Bravura Adhesive Melters

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1 Bravura Adhesive Melters Customer Product Manual Part D 03 Issued 2/0 NORDSON CORPORATION DULUTH, GEORGIA USA

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 475 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, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, ColorMax, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, HDLV, Heli-flow, Helix, Horizon, Hot Shot, icontrol, iflow, Isocoil, Isocore, Iso-Flo, itrax, Kinetix, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, Printplus, Prism, ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, Ultra, Ultrasaver, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, Blue Series, Check Mate, Classicblue, Color-on-Demand, Controlled Fiberization, Control Weave, CPX, CScan, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail, Easy Clean, EasyOn, Eclipse, E-Nordson, Equi=Bead, ESP, FillEasy, Fill Sentry, FluxPlus, G Net, G Site,, ion, Iso-Flex, itrend, Lacquer Cure, Lean Cell, Maxima, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, Multifil, Myritex, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI, Powder Pilot, Powercure, Precise Coat, Primarc, Process Sentry, Pulse Spray, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, Trade Plus, ThruWave, Ultrasmart, Universal, ValveMate, VersaDrum, VersaPail, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners rights. All rights reserved

3 Table of Contents i Table of Contents Safety Safety Alert Symbols Responsibilities of the Equipment Owner Safety Information Instructions, Requirements, and Standards User Qualifications Applicable Industry Safety Practices Intended Use of the Equipment Instructions and Safety Messages Installation Practices Operating Practices Maintenance and Repair Practices Equipment Safety Information Equipment Shutdown Relieving System Hydraulic Pressure De-energizing the System Disabling the Guns General Safety Warnings and Cautions Other Safety Precautions First Aid Safety Labels and Tags Description Intended Use Overview Functional Description Startup Mode Operating Mode Standby Mode Major Components Tank Pump Manifold Manifold Block and Hose Connectors Manifold Filter Drain Valve Pressure Relief Valve Air Pressure Regulator Operator Panel

4 ii Table of Contents Description (contd) Control System Operator Panel Fault and Ready Lights Displays and Keys Selector Display and Up Key Multipurpose Display and Up/Down Keys Actual Temperature Display Enter Key Tank, Hose, and Gun Lights System Controls Monitor/Scan Key and Light Standby Key and LIght Clock Key and Light Celsius/Fahrenheit Key Overtemperature Key Ready Delay Key POWER Switch Installation Introduction Unpacking Inspection Installation Requirements Location Requirements Wiring Requirements Hose/Gun Power Requirements Mechanical Installation Mount the Melter Install the Tank Strainer Connect the Air Supply Install the Guns Air-Operated Gun Electric Gun Hand-Operated Gun Install the Hoses Electrical Installation Connect Gun and Hose Cordsets Open the Electrical Enclosure Connect a Triggering Device for the Pump Solenoid Valve (0: Pump) Connect Output Contacts (Optional) Connect the Electrical Service Connect a Power Cable Connect a Voltage Plug Connect a Contactor Harness (Bravura 4 5/6 Hose/Gun Melters) Close the Electrical Enclosure

5 Table of Contents iii Installation (contd) System Setup Operator Panel Components Programmable Settings Powering On in the Administrator Mode Setting On/Off and Enter Standby/Exit Standby Times Setting the Clock Selecting Celsius or Fahrenheit Degrees Setting the Ready Delay Setting Temperature Setpoints Setting the Overtemperature Setpoint Setting the Standby Temperature Setpoint System Preparation Fill the Tank with Adhesive Flush the System Record of System Settings System Settings Individual Zone Temperature Settings Air Pressure Settings Operation Introduction Turning the Clock On and Off Automatically Starting the Unit Manually Starting the Unit Checking the Adhesive Level and Filling the Tank Monitoring the Zone Temperatures Using the Standby Mode Automatically Shutting Down the Unit Manually Shutting Down the Unit Procedure for Changing Adhesives Maintenance Introduction Maintenance Schedule Maintenance Procedures Relieving System Pressure Replacing Hose Connector or Plug O-Rings Flushing a Standard Manifold Filter Cleaning a Standard Manifold Filter Flushing the System To Prepare for Flushing 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 To Restore the Unit to Normal Operation

