Hot Melt Applicators TrueCoat HP

Transcription

1 Hot Melt Applicators TrueCoat HP Manual - English - Edition 02/14 NORDSON ENGINEERING GMBH LÜNEBURG GERMANY

2 Note This document applies to the entire series. Order number P/N = Order number for Nordson articles Note This is a Nordson corporation publication which is protected by copyright. Copyright No part of this document may be photocopied, reproduced or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice 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, EquiBead, 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 Nordson Corporation

3 Table of contents I Table of contents Nordson International... O 1 Europe... O 1 Distributors in Eastern & Southern Europe... O 1 Outside Europe... O 2 Africa / Middle East... O 2 Asia / Australia / Latin America... O 2 China... O 2 Japan... O 2 North America... O 2 General Instructions Regarding Working with Application Materials Definition of Terms Manufacturer Information Liability Risk of Burns Vapors and Gases Substrate Processing Temperature 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 Applicators General Safety Warnings and Cautions Other Safety Precautions First Aid Nordson Corporation

4 II Table of contents Introduction Intended Use Unintended Use - Examples Residual Risks Note on Manual Definition of Terms Applicator Melter Control Module Description of Components / Functioning TrueCoat HP with Control Modules TrueCoat HP with Throttle Screws Material Flow Material Distribution Control Modules Throttle Screws Heating Slot Nozzle or Nozzle with Rotating Bar Filter Cartridge ID plate Installation Unpacking Transport Storage Disposal Installing Exhausting Material Vapors Electrical Connections Laying Cable Connecting Heater Connecting Solenoid Valves Pneumatic Connections Operation with Nonlubricated Compressed Air Conditioning Compressed Air Connecting Compressed Air Connecting Heated Hose Connecting Disconnecting Relieving Pressure Using Two Open end Wrenches Nordson Corporation

5 Table of contents III Operation Triggering Solenoid Valve Setting Temperatures Enter Standby Setting Control Air Pressure Setting Material Pressure Positioning the Applicator Calculating Material Quantity Sample Calculation Customer-specific Values Correcting Material Quantity and Material Distribution Adjusting needle stroke Setting Material Distribution Evenly with Stem Stroke Adjustment Regulating Material Distribution with the Throttle Screws Optimizing Material Application with Temperature Setpoints. 4 7 Correcting Nozzle Concavity Correcting Nozzle Convexity Setting Rotating Bar Speed Settings Record Settings Record - Spare Copy Maintenance Relieving Pressure Regular Maintenance Visual Inspection for External Damage External Cleaning Inspecting Control Module Changing Type of Material Purging with Cleaning Agent Disassembling and Cleaning Slot Nozzle Disassembling and Cleaning Nozzle with Rotating Bar Replacing Rotating Bar Inserting New Shim Plate Refacing Nozzle Replacing Filter Cartridge Removing Filter Cartridge Installing Filter Cartridge Disassembling and Cleaning Filter Cartridge Maintenance Record Maintenance Record Form Spare Copy Troubleshooting Introduction Troubleshooting Table Repair Replacing Control Module with 4/2 Air Valve Replacing Control Module with 3/2 Air Valve Removing Control Module Installing Control Module Replacing Heater Cartridge or Temperature Sensor Processing Materials Nordson Corporation

6 IV Table of contents Technical Data General Data Air pressure Temperatures Electrical Data Dimensions and Weights Torques Control modules Nozzle Clamps Nordson Corporation

7 Introduction O 1 Nordson International Europe Country Phone Fax Austria Belgium Czech Republic Denmark Hot Melt Finishing Finland France Germany Erkrath Lüneburg Nordson UV EFD Italy Netherlands Norway Hot Melt Poland Portugal Russia Slovak Republic Spain Sweden Switzerland United Kingdom Hot Melt Industrial Coating Systems Distributors in Eastern & Southern Europe DED, Germany Nordson Corporation All rights reserved NI_Q-1112-MX

8 O 2 Introduction Outside Europe For your nearest Nordson office outside Europe, contact the Nordson offices below for detailed information. Contact Nordson Phone Fax Africa / Middle East DED, Germany Asia / Australia / Latin America Pacific South Division, USA China Japan North America China Japan Canada USA Hot Melt Finishing Nordson UV NI_Q-1112-MX 2012Nordson Corporation All rights reserved

9 Introduction 0 3 General Hot Melt Material Processing Instructions (With instructions regarding PUR application materials) Definition of Term Manufacturer Information Application materials are considered to be e.g. thermoplastic hot melt adhesives, adhesives, sealants, liquid adhesives and similar application materials that are also referred to as materials in the following text. NOTE: The materials that may be processed using your Nordson product are described in the manual under Intended and Unintended Use. When in doubt, consult your Nordson representative. Materials may be processed only when the manufacturer's product descriptions and Safety Data Sheets are observed. Among other things, they give information on correct processing of the product, transport, storage and disposal. Information regarding reactivity and potentially hazardous decomposition products, toxic properties, flash points, etc. can also be found there. Liability Risk of Burns Nordson will not be liable for danger or damage resulting from the materials. There is a risk of burns when handling heated materials. Work carefully and wear appropriate safety equipment. Vapors and Gases Ensure that vapors and gases do not exceed the prescribed limits. Exhaust vapors and gases with appropriate devices when necessary and/or ensure sufficient ventilation of the work area. Substrate The substrate should be free of dust, grease and dampness. Experiment to select the suitable material and to determine the optimum working conditions and any pretreatment that may be needed for the substrate Nordson Corporation HMIPUR01_EN_C-0108

