FoamMelt 130 Processors

FoamMelt 130 Processors Models FM-130, FM-132, FM-133 Customer Product Manual Part 104 274 E02 NORDSON CORPORATION DULUTH, GEORGIA USA www.nordson.com

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 date1994. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. 2002 All rights reserved. Trademarks AccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millennium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, OptiMix, Package of Values, Patternview, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Rhino, S. design stylized, Saturn, SC5, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. ATS, AeroCharge, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, Colormax, Control Weave, Controlled Fiberization, Coolwave, CPX, Dry Cure, E-Nordson, EasyClean, Eclipse, Equi=Bead, Fill Sentry, Fillmaster, Gluie, Heli-flow, Ink-Dot, Iso-Flex, Kinetix, Lacquer Cure, Maxima, MicroFin, Minimeter, Multifil, Origin, PermaFlo, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, PurTech, Pulse Spray, Ready Coat, Select Series, Sensomatic, Shaftshield, SheetAire, Spectral, Spectronic, Spectrum, Summit, Sure Brand, Sure Clean, Sure Max, Swirl Coat, Tempus, Tracking Plus, Trade Plus, Universal, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation. Part 104 274 E02 Manual 41-130 E 2002 Nordson Corporation All rights reserved

FM-l 30 Applicators Manual 41-l 30 Page O-3 HOW TO USE THIS MANUAL The Page Numbering System The page number is composed of two parts: the section number followed by the section page. Page 5-03, for example, is the third page in Section 5. Finding Information Quickly Before trying to find information in this manual, become familiar with its organization and contents. Afterwards: 1. Use the Brief Summary of Manual Contents (below) to determine which section contains the information you are seeking. 2. Use the tabs to find thle section that contains the desired information. On the first page of each section is a Table of Contents for that section. It gives the starting page number of all the material in the section. Brief Summary of Manual Contents The following summary lists the mosts important information each section and provides a general idea of where to look for material not included in the summary. in Section 1: Safety Summary Explanation of Safety Symbols Safety during Installation, Operation and Servicing Safety How in Handling Solvents to Treat Adhesive Burns Section 2: Equipment Familiarization General Description Description of Equipment and Features An Explanation of the FoamMelt Process FM-130 Operation Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

Manual 41-l 30 Page O-4 FM-1 30 Applicators. Glossary of Terms Section 3: Installation Unpacking and Inspection Installing the FM-130, Guns, Hoses, Gas Cylinder and Air Supply (if applicable). Electrical Installation Section 4: Operating Instructions Equipment Preparation 9 Operator Record Form Normal Operation Section 5: Preventive Maintenance Table of Periodic Maintenance. Selected Maintenance Procedures Section 6: Troubleshooting Troubleshooting Functional Problems Electrical Self-Diagnostic (Warnings, Faults and Error Messages) List of Default System Parameters Troubleshooting Adhesive and Adhesive-Application Problems Wiring Diagrams and Schematics of the FM-130 Applicator Section 7: Disassembly Mechanical Repairs Electrical Repairs and Repair Gas/Pneumatic Repairs Section 8: Parts Lists Exploded Illustrations of the FM-130 Applicator and its Subassemblies Parts Lists for the FM-130 Applicator and its Subassemblies. Additional Listings of Ship-With Parts, Recommended Spare Parts and Service Items/Kits Issued 9190 0 Nordson Corporation 1990 Publication No. 104 2746

FM-1 30 Applicators Manual 4 1 130 Page O-5 Section 9: Technical Data. Specifications Current and Power Draw Requirements. Type R Solvent Information Section 10: Optional Parts and Equipment FM-130 Hose Lists FM-130 Special Extrusion (Gun Lists Hose/Gun Equipment Lists Accessory Equipment Lists Additional Installation Procedures (as they become available) NOTE: If at any time you are unable to find needed information in this manual, contact your local Nordson representative or your regional sales office. Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

Manual 41-130 Page O-6 FM-1 30 Applicators This Page Intentionally Left Blank Issued 6192 0 Nordson Corporation Publication 104 2746

FM-I 30 Applicators Manual 41-I 30 Page 1-O SECTION 1 Table of Contents Introduction...... l-l Explanation of Terms and Symbols... l-1 Safety During Installation... 1-2 Electrical... l-2 Pneumatic... l-2 Gas System... l-2 Safety During Operation..... l-2 Safety During Servicing... l-3 Safety When Using Hot Melt Materials, Solvents and Reactive Materials Hot Melt Materials... 1-4 Heating Solvents..... i;t Halogenated Hydrocarbon Solvents... t Reactive Materials..... l-6 What to Do if Molten Material Comes in Contact with the Skin... l-6 Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

FM-l 30 Applicators Manual 41-l 30 Page 1-l SECTION 1 SAFETY S ZJMMARY INTRODUCTION This section of the manual contains safety guidelines for the use of Nordson equipment. You will find that many of these warnings are repeated throughout this manual, along with specific warnings and cautions not included in this section. These safety guidelines cover: Installation Equipment operation Working with hot rnelt materials Use of hot melts and solvents Failure to follow these recommendations may result in personal injury from burns or electrocution and/or equipment and property damage. EXPLANATION OF TERMS AND SYMBOLS The following safety symblols and signal words are used throughout this publication to alert the reader to personal safety hazards or to identify conditions that may result in equipment or property damage. A WARNING: This is a general warning. Failure to observe this warning may result in personal injury or death. A r WARNING: This means risk of electrical shock. Failure to observe this warning may result in personal injury or death. A CAUTION: Th is is a general caution. Failure to observe this caution may result in minor personal injury or propert,y damage. NOTE: This indicates important information. Failure to observe this note may result in equipment damage. Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

