MP20 Series Hot-Melt Applicator Units

Transcription

1 MP20 Series Hot-Melt Applicator Units Manual Number: MP20TC-SM005 Release Date: October 2017

2 TOC MP20 series ASU Manual CHAPTER 1 : SAFETY PRECAUTIONS Table of Contents Table-of-Contents Page 1 TOC GENERAL CONSIDERATIONS 1-1 SERVICING EQUIPMENT 1-1 ADDITIONAL CONSIDERATIONS 1-1 SPECIFIC CAUTIONS AND WARNINGS 1-1 HIGH TEMPERATURES 1-1 ELECTRICAL 1-2 HIGH PRESSURE 1-2 PROTECTIVE COVERS 1-2 EYE PROTECTION 1-2 INSTALLATION AND OPERATIONAL SAFETY 1-3 TREATMENT FOR BURNS OF HOT MELT ADHESIVES 1-3 EXPLOSION / FIRE HAZARD 1-3 SHUTTING OFF POWER 1-3 CHAPTER 2 : INTRODUCTION FORWARD 2-1 MP20 SERVICE MANUAL 2-1 CHAPTER 3 : MACHINE DESCRIPTION & SPECIFICATIONS MACHINE DESCRIPTION 3-1 MODEL NUMBER CONFIGURATION 3-1 MACHINE SPECIFICATIONS 3-2 FEATURES & OUTLINE 3-4 CHAPTER 4 : INSTALLATION SELECTING A LOCATION 4-1 MOUNTING THE UNIT 4-1 CONNECTING THE POWER 4-2 CONNECTING THE AIR 4-3 CONNECTING THE GLUE HOSES 4-4 CONNECTING THE HOSES TO THE APPLICATORS 4-5 CHAPTER 5 : INITIAL SETUP INTRODUCTION 5-1 FILLING & STARTING THE UNIT 5-1 SETTING THE SYSTEM READY THERMOSTAT 5-2 PURGING THE SYSTEM 5-3 USING THE PARENT MACHINE INTERLOCK (PMI) 5-4 CHAPTER 6 : OPERATION INTRODUCTION 6-1 OPERATING THE TEMPERATURE CONTROLS 6-1 PROGRAMMING THE SETPOINT TEMPERATURE 6-1 ACCESSING LEVEL-1 PARAMETERS 6-2 ACCESSING LEVEL-2 PARAMETERS 6-2 LEVEL-1 PARAMETERS 6-2 LEVEL-2 PARAMETERS 6-3 HIGH ALARM PARAMETERS 6-4 LOW ALARM PARAMETERS 6-4 PROTOCOL PARAMETERS 6-4 OPERATING THE PISTON PUMP 6-5

3 CHAPTER 7 : MAINTENANCE Table-of-Contents Page 2 TOC INTRODUCTION 7-1 GENERAL MAINTENANCE INSTRUCTIONS 7-1 CLEANING THE EXTERIOR OF THE UNIT 7-1 CHANGING THE ADHESIVE 7-2 FLUSHING THE SYSTEM 7-2 PARTS REPLACEMENT 7-3 PISTON PUMP ASSEMBLY 7-3 GLUE FILTER ASSEMBLY 7-3 DRAIN VALVE ASSEMBLY 7-4 RTD SENSOR REPLACEMENT 7-4 TANK HEATER REPLACEMENT 7-5 OVER-TEMP THERMOSTAT REPLACEMENT 7-6 CIRCUIT FUSE REPLACEMENT 7-7 TEMPERATURE CONTROL REPLACEMENT 7-8 CHAPTER 8 : TROUBLESHOOTING INTRODUCTION 8-1 CHAPTER 9 : PART NUMBER LIST HOW TO ORDER PARTS 9-1 VISUAL OF UNITS LB CHASSIS ASSEMBLY LB CHASSIS ASSEMBLY 9-3 REAR SECTION PARTS 9-4 FRONT SECTION PARTS 9-5 TANK FILTER BREAK-DOWN 9-7 DRAIN VALVE BREAK-DOWN 9-8 PRESSURE RELIEF VALVE BREAK-DOWN 9-9 PISTON PUMP ASSEMBLIES 9-10 PUMP UPPER AIR MOTOR ASSEMBLY LB PUMP LOWER FLUID ASSEMBLY LB PUMP LOWER FLUID ASSEMBLY 9-15 RECOMMENDED SPARE PARTS LIST 9-17 CHAPTER 10 : SCHEMATICS CHAPTER 11 : WARRANTY & SERVICE WARRANTY 11-1 SERVICE TOC

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5 Chapter 1 Safety Precautions Safety Precautions Page 1 Chapter 1 Updated 8/19/2010 GENERAL CONSIDERATIONS Read and follow the instructions in this service manual. Failure to do so could result in severe personal injury or death. Additional safety instructions and/or symbols are located throughout this manual. They serve to warn maintenance personnel and operators about potentially hazardous situations. Inspect all machinery for unsafe conditions daily and replace all worn or defective parts. Keep work area uncluttered and well lit. All covers and guards must be in place before operating this equipment. 1 SERVICING EQUIPMENT 1. Only trained personnel are to operate and service this equipment. 2. Never service or clean equipment while it is in motion. 3. Shut off the equipment and turn off power source before attempting any maintenance. 4. Follow the maintenance and service instructions in this manual (Ch. 7). ADDITIONAL CONSIDERATIONS 1. To ensure proper operation of the equipment, use specified electrical and / or air supply sources. 2. Do not attempt to alter the design of the equipment without written approval from MeltPro Inc. 3. Keep all manuals readily accessible and refer to it often for the best performance from your equipment. SPECIFIC CAUTIONS AND WARNINGS WARNING statements identify conditions or practices that could result in personal injury or loss of life. HIGH TEMPERATURES Severe burns can occur if unprotected skin comes in contact with molten adhesive or hot application system parts. Safety glasses, gloves and long-sleeved clothing must be worn whenever working with or around adhesive application systems.

6 Safety Precautions Page 2 Chapter 1 Updated 8/19/ ELECTRICAL Dangerous voltages exist at several points in this equipment. To avoid personal injury, do not touch exposed connections and components while input power is on. Disconnect, lockout and tag external electrical power before removing protective panels. A secure connection to a reliable earth ground is essential for safe operation. Upon loss of the protective electrical ground connection, all accessible conductive ports (including knobs and controls that may appear to be insulated) can render an electric shock. A disconnect switch with lockout capability must be provided in the line ahead of the unit. Wiring used to supply electrical power should be of sufficient size and insulation to accommodate the unit s power and temperature requirements. To avoid fire hazard, use only the fuses specified in the parts list for your system. Perform all work on an insulating mat if possible. Do not work on the system if water is present. Avoid working in a high humidity atmosphere. Cover any exposed terminals and work areas with rubber sheeting to avoid accidental contact while the power is on. Bodily injury can result from reflex responses as well as from direct contact with an electrical source. HIGH PRESSURE To avoid personal injury, do not operate the equipment without all covers, panels and safety guards properly installed. To prevent serious injury from molten adhesive under pressure, disengage the pumps and relieve the adhesive system hydraulic pressure (e.g., trigger the heads, handguns, and/or other application devices into a waste container) before opening any hydraulic fittings or connections. PROTECTIVE COVERS To avoid personal injury, do not operate the application system without all covers, panels and safety guards properly installed. Do not attempt to perform internal service or adjustment to this system with guards removed and machine energized. To prevent serious injury, leave guards installed on all units unless they re properly de-energized. EYE PROTECTION Wear safety glasses with side shields which conform to ANSI Z 87.1 at all times while operating and in the presence of equipment. Failure to wear safety glasses could result in severe personal injury.

