EQUIPMENT OPERATION MANUAL Loctite Hysol Wheel Coater 98038
Contents Page No. 1 Please observe the following...................................... 1 1.1 Emphasized Sections............................................. 1 1.2 For Your Safety................................................ 1-2 1.3 Items Supplied.................................................. 2 2 Description.................................................... 2 2.1 Description of Machine............................................ 2 2.2 Theory of Operation.............................................. 2 3 Technical Data.................................................. 3 4 Machine Illustration.............................................. 4 5 Operation.................................................... 5-6 5.1 Set up......................................................... 5 5.2 Start up........................................................ 5 5.3 Shut down...................................................... 5 5.4 Film Thickness Adjustment......................................... 6 5.5 Temperature Adjustment........................................... 6 6 Care, Cleaning, and Maintenance................................. 7-8 6.1 Char Removal................................................... 7 6.2 Clutch......................................................... 7 6.3 Drive Chain..................................................... 8 6.4 Fuse, Motor Controller............................................. 8 6.5 Drive Motor..................................................... 8 7 Troubleshooting................................................ 9 8 Documentation............................................... 9-12 8.1 Spare Parts..................................................... 9 8.2 Assembly Drawing............................................... 10 8.3 Wiring Diagram and Schematic..................................... 11 8.4 Parts List...................................................... 12 9 Warranty..................................................... 13
1 Please observe the following 1.1 Emphasized Sections WARNING! Refers to safety regulations and required safety measures that protect the operator or other persons from injury or danger to life. Caution! Emphasizes what must be done or avoided so that the unit or other property is not damaged. Notice: Gives recommendations for better handling of the unit during operation or adjustment as well as for service activities. 1.2 For Your Safety For safe and successful operation of this machine, read these instructions completely. If the instructions are not observed, the manufacturer can assume no responsibility. Observe general safety regulations for the handling of chemicals such as Loctite adhesives and sealants. Observe the manufacturer s instructions as stated in the Material Safety Data Sheet (MSDS). While under warranty, the machine may be repaired only by an authorized Loctite service representative. Wear heat resistant leather gloves when operating or maintaining a hot machine. Always use extreme care when using the Hysol Wheel Coater. Roll temperature and adhesive may reach 400 F. Avoid skin contact with the roll. If molten adhesive is accidentally deposited on skin, immerse immediately in cold water. DO NOT ATTEMP TO REMOVE LARGE AMOUNTS OF GLUE FROM SKIN WITHOUT FIRST SECURING PROPER MEDICAL ATTENTION. Check that the surface to be coated will not melt or be damaged by the temperature of the adhesive and roll. Do not use the machine in damp or wet areas. Make sure the machine is properly positioned and secured to a sturdy, stable work surface to avoid tipping and spilling hot melt adhesive onto the machine operator. Do not operate the machine with the pot cover in the raised position. Keep cover in place over molten adhesive. Always us a properly grounded 120V outlet. Do not remove the grounding prong from the machine electrical plug. 1
