Section 9 NOTE: This section applies to applicators with CC200 modules.
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Table of Contents i Table of Contents Section 9 1. Introduction............................................... 9-1 2. Specifications............................................. 9-2 3. Troubleshooting Pattern Control Problems.................... 9-3 Pattern Too Narrow..................................... 9-3 Pattern Off-Center...................................... 9-4 End Pattern Oriented Toward Center of Applicator........... 9-5 Pattern Breaking Up..................................... 9-6 Gaps or Shots in Pattern................................. 9-7 4. Replacement Procedure............................ 9-8 Removing a..................................... 9-8 Installing a...................................... 9-9 5. Die Procedures.......................................... 9-10 Removing or Installing a Die............................. 9-10 Die Removal........................................ 9-10 Die Installation...................................... 9-12 Cleaning Dies......................................... 9-12 6. Parts................................................... 9-15 CC200 Parts................................... 9-16 Adhesive Die Part Numbers............................. 9-18 Segmented Full Coverage Adhesive Die................ 9-18 Segmented Partial Coverage Adhesive Dies, Left Orientation...................................... 9-19 Segmented Partial Coverage Adhesive Dies, Right Orientation.................................... 9-20 Segmented Partial Coverage Adhesive Dies, Center Orientation................................... 9-21 Non-Segmented Partial Coverage Adhesive Dies, Left Orientation...................................... 9-22 Non-Segmented Partial Coverage Adhesive Dies, Right Orientation.................................... 9-22 Non-Segmented Partial Coverage Adhesive Dies, Center Orientation................................... 9-23 Kits........................................... 9-23 Recommended Spare Parts and Supplies................. 9-24
ii Table of Contents
9-1 Section 9 WARNING: Allow only qualified personnel to perform the following tasks. Observe and follow the safety instructions in this document and all other related documentation. 1. Introduction This section provides specifications, troubleshooting, repair, and parts information for applicators with Control Coat (CC200) modules. The CC200 module is designed to dispense fibrous sheets of adhesive onto a product. CC200 modules have a die set made up of two air dies and one adhesive die. Heated pattern air flows through the air die, causing the adhesive to form a fibrous sheet as shown in Figure 9-1. Ç Ç Ç Ç Ç Ç 6 ÉÉÎÎÉÉ ÉÉÎÉÉ ÇÇ 1 ÉÉ ÉÉÉ Î ÉÉÉÉ Î 2 ÉÉÎ É ÉÉÎÉÉ ÉÉÇ ÉÉ 3 ÇÇÇ ÇÇÇ Î ÎÎÎ ÎÎÎ Î 5 4 420600001 Fig. 9-1 Flow of Adhesive and Air Through a CC200 1. -actuating air inlet 4. Adhesive die 2. Adhesive inlet 5. Rear air die 3. Pattern air inlet 6. Front air die
9-2 2. Specifications Table 9-1 provides specifications for an applicator with CC200 modules. Refer to Applicator-Specific Reference Drawings in Section 8, Parts, for the following information about your applicator: dimensions cordset style number and orientation of filters number of modules type and number of solenoid valves Item Operating temperature range System hydraulic pressure range -actuating air pressure range Pattern air pressure range Pattern air temperature range (recommended) Air consumption Adhesive viscosity range Adhesive pattern capability Adhesive fiber size Adhesive add-on weight Adhesive die selection Die set coating width (see Note A) Adhesive die sizes Size of adhesive die openings Die-to-product distance (recommended) Table 9-1 Applicator Specifications Specification 70 230 C (160 450 F) 14 55 bar (200 800 psi) 103.4 bar (1,500 psi) maximum 3.1 6.2 bar (45 90 psi) 4.1 bar (60 psi) recommended 0.3 3.4 bar (5 50 psi) 9 15 C (15 25 F) above the adhesive application temperature ~56.6 nlm (~2 scfm) per module 500 5,000 cps Continuous 10 50 microns 0.5 10.0 gsm @ 300 m/min (984 ft/min) Coverage: full or partial Orientation: left, right, or center Full coverage die: 22 mm Partial coverage die: 7 19 mm Refer to Adhesive Die Part Numbers in this section. 0.2 mm (0.008 in.) (segmented dies) 13 51 mm (0.5 2.0 in.) NOTE A: The adhesive pattern width is affected by the viscosity of the adhesive. Lower-viscosity adhesives may not produce patterns as wide as those listed.