7 INSTALLATION AND OPERATIONAL SAFETY Safety Precautions Page 3 Chapter 1 Updated 8/19/ To avoid knotting or tangling of the hose, lay it flat and straight. Hoses ran in narrow spaces (8 or more narrow) should be free of friction contact. The radius of the hose should not be less than 8 (203mm). Adhesive hoses should not touch endothermic material such as cold floors or metal sockets. The surface physical property of these materials may change the adhesive flow rate, which will cause incorrect calibration. The surface of hoses should not cover any material such as insulating compounds to avoid losing heat. 2. Read the service manual before the equipment is connected to a power supply. Incorrect connection may cause damage to the equipment. 3. Must use clean adhesive to avoid causing chemical pollution, blockage in the hoses, damage to the pump, and clogging of the dispensing modules and nozzles. 4. Do not direct handguns and other removable applicators towards people. When not in use, turn the handgun trigger off and engage the safety locks to prevent accidental triggering. 5. If gluing operations are halted for longer than 15 min. intervals the system wide temperature settings should be reduced 15% of normal operating set points to prevent adhesive charring. 6. Do not start the heads, handgun or other applications when the temperature is not at the operating level. Otherwise, the internal components will be heavily damaged. 1 TREATMENT FOR BURNS FROM HOT MELT ADHESIVES 1. Seek medical attention in response to scalds or burns caused by hot melt adhesives. 2. Show caution around melted adhesive surfaces and hot glue. 3. During hot melt adhesives expediting setting time, it is very dangerous to attempt contact. 4. Hot melt adhesive is very hot right after solidification and may cause serious scald. Wear safety glasses, gloves and long-sleeved clothing when operating the adhesive application systems. 5. Keep first aid supplies and emergency medical contact information readily accessible at all times. EXPLOSION / FIRE HAZARD 1. Do not operate the application in potentially explosive surroundings. 2. Use cleaning compounds recommended by your adhesive supplier only. 3. Flash points of cleaning compounds vary according to their composition. 4. Consult your supplier to identify the highest temperature and safety guarding for cleaning solvents. SHUTTING OFF POWER Be familiar with all the chain signals of the application according to OSHA and other rules of cut-off as well as the chain program. The application system, especially any capacitors in panel box can store electric energy. To make sure all the electric energy is released, it is advised to wait at least 1 min before attempting any repairs around any capacitors.

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9 Chapter 2 Introduction Introduction Page 1 Chapter 2 Updated 8/19/2010 FOREWORD Welcome to MeltPro Inc Systems of adhesive application systems and accessories. We appreciate you purchasing one of our products and we will work to make you one of our most satisfied customers. 2 Our goal is to design and manufacture the most efficient adhesive application systems and accessories in the industry. We hope you will agree. If, however, you have suggestions to improve our systems, please inform us. You are the best source of information for product improvement. We believe our customers needs always come first. Our company is committed to the pursuit of excellence and our products are built to reflect this philosophy. MP20 SERVICE MANUAL Each section on the manual follows a logical progression to help you get the most from your new application system. The text is concise and written in a way that is easy to understand. However, if you find something confusing or unclear, please do not hesitate to contact us for help. The component illustrations in Chapter 9 are especially helpful when assistance is needed in locating a specific section or part of the application system. Chapter 10 contains all of the wiring schematics and list of electrical components and cable code. The operator or service technician may be requested to reference specific illustrations throughout the manual during troubleshooting or maintenance.

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11 Machine Description & Specifications Page 1 Chapter 3 Chapter 3 MACHINE DESCRIPTION & SPECIFICATIONS MACHINE DESCRIPTION The MeltPro adhesive application systems are designed to melt and pump a wide range of viscosities of hot melt adhesives. The heated tank assembly melts the solid adhesive which is then pumped thru to a 16:1 Piston Pump that transfers the melted adhesive under hydraulic pressure through a heated hose to a heated applicator. The MP20 Series Adhesive Supply Units (ASU) is a microprocessor controlled hot melt adhesive supply unit designed on SAE standards. It is designed to have one cabinet size and offers two tank sizes such as 20 and 30 lb capacities. The MP20 ASU uses microprocessor temperature controls to maintain the temperature of hot melt adhesive for up 2 to 4 hoses / heads. A total of 9 heating controllers are available and the system provides alarms for operator errors and/or system malfunctions. With individual device heating functions, the MP20 can be applied to different applications. The MP20 series ASU has a Teflon-coated hopper design to increase the life of adhesive by reducing adhesive charring. Options available include: 3 Adhesive level control to warn when adhesive needs to be added to the unit. Analog pressure gauge to monitor the output pressure. Internal safety relief valve to prevent users from over exceeding In-House pressure rules for hot melt unit operations. Model Number Configuration MP20TCN- - - Number of hose/guns: 1 = 1 hose & 1 gun 2 = 2 hoses & 2 guns 3 = 3 hoses & 3 guns (240 volt units only) 4 = 4 hoses & 4 guns (240 volt units only) Voltage: 1 = 120 volts 2 = 240 volts Hopper size: (blank) = 20lb 30 = 30lb (240 volt units only) Options: (blank) = none L = level control

12 Machine Description & Specifications Page 2 Chapter 3 MACHINE SPECIFICATIONS Environmental: Storage/Shipping Temperature -40 F ~ 158 F ( -40 C ~70 C ) Ambient Service Temperature. 32 F ~ 122 F ( 0 C ~50 C ) Noise Emission: db 3 Physical: Dimensions.. (See dimensional layouts on following pages) Number of Head/Hose Zones. 2~4 Number of Tank Temperature Zones. 1 Number of Pumps... 1 Piston Pump Ratio. 16:1 Enclosure.. Styled, durable metal and high temp plastic, dust and splatter resistant Hose Connections. Mechanical wrench-secured fluid fittings ( # 6 JIC ) Hopper (Tank) Capacity.. 20 / 30 lbs. Weight of unit empty / 88 lbs. Hopper Structure.. Aluminum PTFE Teflon impregnated Filtration. Manifold basket filter Adhesive Forms.... Accepts most forms Electrical: Supply Voltage 115~120 x 20 amp / 208~240 x 30 amp VAC 1P, 50/60 Hz Power Consumption, system maximum ~120 / 208~240 VAC : 2400 / 7200 W Power Consumption, hopper ~120 / 208~240 VAC 1200 / 3000 W Hopper Heater Type.. Cartridge tubular Temperature Control... Microprocessor Temperature Sensors Ohm Nickel RTD Standard (100 Ohm Platinum RTD Optional) Electrical Connectors. Durable, easy release, latching connectors Max. Current available for Hose & Head Pair.. 115~120 / 208~240 VAC system 10 A

13 Machine Description & Specifications Page 3 Chapter 3 Pressurized Air: Air pressure supply (must be clean & dry)... 20~100 psi ( 1.4~6.8 bar ) ( 10 5 Pa ) Air consumption at 60 pump cycles per minute... Standard 3.2 SCFM for 100 psi (90 L/min) Performance: Adhesive temperature control range.. 0 F ~ 450 F ( 40 C ~232 C ) Adhesive temperature control accuracy. ±1.8 F ( ±1 C ) Over-temperature control cutoff for hopper F ( 240 C ) Adhesive Viscosity. 500 ~ cps Warm-up time, full hopper.. approximately 0.4 hr Adhesive delivery rate, open line 1.32 lbs/min (0.6 kg/min) Adhesive melt rate (depends on adhesive used). 120v system 15 lbs/hr (6.80 kg/hr) 240v system 20 lbs/hr (9.07 kg/hr) Adhesive Pressure. up to 1200 psi maximum ( 82 bar ) 3 Temperature Control: Display Type. Long life, light-emitting diode (LED) Temp. Controllers. 3~9 relay-outputs Power output Hopper 120 / 240 VAC system: / 3000 W Hoses / Heads 120 / 240 VAC system: / 2400 W Fuses... 5 x 20 mm Fast Hopper Solid State Relay control :. 50 Amp Hopper 240v system :.. 10 Amp fast open Hopper 120v system : 12 Amp fast open Hoses / Heads 120v & 240v system : 10 Amp fast open Others: High & Low Temp. Alarm. Yes Sensor open error message. Yes Adjustable System Ready Controls Yes Hopper Level Control... (Optional)

14 Machine Description & Specifications Page 4 Chapter 3 MP20 series ASU Manual Features & Outline This section describes the basic features and outline dimensions of the MP20 series hot-melt systems. Front-Panel Features 3 Tank temp controller Individual temp controllers for each heating device Individual power switches for each temp controller Tank heating indicator Locations for adding more hoses & guns Pump On/Off Switch Main power indicator System Ready indicator Front View of the MP20 Hot-Melt Unit

15 Machine Description & Specifications Page 5 Chapter 3 Back-Panel Features 3 Un-used zone covers Hose/Gun zone plugs Identification name plate Easy open access door to the melting pot heaters, RTD, & thermostat System air input location Hose fluid port fittings Back View of the MP20 Hot-Melt Unit

16 Machine Description & Specifications Page 6 Chapter 3 Side-Panel Features Larger opening for adding adhesive 3 Drain valve Tank filter Right Side View of the MP20 Hot-Melt Unit Easy access pump cover Control door flips fully open for easy access to internal items Piston pump under the pump cover Left Side View of the MP20 Hot-Melt Unit Power & auxiliary hook-up cable grips

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18 Introduction Chapter 4 - Installation Chapter 4 Installation Page 1 This section contains installation procedures for the MP20 hot-melt units. Selecting a Location Before mounting the hot-melt unit to the parent machine, keep in mind that service personnel will need access to the front of the unit for electrical service, the right side of the unit for changing the filter, the rear end of the unit for changing the glue hoses, and enough over-head clearance to be able to remove the piston pump cover for servicing items under the pump cover. Also keep in mind that: 4 1. The location should be proximate to the glue station so that the glue hoses can be routed to the applicators in as straight of a line as possible. 2. The location for the unit should be clean. Dirt in glue tank can cause clogging of the applicator nozzles. 3. The unit should be protected from high and low ambient temperatures, as well as from rapid changes in ambient temperature. 4. The unit should be protected from condensation and water. 5. The unit should be protected from strong vibrations. Mounting the Unit To mount the hot-melt unit, follow these steps: 1. Select the location on the parent machine. If desired, bolt the unit to the parent machine. 2. Use approved hardware parts that can withstand any stress factors that the unit may experience. 3. Use the mounting foot print diagram to properly position the mounting holes and drill the holes. 4. Properly tighten all mounting hardware to ensure that the mounting does not work loose later on. Note! Unit footprint is compatible with most existing hot melt unit bolt patterns.

