Part A, Section 5 This section covers the following unit configurations. Model 3100V 3400V 3830V 3860V 3890V 3930V Voltage 1, 2 Pump AC Gear (K or L) Manifold 4-Port (J)) Control Vista Standard (V) Vista Pattern (PC)
A 5-0
A 5-1 Section A 5 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 Performing routine maintenance can extend the life of your unit and decrease the downtime caused by repairs. This section of the manual describes how to schedule maintenance activities check the run time of the heaters relieve system pressure replace the o-rings on hose connectors and plugs flush the manifold filter clean the manifold filter flush the system For information on repairing your unit, refer to the repair procedures in the Hydraulics, Control, or Tank sections of this manual.
A 5-2 2. Schedule Use Table A 5-1 to develop a maintenance schedule for your unit. Adjust how often you perform maintenance based on your operating environment. You may find that more or less frequent maintenance is required in some cases. Table A 5-1 Recommended Schedule Frequency Based on Run Time of Heaters (See Note A) Every 8 hours Every 40 hours Every 160 hours As needed Description of Clean the exterior surfaces of the unit and guns. Check the system for leaks. To replace damaged hose connector or plug o-rings, refer to Replacing Hose Connector or Plug O-Rings in this section. Flush the manifold filter. Refer to Flushing a Standard Manifold Filter in this section. Clean the manifold filter. Refer to Cleaning a Standard Manifold Filter in this section. Clean removable nozzles. Refer to the nozzle cleaning procedure in the maintenance section of the gun manual. Check all electrical connections and terminal blocks for tightness, including those inside the electrical enclosure. Clean the inside of the electrical enclosure. Check electrical connections and terminal blocks for tightness. Check the hose connections. Disassemble and clean the gear pump. Refer to Pump and Motor Assembly Repair Procedures in the Hydraulics section of this manual. Flush the system with a flushing material. Refer to Flushing the System in this section. NOTE A: To find out how many hours your system has been running with the heaters on, refer to Checking Run Time of Heaters in this section.
A 5-3 Checking Run Time of Heaters Use this procedure to check the total number of hours that the heaters have been running. 1. Press the Move Up or the Move Down key until the SYSTEM SETTINGS light turns on. 2. Press the Up key below the Selector display until feature number 26 appears in the display. 3. Check the displays above the Multipurpose keys and above the Enter key. Read them from left to right to see the total number of hours that the heaters have been running, up to 999,999 hours. 3. Procedures This part of the manual contains the maintenance procedures referenced in Table A 5-1 and the procedure for relieving system pressure. Relieving System Pressure System pressure must be properly relieved before you can safely proceed with many of the maintenance, troubleshooting, and repair procedures in this manual. Follow this procedure whenever you are instructed to relieve system pressure. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. Hot melt material may be released under pressure. 1. Ensure that the unit is at operating temperature. 2. Turn the pump off by pressing the PUMP key. 3. Place a container under all guns and the manifold drain valve. 4. Trigger one or more guns until adhesive stops flowing.
A 5-4 Relieving System Pressure (contd.) 5. Open the manifold drain valve and allow some adhesive to drain from the manifold. 6. Close the manifold drain valve. 4130716 Fig. A 5-1 Opening the Manifold Drain Valve Replacing Hose Connector or Plug O-Rings Use this procedure to replace damaged hose connector or plug o-rings. Refer to Recommended Spare Parts and Supplies at the front of this manual for o-ring part numbers. To Remove Hose Connector or Plug O-Rings 1. Relieve system pressure. Refer to Relieving System Pressure in this section. 2. To remove the o-ring from a hose-port plug, complete steps 3 and 4. To remove the o-ring from a hose connector, complete steps 5 8. 3. Use an Allen wrench to remove the o-ring plug from the hose port on the manifold. 4. Remove the o-ring from the plug. 4130552 Fig. A 5-2 Removing a Hose Plug and O-Ring 5. Disconnect the hose electrical connector from the electrical receptacle directly above the hose connection. 6. Disconnect the hose from the hose connector using two wrenches. Select the wrenches using Table A 5-2 and use them as shown in Figure A 5-3.
