hot melt applicators eb 60 flex -...

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

Hot Melt Applicators

EB 60 Flex

Manual P/N 7179567_04- English -

Edition 05/15

P/N 7179567_04 � 2015 Nordson CorporationEB60FLEX

Note

This document applies to products with the following P/Ns:

7133354

7133515

7150056

7150086

7133540

7133541

This equipment is regulated by the EuropeanUnion under WEEE Directive 2002/96/EC.

See www.nordson.com for information abouthow to properly dispose of this equipment.www.nordson.com

Order numberP/N = Order number for Nordson articles

NoteThis is a Nordson corporation publication which is protected by copyright. Copyright � 2013.

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.

� 2015 All rights reserved.- Original of Original Manual -

TrademarksAccuJet, AeroCharge, Allegro, Apogee, AquaGuard, Artiste, Asymtek, Automove, Autotech, Baitgun, Blue Box, BM-32, BM-58, BM-63, Bowtie, Build‐A‐Part,CanWorks, Century, CF, CleanSleeve, CleanSpray, Color‐on‐Demand, ColorMax, Contour, Control Coat, Coolwave, Cross‐Cut, CrystallCut, cScan+, Dage,Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber, DuraPail, Dura‐Screen, Durasystem, Easy Coat, Easymelt, Easymove Plus, Ecodry, Econo‐Coat,e.dot, EFD, Eliminator, Emerald, Encore, Equatherm, ESP, e-stylized, ETI‐stylized, Excel 2000, Fibrijet, Fillmaster, FlexiCoat, Flexi‐Spray, Flex‐O‐Coat, FlowSentry, Fluidmove, FoamMelt, FoamMelt - stylized, FoamMix, F.R. Gross, Freedom, Fulfill, GreenUV, HDLV, Heli‐flow, Helix, Horizon, Hot Shot, iControl, iDry,iFlow, Isocoil, Isocore, Iso‐Flo, iTRAX, JR, KB30, Kinetix, KISS, Lean Cell, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, MicroCoat,MicroMark, Micromedics, Micro‐Meter, MicroSet, Microshot, Millenium, MiniBlue, Mini Squirt, Moist‐Cure, Mountaingate, MultiScan, NexJet, No‐Drip, Nordson,Nordson - stylized, Nordson and Arc, nXheat, OptiMix, Optimum, Package of Values, Paragon, PatternView, PermaFlo, PICO, PicoDot, Plasmod, PluraFoam,Poly-Check, Porous Coat, PowderGrid, Powderware, Precisecoat, PRIMARC, Printplus, Prism, ProBlue, Prodigy, Pro‐Flo, Program‐A‐Bead, Program‐A‐Shot,Program‐A‐Stream, Program‐A‐Swirl, ProLink, Pro‐Meter, Pro‐Stream, Pulsar, Quantum, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, SC5, S. designstylized, Seal Sentry, Sealant Equipment & Engineering, Inc., SEE and design, See‐Flow, Select Charge, Select Coat, Select Cure, Servo‐Flo, Shot‐A‐Matic,Signature, Signature - stylized, Slautterback, Smart‐Coat, Smart‐Gun, Solder Plus, Spectrum, Speed‐Coat, Spirex, Spraymelt, Spray Squirt, StediFlo,Stratablend, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure‐Max, SureWrap, TAH, Tela‐Therm, Tip‐Seal, Tracking Plus, TRAK, Trends, Tribomatic,Trilogy, TrueBlue, TrueCoat, Tubesetter, Ultra, UniScan, UpTime, U‐TAH, Value Plastics, Vantage, Veritec, VersaBlue, Versa‐Coat, VersaDrum, VersaPail,Versa‐Screen, Versa‐Spray, VP Quick Fit, VP Quick-Fit stylized, VP stylized, Walcom, Watermark, When you expect more., X‐Plane, Xaloy, Xaloy - stylized,YesTech are registered trademarks - ® - of Nordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AltaSlot, Alta Spray, AquaCure, ATS, Auto‐Flo, AutoScan, Axiom, BestChoice, BetterBook, Blue Series, Bravura, CanNeck, CanPro, Celero, Chameleon, Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat, Cobalt, Concert,ContourCoat, Controlled Fiberization, Control Weave, CPX, cSelect, Cyclo‐Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid, DuraCoat, e.dot+, E‐Nordson,Easy Clean, EasyOn, EasyPW, Eclipse, EdgeControl, Equalizer, EquiBead, Exchange Plus, FillEasy, Fill Sentry, FlexSeam, Flow Coat, Fluxplus, G‐Net, G‐Site,Genius, Get Green With Blue, Gluie, Ink‐Dot, IntelliJet, iON, Iso‐Flex, iTrend, KVLP, Lacquer Cure, Maxima, Mesa, MicroFin, MicroMax, Mikros, MiniEdge,Minimeter, MiniPUR, MonoCure, Multifil, MultiScan, Myritex, Nano, OmniScan, OptiStroke, Optix, Origin, Partnership+Plus, PatternJet, PatternPro, PCI,PharmaLok, Pinnacle, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PUReOne, PURJet, PurTech, Quad Cure, ReadyCoat, RediCoat, RollVIA, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, Spectronic, SpeedKing, SprayWorks, StediTherm, StrokeControl, Summit, Sure Brand, SureFoam, SureMix, SureSeal, Swirl Coat, Tempus, ThruWave, TinyCure, Trade Plus, Trio, TruFlow,Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Unity, UNITYMotion, Universal, ValueMate, Versa, VersaPUR, Viper, Vista, Web Cure, 2 Rings (design) aretrademarks - � - of the Nordson Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their ownpurposes, could lead to violation of the owners' right.

Table of Contents I

P/N 7179567_04� 2015 Nordson Corporation EB60FLEX

Table of Contents

Safety Instructions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Labels and Tags 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended System Environment 2. . . . . . . . . . . . . . . . . . . . .Unintended Use - Examples - 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

From Roll Application to Slot Nozzle 3. . . . . . . . . . . . . . . . . . . . . . . .Residual Risks 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Note on Manual 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Definition of Terms 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator ID Plate 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Box ID Plate 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of Components / Functioning 6. . . . . . . . . . . . . . . . . . . .

Adhesive Flow 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor-driven Application Width Adjustment 9. . . . . . . . . . . . . . . .

Nozzle Closure (Pneumatically Driven) 9. . . . . . . . . . . . . . . . .Application Width Adjustment with Handwheel 9. . . . . . . . . . . . .

Nozzle Closure (with Handle) 9. . . . . . . . . . . . . . . . . . . . . . . . .Heating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Module 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Box 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enable Solenoid Valve 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface Motor Enable / Operating Modes (XS2) 10. . . . . . . .Optional Field Bus Interface 10. . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Unit 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsII


Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transport 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Space Requirement 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhausting Adhesive Vapors 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Selecting Sliding Plate 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Applicator 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left model 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Right model 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attaching Applicator to Parent Machine 16. . . . . . . . . . . . . . . . . . .Settings for Edge Banding 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Settings for Soft Forming 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Laying Cable 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAN Bus: Securing Plug Connections 19. . . . . . . . . . . . . . . . . .Connecting the Solenoid Valve (Control Module) 19. . . . . . . . . . .Adjusting/Connecting Proximity Switches (Nozzle Closure) 19. .Connecting Heater 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Applicator, Control Box and Operating Unit 20. . . . .

Pneumatic Connections 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation with Nonlubricated Compressed Air 21. . . . . . . . . . . . .Conditioning Compressed Air 21. . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Compressed Air 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicators without Motor and without Handwheel 22. . . . . . . . . . . .Motor-drive Application Width Adjustment (Provided and Installed by Customer) 22. . . . . . . . . . . . . . . . . . . . .

Connecting Heated Hose 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Second Open-end Wrench 22. . . . . . . . . . . . . . . . . . . . . . . .Connecting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disconnecting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Adhesive Pressure 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .What the Customer's Programmer Must Know 24. . . . . . . . . . . . . . .Important Information for Initial Startup and when Replacing Parts 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe Before Beginning Production 24. . . . . . . . . . . . . . . . . . . . . .

Table of Contents III


Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polyurethane Application Materials (PUR) 25. . . . . . . . . . . . . . . . . . .Setting Temperatures 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Operating Temperature 26. . . . . . . . . . . . . . . . . . . . . . .PUR Adhesives 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Ready 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prerequisite for Application Width Adjustment with Handwheel 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prerequisites for Motor-driven Application Width Adjustment 26.

Calibrating "Application Width" Display (with Handwheel) 27. . . . . .Control Panel Description 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Elements of Control Panel Screens 29. . . . . . . . . . . . . . . . . . . . . . .Signal Beacon and Battery Symbol 29. . . . . . . . . . . . . . . . . . . .Navigation Keys 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Input Window 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Startup (with Control Panel) 30. . . . . . . . . . . . . . . . . . . . . . . . . .Setting Parameters 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering Safety Margin 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Information Line: Entering Text 30. . . . . . . . . . . . . . . . . . . . . . . .Limiting Application Width 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Control Options (with Field Bus Option) 32. . . . . . . . . .Setting Application Width (Handwheel) 33. . . . . . . . . . . . . . . . . . . . . .Setting Application Width (Control Panel) 34. . . . . . . . . . . . . . . . . . . .

Precision of Display 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Opening and Closing Nozzle (Width Adjustment) 34. . . . . . . . . . .

Using Arrow Keys 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .With the Number Field 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation Sequence when Width is Adjusted via the Number Field 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fine Adjustment 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saving/Loading Application Width 37. . . . . . . . . . . . . . . . . . . . . . . . . .

Saving 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Loading 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loading Saved Application Widths 38. . . . . . . . . . . . . . . . . . . . .Loading Special Application Widths 38. . . . . . . . . . . . . . . . . . . .

