bulk melters bm 200 - industrial-stores.com 200 with gear pump - manual.pdf · sure brand, suremix,...

Bulk Melters BM 200with Gear Pump

- EASY Pneumatics -

Manual P/N 397189E- English -

Issued 05/06

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

P/N 397189E � 2006 Nordson CorporationBM200_EASY_GEAR

Note

After approx. December 2003, this manual applies to the entire series.

Order numberP/N = Order number for Nordson products

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2003.

No part of this document may be photocopied, reproduced, or translated to another language without the priorwritten consent of Nordson Corporation. The information contained in this publication is subject to change

without notice.

© 2006 All rights reserved.

TrademarksAccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve,CleanSpray, ColorMax, Control Coat, Coolwave, Cross‐Cut, Cyclo‐Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura‐Screen, Durasystem,Easy Coat, Easymove Plus, Ecodry, Econo‐Coat, e.dot, e.stylized, EFD, ETI, Excel 2000, Fillmaster, FlexiCoat, Flexi‐Spray, Flex‐O‐Coat, Flow Sentry,Fluidmove, FoamMelt, FoamMix, Heli‐flow, Helix, Horizon, Hot Shot, iControl, iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, JR, KB30, Kinetix, Little Squirt,LogiComm, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millenium, Mini Squirt, Moist‐Cure, Mountaingate, MultiScan, Nordson,OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, Printplus,ProBlue, Pro‐Flo, ProLink, Pro‐Meter, Pro‐Stream, RBX, Rhino, Saturn, Scoreguard, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat,Select Cure, Slautterback, Smart‐Coat, Solder Plus, Spectrum, Speed‐Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat,Sure‐Max, Tela‐Therm, Tracking Plus, TRAK, Trends, Tribomatic, Ultra, Ultrasaver, UniScan, UpTime, Vantage, Veritec, VersaBlue, Versa‐Coat,Versa‐Screen, Versa‐Spray, Walcom, Watermark, When you expect more. are registered trademarks - ® - of Nordson Corporation.

Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto‐Flo, AutoScan, Best Choice, BetterBook, Blue Series,CanNeck, Celero, Chameleon, Check Mate, ClassicBlue, Color‐on‐Demand, Controlled Fiberization, Control Weave, CPX, DispensLink, Dry Cure,DuraBraid, DuraCoat, DuraDrum, DuraPail, E‐Nordson, Easy Clean, EasyOn, Eclipse, Equi=Bead, ESP, Exchange Plus, Fill Sentry, Gluie, G‐Net, G‐Site,HDLV, Ink‐Dot, iON, Iso‐Flex, iTrend, KVLP, Lacquer Cure, Lean Cell, Maverick, Maxima, MicroFin, MicroMax, MiniBlue, MiniEdge, Minimeter, Multifil,Myritex, OptiStroke, Origin, PatternPro, PCI, PluraMix, Powder Pilot, Powercure, Primarc, Process Sentry, Prodigy, Pulse Spray, PurTech, Quad Cure,Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit,Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, ThruWave, Trade Plus, TrueBlue, Ultrasmart, Universal, Viper, Vista, VersaDrum,VersaPail, WebCure, 2 Rings (Design) are trademarks - � - of Nordson Corporation.

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.

Table of Contents I

P/N 397189E� 2006 Nordson Corporation BM200_EASY_GEAR

Table of Contents

Safety 1‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use - Examples - 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . .Area of Use 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Residual Risks 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Definition of Term(s) 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Note on Manual 2‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Configuration Code 2‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ID Plate 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Essential Components 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Variations and Options 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Control 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Hood 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changeover System 2‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .High Drum Jacket for Cardboard Drums 2‐8. . . . . . . . . . . . . . . .Divided Base Plate for Pallet Conveyance 2‐8. . . . . . . . . . . . . .

Electrical Cabinet 2‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Button Two‐hand Control and Pneumatic Switch 2‐10. . . . . . . . .Control System 2‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key Switch Remote / Local and Indication Lamp Remote 2‐10. .Main Switch 2‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Cabinet Ventilation 2‐10. . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Connections 2‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Week Timer (Accessory) 2‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Door Lock 2‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Light Tower (Accessory) 2‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating Punch 2‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melting Plates 2‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functioning 2‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Raising and Lowering Heating Punch 2‐14. . . . . . . . . . . . . . . . . . . . .

Deaerating Drum 2‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aerating Drum 2‐14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melting Process and Material Flow 2‐15. . . . . . . . . . . . . . . . . . . . . . .Drive 2‐15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heating and Temperature Control 2‐16. . . . . . . . . . . . . . . . . . . . . . . .

Undertemperature Interlock 2‐16. . . . . . . . . . . . . . . . . . . . . . . . . . .Overtemperature Indication / Shutdown 2‐16. . . . . . . . . . . . . . . .Temperature Setback 2‐16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsII


Installation 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting (Unpacked System) 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transport 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Up 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhausting Material Vapors 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Connections 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Laying Cable 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Line Voltage 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Supply 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hose Receptacle(s) 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating with Assembly Handguns 3‐5. . . . . . . . . . . . . . . . . . .Pilot Voltage / Tach Generator 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . .Interface XS2 3‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Heated Hoses 3‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Laying Hoses 3‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting 3‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disconnecting 3‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Pressure 3‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Second Open‐jawed Wrench 3‐7. . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Connection 3‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparing for Changeover System 3‐8. . . . . . . . . . . . . . . . . . . . . . . . . .Reducing Heating Punch Lifting Speed 3‐8. . . . . . . . . . . . . . . . . . . . . .Accessories 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Light Tower 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Week Timer 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tach Generator 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transformer 3‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Initial Startup 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Switch Rod 4‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Values and Parameters - Notes - 4‐3. . . . . . . . . . . . . . . . . . . .

Speed, Pressure 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Values 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inserting and Replacing Drum 4‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising Heating Punch 4‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lowering Heating Punch 4‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching System ON/OFF 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Startup 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Switchoff 4‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switching Off in an Emergency 4‐7. . . . . . . . . . . . . . . . . . . . . . . . . .

Settings Record Form 4‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents III


Maintenance 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Risk of Burns 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving Pressure 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Maintenance 5‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regular Maintenance 5‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Cleaning 5‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual Inspection for External Damage 5‐4. . . . . . . . . . . . . . . . . . . . . .Electrical Cabinet Ventilation 5‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressed Air Filter 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Condensate 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning Filter Element 5‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Pressure Restrictor Valves 5‐6. . . . . . . . . . . . . . . . . . . . . .Function Testing of Pressure Restrictor Valve 5‐6. . . . . . . . . . . . . .Cleaning Pressure Restrictor Valve 5‐6. . . . . . . . . . . . . . . . . . . . . . .

Changing Type of Material 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging with Cleaning Agent 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning Melting Plate 5‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Record Form 5‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Some Tips 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting with Control System 6‐2. . . . . . . . . . . . . . . . . . . . . . .

