Roll Fed Labeling System

Roll Fed Labeling System Customer Product Manual Issued 4/15 This document contains important safety information Be sure to read and follow all safety information in this document and any other related documentation. NORDSON CORPORATION DULUTH, GEORGIA USA www.nordson.com

For CE Declaration, refer to equipment documentation. Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 11475 Lakefield Drive Duluth, GA 30097 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2009. Nopartofthisdocument may be photocopied, reproduced, or translated to another language without the prior written consent of NordsonCorporation. Theinformationcontained in this publication is subject to change without notice. Trademarks AccuJet, AeroCharge, Allegro, Apogee, AquaGuard, Artiste, Asymtek, Automove, BaitGun, Blue Box, BM-32, BM-58, BM-63, Bowtie, Build A Part, CanWorks, Century, CF, CleanSleeve, CleanSpray, ColorMax, Color on Demand, Contour, ControlCoat, Coolwave, Cross Cut, CrystallCut, cscan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura Screen, Durasystem, EasyCoat, Easymelt, Easymove Plus, Ecodry, Econo Coat, e.dot, EFD, Eliminator, Emerald, Encore, Equatherm, ESP, e stylized, ETI stylized, Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flex O Coat, Flow Sentry, Fluidmove, FoamMelt, FoalMelt - stylized, FoamMix, Freedom, Fulfill, GreenUV, HDLV, Heli flow, Horizon, Hot Shot, icontrol, idry, iflow, Isocoil, Isocore, Iso Flo, itrax, Kinetix, KISS, LeanCell, LittleSquirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, Micromedics, Micro Meter, MicroSet, Microshot, Millennium, MiniBlue, Mini Squirt, Mountaingate, NexJet, No-Drip, Nordson, Nordson - stylized, Nordson and Arc, OptiMix, Optimum, Package of Values, Paragon, Pattern View, PermaFlo, PICO, PicoDot, Plasmod, Poly-Check, PorousCoat, PowderGrid, Powderware, Precisecoat, PrintPlus, Prism, ProBlue, Prodigy, Pro Flo, Program A Bead, Program A Shot, Program A Stream, Program A Swirl, ProLink, Pro Meter, Pro Stream, Pulsar, Quantum, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, Sealant Equipment & Engineering, Inc, SEE and design, See Flo, Seal Sentry, SelectCharge, SelectCoat, Select Cure, Servo Flo, Shot A Matic, Signature, Signature - stylized, Slautterback, Smart Coat, Smart-Gun, SolderPlus, Spectrum, Speed Coat, StediFlo, Stratablend, SureBead, Sure Coat, Sure Max, SureWrap, TAH, Tip-Seal, TrackingPlus, TRAK, Trends, Tribomatic, Trilogy, TrueBlue, TrueCoat, Tubesetter, Ultra, UpTime, u TAH, Value Plastics, Vantage, VersaBlue, Versa Coat, VersaDrum, VersaPail, Versa Screen, Versa Spray,VP Quick-Fit, VP Quick-Fit stylized, VP stylized, Watermark, When you expect more., Xaloy, Xaloy - stylized, X-Plane, and YesTech are registered trademarks of Nordson Corporation. Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, ATS, Auto Flo, AutoScan, Axiom, Best Choice, Blue Series, Bravura, CanPro, Champion, Check Mate, ClassicBlue, Classic IX, CleanCoat, Cobalt, Concert, Controlled Fiberization, ControlWeave, ContourCoat, CPX, cselect, Cyclo Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraPUR, Easy Clean, EasyOn, EasyPW, Eclipse, EdgeControl, e.dot+, E Nordson, Equalizer, EquiBead, FillEasy, FillSentry, FlexSeam, Flow Coat, Fluxplus, Genius, Get Green With Blue, G Net, G Site, IntelliJet, ion, Iso Flex, itrend, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge, Minimeter, MiniPUR, Multifill, MultiScan, Myritex, Nano, OmniScan, OptiStroke, Optix, Partnership+Plus, PatternJet, PatternPro, PCI, PharmaLok, Pinnacle, PowderPilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PUReOne, PURJet, Ready Coat, RediCoat, RollVIA, Royal Blue, SelectSeries, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, SpeedKing, Spray Works, StediTherm, StrokeControl, Summit, SureFoam, SureMix, SureSeal, SwirlCoat, ThruWave, TradePlus, Trio, TruFlow, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, VersaPUR, Vista, Web Cure, and 2Rings (Design) aretrademarks of NordsonCorporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners' rights. Never Seez is a registered trademark of Bostik Inc. All rights reserved

Table of Contents i Table of Contents Safety... 1 Safety Alert Symbols... 1 Responsibilities of the Equipment Owner... 2 Safety Information... 2 Instructions, Requirements, and Standards... 2 User Qualifications... 3 Applicable Industry Safety Practices... 3 Intended Use of the Equipment... 3 Instructions and Safety Messages... 4 Installation Practices... 4 Operating Practices... 4 Maintenance and Repair Practices... 5 Equipment Safety Information... 5 Equipment Shutdown... 6 General Safety Warnings and Cautions... 7 Other Safety Precautions... 10 First Aid... 10 Safety Labels and Tags... 11 Description... 12 Intended Use... 14 Limitations of Use... 14 Theory of Operation... 15 Unit Identification... 17 Key Components... 18 Installation... 20 Electro Magnetic Compliance Information... 20 Experience of Installation Personnel... 20 Customer Supplied Installation Components... 20 Prepare for Installation... 21 Remove Existing Equipment... 21 Install the Vacuum Drum... 21 Install the AltaBlue TT Melter... 22 Install the Controller Mounting Post... 22 Install the EPC30 Pattern Control... 22 Install the SSR Controller... 23 Install the PatternJet Plus Applicator... 24 Adjust the Applicator Position... 26 Connect the Hose... 28 Install the Proximity Switch... 29 Install a Label Presence Sensor... 30 Install the Encoder... 30 Install the Pneumatic PCV and Air Control Assembly... 31 Install a Pressure Switch (Optional)... 31 Make the Air Supply Connections... 32 Make the Electrical Connections... 34 Connect the Applicator Cordsets... 42

