Installation. Part A, Section 3. This section covers the following unit configurations. Voltage 1, 2, 3. Vista Standard (V) A3EN-04-[3V-A-AAXV]-11

Transcription

1 Part A, Section 3 This section covers the following unit configurations. Model All Voltage 1, 2, 3 Pump All Manifold All Control Vista Standard (V)

2 A 3-0

3 A 3-1 Section A 3 WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This section of the manual describes how to install the unit, hoses, and guns program system settings prepare the unit for operation If you have purchased optional features with your unit, such as a low-level indicator or an input/output (I/O) board, refer to the Options section of this manual for installation instructions. 2. Unpacking Besides using normal care, you need no special instructions to unpack the unit or the equipment you purchased with it. All hoses and guns are shipped in separate packages. 3. Inspection After unpacking the equipment, inspect it for any damage that may have occurred during shipping. Look for dents and scratches and make sure all fasteners are tight. Report any damage to your Nordson representative. 4. Requirements This part of the installation section gives you the installation requirements and recommendations that you need to know before installing your unit. It includes Location Requirements Wiring Requirements Hose/Gun Power Requirements Other requirements and recommendations are provided in the installation procedures when they are needed.

4 A 3-2 Location Requirements Carefully select the location for the unit and its associated guns and hoses. Make sure that the location meets the following requirements: There is enough room to open the tank lid, open the electrical enclosure, remove the filter assembly, remove the pump enclosure, and make electrical connections for the hoses. For unit dimensions and recommended clearances, refer to Dimensions in the Description section of this manual. An operator can reach all controls. Maintenance personnel have room to service and repair the unit. Installers can route the hoses without bending them. The minimum bend radius for hoses is shown in Figure A 3-8. The mounting surface can support the weight of the unit when the unit is filled with adhesive. Refer to Specifications in the Description section of this manual. The mounting surface is level. The mounting surface is raised at least 152 mm (6 in.) for draining adhesive. See Figure A 3-1. The drain valve projects over the edge of the mounting surface. 152 mm (6.0 in.) A Fig. A 3-1 Required Clearance for Draining and Filter Flushing

5 A 3-3 Wiring Requirements Follow these guidelines when installing wiring to the unit: Allow enough room to route your electrical service line to the unit. You can use either of the two access holes in the base of the unit for electrical service. One hole is for rear access and the other is for bottom access. Route any wires away from AC power lines, solenoid output lines, and electrical equipment such as motors, contacts, and relays. Make connections with the minimum length of wire needed. A long wire can act as an antenna for electrical noise. Hose/Gun Power Requirements The power requirements of your hoses and guns must be determined to make sure that you do not overload the unit. If your Nordson representative has not already checked to see that your unit can support all of the hoses and guns you plan to install, you need to calculate your hose/gun power requirements now. You also need to check your calculations if you change your system configuration or add new hoses and guns. To determine your hose/gun power requirements, refer to Calculating Hose/Gun Capacity at the end of this manual. If you need help with this procedure, contact your Nordson representative.

6 A Mechanical This part of the installation section gives you the procedures for installing the unit mechanically. It includes Mounting the Unit Installing the Tank Strainer Connecting the Air Supply Installing Guns Installing Hoses On some units, you will not be required to complete all of these procedures. For electrical installation procedures, refer to Electrical later in this section. Mounting the Unit Use this procedure to mount your unit. 1. Remove the bolts that secure the unit to the shipping pallet. Save the bolts for later use. 2. For installation within the European Community, find the packet of adhesive-backed, local-language warning tags that was shipped with the unit. Overlay the non-english language part of the tags already on this unit with the tags from the packet in your own language. Carefully follow the instructions in the packet for the correct placement of the tags. WARNING: Take care when lifting the unit. Using inadequate means to lift the unit can cause equipment damage, personal injury, or both. 3. Using a suitable lifting device that is capable of lifting the unit, position the unit on the mounting surface. To determine the weight of your unit, refer to Specifications in the Description section of this manual. 4. Check to see that the unit is level. Provide shims as needed. 5. Using the unit s base as a guide, drill four holes in the mounting surface for 8-mm ( 5 / 16 -in.) mounting bolts.

7 A See Figure A 3-2. Secure the unit to the mounting surface with the bolts you removed in step 1. Fig. A 3-2 Securing the Unit to the Mounting Surface A

8 A 3-6 Installing the Tank Strainer This procedure describes how to install the tank strainer on Series 3000V units that have tank strainers. The following units have tank strainers: Series 3100V Series 3400V Series 3500V Series 3700V The model number of each unit is listed on the front panel of the unit. If your unit does not have a strainer, go to the next procedure, Connecting the Air Supply. If it has a strainer, complete this procedure. 1. Locate the tank strainer that was shipped with your unit. If you have a Series 3500V or Series 3700V unit, you will find two strainers. 2. Series 3500V and 3700V units only: See Figure A 3-3. Determine the correct strainer to use for your adhesive, the small strainer or the large strainer. If the solid adhesive form you plan to use is small enough to pass through the holes in the strainers (both strainers have the same size holes), use the large strainer. If the solid adhesive is too large to pass through the holes, use the small strainer. Fig. A 3-3 Small Strainer (left) and Large Strainer (right) Remove all wrapping from the strainer. Small pieces of wrapping can cause blockage in the pump. 4. Open the tank lid. 5. Place the strainer on the fins in the bottom of the tank. Position the cutout in the strainer around the pump. 6. Close the tank lid.