Indication Lamps and Light Tower 6‐2. . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Tables 6‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Notes 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Sealing Ring 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing O‐rings 7‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Melting Plate Temperature Sensor and Thermostat 7‐4. .

Technical Data 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Specifications 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motors / Speeds 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures and Thermostats 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cunsumption 9‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Hood 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Pressures 8‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions 8‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Weight 8‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Processing Materials 8‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Heating Punch Sealing Rings 8‐4. . . . . . . . . . . . . . . . .Inserting Thermostats and Temperature Sensors 8‐4. . . . . . . . . . .Lubricating O‐rings 8‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screw Locking Device 8‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Safety 1‐1


Section 1

Safety

Observe and follow all safety instructions, the general safety instructionsincluded as a separate document,

as well as the specific safety instructions in all other related documentation.

Safety1‐2


Introduction 2‐1


Section 2

Introduction

Intended UseBulk melters in the series BM 200 with Gear Pumps - hereafter also referredto as system - may be used only to melt and feed suitable materials. When indoubt, seek permission from Nordson.

CAUTION: Only undamaged and suitable drums (Refer to Technical Data)may be used.

CAUTION: PUR material may be processed only in models with exhausthood and manual drum aeration valve!

Any other use is considered to be unintended. Nordson will not be liable forpersonal injury or property damage resulting from unintended use.

Intended use includes the observance of Nordson safety instructions.Nordson recommends obtaining detailed information on the materials to beused.

Unintended Use - Examples -

The systems may not be used under the following conditions:

� In defective condition

� With electrical cabinet door open

� In a potentially explosive atmosphere

� With unsuitable operating/processing materials

� When safety valves and pressure restrictor valves are not lead‐sealed

� When the values stated under Technical Data are not complied with.

The systems may not be used to process the following materials:

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

Introduction2‐2


Area of Use

The system is designed for use in industrial areas.

When using in industrial areas and in small businesses, the system maycause interference in other electrical units, e.g. radios.

Residual RisksIn the design of the unit, every measure was taken to protect personnel frompotential danger. However, some residual risks can not be avoided.Personnel should be aware of the following:

� Risk of burns from hot material

� Risk of burns from hot system components

� Risk of burns when conducting maintenance and repair work for whichthe system must be heated up

� Risk of burns when attaching and removing heated hoses

� Material fumes can be hazardous. Avoid inhalation

� Pinching parts of the body between heating punch and drum

� The safety valve may malfunction due to hardened or charred material.

Definition of Term(s)The safety valve is also referred to as bypass and bypass valve in Nordsonliterature.

Introduction 2‐3


Note on Manual

� This manual applies to models with PLC‐controlled pneumatics (afterapprox. December 2003)

� This manual is valid only in conjunction with all documents included in thecomplete set of documentation (blue binder)

� When the system has special features, customer specifications and/orsupplements or a higher‐ranking system description may be added to thismanual

� The position numbers in the illustrations do not correspond to the positionnumbers in the technical drawings and parts lists. Refer to separatedocument Parts List for details.

Introduction2‐4


Configuration Code

The configuration code is engraved on the ID plate.

NOTE: An X indicates that the function or component was not ordered,meaning that it is unavailable. An S indicates that the model deviates fromthe configuration code. Such deviations are described in a supplement or asystem description.

Box Code Key

1 BM200 Series or unit designation

Eq

uip

me

nt

2 Melting plate Drum aeration valve Exhaust hood

A Axial Automatic No

B Axial Automatic Yes

R Axial Manual No

C Axial Manual Yes

F Fine‐blade Automatic No

P Fine‐blade Manual No

G Smooth Automatic Yes

U Smooth Manual Yes

3 3 Operating voltage 400VAC, 3 Ph Y

4 400VAC, 3 Ph, Delta

5 480VAC, 3 Ph, Delta

4 K Hose connection 16 mm (5/8 in) installed

8 mm (5/16 in) included

M 20 mm (3/4 in)

L 32 mm (11/4 in)

5 11 Pump type Gear, PR 6m1

12 Gear, PR 12m1

13 Gear, PR 12m2

14 Gear, PR 25m2

50 Gear, PU 15/85

51 Gear, PU 25/85

52 Gear, PU 35/85

53 Gear, PU 50/85

41 Piston pump, 42:1

42 Piston pump, 24:1

6 L Overtemperaturethermostat

150 ° C / 300 ° F

M 176 ° C / 350 ° F

H 230 ° C / 450 ° F

7 1 Number of hoseconnections

1

2 2Continued...

Introduction 2‐5


KeyCodeBoxO

pti

on

s9 D Pressure‐controlled

10 P Profibus interface

11 6 Six additional heating channels (three additional receptacles)

12 J High drum jacket (for cardboard drums)

13 W Divided base plate (for pallet conveyance)

14 S Special

NOTE: Models with a piston pump are not described in this manual.

CAUTION: PUR material may be processed only in models with exhausthood and manual drum aeration valve!

ID Plate

ADHESIVE MELTERBM

Nordson Engineering GmbHLilienthalstr. 6D 21337 Lüneburg - Germany

www.nordson.comSerial No:

3

4

5

1 2

Year

Fig. 2‐1

1 Melter designation

2 Order number

3 Configuration code

4 Electrical connection, operating voltage, line voltage frequency, melter fuse protection

5 Serial number

Introduction2‐6


Essential ComponentsComponents - when they are relevant to installation, operation andmaintenance - are described in the appropriate sections of this manual or inseparate manuals.

1

4

6

3

2

15

12

14

13

10

11

8 79 5

Fig. 2‐2

1 Pressure controller

2 Switch rod

3 Electrical cabinet

4 Automatic drum aeration valve(option) mounted on heatingpunchorManual drum aeration valvemounted on cross beam

5 Safety valve*

6 Pump*

7 Drip pan

8 Drum deaeration valve

9 Heating punch

10 Sensor Drum inserted (mountedon base plate)

11 Hose connection

12 Exhaust hood (option)

13 Drive

14 Hose holder

15 Hose receptacle

Note: There are separate manuals available for components marked with an asterisk (*).

Introduction 2‐7


Model Variations and Options

Pressure Control

The material pressure beyond the pump is measured by a pressure sensorand regulated by a control system to remain at a constant pressure (can beadjusted). Refer to separate manual.

Exhaust Hood

If the bulk melter is used to process polyurethane hot melt adhesives (PUR),fumes are created that should be suctioned off directly at the drum. Anexhaust hood is integrated into the bulk melter for this purpose.

The exhaust hood must be connected to the customer's exhaust device (Alsorefer to Installation, Exhausting Material Vapors).

Changeover System

The changeover system allows uninterrupted operation of two bulk melters.One of the systems is active (feeding material), and the other is in standbymode (system switched on, heating punch heater not yet on).

If a drum is almost empty (in this case, in the system on the right), the heatingpunch heater of the other system is automatically switched on. Now theempty drum can be replaced while the other system is feeding material.

Refer to separate manual.

Fig. 2‐3 Principle drawing

Introduction2‐8


High Drum Jacket for Cardboard Drums

CAUTION: Do not use metal drums with this model! The drum jacket isdesigned only for cardboard drums!