A 5-5 Table A 5-2 Wrench Sizes Needed for Hose Connections Hose Size (Internal Diameter) Connector Wrench Size Hose-Fitting Wrench Size 8 mm ( 5 / 16 in.) 16 mm ( 5 / 8 in.) 18 mm (1 1 / 16 in.) 16 mm ( 5 / 8 in.) 32 mm (1 1 / 4 in.) 32 mm (1 1 / 4 in.) 29 mm (1 1 / 8 in.) Use large, adjustable wrenches. 7. Use an open-end wrench to remove the hose connector from the hose port. 4130594 Fig. A 5-3 Correct Way to Remove or Tighten a Hose 8. Remove the o-ring from the hose connector. Fig. A 5-4 Removing a Hose Connector 4103397
A 5-6 To Install Hose Connector or Plug O-Rings CAUTION: Use only Nordson Viton o-rings. Other o-rings can cause leaks. 1. Check that the new o-ring and the threads of the hose port are free of debris. Lubricate the o-ring groove with o-ring lubricant. CAUTION: Do not stretch the o-ring more than necessary. Stretching the o-ring can cause leaks. 2. Stretch the o-ring and roll it over the threads of the hose connector or plug so that it rests in the o-ring groove. 3. Lubricate the threads of the hose connector or hose plug with PTFE paste. 4. Thread the connector or plug by hand into the port on the unit. 4103398 Fig. A 5-5 Threading a Hose Connector into a Hose Port 5. Tighten the hose connector or hose plug. Hose connector Hose plug To tighten a... Do this... Select two wrenches using Table A 5-2 and use them as shown in Figure A 5-3. Use an Allen wrench.
A 5-7 6. Torque the connector or plug to 0.79-1.13 Nm (7-10 lb-in.). 7. Remove the lockout and restore power to the system. 8. After the unit reaches READY status, purge the system of trapped air by removing the gun nozzles and triggering the guns. 9. Reassemble the nozzles onto the guns. Flushing a Standard Manifold Filter Use this procedure to flush the manifold filter. Flushing the manifold filter removes excess dirt and charred material that can clog the system and cause poor system performance. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. Hot melt material may be released under pressure. 1. Ensure that the unit is at operating temperature. 2. Turn the pump off by pressing the PUMP key. 3. Place containers under all guns and the manifold drain valve. If necessary, open the manifold filter and drain valve cover. WARNING: System or material pressurized. Relieve system pressure. Failure to observe may result in serious burns. 4. Trigger the guns to relieve system pressure. 5. Open the manifold drain valve (see Figure A 5-1).
A 5-8 Flushing a Standard Manifold Filter (contd.) 6. Turn the pump on by pressing the PUMP key. 7. Allow adhesive to flow from the drain valve until no traces of char are present. 8. Turn the pump off by pressing the PUMP key. 9. Close the manifold drain valve. 10. Turn the pump back on by pressing the PUMP key and resume normal operation. Cleaning a Standard Manifold Filter Use this procedure to clean the manifold filter. Cleaning the filter removes excess dirt and charred material that can clog the system and cause poor system performance. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. Hot melt material may be released under pressure. 1. Ensure that the unit is at operating temperature. 2. Flush the manifold filter. Refer to Flushing a Standard Manifold Filter in this section. WARNING: System or material pressurized. Relieve pressure. Failure to observe may result in serious burns. 3. Relieve system pressure. Refer to Relieving System Pressure in this section. 4. Loosen the filter using a wrench. A socket-type wrench is recommended.
A 5-9 5. Pull the filter assembly out of the manifold. 1 2 Fig. A 5-6 Removing a Manifold Filter 1. Loosening the filter 2. Removing the filter 4130717 6. Remove the screw in the back of filter assembly and separate the filter screen from the assembly. 4103999 Fig. A 5-7 Removing the Filter Screen
A 5-10 Cleaning a Standard Manifold Filter (contd.) 7. Use one of the following methods to clean the filter components. WARNING: Risk of fire. Do not heat Nordson Type R cleaning fluid above 246 C (475 F). Do not heat cleaning fluid with an open flame or in an unregulated heating device (for example, a small pan on an unregulated hot plate). A fire hazard exists if an open flame or an unregulated heating device is used to heat cleaning fluid. Use only a controlled heating device (such as a small, deep fat fryer or thermostatically-controlled hot plate) to heat the fluid above the melting temperature of the hot melt material. CAUTION: Do not use a metal brush to clean a manifold filter screen. Doing so can damage the screen and prevent the filter from operating properly. Place the components (except for the o-ring) in a container of Type R cleaning fluid and heat the fluid until it is above the melting point of the adhesive. Scrub the components with a fine-bristled brush. Remember to scrub the filter screen inside and out. Wipe the components with a clean, dry cloth. Use a flameless, electric heat gun or compressed hot air to heat the components. Wipe the components with a clean, dry cloth. Use an ultrasonic cleaner filled with cleaning fluid to soak the components, then wipe the components with a clean, dry cloth. 8. Inspect the filter screen and o-ring for damage. A dent or break in the filter screen mesh means that the screen is damaged beyond repair and should be replaced. 9. Reassemble the filter.