9 A 3-7 Connecting the Air Supply Follow this procedure to connect the air supply to units with piston pumps. If your unit has a gear pump, which is motor-driven, you do not need to connect air to your unit. To determine which kind of pump your unit has, see Figure A 3-4. If your unit has a gear pump, go to the next procedure, Installing Guns. If your unit has a piston pump, complete this procedure. Fig. A 3-4 Piston Pump (left) and Gear Pump (right)

10 A 3-8 Connecting the Air Supply (contd.) 1. See Figure A 3-5. Install the air pressure regulator, gauge, and filter that were shipped with your unit A Fig. A 3-5 Installing the Air Pressure Regulator, Gauge, and Filter 2. Turn the regulator fully counterclockwise (off). NOTE: Nordson recommends installing a shutoff valve with a lock-out in the air supply line to isolate the unit from the air supply for maintenance procedures. 3. Connect a supply of clean, dry air to the input air fitting or shutoff valve. NOTE: To achieve the rated adhesive output of the unit, you must connect a plant air supply that is capable of providing the maximum air pressure specified on the unit. The maximum air pressure is either 483 kpa (70 psi) or 620 kpa (90 psi), depending upon the type of pump your unit has. To find the maximum air pressure for your unit, check the air pressure tag, which is located next to the inlet air port, above the hose connectors.

11 A 3-9 Installing Guns This part of the installation section refers you to the correct installation procedure for the type of gun you plan to install. Use Figure A 3-6 to determine which type of gun you are installing, an air-operated gun, an electric gun, or a hand-operated gun. Then refer to one of the following procedures: To Install an Air-Operated Gun To Install an Electric Gun To Install a Hand-Operated Gun NOTE: Air-operated and electric guns are also referred to as automatic guns Fig. A 3-6 Air-Operated Gun (left), Electric Gun (center), and Hand-Operated Gun (right) To Install an Air-Operated Gun Follow the instructions in the manual shipped with the gun to complete these procedures: Mount the gun on the production line. Install the gun solenoid valve. Connect air to the solenoid valve. Connect a triggering device to the solenoid valve. Connect a hose to the gun. Instructions for connecting the hose and gun cordsets are given later in this section. Refer to Connecting Gun and Hose Cordsets.

12 A 3-10 To Install an Electric Gun Follow the instructions in the manual shipped with the gun to complete the following procedures: Mount the gun on the production line. Install the gun driver. Connect power to the driver. Connect a triggering device to the driver. Connect a hose to the gun. Instructions for connecting the hose and gun cordsets are given later in this section. Refer to Connecting Gun and Hose Cordsets. To Install a Hand-Operated Gun Follow the instructions in the manual shipped with the gun to connect the hose to the hand-operated gun. One end of the hose is wired to the gun; the other end connects to the unit. Instructions for connecting the hose and gun cordsets are given later in this section. Refer to Connecting Gun and Hose Cordsets.

13 A 3-11 Installing Hoses Follow this procedure to route the hoses and connect them to the guns and the unit. If your system is designed for external circulation of the adhesive, which requires both supply and return hoses, you must follow a different procedure for installing hoses. Go to Procedures for Externally Circulating Systems at the end of this section. 1. Follow the instructions in the gun manual to connect a hose to each gun, but do not connect the gun cordsets at this time. 2. Determine whether your unit has a four-port or a six-port manifold. Figure A 3-7 shows both manifolds and the hose port numbers on each type of manifold. Note that the first hose port on a six-port manifold is located on the back side of the unit Fig. A 3-7 Four-Port Manifold (left) and Six-Port Manifold (right)

14 A 3-12 Installing Hoses (contd.) 3. Decide where to install the first hose by referring to the following table. Choose the instructions that apply to the type of manifold on your unit. Type of Manifold Instructions Four-port manifold Use hose port number 1. Six-port manifold Use hose port number 1 or 2. If you plan to install six hoses (either now or in the future), use hose port number 1 for the first hose (see Note A). If you plan to install less than six hoses, you can use hose port number 2 for the first hose. NOTE A: To install six hoses, your unit must have the ability to heat six hoses. Check to see if your unit has six hose electrical receptacles. Units can be ordered with two, four, or six receptacles. CAUTION: Failure to connect the first hose as instructed creates a dead area where char builds up, causing downtime. WARNING: Hose ports that are unused must be closed with a plug. Removing plugs can cause hot adhesive to spray or flow from the port and injure operators. 4. Route the hose from the gun back to the unit. Make sure the hose does not contact sharp or abrasive surfaces. Follow the hose-routing guidelines shown in Figure A 3-8.

15 A 3-13 P/N X X=13 mm (0.50 in.) R=203 mm (8.00 in.) P/N mm (5/16 in.) P/N mm (5/8 in.) P/N mm (1 1/8 in.) ÎÎ Î ÎÎÎ ÎÎ Î ÎÎ ÎÎ ÎÎ ÎÎÎ ÎÎÎ ÎÎ ÎÎ ÎÎÎÎ ÎÎ ÎÎÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎÎÎ ÎÎ ÎÎÎÎ ÎÎ ÎÎ ÎÎÎÎ ÎÎ ÎÎÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎÎ ÎÎÎ ÎÎ ÎÎ Fig. A 3-8 Hose Guidelines

16 A 3-14 Installing Hoses (contd.) 5. Remove the O-ring plug from the hose port where you plan to install the first hose. Keep the O-ring plug for later use during maintenance and servicing procedures. 6. See Figure A 3-9. Take one of the hose-connector fittings that was shipped with the unit and apply an anti-seize compound to the threads. Thread the fitting into the hose port A Fig. A 3-9 Threading the Hose Connector Fitting into the Hose Port 7. Tighten the fitting with a wrench. 8. Connect a hose to the fitting. Use two wrenches to tighten the hose as shown in Figure A Install any additional hoses by repeating steps 4 8. Be sure to connect a second hose next to the first, working from right to left. Depending upon your unit, you can connect a maximum of four or six hoses this way.

