet, 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, KISS, Lean Cell, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, Micromedics, Micro Meter, MicroSet, Microshot, Millenium, Mini Blue, Mini Squirt, Moist Cure, Mountaingate, MultiScan, NexJet, No Drip, Nordson, Optimum, Package of Values, Paragon, PatternView, PermaFlo, PICO, PicoDot, PluraFoam, Porous Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro Flo, Program A Bead, Program A Shot, Program A Stream, Program A Swirl, ProLink, Pro Meter, Pro Stream, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, SC5, S. design stylized, Seal Sentry, Sealant Equipment & Engineering, Inc., SEE and design, See Flow, Select Charge, Select Coat, Select Cure, Servo Flo, Shot A Matic, Signature, Slautterback, Smart Coat, Smart Gun, Solder Plus, Spectrum, Speed Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure Max, Sure Wrap, Tela Therm, Tip Seal, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Tubesetter, Ultra, UniScan, UpTime, u TAH, Value Plastics, Vantage, Veritec, VersaBlue, Versa Coat, VersaDrum, VersaPail, Versa Screen, Versa Spray, VP Quick Fit, Walcom, Watermark, When you expect more., X Plane are registered trademarks - - of Nordson Corporation. Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, Allegro, 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, Freedom, G Net, G Site, Genius, Get Green With Blue, Gluie, Ink Dot, IntelliJet, ion, Iso Flex, itrend, KVLP, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, MonoCure, Multifil, MultiScan, Myritex, Nano, OmniScan, OptiMix, OptiStroke, Optix, Origin, Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet, PurTech, Quad Cure, Quantum, Ready Coat, RediCoat, RollVIA, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, StediFlo, StediTherm, Summit, Sure Brand, SureFoam, SureMix, SureSeal, Swirl Coat, TAH, Tempus, ThruWave, TinyCure, Trade Plus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Viper, Vista, WebCure, YESTECH, 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' right.

3 Table of Contents I Table of Contents Safety Instructions... 1 Description... 1 Intended Use... 1 Unintended Use - Examples Residual Risks... 2 Note on Manual... 2 Definition of Term(s)... 2 Applicator... 2 Melter... 2 Control Module... 2 ID Plate... 2 Function... 3 Constant Pressure Controller... 4 Heating... 4 Overtemperature Shutdown by Thermostat... 4 Adapter plate... 4 Illustration (Examples)... 5 Applicator Without Constant Pressure Controller... 5 Applicator With Constant Pressure Controller... 6

4 II Table of Contents Installation... 7 Unpacking... 7 Transport... 7 Storage... 7 Installing... 7 Exhausting Adhesive Vapors... 7 Installing Parts of Ship-with Kit... 8 Attaching to Parent Machine... 8 Applicator P/N All Other Applicators (Besides P/N )... 8 Observe when Attaching... 8 Adjusting... 9 Parallelism and Application Thickness... 9 Electrical Connection Laying Cable Heating Zones Solenoid valves Information on New Constant Pressure Controller CPR Pneumatic Connection Connecting Control Air Control Modules Constant Pressure Controller Connecting Heated Hose Using Second Open-end Wrench Connecting Disconnecting Observe When Starting up the System Setting Outlet Pressure (CPR) Triggering with Proportional Valve Bleeding Calibrating Application Width Display Motorizing Application Width Adjustment Operation Important When Using Polyurethane Application Materials (PUR) 16 Triggering Solenoid Valves Setting Temperature Maximum Operating Temperature Applying Hot Melt Adhesive Setting Application Width Setting Application Thickness Daily Shutdown Settings Record... 18

5 Table of Contents III Maintenance Relieving Pressure LA330 II CPR Depressurizing via Air Relief Valve Depressurizing via Applicator Processing Materials Maintenance Table Visual Inspection for External Damage External Cleaning Purging with Cleaning Agent Lubricating Plan Bleeding Visual Inspection Replacing Constant Pressure Controller CPR ONLY Constant Pressure Controller LA330 II Cleaning Disassembling Constant Pressure Controller Filter Cartridge Removing Filter Cartridge Replacing Filter Screen Installing Filter Cartridge Maintenance Record Troubleshooting Troubleshooting Table Constant Pressure Controller CPR Repair Parts Replacing Control Module Heater Cartridges, Temperature Sensor and Thermostat Current Flow Diagram Replacing Sealing Cord Technical Data Operating Data Data on New Pressure Controller CPR (Replaces Pressure Controller LA330-II) Electrical Data General Data Dimensions... 41

6 IV Table of Contents

7 Applicator EP 48 V 1 Safety Instructions ATTENTION: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Description Intended Use Applicators of the series EP 48 V may be used only to apply PUR and other hot melt adhesives commonly used in the book binding industry to glue the spines of books. NOTE: UL conformity applies only when the melter types stated on the applicator ID plate are used. Any other use is considered to be unintended. Nordson will not be liable for personal injury and/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 hot melt adhesives not suitable for the unit are used When the values stated under Technical Data are not complied with. The applicator may not be used to process the following materials: Explosive and flammable materials Erosive and corrosive materials Food products.