Manual 41-l 30 Page l-2 FM-1 30 Applicators SAFETY DURING INSTALLATION Electrical Follow these guidelines when installing Nordson equipment. Install Install Ensure a protective ground between this equipment and a reliable earth ground to prevent possible electrical shock. a disconnect switch with lockout capability between the power source and the equipment. that the power supply wire gauge and insulation are sufficient to meet the temperature and power requirements. Use only fuses of the correct type, voltage rating and current rating. Refer to the Nordson equipment parts list for fuse recommendations. Using fuses that are either incorrect or not recommended can present a fire hazard. Pneumatic Nordson recommends installing a lock.out, three-way, manual valve in the air supply line to the filter/ regulator. This valve makes it possible to relieve air pressure and prevent the pneumatic system from becoming operational before and during maintenance or repair procedures. Gas System (FoamMelt@ applicators and nitrogen blanket kits only) SAFETY DURING OPERATION Cylinders of compressed gas are under high pressure and scan present significant safety hazards if handled improperly. Refer to OSHA General Industry Standards, paragraphs 1910.101, 1910.166 and 1910.167, for safety precautions that apply to the use, handling and storage of compressed air. Do NOT operate Nordson equipment under the following conditions: At a pressure higher than the rated maximum working pressure of any component in the system. Near volatile or otherwise explosive gases or materials. With the covers, panels and safety guards improperly installed. Issued 9190 0 Nordson Corporation 1990 Publication No. 104 2748

FM-1 30 Applicators Manual 41-l 30 Page 1-3 At temperatures below 32 F (0 C) or above 120 F (5O C). With large areas of hoses in contact with a cold floor, cold supports or other such surfaces. Cold points along the hose restrict the flow of adhesive inside the hose and can create potential problems during operation. (If With In addition: SAFETY DURING SERVICING in drafty areas) with the applicator guns unshielded from the wind. Rapid heat dissipation due to air movement across the guns may cause operational problems. handgun trigger left unlocked while the gun is unattended. Use only the metal base when attempting to lift or move this equipment. Do not use equipment covers, doors, panels or hose connectors (as braces or grips. Never use this equipment as a ladder or stepping stool. Route all hoses so as to prevent damage from kinking, abrasion and other physical damage. Do not allow a hose to be installed with a bend radius of less than 6 inches ( 15 cm). Never point an applicator handgun at yourself or anyone else.. Only qualified personnel should service Nordson equipment. Do Disconnect, To Remove not perform internal service or adjustment on any equipment unless another person capable of rendering emergency first aid and CPR is present. lock out and tag external electrical power before removing protective panels or replacing electrical components. avoid personal injury, never touch exposed connections and components while power is ON. Dangerous voltages exist at several points in the equipment. all jewelry (rings, watches, etc.) before servicing equipment. Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9/90

Manual 41-l 30 Page l-4 FM-l 30 Applicators If Always TO possible, stand on a rubber mat when servicing Nordson equipment. Do not work on equipment if standing water is present. Avoid working in a high-humidity atmosphere. Cover exposed terminals and work area with rubber sheeting to avoid accidental contact while the power is ON. wear safety glasses, protective gloves (Nordson P/N 902 514 or equivalent) and long-sleeved protective clothing to prevent injury from hot applicator parts, splashed hot melt material and hot gun surfaces. PREVENT BURNS FROM SPLASHED MATERIAL, RELIEVE SYSTEM PRESSURE BEFORE OPENING ANY HYDRAULIC CONNECTION. TO RELIEVE SYSTEM PRESSURE: 1. Stop the pump by pressing the MOTOR touchpad at the operator control panel. 2. (FM-131 and FM-132 units only) Open the pressure control valve by rotating the adjustment screw counterclockwise until it extends approximately 1 inch from the body of the valve. 3. Press the FM-130 PURGE touchpad, restart the motor and allow the pump to operate for 15 minutes. 4. Stop the motor, remove the gun nozzles and trigger all guns in the system to ensure hydraulic pressure is relieved. If material flows from the guns, run the motor for an additional 5 minutes and retest for hydraulic pressure. Open the manifold drain valve as a final check before breaking any hydraulic connection. Never Never use an open torch, drill or broach when cleaning a nozzle. continue to operate equipment with a known leak in the system. SAFETY WHEN USING HOT MELT MATERIALS, TIVE MATERIALS SOLVENTS AND REAC- Hot Melt Materials Use extreme care when working with molten materials. They solidify rapidly at high temperature and present a hazard. Severe burns can occur if the molten materials Issued 9/90 0 Nordson Corporation 1990 Publication No. 104 2746

FM-l 30 Applicators Manual 41-l 30 Page 1-5 Always come in contact with the skin. Even when first solidified, they are still hot. wear protective clothing and eye protection when handling molten material or working near equipment containing hot melt adhesives under pressure. Heating Solvents. Do NOT use an opten flame or uncontrolled heating device to heat solvents (for example, a small pan on an unregulated hot plate). Avoid fire hazard by using only a controlled heating device to heat solvents (for example, a small deep fat fryer or thermostatically controlled hot plate). DO NOT USE PAI:NT-TYPE SOLVENTS UNDER ANY CIRCUMSTANCES! These solvents are volatile and may create a fire and/or toxic vapor hazard even at room temperature. Always be sure the work area is adequately ventilated. Avoid prolonged or repeated breathing of solvent vapors. Halogenated Hydrocarbon Solvents Halogenated hydrocarbon solvents are dangerous when used to clean aluminum components in a pressurized fluid system. No available stabilizers prevent halogenated hydrocarbon solvents from reacting under all conditions with aluminum components in a pressurized fluid pumping system. NEVER clean any aluminum component or flush any system using halogenated hydrocarbon solvents. Use Type R solvents or contact your solvent or hot melt supplier for a non-halogenated hydrocarbon solvent for cleaning and flushing. Halogenated Fluorocarbon fluids include the following solvents: Solvents: Dichlorofluoromethane Trichlorofluoromethane Chlorinated Solvents: Carbon Tetrachloride Chloroform Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