17 A Electrical This part of the installation section includes procedures that require installing wiring or making electrical connections. Before making any electrical connections, first make the required mechanical connections. Refer to Mechanical in this section. WARNING: Allow only qualified personnel to perform electrical connections. Observe the safety instructions. CAUTION: If you are adding hoses and guns to an existing system, make sure that you do not exceed the maximum power capabilities of your unit. Refer to the Calculating Hose/Gun Capacity section of this manual. Connecting Gun and Hose Cordsets Follow this procedure to connect gun and hose cordsets. 1. Determine whether you are installing an automatic gun or a hand-operated gun. An automatic gun is either air-operated or electrically operated. A hand-operated gun is manually operated (see Figure A 3-6). 2. Follow the instructions below that apply to the type of gun you are installing. CAUTION: If you are connecting a hand-operated gun, take care not to connect the heater wires to the resistance temperature detector (RTD) wires. Otherwise, the control system or RTD will be destroyed when the system is placed in operation. Type of Gun Automatic Hand-operated Connection Connect the gun cordset to the electrical connector at the end of the hose. Follow the instructions in the gun manual to connect the cordset and wires at the end of the hose to the gun. Be sure not to connect the wires for heater power to the RTD. Otherwise, the control system or RTD will be destroyed when the system is placed in operation.

18 A 3-16 Connecting Gun and Hose Cordsets (contd.) 3. If you installed hoses for an externally circulating system, you must follow a different procedure to connect hose cordsets. Go to Procedures for Externally Circulating Systems at the end of this section. Return here and go to step Find the hose plug of the first hose you connected to the manifold. 5. See Figure A Connect this hose plug to electrical receptacle number 1 on the unit. 6. If you have additional guns and hoses, continue connecting gun and hose cordsets. Connect the cordset of the next hose (the hose closest to the rear of the unit) to the hose electrical receptacle labeled number 2 on the unit. Continue connecting gun and hose cordsets, working from the rear of the unit to the front of the unit, until you have connected all gun and hose cordsets. ÂÂ ÂÂ Â A Fig. A 3-10 Connecting a Hose Cordset to the Unit

19 A 3-17 Opening the Electrical Enclosure To make the electrical connections inside the unit, follow this procedure to open the unit and access the electrical enclosure. WARNING: Risk of equipment damage, personal injury, or death. Disconnect and lock out electrical power to the unit. 1. Place the unit s POWER switch in the off position and disconnect and lock out electrical power to the unit at the branch circuit disconnect switch. 2. See Figure A Loosen the captive screws on the electrical enclosure lid, lift the lid from the unit, and prop it against the pump cover. Take care not to disconnect the ground wire. 3. Make sure the support strap is not wrapped around any board components. Untangle the strap if necessary. 4. Loosen the two captive screws on either side of the control-end frame and lower the frame. You may need to pull the front and rear panels apart to release the frame. 5. Avoid direct contact with internal electrical connections, components, or wiring. 6. Make sure all ground wires are securely connected. Î Î Î Î Î A Fig. A 3-11 Opening the Electrical Enclosure

20 A 3-18 Connecting a Triggering Device for the Pump Solenoid Valve If your unit has a triggering solenoid valve on the pump, follow this procedure to connect a 24 VDC triggering device to the center frame terminal block. See Figure A 3-12 to determine whether your pump has a triggering solenoid valve (1). If your pump does not have this valve, skip to the next procedure, Connecting Input/Output (I/O) Contacts Î Î Î Î Î ÎÎ ÎÎ A Fig. A 3-12 Connecting a Triggering Device for the Pump Solenoid Valve 1. Triggering solenoid valve 3. Wires from 24 VDC triggering 2. Center frame terminal block device 4. Strain relief

21 A 3-19 WARNING: Risk of equipment damage, personal injury or death. Install a strain relief to protect wires from being damaged by the edges of the knockout hole. CAUTION: Circuit boards can be easily damaged. Avoid any contact with circuit boards when removing a knockout hole plug. 1. See Figure A Remove and discard the plug from a knockout hole on either the back side or the bottom of the unit (whichever is most convenient for your operation) and install a strain relief (4) in the hole. Refer to the following table for the appropriate size strain relief. NOTE: Your unit may have several knockout holes. You should route your triggering device wires through a larger hole. Size of Knockout Size of Strain Relief to Install 23 mm ( 15 / 16 in.) PG-16 or 1 / 2 -in. trade size 29.5 mm ( 15 / 32 in.) PG mm (1 3 / 8 in.) 1-in. trade size CAUTION: Use mm 2 (22 24 AWG) wire. Using a different wire size can cause internal stress-related damage to the unit. 2. Route the wires from a 24 VDC triggering device (3) through the strain relief and connect them to terminals 3 and 4 on the center frame terminal block (2).