8 2 Applicator EP 48 V 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 adhesive and when making adjustments Material fumes can be hazardous. Avoid inhalation. Hardened or charred material may cause the constant pressure controller to cease functioning. Note on Manual Definition of Term(s) Because the unit is continuously being modified and improved, there are several models of the applicator. Thus illustrations in this manual may deviate from the actual design There are other manuals specifically for older models of applicators in the series EP48 V (without UL conformity, recognized by the ID plate; also refer to page 2, ID Plate) Refer to separate document Parts List, P/N for spare parts. 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. ID Plate EP48 V PN Ser.No U f I oper. temp. max. Applicator type Nordson order number Serial number Operating voltage Operating voltage frequency Maximum current consumption Maximum operating temperature

9 Applicator EP 48 V 3 Function NOTE: The applicator is part of an application system. Also refer to page 5, Illustration (Examples). The adhesive flows from a melter through a heated hose then a filter (2) and into the applicator. The adhesive is applied to the spine from underneath as soon as the Application control module (6) is triggered (opened). The Retrosuction control module (5) sucks the adhesive out of the application slot (1) as soon as the application control module closes. This ensures exact adhesive edges. The application width can be set continuously from 1 to 60 mm Fig. 1 Example: Applicator P/N Application slot 2 Filter 3 Display Note: Not all models have all components 4 Guide plates 5 Retrosuction control module 6 Application control module 7 Constant pressure controller

10 4 Applicator EP 48 V Constant Pressure Controller The outlet adhesive pressure is controlled pneumatically via the constant pressure controller. The adhesive pressure or the quantity emitted can be adapted to the speed of the binder with a pattern controller (e.g. LA 404 2) and a proportional valve. NOTE: On models without constant pressure controller, the quantity emitted can be adapted to the speed of the binder by adjusting the pump speed of the melter. Heating Electrical heater cartridges are used to heat the unit. The temperature is continuously measured by temperature sensors and regulated by electronic temperature controllers usually located in the electrical cabinet of the melter. Overtemperature Shutdown by Thermostat Thermostats in the filter and in the body switch off the heater at approx 230 C or 180 C, depending on the model. Adapter plate An adapter plate with plug has been added to applicators P/N and since 02/2013. Remove the plug if a pressure sensor is to be installed. The screw heads for fastening the filter block and adapter plate to the constant pressure controller are located behind the electrical equipment cover on the filter block. Constant pressure controller Adapter plate Filter block

11 Applicator EP 48 V 5 Illustration (Examples) Applicator Without Constant Pressure Controller Encoder, installed in binder Input Encoder Output I/P converter Input Trigger Compressed air dry, non lubricated max. 7.5 bar Output Retrosuction control module Signal transmitter Output Application control module Connection Filter Connection Body Heated hose

12 6 Applicator EP 48 V Applicator With Constant Pressure Controller Incremental transducer (Encoder) LA Automatic pump control Compressed air dry, non lubricated max. 7.5 bar DuraPail / DuraDrum 6 bar I/P converter Input Trigger Signal transmitter EP 48 V Retrosuction control module Application control module Constant pressure controller Heated hose Approx. 50 bar

13 Applicator EP 48 V 7 Installation Unpacking Transport ATTENTION: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Unpack carefully. Then check for damage caused during transport. Reuse packaging materials or dispose of properly according to local regulations. The applicator is a high precision, valuable part. Handle very carefully! Protect the nozzle from damage. The applicators P/N and are secured with washers and hexagonal nuts for transport: Four washers and hexagonal nuts M8 (if re-used, tighten with approx. 5 Nm) Storage Installing Do not store outside! Protect from humidity and dust. Protect the nozzle from damage. When installing the applicator, the following points should be observed in order to avoid unnecessary effort later. Protect from humidity, vibrations, dust and drafts Ensure access to parts relevant for maintenance and operation When installing the unit, ensure that cables, air hoses and heated adhesive hoses can not be bent, pinched, torn off or otherwise damaged. Exhausting Adhesive Vapors Ensure that adhesive vapors do not exceed the prescribed limits. Exhaust material vapors if necessary. Ensure sufficient ventilation of the installation location.