6 iv Table of Contents Control Introduction Overview of the Control System Control Assembly Unit-Specific Boards Troubleshooting Tables Electrical Safety During Troubleshooting Opening and Closing the Electrical Enclosure Tank, Hose, or Gun Zone Not Heating Settings Changed or Lost Unit Not Powering On Control System Indicating a Fault Overtemperature (OT) Fault RTD Fault Fault-Code Fault (F F7) Troubleshooting Procedures Checking the Power Switch Checking the Voltage Plug and Contactor Board Harness Checking a Surge Guard Checking the Transformer Checking a Heater or Heater Circuit Checking a Thermostat Checking an RTD or RTD Circuit Repair Procedures Replacing a Surge Guard 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 Control Assembly Control Assembly Removal Control Assembly Installation Replacing a Unit-Specific Board Replacing an RTD or a Thermostat RTD or Thermostat Removal RTD or Thermostat Installation

7 Table of Contents v Hydraulics Introduction Overview of the Hydraulic System Troubleshooting Table Troubleshooting Procedures Checking for Manifold Blockage Checking the Internal Solenoid Valve (Dual-Acting Pump) Checking the Internal Solenoid Valve (Single-Acting Pump) Checking the Triggering Solenoid Valve (Single-Acting Pump) Testing Solenoid Valve Voltage Checking the Pump Air Section (Dual-Acting Pump) Checking the Actuator (Dual-Acting Pump) Checking the Pump Siphon Ball Seat (Dual-Acting Pump) Checking the Pump Siphon Ball Seat (Single-Acting Pump) Dual-Acting Pump Repair Procedures Servicing the Pump Preparation for Pump Removal Pump Removal Actuator Removal Pump Air Section Disassembly Pump Hydraulic Section Disassembly Pump Component Cleaning Pump Hydraulic Section Assembly Pump Air Section Assembly Actuator Installation Pump Installation System Restoration Repositioning or Replacing the Shifter Fork Dual-Acting Pump Actuator Repair Procedures Replacing the Actuator Actuator Removal Actuator Installation Cleaning or Replacing the Magnet Assembly Magnet Assembly Removal Magnet Assembly Installation Cleaning or Replacing the Air Valve Air Valve Removal Air Valve Installation Replacing the Bumper Assembly Single-Acting Pump Repair Procedures Preparing for Pump Removal Removing the Pump Replacing the Crossover Tube, O-Ring, or Backup Ring Replacing the Check Valve Ball and Seat Replacing the Siphon Ball Cage and Seat Components Installing the Pump Restoring the System to Normal Operation

8 vi Table of Contents Hydraulics (contd) Pump Solenoid Valve Repair Procedures Replacing the Solenoid Valve (Dual-Acting Pump) Solenoid Valve Removal Solenoid Valve Installation Replacing the Internal Solenoid Valve (Single-Acting Pump) Solenoid Valve Removal Solenoid Valve Installation Replacing the Triggering Solenoid Valve (Single-Acting Pump) Solenoid Valve Removal Solenoid Valve Installation Manifold Repair Procedures Replacing the Pressure Relief Valve Replacing the Drain Valve Replacing the Manifold Tank 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 Unit to Normal Operation Parts Introduction Using the Illustrated Parts Lists Melter Assembly Part Numbers Tank and Frame Assembly Parts Lists Bravura 4 Tank Parts Bravura 4 Frame Parts Bravura 6 Tank Parts Bravura 6 Frame Parts Bravura 9 Tank Parts Bravura 9 Frame Parts Bravura 4 Tank Parts Bravura 4 Frame Parts Ground Stud Parts Manifold Assembly Parts Lists Manifold Parts Manifold Filter Parts Pump Assembly Parts Lists : Dual-Acting Pump UpTime Pack Parts : Dual-Acting Pump Parts : Dual-Acting Pump UpTime Pack Parts : Dual-Acting Pump Parts Actuator Parts (Dual-Acting Pump) : Single-Acting Pump Parts