Enabling Solenoid Valve of Application Control Module 39. . . . . . . .Maximizing Application Slot (Greatest Application Width / Maintenance Position) 39. . . . . . . . . .Minimizing Application Slot (Smallest Application Width) 40. . . . . . .Closing Nozzle Closure with a Key on the Control Panel (Closing Applicator Completely) 40. . . . . . . . . . . . . . . . . . . . . . . . . . . .Software Configuration Code 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Resetting to Nordson Default 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Shutdown 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Maintenance 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Processing Materials 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regular Maintenance 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual Inspection for External Damage 44. . . . . . . . . . . . . . . . . . . . . .External Cleaning 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning Control Panel 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing Type of Material 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging with Adhesive 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Purging 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging with Cleaning Agent 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspecting Control Module 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Control Module 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Control Module 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Control Module 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Nozzle 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Model with Motor 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Model with Handwheel 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing Complete Nozzle 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning Nozzle 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Spindle Nut 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Spindle Nut Pretension 53. . . . . . . . . . . . . . . . . . . . . . . . . . .

Increasing Spindle Nut Pretension 53. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Software Version 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Table 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alarms 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servomotor AG03 and Servomotor AG03/1 58. . . . . . . . . . . . . . . .Replacing Battery in AG03/1 59. . . . . . . . . . . . . . . . . . . . . . . . . .

Warning 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fault 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutdown 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Status LED on Motor 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Field Bus Gateway 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Supply (Control Box) 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overvoltage Protection 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reset 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Motor 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Observe when Assembling 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calibrating Slide Position 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Application Width Display 66. . . . . . . . . . . . . . . . . . . . . . . .

First Position Calibration 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Second Position Calibration 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAN Bus Terminating Resistor 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Comparison of Field Bus Gateways 69. . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Dial on Field Bus Gateway (Option) 70. . . . . . . . . . . . . . . .

Delivery State 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Customer's Interface 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Box, Internal Side 70. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Software Update 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Observe When Replacing Heater Cartridges or Temperature Sensor 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents V


Parts 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Use the Illustrated Parts List 72. . . . . . . . . . . . . . . . . . . . . . . .Recommended Spare Parts 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data Dependent on Application 73. . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Flow Diagram (Applicator) 74. . . . . . . . . . . . . . . . . . . . . . .Dimensions 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With Handwheel 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .With Motor 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Box and Operating Device 77. . . . . . . . . . . . . . . . . . . . . . . . . .XION Gateway Board (in the Control Box) 77. . . . . . . . . . . . . . . . .

Replacing Slide‐in Chassis 78. . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Base Module 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Recommendation 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .System Plans and Accessories 79. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Settings Record 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Record 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Password 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsVI


1


Safety InstructionsATTENTION: Observe and follow all safety instructions, the general safetyinstructions included as a separate document, as well as the specific safetyinstructions in all other related documentation.

Safety Labels and TagsFigure 1 shows the places on the applicator where safety signs and labelsare affixed. Table 1 indicates what the labels and symbols mean.

1

3

4

2(2x)

Fig. 1

Tab. 1 Safety Labels and Tags

Position P/N Description

1 290082 CAUTION: Hot surface. Failure to observe can cause burns.

2 290083 ATTENTION: Risk of electrical shock. Failure to observe mayresult in personal injury, death, or equipment damage.

3

4

455754

7133387

CAUTION: Risk of squash. Failure to observe may result in handinjuries.

2


Introduction

Intended UseApplicators in the series EB 60 Flex are intended to be used for EdgeBanding as well as for Soft Forming of severely contoured boards, e.g.S-profiles. They can also be used for filter gluing.

Polyolefines, EVA (ethylene vinyl acetate) and PUR (polyurethane) hot meltadhesives can be processed.

Any other use is considered to be unintended. Nordson will not be liable forpersonal injury and/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.

Recommended System Environment

The applicator works in an application system, in combination with one of thethe following melters:

� System with a bulk melter VP020 or VD200 and an applicator

� System with a melter VersaPUR, VA025 or PURBlue 4 and an applicator

A control box and a control unit are used for motor-driven application widthadjustment. These components can be purchased from Nordson.

Unintended Use - Examples -

The applicator may not be used under the following conditions:

� When changes or modifications have been made by the customer

� In defective condition

� In a potentially explosive atmosphere

� In the food industry

� In any installation position other than that described in this manual.

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

3


Unintended Use - Examples - (contd.)

The applicator may not be used to apply the following materials:

� Explosive and flammable materials

� Erosive and corrosive materials

� Unsuitable adhesives (Refer to From Roll Application to Slot Nozzle)

� Food products.

From Roll Application to Slot NozzleIf production has recently been converted from roll application to slot nozzleapplication, keep in mind that some adhesives that work well with rollapplication may cause problems with slot nozzle application.

One possible complication is that the substrate may not be evenly andproperly coated. When appropriate, consult the adhesive manufacturer.

Residual RisksIn the design of the unit, every measure was taken to protect personnel frompotential danger. However, some residual risks cannot be avoided:

� Risk of burns! The applicator is hot.

� Risk of burns! The material that comes out of the nozzle is hot.

� Risk of burns when connecting and disconnecting heated hoses.

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

� Material fumes can be hazardous. Avoid inhalation.

When the prescribed limits are exceeded, install an exhaust system.Always comply with the processing instructions in the respectiveadhesive data sheets.

� Risk of pinching near swiveling and clamping device and near thepneumatic cylinder.

4


Note on ManualApplicator is also referred to as Application head in older Nordson literature.

In some places Material is used as a general term to designate adhesivesand similar hot melt substances.

Melter is the general term used in this manual for all units that supplyadhesive to the applicator.

Symbol for delivery state

If you have this manual as a .pdf file, you can use the blue links - e.g. Refer topage 65, Calibrating Slide Position to navigate quickly through the file.

Definition of Terms

EB: Edge BandingSF: Soft Forming

Right model means that the right edge - viewed in the direction in which theboard runs through the system - of the board is coated.

SF ‐ Right model means that the left side - viewed in the direction in whichthe product (particle board) runs through the system - of the band is coated(Fig. 2).

Particle board, or: board

Fig. 2 SF - right model

5


Applicator ID Plate

1st. line Applicator designation

2nd. line Serial number

3rd. line Order number and year of construction

4th. line Operating voltage, applicator power consumption, operatingvoltage frequency

Control Box ID Plate

Electrical connectionOperating voltage

Rated currentOperating voltage frequency

Order number

Control box designation

Year of construction

6


Description of Components / Functioning

1

2

3

4

5

6

7

8

9

11 1012

13

14

16

15

17

18

20

9

EB

SF

21

22

19

Fig. 3 Example of Edge Banding with application width adjusted with a handwheel - left model

1 Power cable (heater)

2 Handwheel Application width

3 Handle Nozzle closure

4 (Movable) nozzle closure

5 Nozzle slot

6 Sliding plate

7 Stand

8 Fine height adjuster withcompression spring

9 EB: Swivel limiter

10 Adjusting screws

11 Fixing screws

12 Hose connection

13 Screw plug

14 Solenoid valve

15 Control module

16 Clamping device with clampinglever

17 Swivel holder

18 Clamp limit stop with screw

19 Stop Nozzle closure

20 Tension spring (2x)

21 Swivel holder screw (2x)

22 Display Application width

7


Right model

Left model

1

2

3

4

5

6

7 8

9

11 10

12

13

14

16

15

17

18

20

19

21 22

Fig. 4 Example of Edge Banding with motor-driven application width adjustment


2 Motor Application widthadjustment

3 Pneumatic cylinderNozzleclosure


5 Nozzle slot

6 Sliding plate

7 Stand

8 Fine height adjustment

9 Swivel limiter

10 Adjusting screws

11 Fixing screws

12 Hose connection

13 Screw plug

14 Solenoid valve

15 Control module


17 Swivel holder


19 Compression spring

20 Tension spring (2x)


22 Pneumatic valve Nozzle closure

8


Description of Components / Functioning (contd.)

1

2

3

4

5

6

7

8

9

11 10

12

13

14

16

15

17

18

20

19

21

22

Fig. 5 Example of Soft Forming with motor-driven application width adjustment


2 Motor Application widthadjustment

3 Pneumatic cylinderNozzleclosure


5 Nozzle slot

6 Sliding plate

7 Stand

8 Fine height adjustment

9 Gap limiter

10 Adjusting screws

11 Fixing screws

12 Hose connection

13 Screw plug

14 Solenoid valve

15 Control module


17 Swivel holder


19 Compression spring

20 Pneumatic cylinder


22 Pneumatic valve Nozzle closure

Volume Control(patented)

1

Nozzle

2

9


Adhesive FlowThe adhesive flows from a melter through a heated hose to the applicator.The adhesive supply to the nozzle is switched on and off with anelectro-pneumatic control module.

The volume is equalized inside of the applicator, so when the applicationwidth is decreased no adhesive escapes from the nozzle and when it isincreased no air is sucked into the nozzle. So material is applied preciselybeginning with the first product.

Motor-driven Application Width Adjustment

The motor turns the spindle (1) that moves the mouthpiece (2) up and down.

The application width can be continuously adjusted between 5 mm and themaximum application width (indicated on the ID plate). The currentapplication width can be seen on the control panel at any time. The nozzleslot width can be 0.5 or 1 mm.

NOTE: For extended standstill, the nozzle can be closed with the pneumaticcylinder by touching a key on the control panel (Nozzle closure).

Nozzle Closure (Pneumatically Driven)

The pneumatic cylinder automatically closes the nozzle slot during widthadjustment (but not during fine adjustment). No adhesive flows out. And noair penetrates the nozzle, making purging unnecessary after adjustment. Somaterial is applied precisely beginning with the first product.

Application Width Adjustment with Handwheel

CAUTION: Use the handwheel only when the system is heated!

The handwheel turns the spindle (1) that moves the mouthpiece (2) up anddown.

The application width can be continuously adjusted between 5 mm and themaximum application width (indicated on the ID plate). A digital positionindicator [mm] shows the application width. The nozzle slot width can be 0.5or 1 mm.

CAUTION: Attempting to close the nozzle farther than the minimumapplication width of 5 mm will damage the applicator.

The nozzle can be closed by hand with the nozzle closure for extendedstandstill.

Nozzle Closure (with Handle)

Analogous to Nozzle Closure (Pneumatically Driven).

1

10


HeatingElectrical heater cartridges are used to heat the melter. The temperature iscontinuously measured by a temperature sensor and regulated by anelectronic temperature controller, usually located in the electrical cabinet ofthe melter.