Manual 41-l 30 Page l-6 FM-l 30 Applicators......... Dichloromethane Ethylene Dichloride Methylene Chloride Monochlorobenzene Monochlorotoluene Orthodichlorobenzene Perchloroethylene Trichloroethylene l-l-l Trichloroethane Reactive Materials Reactive Materials Reactive materials may produce fumes when heated. When using reactive materials in this system, do not set the operating temperatures or overtemperature limits of the tank or platen, hose(s) and gun(s) without first consulting the adhesive manufacturer and the Material Safety Data Sheet (MSDS) concerning the use of these materials. IF MOLTEN MATERIAL COMES INTO CONTACT WITH THE SKIN Do NOT try to remove molten material from the skin. Immediately immerse the affected area in cold, clean water. Keep the affected area immersed until the material has cooled. Do NOT try to remove the cooled material. Cover the affected area with a clean wet compress. In cases of severe burns, look for signs of shock. If shock is suspected, have patient lie down, use blankets to preserve body heat and elevate the feet several inches. Call a physician immediately. Issued 9190 0 Nordson Corporation 1990 Publication No. 104 2748

FM-1 30 Applicators Manual 41-130 Page 2-O SECTION 2 Table of Contents General Description..... 2-l FM-130 Hoses, Guns and Related Equipment..... 2-2 Description of Selected Features: Display Screen and Touchpads (All Models)... 2-3 Microprocessor Control (All Models).... 2-5 System Ready Delay (All Models).... 2-5 Parent Machine Interlock (All Models).... 2-5 Sequential Temperature Startup (All Models).... 2-6 Warm System Start-up (All Models)... 2-6 Temperature Standby Mode (All Models).... 2-7 7-Day Clock (All Models)... 2-7 Pattern Control: Gear-to-Line, Timer Modes (FM-132, FM-133 only)... 2-8 Stitching (FM-132, FM-133 only).... 2-8 Run-Up (FM-133 only).... 2-9 The FoamMelt@ Process... 2-9 FM-130 Operation: Melting Process... 2-10 Mixing Process... 2-11 Hydraulic Flow... 2-11 Gas Modulation System..... 2-12 Temperature Control System... 2-13 Auxiliary Equipment... 2-13 Glossary of Terms... 2-14 List of Figures Figure 2.1 - FM-130 End Panel LCD Screen and Toluchpads... 2-3 Figure 2.2 - FM- 130 Front Panel Touchpads, Symbols and LEDs... 2-4 Figure 2.3 - FM-130 System Diagram..... 2-10 NOTE: See Section 9 for Equipment tions and Technica,! Data. Specifica- NOTE: See Section 10 for Auxiliary Equipment descriptions a:nd part number information. Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

FM-l 30 Applicators Manual 41-l 30 Page 2-1 SECTION 2 EQUIPMENT FAMILIARIZATION GENERAL DESCRIPTION The Nordson FM-130 series of FoamMelt@ processors feature state-of-the-art computer technology to control the combination of thermoplastic materials with precisely metered quantities of inert gas and then deposit a foam of uniform density onto a substrate. The FM-130 is composed of three feature levels. Standard on the FM-131, FM-132 and FM:-133 are: Onboard Liquid 11 Electrical Parent microprocessor and tactile membrane keypad control of most functions Crystal Display (LCD) and menu-driven function programming temperature channels with control accuracy to within a 3 F (2 C) setpoint band self-diagnostics with error message display and remote alarm output Machine Interlock for application line operation only after proper hot melt material density reduction and pressure have been reached Operator-adjustable, low-temperature standby mode Remote, automatic: and manual modes for system startup, shutdown and temperature standby Operator-selectable sequential heater channel startup The FM-132 processor features all of the above, plus the following pattern control features: Four-channel Timer Adjustable timer with delay and duration settings to control gun firing or gear-to-line mode operation for consistent bead placement when he speed varies 50% duty cycle stitching for equal bead/gap length selectable on each timer Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

Manual 41-l 30 Page 2-2 FM-l 30 Applicators The FM-133 includes all of the above, plus the following pattern control feature: Run-up control for consistent bead thickness when line speed varies The FM-130 processor is powered by a 3/J-hp AC motor. This motor, in turn, drives a corrosion-resistant,.patented, two-stage gear pump located at the bottom of a heated, one-piece, cast aluminum tank. FM-130 HOSES, GUNS AND RELATED EQUIPMENT The FM-130 is an externally recirculating system, therefore, each dispensing gun requires a supply and a return hose. Up to 6 hoses and 4 automatic extrusion guns can be connected to the FM-130 processor and up to two circulating handguns can be connected. All use Resistance Temperature Detection (RTD) to sense and control temperature. The Nordson conventional, automatic, water-resistant and biaxial hoses can be used with automatic guns configured to the FM-130. Hoses are also available with timer leads to activate gun solenoid valves when using the FM-130 timer. Nordson offers a different biaxial hose (no timer leads) for use when the biaxial handgun is configured to the FM-130. Hose/gun accessories include: A A Special special circulation fitting for configuring any of the automatic guns to a biaxial hose or a pair of standard hoses. Straight-in, 45 and 90 connection kits are available. water-resistant splitter and timer cable kit for configuring a conventional water-resistant hose (no timer leads) and water-resistant gun to an FM-130 unit. extension cords to supply power to a jumper hose beyond reach of the applicator and to connect a Y-connector (from two jumper hoses) to the FM-130 electrical socket #5. A complete parts listing of all FM-130 components, including guns, hoses and auxiliary equipment is located in Section 10 of this manual. Issued 9/90 0 Nordson Corporation 1990 Publication No. 104 274B