1 Please observe the following (continued) Allow machine to cool and adhesive to solidify before attempting to move the machine. A qualified electrician or appliance repair person should perform machine repair. Do not overfill adhesive pot. Molten adhesive should never be above the 1 2" ledge near the top of the pot. 1.3 Items Supplies Hysol Wheel Coater Instruction manual 5 spare fuses 1 tube grease 2 Description 2.1 Description of Machine The Hysol Wheel Coater (98038) is a bulk hot melt adhesive transfer machine. The Hysol Wheel Coater is used to apply a continuous film of hot melt adhesive to the surface of a part. The Wheel Coater is made up of an adhesive reservoir (6.5" wide x 10" long x 2" deep), three 350-watt heaters and a transfer roller, which is driven by a variable speed electric motor. The thickness of the adhesive film is fully adjustable and a thermometer is used to indicate reservoir temperature. The variable speed motor and film thickness control greatly contributes to increase productivity of hot melt adhesive applications. 2.2 Theory of Operation The adhesive is applied by passing the surface of the part over a rotating roller. A thin film of adhesive is transferred from the roller to the part. The roller is six inches in length and is partially submerged in a pool of molten adhesive. With each rotation the roller is recoated. The transfer surface, of the roller, is knurled to hold a greater volume of adhesive. The thickness of the adhesive is controlled by means of an adjustable blade doctor. The adhesive temperature and the viscosity of the adhesive formulation also affect the thickness of the film. 2
3 Technical Data Power supply 120V, 15 amp, Single Phase Power consumption 1100 Watts Roll surface speed 10 to 40 feet per minute Dimensions 15" W x 6 1 4" H x 22 1 2" D Warm up time Approximately 30 minutes Weight 58 lbs. (26.4 Kg) Operating temperature Factory set to 375 F (190 C) Adjustable Thermo Switch Range 50 F to 600 F (10 C to 315 C) Fuse Description Bussman ABC 3 AMP Fuse, #6F041 250 VOLT, Fuse Holder Code G Ceramic Body Fast Acting Notice: Do not exceed 450 F (230 C) 3
550 50 Loctite Corporation 1001 Trout Brook Crossing Rocky Hill, CT 06067 985278 Loctite Corporation 1001 Trout Brook Crossing Rocky Hill, CT 06067 985278 CAUTION ELECTRICAL HAZARD BEFORE REMOVING COVER DISCONNECT FROM POWER SUPPLY 4 Machine Illustration 11 10 9 Wheel Coater Model: 98038, 120V, 1100 Watts 1 HEATER SWITCH ON 2 12 15" MOTOR SWITCH 22 1/2" 3 5 4 8 2 12 Wheel Coater Model: 98038, 120V, 1100 Watts 6 5/16" 6 7 Figure 1 Item Description 1 Power Switch 2 Motor Speed Control 3 Transfer Roller 4 Reservoir Lid 5 Thermometer 6 Machine Base 7 Motor 8 Motor Brushes 9 Gearmotor Bracket 10 Chain Guard 11 Sheet Metal Cover 12 Fuse 4
5 Operation 5.1 Set Up Place the Hysol Wheel Coater on a level, heavy-duty bench and preferably one with adjustable legs. Adjust the height of the table so the working height of the machine is comfortable. Plug the power cord into a properly grounded 120V, 15-amp outlet. 5.2 Start Up Fill reservoir to a depth of 1" minimum and 2" maximum. Do not fill above the 1 2" ledge near the top of the pot. Maintain the level within this range during operation. Turn rotary switch, on motor speed control (item 2), to the off position. Plug power cord into properly grounded 120V, 15 amp outlet. Flip toggle switch (item 1) to ON position. Red indicator light will come on. Allow machine to warm up 30 minutes. Observe thermometer. Add additional pellets as required to bring the fill level to between 1" and 2" deep. Caution! DO NOT ATTEMPT TO ACTIVATE THE COATING ROLL BEFORE OPERATING TEMPERATURE IS ATTAINED. To do otherwise, will cause a motor overload, which will blow the fuse (F1). Turn rotary switch, on the motor speed control, (item 2) clockwise to start the roller turning slowly. For a new unit it may be necessary to turn the rotary switch 50% of scale to start rotation. Turn the switch to a higher number to increase the rate of rotation. 5.3 Shut Down Always turn off the motor speed switch first. This sequence will help ensure that the roller is not accidentally started with a cold machine. Flip the power switch to the Off position. 5