Control Module

The electro-pneumatic control module opens and closes the adhesive supplyto the nozzle by raising or lowering the nozzle stem. A compression springensures that the control module outlet is closed when control air pressuredrops, preventing adhesive from being applied.

Control Box

The control box provides the voltage supply to the applicator motor andsolenoid valve, and it serves as the connection to the operating unit. Alsorefer to control box wiring diagram.

Enable Solenoid Valve

The customer's control system must supply the signal Enable solenoid valvefor the application control module as soon as production begins.

Interface Motor Enable / Operating Modes (XS2)

The melter supplies the signal Enable motor when all of the applicatorheating zones have reached their setpoint temperatures.

The width can be adjusted only when the signal is received by the control box(contact closed). This prevents damage to seals from adhesive that is still toocold.

Optional Field Bus Interface

The field bus interface is used to exchange data between the applicator andthe customer's control system. Refer to separate manual Field Bus onNordson Applicators, Rev. _06 and higher.

Enable solenoid valve: In addition to the signal from the customer's controlsystem, bit 2 of Control also has to be set on the field bus.

Enable motor: In addition to the signal from the melter, bit 1 of Control alsohas to be set on the field bus.

Operating Unit

The operating unit contains an industrial PC (IPC) to control the applicator.

The applicator is essentially operated via the control panel (1) on theoperating unit. The control panel is a touch screen.

11


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

UnpackingUnpack carefully. Then check for damage caused during transport. Reusepackaging materials or dispose of properly according to local regulations.

Transport

The applicator is a high precision, valuable part. Handle very carefully!Protect the nozzle from damage.

StorageDo not store outside! Protect from humidity and dust. Do not lay unit on thenozzle. Protect the nozzle from damage, e.g. by placing it in the originalpackaging.

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

ATTENTION: Risk of explosion from incorrect disposal. The operating unitcontains a lithium battery that is soldered into place.

12


Space RequirementBecause of the restricted space, the applicator should be removed formaintenance and repair.

For operation, leave sufficient clearance around the applicator toaccommodate

� Electrical/pneumatic connections

� Heated hose

� Height adjustment / angle of Incidence

ÏÏÏ

55*

60 m

m77

0 mm

145With motor: 280

With handwheel: 265

With

han

dw

heel

: 385

With

mot

or: 3

70

Fig. 6 * Nozzle motion

13


Exhausting Adhesive VaporsEnsure that adhesive vapors do not exceed the prescribed limits. Exhaustmaterial vapors if necessary. Ensure sufficient ventilation of the installationlocation.

Selecting Sliding PlateThe applicator is supplied with three sliding plates (0.1 / 0.2 / 0.3 mm). Thethickness of the plate should be more or less that of the desired applicationthickness.

If during application it becomes apparent that the film is not continuous, athinner sliding plate should be used. If beads of adhesive form, choose athicker sliding plate.

Installing� Protect from humidity, vibrations, dust and drafts

� Ensure access to parts relevant for maintenance and operation

� To achieve optimum adhesive application, install the applicator such thatthe distance and, when appropriate, the angle between the nozzle andthe substrate can be varied.

� When installing ensure that cables, air hoses and heated hoses cannotbe bent, pinched, torn off or otherwise damaged.

� Installation position of EB and SF: Nozzle vertical (Fig. 7)Installation position of filter gluing: Nozzle horizontal

Fig. 7 Left EB - right SF (prototypes)

14


Swivel in with springs

Swiveling center and max. swiveling angle (approx. 9°)

Plate

0,5 (1) mmNozzle slot

Product operating direction

approx. 30°

Fig. 8 Edge Banding design

Swivel in withpneumatic cylinder

Swiveling center and max. swiveling angle (approx. 9°)

Edge band 0,5 (1) mmNozzle slot


Pneumatic connection

Fig. 9 Soft Forming design

15


Positioning the Applicator

Left model

Product operatingdirection

ÂÂÂÂÂÂÂÂÂÂÂÂ

ÏÏÇÇÇÇÇÇÏÏ

approx. 30°


60*

Nozzle slot

ÏÏÇÇ

Ï

77

Fig. 10 *maximum application width

Right model

Product operatingdirection

ÏÏÏÏÇÇÇÇ

ÇÇÇÇÇÇÏ

approx. 30°

Product operating direction Nozzle slot

ÂÂÂÂÂÂÂÂÂÂÂÂ

Fig. 11

3 x 120°

46

16


Attaching Applicator to Parent Machine

1. Make three threaded bores M8 in a suitable place on the parent machine.

2. Use the adjustment screws to align the stand such that it is parallel to thesubstrate, then screw on.

Fig. 12 Thread bore holes

1 - 2 mm

44.5 mm

Fig. 13 Distance "End of body to board" (right)

17


Settings for Edge Banding

CAUTION: Risk of squash!

� Be aware of the spring restoring force between the swivel holder and theclamping device.

� Support the applicator when releasing the clamp lever and the clamp limitstop.

ÏÇÇÇÇÇÏÏ

1

23

4

Swiveling center

approx. 9°

Fig. 14 Edge Banding

1. Slightly loosen the hexagonal screw (1, Fig. 14 and 21, Fig. 4) at the topand bottom of the swivel holder (17, Fig. 4).

2. Release the clamp lever (3) and hexagonal screw on the clamp limit stop(18, Fig. 4).

3. Turn and slide the applicator on the stand such that the nozzle moves toa suitable position in relation to the substrate. Refer to Fig. 13.

4. Tighten the clamp lever and the hexagonal screw on the clamp limit stop.

5. Tighten both hexagonal screws (1).

6. Make fine adjustments to the height with the snap‐in screw (2) ifnecessary.

7. To prevent the approaching board from causing damage, use a limiter (4)to minimize excessive swiveling out of the applicator.

NOTE: A gap need not be set as for SF, because the gap is determined by the thickness ofthe sliding plate.

18


Settings for Soft Forming

CAUTION: Risk of squash! Support the applicator when releasing the clamplever and the clamp limit stop.

3

4

ÏÏÏÏÏ

ÏÏÏÏ

1Swiveling center

2

approx. 9°

A

Fig. 15 Soft Forming

1. Slightly loosen the hexagonal screw (1, Fig. 15 and 21, Fig. 4) at the topand bottom of the swivel holder (17, Fig. 4).

2. Release the clamp lever (3) and hexagonal screw on the clamp limit stop(18, Fig. 4).

3. Turn and slide the applicator on the stand such that the nozzle moves toa suitable position in relation to the substrate. The edge band must runparallel to the surface A (Fig. 4).

4. Tighten the clamp lever and the hexagonal screw on the clamp limit stop.

5. Tighten both hexagonal screws (1).

6. Make fine adjustments to the height with the snap‐in screw (2) ifnecessary.

7. Set the gap between the surface nozzle and the edge band with thelimiter (4) such that the gap corresponds to the desired applicationthickness.

0.6 Nm(5.3 lbin)

1

1

19


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

Laying Cable

ATTENTION: Ensure that cables do not touch rotating and/or hotcomponents. Do not pinch cables and check regularly for damage. Replacedamaged cables immediately!

CAN Bus: Securing Plug Connections

Tighten the hexagonal head (1) with torque of 0.6 Nm. Nordson recommendsusing a torque wrench made by Murr Elektronik, Murr article number7000-99102-0000000.

Connecting the Solenoid Valve (Control Module)

Secure the plug connection with the screw (1, Fig. 16).

CAUTION: Operate the solenoid valves only with the voltage shown on theID plates.

The solenoid valve on the control module is triggered by a 24 VDC voltagesupply from the control box.

Set the signal Enable solenoid valve only when the applicator is heated tooperating temperature (Signal Enable motor received). Seals in the controlmodule could be damaged if the adhesive were too cold.

Fig. 16

Adjusting/Connecting Proximity Switches (Nozzle Closure)

Connect the proximity switches to the control unit of the parent machine.

The positions of the two proximity switches on the pneumatic cylinderdetermine how far in and out the cylinder moves and thus when the positionsNozzle closure open and Nozzle closure closed are reported.

The proximity switches are preset at the factory.

20


Connecting Heater

1. Plug the cordset into the heated hose receptacle.

2. Use safety clips - when available - to secure the plug connection.

Connecting Applicator, Control Box and Operating Unit

CAUTION: Do not mix up the CAN bus and voltage supply connection of themotor. Plugging the voltage supply into the CAN bus receptacle XS7 woulddestroy the motor.

Motor

CAN bus terminating resistor

Signal Enable motor / operating modes

Control boxOperating unit

Applicator

XS7

XS6XS8

XS6

XS7XS8

Motor

XS

20

XS

21

XS

22

XS

25

XS

19

Cable duct for optional field bus

Signal Enable solenoid valve (application control module)

Vol

tage

sup

ply

to m

otor

XL0 Plug-in socket 2 to 5

XSD

Solenoid valve(s) triggering)Nozzle closure triggeringOperating modes

Operating voltage1 x 230 VAC

CA

N b

us c

able

XS

2

Fig. 17

21


Pneumatic Connections

Operation with Nonlubricated Compressed Air

When an applicator is connected to a compressed air system in which thecompressed air has previously been lubricated, simply ceasing to lubricatethe air is not sufficient. The oil remaining in the compressed air supply willreach the solenoid valves and the control modules and wash out the originallubricant/oil from these parts, substantially decreasing the service life of theunits.

To operate with non-lubricated compressed air, ensure that:

� The system has been converted to absolutely non-lubricated operation

� No oil from a possibly defective compressor can penetrate thecompressed air supply.

NOTE: Nordson will assume no warranty or liability for damage caused byunpermitted, temporary lubrication.

Conditioning Compressed Air

The quality of the compressed air must be at least class 2 as stipulated byISO 8573-1. This means:

� Max. particle size 1 �m

� Max. particle density 1 mg/m3

� Max. pressure dewpoint -40 °C

� Max. oil concentration 0.1 mg/m3.

Connecting Compressed Air

The applicator may only be connected to pressure-controlled andconditioned compressed air.