22 A 3-20 Connecting Output Contacts (Optional) Follow this procedure to connect the standard output contacts that are provided on all units. If you do not wish to connect any outputs, skip to the next procedure, Connecting Electrical Service. Output contacts allow you to automatically activate other equipment or to activate devices for remote monitoring of the unit s operations. Table A 3-1 describes the standard output contacts. If your unit has an optional input/output (I/O) board, there are additional outputs and several inputs you can connect. Refer to Series 3000V Input/Output Board in the Options section. Table A 3-1 Standard Output Contacts Output Contact Function System Warning System Fault System Ready Used to signal a device that will alert remotely located operators of a warning condition Used to signal a device that will alert remotely located operators of a system fault condition. This output is typically used to turn on a light or to sound an alarm. Used to signal a device that will alert remotely located operators that the system is ready for operation (up to temperature) or that the unit s pump is on. This output is typically used to send a ready signal to a production line so that the line turns on only when the unit is ready to pump adhesive. 1. If you have not already done so, open the electrical enclosure. Refer to Opening the Electrical Enclosure in this section. 2. If you have not already done so, carefully remove a knockout hole plug from one of the larger holes on either the back side or the bottom of the unit (whichever is most convenient for your operation). Avoid contact with any printed circuit boards. 3. To protect the wiring, install a strain relief in the hole. Refer to the following table for the appropriate size strain relief. Table A 3-2 Strain Relief Sizes for Knockouts Size of Knockout Hole Size of Strain Relief to Install 23 mm ( 15 / 16 in.) PG-16 or 1 / 2 -in. trade size 29.5 mm ( 15 / 32 in.) PG mm (1 3 / 8 in.) 1-in. trade size

23 A 3-21 WARNING: Risk of equipment damage, personal injury, or death. For a proper and safe installation, make sure you meet the requirements in the following step. 4. See Figure A Route the output contact wires (2) through the strain relief (1) to terminal block TB2 (3). Make sure your installation meets these requirements: Use mm 2 (22 24 AWG) stranded wire that is suitable for National Electrical Code (NEC) Class 1 remote control and signaling circuits. Output contacts are rated for 250 VAC, 2 A maximum. Use the proper length of wire and route the wires so they do not touch any of the printed circuit boards. Make sure the wires reach terminal block TB2 when the electrical enclosure is opened. 3 Î Î Î Î 2 Î Î Î ÎÎ 1 Fig. A 3-13 Connecting Output Contacts 1. Strain relief 3. TB2 terminal block 2. Output contact wires A

24 A 3-22 Connecting Output Contacts (Optional) (contd.) 5. Connect the output wires to the plug for terminal block TB2 from the ship-with kit. Refer to Table A 3-3. Table A 3-3 Output Contact Connections Output Contact as Behavior of Contact Labeled on Power Board Unit Power Off Unit Power On Warning Contact (System Warning) Fault Contact (System Fault) Ready Contact (System Ready) Open Open Open Closed (no warning) Closed (no fault) Open (unit not ready) Open (warning exists) Open (fault exists) Closed (unit ready) TB2 Positions (see Note A) NOTE A: The output contacts are not polarity sensitive. It does not matter which wire is inserted into a position. 1, 2 3, 4 5, 6 6. Connect the plug to TB2. See Figure A 3-13 for the location of TB2. 7. Go to the next procedure, Connecting Electrical Service.

25 A 3-23 Connecting Electrical Service Follow this procedure to connect electrical service to your unit. 1. Open the electrical enclosure. Refer to Opening the Electrical Enclosure in this section. 2. See Figure A Locate the identification plate on your unit A Fig. A 3-14 Location of Identification Plate 3. See Figure A Determine the voltage specification of your unit by looking at the VOLTS (ac) portion (1) of the identification plate. 1 2 Fig. A 3-15 Unit Identification Plate 1. VOLTS (ac) portion 2. AMPS (max.) portion A

26 A 3-24 Connecting Electrical Service (contd.) CAUTION: Operate the unit only when it is connected to the correct line voltage, as shown in Table A 3-4. Operating the unit at a different voltage can damage the unit or impair its performance. 4. Ensure that your unit has the correct voltage specification to accept the type of electrical service that you will be connecting to it. Table A 3-4 shows all the Series 3000V voltage specifications and the types of electrical service that you can connect to each. Table A 3-4 Types of Electrical Service for Each Voltage Specification Voltage Specification (See Note A) Voltage Code (See Note B) Types of Service You Can Connect to the Unit See Note VAC or 3 AC 230V or 3/PE AC V VAC 1 (two wire service without a neutral) VAC 3 (three wire service without a neutral) 3/N/PE AC 400/230V VAC 1 (two wire service, including a neutral) C 400/230 VAC 3 (four wire service, including a neutral) D 3 AC 400V VAC 3 (three wire service without a neutral) NOTE A: The voltage specification is shown in the VOLTS (ac) portion of the unit s identification plate. B: The voltage code is part of your unit configuration code. It is included here for information only and is not something you need to know to install your electrical service line. For more information about your unit configuration code, refer to Explanation of Configuration Code at the end of the Description section. C: This type of service also includes voltage used primarily in the British Commonwealth: 240 VAC 1 (two wire service, including a neutral). D: This type of service also includes voltage used primarily in the British Commonwealth: 415/240 VAC 3 (four wire service, including a neutral).

27 A See Figure A Size your electrical service line based on the maximum amperage shown in the AMPS (max.) portion (2) of the identification plate. The line must also meet local electrical code requirements. WARNING: Risk of equipment damage, personal injury or death. Install a strain relief to protect wires from being damaged by the edges of the knockout hole. CAUTION: Circuit boards can be easily damaged. Avoid any contact with circuit boards when removing a knockout hole plug. 6. If you have not already done so, remove and discard the plug from a knockout hole on either the back side or the bottom of the unit (whichever is most convenient for your operation) and install a strain relief in the hole. Refer to the following table for the appropriate size strain relief. NOTE: Your unit may have several knockout holes. You should route your electrical service wiring through a smaller hole. Table A 3-5 Strain Relief Sizes for Knockouts Size of Knockout Hole Size of Strain Relief to Install 23 mm ( 15 / 16 in.) PG-16 or 1 / 2 -in. trade size 29.5 mm ( 15 / 32 in.) PG mm (1 3 / 8 in.) 1-in. trade size 7. Route the electrical service line to the unit.