5 Operation (continued) 5.4 Film Thickness Adjustment Adjusting the clearance between the doctor blade and the roller can change film thickness on the roller. Loosen the 4 machine screws, which secure the doctor blade. Place a feeler gauge between the roll and blade at one end of the roll. Tap the blade lightly against the feeler gauge. Lightly snug the end most screw. Move the gauge to the other end of the roll and repeat. Snug all four screws down. Do not over tighten. 5.5 Temperature adjustment The operating temperature of the machine is factory set at 375 F. This setting should be sufficient for most EVA adhesives. For other types of adhesives refer to the data sheet for the adhesive application temperature or call Technical Service for assistance. The temperature thermo switch set point shaft is not intended for operator adjustment and is accessible only by removing the sheet metal cover from the adhesive pot. The thermo switch is located at the roller end of the reservoir. A quarter-turn clockwise of the set point shaft will increase the operating temperature about 75 F. Wait at least 15 minutes for the temperature to stabilize. After 1 hour of operation, check the temperature again. Notice: Do not exceed 450 F. 6
6 Care, Cleaning, and Maintenance 6.1 Char Removal If the Hysol Wheel Coater is over heated a brown or black flaky crust will form on exposed surfaces of the glue pot. This is charred adhesive that can be removed using the following procedure. Wear heat resistant leather gloves. Warm the machine to operating temperature. Pour out excess adhesive. Scrape off excess adhesive and char with a wood tongue depressor. Allow machine to cool. Use a paintbrush to apply a coating of solvent-based paint remover to remaining char. Allow paint remover solvent to soak on the char. It may be necessary to allow paint remover to soak overnight. Remove softened char and reapply paint remover as required. 6.2 Clutch The clutch is factory set and seldom needs adjustment. In the event that additional torque is needed the following is the torque setting procedure: 1. Remove chain guard. 2. Remove set screw on clamping nut. 3. Use square socket on thread end of hub to secure shaft. 4. Tighten clamping nut against Belleville washer. Do Not completely flatten Belleville washer. 5. Replace set screws. 6. Replace chain guard. BELLVILLE WASHER SHAFT SPROCKET FRICTION MATERIAL SET SCREW CLAMPING NUT Figure 2 7
6 Care, Cleaning, and Maintenance (continued) 6.3 Drive Chain Remove chain guard and oil chain monthly if machine is used continuously. If chain is loose, loosen motor mount screws and slide motor to tighten. 6.4 Fuse, Motor Controller The motor controller fuse will blow in the event of a motor overload. Before replacing fuse check for cause of motor overload. Notice: Pot must be hot. Remove drive chain and check for free rotation of roll. Replace the motor control fuse with a Bussman ABC 3AMP Fuse, #6F041, 250 VOLT, Fuse Holder Code G, Ceramic Body Fast Acting type AGC 3Amp or equivalent. 6.5 Drive Motor Inspect motor brushes every 300 hours. Replace brushes when worn down to approximately 1/4" length. 8