14 8 Applicator EP 48 V Installing Parts of Ship-with Kit NOTE: Refer to separate document Parts List for an overview of the parts contained in the Ship with kit. Fasten the drip tray (1) to the applicator. The purpose of the other parts of the Ship with kit will be described as they are needed. 1 Attaching to Parent Machine Applicator P/N A separate bracket is needed for attaching to a binder. This bracket is not included in the scope of the applicator delivery; it must be ordered to fit the binder. Screw the applicator onto the separate bracket in the parent machine. All Other Applicators (Besides P/N ) Screw applicator to the intended place on the parent machine or the trolley. Observe when Attaching A. The application slot must be at a right angle to the direction of movement of the book spine. B. The inside edge of the rear book clamp must be aligned to the immobile guide plate of the applicator. NOTE: The fixed guide plate is on the other side of the applicator P/N A. B. With applicator P/N

15 Applicator EP 48 V 9 Adjusting Sensor gage A. Parallelism and Application Thickness NOTE: A sensor gauge for adjusting the application thickness is contained in the Ship with kit and can be attached to the applicator. To achieve even application, the applicator must be adjusted such that the application slot is parallel to the book spine. A. Parallelism: 1. Release the locking screw (1). 2. Release locknuts on setting screws Radial position (2). 3. Turn setting screws Radial position to align the applicator parallel to the book spine. 4. Tighten locknuts. 5. Tighten locking screw. B. 0,4 ±0.1 mm B. Adjusting application thickness (0.4 ± 0,1 mm): Applicator P/N : By adjusting the height on the separate bracket All others: By adjusting the height of the trolley. NOTE: The application thickness on a book spine can be measured with the included measuring magnifier. Only with applicator P/N : A rod (3) can trigger a binder switch for a certain application width.

16 10 Applicator EP 48 V Electrical Connection ATTENTION: Observe voltage values found on the ID plate of the applicator and solenoid valves. ATTENTION: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Laying Cable ATTENTION: Ensure that cables do not touch rotating and/or hot components. Do not pinch cables and check regularly for damage. Replace damaged cables immediately! Heating Zones Connect the plugs (1, 2) to the melter electrical cabinet or to an external electrical cabinet. NOTE: Normally the Filter (2) connection is attached to the receptacle on the heated hose and a separate cable is used for the Head (1) connection. 2. Use safety clips - when available - to secure the plug connection. Solenoid valves Connect the solenoid valves to a pattern controller (e.g. LA 404 2). Also refer to page 5, Illustration (Examples). NOTE: Connecting lines can be part of a special cable harness. Information on New Constant Pressure Controller CPR This pressure controller is designed especially for use in the applicator EP 48 V and replaces the constant pressure controller LA 330 II. Only replace the complete unit! Order the service kit P/N for replacement.

17 Applicator EP 48 V 11 Pneumatic Connection The applicator may only be connected to pressure-controlled and conditioned compressed air. Connecting Control Air Use dry, regulated, nonlubricated compressed air. NOTE: Pneumatic lines can be part of a special cable harness. Also refer to page 5, Illustration (Examples). Control Modules 1. Use the Y-plug (2) and a reducer (3) to link the pneumatic connections (1) to the customer's air conditioning unit. 2. Set air pressure to 6 bar / 0.6 MPa / 87 psi Note: The Y plug (2), the reducer (3) and the compressed air hose (4) are contained in the Ship with kit. Constant Pressure Controller ATTENTION: The maximum control pressure permitted is a factor of the transmission ratio and the maximum inlet pressure of the subsequent system components. Refer to Technical Data. 1. Applicators with constant pressure controller: a. Connect customer's air conditioning unit to the air connection Constant pressure controller (1) via the customer's compressed air controller or proportional valve. b. Adjust control air pressure for constant pressure controller as required (Refer to Operation, Applying Hot Melt Adhesive). 2 1 NOTE: The constant pressure controller has a transmission ratio of 10:1 (material pressure / control pressure). The outlet adhesive pressure is indicated on the pressure gauge (2).

18 12 Applicator EP 48 V Connecting Heated Hose ATTENTION: 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. Connecting If cold material can be found in the hose connection, these components (1, 2) must be heated until the material softens (approx. 80 C, 176 F). 1. First connect the hose (3) electrically to the unit. 2. Heat the unit and hose to approx. 80 C (176 F). 3. Screw on heated hose. Disconnecting ATTENTION: System and material pressurized. Relieve system pressure before disconnecting heated hoses. Failure to observe can result in serious burns. ATTENTION: Hot! Risk of burns. Wear goggles and heat-protective gloves. Refer to page 19, Relieving Pressure.