FM-1 30 Apphcators Manual 41-130 Page 2-3 DESCRIPTION OF SELECTED FEATIJRES: Display Screen and Touchpads The FM-130 features a 2-line-by-40-character liquid crystal display (LCD) located on the end panel of the unit and membrane keypads on both the end panel and front panel. HOSE-1 ACT=300 1 SET=3OO Fn 12:OOA a ( @EEZE TEMP TITHE PATTERN SETUP) Figure 2.1 - FM-130 End Panel LCD Screen and Touchpads The top line of the LCD displays system status information; bottom line lists choices (a menu) for operator selection. the Directly below the LCD is a series of four fingertip touchpads: an up arrow (for UP), a down arrow (for DOWN), an underlined horizontal arrow (for SELECT) and bracketed horizontal arrow (for ENTER). The blinking block at the first letter of each menu item on the bottom line of the LCD is called a cursor. Pressing SELECT moves the cursor to the desired menu option. The cursor will appear at the first letter of each option as the SELECT pad is pressed. Pressing UP and DOWN changes temperature values, times, channels and so on. Pressing ENTEiR completes the selection process. The LCD and four touchpads on the end panel are used to program all of the microprocessor-controlled parameters. The LCD is back-lit to aid viewing. The backlight will turn off automatically if any of the touchpads are not pressed for a period of 15 minutes. The backlight will turn on once any of the touchpads are pressed. Publication No. 104 2748 0 Nordson Corporation 1990 All Rights Res,erved Issued 9190

Manual 41-l 30 Page 2-4 FM-l 30 Applicators On the FM-130 front panel is a series of four more fingertip touchpads labeled with symbols and accompanied by light emitting diode (LED) indicators. From the top, they are: motor on/off, temperature standby mode on/off, clock mode on/off and purge mode on/off. Pressing the appropriate particular function. touchpad either enables or disables that MOTOR ON/OFF w TEMPERATURE STANDBY ON/OFF --) CLOCK ON/OFF * PURGE ON/OFF * - r GAS LOW FLOW GAS SYSTEM WAIT I SYSTEM FAULT LOW LEVEL KIT OPTION (NO LED)- Figure 2.2 - FM-130 Front Panel Touchpads, Symbols and LEDs Finally, directly below these four touchpads are the system status LEDs. From the top, they are: gas flow on, low gas, system wait, system fault and low level indicator (if installed). The indicator LEDs and four touchpads on the front panel are for daily startup and operation. issued 9/90 0 Nordson Corporation 1990 Publication No. 104 274B

FM-I 30 Applicators Manual 41-l 30 Page 2-5 Microprocessor Control (All Models) The FM-130 microprocessor controls all aspects of operation except density reduction and (in the FM-133) hydraulic pressure. The system operating values are programmed by the operator using the end panel keypad and LCD menus. All system setup data is stored in battery back-up, non-volatile random access memory (NV-RAM), therefore, the operator need enter the values only once. All data storeid in RAM is validated at power-up. If the stored data is invalid, default values are loaded for all parameters and an error message is displayed. The FM-130 microprocessor performs constant system diagnostics. If a system fault occurs, a warning message is displayed on the LCD. A minor fault will result in deactivation of only the circuit in which the fault exists. A :major fault will result in automatic shutdown of the motor and all heating zones. See Figure 2.3 for a schematic of the FM-130 microprocessor trol. con- System Ready Delay (All Models) This feature prevents operation of the FM-130 motor and gear pump until all heated zones have reached setpoint and a predetermined time period has elapsed. The system ready time delay (5-40 minute range) is preset by the equipment operator during the setup sequence and is based the time required for the adhesive in the tank to liquify. The delay period begins when all temperature channels are no more than 5 F (3 C) below setpoint. When the delay period has completed, the WAIT indicator LED will flash fast (2 Hz). This indicates that the motor is enabled and can be started. Parent Machine Interlock (PMI) (All Models) This feature prevents operation of equipment configured to the FM-130 until foamed mat(eria1 is ready for delivery and has reached stable density reduction and pressure. With PM1 enabled, the FM-130 energizes an internal electrical contact which permits activation of the packaging line or other equipment configured to the FM-130. Publication No. 104 2746 0 Nordson Corporation 1990 Issued 9190