28 A 3-26 Connecting Electrical Service (contd.) WARNING: Use the proper length of cable. Inadequate wire length could result in disconnection at TB1 when you open the operator panel. Excess wiring can be pinched when you close the panel, causing equipment damage, personal injury, or death. 8. See Figure A Route the electrical service line through the strain relief, determine the length of cable required to reach terminal block TB1 and the ground terminal, and cut the cable. 1 2 Fig. A 3-16 Routing the Electrical Service Line Through the Strain Relief 1. Strain relief 2. Electrical service line

29 A Remove the required amount of cable insulation and wire insulation and then secure the cable with a cable strap of the correct size, as shown in Figure A Three different sizes of cable strap are provided: one is attached to the unit just below the power board and the other two are included in the ship-with kit. 2 1 Fig. A 3-17 Installing the Cable Strap on the Electrical Service Line 1. Electrical service line 2. Cable strap Connect the ground wire of your electrical service line to the ground terminal below TB1 as shown in Figure A Fig. A 3-18 Connecting the Ground Wire

30 A 3-28 Connecting Electrical Service (contd.) 11. Connect the remaining wires of the electrical service line to TB1 as shown in Figure A Refer to Table A 3-6 to determine which illustration in Figure A 3-19 shows the type of service line you are connecting. Table A 3-6 Key to Illustrations in Figure A 3-19 Number of Wires in Your Service Line (excluding the ground wire) Type of Service Illustration in Figure A 3-19 to Use for Connecting Service See Note Four wires (including a neutral) 400/230 VAC 3 Illustration A Three wires (without a neutral) VAC VAC 3 Illustration B Two wires (including a neutral) 230 VAC 1 Illustration C A Two wires (without a neutral) VAC 1 Illustration D B NOTE A: If the VOLTS (ac) label on your unit is 3/N/PE AC 400/230V (voltage code 2), your unit is designed to accept two wires with a neutral. Check the identification plate on your unit for the VOLTS (ac) label. B: If the VOLTS (ac) label on your unit is 3 AC 230 V (voltage code 1), your unit is designed to accept two wires without a neutral. Check the identification plate on your unit for the VOLTS (ac) label. L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N A B C D Fig. A 3-19 Electrical Service Connections at TB1 (with ground wire shown) 12. If you connected three-phase power to the unit, go to Closing the Electrical Enclosure in this section. If you connected single-phase power to the unit, go to the next procedure, Preparing the Unit for Single-Phase Operation.

31 A 3-29 Preparing the Unit for Single-Phase Operation All units are shipped to accept three-phase power. If you are supplying single-phase power to your unit, use this procedure to modify your unit to accept single phase power. CAUTION: Units with 400 Vac 3 (without neutral) service are factory-wired for three-phase operation only and cannot be modified for single-phase operation. If you install a single-phase voltage plug on a 400 Vac 3 unit, you may damage the unit or make it inoperable. 1. See Figure A Locate the voltage plug on the power board. It is plugged into connector X3. X3 Fig. A 3-20 Location of Voltage Plug on Power Board

32 A 3-30 Preparing the Unit for Single-Phase Operation (contd.) 2. Remove this three-phase voltage plug from connector X3 and replace it with the appropriate voltage plug supplied in the installation kit. A voltage plug is shown in Figure A The part number of the plug you must install is listed in Table A 3-7 and on the label of the electrical enclosure lid. Table A 3-7 Voltage Plug Part Numbers Type of Service Part Number of Single-Phase Plug to Install VAC single phase VAC (with neutral) single phase Fig. A 3-21 Typical Voltage Plug NOTE: If you are supplying 230 VAC (with neutral) single-phase service, the voltage plug consists of two connectors jumpered together. The large plug connects to connector X3 on the power board and the small plug connects to connector X4, which is located next to connector X3.

33 A Determine whether your unit is equipped with a contactor board, which is located on a large bracket at the rear of the electrical enclosure, as shown in Figure A Fig. A 3-22 Location of Contactor Board 1. Contactor board 2. Wiring harness X1C/X2C If your unit has a contactor board, go to step 5. If it does not, go to the next procedure, Closing the Electrical Enclosure. 5. Find wiring harness X1C/X2C on the contactor board and remove it. It is identified in Figure A 3-22.

34 A 3-32 Preparing the Unit for Single-Phase Operation (contd.) 6. Replace the harness you just removed with the appropriate single-phase harness supplied in the installation kit. A wiring harness is shown in Figure A The part number of the wiring harness you must install is listed in Table A 3-8 and on the label of the electrical enclosure lid. Fig. A 3-23 Contactor Board Wiring Harness Table A 3-8 Wiring Harness Part Numbers Part Number of Wiring Type of Service Harness to Install VAC single phase VAC (with neutral) single phase Go to the next procedure, Closing the Electrical Enclosure.