9-3 3. Troubleshooting Pattern Control Problems Use these troubleshooting tables if you are experiencing adhesive pattern control problems. For all other troubleshooting, refer to Section 6, Troubleshooting. NOTE: To aid in detecting pattern control problems, direct a strobe light on the adhesive as it flows onto the product. Pattern Too Narrow See Figure 9-2. Problem Possible Cause Corrective Action Adhesive pattern too narrow Blocked adhesive passage in adhesive die Clean or replace the adhesive die. Refer to Removing or Installing a Die or Cleaning Dies in the Die Procedures part of this section. 420305001 Fig. 9-2 Pattern Too Narrow
9-4 Pattern Off-Center See Figure 9-3. Problem Possible Cause Corrective Action Adhesive pattern off-center Partially blocked passages in air die Clean or replace the air die. Refer to Removing or Installing a Die or Cleaning Dies in the Die Procedures part of this section. Partially blocked passages in adhesive die Clean or replace the adhesive die. Refer to Removing or Installing a Die or Cleaning Dies in the Die Procedures part of this section. If cleaning or replacing the die does not improve the pattern, check for blockages in the module, applicator, or hose. Refer to Checking for Blockages in Section 6, Troubleshooting. 420305003 Fig. 9-3 Pattern Off-Center
9-5 End Pattern Oriented Toward Center of Applicator See Figure 9-4. Problem Possible Cause Corrective Action Adhesive stream on an end module oriented toward center of applicator Air currents in area near module Eliminate the air current 420305004 Fig. 9-4 End Pattern Oriented Toward Center of Applicator
9-6 Pattern Breaking Up See Figure 9-5. Problem Possible Cause Corrective Action Adhesive droplets thrown from adhesive stream or adhesive pattern breaking up (overspray) Pattern air pressure too high Adhesive output rate too low Heated zone temperature setpoints too high Decrease the pattern air pressure. Increase the system pressure or troubleshoot the output rate problem at the melter. Refer to the melter manual. Check for blockages in the die, applicator, or hose. Refer to Checking for Blockages in Section 6, Troubleshooting. Adjust the temperature setpoints. Refer to the melter or temperature controller manual. Correct Incorrect 420605005 Fig. 9-5 Side View of Pattern Breaking Up
9-7 Gaps or Shots in Pattern See Figure 9-6. Problem Possible Cause Corrective Action 1. Gaps (unplanned breaks) in adhesive pattern 2. Shots (clumps) in adhesive pattern Pattern air pressure too low Pattern air pressure too high Pattern air temperature too low Increase the pattern air pressure. Decrease the pattern air pressure. Increase the temperature setpoint for the heated air manifold zone(s). Refer to the melter or temperature controller manual. The temperature of the pattern air should match the application temperature of the adhesive. ÏÏ ÏÏ Ï ÏÏ 1 2 Fig. 9-6 Gaps or Shots in Adhesive Patterns 1. Gaps 2. Shots 420605002
9-8 4. Replacement Procedure This part of Section 9 provides the procedure for replacing a module. For an overview of module operation, refer to Introduction in this section or to s and Nozzles or Dies in Section 2, Description. You will need the following items: appropriate tools, including a torque wrench drain pans and disposable rags replacement module replacement O-rings O-ring lubricant anti-seize lubricant NOTE: s can be rebuilt. To rebuild a module, order the appropriate module rebuild kit and follow the instructions in the kit. For kit part numbers, refer to Kits near the end of this section. Removing a Follow this procedure to remove a module 1. Heat the system to application temperature. 2. Relieve system pressure. Refer to Relieving System Pressure in Section 10, Filter. 3. Trigger the applicator solenoid valves to relieve any remaining pressure. 4. Shut off the module-actuating air. 5. Decrease the pattern air pressure. Leave just enough air pressure to prevent adhesive from entering the pattern air inlet. 6. See Figure 9-7. Remove the two socket-head screws that secure the module to the applicator; then remove the module.