19 Applicator EP 48 V 13 Observe When Starting up the System NOTE: Depending on the system, the pressure controller and the connected components may be controlled automatically. Thus it is essential to refer to the technical documentation of the system components! For initial startup it is important to remember that the hydraulic connections and the pressure controller must first fill with material before controlling can occur. Setting Outlet Pressure (CPR) The outlet pressure is set by applying pneumatic control pressure. The outlet pressure reacts proportionally, but it is higher due to the transmission ratio. NOTE: For correct control response, the material pressure at the inlet must be at least 0.5 MPa (5 bar) higher than the outlet pressure. ATTENTION: The maximum control pressure permitted is a factor of the transmission ratio and the maximum inlet pressure of the subsequent system components. Refer to Technical Data. CAUTION: Risk of damage! To prevent hardened material from damaging seals, control pressure may not be applied in heated systems until the material has reached the setpoint temperature. Triggering with Proportional Valve Application of control pressure through an electro pneumatic proportional valve enables the outlet pressure to be controlled by an electrical signal. This is helpful in line speed-controlled application systems to adapt the adhesive quantity emitted to the web speed of the parent machine. Both the proportional valve for run-up in the Dura series and the proportional valve in the Versa series provide maximum air pressure of 4 bar. Trigger the proportional valve with at least 10 to 12 % of the maximum air pressure of 4 bar (= 100 %). The proportional valve is not triggered until the melter is ready for operation. With older melters (only Dura), the kit may need to be installed.

20 14 Applicator EP 48 V Bleeding Example: replacing filter cartridge. After replacing the filter cartridge, bleed the applicator so trapped air can escape. Bleed before beginning production. Refer to the section Maintenance/Bleeding in this manual. Calibrating Application Width Display ATTENTION: Hot! Risk of burns. Wear heat-protective gloves Heat applicator. 2. Use the handwheel Application width (3) to close the application slot until the left and right guide plates (1 and 2) touch one another. 3. Release the setscrew (4). 4. Turn the set collar (5) until the value appears in the display Application width (6). 5. Tighten the setscrew again

21 Applicator EP 48 V 15 Motorizing Application Width Adjustment Observe the following when mounting a motor drive in place of the handwheel for adjusting the application width: Avoid radial load to the spindle Use the coupling: Using a coupling that can be separated (e.g. a simple claw coupling) between the motor drive and spindle makes disassembly for maintenance purposes easier (Refer to page 23, Lubricating Plan). Comply with these values: Applicator Minimum torque [Nm] required Recommended maximum speed * [min -1 ] NOTE: * The recommended maximum speed is 1 mm/sec for all applicators. Higher speeds increase wear to seals and bearing surfaces. Since spindles of different pitches have to be used, different speeds result.

22 16 Applicator EP 48 V Operation ATTENTION: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Important When Using Polyurethane Application Materials (PUR) Triggering Solenoid Valves Setting Temperature Maximum Operating Temperature It is imperative that the following guidelines are complied with 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 20, Processing Materials! Any other grease may cause the PUR material to cross link. CAUTION: Trigger the solenoid valves only when the applicator is heated to operating temperature! Seals in the application control module and the retrosuction control module can become damaged if the material is too cold. 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 adhesive feeding unit or in a separate electrical cabinet. Refer to ID plate, Oper.temp.max NOTE: When setting the temperature, the temperature prescribed by the hot melt adhesive manufacturer is decisive. The maximum operating temperature for the product described here and the heated system components may not be exceeded. Nordson will grant no warranty and assume no liability for damage resulting from incorrect temperature settings.

23 Applicator EP 48 V 17 Applying Hot Melt Adhesive Factors that have a significant influence on application quality: Viscosity of the adhesive (The heat effect and the duration thereof influence the viscosity) Set application width (Medium application widths have proven to require a lower adhesive pressure than small or large application widths) Book spine condition. Setting Application Width CAUTION: The application width may be adjusted only when the application control module is closed and the applicator is heated to operating temperature Set the application width to the width of the book spine mm: 2. Re adjust application width during operation if required. - Setting Application Thickness Refer to page 9, Adjusting. Daily Shutdown 1 To prevent the PUR material to be processed from hardening, open surfaces must be coated with grease. CAUTION: Use only special high temperature grease. Refer to page 20, Processing Materials. Any other grease may cause the PUR material to cross link. 1. If necessary, remove adhesive from nozzle with wooden or plastic spatula, or wipe off with a cloth. 2. Set the application width to approx. 10 mm. 3. Generously cover the application slot with grease. NOTE: For extended standstill: 1. Detach the guide plates 2. Set minimum application width. 3. Generously cover the application slot with grease.