35 A 3-33 Closing the Electrical Enclosure After you have completed electrical installation, follow this procedure to close the electrical enclosure. 1. Reconnect any ground wires that may have become disconnected during electrical installation. 2. Raise the control-end frame into place and tighten the captive screws on each side of the frame. You may need to pull the front and rear panels apart to position the frame. 3. Position the electrical enclosure lid on top of the unit and secure it with the captive screws. 4. Remove the lock-out and turn on the power at the branch circuit disconnect switch. 7. System Programming Procedures Before running your unit, follow the procedures in this part of the section to program the unit for your operations. All programming is done from the System Setup area of the operator panel. From the System Setup area, you can program how the unit operates (SYSTEM SETTINGS) the temperature at which each zone operates (TEMPERATURE) when the system operates (CLOCK) You will probably find it helpful to read Control System in the Description section of this manual before programming any system controls. Control System briefly describes the function of each control you will program Fig. A 3-24 System Setup Area of the Operator Panel

36 A 3-34 Programming System Controls The system controls determine how the unit will operate. 1. To begin programming system controls, first turn power on to the unit by pressing the POWER switch. The following occur: The system scans each heated zone, displaying each zone s temperature in sequence. The Multipurpose display shows four dashes ( ) for each zone until a setpoint temperature is entered. After a setpoint is entered, the display will show the setpoint that was entered as the default when power is turned on. The Actual Temperature display shows the room temperature because no heat has been applied to the zones. Fig. A 3-25 Turning the Power On Customize the system to your operations by completing the procedures listed below. Refer to Table A 3-9 for a summary of all the features that you can customize. Programming Optional Features Programming SYSTEM SETTINGS Controls Programming TEMPERATURE Controls Programming CLOCK Controls

37 A 3-35 Table A 3-9 Summary of Features to Customize Control Area SYSTEM SETTINGS TEMPERATURE Features to Customize From SYSTEM SETTINGS you can customize the following features, which are explained in more detail in Table A 3-10: Password Enable System-Ready Time Delay period Overtemperature Setpoint Celsius or Fahrenheit display Global Temperature Band setting Individual Temperature Bands setting Sequential or Simultaneous Startup Display Heater Proportioning Warning or Power notification Ready or Pump notification Auto-Energize Pump (piston pump units only) Auto-Energize Pump Temperature setting (piston pump units only) Auto-Energize Heaters Time with Heaters On SETPOINT Temperature: This feature sets the temperature that a zone will maintain during normal operation. STANDBY Temperature: This feature sets the desired temperature to which a zone will be reduced when the system is in the standby mode. CLOCK SET TIME: This feature keeps the current day and time. The clock must be on before you can use the HEATERS ON, HEATERS OFF, ENTER STANDBY, and EXIT STANDBY features. ENTER STANDBY and EXIT STANDBY: This feature sets the time that you want the system to automatically enter and exit the standby mode. HEATERS ON and HEATERS OFF: This feature sets the time that you want heaters to automatically turn on and off.

38 A 3-36 Programming Optional Features If your unit has an optional I/O board, you can program additional features. Refer to Series 3000V Input/Output Board in the Options section for information on programming these additional features. Programming SYSTEM SETTINGS Controls Use this procedure to program the SYSTEM SETTINGS features shown in Table A If you have not already done so, turn power on to the unit by pressing the POWER switch. 2. See Figure A Press the Move Up (1) and Move Down (2) keys until the SYSTEM SETTINGS light turns on. When you select SYSTEM SETTINGS, the following occur: The values in the Displays area change. The number in the Selector display changes to a feature number. The Multipurpose display changes to the current value for the feature selected Fig. A 3-26 Selecting SYSTEM SETTINGS Features 1. Move Up key 2. Move Down key NOTE: If you have enabled the password feature, you must change the number in the Multipurpose display (500) to the password (321) and press the Enter key before the system will allow you to change any SYSTEM SETTINGS features.

39 A Determine which SYSTEM SETTINGS feature to customize. Refer to Table A 3-10 for a list of defaults and options for customizing each feature. WARNING: Risk of fire. The default for the overtemperature setpoint is 218 C (425 F). If the Material Safety Data Sheet (MSDS) for your adhesive gives a flash point that is below 218 C (425 F), be sure to reset the overtemperature setting to at least 42 C (75 F) below the flash point. 4. See Figure A Press the Up key below the Selector display until the number of the feature you want appears on the display. As the feature number changes, the Multipurpose display (3) changes to show the setting of each feature selected. 5. Press the Up or Down keys (4) below the Multipurpose display to change the setting. The display flashes. 6. Press the Enter (5) key to save the new setting. The display stops flashing Fig. A 3-27 Changing the Setting of a Selected Feature 1. Up key 4. Up and Down keys 2. Selector display 5. Enter key 3. Multipurpose display Record your setting in the forms provided at the end of this section. Refer to Records of System Settings. 8. Repeat steps 4 through 7 for each feature you wish to change. 9. To exit the System Setup area, press the MONITOR/SCAN key.