9-9 420100024 Fig. 9-7 Removing a Installing a Follow this procedure to install a module 1. Wipe off any adhesive on the applicator, especially around the air passages. 2. Coat three new O-rings with O-ring lubricant and insert them into the O-ring bores on the back of the new module. 3. Coat the module socket-head screws with anti-seize lubricant and use them to secure the new module to the applicator. Tighten the screws to 3.4 N m (30 in.-lb). 4. Restore the system to normal operation. For best results, tighten the module socket-head screws again after the applicator reaches application temperature.
9-10 5. Die Procedures This part of Section 9 provides procedures for removing, installing, or cleaning a die. For an overview of module and die operation, refer to s and Nozzles or Dies in Section 2, Description. Removing or Installing a Die There are three dies on the applicator: one adhesive and two air dies. The adhesive die is held in place by the front and rear air dies. Follow this procedure to remove or install any of the dies. You will need the following items: appropriate tools, including a torque wrench drain pans and disposable rags cleaning solution that is compatible with the adhesive used three new O-rings for the adhesive and air dies new air or adhesive die (if needed) O-ring lubricant anti-seize lubricant Die Removal 1. Heat the system to a temperature that is slightly higher than the application temperature. 2. Relieve system pressure. Refer to Relieving System Pressure in Section 10, Filter. 3. Trigger the applicator solenoid valves to relieve any remaining pressure. 4. Shut off the module-actuating air. 5. Decrease the pattern air pressure. Leave just enough air pressure to prevent adhesive from entering the pattern air inlet. 6. Remove the module and die from the applicator. Refer to Removal in this section. 7. Soak the lower part of the module and die in a cleaning solution. Do not allow fluid to enter the top ports on the back of the module.
9-11 8. See Figure 9-8. Remove the front air die (1). 9. Remove and discard the front air die O-ring (2). 10. Pry the adhesive die (4) out of the die body using a large flat-blade screwdriver or similar tool. 11. Remove and discard the adhesive die O-ring (3). 2 3 1 4 420600002 Fig. 9-8 Front Air Die and Adhesive Die 1. Front air die 3. Adhesive die O-ring 2. Front air die O-ring 4. Adhesive die 12. See Figure 9-9. Remove the rear air die (3). 13. Remove and discard the rear air die O-ring (2). 1 2 3 420600003 Fig. 9-9 Rear Air Die 1. Die body 2. Rear air die O-ring 3. Rear air die
9-12 Die Installation 1. See Figures 9-8 and 9-9. Coat the O-rings with O-ring lubricant and install them on the front and rear air dies and the adhesive die. 2. See Figure 9-9. Loosely assemble the rear air die (3) onto the die body (1). 3. Hold the module and rear air die assembly together while hand-tightening the screws, making sure they are engaging straight into threaded holes. 4. Lay the assembly on its side on a clean flat surface, or clamp the sides of the module in a soft-jaw vise. Tighten the rear air die screws to a final torque of 3 4 N m (25 32 in.-lb). 5. See Figure 9-8. Loosely assemble the front air die (1), the adhesive die (4), and the two socket-head screws and insert this assembly into the module. Tighten the screws 1 / 2 turn at a time to a final torque of 3 4 N m (25 32 in.-lb). 6. Heat the system to a temperature that is slightly higher than the application temperature. 7. Coat the module socket-head screws with anti-seize lubricant and use them to secure the module to the applicator. Tighten the screws to 3.4 N m (30 in.-lb). 8. Restore the system to normal operation. For best results, tighten the module socket-head screws again after the applicator reaches application temperature. Cleaning Dies Dies should be cleaned weekly and as needed to prevent char buildup. Follow this procedure to clean dies. You will need the following items: appropriate tools, including a torque wrench nozzle cleaning kit (recommended) drain pans and disposable rags appropriate cleaning supplies (refer to Table 9-2) three new O-rings for the adhesive and air dies O-ring lubricant anti-seize lubricant 1. Remove the dies. Refer to Removing or Installing a Die earlier in this section.