ii Table of Contents Setup... 43 Check Melter Parameters 40 and 41... 43 Setting the Adhesive Pattern... 43 Preliminary Steps... 43 Create the Label Pattern... 46 Setting Up Gear to Line Operation and Adjusting System Pressure.. 49 Determine Minimum and Maximum Settings... 50 Set Up Runup 1 (Gear to Line Operation)... 51 Set Up Runup 2 (Hydraulic Pressure)... 52 Program the Air Control Assembly Regulator... 53 Unlocking/Locking the Keys... 54 Programming Minimum and Maximum Pressures... 55 Record of Settings... 57 Operation... 59 Daily Startup and Operation... 59 Responding to Alarms... 59 Daily Shutdown... 59 Maintenance... 60 Daily Maintenance... 60 Weekly Maintenance... 60 Monthly Maintenance... 61 As Needed Maintenance... 61 Repair... 62 Placing the Applicator in the Service Position... 62 Replacing the Applicator... 63 Replacing an Applicator Cordset... 64 Replacing a Filter... 64 Troubleshooting... 65 General Applicator Pattern Control Problems... 65 Label Specific Pattern Control Problems... 67 Air Control Assembly Problems... 76

Table of Contents iii Parts... 77 Roll Fed Labeling System Components... 78 PatternJet Plus Applicators and Service Kits... 80 PatternJet Plus Applicator Service Kits... 81 PatternJet Plus Applicator Cordsets... 81 SSR Controller Parts... 82 Controller Mounting Post Parts... 84 Applicator Stand/Mounting Bracket Parts... 86 Applicator Mounting Stand Parts... 88 Encoder Kit Parts... 90 Proximity Switch Kit Parts... 92 Vacuum Drum Hose Bracket Parts (Optional)... 93 Pressure Switch (Optional)... 94 Nozzle Part Numbers... 95 Signature Nozzles... 95 Blank Nozzle... 97 Recommended Spare Parts and Supplies... 98 Technical Data... 99 Roll Fed Labeling System Specifications... 99 Dimensions... 100 Applicator Mounting Stand and Bracket Assembly... 100 Controller Mounting Post... 101 SSR Controller... 101 Cable/Cordset Wiring Diagrams... 102 SSR Controller Schematic... 104

iv Table of Contents

Roll Fed Labeling System 1 Roll Fed Labeling System WARNING! Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment. Safety Read this section before using the equipment. This section contains recommendations and practices applicable to the safe installation, operation, and maintenance (hereafter referred to as use ) of the product described in this document (hereafter referred to as equipment ). Additional safety information, in the form of task specific safety alert messages, appears as appropriate throughout this document. WARNING! Failure to follow the safety messages, recommendations, and hazard avoidance procedures provided in this document can result in personal injury, including death, or damage to equipment or property. Safety Alert Symbols The following safety alert symbol and signal words are used throughout this document to alert the reader to personal safety hazards or to identify conditions that may result in damage to equipment or property. Comply with all safety information that follows the signal word. WARNING! Indicates a potentially hazardous situation that, if not avoided, can result in serious personal injury, including death. CAUTION! IIndicates a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury. CAUTION! (Used without the safety alert symbol) Indicates a potentially hazardous situation that, if not avoided, can result in damage to equipment or property.

2 Roll Fed Labeling System Responsibilities of the Equipment Owner Equipment owners are responsible for managing safety information, ensuring that all instructions and regulatory requirements for use of the equipment are met, and for qualifying all potential users. Safety Information Research and evaluate safety information from all applicable sources, including the owner specific safety policy, best industry practices, governing regulations, material manufacturer's product information, and this document. Make safety information available to equipment users in accordance with governing regulations. Contact the authority having jurisdiction for information. Maintain safety information, including the safety labels affixed to the equipment, in readable condition. Instructions, Requirements, and Standards Ensure that the equipment is used in accordance with the information provided in this document, governing codes and regulations, and best industry practices. If applicable, receive approval from your facility's engineering or safety department, or other similar function within your organization, before installing or operating the equipment for the first time. Provide appropriate emergency and first aid equipment. Conduct safety inspections to ensure required practices are being followed. Re evaluate safety practices and procedures whenever changes are made to the process or equipment.

Roll Fed Labeling System 3 User Qualifications Equipment owners are responsible for ensuring that users: receive safety training appropriate to their job function as directed by governing regulations and best industry practices are familiar with the equipment owner's safety and accident prevention policies and procedures receive equipment and task specific training from another qualified individual NOTE: Nordson can provide equipment specific installation, operation, and maintenance training. Contact your Nordson representative for information possess industry and trade specific skills and a level of experience appropriate to their job function are physically capable of performing their job function and are not under the influence of any substance that degrades their mental capacity or physical capabilities Applicable Industry Safety Practices The following safety practices apply to the use of the equipment in the manner described in this document. The information provided here is not meant to include all possible safety practices, but represents the best safety practices for equipment of similar hazard potential used in similar industries. Intended Use of the Equipment Use the equipment only for the purposes described and within the limits specified in this document. Do not modify the equipment. Do not use incompatible materials or unapproved auxiliary devices. Contact your Nordson representative if you have any questions on material compatibility or the use of non standard auxiliary devices.