40 A 3-38 Programming SYSTEM SETTINGS Controls Feature No. Table A 3-10 SYSTEM SETTINGS Features Feature Description Default Setting 0 Password Provides a password if the password enable feature is turned on. The password (321) cannot be changed. 1 Password Enable Turns the password enable feature on or off. When the password enable feature is on, operators can view the settings for TEMPERATURE, SYSTEM SETTINGS, or CLOCK. To change the settings, operators must enter the correct password (321). When the feature is off, operators can change all settings without entering a password. 2 System-Ready Time Delay 3 Overtemperature Setpoint 4 Celsius/ Fahrenheit 5 Global Temperature Band 6 19 Individual Temperature Bands (See Note D.) 20 Sequential or Simultaneous Startup 21 Display Heater Proportioning 22 System Warning or Power Notification 23 System Ready or Pump Notification Specifies the amount of additional time needed for the adhesive to melt after all zones have reached their setpoint temperatures. At the end of the time delay, the READY light turns on. Specifies the maximum temperature any zone can reach before the system initiates a fault condition. This setting should be at least 14 C (25 F) above the highest operating setpoint. The system will not allow you to set the overtemperature setpoint lower than this, or the operating setpoint higher. (See Note A.) Displays temperature measurements in Celsius or Fahrenheit. Specifies the degree to which a temperature may deviate from any zone before the system indicates an out-of-band warning. (See Note B.) Specifies the degree to which a temperature may deviate for an individual zone before the system initiates a warning. (See Note C.) Specifies whether the system will perform a sequential startup (internal zones and hose zones heat first, then gun zones) or simultaneous startup (all zones heat at once). Displays the heater proportioning (a flashing INTERNAL, HOSE, or GUN light). Changes the System Warning output contact to alert remotely located operators that a system warning has occurred or that power is on. Changes the System Ready output contact to alert remotely located operators that the system is ready (up to temperature) or that the pump is on. Optional Settings 321 none 0 (off) 0 (off) 1 (on) 18 (minutes) 0 60 (minutes) 218/425 (C/F) F (Fahrenheit) 17/30 (C/F) 17/30 (C/F) 1 (sequential) 0 (no display) 1 (warning) 1 (ready) / (C/F) F (Fahrenheit) C (Celsius) 6 28/10 50 (C/F) 6 28/10 50 (C/F) 0 (simultaneous) 1 (sequential) 0 (no display) 1 (show display) 0 (power) 1 (warning) 0 (pump) 1 (ready) NOTE A: The overtemperature setting should be at least 42 C (75 F) below the flash point temperature. B: If entering a setting that is higher than the tank setpoint, the pump will start when the tank reaches its setpoint. C: If entering a new setting for this feature, the new setting is immediately entered for the individual zones (Feature Nos. 6 19). However, it is not saved as the setting for Feature No. 5. Feature No. 5 always returns to the default setting of 6 C (10 F). D: Feature No. 6 = tank, Feature No. 7 = grid, Feature Nos = hoses 1 6, Feature Nos = guns 1 6. Continued on next page

41 A 3-39 Feature No. 24 Auto-Energize Pump 25 Auto-Energize Heaters 26 Time With Heaters On Feature Description Default Setting 27 Fault Log (most recent) 28 Fault Log (second most recent) 29 Fault Log (third most recent) 30 & 31 Auto Standby Timeout and In Standby Timeout 32 Auto-Energize Pump Temperature Setting 34 Remote Pump Enable/Remote Heaters On 35 Warning Log (most recent) 36 Warning Log (second most recent) 37 Warning Log (third most recent) 38 Lose Ready on Remote Enable Piston pump units only: Allows the auto-energize pump feature to be turned on or off. If this feature is on, the system turns the pump on automatically once the tank reaches the preset temperature of Feature No. 32. If the auto-energize pump feature is off, you must turn the pump on by pressing the PUMP key until the PUMP light turns on. Turns the auto-energize heaters feature on or off. If the feature is on, the system turns heaters on automatically once the POWER switch is turned on. However, if you have programmed the system to turn heaters on and off automatically, using the clock feature, your clock settings override the auto-energize heaters feature. If the auto-energize heaters feature is off, you must turn heaters on manually, or allow any clock settings you have programmed to turn heaters on or off. Displays the total time (in hours) that the heaters have been running to assist with servicing and maintenance. Refer to Checking Run Time of Heaters in the Maintenance section of this manual. Displays the cause of the most recent system fault. Refer to Checking the Warning or Fault Log in the Troubleshooting section for a list of fault codes. Displays the cause of the second most recent system fault. Refer to Checking the Warning or Fault Log in the Troubleshooting section for a list of fault codes. Displays the cause of the third most recent system fault. Refer to Checking the Warning or Fault Log in the Troubleshooting section for a list of fault codes. These features are available only on units with an I/O board. Piston pump units only: Determines when the pump automatically starts if using the auto-energize pump feature (Feature No. 24). The pump can start either when the system reaches the READY condition or when the tank reaches a specified temperature. (See Note B.) This feature is available only on units with an I/O board. Displays the cause of the most recent system warning. Refer to Checking the Warning or Fault Log in the Troubleshooting section for a list of fault codes. Displays the cause of the second most recent system warning. Refer to Checking the Warning or Fault Log in the Troubleshooting section for a list of fault codes. Displays the cause of the third most recent system warning. Refer to Checking the Warning or Fault Log in the Troubleshooting section for a list of fault codes. Allows the user to decide whether or not the control system should lose ready status when a cold zone is enabled thorugh the enhanced I/O board. 1 (on) 1 (on) See Note A See Note A See Note A See Note A Optional Settings 0 (off) 1 (on) 0 (off) 1 (on) none none none none 0 (ready) 0 (ready condition) or 1 232/1 450 (C/F) See Note A See Note A See Note A none none none 0 (off) 0 (off) 1 (on) NOTE A: Features and are always ON. There is no default setting. B: If entering a setting that is higher than the tank setpoint, the pump will start when the tank reaches its setpoint.

42 A 3-40 Programming TEMPERATURE Controls From the operator panel you can control each of the system s heated components at a temperature specific to your needs. You can program individual setpoints for the tank, each hose, each gun, and, on Series 3900V units, the grid. For programming purposes, each heated system component is referred to as a zone. In addition to being able to heat each zone individually, you can assign two different temperature settings to each active zone: a setting for the setpoint (operating) temperature and one for the standby temperature. Table A 3-11 Types of Temperature Settings Setting Description Setpoint Temperature Standby Temperature Desired temperature of a zone during normal operation. Temperature to which a zone will be reduced when the system is in the standby mode. If you do not enter standby temperatures, the standby default of OFF will remain in effect for each zone. If you place the system in the standby mode, the zones will cool to room temperature (while the HEATERS light remains on). If you make the standby temperatures equal to the setpoints, pressing the STANDBY key will have no effect on the temperatures, but it will turn the READY light off and disable the pump. NOTE: The default setting for all zones is OFF (less than 38 C or 100 F). To turn a zone on, set the setpoint temperature to 38 C (100 F) or higher.