10 0 4 Introduction Processing Temperature When processing tempered materials, the prescribed processing temperature must be complied with to ensure high quality application. The temperature may not be exceeded! Overheating may cause charring or cracking of the material, which could lead to downtime or damage to the unit. The material should always be melted gently. Avoid long, unnecessary exposure to heat. When work is interrupted, the temperature should be reduced. The temperature in the tank of the unit should be coordinated with the material consumption. When a large amount of material is consumed, the temperature should be set close to the prescribed processing temperature; lower consumption means a lower temperature. When processing cold material, consider the influence of shear heat and ambient temperature. Cool if necessary. Important Note for Polyurethane Materials (PUR) When processing polyurethane materials (PUR), the following additional instructions must be followed: When the maximum level of harmful substance concentration is exceeded, use a gas mask and air purifying equipment. During production stoppages or breaks, reduce the temperature and close the applicator nozzle as well as possible. Cover the remaining opening with high-temperature grease or high-temperature tape. Before the application system is shut down for a longer period of time, rinse it with a suitable cleaning agent. Use only a cleaning agent recommended by the material manufacturer. Close open material connections so that they are airtight. HMIPUR01_EN_C Nordson Corporation

11 Safety 1 1 Section 1 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 Nordson Corporation Safe_PPA1011LUE_EN

12 1 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. Safe_PPA1011LUE_EN 2014 Nordson Corporation

13 Safety 1 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 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 Nordson Corporation Safe_PPA1011LUE_EN

14 1 4 Safety Instructions and Safety Messages 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. 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. This equipment has not been certified for compliance with the ATEX directive nor as nonincendive and should not be installed in potentially explosive environments. Ensure 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. Safe_PPA1011LUE_EN 2014 Nordson Corporation

15 Safety 1 5 Maintenance and Repair Practices Equipment Safety Information Allow only personnel with appropriate training and experience to operate or service the equipment. 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 Nordson 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. 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. 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 2014 Nordson Corporation Safe_PPA1011LUE_EN

16 1 6 Safety Equipment Shutdown 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. De energizing the System Isolate the system (melter, hoses, applicators, and optional devices) from all power sources before accessing any unprotected high voltage wiring or connection point. 1. 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 Applicators NOTE: Adhesive dispensing applicators are referred to as guns in some previous publications. All electrical or mechanical devices that provide an activation signal to the applicators, applicator solenoid valve(s), or the melter pump must be disabled before work can be performed on or around an applicator that is connected to a pressurized system. 1. Turn off or disconnect the applicator triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the applicator solenoid valve(s). 3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the applicator. Safe_PPA1011LUE_EN 2014 Nordson Corporation

17 Safety 1 7 General Safety Warnings and Cautions Table 1 1 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 1 1 as follows: HM = Hot melt (melters, hoses, applicators, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and applicators) Equipment Type Table 1 1 General Safety Warnings and Cautions Warning or Caution HM 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 applicators 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. Continued Nordson Corporation Safe_PPA1011LUE_EN

18 1 8 Safety General Safety Warnings and Cautions (contd.) Equipment Type Table 1 1 General Safety Warnings and Cautions (contd) Warning or Caution 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. HM, PC WARNING! Equipment starts automatically! Remote triggering devices are used to control automatic hot melt applicators. Before working on or near an operating applicator, disable the applicator's triggering device and remove the air supply to the applicator's solenoid valve(s). Failure to disable the applicator'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 has not been cerfified for the ATEX directive or as nonincendive. In addition, this equipment 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. Continued... Safe_PPA1011LUE_EN 2014 Nordson Corporation

19 Safety 1 9 Equipment Type Table 1 1 General Safety Warnings and Cautions (contd) Warning or Caution 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 to the equipment. HM CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of applicators, 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 Nordson Corporation Safe_PPA1011LUE_EN

20 1 10 Safety 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. First Aid If molten hot melt comes in contact with your skin: 1. 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 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. Safe_PPA1011LUE_EN 2014 Nordson Corporation

21 Introduction 2 1 Section 2 Introduction Intended Use Hot melt applicators of the series TrueCoat HP - hereafter also referred to as Applicator - may be used only for contact surface application of hot melt adhesives and similar hot melt products (including PUR). 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: When changes or modifications have been made by the customer In defective condition In a potentially explosive atmosphere When values stated under Technical Data are not complied with. The applicator may not be used to apply the following materials: Explosive and flammable materials Erosive and corrosive materials Food products Nordson Corporation

22 2 2 Introduction 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! The applicator is hot. Risk of burns! The material that comes out of the nozzle is hot. Risk of burns when connecting and disconnecting heated hoses. Risk of burns when conducting maintenance and repair work for which the applicator must be heated up. Material fumes can be hazardous. Avoid inhalation. Note on Manual Definition of Terms 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 Nordson Corporation

23 Introduction 2 3 Description of Components / Functioning TrueCoat HP with Control Modules Fig Electrical connection (body heater) 2 Solenoid valve plug 3 Solenoid valve 4 Control module 5 Filter cartridge 6 Eye-bolt 7 Clamp fixing screw 8 Clamping screw 9 Centering clamping screw 10 Control air connection 11 Clamp 12 Nozzle 13 ID plate 14 Fastening bolts 15 Hose connection (material) 2014 Nordson Corporation

24 2 4 Introduction TrueCoat HP with Throttle Screws Fig. 2 2 TCHP with rotating bar exchangeable nozzle and throttle screws 1 Cable harness temperature 7 Rotating bar sensors 8 Stop plate for exchangeable 2 Cable harness heating zones nozzle 3 Cable harness solenoid valves 9 Clamping screw 4 Hose connection (material) 10 Clamp fixing screw 5 Fastening bolts 11 Throttle screw 6 Air Relief Valve 12 Exchangeable nozzle 13 Clamp 14 Eye-bolt 15 Filter cartridge 16 Control module 17 Solenoid valve 18 Control air connection 2014 Nordson Corporation