19 Connecting the Power Chapter 4 Installation Page 2 The MP20 hot-melt units can be purchased in two power ranges. 115~120 volt VAC x 20 amp supply and 208~240 volt VAC x 30 amp supply 50~60Hz single-phase power supply with ground. All units are configured with a 30-amp thermal breaker for a main power switch. ELECTRICAL Ensure that external power source is turned off before connecting to the MP20 hotmelt unit. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR. Only experienced service personnel should connect power to the MP20 hot-melt unit. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR. To connect the power, follow these steps: A 12ga 3 wire power cable is needed to connect to the unit. 4 Connect one line wire to the L1 terminal, the other line wire to the L2 terminal, and the Green wire to the GND (ground) terminal as shown. Ground L2 Line L1 Line Main power input terminal block Obtain a properly rated electrical power plug that fits your in-house receptacles and attach it to the cable or hard wire the cable to a properly rated power supply box following all of the proper codes for doing so.

20 Connecting the Air To connect the air, follow these steps: Chapter 4 Installation Page 3 CAUTION: The air supply to all hot melt application equipment must be a clean dry air supply or you will risk damaging the equipment or cause the life of internal components to shorten. For proper volume of air flow to the melt unit connect an air line properly fitted for no less than a 1/4 NPT fitting into the female coupling on the rear of the unit. Attach a properly rated air regulator for use with air supplies of up to 100psi of air pressure. For initial installation adjust the air regulator to supply 45~50psi of clean dry air into the unit. CAUTION: Do not exceed 90psi pressure to the unit or you may cause a failure within the unit or personal injury. 4 Air Regulator (Rear View of Unit)

21 Connecting the Glue Hoses to the Unit Chapter 4 Installation Page 4 WARNING! When routing and installing heated hoses, avoid sharp corners and edges. Do not bend hoses sharper than 8 (203mm) radius. Keep hoses away from walk-ways. Do not group heated hoses so that they are in contact with one another. Do not flex hoses back and forth when they are cold. Do not flex hoses for extended periods of time when they are hot. OTHERWISE, DAMAGE TO HOSES COULD OCCUR. To connect the glue hoses to the MP20 hot-melt unit, follow these steps: Select the end of the glue hose that has the cable assembly with the pin contacts in the male electrical connector. Attach this end of the glue hose to the fluid fitting on the hot-melt unit manifold. Note! Straight fittings are standard; 45 & 90 fittings are available from MeltPro, Inc. 4 Hose/Gun connectors Connector with pin contacts Standard straight fluid fitting Fluid Fittings and Hose Electrical Connections on MP20. Connect the cable assembly s male electrical connector to the electrical receptacle on the left side while facing the rear of the MP20. Connections are as follows: Zone-1 receptacle: hose 1, applicator 1 Zone-2 receptacle: hose 2, applicator 2 Zone-3 receptacle: hose 3, applicator 3 Zone-4 receptacle: hose 4, applicator 4 Note! Fuses for each hose & applicator are located in the electrical enclosure.

22 Connecting the Glue Hoses to the Applicators To connect the glue hose to the applicator, follow these steps: 1. Mount the applicator in the desired location on the parent machine. Chapter 4 Installation Page 5 2. Connect the end of the glue hose to the fluid fitting on the applicator so that hose is in the most relaxed position possible and tighten securely. 3. Connect the cable assembly s female connector with the socket contacts to the cable assembly on the applicator. 4 Female connector with socket contacts Glue Hose Male connector with pin contacts Applicator fluid fitting Applicator

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24 Setup Page 1 Chapter 5 MP20 series ASU Manual Chapter 5 Initial Setup Introduction This section contains initial-setup procedures for the MP20 hot-melt applicator units. Initial Setup To conduct initial setup, follow these steps: WARNING! If an air hose is used, use eye protection. OTH- ERWISE, PERSONAL INJURY COULD OCCUR. Filling & starting the unit: Using an air hose or a damp cloth, clean the tank of foreign matter that may have collected during installation. 5 Note! If a damp cloth is used, ensure the tank is completely dry before filling. Fill the tank with adhesive. Note! Tank capacity is 20lbs. (9.0 kg.) for the MP20 20lb. unit and 30lbs. (13.6kg.) for the MP20 30lb. unit. Set the main power on/off switch to the ON position. When the units are shipped from MeltPro, the only temperature controller that is turned on will be the tank controller. If for some reason the tank temperature controller does not come on during main power up check the on/off rocker switch for the tank controller to make sure that the switch is in the on position. Check the set point temperature on the controller by pushing the set button. If the set temperature is not the temperature desired, adjust the temperature by using the up or down arrow buttons on the controller until the desired temperature set point is reached. After the desired set point is reached, you must press "set" again to accept the change. Adjusting buttons Set button Controller power switch Note! The factory default programming of the temperature controllers has the High Temperature Alarm set to alarm at 425 F. If your desired setpoints for the unit or connecting devices need to exceed this amount you will need to alter the internal settings of the controllers. See Chapter-6 for instructions on how to change these settings or contact MeltPro for assistance.

25 Setup Page 2 Chapter 5 MP20 series ASU Manual Note! It will take minutes to melt 20 lbs (9.0 kg) of adhesive depending on the viscosity of your adhesive. During power output to the devices heater elements, the temp controller will display or light up an output indicator in the upper corner of the controller. When the tank temperature has been reached, the heater "output" indicator light will go out until the temperature drops below setpoint. It will then cycle to maintain set temperature. If at this time you have not connected the glue hoses and applicators, do so at this time. Warning: The surface areas around these connection points may already be hot enough to burn you. When connecting a hose or applicator gun be sure to wear protective coverings and gloves. OTHERWISE, PERSONAL INJURY COULD OC- CUR. After properly connecting the hoses and applicators you can now turn on each of those devices by switching on their related temperature controllers on the front panel. As you did with the tank setting, check and set the desired temperature set point for each device. Warning/Caution! Never at any time should you try to connect or install any used device to any hot melt system that is colder than the softening point of any adhesive residue that may be in the connection points of the devices. Doing so will cause you to damage the connection points and cause serious performance problems. 5 Setting the System Ready Controls: The main purpose of the System Ready Controls is to prevent the operation of the units piston pump before the adhesive within the unit has melted enough to allow the pump to operate without causing damage to the pump. At this time, the MP20 series of melt units use an adjustable bulb & capillary type of a thermostat for a system ready control device. To properly set the system ready thermostat: 1. Make sure that the melting pot of the unit is at least half full of adhesive. 2. From a dead cold start up, power the system on and make sure that you have set the tank temperature controller to the desired heating setpoint. 3. Open the main cabinet door and located on the back wall you will see the thermostats control unit. Turn the knob of the control unit clockwise as far as the knob will turn. 4. Monitor the tank temperature controller as it climbs up to your setpoint. As soon as the tank controller gets to the setpoint value, note what the current time is. 5. Once 10 minutes has past since the controller got to setpoint for the first time, slowly turn the thermostats control knob counter clockwise until you see the System Ready light on the front of the control panel turn on. 6. Close the control cabinet door and continue with setting up for normal operation. The default factory setting for this device is 10 minutes after the tank has gotten to a setpoint value of 350 F. If you are using an adhesive at a different operation setpoint or an adhesive that is difficult to melt, it will be necessary for you to re-adjust the system ready to turn on at a different time frame. Be sure to continue reading the next page for additional information regarding the system ready controls.