4 Roll Fed Labeling System Instructions and Safety Messages Read and follow the instructions provided in this document and other referenced documents. Familiarize yourself with the location and meaning of the safety warning labels and tags affixed to the equipment. Refer to Safety Labels and Tags at the end of this section. If you are unsure of how to use the equipment, contact your Nordson representative for assistance. Installation Practices Install the equipment in accordance with the instructions provided in this document and in the documentation provided with auxiliary devices. Ensure that the equipment is rated for the environment in which it will be used. This equipment has not been certified for compliance with the ATEX directive nor as nonincendive and should not be installed in potentially explosive environments. Ensure that the processing characteristics of the material will not create a hazardous environment. Refer to the Safety Data Sheet (SDS) for the material. If the required installation configuration does not match the installation instructions, contact your Nordson representative for assistance. Position the equipment for safe operation. Observe the requirements for clearance between the equipment and other objects. Install lockable power disconnects to isolate the equipment and all independently powered auxiliary devices from their power sources. Properly ground all equipment. Contact your local building code enforcement agency for specific requirements. Ensure that fuses of the correct type and rating are installed in fused equipment. Contact the authority having jurisdiction to determine the requirement for installation permits or inspections. Operating Practices Familiarize yourself with the location and operation of all safety devices and indicators. Confirm that the equipment, including all safety devices (guards, interlocks, etc.), is in good working order and that the required environmental conditions exist. Use the personal protective equipment (PPE) specified for each task. Refer to Equipment Safety Information or the material manufacturer's instructions and SDS for PPE requirements. Do not use equipment that is malfunctioning or shows signs of a potential malfunction.

Roll Fed Labeling System 5 Maintenance and Repair Practices Allow only personnel with appropriate training and experience to operate or service the equipment. Perform scheduled maintenance activities at the intervals described in this document. Relieve system hydraulic and pneumatic pressure before servicing the equipment. De energize the equipment and all auxiliary devices before servicing the equipment. Use only new Nordson authorized refurbished or replacement parts. Read and comply with the manufacturer's instructions and the SDS supplied with equipment cleaning compounds. NOTE: SDSs for cleaning compounds that are sold by Nordson are available at www.nordson.com or by calling your Nordson representative. Confirm the correct operation of all safety devices before placing the equipment back into operation. Dispose of waste cleaning compounds and residual process materials according to governing regulations. Refer to the applicable SDS or contact the authority having jurisdiction for information. Keep equipment safety warning labels clean. Replace worn or damaged labels. Equipment Safety Information This equipment safety information is applicable to the following types of Nordson equipment: hot melt and cold adhesive application equipment and all related accessories pattern controllers, timers, detection and verification systems, and all other optional process control devices

6 Roll Fed Labeling System Equipment Shutdown To safely complete many of the procedures described in this document, the equipment must first be shut down. The level of shut down required varies by the type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure. The levels of shut down are: Relieving System Hydraulic Pressure Completely relieve system hydraulic pressure before breaking any hydraulic connection or seal. Refer to the melter specific product manual for instructions on relieving system hydraulic pressure. De energizing the System Isolate the system (melter, hoses, applicators, and optional devices) from all power sources before accessing any unprotected high voltage wiring or connection point. 1. Turn off the equipment and all auxiliary devices connected to the equipment (system). 2. To prevent the equipment from being accidentally energized, lock and tag the disconnect switch(es) or circuit breaker(s) that provide input electrical power to the equipment and optional devices. NOTE: Government regulations and industry standards dictate specific requirements for the isolation of hazardous energy sources. Refer to the appropriate regulation or standard. Disabling the Applicators NOTE: Adhesive dispensing applicators are referred to as guns in some previous publications. All electrical or mechanical devices that provide an activation signal to the applicators, applicator solenoid valve(s), or the melter pump must be disabled before work can be performed on or around an applicator that is connected to a pressurized system. 1. Turn off or disconnect the applicator triggering device (pattern controller, timer, PLC, etc.). 2. Disconnect the input signal wiring to the applicator solenoid valve(s). 3. Reduce the air pressure to the applicator solenoid valve(s) to zero; then relieve the residual air pressure between the regulator and the applicator.

Roll Fed Labeling System 7 General Safety Warnings and Cautions Table 1 contains the general safety warnings and cautions that apply to Nordson hot melt and cold adhesive equipment. Review the table and carefully read all of the warnings or cautions that apply to the type of equipment described in this manual. Equipment types are designated in Table 1 as follows: HM = Hot melt (melters, hoses, applicators, etc.) PC = Process control CA = Cold adhesive (dispensing pumps, pressurized container, and applicators) Equipment Type Table 1 General Safety Warnings and Cautions Warning or Caution HM WARNING! Hazardous vapors! Before processing any polyurethane reactive (PUR) hot melt or solvent based material through a compatible Nordson melter, read and comply with the material's SDS. Ensure that the material's processing temperature and flashpoints will not be exceeded and that all requirements for safe handling, ventilation, first aid, and personal protective equipment are met. Failure to comply with SDS requirements can cause personal injury, including death. HM WARNING! Reactive material! Never clean any aluminum component or flush Nordson equipment with halogenated hydrocarbon fluids. Nordson melters and applicators contain aluminum components that may react violently with halogenated hydrocarbons. The use of halogenated hydrocarbon compounds in Nordson equipment can cause personal injury, including death. HM, CA WARNING! System pressurized! Relieve system hydraulic pressure before breaking any hydraulic connection or seal. Failure to relieve the system hydraulic pressure can result in the uncontrolled release of hot melt or cold adhesive, causing personal injury. Continued...