25 Introduction 2 5 Description of Components / Functioning (contd.) Material Flow The material is pumped through a heated hose into the applicator. In the applicator the material flows through the filter cartridge(s) and the material channels to the nozzle. The material supply to the nozzle is regulated either by control modules or throttle screws. A slot nozzle or a nozzle with rotating bar applies the material in a contact coating process. The application pattern is determined by grooves in the mouthpiece or by a shim plate. The shim plate is located between the nozzle mouthpiece and the mouthpiece receptacle. The application pattern also depends on the speed at which the substrate moves, the quantity of material and the material temperature. In addition, the quality of the application is influenced by the the angle between the nozzle and the substrate. Refer to page 4 2, Positioning Applicator. Material Distribution The material supply to the nozzle and material distribution across the application width are regulated by control modules or throttle screws. Control Modules The control modules open and close the material supply to the nozzle by raising or lowering the nozzle stem. A compression spring in the control module closes the outlet when the control air pressure drops, preventing material from escaping. Refer to page 4-5, Setting Material Distribution Evenly with Stem Stroke Adjustment. Throttle Screws Refer to page 4 6, Regulating Material Distribution with the Throttle Screws. Heating The applicator is heated with electrical heater cartridges. The temperature is continuously measured by temperature sensors and is controlled with electronic temperature controllers. Temperature controllers are not part of the applicator Nordson Corporation

26 2 6 Introduction Slot Nozzle or Nozzle with Rotating Bar The nozzle or the rotating bar touches the substrate, causing them to naturally wear. The nozzle may need to be refaced, the rotating bar replaced. Refer to page 5 10, Refacing Nozzle or page 5 10, Replacing Rotating Bar. Filter Cartridge The material flows from the inside of the filter cartridge (14, Fig. 2 1) to the outside. Thus dirt particles remain in the filter cartridge. The filter cartridge must be cleaned or replaced regularly (Refer to page 5 11). NOTE: Nordson recommends keeping a supply of replacement filter cartridges to prevent production stoppage. ID plate 1. field Type 2. field Serial number 3. field Nordson order number 4. field Year of construction 5. field Operating voltage [V], rated current [A], Operating voltage frequency [Hz] Fig Nordson Corporation

27 Installation 3 1 Section 3 Installation ATTENTION: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. Unpacking Unpack carefully. Then check for damage caused during transport. Reuse packaging materials or dispose of properly according to local regulations. Transport The applicator is a high precision, valuable part. Handle very carefully! Protect the nozzle from damage. Do this e.g. by placing it back in the original packaging. Storage Do not store outside! Protect from humidity and dust. Do not lay unit on the nozzle. Protect the nozzle from damage. Do this e.g. by placing it back in the original packaging. Disposal When your Nordson product has exhausted its purpose and/or is no longer needed, dispose of it properly according to local regulations Nordson Corporation

28 3 2 Installation Installing Observe the following when installing the applicator: Protect from humidity, vibrations, dust and drafts. Ensure access to parts relevant for maintenance and operation. To achieve optimum material application, install the applicator in the parent machine such that the essential angle between the nozzle and the substrate can be varied. The applicator bracket must allow for heat expansion. Cables, air hoses and heated hoses may not be bent, pinched, torn off or otherwise damaged. Exhausting Material Vapors Ensure that material vapors do not exceed the prescribed limits. Exhaust material fumes when necessary. Provide sufficient ventilation of the location where the unit is installed. ATTENTION: It is imperative that the following additional safety regulations are followed when processing polyurethane hot melt adhesives (PUR) (Refer to General Hot Melt Material Processing Instructions) Nordson Corporation

29 Installation 3 3 Electrical Connections ATTENTION: Risk of electrical shock. Failure to observe may result in personal injury, death, or equipment damage. Laying Cable ATTENTION: Do not pinch cables and check regularly for damage. Replace damaged cables immediately! Connecting Heater Insert the voltage plug into the corresponding receptacle on the melter or terminal box. If the heater lines are integrated into the material hose, the corresponding receptacle is located directly on the material hose. Secure the voltage plug with the clamp if necessary. Connecting Solenoid Valves 1 The solenoid valves on the control modules are controlled either by an external power supply, e.g. control unit, or through the valve control lines of the heated hose. Secure the plug connection with the screw (1, Fig. 3 1). Fig Nordson Corporation

30 3 4 Installation Pneumatic Connections Nordson recommends using dry, controlled and nonlubricated compressed air. Operation with Nonlubricated Compressed Air When an applicator is connected to a compressed air system in which the compressed air has previously been lubricated, simply ceasing to lubricate the air is not sufficient. The oil remaining in the compressed air supply will reach the solenoid valves and the control modules and wash out the original lubricant/oil from these parts, substantially decreasing the service life of the units. NOTE: It must be ensured that the compressed air supply to the applicators has been converted to absolutely nonlubricated operation. NOTE: No oil from a possibly defective compressor may be permitted to penetrate the compressed air supply. NOTE: Nordson will assume no warranty or liability for damage caused by unpermitted, temporary lubrication. Conditioning Compressed Air The quality of the compressed air must be at least class 2 as stipulated by ISO This means: Max. particle size 1 m Max. particle density 1 mg/m 3 Max. pressure dewpoint -40 C Max. oil concentration 0.1 mg/m 3. Connecting Compressed Air 1. Connect customer's air supply to the inlet of an air conditioning unit. Maximum air pressure: 10 bar 1 MPa 145 psi 2. Connect the control modules to the air conditioning unit. 3. Set control air pressure: Approx. 5 to 6 bar Approx. 0.5 to 0.6 MPa Approx to 87 psi 2014 Nordson Corporation

31 Installation 3 5 Connecting Heated Hose ATTENTION: Hot! Risk of burns. Wear heat protective gloves. Connecting If cold material can be found in the hose connection (1, 2), these components must be heated until the material softens (approx. 80 C / 176F). 1. First connect the hose (3) electrically. 2. Heat the unit and hose until the material softens (approx. 80 C / 176 F). 3. Screw on heated hose. CAUTION: Always connect the hose to the side of the body where the filter cartridge is. This is the only way to ensure that the material is filtered. MXHH001S050B0997 Fig. 3 2 Disconnecting Relieving Pressure ATTENTION: System and material pressurized. Before removing heated hoses and applicators, relieve system pressure. Failure to observe can result in serious burns. ATTENTION: Hot! Risk of burns. Wear safety goggles and heat protective gloves. 1. Set the motor speed of the unit feeding the material to 0 min 1 ; switch off the motor(s). 2. Place a container under the nozzle of the applicator Nordson Corporation