26 Setup Page 3 Chapter 5 MP20 series ASU Manual Note! When the thermostat is active (closed) it will allow power to go to the PMI terminal block and to the piston pumps On/Off switch located on the front control panel. Once the PMI terminal block has power going to it, power will be sent out to any parent machine relay you have installed. The piston pump will not turn on until you have turned on the pump switch on the control panel. System Ready thermostat 5 Purging the system: 1. Wait until the hoses and applicators have gotten to their set point temperatures and the system ready light is turned on. 2. Place appropriate containers under the applicator heads to catch any discharged material. 3. Actuate the applicator heads to their open positions. 4. Set the pumps On/Off switch to the On position. 5. Using the air supply line regulator, slowly increase the air pressure until the pump begins to operate. Note! The pump should begin to operate at about 10 psi. 5. Let the pump run slowly until the hoses and applicator heads are filled with adhesive and purged of air and any other liquids that may be in them from the factory. 6. Disengage the applicator heads back to their closed position. 7. Top off adhesive in tank. 8. Increase the input air supply to the desired pressure and test fire the applicators. CAUTION: Do not exceed 90psi pressure to the unit or you may cause a failure within the unit or personal injury.

27 Setup Page 4 Chapter 5 MP20 series ASU Manual Using the Parent Machine Interlock: (PMI) The PMI terminal block is a connection point within the MP20 series units that the customer can use to activate an external device at the same time that the melt unit gets to the Ready state and turns on the piston pump. It is most often used to trigger a Solid State Relay type of device that in turn is connected to the Start-Up signal of the parent machine. This is used to prevent the parent machine from running until the gluing system is fully up to its operational state and ready to dispense glue out the applicators. To connect & use the PMI follow these steps. 1. First you will need to install a device like a solid state relay to the parent machine. The output side of this relay should be connected in line right after the On signal of the parent machine so that even if the parent machine is turned on, it will not start to operate until the solid state relay has been triggered on. 2. Next you will need to run a 3 wire (2 lines & 1 ground) 12~18ga cable from the triggering coil side of the relay to the MP20 unit. There is a cable grip for small cables on the lower front left hand side of the units mounting base. Run the cable thru this cable grip up into the control cabinet of the unit. 3. Connect the ground wire of your cable to a chassis ground location within the unit. 4. Connect the 2 hot lines of the cable to the locations shown on the PMI terminal block. 5. Leave a small amount of excess cable pulled up into the control cabinet or under the cabinet in the base area and tighten the cable grip to prevent the cable from being snared out of the unit. 5 Ground L1 output side L2 output side Caution: Available voltage coming from the PMI for triggering a relay is the same as the supply voltage. Do not connect the PMI to any device that could pull more than 2 amps max of current. To do so you could damage the melt unit or the connecting device.

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29 Chapter 6 Operation Chapter 6 Operation Page 1 Introduction This section contains operational procedures for the MP20 hot-melt applicator units. Operating the Temperature Control The MP20 hot melt unit contains up to nine single-output digital thermo-regulators that are able to cover a temperature range of 99 C to +999 C and 99 F to +999 F. During normal operation, the temperature control displays the current actual temperature read by the probe for that device. If an alarm becomes active, the temperature control displays a flashing alarm code and the buzzer sounds an intermittent tone until the controller has been switched off and back on again. If the cause of the error has not been fixed, this process will continue until the problem has been resolved. Programming the Setpoint Temperature To program the setpoint temperature, follow these steps: 1. Press the set button. The temperature control displays the setpoint value, and the output LED flashes. Note! When the output LED is illuminated, it indicates that the zone is heating up. Once the zone reaches the setpoint temperature, the output LED goes off. 2. Press either the up arrow button or the down arrow button until the desired temperature is displayed. Press the set button again to store the new setpoint and return to the normal operation mode. 6 Note! Pressing the down arrow button decreases the setpoint value; pressing the up arrow button increases the setpoint value. Pressing and holding either of the arrow buttons causes the displayed value to increase or decrease faster. Temperature Controller (units produced prior July 2009) Temperature Controller (units produced after July 2009)

30 Chapter 6 Operation Page 2 Note! The following information for accessing the internal parameters and settings of the temperature controller is for the EVK-411 version of the controller being installed in all units as of July of For information on the older FK-400T settings please contact MeltPro. Internal parameters The internal programming parameters of the controller are pre-set by MeltPro for the most common use of the controller. Other than changing the set-point value to meet your needs or to switch the controller from displaying the temperature from Fahrenheit to Celsius the internal parameters should not be altered. In some cases you may also need to access the internal parameters to help trouble shoot a possible problem with the operation of the controller. Accessing Internal Parameters To access and change the internal parameters, follow these steps: 6 Press the up and down arrow buttons at the same time and hold them for 4 seconds until PA displays. Press the set button. Press the down button to change the value to 19. Press the set button. Press the up and down arrow buttons at the same time and hold them for 4 seconds until SP displays. Use the up and down arrow buttons to cycle through the parameters. Press the set button to display the value of a parameter. Use the up and down arrow buttons to change the parameter value. Press the set button to store the new value. After making the necessary changes to the internal parameters press the up and down arrow buttons at the same time and hold for 4 seconds to exit the parameters menu. Actual temperature is now displayed. Notes: When changing from a Fahrenheit display to a Celsius display (parameter P2) all of the following internal parameters must also be changed to reflect the Celsius value for those parameters: Parameter P2 is changed first. Then SP, R2, and A1. Internal Parameters Temperature-Control Parameters Symbol Name Description SP CA1 Device set point Probe Calibration The working temperature set point. Must be between R1 & R2 value. Set at 350. Establishes an offset that is added algebraically to the signals coming from the measure inputs. Set at 0. P0 Type of probe (Warning: Contact MeltPro before changing) 13 = 2 wire Ni120 5 = 2 wire Pt100 Set at 13. (Warning: Contact MeltPro before changing)

31 Internal Parameters Temperature-Control Parameters (continued) Chapter 6 Operation Page 3 Symbol Name Description / Setting P1 P2 Decimal point position. Display units Position of display decimal place. Set at 0 Establishes the differential in degrees C/F relative to the working setpoint. Set at 1. 0 = Celsius / 1 = Fahrenheit P3 Min transducer range. Set at 20 P4 Max transducer range. Set at 80 P5 Value displayed during normal operation. Value shown during normal operation. Set at 0. 0 = Probe temperature / 1 = Set point R0 Working setpoint differential. Establishes the differential relative to the working setpoint. Set at 2 R1 Minimum set point value. Establishes the minimum working setpoint in degrees. Set at 0. 6 R2 Maximum set point value. Establishes the maximum working setpoint in degrees. Set at 500. R3 R5 Set point locked. Cooling or heating. Set point lock out 0 = Unlocked / 1 = Locked Set at 0 Selection of heating or cooling operation 0 = Cooling / 1 = Heating Set at 1 C1 Minimum minutes between load starts. Set at 0. C2 Minimum minutes load must remain off. Set at 0. C3 C4 C5 Minimum seconds the load must remain turned on. Off time of fault cycle. On time of fault cycle. Set at 0. During probe error, time load is off. Set at 10. (allows heater to activate during a low temperature alarm) During probe error, time load is on. Set at 10.

32 Chapter 6 Operation Page 4 Defrost Parameters None of the defrost parameters of the controller are used. All D parameters are set to 0. HI Alarm Parameters (AL1) Note! Any button can be pressed to turn off the audible alarm. However, pressing the down arrow button does not correct the alarm condition. Symbol Name Description A1 Alarm setpoint. Establishes the temperature at which time the alarm is activated. A2 Alarm disable time from instrument start. Set at 425 Set at 0 A3 Type of alarm. Set at 2 (absolute upper temperature alarm) A4 Alarm disable time from setpoint change. Set at 15 minutes LO Alarm Parameters (AL2) 6 Note! Any button can be pressed to turn off the audible alarm. However, pressing the down arrow button does not correct the alarm condition. Symbol Name Description A5 Alarm setpoint Establishes the temperature at which time the alarm is activated. A6 Alarm disable time from instrument start Set at 0. Set at 1 minutes A7 Type of alarm Set at 1 (absolute lower temperature alarm) Serial Network Settings None of the serial network settings should ever be changed unless instructed so by MeltPro. Symbol Name Description LA Address Set at 247 L6 Baud rate Set at 2 LP Parity Set at 2 E9 Reserved for future Set at 1