Manual 41-l 30 Page 2-6 FM- 130 Applicators The time delay (30-300 second range1 is preset by the equipment operator during the setup sequence and is based on characteristics of the hot melt material being used. The time delay begins cycling once the motor is started. During the delay period, the WAIT indicator LED flashes slower (1 Hz). When the delay period has completed, the WAIT indicator LED will turn off and the PM1 relay contact is energized. Sequential Temperature Startup (All Models) The FM-130 features operator-selectable sequential startup, where each temperature channel is activated automatically in a predetermined order after a system self-check has been completed. The sequential startup sequence is: 1. Tank heater channel on. 2. Hose heater channels on setpoint). 3. Gun heater channels on 80 percent of setpoint). (after tank has reached 80 percent of (after all hose channels have reached Warm System Startup (All Models) 4. Begin SYSTEM READY delay (after all channels are within 5 F (3 C) of setpoint). 5. Enable motor start (after SYSTEM READY delay has elapsed!. 6. Begin PM1 delay (after motor has been started). 7. Activate PM1 output (after PM1 delay has elapsed). The temperature control system features warm system recognition to allow for faster system startup and operation after a brief power-down. Once the system is up to setpoint temperature and all time delays have completed, the microprocessor stores a hot indicator flag in memory at power-down. At power-up, if the tank temperature is within 50 F (27 C), of its setpoint, a warm system startup is executed. If the tank temperature is below 250 F (121 C>, the tank must be within 15 F (S C) of its setpoint temperature for the warm system startup to execute. Issued 9190 0 Nordson Corporation 1990 Publication No. 104 2748

FM-l 30 Applicators Manual 41-l 30 Page 2-7 The warm system startup sequence consists of: 1. Start all connected heater channels (do not perform sequential start, if enabled). 2. Wait for all channels to reach 20 F (11 C) of setpoint. 3. Enable motor immediately (do not perform system ready delay time sequence). NOTE: If the power-down occurs during the ready delay time period, only the remaining portion of the delay period must be completed. 4. Wait for the PM1 delay to complete. 5. Activate PM1 output and turn WAIT indicator LED off. Temperature Standby Mode (All Models) I-Day Clock (All Models) Temperature standby mode provides a means by which the heating channel temperatures can be lowered to retard hot melt material degradation. Standby mode is recommended when normal operation of the unit is interrupted for long periods of inactivity. The time required for the unit to reach normal operating temperature is reduced. The standby temperature is set by the operator via the computerdriven menu. Standby mode can be enabled/disabled via either a separate touchpad on the FM-130 front panel, the automatic clock feature or by a remote input signal. The motor and gun timer output signals are disabled in the standby mode. This features allows for automatic startup, shutdown and standby control of the FM-130 heater channels. The end panel touchpads and menu selections on the LCD screen are used to complete timesetting functions for heater startup, shutdown and standby mode. The system can also can be set up to display times in 12- or 24- hour format. If it is necessary to temporarily interrupt the clock-operated automatic functions, a separate touchpad on the front panel CLOCK) is used to enable and disable the function. Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9/90

Manual 41-l 30 Page 2-8 FM-l 30 Applicators If the FM-130 motor is not started within 2 hours of system ready status after an automatic startup, all heater channels are set to standby mode. Pattern Control: Gear-to-Line, Timer Modes (FM-132 and FM-133 Units Only) These functions, used in conjunction with automatic extrusion guns, ensure that bead length and placement on the substrate will be consistent, regardless of changes in line speed. If the line speed remains fixed, the timer mode should be used and an electronic triggering device must be configured to the application line to provide a part present signal to FM-130 unit. If line speed varies, the gear-to-line mode should be used and both a triggering device and an encoder must be configured to the application line. The encoder provides a line speed signal to allow for the FM-130 timer to adjust when the gun should open (delay) and how long it should remain open (d.uratior-0. The delay interval is the period of timle from when the sensor trigger signal is sent to the FM-130 timer and when the FM-130 signals the gun solenoid valve to open. The duration interval is the length of time that the gun is actually open. FM-132 and FM-133 units can be programmed for both pull-in and drop-out gun compensation to allow for fixed gun and solenoid valve response time. Pull-in a.djusts the gun signal to be sent slightly before the substrate reaches the correct position on the packaging line. Similarly, drop-out adjusts the gun cut-off signal to be sent just before the substrate reaches the correct position on the line. Gun compensation in the FM-132 and FM-133 can be set for 0 to 50 milliseconds. Gear-to-line operation maintains bead placement at line speeds from 3 fpm to 1,000 fpm (1 mpm to 300 mpm). If the line speed drops below 3 fpm (1 mpm), the gear-to-line circuitry automatically inhibits the gun actuation signal, thereby preventing the guns from firing continuously if the line speed should stop during a duration cycle. Pattern Control: Stitching (FM-132 and FM-133 Units Only) Some applications require very short depositions called stitched beads. This stitching feature is also used in conjunction with automatic extrusion guns. The FM-130 produces stitched beads of equal length and gap (50 percent duty cycle) during the timer Issued 9190 0 Nordson Corporation 1990 Publication No. 104 274B

FM-l 30 Applicators Manual 41-l 30 Page 2-9 duration cycle. The stitch feature can be selected for each of the four timer channels individually. Pattern Control: Run-Up (FM-133 Only) THE FOAMMELT PROCESS The FM-133 run-up function, used in conjunction with automatic extrusion guns, adjusts hydraulic pressure as line speed varies to maintain consistent bead thickness. If line speed drops, system hydraulic pressure is automatically lowered so that bead thickness is unaffected. Likewise, if line speed increases, hydraulic pressure is raised in order to deposit more material onto the substrate and maintain bead thickness consistency. Because run-up control is; a function of varying line speed, the gear-to-line mode rather than timer mode should be used and an encoder must be configurled between the application line and FM- 133 unit. The FoamMelt application system is a process by which an inert gas (usually nitrogen) is mechanically combined with a hot melt material and held in solution, much like a carbonated beverage under pressure in its shipping container. As the material is exposed to atmospheric pressure and deposited onto a substrate, the gas expands, producing foam. The FoamMelt process results in major improvements properties, including: Longer open time to adhesive Faster set time. Improved spreadability Volumetric increase for greater gap filling Improved Lower Reduced Reduced substrate wetting heat density sagging or running adhesive consumption. Increased penetration in porous substrate Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