9-13 2. Clean the dies using one of the methods shown in Table 9-2. Use only cleaning agents recommended by the adhesive supplier. WARNING: Risk of explosion or fire. Use a controlled heating device, such as a thermostatically controlled hot plate to heat the cleaning fluid. Serious injury or property damage could result from uncontrolled heating of Nordson Type R fluid. CAUTION: Risk of equipment damage. Do not use a wire brush to clean dies. Table 9-2 Die Cleaning Methods Cleaning Method Procedure Nordson Type-R fluid a. Place the dies in a controlled heating device containing Nordson Type-R fluid and heat it above the melting point of the adhesive. b. Scrub the dies with a fine-bristle brush to remove debris. Electric heat gun a. Heat the dies with a flameless electric heat gun. b. Scrub the dies with a fine-bristle brush to remove debris. Ultrasonic cleaner a. Use an ultrasonic cleaner filled with a solvent to clean the dies. Air b. Scrub the dies with a fine-bristle brush to remove debris. Blow air through the adhesive and air orifices in the dies.
9-14 Cleaning Dies (contd) CAUTION: Risk of equipment damage. Use of an open torch, drill, or broach can damage dies. Use only a pin-type probe to clean die openings. For a nozzle cleaning kit, which contains a holder and several sizes of probes, refer to Recommended Spare Parts and Supplies at the end of this seciton. 3. See Figure 9-10. Use a pin-type probe to clean the openings in the die. 4. Reinstall the dies. Refer to Removing or Installing a Die earlier in this section. 5. Restore the system to normal operation. 430200001 Fig. 9-10 Cleaning an Adhesive Die With a Pin-Type Probe
9-15 6. Parts This part of Section 9 provides detailed parts lists for the module and adhesive dies. For all other parts, including a reference drawing and bill of materials specific to your applicator, refer to Section 8, Parts. The following chart provides guidance for reading the parts lists. The number in the Item column corresponds to the circled item number in the engineering drawing. A dash in this column indicates that the item is an assembly. The number in the Part column is the Nordson part number you can use to order the part. A series of dashes indicates that the part is not saleable. In this case, you must order either the assembly in which the part is used or a service kit that includes the part. The Description column describes the part and sometimes includes dimensions or specifications. The Note column contains letters that refer to notes at the bottom of the parts list. These notes provide kit part numbers and other key information you need to order parts. The Quantity column tells you how many of the part is used to manufacture the assembly shown in the engineering drawing. A dash in this column indicates that the amount of the item required in the assembly is not quantifiable. Item Part Description Quantity Note xxx xxx Assembly A 1 xxx xxx Part of assembly A x 2 - - - - - - Part of item 1 x 3 xxx xxx Part of item 1 x A 4 xxx xxx Part of item 3 x NOTE A: Important information about item 3. AR: As Required NS: Not Shown