33 Chapter 6 Operation Page 5 Operating the Piston Pump The MP20 series hot melt units have a mechanical thermo-regulator tied into the piston pumps air solenoid valve that prohibits the operation of the piston pump unless the adhesive within the unit has reached a usable liquid state. During the initial set-up of the unit or at any time that the type of adhesive or the setpoint value of the melting pot is changed, this adjustable thermostat must be reset to turn on the pump solenoid valve when the adhesive is at least to a 30% all liquid state. The default way to set this thermostat is using a combination of temperature and time. From a dead cold start up, you will turn the unit on and wait until a minimum of 10 minutes has past since the tank temperature has made it to the setpoint value for the first time. Then you will turn the thermostat knob counter clockwise just until the System Ready light comes on and the pump starts running. Once the units System Ready light has turned on, you can control the on/off operation of the pump by way of a toggle switch located on the front of the main control panel. Piston Pump On/Off switch 6 The piston pump is powered by an air cylinder. Shop air drives the cylinder downwards to trigger a pneumatic switch. The pneumatic switch shifts the four-way air valve that reverses the piston s direction of travel. The cylinder rises until it activates the pneumatic switch at the top of its travel and again the air valve is activated to reverse the direction of travel. The piston is powered continuously by the shop air supply. Typical operation range for the 16:1 ratio pump is from 30~60 psi of air pressure. The minimum required air pressure to operate the pump is 10psi and the maximum air pressure to supply the pump must not exceed 90psi. CAUTION: Do not exceed 90psi pressure to the unit or you may cause a failure within the unit or personal injury. A pressure-relief pop-off valve can be ordered from MeltPro to install at the inlet of the air cylinder to prevent accidental overpressurization of the system. This pop-off valve can be ordered for a range of operational settings. To further protect the system from over-pressure, a fluid-pressure relief valve is provided in the floor of the units hopper. This fluid-pressure relief valve is preset at 1200 psi and should not be changed under any circumstances without first consulting MeltPro, Inc. Engineers.

34 Chapter 6 Operation Page 6 THIS PAGE IS BLANK. 6

35 Chapter 7 Maintenance Maintenance Page 1 Chapter 7 Introduction This section contains guidelines and procedures for maintaining the MP20 hot-melt unit. Your hot-melt system will run longer and more consistently if a preventative maintenance program is used. Daily attention to the maintenance of your system is recommended. General Maintenance Instructions MeltPro recommends the following general maintenance: Keep the tank as full of adhesive as possible. This reduces the formation of charred adhesive on the interior side walls of the tank. Keep the tank lid closed. (Any contamination in the tank will increase the chance of poor performance. Moisture, dirt, and charred adhesive are the major causes of clogged nozzles.) Note! In order to prevent pressure buildup in the tank, the tank lid does not have a seal. Remove adhesive spills immediately. (Use a putty knife while the material is still soft.) While the unit is still hot but not operating, use cheesecloth to remove material leaking from the pump seal and other connectors. External leakage indicates that service is required. Shut down the system once a week, remove and clean the manifold filter. Replace the filter if it cannot be thoroughly cleaned. Completely drain and clean the system when clogging due to charred adhesive or dirt becomes frequent. Periodically clean the exterior of the MP20 hot-melt unit. 7 Cleaning the Exterior of the Unit To clean the exterior of the MP20 hot-melt unit, follow these steps: 1. Turn off the main power. CAUTION! Never hose or steam-clean the unit. If the surrounding are is cleaned in this manner, protect the unit by covering it with plastic or other waterproof material. OTHERWISE, DAMAGE TO EQUIPMENT COULD OCCUR. 2. Using a damp cloth, clean the control cabinet with a mild soap-and-water solution. 3. The rear half of the unit can be cleaned in this manor as well but caution must be taken if the rear half of the unit is still close to its operating temperature. Heat will move very quickly thru a damp cloth and it could burn you if you are not careful.

36 Changing the Adhesive Chapter 7 Maintenance Page 2 CAUTION! When changing adhesives, always consult adhesive suppliers to check compatibility between adhesives. OTHERWISE, DAMAGE TO EQUIPMENT COULD OCCUR. To change the adhesive, follow these steps: If the old adhesive and the new adhesive are compatible, pump enough of the new adhesive through the system to ensure that all of the old adhesive has been cleared out (generally 3 to 5 lbs or 1.1 to 1.9 kg.) If the two materials are not compatible, flush the system (see Flushing the System below) Flushing the System The system needs to be flushed under the following circumstances: When changing to an adhesive that is not compatible with the previously used adhesive When loose particles of charred adhesive are causing frequent clogging of screens and nozzles MeltPro recommends using paraffin wax to flush the unit. CAUTION! If a solvent is to be flushed through the hot-melt system, consult the adhesive manufacturer about which solvents are recommended for use with the specific adhesive you are using. The solvent must be compatible with silicone, Viton, Teflon, carbon graphite, and aluminum. OTHERWISE, DAMAGE TO EQUIPMENT COULD OCCUR. To flush the system follow these steps: 7 1. Place an adequate supply of either paraffin wax or suitable cleaning solution into the unit. Note! Reduce the temperature control setting to 300 F (148 C) for paraffin wax. Consult your supplier for proper temperature setting if cleaning solution is being used. 2. Pull up on the air-pressure regulator knob and turn it counterclockwise as far as it will go. (The airpressure gauge should indicate zero pressure.) WARNING! If the system is hot, wear insulated gloves and eye protection when disconnecting hoses. TRAPPED PRESSURE MAY CAUSE ADHESIVE SPRAY, RESULTING IN DEATH OR PERSONAL INJURY. 3. Manually activate the applicators to relieve any system pressure buildup if the system is hot. 4. Disconnect glue hoses from applicators and collect purged material with appropriate container. 5. Turn the MP20 unit on and allow minutes for hoses and heads to reach temperature and for the system ready light to turn on. 6. Pull out on the air-pressure regulator knob and slowly turn it clockwise until the pump begins to operate. 7. Pump 5-6 lbs (2 kg) of material through the unit and glue hoses. Note! If particles are still present in the discharged material, additional material may be needed to flush the unit completely free of charred adhesive. 8. Once adhesive has been purged through the glue hoses, pull out on the air-pressure regulator knob and turn it counterclockwise as far as it will go. (The air-pressure gauge should indicate Zero pressure.)

37 Maintenance Page 3 Chapter 7 MP20 series ASU Manual 9. Remove to clean or replace any inline filter attachments going to each applicator on the system. 10. Remove to clean or replace the tank hopper glue filter. 11. Reconnect the glue hoses to the applicators. 12. Turn the air pressure back on and activate the applicators to purge remaining adhesive through the valve's. 13. Reset the temperature control to the correct setting for the material you are using. Note! The new material can now be pumped through the system. Parts Replacement Occasionally, parts may need to be repaired or replaced. The following paragraphs contain instructions for removing parts from the MP20 hot-melt unit. For drawings and a complete list of part numbers, see Chapter 9 - Part-Number List. Piston-Pump Assembly To remove the piston-pump assembly, follow these steps: 1. Disconnect air. 2. Remove the pump cover housing. 3. Warm the unit so adhesive is fluid. 4. Turn off the main power. 5. Disconnect the air line from the pump body. 6. Remove the three mounting bolts from the pump-mounting flange. 7. Lift out the pump assembly. Pump cover Pump air line Pump cover screws Piston Pump 3 Pump Mtg Screws Tank hopper filter 7 Glue-Filter Assembly To remove the glue-filter assembly, follow these steps: 1. Heat the tank until the manifold is hot. 2. Disconnect the air supply line. 3. Open the applicator valves to release the pressure. 4. Turn off the main power. 5. Using a flathead screwdriver, a 1/2 SAE wrench, or 1/2 SAE socket remove the filter assembly by turning it counter-clockwise. 6. Install a new or properly cleaned filter assembly in the reverse order.