24 18 Applicator EP 48 V Settings Record Production information Adhesive Cleaning agent Temperatures Applicator Filter block Manufacturer Max. processing temperature Viscosity Manufacturer Flash point Setpoint Undertemperature Overtemperature Setpoint Undertemperature Overtemperature Notes Form filled out by: Name Date

25 Applicator EP 48 V 19 Maintenance ATTENTION: 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 service life of the unit. It should never be neglected. Relieving Pressure ATTENTION: System and adhesive pressurized. Relieve system of pressure before disconnecting heated hoses, applicators or e.g. application modules. Failure to observe can result in serious burns. ATTENTION: Hot! Risk of burns. Wear goggles and heat-protective gloves. LA330 II 1 1. Set the motor speed of the melter to 0 rpm; switch off motor(s). 2. Reduce control air pressure for constant pressure controller (if included) to 0 bar. 3. Open the air relief valve Filter (1) by turning with a screwdriver. 4. Close air relief valve Filter again.

26 20 Applicator EP 48 V CPR The pressure controller can be depressurized in two ways: open 1 clos Depressurizing via Air Relief Valve 1. Switch off material supply motor(s) (bulk melter, melter). 2. Reduce the control air of the pressure controller to 0 bar. 3. Hang the bleeding reservoir next to the air relief valve, or use the customer's drain channel. 4. Verify that the hole in the air relief valve is pointing down. 5. Slowly open the air relief valve until material escapes. 6. Close the air relief valve again as soon as no more material flows out. 7. Properly dispose of material according to local regulations. Depressurizing via Applicator 1. Switch off material supply motor(s) (bulk melter, melter). 2. Position bleeding reservoir (1) and clamp in place lightly by adjusting application width. Refer to applicator manual. 3. Reduce the control air of the pressure controller to 0 bar. 4. Electrically or manually trigger the solenoid valve Application control module until no more material flows out. 5. Properly dispose of material according to local regulations. Processing Materials High temperature grease Tube 250 g Cartridge 400 g P/N P/N Caution: Do not mix this lubricant with other lubricants! If necessary, first clean grease off of parts.

27 Applicator EP 48 V 21 Maintenance Table 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 Entire application system Purge with cleaning agent When changing adhesive, if the adhesives used cannot be mixed Before prolonged production interruptions, if PUR adhesive is processed Page 22 Observe adhesive manufacturer's instructions Entire applicator Visual inspection Daily Page 22 External cleaning Daily Page 22 Application control module and retrosuction control module Check performance When bleeding - Replace When malfunction occurs Page 35 Movable parts, seals Lubricate When reassembling Weekly, when the application width is changed frequently Page 23 Sealing cord Replace When adjustable mouthpiece leaks Page 37 Filter cartridge Constant pressure controller Clean or replace filter screen if necessary Visually inspect for leakage Function check to detect poor coating Approx. every 100 hours of operation Page 30 Daily Page 25 Send in leaking/defective pressure controller to Nordson to be replaced Page 25 Constant pressure controller LA330 II Disassemble and clean Depending on production conditions, approx. every six months Page 28

28 22 Applicator EP 48 V Visual Inspection for External Damage ATTENTION: 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. External Cleaning External cleaning prevents pollution created by production from causing the unit to malfunction. CAUTION: Use only a cleaning agent recommended by the adhesive manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. CAUTION: Do not damage or remove warning labels. Damaged or removed warning labels must be replaced by new ones. ATTENTION: Hot! Risk of burns. Wear heat-protective gloves. Remove adhesive residue only 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. 1. Remove adhesive residue from the nozzle promptly with a soft cloth, before it chars. 2. Remove severe and hardened residue with a wooden or plastic spatula if necessary. 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. 1. Empty the melter and fill with cleaning agent. 2. Continue as described under Bleeding. Refer to page 24, Bleeding. Feed cleaning agent until cleaning agent comes out free of adhesive residue. 3. Properly dispose of the cleaning agent according to local regulations. NOTE: Before starting production again, flush out cleaning agent residue using the new adhesive.

29 Applicator EP 48 V 23 Lubricating Plan Fig. 2 1 Drip tray 2 Left guide plate 3 Seal 4 Right guide plate 5 Seal 6 Clamp bar 7 Mouthpiece CAUTION: Use only special high-temperature grease! Any other grease may cause the PUR material to cross link. Refer to page 20, Processing Materials. Pos. Place to lubricate Interval 1 Contact surface between drip tray and body When reassembling 4 Sliding surface between mobile guide plate and body When reassembling 3, 5 Complete seal Weekly, when the application width is changed frequently 6, 7 Contact surface between mouthpiece and clamp bar Refer to page 37, Replacing 6 Mouthpiece bearing surface Sealing Cord - Screw, spindle threads When reassembling