9-16 CC200 Parts See Figure 9-11. Item Part Description Quantity Note 297 203, CC200 A 1 272 288 Screw, loading 1 2 272 289 Nut, locking, 1 / 2-28 1 3 276 112 Air cap, adjuster 1 4 144 892 Spring, compression, 0.420 x 0.750 in. 1 B 5 - - - - - - Needle and piston assembly 1 B, C 6 940 111 O-ring, Viton, 0.301 ID x 0.070 W in. 3 B 7 - - - - - - Body, module 1 8 9 Item nos. not used 10 982 743 Screw, socket, 8-32 x 1.375 4 11 981 171 Screw, socket, 10-32 x 1.250 2 12 981 758 Screw, fillister, 6-32 x 0.625 2 13 900 223 Lubricant, O-ring, Parker, 4 oz AR 14 117 544 Seal, spring, 1 / 8 x 7 / 16 x 3 / 32, PTFE 1 B 15 940 121 O-ring, Viton, 0.364 ID x 0.070 W in. 1 B 16 986 502 Retaining ring, internal, 43, push-on 1 B 17 983 012 Disc, seal support 2 B 18 - - - - - - Seal, hat, formed 1 B, D 19 900 290 Oil, neat s foot AR 20 987 022 Spring, compression, 1.146 x 0.360 OD x 0.065 in. 1 B 21 985 024 Pin, dowel, 0.094 x 0.250 in. 1 22 - - - - - - Die body, with seat, CC200 1 23 297 206 Die, air, CC200 2 24 945 131 O-ring, Viton, 0.176 x 0.276 x 0.050 in. 2 25 - - - - - - Die, adhesive, CC200 1 E 26 945 131 O-ring, 0.176 x 0.276 x 0.050 in. 1 NOTE A: s can be rebuilt. For module rebuild kit part numbers, refer to Kits later in this section. B: This part is available in a service kit. Refer to Kits later in this section. C: For this part, order service kit 272 822. This kit includes the needle and piston assembly along with the retaining ring (item 16), the seal support disc (item 17), and a formed hat seal (item 18). D: To replace the hat seal, order part 750 553. This part is a formed hat seal. E: Adhesive dies must be ordered separately. Refer to Adhesive Die Part Numbers later in this section. AR: As Required
9-17 11 2 7 1 13 6 20 12 14 17 3 4 19 13 15 22 5 13 6 13 24 21 26 13 24 13 16 15 23 18 23 10 25 10 420601003 Fig. 9-11 CC200 Parts
9-18 Adhesive Die Part Numbers Normally, the choice of adhesive die for your applicator will have already been made by you and your Nordson representative. Refer to your sales order to determine what adhesive die choices were made. The part numbers for all available adhesive dies are provided here. Adhesive dies may be partial coverage or full coverage dies: A full coverage die has 10 openings that extend along the entire die. The adhesive coating width is 22 mm. A partial coverage die has 1 9 openings through only part of the die, leaving a closed area at one or both ends. A partial coverage die may be oriented to apply adhesive starting at the left, right, or center of the die. The adhesive coating width ranges from 7 19 mm. Adhesive dies may also be segmented or non-segmented. The adhesive opening on segmented dies is partitioned into channels (segments). The adhesive opening on non-segmented is not partitioned. Segmented Full Coverage Adhesive Die See Figure 9-12. The die O-ring (part 945 131) is included. Part Number of Openings Coating Width 297 571 10 22 mm NOTE: For a kit that includes 50 of this die, order part 757 536. 430201001 Fig. 9-12 Segmented Full Coverage Adhesive Die
9-19 Segmented Partial Coverage Adhesive Dies, Left Orientation See Figure 9-13. The die O-ring (part 945 131) is included. Part Number of Openings Coating Width 297 234 9 19 mm 297 236 8 17 mm 297 238 7 15 mm 297 240 6 13 mm 297 242 5 11 mm 297 244 4 9 mm 297 246 3 7 mm 297 248 2 5 mm 297 250 1 3 mm 430201002 Fig. 9-13 Segmented Partial Coverage Adhesive Die, Left Orientation
9-20 Segmented Partial Coverage Adhesive Dies, Right Orientation See Figure 9-14. The die O-ring (part 945 131) is included. Part Number of Openings Coating Width 297 235 9 19 mm 297 237 8 17 mm 297 239 7 15 mm 297 241 6 13 mm 297 243 5 11 mm 297 245 4 9 mm 297 247 3 7 mm 297 249 2 5 mm 297 251 1 3 mm 430201003 Fig. 9-14 Segmented Partial Coverage Adhesive Die, Right Orientation