9 Table of Contents vii Parts (contd) Solenoid Valve Assembly Parts Lists Internal Solenoid Valve Parts (4: Dual-Acting Pump) Internal Solenoid Valve Parts (2: Dual-Acting Pump) Triggering and Internal Solenoid Valve Parts (0: Single-Acting Pump) Air Pressure Regulator Parts Electrical Assembly Parts Lists Control Assembly Parts Bravura 4 5/6 Hose/Gun Board Parts Bravura 4 Tank Board Parts Recommended Spare Parts Major Assemblies Standard Circuit Boards and Fuses Bravura 4 5/6 Hose/Gun and Bravura VAC Boards and Fuses Consumables and Wear Items Software Upgrade Kit Test Plugs Supplies and Tools Technical Data General Hot Melt Material Processing Instructions Storage Preparation for Material/Application Coating Processing Temperature Danger of Burns Mixing Hot Melt Materials Disposal of Hot Melt Material Melter Configurations Melter Specifications Bravura 4 Melter Bravura 6 Melter Bravura 9 Melter Bravura 4 Melter Hose Specifications Melter Dimensions Bravura 4 Melter Bravura 6 Melter Bravura 9 Melter Bravura 4 Melter Torque Specifications Mechanical Electrical Procedure for Calculating Hose/Gun Capacity Calculating Hose/Gun Capacity Power Data Tables Wiring Diagrams

10 viii Table of Contents

11 Safety - Section Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as use ) of the product described in this document (hereafter referred to as equipment ). Additional safety information, in the form of task-specific safety alert messages, appears as appropriate throughout this document. WARNING! Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property. Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all safety information that follows the signal word. WARNING! Indicates a potentially hazardous situation that, if not avoided, can result in serious personal injury, including death. CAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION: (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property. Issued 4-02 AEN 0 [XX SAFE] 0

12 -2 Safety Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment are met, and for qualifying all potential users. Safety Information Research and evaluate safety information from all applicable sources, including the owner-specific safety policy, best industry practices, governing regulations, material manufacturer s product information, and this document. Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information. Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices. If applicable, receive approval from your facility s engineering or safety department, or other similar function within your organization, before installing or operating the equipment for the first time. Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re-evaluate safety practices and procedures whenever changes are made to the process or equipment. AEN 0 [XX SAFE] 0 Issued 4-02

13 Safety -3 User Qualifications Equipment owners are responsible for ensuring that users: receive safety training appropriate to their job function as directed by governing regulations and best industry practices are familiar with the equipment owner s safety and accident prevention policies and procedures receive, equipment- and task-specific training from another qualified individual NOTE: Nordson can provide equipment-specific installation, operation, and maintenance training. Contact your Nordson representative for information possess industry- and trade-specific skills and a level of experience appropriate to their job function are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in the manner described in this document. The information provided here is not meant to include all possible safety practices, but represents the best safety practices for equipment of similar hazard potential used in similar industries. Intended Use of the Equipment Instructions and Safety Messages Use the equipment only for the purposes described and within the limits specified in this document. Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non-standard auxiliary devices. Read and follow the instructions provided in this document and other referenced documents. Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Issued 4-02 AEN 0 [XX SAFE] 0