32 3 6 Installation Relieving Pressure (contd.) 3. Relieving pressure: On an applicator with throttle screws, use the screws to open the material supply to the nozzle. On an applicator with solenoid valves, activate the solenoid valves electrically or manually (Refer to Figure 3 3). Do not use sharp objects! Repeat until no more material flows out. Fig Re use the material or dispose of it properly according to local regulations. Using Two Open end Wrenches Use two open end wrenches when connecting and disconnecting the heated hose. This prevents the hose connection on the unit from turning. Fig. 3 4 MXHH002S033A Nordson Corporation

33 Operation 4 1 Section 4 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. Triggering Solenoid Valve CAUTION: Trigger the solenoid valves only when the applicator is heated to operating temperature! Setting Temperatures NOTE: The basis for temperature setting is the processing temperature stipulated by the material manufacturer (usually 150 to 180 C / 302 to 356 F). The maximum operating temperature of the product described here may not be exceeded. The applicator temperature required is set on the melter (maximum 200 C / 392 F). Enter Standby CAUTION: When processing PUR adhesives, enter standby when production is to cease for longer than 30 minutes. Setting Control Air Pressure The control air pressure is set to suit each application on an air conditioning unit. The air conditioning unit with pressure control valve is not part of the applicator. Set control air pressure: Approx. 5 to 6 bar Approx. 0.5 to 0.6 MPa Approx to 87 psi Nordson will assume no warranty or liability for damage caused by an incorrect pressure setting Nordson Corporation

34 4 2 Operation Setting Material Pressure The material pressure is generated by the melter pumps. The maximum material pressure may not be exceeded: 60 bar 6 MPa 870 psi Positioning the Applicator TrueCoat HP applicators can be used to coat against a roll Fig Applicator 2 Nozzle 3 Coating Roll 4 Substrate 5 Contact line Nozzle/substrate The optimum angle of incidence of the applicator depends on various customer-specific parameters. It is within the range of - 5 to The contact line (5 ) should be at the line at which the substrate (4 ) runs onto the roll (3 ). The nozzle always has contact to the substrate (Refer to Fig. 4 1). Ensure that contact is only on the dark gray segment of the coating roll (Fig. 4 1, right); otherwise the applied material could drip Nordson Corporation

35 Operation 4 3 Calculating Material Quantity Sample Calculation Nordson recommends following the sample calculation before starting up the applicator and making a note of the application-specific values for application weight and width, substrate speed and pump output capacity in the table Customer-specific Values. These values can be used to calculate the pump speed and material quantity. Nordson also recommends entering results of the calculations in the table. This ensures that all values can be reproduced at any time. NOTE: The material quantity for intermittent application is calculated the same as for continuous material application. Application weight (grammage) m = 20 g/m 2 Application width of each material track b = 10 mm = 0.01 m Substrate speed v = 500 m/min Material quantity M = m b v = 20 g/m m 500 m/min = g/min Output capacity of pump D = 2.4 g/revolution Pump speed n = M D = g/min 2.4 g/revolution 42 rev/min Customer-specific Values Application weight (grammage) m Application width b Substrate speed v Material quantity M = m b v Output capacity of pump D Pump speed n = M D 2014 Nordson Corporation

36 4 4 Operation Correcting Material Quantity and Material Distribution Adjusting Needle Stroke NOTE: Only the Control module DC-D5, P/N , offers the stem stroke adjustment feature. CAUTION: The control module stem stroke adjustment is preset at the factory. It may be modified only when material is distributed unevenly across the application width. The material flow quantity is regulated with the stem stroke adjustment (1, Fig. 4 2). By setting the nozzle stem stroke differently on the individual control modules, the material distribution can be corrected. ATTENTION: Hot! Risk of burns. Wear heat protective gloves. 1 2 Fig Nordson Corporation

37 Operation 4 5 Setting Material Distribution Evenly with Stem Stroke Adjustment 1. Identify the control module through which too much or too little material is flowing. 2. Release the stem stroke adjustment locknut (2, Fig. 4 2) on this control module. 3. Turn the stem stroke adjustment all the way clockwise. The control module is now closed. CAUTION: The maximum that the stem stroke adjustment can be moved is two revolutions. Turning farther against the stop will destroy the control module. 4. Turn the stem stroke adjustment counterclockwise approx. one quarter of a revolution. 5. Measure the application weight: 6. If the application weight under the control module is too little, turn the stem stroke adjustment another one quarter of a revolution counterclockwise. 7. Repeat steps 5. and 6. until the desired application weight is achieved. If too much material is being applied, turn the stem stroke adjustment back less than a quarter of a revolution. 8. Measure the application weight after every correction to the stem stroke adjustment. Continue to correct the stem stroke adjustment in smaller and smaller steps until the application weight setpoint is achieved with the desired precision. 9. Tighten the stem stroke adjustment locknut (2, Fig. 4 2) again Nordson Corporation

38 4 6 Operation Regulating Material Distribution with the Throttle Screws ATTENTION: Hot! Risk of burns. Wear heat protective gloves. The material supply into the nozzle can be altered using the throttle screws. Individually adjust the throttle screws to achieve uniform material distribution. Turn throttle screws clockwise: less material Turn throttle screws counterclockwise: more material. NOTE: The throttle screw thread pitch is 1 mm. 1. Turn all throttle screws all the way clockwise to achieve a defined starting point. 2. Unscrew all throttle screws two complete revolutions. 3. Measure the material distribution across the entire application width. 4. Optimize the setting step by step. Depending on how greatly the measurement result deviates from the desired material distribution, turn single screws or all of the screws farther out or back in. When doing this Turn the screws in or out only a quarter to half revolution with each step Measure material distribution again after each step. 5. Make a note of the optimum setting for all throttle screws. Throttle screw settings Note: The number of throttle screws depends on the application width Nordson Corporation