9-21 Segmented Partial Coverage Adhesive Dies, Center Orientation See Figure 9-15. The die O-ring (part 945 131) is included. Part Number of Openings Coating Width 297 581 9 19 mm 297 582 8 17 mm 297 583 7 15 mm 297 584 6 13 mm 297 585 5 11 mm 297 586 4 9 mm 297 587 3 7 mm 297 588 2 5 mm 297 589 1 3 mm 430201004 Fig. 9-15 Segmented Partial Coverage Adhesive Die, Center Orientation
9-22 Non-Segmented Partial Coverage Adhesive Dies, Left Orientation See Figure 9-16. The die O-ring (part 945 131) is included. Part Size of Opening Coating Width 1016242 0.008 in. 9 mm 1016243 0.008 in. 13 mm 1016244 0.008 in. 15 mm 1016245 0.008 in. 19 mm 430201005 Fig. 9-16 Non-Segmented Partial Coverage Adhesive Die, Left Orientation Non-Segmented Partial Coverage Adhesive Dies, Right Orientation See Figure 9-17. The die O-ring (part 945 131) is included. Part Size of Opening Coating Width 1016246 0.008 in. 9 mm 1016247 0.008 in. 13 mm 1016248 0.008 in. 15 mm 1016249 0.008 in. 19 mm 430201006 Fig. 9-17 Non-Segmented Partial Coverage Adhesive Die, Right Orientation
9-23 Non-Segmented Partial Coverage Adhesive Dies, Center Orientation See Figure 9-18. The die O-ring (part 945 131) is included. Part Size of Opening Coating Width 757 649 0.008 in. 22 mm 757 467 0.008 in. 18 mm 757 424 0.008 in. 16 mm 757 423 0.008 in. 14 mm 297 569 0.008 in. 12 mm 297 567 0.008 in. 10 mm 297 565 0.008 in. 8 mm 757 648 0.008 in. 5 mm 758 085 0.008 in. 3 mm 430201007 Fig. 9-18 Non-Segmented Partial Coverage Adhesive Die, Center Orientation Kits Part Description Contains These Parts 272 818 Kit, module rebuild, 1 module, with needle and piston assembly (to rebuild 1 module) 142 753 Kit, module rebuild, 10 modules, with needle and piston assembly (to rebuild 10 modules) 161 414 Kit, module rebuild, 10 modules, without needle and piston assembly (to rebuild 10 modules) 117 544, 144 892, 272 287, 272 822, 940 111, 940 121, 983 012 117 544, 144 892, 272 287, 272 822, 940 111, 940 121, 983 012 117 544, 144 892, 272 287, 705 553, 940 111, 940 121, 983 012, 986 502 147 473 Kit, compression springs and seal support discs 144 892, 983 012 (6 of each) 272 822 Kit, module seal subassembly 150 170, 986 502, 983 012, 750 553 272 290 Kit, needle and piston assembly 150 170
9-24 Recommended Spare Parts and Supplies For a complete spare parts and supplies list, refer to Recommended Spare Parts and Supplies in Section 8, Parts. Part Description Note 297 203, CC200 A 940 111 O-ring, Viton, 0.301 ID x 0.070 W in. (for the back of the module) 981 171 Screw, socket, 10-32 x 1.250 (for securing the module to the applicator) - - - - - - Adhesive dies B 297 206 Air die, front and rear 945 131 O-ring, Viton, 0.176 x 0.276 x 0.050 in. (for the dies) C 901 915 Kit, nozzle cleaning 900 223 Lubricant, O-ring, Parker, 4 oz (for lubricating O-rings) 900 344 Lubricant, Never Seez, 8 oz can (for the module socket-head screws) NOTE A: For a kit that includes 30 modules, order part 757 204. B: Refer to Adhesive Die Part Numbers earlier in this section for a list of available adhesive dies. C: The following value packs of this O-ring are available: 237 803 (contains 10 O-rings), 237 804 (contains 25 O-rings), and 237 805 (contains 100 O-rings).