14 -4 Safety Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices. Ensure that the equipment is rated for the environment in which it will be used and that the processing characteristics of the material will not create a hazardous environment. Refer to the Material Safety Data Sheet (MSDS) for the material. If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance. Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects. Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources. Properly ground all equipment. Contact your local building code enforcement agency for specific requirements. Ensure that fuses of the correct type and rating are installed in fused equipment. Contact the authority having jurisdiction to determine the requirement for installation permits or inspections. Operating Practices Familiarize yourself with the location and operation of all safety devices and indicators. Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist. Use the personal protective equipment (PPE) specified for each task. Refer to Equipment Safety Information or the material manufacturer s instructions and MSDS for PPE requirements. Do not use equipment that is malfunctioning or shows signs of a potential malfunction. Maintenance and Repair Practices Perform scheduled maintenance activities at the intervals described in this document. Relieve system hydraulic and pneumatic pressure before servicing the equipment. De-energize the equipment and all auxiliary devices before servicing the equipment. Use only new factory-authorized refurbished or replacement parts. Read and comply with the manufacturer s instructions and the MSDS supplied with equipment cleaning compounds. NOTE: MSDSs for cleaning compounds that are sold by Nordson are available at or by calling your Nordson representative. AEN 0 [XX SAFE] 0 Issued 4-02

15 Safety -5 Confirm the correct operation of all safety devices before placing the equipment back into operation. Dispose of waste cleaning compounds and residual process materials according to governing regulations. Refer to the applicable MSDS or contact the authority having jurisdiction for information. Keep equipment safety warning labels clean. Replace worn or damaged labels. Equipment Safety Information Equipment Shutdown This equipment safety information is applicable to the following types of Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices To safely complete many of the procedures described in this document, the equipment must first be shut down. The level of shut down required varies by the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure. The levels of shut down are: Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal. Refer to the melter-specific product manual for instructions on relieving system hydraulic pressure. Issued 4-02 AEN 0 [XX SAFE] 0

16 -6 Safety De-energizing the System Isolate the system (melter, hoses, guns, and optional devices) from all power sources before accessing any unprotected high-voltage wiring or connection point.. Turn off the equipment and all auxiliary devices connected to the equipment (system). 2. To prevent the equipment from being accidentally energized, lock and tag the disconnect switch(es) or circuit breaker(s) that provide input electrical power to the equipment and optional devices. NOTE: Government regulations and industry standards dictate specific requirements for the isolation of hazardous energy sources. Refer to the appropriate regulation or standard. Disabling the Guns All electrical or mechanical devices that provide an activation signal to the guns, gun solenoid valve(s), or the melter pump must be disabled before work can be performed on or around a gun that is connected to a pressurized system.. Turn off or disconnect the gun triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the gun solenoid valve(s). 3. Reduce the air pressure to the gun solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the gun. AEN 0 [XX SAFE] 0 Issued 4-02

17 Safety -7 General Safety Warnings and Cautions Table - contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual. Equipment types are designated in Table - as follows: HM = Hot melt (melters, hoses, guns, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and guns) Equipment Type HM Table - General Safety Warnings and Cautions Warning or Caution WARNING: Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent-based material through a compatible Nordson melter, read and comply with the material s MSDS. Ensure that the material s processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with MSDS requirements can cause personal injury, including death. HM WARNING: Reactive material! Never clean any aluminum component or flush Nordson equipment with halogenated hydrocarbon fluids. Nordson melters and guns contain aluminum components that may react violently with halogenated hydrocarbons. The use of halogenated hydrocarbon compounds in Nordson equipment can cause personal injury, including death. HM, CA WARNING: System pressurized! Relieve system hydraulic pressure before breaking any hydraulic connection or seal. Failure to relieve the system hydraulic pressure can result in the uncontrolled release of hot melt or cold adhesive, causing personal injury. HM WARNING: Molten material! Wear eye or face protection, clothing that protects exposed skin, and heat-protective gloves when servicing equipment that contains molten hot melt. Even when solidified, hot melt can still cause burns. Failure to wear appropriate personal protective equipment can result in personal injury. Continued... Issued 4-02 AEN 0 [XX SAFE] 0