1. Connect customer's air supply to the inlet of an air conditioning unit.

2. Use a hose (D6/d4) to connect the control module to the air conditioningunit.

3. Set control air pressure:

4 to 6 bar 0.4 to 0.6 MPa 58 to 87 psi

4. Connect the pneumatic cylinder Nozzle closure and, when necessary,the additional cylinder for SF. Air pressure required:

6 to 10 bar 0.6 to 1.0 MPa 87 to 145 psi

22


Applicators without Motor and without Handwheel(for example: P/N 7133540, P/N 7133541)

Motor-drive Application Width Adjustment (Provided and Installed byCustomer)

CAUTION: Risk of injury from moving parts! Protect from direct contact.

Nordson recommends programming temperature enable for the motor sothat the application width cannot be adjusted until the applicator has reachedoperating temperature.

Observe the following when installing the drive:

� Maximum torque: 3.2 Nm

� Recommended maximum spindle speed*: 100 min-1

* Higher speeds increase wear to seals and bearing surfaces.

Connecting Heated Hose

Using Second Open-end Wrench

Use a second open-end wrench when connecting and disconnecting theheated hose. This prevents the hose connection on the unit from turning.

If cold adhesive can be found in the hose connection, these components (1,2) must be heated until the adhesive softens (approx. 70 °C/158 °F,depending on the adhesive).

CAUTION: Nordson melters are usually subjected to extensive testing priorto shipment. There may be some of the test material, similar to adhesive, leftin the hose connection.

Continued ...

1 32

23


Connecting

ATTENTION: Hot! Risk of burns. Wear heat-protective gloves.

1. First connect the hose (3) electrically.

2. Heat applicator and hose until the adhesive softens.

3. Screw on heated hose.

Disconnecting

ATTENTION: System and material pressurized. Before disconnecting,Relieve System of Adhesive Pressure. Failure to observe can result inserious burns.

Relieving Adhesive Pressure

ATTENTION: Hot! Risk of burns. Wear safety goggles and heat‐protectivegloves.

1. Set the motor speed of the unit feeding the adhesive to 0 min‐1 (rpm);switch off motor(s).

2. Place a suitable container under the nozzle of the applicator to collect theadhesive.

3. Activate the solenoid valve electrically or manually (arrow). Do not usesharp objects! Repeat this procedure until no more adhesive flows out.

4. Properly dispose of adhesive according to local regulations.

24


What the Customer's Programmer Must Know

When integrating the software into the production line:

� Do not open the nozzle closure until just before application

� EB: When the nozzle closure is closed, no board may be conveyed pastthe applicator; this would damage the applicator

� SF: Do not swivel in the applicator with the pneumatic cylinder until thenozzle closure is open

� Program enable for the control module solenoid valve.

NOTE: Enable must be deactivated in the control system until the nozzleclosure is completely opened (upper proximity switch). A nozzle closurethat is not completely opened will trigger the indication System not ready.

When the solenoid valve is activated, the control module opens (digitaloutput = 24 VDC). The control module cannot be opened duringcalibration (Refer to page 65, Calibrating Slide Position).

The applicator mode, warnings and indications are connected to theinterface XS2 to be evaluated by the customer.

Important Information for Initial Startup and whenReplacing Parts

If the applicator is ordered and delivered along with its control boxes, theslide position will have been calibrated by Nordson.

ATTENTION: When spare parts are ordered - either a motor (for widthadjustment) or the entire applicator - calibration must be performed on site,following the instructions on page 65, Calibrating Slide Positions. Thisensures that the control unit and applicator are attuned to one another.

Failure to observe can result in irreversible damage to the applicator.

Observe Before Beginning ProductionUnless agreed otherwise, the applicator was tested with a material similar toadhesive before it left the factory. Flush out the test material residue beforebeginning production.

With Handwheel

With Motor

25


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

Polyurethane Application Materials (PUR)

It is imperative that the following guidelines are followed when processingpolyurethane application materials (PUR):

� Wear respiratory protection when the maximum permissibleconcentration of hazardous substances is exceeded.

� Reduce the temperature during production interruptions or breaksthroughout the day. Close the nozzle closure.

� Opening and closing the nozzle is also a form of cleaning.

� When PUR adhesive is used, it must be prevented from reacting to thethermal load in the applicator. The applicator must be purged every daywhen work is completed. Set to the maximum width during purging. Rinseout cleaning agent just before beginning production again.

CAUTION: If adjustment is difficult, the piston may be blocked, e.g. bycharred adhesive. If this is the case, clean the nozzle.

CAUTION: The motor has a torque limit. Unintentional stopping duringwidth adjustment may indicate that the slide is blocked (e.g. by charredmaterial). To prevent damage, do not continue to attempt to adjust thewidth. Clean the nozzle instead.

� Before prolonged standstill of the application system, purge with asuitable cleaning agent. Use only a cleaning agent recommended by theadhesive manufacturer.

� Close open adhesive connections, e.g. hose connections, airtight.

26


Setting TemperaturesIf there are multiple applicator heating zones, set them all to the sametemperature.

The procedure for setting the temperatures is described in the temperaturecontroller manual and/or the melter manual. Temperature controllers are notpart of the applicator. They are usually located in the electrical cabinet of themelter.

Maximum Operating Temperature

The maximum operating temperature of the applicator is 200 °C (392 °F).

NOTE: The maximum operating temperature may not be exceeded.

The values stipulated by the adhesive manufacturer serve as the basis fortemperature selections.

Nordson will assume no warranty or liability for damage resulting fromincorrect temperature settings.

PUR Adhesives

CAUTION: Reduce temperature when production is to cease for longer than30 minutes.

System Ready

Prerequisite for Application Width Adjustment with Handwheel

� Setpoint temperature for applicator has been reached

� Nozzle closure is open

CAUTION: Attempting to close the nozzle farther than the minimumapplication width of 5 mm will damage the applicator.

Prerequisites for Motor-driven Application Width Adjustment

� Enable motor signal received (Setpoint temperature for applicator hasbeen reached)

� Calibrate slide position was completed (after replacing motor or updatingsoftware)

� The actual application width is within the permitted range

� Nozzle closure is open

� No fault has occurred.

1

32

Screen saver

27


Calibrating "Application Width" Display (withHandwheel)

Turn to the right to increase the number in the display and thus theapplication width.

ATTENTION: Hot! Risk of burns. Wear heat-protective gloves.

1. Heat the applicator.

2. Set any application width [mm] with the handwheel (1).

3. Measure the open slot width (= application width) to a precision of onedecimal place.

4. Release the setscrew (2).

5. Turn the set collar (3) until the display corresponds to the measuredvalue.

6. Tighten the setscrew again.

Control Panel Description

The screen saver is activated when the screen has not been touched for tenminutes.

To deactivate the screen saver:

1. Touch the screen and then touch the key that appears.

The starting screen appears.

2. Call up the control panel screens by touching the respective keys.

Continued ...

28


Control Panel Description (contd.)

Key Control panel screen

Starting screen

Set the application width.

Refer to page 34, Setting Application Width (Control Panel).

Open/close the nozzle closure.

NOTE: If the nozzle closure was closed with this key, it alsohas to be opened with this key before application widths canbe loaded or be selected via the number field.

Fine adjustment

The keys Application width are enlarged. This makes fineadjustment during operation easier, when the operator islooking at the substrate and not at the control panel.

Refer to page 36 Fine Adjustment.

Save / load application width

There are five memory locations available.

Special application widths can also be loaded/selected.

Refer to page 37, Saving/Loading Application Width.

V 1.30.020

Setup

Settings that need be made only rarely, e.g. upon initialstartup.

Refer to page 30, Initial Startup (with Control Panel).

NOTE: Some settings are protected with passwords. Referto page 83, Password.

When a field or key is touched, an input window opens in which to enter thepassword. If no key is touched for ten minutes after pressing apassword-protected feature, password protection is reactivated. Then thepassword prompt appears again for password-protected features.

5.0

60.0

29


Elements of Control Panel Screens

Signal Beacon and Battery Symbol

The signal beacon indicates the status of the applicator:

� Red = fault or shutdown

� Yellow = warning

� Green = ready for operation

If the battery symbol appears next to the signal beacon, the battery voltage ofthe motor's absolute encoder is low.

NOTE: The absolute encoder remembers the position even after switchingoff. The operating unit reads out the position and uses it to display theapplication width.In some situations, the position must be calibrated (Refer to page 65,Calibrating Slide Position).

Touch the signal beacon to display the control panel screen Alarms. Refer topage 58, Alarms.

Navigation Keys

BackTo the next-higher control panel screen

Cancel and close when in input windows

To the nextsubscreen

A control panel screen can have multiplesubscreens

Input Window

When a field for entering text or a numerical value is touched, an inputwindow appears when the field is touched.

CancelExit input window without implementingchanges

Backspace, delete To correct unintended input

Confirm Acceptance of a value

1

30


Initial Startup (with Control Panel)Switch on the control box for startup: I.

Setting Parameters

Upon initial startup, set the following parameters in the control panel screenSetup as required.

NOTE:

� Some parameters are protected with passwords. Refer to page 83,Password.

� Keys and fields in this control panel screen that are not relevant to initialstartup are explained in the appropriate part of this manual.

Entering Safety Margin

Setting range: 0 - 10 mm

When an application width is loaded (Refer to page 37, Saving/LoadingApplication Width), an application width is selected that is reduced by thissafety margin. This prevents material from being applied beyond the edge ofthe substrate.Thus the application width needs to subsequently be corrected with the

application width key or the Fine adjustment.

Information Line: Entering Text

The operator can enter any text that is to appear in the Information line. Theinformation line appears in most control panel screens:

10.0

55.0

ÏÏÏ

60

77

0

31


Limiting Application Width

10

55

Fig. 18

A limit can be set for the motor to prevent an application width from beingselected when the production system is not intended for this purpose. Theselimits are visible in the input window.

Example Fig. 18: Touch the following keys in the screen Load applicationwidth

Select the minimum application width: The applicator closes to

10 mm

Select the maximum application width: The applicator opens to

55 mm.

Notes

� The values refer to the closed nozzle (nozzle slot: 0 mm)

� Values beyond the range cannot be entered.