NOTE: Models for cardboard drums have only the lower sealing ring on theheating punch (configuration code: box 12 = J).

Divided Base Plate for Pallet Conveyance

The bulk melter is set up on a divided base plate. This enables a drum to bemoved under the punch on a pallet.

CAUTION: Risk of damage! Do not operate equipment until it is screwedsecurely to the floor. Otherwise the descending punch would lift the systemoff of the floor.

Introduction 2‐9


Electrical Cabinet

2

4

5

6

7

11

12

3

9

1

1

7

8

10

Fig. 2‐4

1 Button Two‐hand control

2 Pneumatic switch

3 Control system*

4 Indication lamp Remote(only with option Profibus)

5 Key switch Remote / local(only with option Profibus)

6 Main switch

7 Electrical cabinet ventilation

8 Base

9 Light tower

10 Electrical connections

11 Door lock

12 Week timer* (accessory)

Note: There are separate manuals available for components marked with an asterisk (*).

Introduction2‐10


Button Two‐hand Control and Pneumatic Switch

Used to manually control the heating punch when the drum is beingchanged.

WARNING: The two‐hand control may only be operated by one personusing both hands!

The pneumatic switch lights up green when the drum is inserted.

Control System

On the control system, values and parameters are set, and operating modesand faults are displayed.

Refer to manual for the Control System used.

Key Switch Remote / Local and Indication Lamp Remote

When set to Remote, the system is not controlled by the internal controlsystem but via the interface Profibus (Option).

Main Switch

The main switch is used to switch the system on and off.

Position 0/OFF = System is switched off.

Position I/ON = System is switched on.

Padlocks can be used to protect the main switch from unauthorized access.

Black Main Switch (Special Model)

Systems with a black main switch are normally supplied with power by ahigher‐ranking system; the higher‐ranking main switch is on that system. Theblack main switch does not perform the EMERGENCY OFF function.Connected components can still be switched on!

Electrical Cabinet Ventilation

Air Filter / Fan with Filter

Electrical cabinet ventilation reduces the temperature inside of the electricalcabinet. It must be serviced regularly. Refer to Maintenance.

Introduction 2‐11


Electrical Connections

Also refer to section Installation and to the wiring diagram.

1

2

3

4

Fig. 2‐5

1 Additional receptacles (with optionAdditional heating channels)

2 Interface Profibus (Option)

3 Receptacle XS5, tach generator

4 Interface XS2

Additional Receptacles

Depending on the model, up to three additional receptacles are available.Two heating zones (usually for hose and application head) can be controlledvia each receptacle.

NOTE: Hose receptacles on the terminal box (Pos. 15, Fig. 2‐2) are forhoses connected to the bulk melter heating punch.

Interface PROFIBUS (Option)

The PROFIBUS interface enables Remote operation by a higher‐rankingcontrol unit. Refer to separate manual.

Receptacle XS5

The receptacle is used to connect pilot voltage that regulates the system'selectrical motor synchronously to the speed of the parent machine. The pilotvoltage can be supplied e.g. by a tach generator (accessory) driven by theparent machine. Refer to Installation.

Interface XS2

Serves as a connection between the system and external devices.

Introduction2‐12


Week Timer (Accessory)

The week timer is used to automatically switch the system on and off. Themain switch must be set to I/ON (switched on) when using the week timer.Refer to separate manual.

Door Lock

The electrical cabinet can be opened for installation, maintenance and repair.Store the included key such that it is accessible only to qualified andauthorized personnel. The system may not be operated when the electricalcabinet is open.

WARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

WARNING: Disconnect equipment from the line voltage.

Light Tower (Accessory)

The light tower shows the system operating modes.

Refer to section Troubleshooting and manual Control System.

White Switched on

Green Ready for operation

Yellow Drum almost empty (flashing light) and drum empty (light on)

Red Collective fault

Introduction 2‐13


Heating Punch

The heating punch consists of the heating plate, the melting plate andsealing rings.


1

2

3

Fig. 2‐6

1 Heating plate 2 Sealing rings 3 Melting plate (if present)

Melting Plates

Depending on what the bulk melter is used for, one of these melting plates isused. The melting plates are all release coated.

Axial melting plateFine‐blade melting plateSmooth melting plate

Fig. 2‐7

Introduction2‐14


Functioning

Raising and Lowering Heating Punch

A pneumatic cylinder controls raising and lowering of the heating punch.When lowering the heating punch, a two‐hand control must be operated forsafety reasons until the heating punch is in the drum.

The air pressure in the pneumatic cylinders is limited to 7.5 bar (0,75 MPa /109 psi) by a pressure restrictor valve.

Deaerating Drum

The drum deaeration valve must be opened manually so that air can escape(drum is deaerated) when the heating punch is lowered into the drum.

Aerating Drum

Air must be introduced into the drum (drum is aerated) to prevent a vacuumfrom forming when the heating punch is raised. Depending on the model, thisis done with an automatic drum aeration valve or must be prepared manuallyby screwing in an aeration pipe.

The air pressure in the drum is limited to 1 bar (0.1 MPA / 14.5 psi) by apressure restrictor valve.

Deaerating Aerating

Air

Heating punch

Drum

Compressed air

Heating punch

Drum

Fig. 2‐8

Introduction 2‐15


Melting Process and Material Flow

The material is melted only directly below the melting plate (4). A pump (1)(gear pump) feeds the melted material to the hose connection (3). Fromthere it flows through a heated hose to an application head or an assemblyhandgun, possibly to a melter, to fill that unit.

A safety valve (2) limits the material pressure generated by the pump andkeeps it constant.

3

4

1 2

Fig. 2‐9 Principle drawing

Drive

An electronically controlled electrical motor drives a gear pump. It standardlyruns in manual mode. Automatic mode is also possible.

� Manual mode: In manual mode the motor/pump speed is held steady atthe manually set value.

� Automatic mode: In automatic mode (key‐to‐line mode) the motor/pumpspeed is regulated synchronously to the speed of the parent machine.For this to occur, the system must receive pilot voltage from the parentmachine.

NOTE: With the option Pressure control, the speed is regulated such thatthe material pressure behind the pump is kept steady.

Introduction2‐16


Heating and Temperature Control

The heating punch is heated by cast‐in heating elements.

Temperatures are measured by sensors and electronically controlled.

Undertemperature Interlock

The undertemperature interlock prevents the system from being started upbefore the material has exceeded the temperature setpoint minusundertemperature value. However, every time initial heating occurs, theinterlock is not released until the actual temperature is 3 °C (5.4 ° F) belowthe temperature setpoint.

The undertemperature interlock locks the motors, solenoid valves and, insome cases, other components of the application system. Refer to the wiringdiagram to determine which components are locked.

Overtemperature Indication / Shutdown

The independently operating overtemperature shutdown mechanismsprotect the system and the material from overheating. For overtemperatureshutdown, the heating and motor are switched off. The red indication lampCollective fault lights up.

� Overtemperature indication through temperature controller: When thetemperature setpoint plus overtemperature value has been reached, therelay output Collective fault is switched and the red indication lampCollective fault lights. The system remains ready for operation.