A 5-11 4103992 Fig. A 5-8 Assembling the Manifold Filter CAUTION: Ensure that the unit is at operating temperature before reinstalling the filter. Cold material from the filter or manifold walls can cause the filter screen to collapse if it is tightened in a cold system. 1. Ensure that the unit is at operating temperature. 2. Slide the filter assembly into the manifold and tighten it until it is finger-tight only. 3. Follow these steps to flush the manifold again: a. Open the manifold drain valve. b. Turn the pump on by pressing the PUMP key. c. Allow adhesive to flow from the drain valve. d. Turn the pump off by pressing the PUMP key. e. Close the manifold drain valve. 4. Tighten the filter assembly until it seats. Do not overtighten. 5. Turn the pump on by pressing the PUMP key and resume normal operation.
A 5-12 Flushing the System Use this procedure to periodically flush the system with hot melt material, a flushing material, or Type R cleaning fluid. System flushing removes excess dirt and charred material that can clog the system and cause poor system performance. You should also flush the system when you switch to a new type of hot melt material that is incompatible with the old material. If you are unsure whether the materials are compatible, contact your material supplier. To Prepare for Flushing the System 1. Ensure that the unit is at operating temperature. WARNING: System or material pressurized. Relieve system pressure. Failure to observe may result in serious burns. 2. Relieve system pressure. Refer to Relieving System Pressure in this section. 3. Drain the unit by pumping as much hot melt material from the tank as possible using one of the following methods. Method of Draining Gun Manifold Hose Description Place a suitable container under each gun nozzle. Remove each nozzle from its gun. Turn on the pump by pressing the PUMP key and pump the hot melt material out through the gun. Pump the hot melt material out through the manifold. Refer to Flushing a Standard Manifold Filter in this section. Disconnect a hose from its gun. Replace the dust cover, which was removed during installation, over the hose electrical receptacle. Position the hose over a suitable waste container and secure it. Turn the pump on by pressing the PUMP key and pump the hot melt material out through the hose.
A 5-13 Fig. A 5-9 Methods of Draining the Unit 1. Draining through the gun 2. Draining through the manifold 3. Draining through the hose 4130770 4. If you have not already done so, disconnect each hose in the system from its gun. 5. Clean each automatic gun and handgun as needed. Refer to the gun manual for information on gun disassembly, cleaning, and rebuilding. 6. Refer to Table A 5-3 to determine which method of flushing the system is best for your operation.
A 5-14 Flushing the System (contd.) Table A 5-3 Advantages and Disadvantages of System Flushing Procedures Flushing Procedure Time Needed (See Note A) Best Used for... (See Note B) Advantages and Disadvantages Using hot melt material About 1 hour Routine cleaning when the system is relatively free of char. The advantage of this method is that it requires less downtime. However, it is not as thorough as the other two methods. Using a flushing material recommended by your adhesive supplier and approved by your Nordson representative From 2 1 / 2 to 5 hours Occasional cleaning when there is some char buildup. Although this method requires more downtime, it does a good job of removing char buildup from the system. However, to remove all char you may need to scrub the tank. You will also need to purchase and store flushing material, which may have special storage and disposal requirements. Using Type R fluid From 3 to 13 hours Thorough cleaning when there is significant char buildup. This procedure is the most thorough way to remove char. You may also need to scrub the tank to remove all char. Disadvantages are that you cannot flush Type R fluid through the hoses; accidentally doing so can cause later downtime. Type R fluid is expensive but can be reused several times if the used fluid is strained into a storage container. The fluid is considered a regulated waste. NOTE A: Time needed varies depending on how much char must be removed. D: Because operating conditions vary from plant to plant, you may find that more or less frequent flushing is required.