FM-l 30 Appkators Manual 41-l 30 Page 2-1 1 Mixing Process From the tank, melted material is fed into a constant displacement, two-stage gear pump where it is mixed with an inert gas. The most commonly used gases are industrial-grade carbon dioxide or nitrogen. The gas (customer-supplied) is metered into the material based on system demand. The FoamMelt system gear pump, comparable to a pair of standard gear pumps stacked one on top of the other in a single housing, is driven at a constant 300 rpm. The first stage (upper portion) of the pump meters material from the heated FM-130 tank into the second stage (lower portion) of the pump. The gas is injected at low pressure (3-5 psi) into the gear pump. Pump gear rotation creates a vacuum which draws the gas into the second stage gear set. Here it is combined with the hot melt material from the first stage. As the gas/hot melt mixture moves toward the pump discharge port, hydraulic pressure in the pump increases. This pressure forces the gas into solution with the hot melt material to form a single state fluid, like a carbonated beverage in its bottle or can. A series of mixing slots cut into the plates above and below the second stage gear teeth aid the combination process. As material travels through the gear pump, some is forced into a mixing slot instead of exiting through the discharge port. Material circulates repeatedly through the slots, ensuring that the hot melt and gas are thoroughly mixed before the solution leaves the pump. Hydraulic Flow From the gear pump, the hot melt/gas solution enters the FM-130 manifold where it flows through the density control/filter assembly. There, any solid particles, such as flakes of char, are removed and the gas/hot melt ratio is measured. From the density control/filter, material exits the manifold and enters one or more heated supply hoses. Material then circulates through automatic or hand-operated extrusion gun(s) attached to the end of the supply hoses. Remaining material re-enters the FM- 130 unit via heated return hoses connected between the guns and return ports in the manifold. Before material enters the gear pump return port in the manifold, it passes through a pressure control valve. The pressure control valve maintains system h:ydraulic pressure by means of a spring- Publication No. 104 2748 0 Nordson Corporation 1990 Issued 9190

Manual 41-130 Page 2-12 FM-l 30 Applicators loaded, ball-and-seat arrangement. The valve spring pressure is variable and can be increased or decreased by the operator to regulate system pressure. The FM-130 pressure control valve is located on the manifold, directly between the two return ports. On FM-131 and FM-132 units, the pressure control valve is manually adjusted by means of a slotted hex head screw-and-locknut arrangement. In FM-133 units, the run-up control valve requires only initial setting by the equipment operator; system electronic and pneumatic circuitry automatically adjusts the run-up control valve as the production line speed varies. Finally, hydraulic overpressure protection is provided by a pressure relief valve mounted in the bottom of the FM-130 tank. If hydraulic pressure reaches 1,500 psi (1.00 psi), the valve drains material from the manifold into the tank for recirculation. Gas Modulation System Carbon dioxide or nitrogen gas should be supplied to the FM-130 system from a user-supplied gas cylinder equipped with a regulator. Once connected, the gas flows through a pressure switch that signals the LOW GAS indicator LED when supply pressure falls below 30 psi (4.5 kpa). Past the pressure switch, are a pressure regulator and pressure gauge which permit the equipment operator to control input gas pressure to the pump. The actual flow of gas into the system is controlled by a reed valve. This valve is activated by the density control/filter when pump output flow indicates that more gas is needed. Turning the density control knob clockwise increases gas flow which increases the gas-to-material ratio and density reduction. Likewise, turning the density control knob counterclockwise decreases gas flow and the gas-to-material ratio and density reduction. A check valve mounted near the gear pump eliminates backflow of hot melt into the gas line. As the gas is supplied to the pump, it is drawn into the vacuum area created in the second stage of the gear pump and mixed with hot melt. Issued 9190 Q Nordson Corporation 1990 Publication No. 104 2748

FM-l 30 Applicators Manual 41-l 30 Page 2-l 3 Temperature Control System The FM-130 is equipped with a microprocessor-based temperature control system which monitors and regulates temperatures in the tank, hoses, guns and the FM-130 electronics enclosure. Heater control is accomplished through pulse width modulation and a proportional integral derivative (PID) control equation. Temperatures can be checked and adjusted by the operator at the end panel. The unit offers digital temperature readout of the actual and setpoint temperatures in either degrees Fahrenheit ( F) or degrees Celsius ( C). During start-up, the temperature control system examines RTD sensors and actual temperatures for fault conditions. If a fault is detected, the system responds selectively, depending on the type of fault detected. If any heater temperature channel reaches 455 F (235 C), the system shuts down. Of the 11 temperature control channels, the tank is the only one that must be connected for system operation. The software will only control and display hose and gun channels which are physically connected. A channel not connected is considered vacant. Hoses with vacant gun channels, that is with no gun connector attached, require a blue dust cap in the unused socket. Otherwise the FM-130 electrical self-diagnostics system will detect the open socket as an open sensor fau.lt. As described earlier, the FM-130 features an operator-selectable sequential startup option, where the system activates each temperature channel in a predetermined order. In non-sequential startup mode, all heating channels are energized simultaneously. In sequential startup mode, each channel must reach the preset start-up temperature before the next zone s heater is enabled. The startup temperature is slightly lower than the setpoint temperature. NOTE: Sequential start-up may increase applicator warm-up time beyond 30 to 45 minutes. To shorten the warm-u.p period, the sequential startup feature can be disabled as detailed in Section 4 of this manual. Publication No. 104 274C 0 Nordson Corporation 1990 Issued 9/95