18 -8 Safety General Safety Warnings and Cautions (contd) Equipment Type Table - General Safety Warnings and Cautions (contd) Warning or Caution HM, PC WARNING: Equipment starts automatically! Remote triggering devices are used to control automatic hot melt guns. Before working on or near an operating gun, disable the gun s triggering device and remove the air supply to the gun s solenoid valve(s). Failure to disable the gun s triggering device and remove the supply of air to the solenoid valve(s) can result in personal injury. HM, CA, PC WARNING: Risk of electrocution! Even when switched off and electrically isolated at the disconnect switch or circuit breaker, the equipment may still be connected to energized auxiliary devices. De-energize and electrically isolate all auxiliary devices before servicing the equipment. Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injury, including death. HM. CA, PC WARNING: Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and should not be used with solvent-based adhesives that can create an explosive atmosphere when processed. Refer to the MSDS for the adhesive to determine its processing characteristics and limitations. The use of incompatible solvent-based adhesives or the improper processing of solvent-based adhesives can result in personal injury, including death. HM, CA, PC WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others and can damage the equipment. Continued... AEN 0 [XX SAFE] 0 Issued 4-02

19 Safety -9 Equipment Type HM Table - General Safety Warnings and Cautions (contd) Warning or Caution CAUTION: Hot surfaces! Avoid contact with the hot metal surfaces of guns, hoses, and certain components of the melter. If contact can not be avoided, wear heat-protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. HM CAUTION: Some Nordson melters are specifically designed to process polyurethane reactive (PUR) hot melt. Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipment and cause premature reaction of the hot melt. If you are unsure of the equipment s ability to process PUR, contact your Nordson representative for assistance. HM, CA CAUTION: Before using any cleaning or flushing compound on or in the equipment, read and comply with the manufacturer s instructions and the MSDS supplied with the compound. Some cleaning compounds can react unpredictably with hot melt or cold adhesive, resulting in damage to the equipment. HM CAUTION: Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment. Before using the equipment, confirm that the hot melt is compatible with Type R fluid. Other Safety Precautions Do not use an open flame to heat hot melt system components. Check high pressure hoses daily for signs of excessive wear, damage, or leaks. Never point a dispensing handgun at yourself or others. Suspend dispensing handguns by their proper suspension point. Issued 4-02 AEN 0 [XX SAFE] 0

20 -0 Safety First Aid If molten hot melt comes in contact with your skin:. Do NOT attempt to remove the molten hot melt from your skin. 2. Immediately soak the affected area in clean, cold water until the hot melt a has cooled. 3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the MSDS for the hot melt to the medical personnel providing treatment. Safety Labels and Tags Figure- illustrates the location of the product safety labels and tags affixed to the equipment. Table -2 provides an illustration of the hazard identification symbols that appear on each safety label and tag, the meaning of the symbol, or the exact wording of any safety message. Table -2 Safety Labels and Tags Item Part Description WARNING: Remove pressure before servicing. Serious burns and/or equipment failure may result if adhesive is allowed to splash or if adhesive is overheated. WARNING: Remove pressure before opening filter or drain valve. Failure to follow this instruction may result in serious burns. WARNING: This equipment may be connected to more than one power supply. Disconnect all power supplies before opening enclosure. Failure to follow this instruction may result in death. CAUTION: Hot surfaces. Do not touch. AEN 0 [XX SAFE] 0 Issued 4-02

21 Safety - A C E D B E B A D E C Figure - Safety labels and tags Issued 4-02 AEN 0 [XX SAFE] 0

22 -2 Safety AEN 0 [XX SAFE] 0 Issued 4-02

23 Description 2- Section 2 Description Intended Use Overview Bravura melters may be used only to melt and pump hot melt material. They are not intended for use with polyurethane-reactive hot melt material. Use the melters only as described in this manual. This manual describes how to install, operate, and service a Bravura melter. It also explains how the melter works with other major components of a hot melt system. This section of the manual describes the key parts of the melter and how they work. It includes the following topics: Functional Description Major Components Control System