30 24 Applicator EP 48 V Bleeding The applicator must be bled if air or gas penetrates the system. The sections Filter and Application slot must be relieved of air one after the other: ATTENTION: Hot! Risk of burns. Wear goggles and heat-protective gloves. 1. Heat up heated system components. 2. Completely close the application slot. 3. Switch on the melter motor(s) Bleeding filter section: a. Open the air relief valve Filter (1) by turning with a screwdriver until material flows out free of bubbles. b. Close air relief valve Filter again Bleeding application slot section a. Position bleeding reservoir (1) and clamp in place lightly by adjusting application width. b. Pressurize the constant pressure controller with control pressure and electrically or manually trigger the solenoid valve Application control module until material flows out free of bubbles. c. Remove the bleeding reservoir. 6. If necessary, remove adhesive from nozzle with wooden or plastic spatula, or wipe off with a cloth. 7. Properly dispose of adhesive according to local regulations.

31 Applicator EP 48 V 25 Visual Inspection If adhesive escapes between the top and bottom parts (arrow), the interior seals are worn. Replacing Constant Pressure Controller CPR The replacement kit contains O rings and seals for the control modules (Fig. 3) and the applicator (Fig. 4). 1 (206090) 3 (250257) 2 (250254) Fig. 3 1 O-RING 17x1.5 Viton 70 shore A black 2 O-RING 12x2.5 VITON 70 shore A black 3 O-RING 16x2 Viton 80 shore A black Continued...

32 26 Applicator EP 48 V Fig. 4 1 O ring 60 x 3 Viton 2 Seal EP48-V LH 3 Seal EP48-V RH 4 O Ring 16x2.5 Viton

33 Applicator EP 48 V Refer to Relieving Adhesive Pressure. 2. Disconnect the applicator from the voltage supply (pull the plug). 3. Detach the heated hose Screw on the drip tray. 5. Remove the filter block electrical equipment cover (1) and release the four screws that secure the filter block and the adapter plate* (2). *There is an adapter plate for DuraPail/Drum systems in the kit , and for VersaPail/Drum systems in the kit Detach the old pressure controller (4). Nordson recommends thorough cleaning, particularly of the adhesive channels. Remove the modules for cleaning. 7. Clean the adhesive channels. If leakage is detected on the modules, replace the O-rings (Fig. 3). Follow the instructions Repair / Replacing Control Module in the applicator manual. 8. Replace the seals (1, 2 and 3, Fig. 4). Follow the instructions Repair, Replacing Sealing Cord in the applicator manual. Clean the adhesive channels. Continued...

34 28 Applicator EP 48 V Delivery of the new pressure controller includes, among other parts, the O-rings* (3). Always replace them. 9. Clean the O ring grooves. 10. Apply high temperature grease to the O-rings and ensure that they are positioned properly in the groove. 11. When putting the electrical equipment cover back into place, verify that the PE line is connected and no lines are pinched. ONLY Constant Pressure Controller LA330 II Cleaning Clean format piston, socket and holes through which material passes approx. every six months, depending on production conditions. This removes material residue that has hardened and could hinder motion of the format piston or cause blockage. ATTENTION: Risk of explosion! Never use solvents or cleaning agents containing halogenated hydrocarbons! Refer to the material safety data sheet of the material to be used! Use only a cleaning agents recommended by the hot melt material manufacturer. CAUTION: Do not use hard or metallic tools to clean. Do not use wire brushes! This could irreparably damage the release coating. Use only soft aids (wooden or PTFE spatula or soft brush). Disassembling Constant Pressure Controller CAUTION: Before removing the format piston, verify that the assembly tool (P/N ) is at hand. It is not included in the scope of the applicator delivery and must be ordered separately. NOTE: Refer to separate document Parts List for spare parts kits Relieve system pressure. Refer to page 19, Relieving Pressure. 2. Detach pneumatic part (1) and adapter plate (2). Continued...

35 Applicator EP 48 V Extract the format piston. To extract the format piston, screw an M4 screw into its face. a. Check format piston and guide ring (8); replace if necessary b. Always replace the sealing rings when the format piston has been removed. Observe the following (Refer to Fig. 5): Always use the assembly tool (9, P/N ) to put the sealing ring (6) on the top section (3) into place, ensuring that it is positioned correctly. Guide the bottom section (4) with the seal (5) in from underneath, taking care to place is properly. Guide in the top section from above, then screw together the top and bottom sections. Otherwise the lower seal (5) will be damaged Lubricate seals and guide ring with special temperature resistant grease (Refer to page 20, Processing Materials), completely filling the groove (7) Fig Check the socket bearing surface (10) and replace the socket if necessary. Observe the following: Always replace the O rings when the socket has been removed. Lubricate O rings special temperature resistant grease. Position socket correctly when inserting: Notch towards the cylinder pin (11, in the constant pressure controller). 11