� Overtemperature shutdown by temperature controller: Theovertemperature shutdown value is set automatically 30 ° C (54 ° F)higher than the highest temperature setpoint value.

� Overtemperature shutdown by thermostat(s): Serves as an emergencyswitch OFF in case the overtemperature shutdown of the temperaturecontroller does not function properly. Refer to section Technical Data forshutdown value.

WARNING: When the overtemperature shutdown is triggered, there is eithera fault in settings or system malfunction. Switch off the system and have thefault remedied by qualified personnel.

Temperature Setback

Serves to protect the material and save energy during interruptions inproduction or work stoppages. Setback value and setback period areadjustable.

Installation 3‐1


Section 3

Installation

WARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

UnpackingUnpack carefully and check for damage caused during transport. Save palletand fastening and packing material for later use, or dispose of properlyaccording to local regulations.

Lifting (Unpacked System)

Refer to Technical Data for weight. Lift only with a suitable floor conveyor (lifttruck or fork lift).

Transport

� For systems with divided base plate:

CAUTION: Risk of damage! Do not move system without attachingtransport protection to the base plate.

� Refer to Technical Data for weight. Use only suitable transport devices.

� If possible, use the pallet on which the system was delivered, and fastenthe system to the pallet.

� Protect from damage, moisture and dust with suitable packing material.

� Avoid jolts and vibrations.

Installation3‐2


StorageDo not store system outside! Protect from humidity, dust and extremetemperature fluctuations (formation of condensation).

Setting Up

� For systems with divided base plate:

CAUTION: Risk of damage! Do not operate equipment until it isscrewed securely to the floor. Otherwise the descending punchwould lift the system off of the floor.

� Set up only in an environment that corresponds to the stated Degree ofProtection (Refer to Technical Data). Do not set up in a potentiallyexplosive atmosphere!

� Protect from vibration. Remove transport protection (if present).

� Ensure that there is sufficient free space around the system, especiallyabove it. Refer to Technical Data for dimensions.

Fig. 3‐1

Installation 3‐3


Removing1. Convey all material out of system and remove drum.

2. When system will not be used for longer periods of time, purge withcleaning agent if necessary (Refer to Maintenance).

3. Wipe off sealing ring and clean melting plate (Refer to Maintenance).

4. Disconnect all lines to the system, and allow system to cool.

DisposalWhen your Nordson product has exhausted its purpose and/or is no longerneeded, dispose of it properly according to local regulations.

Installation3‐4


Exhausting Material VaporsEnsure that material vapors do not exceed the prescribed limits. Alwaysobserve the safety data sheet (MSDS) for the material to be processed.

If necessary, exhaust material vapors and/or provide sufficient ventilation ofthe location of the system. On systems with exhaust hoods, material vaporsare suctioned directly at the drum.

NOTE: The exhaust hood must be connected to the customer's exhaustdevice. Refer to Technical Data.

System without exhaust hood System with integrated exhaust hood

Customer's

Fig. 3‐2

Installation 3‐5


Electrical ConnectionsWARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

Laying Cable

WARNING: Use only temperature resistant cable in the heating part of thesystem. Ensure that cables do not touch rotating and/or hot parts. Do notpinch cables and check regularly for damage. Replace damaged cablesimmediately!

Line Voltage

WARNING: Operate only with the line voltage stated on the ID plate.

NOTE: Permitted deviation from the rated line voltage is +5% / ‐10%.

NOTE: The power connection cable must have a cross‐section matching thepower consumption Pmax. (Refer to ID Plate).

Power Supply

The mains terminals are located in the electrical cabinet. Refer to WiringDiagram for connecting arrangement.

Hose Receptacle(s)

For electrical connection values, refer to Technical Data.

Operating with Assembly Handguns

For applications with assembly handguns that switch the motor via theheated hose, the bridge XLS1: 1 ‐ 2 (Refer to Wiring Diagram) must beremoved.

Pilot Voltage / Tach Generator

For automatic mode, pilot voltage must be connected to XS5. The pilotvoltage can be supplied e.g. by a tach generator (accessory) driven by theparent machine.

CAUTION: The pilot voltage may not exceed 160 VDC. Failure to observewill result in damage to succeeding components.

Installation3‐6


Interface XS2

The interface serves as a connection between the system and externaldevices. The functions are described in detail in the manual Control SystemCS 20 for Bulk Melters, section Central Module with Digital Input/Output.

NOTE: It is essential to bridge Pin 9 with Pin 1 (24 VDC) before initial startup.Also refer to plug connection diagram Interface XS2 for BM 20 (wiringdiagram).

NOTE: To conform with a European standard regarding electro‐magneticcompatibility, only shielded cable may be connected. The shield must beconnected to ground in compliance with the standard (PE connection in plugconnector).

NOTE: Inductive loads (e.g. solenoid valves) connected to the system mustbe equipped with a protective device (e.g. recovery diode) that disables theinductive voltage generated when an inductive load is switched off.

Pin Input Output Function

1 ‐ 24 VDC Internal switching voltage for activating inputs 2, 3, 4, 5, 7 and 9.

The switching voltage must be connected to the appropriate input.

2 24 VDC ‐ Unit release (main contactor)

3 24 VDC ‐ Release Drives

4 24 VDC ‐ Switch on/off Temperature setback

5 24 VDC ‐ Release Motor for application 1

6 - ‐ Not assigned

7 24 VDC ‐ Release Motor for application 2

8 ‐ ‐ Not assigned

9 ‐ ‐ Internal link




13‐16 ‐ ‐ Not assigned

17 24 VDC external

‐ External potential for outputs 18, 19, 20, 21, 24 and 2624 VDC +/‐ 10 %

18 ‐ 24 VDC max. 2 A Indication Ready for operation

19 ‐ 24 VDC max. 2 A Indication Collective fault

20 ‐ 24 VDC max. 2 A Indication Drum almost empty

21 ‐ 24 VDC max. 2 A Indication Drum empty



24 ‐ 24 VDC max. 2 A Valve control application 1


26 ‐ 24 VDC max. 2 A Valve control application 2

27‐32 ‐ ‐ Not assigned

PE ‐ ‐ Shield

NOTE: Refer to Wiring Diagram for electrical connection.

1 2 3

Installation 3‐7


Installing Heated HosesWARNING: Hot! Risk of burns. Wear heat‐protective gloves.

Laying Hoses

Guide hose through the hose guide. The hose connection is located on theheating punch.

Connecting

If cold material can be found in the hose connection (1) and/or hose fitting(2), these components must be heated until the material softens (approx. 80 �C, 176 �F).

1. First connect the hose (3) electrically to the unit. For more than one hose:Every hose connection is allocated to a corresponding receptacle. Do notmistakenly exchange!

2. Heat the system and hose to approx. 80 �C (176 �F).

3. Screw the heated hose onto the unit.

NOTE: Close unused hose connections with Nordson port plugs.

Disconnecting

WARNING: System and material pressurized. Relieve system pressurebefore disconnecting heated hoses. Failure to observe can result in seriousburns.