8 Roll Fed Labeling System Equipment Type General Safety Warnings and Cautions (contd) Table 1 General Safety Warnings and Cautions (contd) Warning or Caution HM WARNING! Molten material! Wear eye or face protection, clothing that protects exposed skin, and heat protective gloves when servicing equipment that contains molten hot melt. Even when solidified, hot melt can still cause burns. Failure to wear appropriate personal protective equipment can result in personal injury. HM, PC WARNING! Equipment starts automatically! Remote triggering devices are used to control automatic hot melt applicators. Before working on or near an operating applicator, disable the applicator's triggering device and remove the air supply to the applicator's solenoid valve(s). Failure to disable the applicator's triggering device and remove the supply of air to the solenoid valve(s) can result in personal injury. HM, CA, PC WARNING! Risk of electrocution! Even when switched off and electrically isolated at the disconnect switch or circuit breaker, the equipment may still be connected to energized auxiliary devices. De energize and electrically isolate all auxiliary devices before servicing the equipment. Failure to properly isolate electrical power to auxiliary equipment before servicing the equipment can result in personal injury, including death. HM, CA, PC WARNING! Risk of fire or explosion! Nordson adhesive equipment is not rated for use in explosive environments and has not been certified for the ATEX directive or as nonincendive. In addition, this equipment should not be used with solvent based adhesives that can create an explosive atmosphere when processed. Refer to the SDS for the adhesive to determine its processing characteristics and limitations. The use of incompatible solvent based adhesives or the improper processing of solvent based adhesives can result in personal injury, including death. HM, CA, PC WARNING! Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others and can damage to the equipment.

Roll Fed Labeling System 9 Equipment Type Warning or Caution HM CAUTION! Hot surfaces! Avoid contact with the hot metal surfaces of applicators, hoses, and certain components of the melter. If contact can not be avoided, wear heat protective gloves and clothing when working around heated equipment. Failure to avoid contact with hot metal surfaces can result in personal injury. HM CAUTION! Some Nordson melters are specifically designed to process polyurethane reactive (PUR) hot melt. Attempting to process PUR in equipment not specifically designed for this purpose can damage the equipment and cause premature reaction of the hot melt. If you are unsure of the equipment's ability to process PUR, contact your Nordson representative for assistance. HM, CA CAUTION! Before using any cleaning or flushing compound on or in the equipment, read and comply with the manufacturer's instructions and the SDS supplied with the compound. Some cleaning compounds can react unpredictably with hot melt or cold adhesive, resulting in damage to the equipment. HM CAUTION! Nordson hot melt equipment is factory tested with Nordson Type R fluid that contains polyester adipate plasticizer. Certain hot melt materials can react with Type R fluid and form a solid gum that can clog the equipment. Before using the equipment, confirm that the hot melt is compatible with Type R fluid.

10 Roll Fed Labeling System Other Safety Precautions Do not use an open flame to heat hot melt system components. Check high pressure hoses daily for signs of excessive wear, damage, or leaks. Never point a dispensing handgun at yourself or others. Suspend dispensing handguns by their proper suspension point. First Aid If molten hot melt comes in contact with your skin: 1. Do NOT attempt to remove the molten hot melt from your skin. 2. Immediately soak the affected area in clean, cold water until the hot melt has cooled. 3. Do NOT attempt to remove the solidified hot melt from your skin. 4. In case of severe burns, treat for shock. 5. Seek expert medical attention immediately. Give the SDS for the hot melt to the medical personnel providing treatment.

Roll Fed Labeling System 11 Safety Labels and Tags Figure 1 illustrates the location of the product safety labels and tags affixed to the equipment. Table 2 provides an illustration of the hazard identification symbols that appear on each safety label and tag, the meaning of the symbol, or the exact wording of any safety message. 1 Figure 1 Safety labels and tags Note: Refer to the melter, applicator, and pattern controller manuals to obtain this information for those components. Table 2 Safety Labels and Tags Item Part Description 1. 338099 WARNING! MOVING PARTS CAN CRUSH AND CUT. KEEP HANDS CLEAR. DO NOT OPERATE WITH GUARD REMOVED.

12 Roll Fed Labeling System Description This manual describes the installation and use of the Nordson roll fed labeling system. When necessary, the reader is referred to the documentation supplied with other Nordson products or products supplied by third parties. The roll fed labeling (RFL) system applies labels to bottles. The labels are fed from a continuous band wound on a spool. Generally, clear, printed, lacquered, or aluminum coated OPP (oriented polypropylene) or OPS (oriented polystyrene) foils are used as the label material. The roll fed labeling system includes the following components: AltaBlue TT 10 melter (8.5 kg/hr, two hoses/applicators) Blue Series hot melt adhesive hose EPC30 pattern control with input/output SSR controller Mounting post and associated hardware for the SSR controller, EPC30 pattern control, and air control assembly PatternJet Plus applicator Mounting stand, bracket, and associated hardware for the PatternJet Plus applicator Air control assembly and associated hardware Encoder and associated hardware Proximity switch and associated hardware Vacuum drum hose bracket and associated hardware (optional) This manual applies to the SSR controller, applicator mounting assemblies, air control assembly, encoder, proximity switch, and vacuum drum hose bracket. Refer to the other manuals provided with the system for the installation and use of those components.