39 Operation 4 7 Optimizing Material Application with Temperature Setpoints NOTE: Only possible when applicators have heated manifolds. If material is properly applied to the outer edges of the application pattern but not in the middle, the applicator nozzle is concave (hollow) to the coating roll. If the material is applied properly in the middle but not near the edges, the nozzle is convex (spherical). These deviations from the parallel path can be corrected by setting different temperature setpoints for the manifolds on the back of the applicator than for the remaining heating zones. Correcting Nozzle Concavity Fig. 4 3 Nozzle is hollow (concave) 1. Set the temperature setpoints for the manifolds one to two degrees lower than the setpoints for the remaining heating zones. The lesser heat expansion of the heating zones on the back of the applicator compensates for the concavity on the nozzle side. 2. As long as material application is not uniform across the application width, continue to adjust the temperature setpoints in steps. The temperature difference between the heating zones should never exceed 10 C Nordson Corporation

40 4 8 Operation Correcting Nozzle Convexity Fig. 4 Nozzle is spherical (convex) 1. Set the temperature setpoints for the manifolds one to two degrees higher than the setpoints for the remaining heating zones. The greater heat expansion of the heating zones on the back of the applicator compensates for the convexity on the nozzle side. 2. As long as material application is not uniform across the application width, continue to adjust the temperature setpoints in steps. Setting Rotating Bar Speed The speed of the rotating bar drive is either set manually or is a factor of the line speed signal (key to line). In an application system with Nordson components, the control element used to set the speed setpoint in manual mode (e.g. potentiometer or control panel) is located either on the melter or on a separate control box. Speed controlled by the line speed signal can also be adjusted with the same control element. Set the speed [min -1 ] to approx. 10% of the web speed [m/min] Nordson Corporation

41 Operation 4 9 Settings Record Production information Material Manufacturer Max. processing temperature Viscosity Cleaning agent Manufacturer Flash point Basic settings Application weight (grammage) Application width Substrate speed Material quantity Output capacity Air pressure at applicator Control air Basic settings temperature (heating zones) Applicator body Heated hose Pump speeds Melter Motor controller (setpoint) Material pressure Melter Motor controller (setpoint) Notes Form filled out by: Name Date 2014 Nordson Corporation

42 4 10 Operation Settings Record - Spare Copy Production information Material Manufacturer Max. processing temperature Viscosity Cleaning agent Manufacturer Flash point Basic settings Application weight (grammage) Application width Substrate speed Material quantity Output capacity Air pressure at applicator Control air Basic settings temperature (heating zones) Applicator body Heated hose Pump speeds Melter Motor controller (setpoint) Material pressure Melter Motor controller (setpoint) Notes Form filled out by: Name Date 2014 Nordson Corporation

43 Maintenance 5 1 Section 5 Maintenance Relieving Pressure 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: System and material pressurized. Before removing heated hoses and applicators, relieve system pressure. Failure to observe can result in serious burns. ATTENTION: Hot! Risk of burns. Wear safety goggles and heat protective gloves. 1. Set the motor speed of the unit feeding the material to 0 min 1 ; switch off the motor(s). 2. Place a container under the nozzle of the applicator. 3. Relieving pressure: On an applicator with throttle screws, use the screws to open the material supply to the nozzle. On an applicator with solenoid valves, activate the solenoid valves electrically or manually (Refer to Figure 5 1). Do not use sharp objects! Repeat until no more material flows out. Fig Nordson Corporation

44 5 2 Maintenance Relieving Pressure (contd.) 4. Re use the material or dispose of it properly according to local regulations. Regular Maintenance NOTE: Maintenance is an important preventive measure for maintaining operating safety and extending the service life of the applicator. It should never be neglected. Unit part Activity Interval Refer to Entire applicator Inspect for damage Daily Page 5 3 External cleaning Daily Page 5 3 Purge with cleaning agent Daily when using PUR adhesives Page 5 4 Control modules Check for leakage Daily - Nozzle Cleaning Regularly, or when the application Page 5 5 pattern deteriorates Replace shim plate When damaged Page 5 10 Have it refaced Replace Cordset Inspect for damage Every time maintenance is performed - Air hoses Control modules Check detection holes Daily Page 5 3 Filter Clean filter cartridge and replace filter screen Depending on degree of material pollution. Recommendation: Every 100 hours of operation Page Nordson Corporation

45 Maintenance 5 3 Visual Inspection for External Damage CAUTION: When damaged parts pose a risk to the operational safety of the applicator and/or safety of personnel, switch off the applicator or application system and have the damaged parts replaced by qualified personnel. Use only original Nordson spare parts. External Cleaning External cleaning prevents impurities created during production from causing the unit to malfunction. Always follow the manufacturer's instructions when using cleaning agents! 1. Electrically heat the cold applicator until the material is liquid. 2. Thoroughly remove the warm material with a cleaning agent and/or a soft cloth. 3. Remove dust, fluffs, etc. with a vacuum cleaner or a soft, lint-free cloth. CAUTION: Do not damage or remove warning labels. Damaged or removed warning labels must be replaced by new ones. Inspecting Control Module If material escapes from the detection hole, the interior seals are worn. Replace the control module when this occurs. Refer to page 7 1, Replacing Control Module with 4/2 Air Valve or page 7 2, Replacing Control Module with 3/2 Air Valve.. Changing Type of Material NOTE: Before changing the type of material, determine whether the old and new material may be mixed. May be mixed: Remaining old material can be flushed out using the new material. May not be mixed: Thoroughly purge the unit with a cleaning agent recommended by the material supplier. Refer to page 5 4. NOTE: Properly dispose of the material and cleaning agent according to local regulations Nordson Corporation