Fig. 19

Example: Control panel selected, Field bus selected

32


Selecting Control Options (with Field Bus Option)

10

55

Control option Function

Co

ntr

ol

pa

ne

l

The applicator can be controlled via the control panel

The applicator can not be controlled via the control panel. Exception:Fine adjustment. Refer to page 36 Fine Adjustment.

Values can be read.

When an attempt is made to control via thecontrol panel, a message appears:

Fie

ld b

us

The applicator can be controlled with field bus signals

The applicator can not be controlled with field bus signals.

Data from the applicator can be received

NOTE: It is not possible to deselect both control options. This is why onlyone of the selected control option keys is faded gray.

Control panel selected, Field bus deselected:

33


Setting Application Width (Handwheel)

CAUTION: To prevent damage to the applicator (e.g. to the seals), adjustthe application width only when the applicator is heated to operatingtemperature.

� Do not open the nozzle closure until just before application

� When the nozzle closure is closed, no board may be conveyed past theapplicator; this would damage the applicator.

NOTE: Application width adjustments up to 1 mm can be made duringoperation. But then the nozzle closure should not be closed; this wouldcause a passing board to damage the applicator.

� When the nozzle closure is closed, the control module solenoid valvemay not be activated.

When the solenoid valve is activated, the control module opens (digitaloutput = 24 VDC).

1. Close the nozzle closure.

2. Use the handwheel to adjust the application width.

NOTE: Turn to the right to increase the number in the display and thusthe application width.

The maximum application width can be continuously reduced to 5 mm.

If adjustment is difficult, the spindle may be blocked. If this is the case,extract and clean the nozzle.

3. Open the nozzle closure again.

34


Setting Application Width (Control Panel)

Precision of Display

The actual application widths may deviate slightly from the application widthsindicated on the control panel. Possible causes:

� Tolerances in mechanical components (e.g. manufacturing tolerances)

� Different heat expansion at different operating temperatures

Refer to page 66, Adjusting Application Width Display.

Opening and Closing Nozzle (Width Adjustment)

Open and closenozzle

Close/open nozzleclosure

Using Arrow Keys

Touch the keys .

� Adjustment occurs immediately and without the nozzle closure

� The speed of adjustment increases with the length of time that the key istouched.

Recommendation

Nordson recommends using the arrow keys only when the adjustment to theapplication width is no more than 1 mm. Small adjustments like this can bedone during operation without the applicator being damaged by a passingboard.

57.5

Input Window

35


With the Number Field

NOTE: Automatic nozzle closure when the width is adjusted via the numberfield.

Touch the number field.

� An input window opens. Enter a value (in mm, resolution 0.1 mm) andconfirm.

� Stop application width adjustment: Touch the Stop key to stopadjustment prematurely:

57.5

Operation Sequence when Width is Adjusted via theNumber Field

A. Only SF: The pneumatic cylinder swivels the applicator out.

B. The nozzle closure closes until the pneumatic cylinder reaches the lowerend position (lower proximity switch). Indicator beacon is yellow.

C. The motor is triggered until the width adjustment reaches the enteredvalue.

D. The nozzle closure opens until the pneumatic cylinder reaches the upperend position (upper proximity switch).

E. Only SF: The pneumatic cylinder does not swivel in the applicator untilthe nozzle closure is open.

F. Signal System ready received. Indicator beacon is green.

Also refer to 26, System Ready / Prerequisites for Motor-drivenApplication Width Adjustment.

Second key

36


Fine Adjustment

NOTE: No automatic nozzle closure with fine adjustment.

Nordson recommends using the arrow keys only when the adjustment to theapplication width is no more than 1 mm. Small adjustments like this can bedone during operation without the applicator being damaged by a passingboard.

The keys Application width are enlarged:

This makes fine adjustment during operation easier, when the operator islooking at the product and not at the control panel.

To return to the normal view:

1. Touch the key

2. Touch the second key , which then appears.

This prevents incorrect operation when the first key is touchedunintentionally.

Save mode

48.9

37


Saving/Loading Application WidthThere are five memory locations available. The label for each memorylocation depends on the saved application width and is enteredautomatically.

SavingTo save the current application width:

1. Touch the key to go to Save mode:

2. Touch the key for the desired memory location.The following confirmation prompt appears:

48.9 mm

48.9 mm

3. Save the current application width with or cancel with .

Loading

NOTE: After loading an application width, adjustment occurs automatically.

Stop application width adjustment: Touch the Stop key to stop adjustmentprematurely.

Load mode

38


Loading Saved Application Widths

1. Verify that the key is in Load mode, meaning that it is not pressed.

2. Touch the key for the desired memory location.The following confirmation prompt appears:

48.9 mm

48.9 mm

3. Load the application width with or cancel with .

NOTE: An application width is selected that is reduced by the safetymargin (Refer to page 30, Entering Safety Margin). So the applicationwidth should then be corrected with the Fine adjustment.

Loading Special Application Widths

1. Select the desired application width:

Maximum applicationwidth NOTE: The maximum and

minimum application widths can bespecified. Refer to page 31,Limiting Application Width.Minimum application

width

The following confirmation prompt appears:

2. Load the application width with or cancel with .

39


Enabling Solenoid Valve of Application Control Module

The status is indicated by these symbols:

� Gray control module: Solenoid valve not enabled

Wait until the parent machine is ready and the signal Enable solenoid valve hasbeen transmitted to the control box.

NOTE: The message Solenoid valves not enabled will also appear if the enablecable is missing.

� Green control module: Solenoid valve enabled

� Red control module: Solenoid valve control failed

Maximizing Application Slot (Greatest Application Width / Maintenance Position)

10

55

This key can open the applicator to the maximum application width, e.g. formaintenance and repair purposes.

The stated maximum value for motor 1 (55 mm in the illustration) is ignored.

40


Minimizing Application Slot (Smallest ApplicationWidth)

The nozzle can be reduced to 5 mm on all models.

Closing Nozzle Closure with a Key on the Control Panel(Closing Applicator Completely)

In addition to automatically closing the nozzle, there is a key with which theoperator can close the nozzle closure, e.g. during production stoppage.

Open

CAUTION: The applicator must be at operating temperature before thenozzle closure can be opened.

Touch the key a second time to open the nozzle closure.

41


Software Configuration Code

Symbol Restart

Software configuration code

Fig. 20

1. Touch the input field.

2. Confirm the warning.

CAUTION: Only change the software configuration code when theconfiguration has actually changed (e.g. due to retrofitting). Otherwise theapplicator may not function properly.

Nordson will inform of the new, changed software configuration code.

3. Enter the software configuration code. Then the operator will beprompted to restart.

4. Touch the Restart symbol to boot the operating unit.

Resetting to Nordson Default

Nordson default

Delivery state of parameters that can be reset to the default with

the key (Fig. 20).

Daily Shutdown1. Perform daily maintenance.

2. With motor-driven application width adjustment: Switch off the controlbox.

42


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

NOTE: Maintenance is an important preventive measure for maintainingoperating safety and extending the service life of the applicator. It shouldnever be neglected.

ATTENTION: System and material pressurized. Relieve the system ofadhesive pressure before disconnecting pressurized components (e.g.hoses, pressure sensors). Failure to observe can result in serious burns.

Refer to page 23, Relieving Adhesive Pressure in the section Installation.

With the Field Bus Option

CAUTION: Verify that the control option Field bus is deselected. Thisprevents unintentional adjustment of the mouthpiece. Refer to page 32,Selecting Control Options (with Field Bus Option).

Processing Materials

Designation Order number Use

High temperature grease Apply to O-rings and threads

NOTE: The grease should not be mixedwith other lubricants. Oily/greasy partsmust be cleaned before application.

� Can 10 g P/N 394769

� Tube 250 g P/N 783959

� Cartridge 400 g P/N 402238

Aluminum tape (50 mm)

Aluminum tape (80 mm)

Length 20 m

P/N 7053121

P/N 7053122

Applicators without nozzle closure: Totape the nozzle closed during productionbreaks when processing PUR

Loctite 620 50 ml P/N 219353 Refer to page 53

43


Regular Maintenance

Unit part Activity Interval Refer to

Entire applicator

Cordset

Air hoses

Visual inspection for externaldamage

Daily Page 44

Entire applicator External cleaning Daily Page 44

Purge with cleaning agent Daily when using PURadhesives

When adhesive is changed orbefore extended productionstandstill

Page 46

Control panel Clean When dirty Page 44

Control module Check detection hole forleakage

Daily Page 47

Replace When leakage or a functionalfault occurs

Page 47

Nozzle Extract and clean Every three months, or whenthe application patterndeteriorates

Purge with adhesive

(All adhesives except PUR. If PURadhesive is used, purge withcleaning agent daily. Refer to page46)

Daily Page 45

Replace When damaged Page 49 ff.

Spindle inlet in nozzle Inspect for leakage*) Monthly -

Spindle Increase pretension of spindlenuts with additional shim ringsor replace the spindle nuts andadjust the pretension

When noticeably slack Page 53or

Page 52and

Page 53

Sliding plate Replace When worn -

44


Visual Inspection for External Damage

CAUTION: When damaged parts pose a risk to the operational safety of theapplicator and/or safety of personnel, switch off the applicator or applicationsystem and have the damaged parts replaced by qualified personnel. Useonly original Nordson spare parts.

External CleaningExternal cleaning prevents impurities created during production from causingthe unit to malfunction.

CAUTION: Do not use hard tools to clean the coated nozzle. Do not usewire brushes! This could cause scratches that are detrimental to application.Nordson recommends using a wooden or plastic spatula.

Always follow the manufacturer's instructions when using cleaning agents!

1. Electrically heat the cold applicator until the material is liquid.

2. Thoroughly remove the warm material with a cleaning agent and/or a soft,lint-free cloth.

3. Remove dust, fluffs, etc. with a vacuum cleaner or a soft, lint-free cloth.

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

Cleaning Control Panel

CAUTION: De-energize the control box. This ensures that no functions areunintentionally triggered.

� Do not use any sharp objects (e.g. knife) to clean

� Do not use aggressive or abrasive cleaning agents or solvents

� Prevent liquids from penetrating the operating unit.