Relieving Pressure

1. Set motor speed to 0 min‐1 (rpm); switch off motor(s).

2. Place a container under the nozzle(s) of the application head/assemblyhandgun.

3. Activate the application head / assembly handgun electrically ormanually. Repeat this procedure until no more material flows out.

4. Re‐use the material or dispose of properly according to local regulations.

Second Open‐jawed Wrench

Use a second open‐jawed wrench when connecting and disconnecting theheated hose. This prevents the unit's hose connection from turning.

1

2

1

2

Installation3‐8


Pneumatic ConnectionConnect dry, clean and non‐lubricated compressed air (2). Set air pressurefor pneumatic cylinder to approx. 5 bar (0.5 MPa / 72.5 psi) on the pressurecontroller (1). The setting can be modified according to the materialprocessed (max. 7.5 bar / 0.75 MPa / 109 ps).

The air pressure in the pneumatic cylinders is limited to 7.5 bar (0.75 MPa /109 psi) by a pressure restrictor valve.

Preparing for Changeover SystemThe DIP switches S 8.1 and S 8.2 of the CS 20 control system's temperaturecontrol panel board must be set to OFF (no leading channel) in changeoversystems. Refer to separate manual for control system.

Reducing Heating Punch Lifting SpeedNOTE: The lifting speed need only be reduced if the heating punch often liftsthe drum as it moves up.

1. Remove protective plate (1) from pneumatics.

2. Turn throttle screw (2) clockwise slightly with a screwdriver. The correctsetting must be determined by trial and error.

3. Attach protective plate again.

Installation 3‐9


AccessoriesThe following components can also be installed later as accessories:

Light Tower

The light tower must be screwed onto the electrical cabinet. It must beconnected to terminal XLWT according to the Wiring Diagram.

Week Timer

The week timer must be installed in the electrical cabinet. To do this, removeclamp XLWZ and install the week timer in its place. Wire according to WiringDiagram.

Tach Generator

It is connected to receptacle XS 5.

Also refer to Wiring Diagram and manual Tach Generator.

NOTE: The pilot voltage produced by the tach generator must be adjusted(Refer to manual for the control system used).

CAUTION: The pilot voltage may not exceed 160 VDC. Failure to observewill result in damage to succeeding components.

Transformer

Systems designed for operating voltage of 400VAC, 3 Ph Y can be operatedat 200 or 240 VAC with the transformer.

Installation3‐10


Operation 4‐1


Section 4

Operation


Initial StartupNOTE: Some of the following tasks are described in detail in the subsequenttext.

1. Ensure that the switch rod is set to the drum height.

2. Set pneumatic switch to 0.

3. Set main switch to I/ON.

4. Control system: Set values and parameters.

5. Set week timer, if present.

6. Insert drum.

7. Pre‐select motor and switch on.

8. Set motor speed on control system to achieve desired output quantity.With option Pressure Control: Set the setpoint pressure instead of themotor speed.

NOTE: To prevent excessive wear, the motor/pump speed should notcontinuously fall below 5 min‐1 (rpm) or continuously exceed 80 min‐1

(rpm).

9. Optimize settings and record in settings record form.

NOTE: All system functions were tested before the system left the factory.Special test material was used. There may be residue from this material onthe melting plate, in the pump, etc. To remove such residue, melt and feedseveral kilograms of material before starting production.

2

4

5

6

3

1

Operation4‐2


Adjusting Switch RodSet the switch rod (2) such that it activates switch 4 when the upper sealingring (3) is completely submerged in the drum. To do this, release hexagonalsocket screw (1).


Setting the switch rod adjusts the system to the drum height used. The switchrod activates the switches (4, 5 and 6) one after the other and thus triggersthe following switching functions:

Switching Functions when Lowering

� Switches from two‐hand lowering mode to normal lowering mode whenthe sealing ring (3) is completely submerged in the drum (switch 4).

� Triggers the drum almost empty indication (switch 5).

� Triggers the drum empty indication (switch 6).

Switching Functions when Raising

� Switches off the automatic drum aeration (switch 4).

Operation 4‐3


Setting Values and Parameters - Notes -Many values and parameters are set on the control system.

For additional information, refer to control system used.

Speed, Pressure

With the option Pressure control, the speed is not regulated to a preset value;the pressure at the material outlet is regulated.

In automatic mode, the speed and thus the output quantity is determined by apilot voltage. The pilot voltage is supplied e.g. by a tach generator driven bythe parent machine.

Temperatures

CAUTION: The temperature setting is determined by the processingtemperature prescribed by the adhesive supplier. The maximum operatingtemperature for the product and heated components described here may notbe exceeded.

Nordson will grant no warranty and assume no liability for damage resultingfrom incorrect temperature settings.

Recommended Values

The values stated in the tables are general values determined by experience;deviation may prove necessary.

Heating zone / temperature / time Setting

Heating punch 10 °C (18 °F) below prescribed processing temperature

Undertemperature value 10 °C (18 °F) (deviation from setpoint)

Overtemperature value 10 to 30 °C (18 to 54 °F) (deviation from setpoint)

Temperature setback value (standby) As needed

Setback period As needed

Application head (accessory) Prescribed processing temperature

Heated hose (accessory) Prescribed processing temperature

Operation4‐4


Inserting and Replacing DrumCAUTION: Place only undamaged, suitable drums in the system; otherwisethe heating punch sealing ring will be damaged. Always keep the base plateof the system clean so that the drum is positioned straight.

WARNING: Risk of burns! Hot material can splash out when the heatingpunch exits the drum. Hot material may flow out of the deaeration valve.Wear suitable protective clothing!

NOTE: Some of the following tasks are described in detail in the subsequenttext.

1. Raise heating punch.

2. Set pneumatic switch to 0/Stop.

3. Insert or replace drum. The pneumatic switch lights up green when thedrum is inserted.

4. Lubricate sealing ring. Refer to Processing Materials in the sectionTechnical Data.

5. Lower heating punch.

6. Properly dispose of empty drum according to local regulations.

1

2

2

3

a

b

c

1

2

3

Operation 4‐5


Raising Heating Punch

If the heating punch is inside of the drum, the drum must be aerated tosupport raising. Aerating means that compressed air is forced under theheating punch.

1. Aeration must be done manually for models without automatic aerationvalve:

a. Screw out rod (1).

b. In place of the rod, screw in the aeration pipe (2, stored in the holderon the electrical cabinet).

c. Attach aeration connection (3, stored on the cross beam) to aerationpipe.

2. Set pneumatic switch to Raise.

Automatic drum aeration begins when the pneumatic switch is moved toRaise and ceases when the punch leaves the drum. In case the heatingpunch lifts the drum:

� Quick fix: Set pneumatic switch to 0 and press two‐hand control toincrease air pressure in drum.

� Long term solution: Reduce heating punch lifting speed (Refer toInstallation).

The air pressure in the drum is limited to 1 bar (0.1 MPA / 14.5 psi) by apressure restrictor valve.