38 Maintenance Page 4 Chapter 7 MP20 series ASU Manual Drain-Valve Assembly To remove the drain-valve assembly, follow these steps: 1. Heat the tank until the manifold is hot. 2. Disconnect the air hose from the regulator. 3. Open the applicator valves to release the pressure. 4. Turn off the main power. 5. Remove the drain-valve position screw and remove drain-valve assembly Note! Allow all liquid to drain from tank. Re-insert drain-valve assembly and the positioning screw. Drain valve position screw RTD Sensor Replacement The RTD sensor used in the MP20 units will be of different sensing types depending on what type of external devices that the unit was ordered to work with. Example: If the MP20 was ordered to work with Nordson type of hoses & guns then the sensor will be the Ni120 type of sensor and the Pt100 type of sensor if the unit was ordered to work with ITW or Slaughterback types of equipment. 7 To replace a faulty sensor: 1. Disconnect power. 2. Open the rear access door. 3. On the backside of the door remove the 2 wires going out the RH side of the 2 pole terminal block. 4. Remove the faulty sensor from its location in a hole to the right side of the opening. 5. Insert the new RTD into the hole in the base of the pot. 6. Run the 2 new wires down to the 2 pole terminal block and install them into the block. 7. Close the rear access door and re-connect the power to the unit. RTD terminal block RTD Sensor

39 Maintenance Page 5 Chapter 7 MP20 series ASU Manual Tank Heater Replacement In the unlikely event that one or more of the melting pots heater elements fail, any one or all of the heaters can be replaced in the MP20 series units. The troubleshooting guide can help you to determine if any of the heaters are faulty and which one of them may need to be replaced. Use this section here to guide you thru replacing a heater element. 1. Disconnect power. 2. Open the rear access door. 3. On the backside of the door there is a 4 pole terminal block. The 2 poles to the left of the block are where the heater wires are connected. Remove the 2 groups of heater wires from the terminal block. 4. There are 4 cartridge heater elements along the base of the melting pot behind the insulating blanket material. There are slits cut into the blanket to help you find the location of the heater elements. 5. Locate the heater that needs to be replaced and slide the heater out of the base of the melting pot. You may have to use something like a small screwdriver and a hammer to gently tap on the outer edges of the heater wall to loosen the heater from its hole in the event that the heater has heat seized itself to the heater hole or if the burning out of the heater has caused it to warp. 6. When replacing the new cartridge heater coat the heater element with a thermal transfer paste and let it dry prior to installing it into the pot base. 7. Properly reconnect all the heater wires per the heater wiring diagram in the Schematics section of this manual. 8. Reconnect the heater wires to the 4 pole terminal block where they came from. 9. Close the rear access door and re-connect the power supply to the unit. CAUTION: When re-connecting the heater wires to the ceramic terminal block, make certain that you DO NOT have and bare wire showing outside of the terminal block. Doing so may result in a short circuit flash that will harm you or damage the melt unit. 7 Cartridge Heaters 4 Cartridge Heaters L2 Black L1 Red Power Terminal block

40 Maintenance Page 6 Chapter 7 MP20 series ASU Manual Thermal Fuse Replacement (Thermostat) The over-temperature protection used in the MP20 melt units is a manual reset thermostat that can easily be accessed and reset, reducing downtime and improving product quality. Field replacement or re-setting of the thermostat can be performed as follows: 1. Disconnect power. 2. Open the rear access door. 3. To re-set the thermal fuse simply push in on the center peg, close the access door, re-connect the power and test the system for proper operation. 4. To replace the thermal fuse perform steps #1 & #2. 5. Disconnect the 2 thermostat leads from the terminal block. 6. Remove the mounting screws, and thermal fuse. 7. Replace the thermostat with the new one. 8. Re-connect leads to the terminal block. 9. Close the rear door and re-connect the power. 7 Over-Temp Thermostat Power Terminal block

41 Maintenance Page 7 Chapter 7 MP20 series ASU Manual Circuit Fuse Replacement The fused circuits within the MP20 units are a type that has a Blown Fuse Indicator light on the top of the fuse holder casing. When looking across the top of the fuse holders if you see a light turned on then the fuse within that holder has blown. First of all steps must be taken to determine why the fuse has blown. A blown fuse is an indication that something has allowed a larger amount of current to flow thru that circuit of the system then what is allowed for that circuit. Once you have verified that the circuits have been properly fixed follow these steps to replace the blown fuse. 1. Disconnect the power on the unit. 2. Unplug from the main terminal block the fuse holder that had the blown fuse indicator light lit up. 3. The side of the fuse holder that has the small window that lets you see the fuse is the door of the fuse holder. Snap the door open on the holder. 4. The fuse is attached to the inside of the holder door by fuse clips. Remove the blown fuse from the door clips and properly discard the bad fuse. 5. Install the new properly sized fuse into the door clips of the fuse holder door. Note! See the Part number or Schematic chapter for the proper fuse size used in this unit. 6. Snap the door closed. 7. Plug the fuse holder back into its location on the terminal block. 8. Re-connect the power to the unit. Fuse holder Blown fuse Indicator light 7 Window Fuse holder door Fuse Fuse holder Fuse clips

42 Maintenance Page 8 Chapter 7 MP20 series ASU Manual Temperature Controller Replacement To replace a faulty temperature controller follow the following steps. 1. Turn off and disconnect the main power to the unit. 2. Open & swing the control panel door to the fully open position. 3. Disconnect the controller-to-switch wire from the rocker switch. 4. Follow the controller cable assembly back to the plug & socket connection and disconnect the two from each other. 5. Push in on the center of each of the controller mounting tabs to unlock the tabs and slide them towards the back of the controller to remove them. 6. Slightly raise the control door and slide the faulty controller out away from the front of the control door. 7. Re-install the new controller in the reverse order. When reinstalling the controller mounting tabs be certain to slide the tabs on enough to firmly secure the controller to the control panel. Control to Switch wire 7 Control cable plug Controller Mtg tabs Temp Controller

43 Chapter 7 Maintenance Page 9 THIS PAGE IS BLANK. 7

44 Chapter 8 Troubleshooting Troubleshooting Page 1 Chapter 8 Introduction This section contains troubleshooting procedures for the MP20 hot-melt applicator units. WARNING! Turning off the power on the MP20 Hot-melt unit does not render the unit harmless. Input supply power is accessible at the terminal block on the MP20 hot-melt unit. Disconnect the power cord or the main breaker box that the unit is connected to. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Problem Possible Cause Solution 1. Material in tank will not melt 1a. Temperature control malfunction or adjustment 1b. Loose connectors 1c. Broken connectors 1d. Shorted connectors 1a. Check indicator lights. Reset adjustments. 1b. Tighten connectors. 1c. Repair connectors. 1d. Repair connectors 2. No Adhesive output 2a. Adhesive not hot enough 2b. System Ready T-Stat not ready 2c. Temperature control malfunction 2d. Pump intake clogged 2e. Pump clogged internally 2a. Allow additional warm-up time (20-45 minutes) 2b. Check adjustment, replace if needed. 2c. Replace temperature control 2d. Remove pump assembly and clean intake port. 2e. Remove pump assembly, disassemble pump and clean. Cylinder problem: 8 2e. No air supply 2f. Regulator set incorrectly 2g. Regulator malfunction 2h. Control circuit malfunction 2i. Cold glue modules 2j. Manifold filter clogged 2k. Damaged hose 2l. Temperature control not working 2e. Check shop air system. 2f. See setup procedures 2g. Replace regulator. 2h. Check fuses 2i. Check RTD. Replace if necessary. 2j. Replace manifold filter 2k. Replace hose 2l. Check parameters. Replace if necessary.

45 Chapter 8 Troubleshooting Page 2 Problem Possible Cause Solution 3. Uneven flow of adhesive to applicators 3a. Material viscosity too high due to tank temperature being too low. 3a. Raise tank temperature in accordance with adhesive manufacturer s specifications. 3b. Wrong adhesive 3c. Adhesive overheated 3d. Glue hoses not at the same temperature 3e. Adhesive supply low 3f. Manifold partially clogged 3b. Seek adhesive manufacturer s recommendations 3c. Reduce tank temperature in accordance with adhesive manufacturer s specifications. 3d. Reset temperature controls. 3e. If sides of tank are charred, drain, clean, flush and refill. 3f. Drain, clean, flush and refill. 3g. Nozzles partially clogged Different pressure drop through each hose: 3h. Hoses not the same length 3g. Inspect system for charred adhesive and foreign matter. Drain, clean, flush, and refill. 3h. Use same length hoses 3i. Crimped hoses(s) 3i. Replace hose 4. Air in applied adhesive 5. Charring or gelling of adhesive in the tank 3j. Leaking hoses(s) 3j. Replace hose 4a. Adhesive supply low 4a. Refill and purge system of air. 5a. Tank temperature too high 5a. Lower tank temperature in accordance with adhesive manufacturer s specifications 8 5b. Temperature control malfunction 5c. Surface oxidation of the adhesive in the tank 5d. Poor adhesive heat stability 5e. Low tank level 5b. Replace temperature control 5c. Keep tank closed 5d. Change adhesive. If not possible, keep tank temperature to a minimum. 5e. Keep tank full