7 Troubleshooting Notice: Electrical troubleshooting must be performed by a qualified electrician or appliance repair person. Type of Malfunction Possible Cause Correction No Heat No power to unit Plug power cord into proper outlet 120V, 15 amp, Single Phase Faulty thermostat Check for electrical continuity when cold Discontinuity of circuit Check circuit Inadequate Heat Improper thermostat setting Adjust Roll does not turn One or more faulty heating elements Check for discontinuity and replace Adhesive pot is cold Turn on or repair heaters Chain is broken Replace chain Motor is defective Check motor brushes, replace Motor is defective Replace motor Clutch is loose Tighten clutch Roll slows or stops under load Motor torque exceeded Reduce load Clutch is loose or contaminated Clean and/or adjust clutch with oil Rapid accumulation of Char or Pot temperature too high Reduce pot temperature excessive smoking of adhesive 8 Documentation 8.1 Spare Parts Description Drive Motor Motor Controller Motor Brush Set, 458 Clutch Drive Chain and Link Part No. EMZ002N01 EPZ001N01 ERZ001N01 AZZ049N01 AZZ036N01 Description Part No. Heater EHC015N01 Thermo Switch ENE003N01 Thermometer HEZ001N01 Cordset EDZ003N01 Super Lube Grease with PTFE 82324 9
50 550 CAUTION ELECTRICAL HAZARD BEFORE REMOVING COVER DISCONNECT FROM POWER SUPPLY ON 8 Documentation (continued) 8.2 Hysol Wheel Coater Assembly Drawing BOTH ENDS 4 63 31 2 3 6 5 55 2X 36 41 22 4X 32 45 19 60 18 7 29 2X 31 61 1 HEATER SWITCH 4X 38 17 MOTOR SWITCH 62 50 52 34 23 51 58 15 8 4X 37 53 4X 37 4X 32 42 22 22 49 4X 57 8X 28 47 SHIP WITH MACHINE 16 4X 35 2X 33 43 4X 36 13 25 INSULATION COVERS BOTTOM AND SIDES OF ADHESIVE POT Figure 3 10
BLACK WHITE RED SILVER SILVER GOLD GOLD BLACK GREEN 8 Documentation (continued) 8.3 Wiring Diagram and Schematic CONDUIT CARRIES HEATER WIRES & PASSES UNDER GEARMOTOR SECURES COILED CORD FOR SHIPMENT HEATER CABLES 9 26 ENCASE CABLES & CRIMPED END OF RING TERMINAL WITH APPROX. 2" SLEEVE 14 10 ON GND 5X 11 14 10 21 ENCASE CABLE & CRIMPED END OF RING TERMINAL WITH APPROX. 2" SLEEVE A1 A2 L1 L2 20 12 THERMOSWITCH 40 MOTOR LEADS 14 SHIP FIVE SPARES WITH MACHINE ENCASE MOTOR LEADS FROM MOTOR TO SWITCH BOX TERMINAL STRIP INSIDE MOTOR CONTROLLER ELECTRICAL SCHEMATIC GRN SWITCH BOX GND DC MOTOR CONTROLLER 3 AMP DC GEARMOTOR LINE IN WHT 3 L1 RED BLK ON/OFF SWITCH 1 2 4 L2 A1 A2 BLK THERMOSWITCH HEATERS Figure 4 11
8 Documentation (continued) 8.4 Parts List Item Qty. Description Available Part # 1 1 POT, ADHESIVE 2 30" STEEL CHAIN AZZ036N01 3 1 CONNECTING LINK AZZ036N01 4 1 SPROCKET 20T 5 1 OVERLOAD CLUTCH AZZ049N01 6 1 OVERLOAD SPROCKET 7 1 ELECTRICAL BOX UNFINISHED 8 2 CONNECTOR, 1 2" EMT 9 1 CORDSET EDZ003N01 10 2 RING TERMINALS #6 STUD 11 5 FORK TERMINAL 12 5 BUSSMAN ABC 3AMP FUSE, #6F041 250 VOLT, FUSE HOLDER CODE G CERMIC BODY FAST ACTING 13 3 HEATER 350W EHC015N01 14 10" SLEEVE INSULATION 15 1 GEARMOTOR, 90VDC, EMZ002N01 50 RPM 16 1 THERMOSWITCH ENE003N01 17 1 CONTROLLER, DC MOTOR EPZ001N01 18 1 SWITCH COMBINATION #5226 19 2 CONNECTOR, ROMEX 3 8" 20 72" WIRE, HIGH TEMP., #20 600V 392 F 21 54" WIRE, HIGH TEMP., #14 600V 250 C 22 2 O RING, #2-206 VITON 23 1 THERMOMETER, 50-550 F HEZ001N01 24 1 KNOB, BLACK PHENOLIC 25 1.5 INSULATION, CERAMIC FIBER 26 1 TIE, 6" 27 2 RETAINER, PUSH #6 SCREW 28 8 NUT, HEX 1 4-20 29 1 COVER, SWITCH UNFINISHED 600 WC 30 4 RIVET, S-42-SB 31 7 SCREW, RHMS 10-32 X 3 8" PHILLIPS Item Qty. Description Available Part # 32 8 SCREW, RHMS 10-32 X 5 8" PHILLIPS 33 4 SCREW, RHMS 6-32 X 1 4" PHILLIPS 34 1 SCREW, SET 1 4-20 X 1 4" 35 4 SCREW, HEX HEAD CAP 1 4-20 X 1 3 4" 36 6 SCREW, HEX HEAD CAP 1 4-20 X 3 4 37 8 SCREW, RHMS 8-32 X 1 2 38 4 SCREW, RHMS 8-32 X 3 8 39 3 SCREW, #6 SHEET METAL 40 1 CONNECTOR WITH SET SCREW 41 2 WASHER, FLAT 1 4" 42 4 WASHER, FLAT #10 43 2 WASHER, FLAT #6 44 1 GREASE, 82324 SUPER LUBE 1 2 OZ. 45 1 BASE, MACHINE 46 1 BRACKET, PIVOT 47 1 COVER MOTOR CONTROL 48 1 COVER, POT 49 1 COVER, SHAFT 50 1 COVER SHAFT DRIVE END 51 1 BLADE DOCTOR 52 1 ROLL 53 1 SHAFT, ROLL 54 1 GUARD, CHAIN 55 1 MOUNT, GEARMOTOR 56 1 ENCLOSURE CASTING 57 4 STANDOFF, POT 58 1 CONDUIT, WIRE LEAD 59 1 COVER POWER SUPPLY 600 WC 60 1 LABEL, CAUTION 61 1 LABEL, HEATER SWITCH 62 1 LABEL, MOTOR SWITCH 63 1 MOTOR BRUSH SET ERZ001N01 12