Lowering Heating Punch

The drum must always be deaerated when the heating punch is moved intothe drum. When the drum is deaerated, the air that is under the heatingpunch escapes.

1. Set pneumatic switch to Lower.

2. Place the drip pan (3) in front of the deaearation valve (2).

3. Open deaeration valve on lever (1).

4. Press both buttons on the two‐hand control at the same time (within 0.5 seconds) until the heating punch is inside of the drum. The downward movement continues on its own.

5. Close deaeration valve when material flows out free of bubbles.

6. Properly dispose of material according to local regulations.

Operation4‐6


Switching System ON/OFFNOTE: Before initial startup, read and observe the instructions in InitialStartup. Start up only as described under Initial Startup.

NOTE: The main switch must be set to I/ON (switched on) when using theweek timer (accessory). Additional information on the week timer can befound in the manual Week Timer.

NOTE: When external system release via interface XS2 is used, the mainswitch must be set to I/ON (switched on).

Daily Startup

NOTE: Do not operate Nordson pumps without material. Before switching onmotor, ensure that a drum that is not empty is in the system and that theheating punch has contact with the material.

NOTE: To prevent excessive wear, the motor/pump speed should notcontinuously fall below 5 min‐1 (rpm) or continuously exceed 80 min‐1 (rpm).

1. Set main switch to I/ON.

2. Set pneumatic switch to Lower.

3. Wait until system is ready.

4. Pre‐select motor.

5. Switch on motor.

Daily Switchoff

1. Set main switch to 0/OFF and protect from unauthorized access withpadlocks if necessary.

2. Set pneumatic switch to Stop.

3. Perform daily maintenance.

Operation 4‐7


Switching Off in an Emergency

WARNING: Immediately switch off the system in any emergency situation.

1. Set main switch to 0/OFF or - when available - press EMERGENCY OFFbutton (special feature).


3. After standstill and before switching the system back on, have the faultremedied by qualified personnel.

Black Main Switch (Special Model)

Systems with a black main switch are normally supplied with power by ahigher‐ranking system; the higher‐ranking main switch is on that system. Theblack main switch does not perform the EMERGENCY OFF function.Connected components can still be switched on!

Operation4‐8


Settings Record Form

Production information:

Application material Manufacturer

Processing temperature

Viscosity

Cleaning agent: Manufacturer

Flash point

Leading channel: Factory‐set

Processing temperatures (Setpoint temperatures):

Heating punch

Heated hose (accessory) 1) 2) 3) 4)

Application head (accessory) 1) 2) 3) 4)

Assembly handgun (accessory) 1) 2) 3) 4)

Motor/pump speeds:

Motor/pump

Air pressure: bar MPa psi

Operating pressure

Notes:

Name Date

Maintenance 5‐1


Section 5

Maintenance


NOTE: Maintenance is an important preventive measure for maintainingoperating safety and extending the lifetime of the unit. It should not beneglected under any circumstances.

Risk of Burns

WARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment. Some maintenance work can only be done when thesystem is heated up.

Relieving PressureWARNING: System and material pressurized. Relieve system of pressurebefore disconnecting heated hoses, application heads and assemblyhandguns. Failure to observe can result in serious burns.

1. Set motor speed to 0 min‐1 (rpm); switch off motor(s).

2. Place a container under the nozzle(s) of the application head/assemblyhandgun.

3. Activate the application head / assembly handgun electrically ormanually. Repeat this procedure until no more material flows out.

4. Re‐use the material or dispose of properly according to local regulations.

Maintenance5‐2


Daily MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on the location of the system, production conditions andoperating time of the system, other maintenance intervals may provenecessary.

Unit part Activity Interval Refer to

Complete system External cleaning Daily Page 5‐4

Inspect for external damage Page 5‐4

Power cable Inspect for damage -

Air hoses Inspect for damage -

Displays and lamps Function check (test) Manual Control System

Electrical cabinet ventilation Clean fan screens, clean orreplace filter

Daily, if dustaccumulation issevere

Page 5‐4

Melting plate Check melting plate forcharred material, clean ifnecessary

Every time thedrum is changed

Page 5‐7

Sensor Drum inserted Check sensor for materialresidue or other impurities,clean if necessary

-

Base plate Check base plate for materialresidue or other impurities,clean if necessary

-

Electrical motor Clean fan cover Daily, if dustaccumulation issevere

Manual Motor

Maintenance 5‐3


Regular MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on the location of the system, production conditions andoperating time of the system, other maintenance intervals may provenecessary.

Unit part Activity Interval Refer to

Compressed air filter Drain condensate Weekly Page 5‐5

Clean filter element Every threemonths

Clean condensate collector When cleaningfilter element

Pneumatic pressure restrictorvalve

Function test Every six months Page 5‐6

Clean When notfunctioningcorrectly

Safety valve Refer to separate manual

Pump

Electrical motor

ÂÂÂÂÂÂÂÂÂÂÂÂ

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

ÂÂÂÂÂÂÂ

ÂÂ

Maintenance5‐4


External CleaningExternal cleaning prevents pollution created by production from causingsystem malfunctions.

CAUTION: Observe the unit's Degree of Protection when cleaning (Refer tosection Technical Data).

CAUTION: Do not damage or remove warning signs. Damaged or removedwarning signs must be replaced by new ones.

Remove material residue only with a cleaning agent recommended by thematerial supplier. Heat with an air heater if necessary.

Remove dust, flakes etc. with a vacuum cleaner or a soft cloth.

Visual Inspection for External DamageWARNING: When damaged parts endanger the operating safety and/or thesafety of personnel, switch off the system and have the damaged partsreplaced by qualified personnel. Use only original Nordson spare parts.

Electrical Cabinet VentilationThe electrical cabinet fans require no maintenance. The filters must becleaned or replaced, depending on dust accumulation.

A dirty filter can be recognized by its dark color. It is cleaned by shaking thefilter out.

10 m

m 7

7

6

5

4

3

2

1

Maintenance 5‐5


Compressed Air FilterThe compressed air filter dehydrates and cleans the compressed air.

Draining Condensate

Drain condensate before it reaches a level approx. 10 mm below the filterdisk.

To do this, open the condensate drain valve (7).

Cleaning Filter Element

Under normal conditions, clean filter element (5) approx. every three months.Clean sooner if compressed air filter outlet pressure falls.

1. Stop compressed air supply and release residual pressure by openingthe condensate drain valve (7).

2. Unscrew condensate collector (6).

3. Unscrew filter element (5) by turning to the left.

4. Rinse filter element (5) with suitable cleaning agent. Then blow out fromthe inside. The condensate collector (6) may not come into contact withthe cleaning agent!

5. Clean condensate collector (6) if necessary. Use only water!

6. Reassemble compressed air filter.

1

Maintenance5‐6


Pneumatic Pressure Restrictor ValvesThe factory‐set, lead‐sealed pressure restrictor valves prevent unpermissiblyhigh pressurization of subsequent pneumatic components. When the valuesset at the factory are exceeded, the compressed air is audibly discharged.

NOTE: There are pressure restrictor valves

� on the drum aeration valve (4, Fig. 2‐2)

� in the pneumatic box (1).