� Clean the control panel regularly with a soft, damp cloth. Use caution toensure that the surface is not scratched or scoured, particularly whenremoving hard residue and abrasive dust.

45


Changing Type of MaterialNOTE: Before changing the type of material, determine whether the old andnew material may be mixed.

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

� May not be mixed: Thoroughly purge the unit with a cleaning agentrecommended by the material supplier.

NOTE: Properly dispose of the material and cleaning agent according tolocal regulations.

Purging with AdhesiveNOTE: Daily with all adhesives except PUR. If PUR adhesive is used, purgewith cleaning agent daily.

Daily Purging

As the nozzle opens and closes, adhesive charring is prevented around thesurface nozzle, and the nozzle slot and spindle are cleaned.

1. With the pump switched off, go to the minimum application width (5 mm).

2. With the pump switched off, go to the maximum application width(maintenance position).

3. Purge at the maximum application width at high speed until the adhesiveflows out free of bubbles and clots. Switch the pump off again.

4. With the pump off, reduce to the production application width.

5. Externally clean the nozzle.

21

46


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

NOTE: When PUR adhesive is used, it must be prevented from reacting tothe thermal load in the applicator. The applicator must be purged every daywhen work is completed. Set to the maximum width during purging. Rinse outcleaning agent just before beginning production again.

1. Maintain operating temperature.

2. Relieve adhesive pressure.

3. Detach the heated hose from the applicator to prevent impurities from themelter and hose from being forced into the applicator during purging.

4. Purge melter and heated hose.

5. Screw the heated hose onto the applicator again and purge theapplicator:

As the nozzle opens and closes, adhesive charring is prevented aroundthe surface nozzle, and the nozzle slot and spindle are cleaned.

a. With the pump switched off, go to the minimum application width(5 mm).

b. With the pump switched off, go to the maximum application width(maintenance position).

c. Clean the screw (1) and spindle (2).

d. Purge at the maximum application width at high speed (withgrammage control: 50 % of Maximum pump speed threshold value)until the adhesive flows out free of bubbles and clots. Switch thepump off again.

Especially when PUR adhesive is used, do not proceed until right beforeproduction is to begin again.

6. With the pump off, reduce to the production application width.

7. Purge the system (melter, hose, applicator) with the material currently inuse to flush out the cleaning agent; continue until the adhesive flows outfree of bubbles and clots.

8. Switch off the pump and clean the outside of the nozzles.

NOTE: Properly dispose of the cleaning agent according to localregulations.

47


Inspecting Control Module

If material escapes from the detection hole (arrow), the internal O-rings haveworn and the control module must be replaced.

Replacing Control Module

ATTENTION: Hot! Risk of burns. Wear safety goggles and heat‐protectivegloves.

CAUTION: The control module is a high precision, valuable part. Handlevery carefully!

Removing Control Module


2. Release the air connection and electrical connection.

3. Release screws (M4).

4. Extract the control module from the warm applicator.

48


Installing Control Module

NOTE: Required tool: Torque wrench.

1. Apply high temperature grease (arrow, Figure 21):

� To the O‐rings

� To the screw threads

� Under the screw heads.

Fig. 21

2. Insert the new control module. Do not tilt!

3. Screw in the screws by hand.

4. Tighten the screws uniformly and crosswise.

5. Re-connect air and electrical connections.

NOTE: Observe the voltage stated on the ID plate of the solenoid valve.

49


Removing Nozzle

Model with Motor

1

2

3

4

5

5

7

Fig. 22


2. Release the set screw (1, Fig. 22) and slide the shaft up to expose theend of the spindle.

3. Release the hex bolt (2) to detach the nozzle closure (7).

4. In the first step, loosen all four screws (3) on the clamp only a fewrevolutions. They are secured to prevent them from falling out. Thenunscrew them completely.

5. Release the two fixing screws (4) and detach the assembly from theapplicator.

The mouthpiece receptacle (5) remains on the applicator.

If the whole nozzle is to be replaced, refer to Removing Complete Nozzle.

50


Model with Handwheel

5

6

7

11

22

3

4

8

Fig. 23


2. Release the setscrews (1, Fig. 23) on the handwheel and for the positionindicator and remove the parts. If this is done carefully, the display will notneed to be calibrated after re-assembly.

3. Release the setscrew (3) and the two screws (2). The bearing block canthen be detached along with the shaft.

4. In the first step, loosen all four screws (4) on the clamp only a fewrevolutions. They are secured to prevent them from falling out. Thenunscrew them completely.

5. Release the two fixing screws (8) and detach the assembly from theapplicator.

The mouthpiece receptacle (5) remains on the applicator.

If the whole nozzle is to be replaced, refer to Removing Complete Nozzle.

1

2

51


Removing Complete Nozzle

If the whole nozzle is to be removed, these additional tasks must beperformed.

1. Detach the mouthpiece receptacle (5, Fig. 22 and 23). It belongs to the(old) nozzle.

2. Remove the nozzle closure (7, Fig. 22 and 23) and, on the model withhandwheel, also remove the limit screw M4 (6, Fig. 23). They will be usedagain.

After installation

3. Adjust the nozzle closure plate (1, Fig. 24) in the slots and with thesetscrews (2, Fig. 24) such that the plate rests against the nozzle slot butcan still be moved.

4. Model with handwheel: Calibrate the display. Refer to Calibrating"Application Width" Display (with Handwheel).

Fig. 24

Cleaning Nozzle

� Wipe off the adhesive with a soft, lint-free cloth

� Heat adhesive residue with a hot air fan

� Clean the spindle thread with a brass brush.

52


Replacing Spindle Nut

Spindle nut

4

1

3

2

Anti‐twist device

SW 15

1

1

Fig. 25 SW: Wrench width

1. Remove the nozzle.

A tool can be inserted into the 6 mm hole (arrow) to unscrew the spindle.

2. Unscrew the spindle (4) far enough that the screw (1) can be extracted.

3. Extract the screw (1).

4. Pull out the spindle nut along with the spindle.

5. Insert a new spindle nut and use the cylinder pin to prevent it fromturning.

Adjust the pretension as described in the section Adjusting Spindle NutPretension (page 53).

53


Adjusting Spindle Nut PretensionCorrect pretension ensures hydraulic sealing on the spindle, similar to agland. It has to be adjusted when the spindle nut is replaced.

ÏÏÇÇ

ÏÏÏÇÇ

Loctite 620

0,4

mm

Spindle nut

1

1

2

4

3

Fig. 261. Remove the nozzle.

A tool can be inserted into the 6 mm hole (arrow) to unscrew the spindle.

2. Unscrew the spindle (4) far enough that the screw (1) can be extracted.


4. Unscrew the spindle all the way.

Adjust pretension

5. Set the gap to 0.4 mm by inserting 0.1 mm shim rings (2). Always tightenthe screw (1) only hand-tight.

6. When the gap size has been achieved, extract the screw again and applyLoctite 620 to the screw thread.

CAUTION: Tighten the screw all the way only when the mouthpiece (3) is onthe spindle (4).

7. Screw the spindle back in again and tighten the screw (1) all the way.

Increasing Spindle Nut Pretension

If there is leakage or the spindle is slack, the pretension can be increasedwith additional shim rings (2, Fig. 26).

54


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

IntroductionTroubleshooting tables are intended as an orientation for qualified personnel.They cannot, however, replace targeted troubleshooting with the aid of wiringdiagrams and measuring instruments. They also do not include all possibleproblems, only those which most typically occur.

The following problems are not included in the troubleshooting tables:

� Faults in installation

� Faults in operation

� Defective cables

� Loose plug and screw connections.

Software VersionThe software version may be relevant for troubleshooting or when calling theNordson hotline. It is displayed on the control panel screen Setup.

V 1.30.020

Fig. 27 Example

55


Troubleshooting Table

Problem Possible cause Corrective action Refer to

No material Melter tank is empty Fill

Separate manualMelter

Melter motor is not switchedon

Switch on

Melter pump is not working Check

Applicator has not yetreached operatingtemperature

Wait until temperature hasbeen reached; checktemperature setting ifnecessary

Applicator cold or not yetwarm enough

Refer to Applicator does notheat

- -

Compressed air notconnected

Connect Page 21

Nozzle clogged Clean nozzle Page 51

Nozzle stem is stuck Replace control module Page 47

Solenoid valve does notswitch

Control unit not switched on - -

If the plug is not connectedor is loose, secure theconnection with a screw

Page 19

Nozzle closure closed Control fault?

Proximity switch defective?

- -

Applicator doesnot heat

Temperature is not set Set on the melter controlpanel

Separate manualMelter

Plug not connected Connect Page 20

Fuses in melter defective Disconnect melter from linevoltage, check fuses andreplace if necessary

- -

Heater cartridge(s) inapplicator defective

Replace - -

Applicator doesnot reach the settemperature

Heater cartridge(s) inapplicator defective

Replace - -

Ambient temperature toolow

Increase ambienttemperature

- -

Continued...

56



Applicationpattern not exact

Production parameters notattuned to one another

Check/correct systemtemperatures and adhesivequantity/pressure

- -

Applicator does not haveeven contact with thesubstrate

Check height and angle ofincidence, adjust ifnecessary

Fig. 13 to Fig. 15

EB: Sliding plate worn

SF: Gap set incorrectly

Replace sliding plate

Set with limiter (Fig. 15)

- -

Control unit notprogrammed correctly

Correct programming - -

Nozzle partially blocked ordamaged

Extract and clean nozzle Page 51

Pollution inside of nozzle Clean Page 51

Nozzle damaged Replace nozzle - -

Application quantity andsubstrate processing speednot attuned to one another

Check settings; change soas to be attuned to oneanother if necessary

- -

Unsuitable adhesive, e.g.after switching from rollapplication to slot nozzle

Ask manufacturer Data sheet of materialmanufacturer

Poor cut-off Adhesive is offgassed dueto extended standstill

Purge system - -

Air has penetrated theapplicator because thesystem was cooled off

Pause time toolong

Muffler in control moduleclogged

Replace muffler - -

The open time* istoo long

* The open time is the time from

when the adhesive leaves the

nozzle until it hardens on the

substrate.