Manual 41-130 Page 2-l 4 FM-1 30 Applicators NOTE: Some thermoplastic materials expand rapidly when initially heated. When using such materials, always employ the sequential startup feature. When all temperature channels are within 5 F (3 C) of the setpoint temperature, the system ready time delay begins to elapse. After this delay has elapsed, the FM-130 motor can be started and, if applicable, the PM1 delay begins. After this delay has elapsed, the parent machine is released for operation. FM-130 electronics enclosure temperature control is maintained by a thermistor-controlled fan. If the enclosure air temperature reaches 149 F (65 C), the fan switches on. If the enclosure air temperature reaches 167 F (75 C), an error message is displayed on the LCD and the system shuts down after a go-second delay. AUXILIARY EQUIPMENT Refer to Section 10, Optional Parts and Equipment, tions. for descrip- GLOSSARY OF TERMS The following terms and abbreviations are used throughout this manual. In some cases, conversion formulas are given for methods of measurement. applicator bead bead thickness That part of the hot melt system which is used to heat thermoplastic material to its required application temperature and pump it to the hoses and guns. The FM-130 applicator consists of a tank, a pump, a distribution manifold, gas modulation system and a temperature-controlled heating system. A deposition of hot melt material, usually of several inches or more in length. The width of a hot melt bead on a substrate before the bead is compressed. Bead thickness is affected by system hydraulic pressure, the application line speed or by using a gun with a microadjuster, such as zero cavity extrusion guns. Increased system pressure and slower line speed both produce thicker beads. biaxial Relating to a specially designed and manufactured extrusion gun or hose where the hydraulic delivery channel and return channel are contiguous to each other. Issued 9195 0 Nordson Corporation 1990 Publication No. 104 274C

FM-l 30 Applicators Manual 41-l 30 Page 2-l 5 Celsius cm cursor delay density reduction The metric method of temperature measurement, shown as C, where water freezes at 0 degrees and boils at 100 degrees; F (Fahrenheit) - 32 + 1.8 = C; formerly known as Centigrade. Abbreviation for centimeter ; a metric measurement of length; 100 cm = 1 meter; 2.54 cm = 1 inch. An onscreen blinking marker used to indicate the current1 tive selection during the system programming sequence. y ac- The amount of lag time between when a sensor on the application line provides a part present signal to the timer (make or break) and when the extrusion gun opens. The percentage of weight reduction due to the presence of gas in the hot melt deposit; usually determined by measuring the weights of equal volumes of foamed and non-foamed material and calculating density reduction (DR) based on: DR = 1 - Weight Foamed + Weight Solid x 100% drop out duration encoder EPROM extrusion gun Fahrenheit FoamMelt The time interval in milliseconds that it takes for material to reach the substrate after the timer signals the gun to close. The time interval that the gun is open and extruding hot melt material onto a substrate. A device which registers application line speed and transmits that data to a timing control device in the form of electrical pulses; Nordson offers both 200 ppm and 500 ppm encoders. Erasable Programmable Read-Only Memory; a storage device used for data retrieval purposes only. The EPROM stores the master program (software) for the microprocessor control system. A spring-loaded valving mechanism for dispensing or depositing hot melt material. There are two basic types of gun: the manual gun, in which the valve is actuated by a finger trigger; and the automatic gun, in which the valve is actuated pneumatically via a solenoid valve. The non-metric method of te OF, where water freezes at C (Celsius) x 1.8 + 32 = F. mperature measurement, shown as 32 degrees and boils at 21.2 degrees; The registered trademark name given to the process and equipment patented by Nordson by which an inert gas (carbon dioxide or nitrogen) is mechanically combined with hot melt material and held in solution until the hot melt material is extruded in a foamed state onto a substrate. Publication No. 104 274C 0 Nordson Corporation 1990 Issued 9195

Manual 41-l 30 Page 2-16 FM-l 30 Applicators fpm Abbreviation for feet per minute ; a measurement of speed. gear-to-line A method of pattern control; an interconnection between the application line and the applicator that assures consistent bead length when application line speed varies. holding capacity hot melt system The weight of hot melt that the tank can hold when the tank is filled to the top flange. The measurement is based upon thermoplastic with a specific gravity of 1.0. The applicator, the hose(s), the gun(s) and other peripheral devices configured to the applicator. in. Abbreviation for inch ; a non-metric measure of length. kpa Abbreviation for kilo Pascal ; a metric measurement of pressure; psi x 6.894757 = kpa. LCD LED MCDR meter Liquid Crystal Display; a device that converts applied voltage into optically polarized segments within a transparent panel. The FM- 130 uses a 2-line-by-40-character LCD panel to show system status, options, etc. Each character is produced by a 5x7 dot matrix of LCD segments. Light Emitting Diode; a device that converts applied voltage into light; used to display operating conditions on the FM-130. Maximum Continuous Delivery Rate; same as MIDR, but on a continuous basis. A metric measure of length; 39.37 inches = 1 meter. MIDR Maximum Instantaneous Delivery Rate; the hot melt delivery rate measured at the manifold outlet, under the conditions that produce maximum flow without exceeding any operating parameter limits within a specified time period. microprocessor An integrated circuit which interprets data and executes instructions electronically. mm Abbreviation for millimeters ; a metric measure of length; 1 inch = 25.4 mm. mpm Abbreviation for meters per minute ; a metric measure of speed; 3.28 fpm = 1 mpm. ms Abbreviation for milliseconds ; a time interval; 1,000 ms = 1 second. Issued 9/95 0 Nordson Corporation 1990 Publication No. 104 274C