A 5-15 7. Refer to the appropriate procedure for the flushing method you have selected: To Flush the System with Hot Melt Material To Flush the System with a Flushing Material To Flush the System with Type R Fluid To Flush the System with Hot Melt Material 1. Before beginning this procedure, first complete the procedure To Prepare for Flushing the System earlier in this section. NOTE: This procedure describes how to flush all hoses at once. However, for maximum cleaning of badly charred hoes, use this procedure and flush each hose one at a time. 2. If you have not already done so, secure the free end of each hose to a container that will be used to collect the hot melt material. 1 2 Fig. A 5-10 Securing a Hose to a Waste Container 1. Hose 2. Waste container 4904034 3. Using a metal or plastic scoop, fill the tank to within 25 mm (1 in.) of the top with fresh, clean hot melt material. 4. Allow the unit to reach operating temperature. 5. When the READY light turns on, turn the pump on by pressing the PUMP key. 6. Pump hot melt material through the hoses until the material is free of char and contaminants. 7. Turn the pump off by pressing the PUMP key.
A 5-16 Flushing the System (contd.) CAUTION: Using a metal brush or scraper can damage PTFE-coated tanks. Use a stiff-bristled, nonmetal brush when cleaning a PTFE-coated tank. 8. Use a stiff-bristled, non-metal brush or similar tool to scrub the tank or dislodge as much char and debris as possible. Do not use a metal brush or scraper on PTFE-coated tanks. NOTE: If this procedure does not remove all the charred material, you may need to replace the tank. Refer to the procedure for replacing the tank in the Tank section of this manual. 9. Clean the manifold filter. Refer to Cleaning a Standard Manifold Filter in this section. 10. Go to the procedure To Restore the Unit to Normal Operation in this section. To Flush the System with a Flushing Material WARNING: Use the flushing material at the manufacturer s recommended temperature, which will be below the hot melt material s flash point. Failure to observe this warning can cause a fire. WARNING: Never flush your system or clean any aluminum components with halogenated hydrocarbon cleaning solutions. These cleaning solutions are extremely dangerous when used to clean aluminum components in a pressurized fluid system. CAUTION: Do not use this procedure to flush your system with Type R fluid. This procedure instructs you to pump flushing material through the hoses. Flushing Type R fluid through hoses can cause large pieces of char to break off and clog the nozzles during later operation. If you plan to use Type R fluid to flush your system, refer the procedure To Flush the System with Type R Fluid in this section.
A 5-17 CAUTION: Certain flushing materials can damage seals and o-rings, resulting in poor pump performance. Be sure that the flushing material you use has been approved by your Nordson representative. To determine the best flushing material to use, contact your adhesive supplier. 1. Before beginning this procedure, first complete the procedure To Prepare for Flushing the System earlier in this section. NOTE: This procedure describes how to flush all hoses at once. However, for maximum cleaning of badly charred hoses, use this procedure and flush each hose one at a time. 2. If you have not already done so, secure the free end of each hose to a container that will be used to collect the hot melt material (see Figure A 5-10). 3. Set the tank and hose temperature to the recommended temperature of the flushing material. Refer to Programming TEMPERATURE Controls in the Installation section of this manual. 4. Pour the flushing material into the empty tank to within 25 mm (1 in.) of the top of the tank. 5. When the unit reaches the preset temperature (at which point the READY light will turn on), turn the pump on by pressing the PUMP key. 6. Pump material through the hoses until the flushing material starts to come out. 7. Turn the pump off by pressing the PUMP key. 8. Allow the remaining material to drain from the hoses. 9. Remove the hoses from the collection container, place them over the tank, and secure them. 4130769 Fig. A 5-11 Securing a Hose to the Tank
A 5-18 Flushing the System (contd.) 10. Turn the pump on by pressing the PUMP key. 11. Allow the flushing material to circulate through the system for 1 1 / 2 to 4 hours. 12. Turn the pump off by pressing the PUMP key. 13. Wait for any remaining material to drain from the hoses. 14. Remove the hoses from the tank, secure them over a waste container (see Figure A 5-10), and drain the flushing material from the tank into the container. CAUTION: Using a metal brush or scraper can damage PTFE-coated tanks. Use a stiff-bristled, nonmetal brush when cleaning a PTFE-coated tank. 15. Use a stiff-bristled, nonmetal brush or similar tool to scrub the tank or dislodge as much char and debris as possible. Do not use a metal brush or scraper on PTFE-coated tanks. NOTE: If this procedure does not remove all the charred material, you may need to replace the tank. Refer to the procedure for replacing the tank in the Tank section of this manual. 16. Using a metal or plastic scoop, fill the tank to within 25 mm (1 in.) of the top with fresh, clean hot melt material. 17. Set the temperature of the tank to the lowest temperature that the adhesive can be pumped at. Refer to Programming TEMPERATURE Controls in the Installation section of this manual. 18. Wait for the unit to reach the preset temperature, then drain 3 / 4 of the adhesive through the hoses into the waste container. 19. After you have drained 3 / 4 of the material, turn the pump off by pressing the PUMP key.