46 5 4 Maintenance Purging with Cleaning Agent CAUTION: Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. NOTE: When PUR adhesive is used, it must be prevented from reacting to the thermal load in the applicator. The applicator must be purged every day when work is completed. Rinse out cleaning agent just before beginning production again. 1. Maintain operating temperature. 2. Place a container under the nozzle. 3. Relieve pressure (Refer to page 5 1). 4. Detach heated hose from applicator (Refer to page 3 5). 5. Purge melter and heated hose if necessary (Refer to separate manuals). 6. Connect purging hose to the applicator. 7. Purge the applicator until the material has been flushed out completely. NOTE: When PUR adhesive is used, do not proceed until right before production is to begin again. 8. Unscrew purging hose. 9. Screw the heated hose onto the applicator again. 10. Purge applicator (and, when appropriate, melter and hose) with the material currently in use to flush out the cleaning agent. NOTE: Properly dispose of the cleaning agent according to local regulations Nordson Corporation

47 Maintenance 5 5 Disassembling and Cleaning Slot Nozzle Fig Clamp 2 Fixing screw 3 Centering clamping screw (option) 4 Clamping screw 5 Nozzle 6 Mouthpiece 7 Shim plate 8 Mouthpiece receptacle 2014 Nordson Corporation

48 5 6 Maintenance Disassembling and Cleaning Slot Nozzle (contd.) ATTENTION: Hot! Risk of burns. Wear heat protective gloves. The nozzle must be regularly disassembled (mouthpiece, shim plate and mouthpiece receptacle) and cleaned. Material residue affects the quality of the application. It must be removed. 1. Heat applicator until material is soft. 2. Before releasing the clamping screws, ensure that the nozzle (5, Fig. 5 2) can not fall off. 3. Release all clamping screws (4, Fig. 5 2) and - if applicable - the centering clamping screw (3, Fig. 5 2). Now the nozzle can be extracted out the side. If there is not enough space to the side of the applicator: Unscrew all of the clamps (1, Fig. 5) and extract the nozzle out the front of the unit. 4. Place the nozzle aside, somewhere out of harm's way. 5. Reduce the nozzle to the individual components: mouthpiece receptacle (8, Fig. 5 2), mouthpiece (6 Fig. 5 2) and shim plate (7, Fig. 5 2). 6. Clean the individual parts. Refer to the data sheet from the material manufacturer for information on cleaning agents. 7. Reassemble the nozzle. 8. Install the nozzle in the applicator again by logically reversing steps 1 to 4. When nozzles have a centering clamping screw, insert it in the center clamp Nordson Corporation

49 Maintenance 5 7 Disassembling and Cleaning Nozzle with Rotating Bar Fig. 5 3 Example of an applicator with rotating bar exchangeable nozzle, shown without rotating bar motor 1 Clamp fixing screw 2 Clamp 3 Clamping screw 4 Nozzle 5 Mouthpiece receptacle 6 Rotating bar 7 Shim plate 8 Mouthpiece 9 Bar 2014 Nordson Corporation

50 5 8 Maintenance Disassembling and Cleaning Nozzle with Rotating Bar (contd.) ATTENTION: Hot! Risk of burns. Wear heat protective gloves. The nozzle must be regularly disassembled (mouthpiece, shim plate, mouthpiece and, when applicable, rotating bar) and cleaned. Remove material residue. Material residue affects the quality of the application. 1. Heat applicator until material is soft. 2. Switch off the rotating bar motor (6, Fig. 5 3) and detach the rotating bar from the motor. Refer to page 5 10 Replacing Rotating Bar. 3. Remove all clamping screws (3, Fig. 5 3). Now the nozzle can be extracted out the side. If there is not enough space to the side of the applicator: Unscrew all of the clamps (2, Fig. 5 3) and extract the nozzle out the front of the unit. 4. Place the nozzle aside, somewhere out of harm's way. 5. Extract the rotating bar sideways out of its track. 6. Unscrew the bars (9, Fig. 5 3). Ensure that the bars are not mixed up when reinstalling at a later time. 7. Reduce the nozzle to the individual components: mouthpiece receptacle (5, Fig. 5 3), mouthpiece (8 Fig. 5 3) and shim plate (7, Fig. 5 3). 8. Clean all individual parts. Refer to the data sheet from the material manufacturer for information on cleaning agents. 1 NOTE: Nordson supplies a test pin with every rotating bar (1, Fig. 5 4). It helps to optimally adjust the position of the the rotating bar. The diameter of the test pin is 0.02 mm larger than that of the rotating bar For information on how to use the test pin, refer to 9. and 12. NOTE: If necessary, order a new test pin, 8 mm, P/N Fig Clean the rotating bar seat. If there are stress marks visible on the rotating bar seat, polish them with cutting oil. To do this, emery paper can be wrapped around the test pin and used as a polishing tool. 10. Re-assemble to mouthpiece receptacle, mouthpiece and shim plate Nordson Corporation

51 Maintenance 5 9 Disassembling and Cleaning Nozzle with Rotating Bar (contd.) 11. Put the bars back into place and secure with screws. Use a torque wrench to tighten the bar fastening screws. Refer to the table for torque: Thread size Property class Torque M Nm M Nm 12. Slide the test pin through the rotating bar seat, with the side that is not beveled leading. If this is not possible, loosen the fastening screws somewhat in the tight places and re-position the bars. If the test pin has too much leeway, tighten the fastening screws somewhat. 13. Extract the test pin and save it for later use. 14. Slide the rotating bar under the doctor blade. 15. Install the nozzle in the applicator again by logically reversing steps 1 to Connect the rotating bar to its motor again Nordson Corporation