Roll Fed Labeling System 13 4 1 5 2 6 3 9 7 8 Figure 2 Roll-fed labeling system components 1. AltaBlue TT melter 4. SSR controller 2. Applicator mounting stand and bracket 5. EPC30 pattern control 3. PatternJet Plus applicator 6. Controller mounting post 7. Air control assembly 8. Proximity switch components 9. Encoder components

14 Roll Fed Labeling System Intended Use Roll fed labeling systems are specifically designed to: Melt and pump hot melt adhesives that are engineered to be liquified and extruded at temperatures that are typically between 121 177 C (250 350 F). Be used with compatible equipment manufactured by Nordson Corporation Be used in non explosive environments The roll fed labeling system is virtually complete, but is intended to be incorporated into machinery or assemblies by an integrator. The equipment must not be placed into use in a member state of the European Union until the parent machinery or assemblies have been declared by the integrator to be in conformity with the applicable directives of the European Commission. Limitations of Use Use roll fed labeling systems only for the purpose for which they are designed. Roll fed labeling systems should not be used: to melt or pump any material that creates a health or safety hazard when heated in environments that will require the system to be cleaned using a water wash or spray

Roll Fed Labeling System 15 Theory of Operation See Figure 3 for a diagram of the processes of a typical labeling application. A continuous band of labels is fed from a spool through a series of guide rollers. A tension control function keeps the label band tension even as the diameter of the label spool decreases. Web alignment sensors are used to correct the vertical position of the label band to ensure proper label positioning. The label band is guided into the cutter where it is cut into individual labels. In most cases, recognition of the correct label length is achieved through the printed cut marks on the labels. The cut mark recognition photocell is mounted ahead of the cutter. Nordson Corporation adds a proximity switch and an encoder to the labeling process. The proximity switch senses the beginning of a label. The encoder measures labels and also allows the melter to be operated in the automatic mode, in which adhesive output is geared to the line speed. The signals generated by the proximity switch and the encoder are fed to the EPC30 pattern control, and the proximity switch is wired in parallel with the parent machine's label presence sensor. The EPC30 pattern control will not fire the applicator until the label is in the correct position on the vacuum drum. The SSR controller allows you to start or stop up to six high speed adhesive dispensing modules without making program changes in the EPC30 pattern control. NOTE: Some machines use an absolute encoder paired with a microprocessor to determine label position and length. After the labels are cut, they are sucked onto the vacuum drum. The leading and trailing edge of each label is sprayed with adhesive by the PatternJet Plus applicator (this is known as a pickup and lap pattern). After adhesive is applied to the labels, the labels are applied to bottles. The bottles rotate during label transfer, pulling each label from the vacuum drum until it is firmly seated on a bottle.

16 Roll Fed Labeling System Theory of Operation (contd) PatternJet Plus applicator Figure 3 Roll-fed labeling system theory of operation

Roll Fed Labeling System 17 Unit Identification See Figure 4. You will need the model and part number of your equipment when requesting service or ordering spare parts and optional equipment. The model and part number are indicated on the equipment identification plate. Figure 4 Location of the equipment identification plates on the applicator mounting hardware Note: Refer to the product manuals supplied with this system to obtain this information for other system components.

18 Roll Fed Labeling System Key Components 1 6 5 2 3 7 4 Figure 5 Key components of the applicator and mounting assemblies 1. Handwheel 5. Module actuating air input fitting 2. PatternJet Plus applicator adjustable 6. Applicator mounting stand vertical bracket position indicator 3. Vacuum hose bracket (optional) 7. Applicator mounting stand vertical 4. PatternJet Plus applicator adjustment screw 8. Applicator mounting stand service position adjustment screw 11 10 9 9. Saturn inline filter hose fitting (adhesive input) 10. PatternJet applicator cordsets 11. Pattern air input fitting Note: Refer to the product manuals supplied with this system to obtain this information for other system components. 8

Roll Fed Labeling System 19 3 4 2 5 1 Figure 6 SSR controller operator interface 1. POWER OFF/ON switch 2. Nozzle OFF/ON switches 3. POWER light 4. READY light 5. FAULT light

20 Roll Fed Labeling System Installation Installation involves removing existing equipment as needed, placing new system components in the desired locations, and making hydraulic, pneumatic, and electrical connections. Electro Magnetic Compliance Information This system is classified as Class A, Group 2 under the European standard for limits and methods of measurement, EN 55011. Experience of Installation Personnel The instructions provided in this section are intended to be used by personnel who have experience in the following subjects: Hot melt application processes Industrial power and control wiring Industrial mechanical installation practices Basic process control and instrumentation Customer Supplied Installation Components In addition to the components provided by Nordson Corporation, installation of the roll fed labeling system requires the following customer supplied components: label presence sensor 3 / 8 NPT air input fitting

Roll Fed Labeling System 21 Prepare for Installation Ensure that the installation location meets the electrical and pneumatic supply requirements shown in Table3. Table 3 Electrical and Pneumatic Installation Requirements Component AltaBlue TT 10 melter (8.5 kg/hr, 2 hoses/applicators) PatternJet Plus applicator SSR controller Installation Requirements Voltage: 400/230 VAC 3 phase, 3/N/PE AC, 400/230V 230 VAC 1 phase, 1/N/PE AC, 200 240V 200 240 VAC 3 phase, 3/PE AC, 200 240V 200 240 VAC 1 phase, 1/PE AC, 200 240V Input voltage tolerance: +10%, 15% Current: 25 A maximum Compressed air: 8.3 bar (120 psi) maximum, clean/dry air Voltage: 110 V, 48 62 Hz Current: 8 A maximum Remove Existing Equipment 1. Disconnect and lock out power to the labeling system and allow the adhesive wheel to cool. 2. Shut off the air supply. 3. Disconnect the air supply tubing to the adhesive wheel and close the air supply shutoff valve. 4. Remove the existing adhesive supply melting equipment. 5. Disconnect the adhesive hose from the adhesive wheel assembly. 6. Remove the existing vacuum drum assembly. 7. Remove the adhesive wheel assembly from its supports using a forklift and/or other lifting equipment as needed. Install the Vacuum Drum Replace the existing vacuum drum with a new vacuum drum or a customer supplied modified vacuum drum. Contact your Nordson representative for assistance as needed.