Function Testing of Pressure Restrictor Valve

Functioning of the pressure restrictor valve should be checked approx. everysix months. Do this by turning the knurled screw until the compressed air isaudibly released. When functioning is not correct, the pressure restrictorvalve should be cleaned. If it is still not working as it should, it must bereplaced.

NOTE: A defective pressure restrictor valve may be replaced only with anoriginal spare valve. Repairs to the pressure restrictor valve may be madeonly by the manufacturer!

Cleaning Pressure Restrictor Valve

Pollution that has penetrated seat surfaces and conical nipples can beremoved by unscrewing the entire top piece - without changing the minimumoperating pressure. Use a sickle wrench to unscrew.

Function test Unscrewing top

ÂÂÂÂ

Fig. 5‐3

Note: The illustration shows the old model with locking wire instead of a lead sealing disk.

Maintenance 5‐7


Changing Type of MaterialCAUTION: PUR material may be processed only in models with exhausthood and manual drum aeration valve!

NOTE: Before changing the material type, determine whether the old andnew material can be mixed.

� May be mixed: Remaining old material can be flushed out using the newmaterial.

� May not be mixed: Purge thoroughly and clean melting plate with acleaning agent recommended by the material manufacturer (Refer toCleaning Melting Plate).

NOTE: Properly dispose of the old material according to local regulations.

Purging with Cleaning AgentCAUTION: Use only a cleaning agent recommended by the hot meltmaterial manufacturer. Observe the Material Safety Data Sheet for thecleaning agent.

Before starting production again, flush out residue of the cleaning agentusing the new material.

NOTE: Properly dispose of cleaning agent according to local regulations.

Cleaning Melting PlateThe melting plate is standardly release‐coated. This makes it easy to clean.Cooled material can usually be pulled off of the melting plate; if necessary,first heat to 60 �C / 140 �C.

CAUTION: Do not use hard or metallic tools to clean. Do not use wirebrushes! This could damage the release coating. Use only soft aids (woodenor PTFE- spatula or soft brush).

Maintenance5‐8


Maintenance Record Form

Unit part Date / name Date / name Date / name

Electrical cabinet ventilation

Compressed air filter

Pneumatic pressure restrictorvalve

Safety valve

Pump

Electrical motor

Troubleshooting 6‐1


Section 6

Troubleshooting


WARNING: Troubleshooting activities may sometimes have to be carriedout when the system is energized. Observe all safety instructions andregulations concerning energized unit components (active parts). Failure toobserve may result in an electric shock.

Some Tips

Before systematic troubleshooting is begun, the following should bechecked:

� Are all parameters set correctly?

� Is the XS 2 interface connected correctly?

� For automatic mode: Is pilot voltage present?

� Do all plug connections have sufficient contact?

� Have circuit breakers/fuses been activated?

� Could the fault have been caused by an external PLC?

� Are external, inductive loads (e.g. solenoid valves) equipped withrecovery diodes? The recovery diodes must be directly allocated to theinductive load, e.g. through luminous sealings.

Troubleshooting6‐2


Troubleshooting with Control System

The control system offers the following troubleshooting aids, described in themanual Control System:

� Indication lamps and light tower

� Diagnosis program in the temperature section

� Automatic fault display in the temperature section

� Service display Error in the motor section

� LEDs on the modules and boards.

Indication Lamps and Light Tower

With the exception of the yellow light on the light tower, the indication lampsand the light tower indicate the same modes as the control system:

� Red = Collective fault. The red lamp indicates that the control system hasrecognized a fault.

� White = Switched ON. After switching on and during the heatup phase, atfirst only the white indication lamp is lit (normal condition). A fault has onlyoccurred when the temperature does not increase (observe temperaturedisplay) and when the green indication lamp is not lit after the heatupphase has ended (1 hour and longer).

� Green = Ready for operation. The green indication lamp lights when allchannels have reached their setpoint temperatures.

� Yellow = Lower tank level, as set by customer.

Red

Green

White

17

18

19

1 2 3 54 6 7

1 1 2 2 3

M1 min-1

1

barpsi

2 3 54 76

8 109 11 12

CF

3 44 21

8 9 10 11 12

Fig. 6‐1 (Refer to manual Control System for position numbers)

Troubleshooting 6‐3


Troubleshooting TablesThe troubleshooting tables serve as an orientation for qualified personnel.They cannot, however, replace targeted fault location with the help of wiringdiagrams and measuring instruments. They also do not include all possibleproblems, only those which most typically occur.

Problem Possible Cause Corrective Action

System has noelectrical function

Main switch is set to 0 Set main switch to 1

Fuses are defective Check fuses in electrical cabinet

No line voltage supplied Check whether there is line voltage atthe line voltage terminals in the electricalcabinet

Week timer programmed incorrectly Program differently

System has nopneumaticfunction

There is no compressed air Connect compressed air

Pressure controller set incorrectly Set pressure controller to max. 7.5 bar(0.75 MPa / 109 psi)

System does notreach Ready

Only the whiteindication lamp islit

Temperatures not set correctly ontemperature controller

Check temperature settings for allchannels

Fuses for individual channels defective Check fuses for individual channels

Temperature setback switched on Switch off or wait until the setback periodhas expired

Automatic temperature setback aftermotor standstill activated

Stop temperature setback

Channel is switched off Switch on

Channel is switched to measuring mode Switch to control mode

Channel/Heating zone defective Activate diagnosis program of thetemperature section

Continued...

Troubleshooting6‐4


Problem Corrective ActionPossible Cause

Too little or nomaterial comesout

System, hose and application head /assembly handgun are cold or have notthe right temperature

Check all temperature settings.Consider heating phase

Material viscosity too high Observe temperature instructions ofmaterial manufacturer

Increase operating air pressure of bulkmelter (max. 7.5 bar / 0.75 MPa /109 psi)

Motor does not turn Undertemperature interlock has not yetreleased

Check position of motor switch

Check speed setting

Are fuses on motor controller functional?

Is motor controller functional? Is motorfunctional?

Have motor controller or motor checked- and, if necessary, replaced - byqualified personnel

Pump turns, but feeds no or too littlematerial

Check that pump functions correctly

Nozzle on application head or assemblyhandgun blocked

Unscrew warm nozzle and clean

Filter - if present on application head - isblocked

Replace filter cartridge

Heating punch cannot be lowered

Sensor Drum inserted transmits nosignal

Clean sensor, check position

The pneumatic switch lights up greenwhen the drum is inserted

Is the pneumatic switch set to Lower? Set pneumatic switch to Lower

Is the drum deaerated? Deaerating drum

Heating punchmoves irregularlyor not at all

Set pneumatic switch to 0 If air continuously escapes from theswitch in this position, the switch isdefective and must be replaced

Set pneumatic switch to Raise If air continuously escapes from thevalve drain hole in this position, theseals in the air cylinders are probablydefective and must be replaced

Pneumatic cylinder seals leak Replace seals

Heating punch liftsdrum

Lifting speed too high Reduce heating punch lifting speed(Refer to Installation)

Repair 7‐1


Section 7

Repair


WARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment. Some maintenance work can only be done when thesystem is heated up.