24 2-2 Description Functional Description The melter is the main component of your hot melt system. The melter melts the adhesive, controls it at your setpoint (operating) temperatures, and pumps it through hoses to the dispensing guns. The dispensing guns apply the adhesive to the surface of your product or package. Figure 2- shows a Bravura melter along with other key components of a hot melt system. The melter has three basic modes of operation: the startup mode the operating mode the standby mode Each mode is briefly described in the following paragraphs. Bravura 4/6/9 Bravura Figure 2- Hot melt system with a Bravura melter

25 Description 2-3 Startup Mode During a sequential startup, when the clock timer or an operator turns the system on, the tank and hoses begin to heat first. After the temperatures of the tank and hoses are all within 9.5 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. You can program the system so the pump starts automatically, either when the Ready light turns on or when the tank reaches the temperature you have specified. Or you can program the system so the pump must be started manually. Operating Mode When you trigger a gun, the pump draws in the melted adhesive and sends it through a manifold, a filter, and a hose to the gun, which then applies the adhesive to the product or package surface. Figure 2-2 shows the components of a typical hot melt system and the path that melted adhesive follows when being pumped through the system. In most systems, an air-operated automatic gun is used to apply the melted adhesive. An electrically driven gun or a handgun (shown in dotted lines in Figure 2-2) may also be used to apply adhesive. 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.

26 2-4 Description Functional Description (contd) ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ 5 6 ÇÇ ÇÇ Figure 2-2 Adhesive flow path of a typical hot melt system (standard filter shown). Air piston 6. Tank 2. Air cylinder 7. Pressure relief valve 3. Pump 8. Manifold 4. Air pressure regulator 9. Manifold filter 5. Hydraulic plunger 0. Drain valve 2. Hose 2. Air-operated gun 3. Handgun and hose

27 Description 2-5 Major Components The major components of the melter are briefly described on the following pages Bravura 4/6/9 Bravura Figure 2-3. Pump 2. Tank Major components of a typical Bravura melter 3. Air pressure regulator 4. Manifold components 5. Operator panel

28 2-6 Description Tank The tank melts the adhesive and holds it until it is pumped to the dispensing guns. With its aluminum construction, cast-in heaters, and integral melting fins, the tank is designed for efficient heat transfer. A strainer in the tank prevents unmelted adhesive from blocking the pump inlet when you fill the tank. It also prevents pieces of cardboard and other small objects from entering the pump. The standard tank is PTFE-coated for easy cleaning. A non-coated tank is available on some units. Refer to Melter Specifications in the Technical Data section for the tank storage capacity and other key information about the tank. 2 4 Figure 2-4. Tank casting 2. Strainer Key parts of the tank 3 3. Melting fins 4. Heater connector

29 Description 2-7 Pump The pump transfers melted adhesive from the tank to the dispensing guns. Your unit may have either a dual-acting or single-acting piston pump. A dual-acting piston pump delivers adhesive on both the upstroke and the downstroke. A single-acting piston pump delivers adhesive on the down stroke and draws in fresh adhesive on the upstroke. The pump has the following main parts: an air section a hydraulic section an actuator (dual-acting pumps) or a triggering solenoid valve (single-acting pumps) Refer to Melter Specifications in the Technical Data section for the pump delivery rate and other key information about the pump Figure 2-5. Air motor 2. Hydraulic section A B Key parts of the dual-acting (A) or single-acting (B) pump 3. Actuator 4. Triggering solenoid valve

30 2-8 Description Manifold The manifold directs the flow of adhesive from the pump to the filter and from the filter to the hoses and guns. The manifold has four main parts: a manifold block with hose connectors a manifold filter a drain valve a pressure relief valve Figure 2-6 Key parts of the manifold (4-port manifold shown). Adhesive inlet 4. Manifold filter 2. Manifold block with hose connectors 5. Pressure relief valve 3. Drain valve Manifold Block and Hose Connectors The manifold block has a 45-degree face for either horizontal or vertical hose routing. A maximum of four hoses can be connected to the manifold. Manifold Filter The manifold filter traps any char or foreign material, keeping it from being pumped to the hoses and guns. The melter is shipped with a 0.5-mm (0.006-in.) filter screen. Other screen sizes are available. Drain Valve The drain valve allows you to drain the tank and manifold or to flush char and debris from the filter screen. Operators can perform the filter flushing procedure without removing the filter from the manifold.