52 5 10 Maintenance Replacing Rotating Bar The way in which the rotating bar drive is connected to the applicator is a factor of the available space in the parent machine and other conditions specific to the customer. Thus the procedure to detach the rotating bar drive cannot be described precisely here. In general: ATTENTION: Hot! Risk of burns. Wear heat protective gloves. 1. Stop the material supply to the applicator and stop the rotating bar motor. 2. Detach the protective covers from moving drive elements if necessary. 3. Disconnect the drive from the rotating bar. 4. Refer to page 5 7, Disassembling and Cleaning Nozzle with Rotating Bar, step 3. ad the following steps, for instructions on how to proceed. Inserting New Shim Plate Fig. 5 5 Reface The nozzle must be removed from the applicator and disassembled to replace the shim plate. Refer to page 5 5, Disassembling and Cleaning Nozzle. 1. Disassemble nozzle. 2. Fit new shim plate between mouthpiece and mouthpiece receptacle. The shim plate is held in place by two or more cylinder pins. 3. Screw nozzle halves together. NOTE: The shim plate protrudes 0.1 to 0.3 mm out of the nozzle. 4. The shim plate must be ground until it is even with the mouthpiece and the mouthpiece receptacle. 5. Screw the nozzle onto the applicator again. Refacing Nozzle The nozzle touches the substrate, causing it to naturally wear. The nozzle may need to be refaced to compensate for wear. NOTE: Nordson will assume no warranty or liability for damage resulting from incorrect refacing. The nozzle should be sent to Nordson for refacing Nordson Corporation

53 Maintenance 5 11 Replacing Filter Cartridge NOTE: Remove the filter cartridge only when the nozzle filter is hot and not pressurized. Install only when nozzle filter is hot. ATTENTION: Hot! Risk of burns. Wear heat protective gloves. ATTENTION: System and material pressurized. Relieve system of pressure before replacing filter cartridge. Failure to observe can result in serious burns. Removing Filter Cartridge 1. Heat applicator until material is soft. 2. Relieve pressure. Refer to page Insert a screw with M8 thread into the center tapped hole (Fig. 5 6). Fig Place a container under the filter bore. 5. Unscrew the filter cartridge counterclockwise with an open end wrench or ring wrench (Fig. 5 7). Fig Use pliers to remove the filter cartridge (Fig. 5 8). 7. Purge the filter bore with material by allowing the melter pump to run slowly. This rinses out particles of dirt that may still be in the filter bore. 8. Properly dispose of material according to local regulations. Fig Nordson Corporation

54 5 12 Maintenance Installing Filter Cartridge ATTENTION: Hot! Risk of burns. Wear heat protective gloves. 1. Heat applicator until material is soft. 2. Slide the filter cartridge into the filter bore. 3. Screw in the filter cartridge with an open end wrench or ring wrench. Tighten only hand tight; do not use excessive force (Fig. 5 9). Fig. 5 9 Disassembling and Cleaning Filter Cartridge ATTENTION: Hot! Risk of burns. Wear heat protective gloves. The filter cartridge can be disassembled only when it is warm. If the filter cartridge is not disassembled immediately after removal, it must be heated (e.g. with an air heater) NOTE: Use only a cleaning agent recommended by the hot melt material manufacturer. Observe the Material Safety Data Sheet for the cleaning agent. NOTE: Always replace the filter screen (5). 1. Disassemble the filter cartridge Replace the filter screen (5). 3. Clean all other parts. 4. Check O rings (3 and 6) and sealing ring (2); replace if necessary. 5. Properly dispose of the cleaning agent according to local regulations. Fig Filter screw 2 Sealing ring 3 O ring 44x3 4 Filter sheath 5 Filter screen 6 O ring 35x2 7 Perforated disk 8 Serrated lock washer 9 Nut 2014 Nordson Corporation

55 Maintenance 5 13 Maintenance Record Applicator Unit part Activity Date Name Date Name External inspection and cleaning Nozzle Cleaning Replace nozzle Replace shim plate Control module External cleaning Replace control module Filter cartridge Replace filter screen 2014 Nordson Corporation

56 5 14 Maintenance Maintenance Record Form Spare Copy Applicator Unit part Activity Date Name Date Name External inspection and cleaning Nozzle Cleaning Replace nozzle Replace shim plate Control module External cleaning Replace control module Filter cartridge Replace filter screen 2014 Nordson Corporation

57 Troubleshooting 6 1 Section 6 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. Introduction Troubleshooting tables are intended as an orientation for qualified personnel. They cannot, however, replace targeted troubleshooting with the aid of wiring diagrams and measuring instruments. They also do not include all possible problems, only those which most typically occur. The following problems are not included in the troubleshooting tables: Faults in installation Faults in operation Defective cables Loose plug and screw connections. In the column Corrective action, the remark that defective parts should be replaced is generally not included Nordson Corporation

58 6 2 Troubleshooting Troubleshooting Table Problem Possible cause Corrective action Refer to No material Melter tank is empty Fill Separate manual Melter Applicator does not heat Melter motor is not switched on Switch on Separate manual Melter Melter pump is not working Check Separate manual Pump Applicator has not yet reached operating temperature Applicator cold or not yet warm enough Compressed air not connected Wait until temperature has been reached; check temperature setting if necessary Refer to Applicator does not heat Separate manual Temperature controller Connect Page 3 4 Nozzle clogged Clean nozzle Page 5 5 Nozzle stem is stuck Replace control module Seite 7 1 or 7 2 Filter cartridge is clogged Clean or replace filter Page 5 12 screen if necessary Solenoid valves do not switch Refer to Solenoid valves do not switch - - Temperature is not set Set on temperature controller - - Separate manual Temperature controller Plug not connected Connect Page 3 3 Fuses in melter defective Disconnect melter from line - - voltage, check fuses and replace if necessary Heater cartridge(s) in applicator defective Replace Page 7 4 Problem Possible cause Corrective action Refer to Applicator does not reach the set temperature Solenoid valves do not switch Heater cartridge(s) in applicator defective Ambient temperature too low Replace Page 7 4 Increase ambient temperature Control unit not switched on Switch on Separate manual Control Unit Plug not connected or loose Secure plug connections with a screw. Page Nordson Corporation