WARNING: System and material pressurized. Relieve system of pressurebefore disconnecting heated hoses, application heads and assemblyhandguns. Failure to observe can result in serious burns.

General Notes

� Material hoses can not be repaired. However, defective hoses can beexchanged for overhauled hoses with full guarantee through Nordson'sAT program (replacement program).

� The processed material must be soft for disassembly of somecomponents. Heat the system to softening temperature. Use a hot air fanif necessary.

� Use only original Nordson spare parts. Refer to separate document Parts

List for details.

� Also refer to separate manuals for the individual components.

Repair7‐2


Replacing Sealing RingWARNING: Hot! Risk of burns. Wear heat‐protective gloves.


1. Heat heating punch to operating temperature.

2. Aerate drum.

3. Set pneumatic switch to Raise until the heating punch exits the drum.


5. Place a clean, hard, heat‐resistant surface (e.g. metal plate) on the drumunder the melting plate.

6. Set pneumatic switch to Lower until the melting plate reaches the restingsurface.


8. Cut old sealing rings with a knife and dispose of properly.

CAUTION: Do not damage release coating.

9. Heat solid rubber or PTFE‐coated sealing rings in an oven.

10. Clean and lubricate grooves. Refer to Processing Materials in sectionTechnical Data for lubricant.

11. Put heated sealing rings into place on heated punch with two people.

180 ‐ 200 ° C(356 ‐ 392 °F)

Fig. 7‐1

Repair 7‐3


Replacing O‐ringsWhen leakage occurs, e.g. at the hose connections, the O‐rings must bereplaced. Observe the following:

� Clean and lubricate O‐ring groove. Nordson recommendshigh‐temperature grease; refer to Processing Materials in sectionTechnical Data.

� Also lubricate O‐ring.

� Do not use removed O‐rings again.

� Tighten hose connections and blind covers with a torque wrench to 9.5 Nm.

Repair7‐4


Replacing Melting Plate Temperature Sensor andThermostat

WARNING: Hot! Risk of burns. Wear heat‐protective gloves.

1. Heat heating punch to operating temperature.

2. Aerate drum.

3. Set pneumatic switch to Raise until the heating punch exits the drum.


5. Place a clean, hard, heat‐resistant surface (e.g. metal plate) on the drumunder the melting plate.

6. Set pneumatic switch to Lower until the melting plate reaches the restingsurface.


WARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

8. Disconnect the system from the line voltage.

9. Remove cover (1).

4

3 2

1

Fig. 7‐2

Repair 7‐5


NOTE: If the temperature sensor is defective: Continue with Step 16.

10. Remove thermostat (2) along with fastening screws and spring washers.

11. Extract connecting cable from porcelain terminals.

12. Apply heat transfer compound to contact surfaces of the new thermostat(Refer to Processing Materials in section Technical Data), then install thethermostat with spring washers and screws.

13. Connect thermostat wires to porcelain terminals.

14. Screw on cover.

15. Start up system.

Replacing Temperature Sensor

First perform steps 1 to 9.

16. Release nipple (4) on temperature sensor (3), then remove temperaturesensor.

17. Apply heat transfer compound to the new temperature sensor, then pressit into the nipple. Then fasten the nipple.

18. Install cover (1) again.

19. Start up system.

Repair7‐6


Technical Data 8‐1


Section 8

Technical Data

General Data

Type of heating Cast‐in electrical resistance heating elements

Temperature sensor Ni 120

Degree of protection IP 54

Heatup time 30 to 60 minutes, depending on system, materialused and ambient temperature

Noise emission < 72 dBA

Electrical SpecificationsWARNING: Operate only at the operating voltage shown on the ID plate.

Operating voltage Refer to ID plate

Operating voltage frequency 50/60 Hz

Fuse rating Refer to ID plate

Power consumption P Refer to ID plate

Power consumption Pmax Refer to ID plate

Load per hose receptacle (2 channels) Max. 1�800 Watt

Max. pilot voltage (input voltage) 160 VDC

The pilot voltage may not exceed 160 VDC. Failureto observe will result in damage to succeedingcomponents.

or 0 ‐ 10 V

The pilot voltage must be adjusted (Refer to manualControl System).

Technical Data8‐2


Motors / Speeds

Motor Motor / gear pump speed setting range

3‐phase AC motor with helical gear 1 to 100 min‐1

To prevent excessive wear, the motor/pump speedshould not continuously fall below 5 min‐1 (rpm) orcontinuously exceed 80 min‐1 (rpm).

Temperatures and Thermostats

Temperatures System / components °C °F

Min. ambient temperature - 10 50

Max. ambient temperature - 40 104

Min. operating temperature - 50 122

Adjustable operating temperatures

CAUTION: When setting thetemperature, the temperatureprescribed by the hot melt adhesivemanufacturer is decisive. Themaximum operating temperature for theproduct and heated componentsdescribed here may not be exceeded.

Depending on the heating channel max. . . . 230 446

Overtemperature shutdown bythermostat

Permissible thermostats

230 °C 450 °F

177 °C 350 °F

150 °C 300 °F

Replacing thermostat: refer to Repair

Air Consumption

Per cycle (melting plate down and up) Approx. 600 l

Exhaust Hood

Nominal air quantity (recommendation) 510 m3/h

Pressure loss at nominal air quantity Approx. 180 Pa

Connecting sleeve ∅ 150 mm

Technical Data 8‐3


Material Pressures

Motor/pump model (standard) bar MPa psi

Three‐phase AC motor with gear pump 5 to 100 0.5 to 10 72.5 to 1�450

Note: Safety valve setting is decisive for maximumoutlet pressure. Factory setting:

35 3.5 507.5

Dimensions

System Drum diameter Min. drum height* Max. drum height*

BM 200 571 mm 830 930

* The switch rod must be adapted to the max. drum height (Refer to section Operation)

B 800

1730

2720

953*

1270

*

Fig. 8‐1

Note: Dimensions with an asterisk (*) apply to models with an exhaust hood.

Technical Data8‐4


Weight

System Weight

BM 200 Approx. 730 kg

Processing MaterialsBefore using, read the included EU safety data sheet.

Lubricating Heating Punch Sealing Rings

Lubricant Centoplex H0

Chemical characterization Mineraloil, lithium soap

Manufacturer Klüber Lubrication, D‐81379 München

Nordson order number P/N 285600

Inserting Thermostats and Temperature Sensors

Type Heat transfer compound

Nordson order number P/N 257326

Lubricating O‐rings

High temperature grease Caution: Do not mix thislubricant with other lubricants!Tube 250 g P/N 783959

Cartridge 400 g P/N 402238

Screw Locking Device

Screw locking device Warning: Observemanufacturer's safetyinstructions

Thread seal Loctite 241,50 ml bottle

P/N 789772

Activator Loctite 7471,500 ml bottle

P/N 219186

bulk melters bm 200 - industrial-stores.com 200 with gear pump - manual.pdf · sure brand, suremix,...

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