A 5-19 20. Place a container under the manifold drain valve, open the valve, and drain the remaining adhesive (see Figure A 5-1). 21. Clean the manifold filter. Refer to Cleaning a Standard Manifold Filter in this section. 22. Go to the procedure To Restore the Unit to Normal Operation in this section. To Flush the System with Type R Fluid 1. Before beginning this procedure, first complete the procedure To Prepare for Flushing the System earlier in this section. 2. Set the tank temperature 14 17 C (25 30 F) higher than the recommended application temperature of the adhesive. Refer to Programming TEMPERATURE Controls in the Installation section of this manual. 3. Pour Type R fluid into the empty tank to within 25 mm (1 in.) of the top of the tank. 4. Use a clean paint brush or similar tool to apply fluid to areas not submerged in the fluid. 5. Allow the fluid to heat in the tank for 2 12 hours. 6. As needed, use a wooden or plastic strainer to skim off the char and adhesive that floats to the top of the tank. CAUTION: Do not pump Type R fluid through hoses. Fluid absorbed by char in the hoses may leach out or cause large pieces of char to break off and clog a nozzle during later operation. 7. Place a container under the manifold drain valve, open the valve, and drain the fluid from the manifold (see Figure A 5-1). NOTE: You can reuse the fluid if you place a strainer on the top of the container used to collect it.
A 5-20 To Flush the System with Type R Fluid (contd.) 8. Close the manifold drain valve. 9. Using a metal or plastic scoop, place several pounds of fresh, clean hot melt material into the empty tank. 10. Set the temperature of the tank and hoses to the lowest temperature that the adhesive can be pumped at. Refer to Programming TEMPERATURE Controls in the Installation section of this manual. 11. Secure the free end of the hose to a container that will be used to collect the hot melt material (see Figure A 5-10). 12. When the tank and hoses reach their setpoint temperatures (at which point the READY light will turn on), turn the pump on by pressing the PUMP key. 13. Pump adhesive into the containers until a clean, steady stream of material flows from each hose. 14. When material has finished draining, turn the pump off by pressing the PUMP key. 15. Clean the manifold filter. Refer to Cleaning a Standard Manifold Filter in this section. 16. Go to the procedure To Restore the Unit to Normal Operation in this section.
A 5-21 To Restore the Unit to Normal Operation After flushing your system with hot melt material, a flushing material, or Type R fluid, follow this procedure to restore your unit to normal operation. 1. Disconnect and lock out electrical power to the unit. 2. Reconnect each gun to its hose both electrically and mechanically. Refer to Mechanical Installation and Electrical Installation in the Installation section of this manual. 3. Remove the lock-out and restore power to the unit. 4. If you have changed the unit s temperature setpoint or if the recommended operating temperature of the new adhesive is different from the previous adhesive, reprogram the temperature settings. Refer to the appropriate procedure as directed by Table A 5-4. Table A 5-4 Reprogramming Temperature Settings To reprogram this setting... Overtemperature setpoint SETPOINT or STANDBY temperature Follow this procedure... Programming SYSTEM SETTINGS Controls in the Installation section of this manual Programming TEMPERATURE Controls in the Installation section of this manual. 5. Use a metal or plastic scoop to fill the tank with adhesive. Refer to Filling the Tank with Adhesive in the Installation section of this manual. 6. When the READY light turns on, turn the pump on by pressing the PUMP key. 7. Resume normal operation.