46 Chapter 8 Troubleshooting Page 3 Problem Possible Cause Solution 6. Fuming or smoking of adhesive in the tank 6a. Poor heat control 6b. Poor heat stability of adhesive 6a. If necessary, replace tank temperature control Keep tank covered 6b. Lower tank temperature in accordance with adhesive manufacturer s specifications Consider another adhesive Keep tank covered 7. Tank will not Heat 7a. Overtemp Thermostat has been tripped 7b. Faulty RTD 7a. Disconnect Power. Open the rear access door. Pull back the insulation and locate the small round thermostat with white button in the center. Depress button and thermostat should reset. 7b. Check resistance (refer to RTD resistance chart) 8. Temperature Controller flashes Pr1 message error (RTD sensor fault) 8a. Temperature Controller Faulty 8b. Electrical Plugs not engaged 8c. Faulty Tank, Hose, or Gun RTD 8a. Replace temperature controller 8b. Ensure that gun and hose electrical plugs are securely attached. 8c. Check RTD on Tank, Hose, and Gun (refer to Check RTD Section) 8 9. Temperature Controller flashes AL1 or AL2 (High alarm & Low alarm fault) 9a. Temperature Controller Faulty 9b. Faulty Tank, Hose, or Gun RTD 9c. Faulty Heater on Tank, Hose, or Gun 9a. Replace temperature controller 9b. Check RTD on Tank, Hose, and Gun (refer to Check RTD Section) 9c. Check Heater on Tank, Hose, and Gun (refer to Check Heater Section) 10. Temperature that is displayed is erratic and inconsistent. 10a. Faulty RTD 10a. Check electrical connection and then Check RTD (refer to Check RTD section)

47 Chapter 8 Troubleshooting Page 4 THIS PAGE IS BLANK. 8

48 Parts Page 1 Chapter 9 MP20 series ASU Manual How to Order Parts Chapter 9 Part-Number List To order parts, please contact one of the following offices: MeltPro, Inc Berryhill Road Milton, FL Phone (800) Phone (850) Fax: (850) Note! You may also contact a MeltPro sales representative in your region. MP20 Applicator-Units 9 MP20 20lb Unit MP20 30lb Unit

49 Parts Page 2 Chapter 9 MP20 series ASU Manual MP20 Chassis Assembly 20lb Unit 9

50 Parts Page 3 Chapter 9 MP20 series ASU Manual MP20 Chassis Assembly 30lb Unit 9

51 Parts Page 4 Chapter 9 MP20 series ASU Manual MP20 Rear Section Parts Pump air line 30 Piston Pump MPS1200 for 20lb units MPS for 30lb units Handle W/Stud Locknut Thermal rods Male door hinge A Mtg screw MPS1600 Pressure relief valve Female door hinge SW3029 Mtg nut MPS1400 Tank Filter MPS1415 Filter fitting OR-2122 Viton O-ring MPS1500 Drain valve SW20AS012 stop screw Blank cover B Mtg screw B screw Thumb nut Zone Connector (part of rear zone cable assy) A Name plate Screw SW20AS501 Ni120 RTD Temp sensor 9 SW20AS019 Fitting OR-3902 O-ring SW20AS002 Fluid fitting OR-3902 O-ring terminal block Air coupling block SW20AS005 Tube fitting terminal block MPS3024 Over-temp thermostat SW20AS012 Mtg screw Tank Heaters (240 volt units) (4) watts (120 volt units) (4) watts

52 Parts Page 5 Chapter 9 MP20 series ASU Manual MP20 Front Section Parts Lift & Turn Latch assy Rocker switch (240v) B (120v) Red light Temp Controller (see the end of the wiring schematic Chapter for proper part number) Pump On/Off switch Cover plates for un-used zones C screws Washers Nuts Main Terminal block assy (See next sheet) A (240v) C (120v) Green light Power switch B Mtg screws System ready thermostat Cable Harnesses Tank control = Main cabinet harness = v Rear zone cables = v Rear zone cables = Pump air line Valve-to-pump Main air line Valve-to-rear Solid Stae Relay Relay cover PMI Terminal Block (4 pole section) 9 Pump Solenoid Valve (240v) (120v) * tube fitting SW20AS024 90* pipe fitting Main power block Zone cover Plate brkts

53 Parts Page 6 Chapter 9 MP20 series ASU Manual Cable clamp Wing nut nut A set screw Swing hinge brkt R RH swing hinge L LH swing hinge Grommet Grommet Fuseable terminal block Din rail Regular terminal block TB end cap End tie-down Fuse holder Fuses: Fast blow ceramic for 10 amp for 12 amp

54 Parts Page 7 Chapter 9 MP20 series ASU Manual MPS1400 Filter Assembly Item Number Description Part Number 1 Filter Bung MPS Filter Core MPS Filter screen assembly.006 mesh MPS Pan head screw #10-32 X 6 MPS Viton O-ring OR MPS1400 Filter Assembly

55 Parts Page 8 Chapter 9 MP20 series ASU Manual MPS1500 Drain-Valve Assembly Item Number Description Part Number 1 Drain valve main body MPS Ball, ¼ inch diameter, steel MPS Filter drain screw MPS Viton O-ring OR Retaining ring MPS Teflon split ring NO MPS1500. Drain-Valve Assembly

56 Parts Page 9 Chapter 9 MP20 series ASU Manual Pressure-Relief-Valve Assembly MPS1600 Item Number Description Part Number 1 5/16-24 Socket set screw Spring compression Pressure-relief valve Plunger MPS Pressure-relief valve main body MPS MPS1600 Pressure-Relief-Valve Assembly

57 Parts Page 10 Chapter 9 MP20 series ASU Manual MP20 Piston-Pump Assemblies Item # Part Number Description 1 MPS1201 UPPER AIR MOTOR ASSY. 2 MPS1202 LOWER FLUID ASSY FOR 20LB UNIT Item # Part Number Description 1 MPS1201 UPPER AIR MOTOR ASSY. 2 MPS1204 LOWER FLUID ASSY FOR 30LB UNIT 9 Piston-Pump Assembly

58 Parts Page 11 Chapter 9 MP20 series ASU Manual MPS1201 Upper Air Motor Assy 9

59 Parts Page 12 Chapter 9 MP20 series ASU Manual MPS1201 Upper Air Motor Assy ITEM NO. QYT. PART NO. DESCRIPTION 1 1 MPS1235 AIR CHAMBER BODY 2 1 MPS1233 AIR CHAMBER TOP ** ** ** ** 3 1 MPS1234 AIR CHAMBER BOTTOM 4 2 SV0009 1/8 NPT LONG MUFFLER 5 2 MPS BORE AIR PISTON SEAL 6 1 MPS1232 AIR PISTON BEARING RING 7 1 MPS WAY 2 POS AIR VALVE 8 1 MPS1224 ALIGNMENT COLLET 9 4 MPS1238 STAND OFF RODS 10 1 MPS1229 AIR PISTON SHAFT 11 1 MPS1231 AIR PISTON HEAD ** ** 12 1 MPS1227 AIR VALVE BLOCK 13 1 MPS1228 AIR SEAL COLLET 14 1 MPS1225 AIR WIPER SEAL ** ** ** ** ** 15 2 SW20AS020 SET SCREW X.187 CUP POINT 16 1 SW20AS X 1/8 COMPRESSION FITTING 17 6 OR-2009 VITON O-RING 18 2 OR-2033 VITON O-RING A #M2 X.4-6G MTG SCREW A #6-32 X 1 SHCS 21 4 SL-4431-GDO 1/4-20 X.750 SHCS 22 4 SW20S0401 1/4-20 X 1.00 SHCS A 1/4-20 X.750 FHCS A 1/4-20 X SHCS 25 1 MPS1222 PUMP NAME PLATE 26 1 SW20AS012 #5-40 X.187 BHSCS 9 ** = Items part of MPS1201-K rebuild kit

60 Parts Page 13 Chapter 9 MP20 series ASU Manual MPS1202 Lower Fluid Assy for 20lb Units 9

61 Parts Page 14 Chapter 9 MP20 series ASU Manual MPS1202 Lower Fluid Assy for 20lb Units ** ** ** ** ** ** ** ** ** ** ** ITEM NO. QYT. PART NO. DESCRIPTION 1 1 MPS1213 PUMP FLUID BODY 2 2 MPS1223 FLUID STOPPER BALL 3 1 MPS1212 FLUID PICKUP FITTING 4 1 MPS1217 FLUID PISTON SHAFT 5 1 MPS1216 FLUID PISTON SPRING 6 1 MPS1218 FLUID PISTON SEAT 7 1 MPS1219 FLUID PISTON BODY 8 1 MPS1215 FLUID SHAFT TEFLON SEAL 9 1 MPS1237 #3 O-RING PLUG 10 1 MPS PUMP CROSSOVER TUBE 11 1 MPS1214 5/64: SS SPRING PIN 12 4 SW20S0401 1/4-20 X 1.00 SHCS 13 2 OR-2013 VITON O-RING 14 1 OR-3903 VITON O-RING 15 1 OR-2014 VITON O-RING 16 1 MPS1210 MTG PLATE FOR NC20; MP20; ** = Items part of MPS1202-K rebuild kit