9 Warranty Loctite expressly warrants that all products referred to in this Instruction Manual for Hysol Wheel Coater hot melt applicator, (hereafter called "Products"), shall be free from defects in materials and workmanship. Liability for Loctite shall be limited, as its option, to replacing those Products which are shown to be defective in either materials or workmanship or to credit the purchaser the amount of the purchase price thereof (plus freight and insurance charges paid therefor by the user). The purchaser s sole and exclusive remedy for breach of warranty shall be such replacement or credit. A claim of defect in materials or workmanship in any Products shall be allowed only when it is submitted in writing within one month after discovery of the defect or after the time the defect should reasonably have been discovered and in any event, within 1 year after the delivery of the Products to the purchaser. This warranty does not apply to perishable items, such as fuses. No such claim shall be allowed in respect of products which have been neglected or improperly stored, transported, handled, installed, connected, operated, used or maintained. In the event of unauthorized modification of the Products including, where products, parts or attachments for use in connection with the Products are available from Loctite, the use of products, parts or attachments which are not manufactured by Loctite, no claim shall be allowed. No Products shall be returned to Loctite for any reason without prior written approval from Loctite. Products shall be returned freight prepaid, in accordance with instructions from Loctite. NO WARRANTY IS EXTENDED TO ANY EQUIPMENT WHICH HAS BEEN ALTERED, MISUSED, NEGLECTED, OR DAMAGED BY ACCIDENT, OR IF THE SYSTEM USED TO DISPENSE ANY LIQUID MATERIAL OTHER THAN LOCTITE PRODUCTS. EXCEPT FOR THE EXPRESS WARRANTY CONTAINED IN THIS SECTION, LOCTITE MAKES NO WARRANTY OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THE PRODUCTS. ALL WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND OTHER WARRANTIES OF WHATEVER KIND (INCLUDING AGAINST PATENT OR TRADEMARK INFRINGEMENT) ARE HEREBY DISCLAIMED BY LOCTITE AND WAIVED BY THE PURCHASER. THIS SECTION SETS FORTH EXCLUSIVELY ALL OF LIABILITY FOR LOCTITE TO THE PURCHASER IN CONTRACT, IN TORT OR OTHERWISE IN THE EVENT OF DEFECTIVE PRODUCTS. WITHOUT LIMITATION OF THE FOREGOING, TO THE FULLEST EXTENT POSSIBLE UNDER APPLICABLE LAWS, LOCTITE EXPRESSLY DISCLAIMS ANY LIABILITY WHATSOEVER FOR ANY DAMAGES INCURRED DIRECTLY OR INDIRECTLY IN CONNECTION WITH THE SALE OR USE OF, OR OTHERWISE IN CONNECTION WITH, THE PRODUCTS, INCLUDING, WITHOUT LIMITATION, LOSS OF PROFITS AND SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER CAUSED BY NEGLIGENCE FROM LOCTITE OR OTHERWISE. 13
Loctite Industrial Loctite Corporation 1001 Trout Brook Crossing Rocky Hill, CT 06067-3910 Loctite Automotive Technology Center 2455 Featherstone Road Auburn Hills, Michigan 48326 Loctite Canada Inc. 2225 Meadowpine Blvd. Mississauga, Ontario L5N 7P2 Loctite Company de México, S.A. de C.V. Calzada de la Viga s/n, Fracc. Los Laureles Loc. Tulpetlac, C.P. 55090 Ecatepac de Morelos, Edo. de México México Loctite Brazil Av. Prof. Vernon Krieble, 91 06690-11-Itapevi São Paulo-Brazil www.loctite.com Loctite and Hysol are trademarks of Loctite Corporation, U.S.A. Copyright 2001. Loctite Corporation. All rights reserved. Data in this manual is subject to change without notice. P/N985277 10/01 A Company