31 Description 2-9 Pressure Relief Valve The pressure relief valve prevents system hydraulic pressure from exceeding 03.4 bar (0342 kpa, 500 psi). At this pressure, the valve opens and returns adhesive to the tank. Air Pressure Regulator The air pressure regulator allows you to adjust the system air pressure, which controls the hydraulic pressure. The regulator assembly has three main parts: a regulator a filter a gauge The gauge indicates the air pressure and the filter removes contaminants from the plant air supply Figure 2-7 Key parts of the air pressure regulator. Regulator 3. Air pressure gauge 2. Filter 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.

32 2-0 Description Control System The control system regulates all temperature settings and controls how the unit functions. Heated zones are controlled individually, giving you more flexibility in setting up your system, and the clock feature allows you to tailor the unit s on/off and enter standby/exit standby times to your operational needs. The control system is designed so that a brownout or power failure will not cause a loss of your programmed settings. Operator Panel The operator panel provides the controls, indicators, and messages needed to operate the system. Multipurpose display (4) Selector display (3) Up key (6) Up/down keys (7) Monitor/Scan key and light (0) Fault light () Ready light (2) Actual temperature display (5) Enter key (8) Tank, hose, and gun lights (9) Standby key and light () Clock key and light (2) Celsius/Fahrenheit key (3) Overtemperature key (4) Ready Delay key (5) POWER switch (6) Figure 2-8 Operator panel components. Fault light 2. Ready light 3. Selector display 4. Multipurpose display 5. Actual temperature display 6. Up key 7. Up/down keys 8. Enter key 9. Tank, hose, and gun lights 0. Monitor/scan key and light. Standby key and light 2. Clock key and light 3. Celsius/Fahrenheit key 4. Overtemperature key 5. Ready Delay key 6. POWER switch

33 Description 2- Fault and Ready Lights The Fault and Ready lights let you know if the system is prepared for operation. The red Fault light indicates different types of fault conditions. Refer to Table 2-. Table 2- System Notification of Fault Conditions Fault Light Status (see Note) Fault light turns on and stays on. Fault light flashes for two minutes, then stays on. Fault light flashes continuously. System Condition A heater zone is overtemperature. A resistance temperature detector (RTD) in any zone is open or shorted. NOTE: When the Fault light turns on and stays on, the system removes heater power for all zones. When the Fault light flashes, heater power stays on. The green Ready light turns on when the following conditions exist: All zones are within +/ 3 C (+/ 5 F) of the setpoint temperatures. The system-ready time delay has elapsed. No faults exist.

34 2-2 Description Displays and Keys The Selector, Multipurpose, and Actual Temperature displays give you detailed information about the status of your system. When you are running the system, they show the status of each heating zone. When you are customizing the system, they show your current system setup. The keys below the displays are used to program the system. 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 programming temperature setpoints and when scanning zones shows a code for entering times for automatic settings when used with Clock The up key, which is located below the Selector display, changes the value of a setting in the Selector display when you are programming the unit. Multipurpose Display and Up/Down 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. The up/down keys, which are located below the Multipurpose display, changes the value of a setting in the Multipurpose display when you are programming the unit. 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. Tank, Hose, and Gun Lights These lights are used in conjunction with the Selector and Multipurpose displays to indicate the current selected heating zone. There are three types of heating zone: tank, hose, and gun.

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