Application temperature toohigh

Set temperature lower Separate manualMelter

Adhesive unsuitable Ask manufacturer Data sheet of materialmanufacturer

The open time* istoo short

Application temperature toolow

Set temperature higher Separate manualMelter

Adhesive unsuitable Ask manufacturer Data sheet of materialmanufacturer

Continued...

57



Edge band stuck - Check edge band guidanceand applicator position

- -

Edge band is notcleanly coated

Gap (space betweensurface nozzle and band)set incorrectly

Set with limiter Fig. 15

The curvature of the edgeband is too great (with edgebands thicker than 0.5 mm)

Place a flattening devicebefore application

- -

The edge bandcross-section is concave orconvex

Soft Forming not possible;switch to Edge Banding

- -

Temperature is setincorrectly

Correct temperature Data sheet of materialmanufacturer

Unsuitable adhesive, e.g.after switching from rollapplication to slot nozzleand/or web speed too high

Ask manufacturer - -

Distance betweencoating and upperor lower edgeincorrect

Lower: Height is not set toproduction reference point

Adjust applicator Fig. 13 to Fig. 15

Upper: Distance setincorrectly

Nozzle slot nolonger properlysealed

Setscrews are loose Increase preliminary tensionby carefully tighteningsetscrews

CAUTION: Do notovertighten; this would blockthe pump cylinder.

58


AlarmsTouch the signal beacon to display the control panel screen Alarms.

Fig. 28 Alarms screen: no warning, no fault

If a motor is affected, it is shown in color: yellow for Warning, red forFault / shutdown. The alarm is explained with a symbol. Example:

Affected motor

Explanatory symbol

Fig. 29 Fault Motor 1 is blocked

Servomotor AG03 and Servomotor AG03/1

The model AG03 is not longer available. It has been replaced with theAG03/1:

Round cover (DIPswitch)

Square cover (DIP switchand battery)

AG03 AG03/1

59


Replacing Battery in AG03/1

1. When the battery is replaced with the voltage supply connected, theposition has to be re-calibrated upon completion. But then verify that thecontrol option Field bus is deselected. This prevents unintentionaladjustment of the nozzle mouthpiece.

2. Release the screws in the cover but do not remove them.

3. Carefully remove the cover with the four screws such that the opticalfibers do not break and the four rings in the body do not fall out.

4. Risk of short-circuit when tools are conducting. For this reason, extractthe battery with your fingers.

5. Snap the new battery (CR2477N; 3 V lithium; 950 mAh) into the bracket.

6. Verify that the O-ring is completely submerged in the groove and then putthe cover back into place. Tighten the screws uniformly until the lid liesflat.

7. If the voltage supply was not connected when the battery was replaced,proceed as described under Calibrating Slide Position (page 65).

WarningThe ready state yes/no remains the same.

Symbol Possible cause Corrective action

The battery voltage of the motor'sabsolute encoder is low

AG03/1: The battery lasts about fiveyears and can be replaced by thecustomer. Refer to Replacing Batteryin AG03/1

AG03: The customer cannot replacethe battery. The battery lasts approx.10 years. Replace the motor as soonas possible (within six months). Referto page 64 Replacing Motor

Signal Enable motor not received Wait until the setpoint temperaturehas been reached (the melter doesnot transmit the Enable motor signaluntil then).

Check wiring

A position was selected that isoutside of the application width limit.

Refer to page 31, LimitingApplication Width

Upon completion of the task, return tothe permitted application width

Nozzle closure not open (upperproximity switch)

Wait until the nozzle closure is open.

Open the nozzle closure with the keyNozzle closure when the nozzle wasclosed using this key

60


FaultThe applicator is no longer ready for operation. After remedying the cause ofthe fault, touch RESET (= acknowledge fault)


Motor electronic control componentfault

The fault is more clearly indicated byLEDs on the motor. Refer to page 62,Status LED on Motor

Motor is blocked Find the cause and remedy:

� Is the spindle blocked by charredmaterial in the nozzle? Cleannozzle

Field bus communication disrupted:

� Transmission data block faulty

� Field bus cable defective or notconnected to the customer'scontrol system

� Field bus terminating resistormissing or defective

� Communication disrupted (e.g.customer's control system notswitched on)

� Network not set up correctly

� Sudden resets or crashes, e.g.caused by electromagneticinterference

Find the cause and remedy. Refer tothe separate manual Field Bus onNordson Applicators.

NOTE: This fault cannot be reset(acknowledged); it goes away as soonas field bus communication has beenrestored.

61


Shutdown

The applicator is no longer ready for operation. After remedying the cause ofthe fault, touch RESET (= acknowledge fault) - the control unit boots


Motor not connected to CAN bus Check the CAN bus plug on the motor.Refer to page19, CAN Bus: Securing PlugConnections

Check CAN bus terminating resistors.Refer to page 68, CAN Bus TerminatingResistor

Motor not connected to voltagesupply

Measure to determine cause

Motor defective

Motor CAN address setincorrectly

Refer to page 64, Observe whenAssembling

Solenoid valve control failed XI/ON digital output modulesdefective

NOTE: Enable cable missing or loose(XS25 on control box or customer'scontrol system), triggers the indicationSolenoid valves not enabled.

Field bus gateway:

� No power supply

� Sudden resets or crashes, e.g.caused by electromagneticinterference

� CAN address set incorrectly

Find the cause and remedy. Also referto the control box wiring diagram andto the separate manual Field Bus onNordson Applicators

CAN bus terminating resistormissing or defective

Refer to page 68, CAN BusTerminating Resistor

CAN BUS cable defective or notconnected

Refer to page 20, ConnectingApplicator, Control Box and OperatingUnit

62


MotorThe motor contains the required electronic control components. LEDsindicate various states:

1 2

LED State Meaning

Status

(1, green)

flashing Motor malfunction (Refer to Status LED on Motor)

ON Signal Enable motor received

OFF No signal Enable motor or voltage supply

Bus

(2, orange)

ON Normal state

flashing Boot process. If it continues to flash: Refer to page 58,Alarms.

Status LED on Motor

The green status LED (1) indicates the fault by the number of times that itflashes:

Flashing Fault Corrective action

1 x Supply voltage too low Measure to determine cause

2 x Blocked spindle Find the cause and remedy:

� Is the spindle blocked by charred material in thenozzle? Clean nozzle

� Is the ambient temperature of the motor elevated,e.g. by hot air flow or heat build-up?

3 x Motor current too high

4 x Output temperature too high

5 x

Reserved -6 x

7 x

8 x CAN bus fault at motor Refer to page 58, Alarms

9 x

GW statusNot in useRUNERRPWR

Customer's network

Internal Nordson network

GW statusNot in useRUNERRPWR

63


Optional Field Bus Gateway

With its LEDs, the gateway P/N 7186458, in use since November 2014,provides additional help in troubleshooting.

LED Color / status Meaning

GW (gateway) status Green Communication inprocess

Red Communication error

Flashing red Network fault

RUN On Ready for operation

Flashing Not yet ready

Flashes once Stopped

Off No line voltage

ERR On Transmission off

Flashes once Warning limit reached

Flashes twice Fault

Flashes 3 times Synchronization fault

Off No fault

PWR On Line voltage connected

Off No line voltage

Power Supply (Control Box)

Overvoltage Protection

The power supply's overvoltage protection switches off the output voltage assoon as it reaches approx. 130 % of the nominal voltage. Remedy the causeof overvoltage and reset the power supply.

Reset

Switch off the control box for 3 minutes and then switch it on again.

ON

DIP switch

64


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

CAUTION: Verify that the control option Field bus is deselected. Thisprevents unintentional adjustment of the nozzle mouthpiece. Refer to page 32, Selecting Control Options (with Field Bus Option).

Replacing Motor1. Detach the cable and terminating resistor from the connections on the

motor.


3. Release the screws on the underside of the motor.

4. Pull the motor up and out (arrow).

12

AG03 AG03/1

2

Battery

O‐ring

Fig. 30

Observe when Assembling

CAUTION: Do not mix up the CAN bus and voltage supply of the motor.Plugging the voltage supply into the CAN bus receptacle would destroy themotor.

� Set the DIP switch

� Insert the screw (1) with washer and tighten the screw

CAUTION: After assembly, proceed with Calibrating Slide Position(page 65). Otherwise the application width will not correspond to the setvalue.

65


Calibrating Slide PositionThe position must be calibrated anew when one of the following situationsoccurs:

a. The spindle and the motor shaft have been separated

b. The motor has been replaced

c. After a software update.

In the event that b. or c. applies, the control panel screen for calibrationopens automatically.

Calibration sets a reference point that the software uses to calculate theapplication width.

CAUTION: When calibrating, never adjust the application width usingsetpoint input; use only the arrow keys.

5. Open the calibration screen:

6. Enter any application width using the arrow keys.

NOTE: The value in the number field does not change. The valuemeasured in step 7. is entered here.

ACTUAL

66


7. Measure the actual application width (ACTUAL value) with a calipergauge.

8. Enter the ACTUAL value in the control panel screen.

9. Save the input with , or cancel with .

NOTE: If no values have been saved (e.g. after a motor is replaced), theprocess cannot be canceled.

If any imprecisions are determined in the application width display, continuewith Adjusting Application Width Display / Second Position Calibration.

Adjusting Application Width DisplayDefinition of Transmission ratio: Rotation of motor in relation to linear motionof mouthpiece. In this case 1:Spindle pitch.

If the transmission ratio changes greatly, e.g. due to a significantly differentoperating temperature, the display can become imprecise. Adjustmentcompensates for the change.

Verify that the applicator is heated to operating temperature.

First Position Calibration

CAUTION: For the first position calibration, never adjust the applicationwidth using setpoint input; use only the arrow keys.

Refer to page 65, Calibrating Slide Position.

As a result of the first position calibration, the actual value [ACTUAL] becamethe reference point for further internal calculations.

However, the actual spindle pitch can deviate from the theoretical pitchsaved in the software, either because of heat expansion or manufacturingtolerances.

The second position calibration is needed to store the actual pitch in thesoftware.

Continued ...

67


Second Position Calibration

Now the application width can be adjusted using setpoints.