22 Roll Fed Labeling System Install the AltaBlue TT Melter Replace the existing adhesive melter with the AltaBlue TT melter. Refer to the melter manual as needed. NOTE: The AltaBlue melter uses the same bolt mounting pattern as a DuraBlue or Slautterback KB Series melter. Install the Controller Mounting Post See Figure 7. Secure the 1.83 m (6 ft), 80 x 80 mm mounting post for the EPC30 pattern control and SSR controller to the floor near the parent machine. 140 5.512 8 mm 160 6.299 Figure 7 130 5.118 200 7.874 Controller mounting post bolt mounting pattern Install the EPC30 Pattern Control See Figure 8. DIN rail mount the EPC30 pattern control on the controller mounting post.

Roll Fed Labeling System 23 Install the SSR Controller See Figure 8. Use the 8 mm bolts from the installation kit to secure the SSR controller to the controller mounting post. 1 2 Figure 8 SSR controller and EPC30 pattern control installed on the controller mounting post 1. SSR controller 2. EPC30 pattern control

24 Roll Fed Labeling System Install the PatternJet Plus Applicator 1. If needed, secure the PatternJet Plus applicator on the applicator mounting bracket using the supplied screws. Figure 33 later in this manual shows how the applicator stand components are mounted. 2. See Figure 9. Position the applicator and mounting stand assembly (1) next to the wheel support post (2). 3. Position the applicator nozzles against the vacuum drum (3) pointed toward the center tangent of the vacuum drum. 3 1 2 Figure 9 Positioning the applicator mounting stand 1. Applicator mounting stand assembly 3. Vacuum drum 2. Wheel support post

Roll Fed Labeling System 25 4. See Figure 10. Using a center punch and the 8 mm holes in the applicator mounting stand base plate as a guide, mark and punch the four mounting hole positions and then drill and tap through the holes on the mounting surface. 5. Bolt the applicator mounting stand to the mounting surface..344 TYP. 5.905 8 mm.787 0 5.433.394 0 Figure 10 Applicator mounting stand base hole pattern (all dimensions are in inches except as noted)

26 Roll Fed Labeling System Adjust the Applicator Position The applicator mounting stand assembly allows you to adjust the applicator as follows: rotate the applicator up to 100 degrees set the vertical position of the applicator from 0 300 mm place the applicator in the service position (moved back 100 mm; refer to Placing the Applicator in the Service Position under Repair later in this manual) To adjust the vertical position of the applicator See Figure 11. 1. Loosen the vertical adjustment locking screw (1). 2. Turn the handwheel (2) in the desired direction (clockwise to move the applicator up, counterclockwise to move the applicator down) until the applicator is in the desired position. 3. Record the travel distance on the position indicator (3). A form for recording settings is provided at the end of Setup. 4. Tighten the locking screw. 2 3 1 Figure 11 Components used to adjust the vertical position of the applicator 1. Vertical adjustment locking screw 3. Position indicator 2. Handwheel

Roll Fed Labeling System 27 To adjust the rotation of the applicator See Figure 12. 1. Loosen the locking screw (1), rotate the applicator to the desired position, and tighten the screw. 2. Permanently score the applicator mounting bracket (2) to mark the correct position. 2 45 45 1 Figure 12 Adjusting the rotation of the applicator 1. Locking screw 2. Applicator mounting bracket

28 Roll Fed Labeling System Connect the Hose NOTE: Refer to the hose manual for additional information on connecting and disconnecting hoses. 1. See Figure 13. Connect the cordset end of the hose to hose port 1 on the melter. 2. Connect the hose cordset to hose/applicator electrical receptacle 1. 3. Connect the other end of the hose to the hose connector fitting on the applicator. NOTE: An optional hose bracket assembly is available to secure the hose to the applicator mounting stand. Refer to Parts. Figure 13 Connecting the hose

Roll Fed Labeling System 29 Install the Proximity Switch NOTE: The proximity switch supplies the firing sequence to the EPC30 pattern control. Both the proximity switch sensor and the label presence sensor must be energized before the applicator will apply adhesive to the label. 1. Remove the safety panels from the front of the labeling machine to access the primary drives. See Figure 14. Installed proximity switch 2. Mount the collar (1) on the parent machine cutter shaft. The shaft diameter is 31.75 mm (1.25 in.). 3. Position the proximity switch sensor (2) and mounting post such the sensor is 2 5mm (0.08 0.20 in.) from the collar. Using a center punch and the 6 mm holes (3) in the post as a guide, mark and punch the positions for the mounting holes. 4. Remove the mounting post and drill and tap holes for 6 mm machine screws (2 locations). 5. Use the supplied 6 mm machine screws to secure the proximity switch mounting post to the installation location. 2 1 3 Figure 14 Proximity switch components 1. Collar 2. Proximity switch sensor 3. Mounting post holes

30 Roll Fed Labeling System Install a Label Presence Sensor Install a label presence sensor (customer supplied) to ensure that a label is present on the vacuum drum. Wire the label presence sensor in parallel with the proximity switch. Both sensors must be engaged before the EPC30 pattern control will allow the applicator to apply adhesive to a label. Nordson Corporation also recommends adding the parent machine adhesive on/off switch to the label presence sensor/proximity switch circuit during this installation. Install the Encoder NOTE: The encoder allows the EPC30 pattern control to understand the position and speed of the labels so that the applicator dispenses adhesive in the correct pattern and amount regardless of the line speed. 1. Remove the safety panels from the front of the labeling machine to access the primary drives. 2. Position the encoder assembly such that the encoder spur gear meshes with the drive gear of the vacuum drum. Using a center punch and the slots in the bracket as a guide (see Figure 15), mark and punch two mounting hole positions. 3. Drill and tap through the holes in the mounting surface and install the encoder using the supplied 8 mm machine screws. Figure 15 Encoder assembly bracket slots

Roll Fed Labeling System 31 Install the Pneumatic PCV and Air Control Assembly 1. Replace the manual PCV on the AltaBlue TT melter with the pneumatic PCV contained in service kit part number 1034042. Refer to the instruction sheet supplied with the kit. 2. Mount the air control assembly on the controller mounting post (1) using the supplied 8 mm machine screws. Figure 16 shows the location of the air control assembly mounting bracket holes (2). 1 2 Figure 16 Mounting the air control assembly 1. Controller mounting post 2. Air control assembly mounting bracket holes Install a Pressure Switch (Optional) The optional pressure switch provides an fault signal if the line pressure drops below the value set on the pressure switch. Refer to Parts for the pressure switch part number. If desired, install the optional pressure switch in the main air supply line going into the air control assembly.