36 30 Applicator EP 48 V Filter Cartridge ATTENTION: Hot! Risk of burns. Wear appropriate protective clothing/equipment. ATTENTION: System and material pressurized. Relieve system pressure. Failure to observe can result in serious burns. Removing Filter Cartridge NOTE: Remove the filter cartridge only when the applicator is hot. CAUTION: As soon as the thread is disengaged, cease turning. Otherwise part of the filter cartridge may remain in the bore. Replacing Filter Screen Refer to separate document Parts List. Installing Filter Cartridge NOTE: Install the filter cartridge only when the applicator is hot. 1. Apply high temperature grease to all threads and O rings. Refer to page 20, Processing Materials. 2. Slide in the filter cartridge and tighten somewhat (approx. 1 Nm / 8.85 lbin). 3. Feed material by allowing the pump to run until the material comes out of the applicator free of bubbles. 4. Properly dispose of material according to local regulations.

37 Applicator EP 48 V 31 Maintenance Record Unit part Activity Date Name Date Name Complete applicator Lubricate weekly Filter cartridge Clean or replace filter screen if necessary ONLY constant pressure controller LA330 II Disassemble and clean Constant pressure controller CPR Visual inspection Replace

38 32 Applicator EP 48 V Troubleshooting ATTENTION: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. ATTENTION: 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. Troubleshooting Table Optimal material application is only possible when all system components work together. Thus other system components should be examined during troubleshooting when the material application quality deteriorates. The troubleshooting table serves as an aid to qualified personnel. It cannot however replace targeted troubleshooting using e.g the wiring diagram and measuring instruments. It also does not include all possible problems, only those which most typically occur. Problem Possible cause Corrective action Refer to Applicator or parts thereof do not get hot Temperature on corresponding temperature controller set incorrectly or not at all Adjust temperature Page 16 Plug has no contact Secure plug - Fuses in melter or electrical cabinet defective Disconnect unit from line voltage, check fuses and replace if necessary Melter manual, wiring diagram Heater cartridge(s) defective Have heater cartridge(s) checked by qualified personnel; replace if necessary - Thermostat defective Have thermostats checked by qualified personnel; replace if necessary - Adjustable mouthpiece leaks Cross linked adhesive or damaged sealing cord around sliding surface between mouthpiece and body Clean section, replace sealing cord Page 37 Lubricate sliding surfaces and seals Page 23 Continued on next page

39 Applicator EP 48 V 33 Problem Possible cause Corrective action Refer to No hot melt adhesive comes out of application slot Applicator has not yet reached operating temperature Wait until temperature has been reached, check temperature setting if necessary Page 16 Not enough adhesive in melter Fill Manual for melter Control air not connected Connect Page 11 Melter pump is not working Check; replace if necessary Manual for melter Application slot blocked External cleaning Page 22 Nozzle stem of application control module stuck Format piston in constant pressure controller is blocked If the nozzle stem does not move when triggered, the application control module must be replaced Constant pressure controller LA330 II maintenance Replace constant pressure controller CPR Page 35 Page 28 Page 25 Adhesive application is not exact Application slot partially clogged External cleaning Page 22 Nozzle damaged Replace Parts List Distance between applicator and book spine not even Adjust applicator Page 9 Application quantity and book spine processing speed not attuned to one another Attune process variables to one another by trial and error - Hot melt adhesive unsuitable Consult adhesive manufacturer - Air within system Bleed Page 24 Control air pressure fluctuates on constant pressure controller Format piston in constant pressure controller is blocked Check compressed air controller and proportional valve Constant pressure controller LA330 II maintenance Replace constant pressure controller CPR - Page 28 Page 25

40 34 Applicator EP 48 V Constant Pressure Controller CPR Problem Possible cause Corrective action Impaired control characteristics Hardened material residue hinders format piston movement O ring in pneumatic section is worn Control pressure hose obstructed (e.g. kink, leak) Insufficient inlet material pressure Replace pressure controller (page 25) Check control pressure hose Increase inlet material pressure Leakage Seals, O rings worn Replace pressure controller (page 25) Material leakage at inlet or outlet Damaged hydraulic connections Replace O rings