FM-l 30 Applicalors Manual 41-l 30 Page 2-l 7 NV-RAM operator display pattern control Non-Volatile Random Access Memory; a computer data storage device capable of maintaining data without an external power SUPPlY. The LCD located on the FM-130 end panel. The ability to maintain consistent bead length and/or thickness even though line speed varies; two methods of pattern control include gear-to-line and run-up. PM1 Parent Machine Interlock; an interconnection between two devices which causes one device to affect the operation of the other. The FM-130 PM1 feature releases the application line for operation only after the hot melt material in the applicator has reached the proper density reduction and pressure. PPm psi pull-in rpm RTD Abbreviation for pulse per minute ; a measurement of frequency produced by an encoder configured to a FM-132 or FM-133 applicator. The pulse frequency is converted into a measure of the line speed by the FM-130 tirner. Abbreviation for pou nds per square inch ; a measure of air or hydraulic pressure. The time interval in milliseconds that it takes for the solenoid valve and gun nozzle to open and begin extruding hot melt material after a timer signal to begin the duration sequence. Abbreviation for revolutions per minute ; a measure of speed. Resistance Temperature Det,ector; a method of temperature sensing where the resistance of a metal conductor is measured and used as a temperature indicator. The resistance of the metal conductor varies directly with t:he temperature. run-up A method of pattern control; an interconnection between the application line and the FM-130 applicator causes hydraulic pressure to vary with application line speed, thereby assuring consistent bead thickness. sequential startup service block The mode that entails activa.tion of individual heater channels and functions in a predetermined order. One of the two main parts of a Nordson automatic extrusion gun, the other being either a module (automatic gun) or a cartridge (handgun). The automatic guns are constructed so that the module or cartridge contains the spring-loaded closing mechanism of the gun and the service block supplies the needed air, hot melt, and heat to make the gun operate. It consists of an aluminum Publication No. 104 274C 0 Nordson Corporation 1990 Issued 9/95

Manual 41-l 30 Page 2-l 8 FM-l 30 Applicators block drilled with air and hot melt passages and with a cavity for a cylindrical heater ( cartridge heater ) and also contains a provision for a temperature sensoir; typically an RTD or a non-adjustable thermostat. software stitch substrate system melt rate temperature standby thermoplastic material timer mode The computer program stored in electronic memory and utilized by the microprocessor to electronically execute system control functions. Very short (usually less than one inch) depositions of hot melt material; two or more stitches may be configured to form a pattern during a timer duration sequence. The surface upon which the hot melt material is applied. The amount of thermoplastic material, measured in pounds per hour, that a system (including hoses and guns) can melt and pump continuously within 10 F (5.6 C) of the set application temperature. The operational mode whereby heater channel temperatures are dropped to a slightly lower, predetermined level during periods of extended inactivity so as to retard hot melt material degradation. A material which is solid at room temperature, becomes liquid when heated, and returns to solid form upon cooling. A hot melt adhesive is a thermoplastic material. Operation based on absolute positioning of substrates on a constant-speed application line; as 1o:ng as line speed remains fixed and substrates remain evenly spaced, each hot melt extrusion will be consistently placed on each substrate; alternate to gear-toline mode. Issued 9/95 0 Nordson Corporation 1990 Publication No. 104 274C

FM-l 30 Applicators Manual 41-l 30 Page 3-O SECTION 3 Table of Contents Introduction... 3-1 Unpacking... 3-1 Inspection... 3-1 General Instructions... 3-2 Component Installation: FM-130 Applicator Installation..... 3-3 Automatic Gun Installation..... 3-3 Solenoid Valve Installation... 3-5 Handgun Installation... 3-6 Hose Installation..... 3-6 Gas Cylinder Installation... 3-8 Air Supply (FM-133 Run-up Control)... 3-9 Timer Trigger Device Installation (FM-132 and FM-133 Units).... 3-9 Sensitivity Adjustment for Timer Trigger Device..... 3-11 Encoder Installation (FM-132 and FM-133 Units).... 3-12 Friction Wheel Installation..... 3-14 Electrical Connections: Applicator Power Connections... 3-15 Timer Trigger and Encoder Connections (FM-132 and FM-133 Units Only).....3-16 Hose and Gun Connections... 3-18 Solenoid Valve Connection (FM-131 Units Only).... 3-19 Solenoid Valve Connection (FM-132 and FM-133 Units Only)... 3-19 Remote Input/Output Connections... 3-21 Remote Input Connections... 3-22 Remote Output Connections... 3-23 List of Figures Figure 3.1 - FM-130 Applicator Mounting Slot Dimensions... Figure 3.2 - Hose/Gun/Applicator Hydraulic and Electrical Configurations (Non-Biaxial Hoses).... Figure 3.3 - Hose/Gun/Applicator Hydraulic and Electrical Configurations (Biaxial Hoses)... Figure 3.4 - Friction Wheel Installation..... Figure 3.5 - Location of Parts Used in Electrical In,stallation... Figure 3.6 - Timer Input/Output Connections..... Figure 3.7 - Remote Input Connections (Manual Switch or Relay Contact).... Figure 3.8 - Remote Input Connections (PLC Output).... Figure 3.9 - Remote Output Connections (Indicator Device or Relay Coil)... Figure 3.10 - Remote Output Connections (PLC Input)............... 3-3........~.. 3-4... 3-5... 3-14... 3-15... 3-17... 3-23... 3-23... 3-24... 3-24 Publication No. 104 2746 0 Nordson Corporation 1990 Issued 9190