1. Set the application width.

NOTE: The greater the application width discrepancy to the first positioncalibration, the more precise is the adjustment.

2. Open the adjustment screen:

3. Measure the actual application width (ACTUAL value) with a calipergauge.

4. Enter the actual value in the control panel screen:

5. Save input with .

68


CAN Bus Terminating Resistor

There must be a terminating resistor on each end of the CAN bus.

NOTE: The two CAN bus terminating resistors are connected in parallel viathe bus. When the resistance is measured in the installed state, the result is60 ��

One terminating resistor is located in the operating unit.

120 �

4 x

The second terminating resistor must be mounted on the XS8 of the motor

120 �

Also refer to page 19, CAN Bus: Securing Plug Connections.

Continued ...

69


There is a third terminating resistor in the CAN plug in the control box on thegateway. It must be switched OFF:

OFF

Dial Customer's interface

Dial Control box, internal side

Fig. 31 CANopen gateway (P/N 7157449)

Comparison of Field Bus Gateways

P/N 7157449 (until Oct. 31, 2014)AB7894-C

P/N 7186458 (beginning Nov. 1, 2014)AB7894-F

24 VDC

Control box, internal side

Customer's interface

LEDs

The EDS file AB7894-F is provided for gateway P/N 7186458.

NOTE: The CD supplied with the applicator contains both the EDSfile AB7894-F and the EDS file AB7894-C. Do not mistakenly exchange!

Baud

6 1 0

24 VDC

Baud

9 0 6

70


Adjusting Dial on Field Bus Gateway (Option)

Refer to separate manual Field Bus on Nordson Applicators.

CAUTION: Adjust the dials only when the control box is deenergized.

The dials are very small. The switch setting is indicated by the small grooveon the flattened side.

In this example, the dial is set to 1.

Delivery State

Customer's Interface

NOTE: Each unit on the CANopen field bus needs a field bus address forcommunication purposes. Each address may be assigned only once in theentire network.

Baud rate (500 kbit/s): 6

CANopen field bus address: 10

Control Box, Internal Side

Baud rate (500 kbit/s): 6

Internal CAN bus address (Do not change): 9

Message Copying completed

71


Software UpdateThe new software version is loaded onto the IPC from an SD memory card.All of the previous settings are lost. Nordson recommends making a note ofthe existing settings (e.g. Fig. 20: Software configuration code) before theupdate.

CAUTION: The memory card may be inserted and removed only when theIPC is deenergized.

1. Disconnect the operating unit from the voltage supply. To do this, either� Disconnect the plug and detach from operating unit� Switch off control box.

2. Open the operating unit, release the screws from the IPC and press it outsomewhat to be able to insert the memory card:

4 x

Connector IPC screws

3. Start voltage supply again. After about one minute, a message on thecontrol panel indicates that copying has been completed.

4. Disconnect the operating unit from the voltage supply again.

5. Remove the memory card.

6. Secure the IPC again and close the operating unit.

7. Start voltage supply again. If the connector to the operating unit wasreleased, plug it in again and secure with knurled nuts. The screen forcalibrating the position opens automatically.

8. Calibrating Slide Position. Refer to page 65.

9. Enter the configuration code.Refer to page 41, Software Configuration Code.

10. Refer to page 30, Initial Startup for instructions on how to proceed.

72


Observe When Replacing Heater Cartridges orTemperature Sensor

ATTENTION: Risk of electrical shock. Before removing the electricalequipment covers, ensure that the applicator is deenergized. Failure toobserve may result in personal injury, death, or equipment damage.

Nordson electrical boxes are protected either with a seal between theelectrical equipment cover and electrical box or with a PE connection on theelectrical equipment cover. Depending on the model, restore this protectivefeature after completing work.

Parts

How to Use the Illustrated Parts ListThe parts lists in the separate document Parts List are divided into thefollowing columns:

Item - Identifies the parts shown, available from Nordson.

Part - Nordson spare part number for each available part shown in theillustration. A series of hyphens (‐ ‐ ‐ ‐ ‐) in the Parts column means thatthe part cannot be ordered separately.

Description - This column contains the name of the part and, whenappropriate, the dimensions and other properties. The dots in theDescription column illustrate the relationship between assemblies,subassemblies and individual parts.

Quantity - The quantity required per unit, assembly or subassembly. Theabbreviation AR (as required) is used to designate that items are statedin drum sizes or that the quantity required per assembly is a factor of theproduct version or the model. A [w] after the quantity indicates a part thatwears.

Applicator - This column shows the applicator P/N containing the part.Not all applicators listed on the back of the cover page contain the part.

NOTE: The texts are available only in English. Refer to separate documentParts List, P/N 7192555.

Recommended Spare PartsTo prevent production stoppage, Nordson recommends keeping a spare

� Control module� Temperature sensor� Complete nozzle assembly, Quadring, nozzle assembly sealing rings� Spindle nuts, shim rings, seals

73


Technical Data

General Data

Maximum operating height 3000 m (9840 ft)

Humidity 10 to 95 %, not condensing

Use (inside oroutside)

Only inside

Required degree of cleanliness 1 (e.g. metal foundry) ...6 (e.g. residential area) ...10 (e.g. operating room)

4

Operating air pressure, controlmodule

Operating air pressure, nozzle closure

4-6 bar (58-87 psi)

6-10 bar (87‐145 psi)

Noise emission < 85 dB(A)

Degree of protection IP50

Temperature sensors Ni120

Data Dependent on Application

Minimum (= technically possible*)application width

*The actual minimum application widthdepends on the system, meaning it is a factorof the minimum possible output quantity of thepump(s) used

5 mm

Caution with model with handwheel: Attempting to close the nozzlefarther than the minimum application width of 5 mm will damage theapplicator.

Maximum application width 60 mm

Applicator weight

(Also refer to consignment note)

10 kg (without T-box and control unit)

Maximum operating temperature forapplicator

200 °C (392 °F)

Heatup time 150 °C (302 °F)

Approx. 15 min, depending on system environment

Max. adhesive pressure 30 bar (435 psi)

74


Electrical Data

Power consumption, applicator

Power consumption, control box

450 W

230 W

Operating voltage 230 V

Operating voltage frequency 50/60 Hz

IP class (I, II, III, protective insulation pursuant to DINEN 61140)

I

Current Flow Diagram (Applicator)

Refer to the technical drawings for information on connecting the heatercartridges and the temperature sensor.

75


Dimensions

With Handwheel

H

*

**77

(3

in.)

0 mm

LB

Fig. 32

Length L Width B Height H * **

265 mm / 14.4 in. 145 mm / 5.7 in. 385 mm / 15.2 in. 55 mm / 2.2 in. 60 mm / 2.4 in.

76


With Motor

ÏÏÏ

H

*

**

0 mm

L B

77 (

3 in

.)

Fig. 33

Length L Width B Height H * **

280 mm / 11 in. 145 mm / 5.7 in. 370 mm / 14.6 in. 55 mm / 2.2 in. 60 mm / 2.4 in.

77


Control Box and Operating Device

54

179

5,2

110

200

T= 210 (height)

T= 60 (height)

380

380

8,2

All dimensions in mm

Control box connection Customer's connection: 1 x 230 VAC / 230 W

Degree of protection IP 54

XION Gateway Board (in the Control Box)

Base module switch settings

(delivery state)

Baud rate for bus lengths up to 100 m: 500 kbit/s

Internal CAN bus address: 8NOTE: Do not change internal addresses. Adjust the switches only when thecontrol box is deenergized.

XI/ON digital output modules Normal load voltage: 24 VDC

Output current at 24 VDC

Max. constant current (ohmic): 2 A

Minimum load current (recommended): 10 mA

78


Replacing Slide‐in Chassis

A single chassis can be replaced with a chassis with the same function.

CAUTION: Follow the order of the plug-in sockets. Do not change.

gray Base module / voltage supply

white Digital inputs

light blue Analog inputs

orange Relay outputs

green Analog outputs

Replacing Base Module

CAUTION: Adjust only when the control box is deenergized. Do not changethe dial settings.

USYS

GNDSYS

UL

GNDL CAN connection

BIT RATE

SET

H:0 L:8NODE ID

1

2

3

4

ON

Voltage supply

500kbit/s:

Fig. 34 Base module

After replacing the base module, switch the control box on and load themodule configuration by pressing the SET button with a sharp object for atleast two seconds.

79


System Recommendation

System Plans and Accessories

If other hose and cable lengths are needed, please contact your Nordsonrepresentative.

System (Fig. 35) - Example with bulk melter

1 P/N configurable Bulk melter VersaPail

Melter VersaBlue

2 P/N 150155 Hose

3 P/N 7163497 Kit-SVC cable XS2 (Standard I/O)

4 P/N 7163498 Kit-SVC cable XS5 (pilot voltage)

5 P/N 254329 Extension, valve connection L = 10 m (Enable motor)

80


4‐6 bar

3

4

1

2 5

Enable solenoid valve

Field bus (option)

Operating voltage 1 x 230 VAC

Control valve triggering

Parent machine

Operating voltage

Fig. 35

81


AppendixSettings and maintenance record.

Settings Record

Production information

Material Manufacturer

Max. processing temperature

Viscosity

Cleaning agent Manufacturer

Flash point

Basic settings Application weight (grammage)

Application width

Substrate speed

Material quantity

Output capacity

Air pressure at applicator Control air

Basic settings temperature(heating zones)

Applicator

Heated hose

Pump speeds Melter

Motor controller (setpoint)

Material pressure Melter

Motor controller (setpoint)

Notes

Form filled out by:

Name Date

82


Maintenance Record

Unit part Activity Date Name Date Name

Entire applicator

Power cable / air hoses

Control module

Nozzle

Sliding plate

Spindle / spindle nut

Clean control panel

83


PasswordSome settings are protected with passwords. When a field or button ispressed, an input window opens in which to enter the password. If no key istouched for ten minutes after pressing a password-protected feature,password protection is reactivated. Then the password prompt appearsagain for password-protected features.

If appropriate, remove the bottom section of this page and store in a safelocation.

Serial number (applicator)

To be entered by the customer (Refer to applicatorID plate)

Password (operating unit)

1234

84


hot melt applicators eb 60 flex -...

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