32 Roll Fed Labeling System Make the Air Supply Connections 1. See Figure 17. Make the air supply connections shown in Table 4. The air supply must be clean, dry, regulated, unlubricated compressed air. 2. Record your air pressure settings for future reference. Refer to Record of Settings later in this section. Item No. in Fig. 17 Table 4 Air Supply Connections (see Figure 17) Connect air supply tubing To... from.. 1 Pattern air input fitting on left side of air control assembly Pattern air input fitting on applicator 2 Main air supply Main air supply input fitting on the air control assembly 3 Module actuating air input fitting on top of air control assembly 4 Melter PCV air input fitting on right side of air control assembly Module actuating air input fitting on applicator Pneumatic PCV on melter Recommended Pressure 1 2 (15 30 psi) 8.3 bar (120 psi) Not applicable 0 1.4 bar (0 20 psi) NOTE: This setting is controlled through the EPC30 pattern control.

Roll Fed Labeling System 33 MAIN AIR SUPPLY SOURCE 8.3 BAR (120 PSI) 1 8 mm 8 mm 2 3 8 mm 4 8 mm Figure 17 Air supply connections (refer to Table 4)

34 Roll Fed Labeling System Make the Electrical Connections See Figures 18 22. Ensure that the wiring connections shown in Table 5 are correctly and securely made. Callout in Fig. 18 22 A Table 5 Customer Wiring Connections (see Figures 18 22) Terminal Block: Description Component Connect to... Terminal Encoder cable leads B Applicator 1 output (see Note A) C Power to air control module solenoid (see Note A) D E F G Power from SSR controller to EPC30 pattern control (see Note A) Power supply to SSR controller On/off control for adhesive control module solenoids (see Note A) Warning and fault outputs to EPC30 pattern control (see Note A) Encoder N/A EPC30 pattern control terminal block X8 EPC30 pattern control terminal block EPC30 pattern control terminal block EPC30 pattern control SSR controller cable SSR controller terminal block EPC30 pattern control terminal block X7:1 SSR controller X7:2 terminal block 3 X7:3 Air control module X7:4 solenoid (7) X7:9 SSR controller terminal block Terminal Block: Terminal Refer to Table 6 for the encoder cable connections. 1 N/A DC+ X7:10 COM N/A Customer power source (110V, 10 A) 5-10 Adhesive control module solenoids (1-6, COM as applicable) X1:3 SSR controller terminal block N/A N/A 21 X1:4 DC+ Continued...

Roll Fed Labeling System 35 Item No. in Fig. 18 20 H I J K L Table 5 Customer Wiring Connections (see Figures 18 22) (contd) Terminal Block: Description Component Connect to... Terminal Power and signal to air control assembly NOTE: Cut off the black lead. Gear to line control input to melter (see Note A) Output from melter to SSR controller READY and FAULT lights (see Note A) (Optional) Fault signal from pressure switch (see Note B) Proximity switch signal EPC30 pattern control terminal block EPC30 pattern control terminal block Expansion board in AltaBlue TT melter X1:9 E/P transducer on air control assembly Terminal Block: Terminal Brown lead X1:10 White lead X1:11 Blue lead X1:7 Gear to line XT3 1 (+) X1:6 input terminals in AltaBlue TT melter XT3 2 (-) XT7:1 SSR controller DC+ XT7:2 terminal block 20 XT7:3 DC+ XT7:4 22 Pressure switch Brown lead SSR controller 22 terminal block Blue lead 23 NOTE: See Figures 21 and 22 for wiring options. NOTE A: Use the 3 conductor shielded wire (part 931158) supplied with the system. Cut the wire to the lengths needed. The longest length will be approximately 0.6m (2 ft) longer than the hose length. B: If no pressure switch is present, there is a factory installed jumper between terminals 22 and 23 on the SSR terminal block.

36 Roll Fed Labeling System Make the Electrical Connections (contd) A B C D EPC30 pattern control terminal blocks (continued on next page) SSR controller terminal block FU1 GND 1 3 5 7 9 21 23 31 33 35 37 41 43 45 N 2 4 6 8 10 20 22 30 32 34 36 40 42 44 COM COM COM COM COM DC + DC + CR1 CR2 CR3 Red F Black (common) E Customer-supplied 110 V, 10 A) Adheisve control module solenoid valves Figure 18 Wiring connections (1 of 3, refer to Table 5) Air control module solenoid valve

Roll Fed Labeling System 37 I XT3-1 (+) Refer to the AltaBlue TT melter manual for the location of these terminals EPC30 terminal blocks (continued) XT3-2 ( ) Refer to the AltaBlue TT melter manual for the location of these terminals G H Brown (11) White (10) Blue (9) Black (cut off) E/P transducer on air control assembly FU1 GND N 1 2 3 4 5 6 7 8 9 21 23 31 33 35 37 41 43 45 10 20 22 30 32 34 36 40 42 44 COM COM COM COM COM DC + DC + CR1 CR2 CR3 SSR controller terminal block (repeated) Figure 19 Wiring connections (2 of 3, refer to Table 5)

38 Roll Fed Labeling System Make the Electrical Connections (contd) K J XT7 Expansion board in AltaBlue TT melter Brown (8) Blue (10) K Pressure switch (optional) FU1 GND 1 3 5 7 9 21 23 31 33 35 37 41 43 45 N 2 4 6 8 10 20 22 30 32 34 36 40 42 44 COM COM COM COM COM DC + DC + CR1 CR2 CR3 SSR controller terminal block (repeated) Figure 20 Wiring connections (3 of 3, refer to Table 5) Note: If no pressure switch is present, there is a factory installed jumper between terminals 22 and 23 on the SSR terminal block.