59 Troubleshooting 6 3 Problem Thickened material at end of application pattern Application pattern not exact Possible cause Corrective action Note: Material thickening can not be prevented; it can only be reduced. Stem stroke too high Temperature not set precisely on melter Temperature of applicator not set precisely Material quantity/pressure not set precisely Control unit not programmed correctly Check stem stroke between piston and socket block Setpoint at DC-D3: 0.5 mm Setpoint at DC-D5: 1.0 mm Correct setting Refer to - - Separate manual Melter Correct setting Page 4 1 Correct setting Page 4 2 Correct programming Separate manual Control Unit External pollution on nozzle Clean Page 5 5 Pollution inside of nozzle Nozzle damaged Application quantity and substrate processing speed not attuned to one another Replace nozzle Check settings; change so as to be attuned to one another if necessary Page 4 3 Material unsuitable Ask manufacturer Data sheet of material manufacturer 2014 Nordson Corporation

60 6 4 Troubleshooting Troubleshooting Table (contd.) Problem Possible cause Corrective action Refer to The open time* is too long The open time* is too short Application temperature too high Set temperature lower Separate manual Temperature controller Material unsuitable Ask manufacturer Data sheet of material manufacturer Application temperature too low Set temperature higher Separate manual Temperature controller Material unsuitable Ask manufacturer Data sheet of material manufacturer * The open time is the time from when the material leaves the nozzle until it hardens on the substrate Nordson Corporation

61 Repair 7 1 Section 7 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. Replacing Control Module with 4/2 Air Valve 1. Relieve pressure. Refer to page Detach the solenoid valve plug, release the control air connection and unscrew the material hose. 3. Extract the four screws M8 (1, Fig. 7 1). 4. Extract the old control module from the warm applicator. 5. Apply high temperature grease (Refer to the page 7 4, Processing Materials) to the new control module: To the O rings To the screw threads Under the screw heads. 6. Insert the new control module, screw it into place and connect it. 1 2 Fig Nordson Corporation

62 7 2 Repair Replacing Control Module with 3/2 Air Valve Nordson recommends keeping a supply of control modules to prevent production stoppage. CAUTION: The control module is a high precision, valuable part. Handle very carefully! Removing Control Module 1. Relieve pressure. Refer to page Release screws (M4). 1 Fig Use a suitable tool, e.g. a screwdriver, to detach the control module from the air bar (instant plug connection) (1, Fig. 7 2). 4. Extract the control module from the warm applicator Nordson Corporation

63 Repair 7 3 Replacing Control Module with 3/2 Air Valve (contd.) Installing Control Module NOTE: Required tool: Torque wrench. 1. Apply high temperature grease (Refer to page 7 4, Processing Materials) (Figure 7 3): To the O rings To the screw threads Under the screw heads. 2. Insert the new control module. Do not tilt! The control module is positioned correctly when the cylindrical part rests evenly on the body, below the detection holes. The gap between the square part and the body is then 2 mm. Also compare to the adjacent control modules or to Figure Screw in the screws by hand. Do not tighten yet. Fig Alternately tighten the two screws with a torque wrench. a. Tighten both screws to 1.0 Nm. b. Tighten both screws to 2.0 Nm. c. Tighten both screws to 2.7 Nm. 5. Re-connect air and electrical connection. NOTE: Observe the voltage stated on the ID plate of the solenoid valve Nordson Corporation

64 7 4 Repair Replacing Heater Cartridge or Temperature Sensor ATTENTION: Hot! Risk of burns. Wear heat protective gloves. 1. Heat applicator to material processing temperature. 2. Disconnect the applicator from the voltage supply. 3. Unscrew electrical equipment cover of the affected heating zone. 4. Disconnect the heater cartridge or temperature sensor. 5. Extract temperature sensor from the hole. Use a suitable pin to push the heater cartridge out of the hole. If a heater cartridge or temperature sensor firmly sticks, drill open the hole. 6. Connect the new heater cartridge or temperature sensor. 7. Apply PTFE grease to the new heater cartridge or temperature sensor, e.g. GLS 595/NZ, order number: P/N Insert the new heater cartridge or temperature sensor. 9. Screw on electrical equipment cover. 10. Reconnect the voltage supply. Processing Materials Designation Order number Use High temperature grease Apply to O-rings and threads Can 10 g P/N NOTE: The grease should not be mixed with other lubricants. Tube 250 g P/N Oily/greasy parts must be cleaned Cartridge 400 g P/N before application Nordson Corporation

65 Technical Data 8 1 Section 8 Technical Data General Data Type of heating Possible temperature sensors Max. closing pressure without compressed air Max. closing pressure with compressed air Max. locking pressure without compressed air Max. locking pressure with compressed air Electrical resistance heating elements FeKo thermal Pt 100 Ni 120 element 15 bar 1,5 MPa 218 psi 60 bar 6 MPa 870 psi 100 bar 10 MPa 1450 psi 100 bar 10 MPa 1450 psi Max. processable viscosity mpas cp Air Pressure Control air Approx. 5 to 6 bar Approx. 0.5 to 0.6 MPa Approx to 87 psi Temperatures Max. ambient temperature 60 C 140 F Max. operating temperature 200 C 392 F 2014 Nordson Corporation

66 8 2 Technical Data Electrical Data ATTENTION: The applicator is designed for only one operating voltage. Operate only at the operating voltage shown on the ID plate. Operating voltage 230 V AC Operating voltage frequency 50/60 Hz Degree of protection IP 30 Power consumption Refer to ID plate Voltage for solenoid valve 24 V DC Dimensions and Weights Dimensions Weight Refer to technical drawing See consignment note 2014 Nordson Corporation

67 Technical Data 8 3 Torques Control Modules Fig. 8 1 Alternately tighten the two screws with a torque wrench. 1. Tighten both screws to 1.0 Nm. 2. Tighten both screws to 2.0 Nm. 3. Tighten both screws to 2.7 Nm. Nozzle Thread size Property class Torque M Nm M Nm M Nm M Nm 2014 Nordson Corporation

68 8 4 Technical Data Clamps M8: 25 Nm M8: 25 Nm M10: 10 Nm Fig. 8 2 M12: 100 Nm M12: 100 Nm M12: 20 Nm Fig Nordson Corporation