62 Parts Page 15 Chapter 9 MP20 series ASU Manual MPS1204 Lower Fluid Assy for 30lb Units LEGEND: (APPLY TO PART) 9 GLT = 620 GREEN LOCK-TITE RLT = THREAD LOCKER RED LOCK-TITE TT = TEFLON TAPE AS = ANTI-SIZGE OL = HIGH TEMP O-LUBE ** = ITEMS PART OF MPS1204-K REBUILD KIT

63 Parts Page 16 Chapter 9 MP20 series ASU Manual MPS1204 Lower Fluid Assy for 30lb Units ** ** ** ** ** ** ** ** ** ** ** ITEM NO. QYT. PART NO. DESCRIPTION 1 1 MPS1213 PUMP FLUID BODY 2 2 MPS1223 FLUID STOPPER BALL 3 1 MPS1212 FLUID PICKUP FITTING 4 1 MPS1240 FLUID PISTON SHAFT 5 1 MPS1216 FLUID PISTON SPRING 6 1 MPS1218 FLUID PISTON SEAT 7 1 MPS1219 FLUID PISTON BODY 8 2 MPS1215 FLUID SHAFT TEFLON SEAL 9 1 MPS1237 #3 O-RING PLUG 10 1 MPS PUMP CROSSOVER TUBE 11 1 MPS1214 5/64: SS SPRING PIN 12 2 OR-2013 VITON O-RING 13 1 OR-3903 VITON O-RING 14 1 OR-2014 VITON O-RING 15 1 MPS1239 FLUID BODY EXTENSION 16 2 SW20M0115 1/16-27 PIPE PLUG B 1/4-20 X 3.50 SHCS 18 1 MPS1210 MTG PLATE FOR NC20; MP20; ** = Items part of MPS1204-K rebuild kit

64 Parts Page 17 Chapter 9 MP20 series ASU Manual Recommended Spare Parts List PART NO. DESCRIPTION QYT. PISTON PUMPS & PARTS MPS1200 PISTON PUMP FOR 20LB UNIT 1 MPS PISTON PUMP FOR 30LB UNIT 1 SV0009 UPPER PUMP AIR MUFFLER (#4) 2 MPS1236 UPPER PUMP SHIFTER VALVE (#7) 1 MPS1215 LOWER PUMP SHAFT SEAL (#8) 1 OR-2013 LOWER PUMP O-RING (20LB #13) (30LB #12) 10 POT ITEMS MPS1400 POT FLUID FILTER ASSY. 1 MPS1413 FLUID FILTER ASSY. SCREEN 1 OR-2117 FLUID FILTER BUNG O-RING 10 MPS1500 POT DRAIN VALVE 1 MPS1600 POT PRESSURE RELEIF VALVE 1 ELECTRICAL ITEMS TEMP CONTROLLERS (unit type dependant) TEMP CONTROLLER Ni120 X 240v (with QD cable) TEMP CONTROLLER Pt100 X 240v (with QD cable) TEMP CONTROLLER Ni120 X 120v (with QD cable) TEMP CONTROLLER Pt100 X 120v (with QD cable) PUMP READY THERMOSTAT 1 9 SW20AS501 POT RTD TEMP SENSOR (for Ni120 units) 1 LT20AS500 POT RTD TEMP SENSOR (for Pt100 units) AMP FAST BLOW FUSES CIRCUIT BREAKER (main power switch) 1 MPS3024 POT OVER-TEMP THERMOSTAT POT SOLID STATE RELAY PISTON PUMP AIR SOLENOID VALVE 1

65 Chapter 10 Schematics Wiring Schematics Page 1 Chapter 10 LEGEND: L1 = POWER LINE LEG 1 L2 = POWER LINE LEG 2 TB = MAIN TERMINAL BLOCK MPL = MAIN POWER LIGHT ON CONTROL DOOR SRL = SYSTEM READY LIGHT ON CONTROL DOOR THL = TANK HEATING LIGHT ON CONTROL DOOR RI = RELAY POWER IN RO = RELAY POWER OUT PMI = PARENT MACHINE INTERLOCK TERMINAL BLOCK SSR = SOLID STATE RELAY IN MAIN CONTROL CABINET WIRE LOCATION EXAMPLE: 10 MP20 ELECTRICAL DIAGRAM FOR 240 VOLT UNITS L2 #6U = TB L2 SECTION - POLE #6 - UPPER POLE ALL FUSES ARE 5 X 20 MM 10 AMP FAST BLOW FOR 240 VOLT UNITS ALL FUSES ARE 10 AMP FAST BLOW. FOR 120 VOLT UNITS L1 & L2 TANK FUSES ARE 12 AMP FUSES, ZONE 1 & 2 FUSES ARE 10 AMP. ZONES 3 & 4 ARE NOT PRESENT IN 120 VOLT UNITS.

66 Wiring Schematics Page 2 Chapter 10 MP20 ELECTRICAL DIAGRAM FOR 240 VOLT UNITS 10

67 Wiring Schematics Page 3 Chapter MP20 ELECTRICAL DIAGRAM FOR 120 VOLT UNITS

68 Wiring Schematics Page 4 Chapter 10 10

69 Warranty Information Warranty & Service Page 1 Chapter 11 Chapter 11 Warranty & Service Updated 8/19/2010 MeltPro, Inc. warrants its equipment worldwide against defects in material and workmanship as outlined in this section. Hot-Melt Units, Hoses, Valves, and Related Equipment Warranty: MeltPro, Inc. offers the following warranty: Five Years on Tank Heaters, One Year / 2,000 hours of use (whichever occurs first) on Tank & Pumps, One Year / 2,000 hours of use (whichever occurs first) on Temperature Control Boards, Six-Month / 2,000 hours of use (whichever occurs first) on Glue Heads (Hot/Cold) and Modules, and Six Month / 2,000 hours of use (whichever occurs first) on Stationary Hoses, Handguns and Handgun Hoses. MeltPro/TA warrants that product manufactured by MeltPro/TA shall be free of defects in material and workmanship, when operated in accordance with MeltPro/TA s Operating and Maintenance Procedures. MeltPro/TA s liability is limited to the repair or replacement, at MeltPro/TA s option, of any product, which proves to be defective in material or workmanship during the warranty period as stated above. MeltPro/TA shall have the right of final determination as to the existence and cause of defect. Warranty does not cover repairs attempted, normal wear and tear, abuse, misuse, improper maintenance, voluntary or involuntary damages, tampering or deterioration, coatings, adhesives or other customer supplied materials, downtime, continued use after partial failure, or product not being used for its intended purpose. This warranty is in lieu of all other warranties, whether written, oral expressed or implied. MeltPro/TA, Inc. shall in no way be liable for any losses caused by delays or for any expenses for labor, supplies, machine rental, loss or damages to other property, direct or indirect. All warranty claims must be accompanied with a Return Authorization number issued by MeltPro/TA, Inc. Warranty material should be returned to MeltPro/TA Freight Paid. If the product is deemed warranty, it will be repaired or replaced and sent freight paid to the customer via routing that provides the lowest possible rate with the best possible service. If customer requires UPS Red, Melt- Pro/TA will invoice for UPS Red charges. If the product is not covered under MeltPro/TA warranty, a quotation will be advised to the customer before repairs will be made to the product. If a replacement product needs to be sent before warranty inspection, the replacement product will be invoiced. Credit will be issued if the used product is covered under warranty. Warranty for items repaired or replaced by MeltPro/TA shall continue for the remainder of the original warranty or for ninety (90) days from shipment of repair or replacement, whichever period is longer. MeltPro/TA is not in anyway responsible for the customer s machine / line downtime during installation / startup or during any type of MeltPro/TA failure. This warranty is nontransferable. Warranty card information must be complete and verifiable with the user, for the warranty to be valid. All warranty items are from date of purchase. Returned warranty parts after 6 months will be prorated to replace no charge to repair. 11

70 Warranty & Service Page 2 Chapter 11 Updated 8/19/2010 Service Needs If you have problems with your system, please contact your MeltPro representative. If your need is urgent, we encourage you to contact our corporate office in Milton, Florida U.S.A. at (850) If the problem cannot be resolved, MeltPro will promptly arrange to have a technical representative visit your facility. Any charges for a service call will be quoted at that time. Any part that fails during the warranty period shall be returned prepaid to MeltPro, Inc. by the customer for disposition. Note! Upon request, MeltPro personnel are available to repair or replace such parts at the customer s facility. Charges for this service include travel time and expenses. If an equipment problem is the result of customer abuse, improper installation or operation, all travel time, labor, parts, and expenses will be charged to the customer. If the responsibility for a problem cannot be absolutely determined, the customer will be charged for travel time and expenses only. No charge will be made for parts and labor. 11