Roll Fed Labeling System 39 L (1 of 2) FU1 GND 1 3 5 7 9 21 23 31 33 35 37 41 43 45 N 2 4 6 8 10 20 22 30 32 34 36 40 42 44 COM COM COM COM COM DC + DC + SSR controller terminal block CR1 EPC30 pattern control terminal blocks CR2 CR3 Black (32) Blue (COM) Brown (DC+) 24V+ 24V (to customer 24V wheel latch) Proximity switch Figure 21 Optional proximity switch wiring for the 24 VDC adhesive wheel latching signal (1 of 2)

40 Roll Fed Labeling System Make the Electrical Connections (contd) L (2 of 2) EPC30 pattern control terminal blocks FU1 GND 1 3 5 7 9 21 23 31 33 35 37 41 43 45 N 2 4 6 8 10 20 22 30 32 34 36 40 42 44 COM COM COM COM COM DC + DC + SSR controller terminal block CR1 CR2 CR3 Black (36) Blue (COM) Brown (+DC) 110V+ 110V (to customer 110V wheel latch) Proximity switch Figure 22 Optional proximity switch wiring for the 110 VDC adhesive wheel latching signal option (2 of 2)

Roll Fed Labeling System 41 Terminal Block: Terminal Table 6 Encoder Cable Connections to Terminal Block X8 on the EPC30 Pattern Control Wire Label/Color Comment Note X8: 1 Power +V (red) Connect encoder wire according to label on wire. X8: 2 Signal A (brown) Connect encoder wire according to label on wire. X8: 3 Signal A-not (brown/white) Connect encoder wire according to label on wire. X8: 4 Signal B (orange) Connect encoder wire according to label on wire. X8: 5 Signal B-not (orange/white) Connect encoder wire according to label on wire. X8: 6 Common (black) Connect encoder wire according to label on wire. X8: 7 Shield (black/white) Connect both the encoder shield and the trigger shield (or shields if a second trigger is used). X8: 8 Red Connect power wire from trigger 1. If second trigger is used, connect both trigger power wires to this terminal. If a through-beam type of sensor is used, connect the power wires from both the emitter and receiver to this terminal. If a limit switch is used, do not connect any wire to this position. A X8: 9 White Connect current-sinking output wire from trigger 1. B X8: 10 Black Connect common wire from trigger 1. If a through-beam sensor is used, connect the common wire from the emitter to this terminal also. X8: 11 White Connect current-sinking output wire from trigger 2 (if used). B X8: 12 Black Connect common wire from trigger 2 (if used). If a through-beam sensor is used, connect the common wire from the emitter to this terminal also. X8: 13 Unused terminal block position X8: 14 Unused terminal block position NOTE A: A mechanical limit switch can also be used as a trigger. For trigger 1, connect the limit switch wires to X8: 9 and X8: 10. For trigger 2 (if used), connect the limit switch wires to X8: 11 and X8:12. B: Clip off (or tape back) the green sourcing output wire.

42 Roll Fed Labeling System Connect the Applicator Cordsets The PatternJet Plus applicator has two cordsets: one for adhesive heating and temperature sensing and one for pattern air heating and temperature sensing. 1. See Figure 23. Connect the applicator adhesive cordset to electrical receptacle on the hose. ÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄÄÄÄ Figure 23 Connecting the applicator adhesive cordset to the electrical receptacle on a hose 2. See Figure 24. Using the supplied extension cable (part 728023), connect the applicator air cordset to hose/applicator electrical receptacle 2 on the melter. Figure 24 Connecting the applicator air cordset to hose/applicator receptacle 2 on the AltaBlue TT melter

Roll Fed Labeling System 43 Setup Before performing any setup procedures, ensure that you have completed the procedures in the Installation section. Procedures for daily operation are in the next section, Operation. Check Melter Parameters 40 and 41 Ensure that melter parameters 40 and 41 are set to their default values, shown in Table 7. Refer to the melter manual for the procedure for setting melter parameters. Table 7 AltaBlue TT Melter Ready and Fault Parameter Settings for Parameters 40 and 41 Parameter Name Range of Values Default Value Output Setup 40 Standard Output 1 (A10/A16 only) 0 6 1 (Ready) 41 Standard Output 2 (A10/A16 only) 0 6 3 (Fault) Setting the Adhesive Pattern Follow these procedures to achieve a quick pattern placement with minimal buildup on the vacuum drum. NOTE: Refer to the EPC30 pattern control manual and user's guide and to the AltaBlue TT melter manual for operating instructions as needed. Specific operating instructions for these components are not included in these procedures. Preliminary Steps 1. See Figure 25. Make the following temporary changes to the air supply connections: a.. Temporarily install a Y splitter fitting (1) in the main air supply line to the air control assembly. b.. Connect one of the air lines from the Y fitting to a manual pressure regulator and gauge (2). c.. Disconnect the existing air line from the pneumatic PCV (3) and instead connect the air line from the temporary regulator.