41 Applicator EP 48 V 35 Repair ATTENTION: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. CAUTION: Before beginning any repair work, ensure that the applicator has been relieved of pressure. Refer to page 19, Relieving Pressure. Parts Refer to separate document Parts List Comply with the lubricating plan when installing spare parts. Refer to page 23, Lubricating Plan. Replacing Control Module ATTENTION: Hot! Risk of burns. Wear heat-protective gloves. CAUTION: To prevent damage to seals and nozzle stem, replace control modules only when the applicator is heated. CAUTION: The application control module is attached to the body with an adapter plate (1). Do not detach the adapter plate. Otherwise the control module may not be positioned correctly Electrically heat cold applicator until adhesive is liquid. 2. Relieve pressure. 3. Detach the compressed air connections. 4. Release fixing screws and replace control module. CAUTION: Ensure that the old O-ring is removed and does not remain in the applicator body. 5. Screw new control module into place. 6. Reconnect compressed air. O ring

42 36 Applicator EP 48 V Heater Cartridges, Temperature Sensor and Thermostat These parts are located behind the electrical equipment covers on the filter unit and the body. ATTENTION: Risk of electrical shock. Before removing the electrical equipment covers, ensure that the applicator is deenergized. Failure to observe may result in personal injury, death, or equipment damage. When putting an electrical equipment cover back into place, verify that the PE line is fastened to to the connection (3) Fig. 6 1 Electrical equipment cover Body 2 Electrical equipment cover Filter Unit 3 Connection PE line Current Flow Diagram Applicator Filter Unit Fig. 7 Current flow diagram 1 Temperature sensor 2 Heater cartridges Note: The temperature sensor is part of the cable harness

43 Applicator EP 48 V 37 Replacing Sealing Cord ATTENTION: Hot! Risk of burns. Wear heat protective clothing, safety goggles, and heat protective gloves. NOTE: Spare parts kit required: P/N Also refer to separate document Parts List. 1. Electrically heat cold applicator until adhesive is liquid. 2. Set maximum application width. 3. Remove the left and right guide plates (1 and 2) as well as the seals (6). 4. Release both screws of spindle guide (3) approx. 2 mm. 5. Remove the screws (4) and detach the clamp bar (5). 6. Pry mouthpiece (7) away from body somewhat and extract out the front along with the spindle and the handwheel Continued...

44 38 Applicator EP 48 V 7. Remove old sealing cord from the groove (8): 8 8. Clean groove and sliding surfaces on the body and mouthpiece: CAUTION: Use only a cleaning agent recommended by the adhesive manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. Remove adhesive residue with cleaning agent. Heat with a hot air fan if necessary Remove severe and hardened residue with a wooden or plastic spatula if necessary. 9. Cut open the O ring (contained in the parts kit) and insert it into the groove (8) as a sealing cord. 10. Re-assemble the parts. Observe particularly: a. Lubricating plan, refer to page 23, Lubricating Plan. b. Seat of both pulley keys c. Clamp bar fastening: Correct order of spring washers Insert the screws with spring washer package all the way. 10.b. 10.c.

45 Applicator EP 48 V 39 Technical Data Operating Data Maximum operating temperature Overtemperature shutdown by 200 C 230 C 390 F 446 F Delivered until June 2014 thermostat (P/N ) Maximum operating temperature Overtemperature shutdown by 170 C 180 C 340 F 356 F Delivered beginning July 2014 thermostat (P/N ) Maximum operating air pressure 6 bar 0,6 MPa 87 psi Maximum operating pressure (adhesive) 40 bar 4 MPa 580 psi Maximum adhesive viscosity that can be processed Application width Max. deviation of application quantities Heatup time mpas 30 Ms/m cp 1 to 60 mm < 5 %, depending on adhesive 30 min Data on New Pressure Controller CPR (Replaces Pressure Controller LA330-II) Warning: Select inlet pressure and control pressure such that the inlet pressure permitted for subsequent system components is not exceeded! Max. inlet pressure 4,5 MPa 45 bar 655 psi Min. inlet pressure Desired outlet pressure + 5 bar Permitted control pressure (limited to max. 4 bar by triggering of melter) 0 to 0.4 MPa 0 to 4 bar 0 to 58 psi Transmission ratio control pressure : 1:10 outlet pressure Permitted operating temperature 0 to 180 C 32 to 356 F Weight Approx. 2.2 kg

46 40 Applicator EP 48 V Electrical Data Operating voltage (heater) 230 V AC Power consumption (heater) Body: 960 W Filter: 600 W Operating voltage (solenoid valves) 24 V DC Power consumption (solenoid valves) Application control module: 2.5 W Retrosuction control module: 1.8 W General Data Weight Approx. 45 kg Noise emission < 70 db(a) Degree of protection IP 44

47 Applicator EP 48 V 41 Dimensions NOTE: Example: Applicator P/N The dimensions of other applicators may differ slightly. M8-15 deep mm approx. 174 approx. 206 approx approx

48 42 Applicator EP 48 V

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