43 A 3-41 Because Series 3000V units can have up to six hose and gun zones and one or two internal zones, zone numbers are used to identify specific zones of each type. When you program TEMPERATURE settings, the number in the Selector display represents a particular zone number. Table A 3-12 Heating Zone Numbers Zone Number (See Note A) Zone Type INTERNAL HOSE GUN 0 Set All (See Note B) 1 Tank Hose 1 Gun 1 2 Grid (See Note C) Hose 2 Gun 2 3 Hose 3 Gun 3 4 Hose 4 Gun 4 5 (See Note D) 6 (See Note D) Hose 5 Gun 5 Hose 6 Gun 6 NOTE A: Your unit may be able to control the temperature of two, four, or six hoses and guns, depending upon the unit and features you have selected. B: Use Set All to set all zones to the same temperature. Only zones that are turned on are affected. C: Some units do not have a grid. D: Some units can accept only four hoses and four guns.

44 A 3-42 Programming TEMPERATURE Controls (contd.) Follow these guidelines when programming temperature settings: Check the Manufacturer s Safety Data Sheet (MSDS) for the recommended operating temperature of the adhesive that you will use. For a zone to be on, the operating temperature must be set at 38 C (100 F) or higher. Set the standby temperature 56 C (100 F) lower than the operating temperature. Before programming any temperature settings, make sure that the overtemperature setpoint is at least 14 C (25 F) higher than the highest operating setpoint used. Refer to Table A 3-10, Feature No. 3. Use this tip to program temperature settings quickly: Zone All zones to the same temperature Most zones to the same temperature Procedure Follow the procedure To Program All Zones to the Same Temperature. 1. First, follow the procedure To Program All Zones to the Same Temperature. 2. Then, follow the procedure To Program Setpoint and Standby Temperatures Individually to change the settings that you wish.

45 A 3-43 To Program Setpoint and Standby Temperatures Individually Follow this procedure to set the setpoint and standby temperatures for each zone. 1. If you have not already done so, turn power on to the unit by pressing the POWER switch. 2. In the System Setup area, press the Move Up and Move Down keys until the SETPOINT or STANDBY light turns on. The system defaults to the internal zone type and the INTERNAL light turns on. NOTE: If you have enabled the password feature, you must change the number in the Multipurpose display (500) to the password (321) and press the Enter key before the system will allow you to change any of the temperature setpoints. 3. If you want to select the hose-zone type or the gun-zone type instead of the internal-zone type, press the Move Right key until the light beneath the zone type you want to set turns on. 4. See Figure A In the Displays area, press the Up key (1) below the Selector display (2) until the zone number you want appears on the display. (Refer to Table A 3-12.) The Multipurpose display (3) changes to show the current temperature setting for the zone you selected. 5. In the Displays area, press the Up or Down key (4) below the Multipurpose display to change the temperature. The display flashes. NOTE: Pressing the Up or Down keys in the Displays area once changes the number shown in increments of one. Pressing and holding the key changes the number in increments of five.

46 A 3-44 To Program Setpoint and Standby Temperatures Individually (contd.) 6. Press the Enter key (5) to save the setting. The display stops flashing Fig. A Using the Displays Keys to Set the Temperature of a Zone (Displays Area) 1. Up key 2. Selector display 3. Multipurpose display 4. Up and Down keys 5. Enter key Record your setting in the forms provided at the end of this section. Refer to Records of System Settings. 8. Press the Up key below the Selector display to select the next zone number for the zone that you wish to customize, and repeat this procedure until you have set temperatures for all zones. To Program All Zones to the Same Temperature Follow this procedure to set all zones to the same temperature. Also use this procedure along with the procedure To Program Setpoint and Standby Temperatures Individually to set most zones to the same temperature. NOTE: This procedure works only for zones that have been previously turned on. The default setting for all zones is OFF. To turn a zone on, refer to the previous procedure, To Program Setpoint and Standby Temperatures Individually, and set the temperature of each zone you want to turn on to at least 38 C (100 F). 1. If you have not already done so, turn power on to the unit by pressing the POWER switch.

47 A See Figure A In the System Setup area, press the Move Up (1) and Move Down (2) keys until the SETPOINT or STANDBY light turns on. The system defaults to the internal-zone type and the INTERNAL light turns on. NOTE: If you have enabled the password feature, you must change the number in the Multipurpose display (500) to the password (321) and press the Enter key before the system will allow you to change any of the temperature setpoints. 1 2 Fig. A 3-29 Selecting the Set All Feature (System Setup Area) 1. Move Up key 2. Move Down key A 3. In the Display area, press the Up key below the Selector display until 0 (Set All) appears on the display. All three zone-type lights turn on and the Multipurpose display shows a default temperature of 177 C (350 F). 4. Press the Up or Down keys below the Multipurpose display to change the temperature. The Multipurpose display flashes. 5. Press the Enter key to change the temperature setting of all zones that are turned on to the temperature shown in the Multipurpose display. The display stops flashing. NOTE: When you exit the Set All feature, it always returns to the default setting of 177 C (350 F). 6. Record your setting in the forms provided at the end of this section. Refer to Records of System Settings.