hot melt applicators truecoat hp -...

NORDSON ENGINEERING GMBH � LÜNEBURG � GERMANY

Hot Melt ApplicatorsTrueCoat® HP

Manual P/N 7179962_02- English -

Edition 02/14

P/N 7179962_02 � 2014 Nordson Corporation

Note

This document applies to the entire series.

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.

� 2014 All rights reserved.- Translation of Original -

TrademarksAccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, Bowtie, Build‐A‐Part, CanWorks, Century, CF, CleanSleeve,CleanSpray, Color‐on‐Demand, ColorMax, Control Coat, Coolwave, Cross‐Cut, cScan+, Dage, Dispensejet, DispenseMate, DuraBlue, DuraDrum, Durafiber,DuraPail, Dura‐Screen, Durasystem, Easy Coat, Easymove Plus, Ecodry, Econo‐Coat, e.DOT, EFD, Emerald, Encore, ESP, e stylized, ETI‐stylized, Excel 2000,Fibrijet, Fillmaster, FlexiCoat, Flexi‐Spray, Flex‐O‐Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Fulfill, GreenUV, HDLV, Heli‐flow, Helix, Horizon, HotShot, 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, Mini Blue, Mini Squirt, Moist‐Cure, Mountaingate, MultiScan, NexJet,No‐Drip, Nordson, Optimum, Package of Values, Paragon, PatternView, PermaFlo, PICO, PicoDot, PluraFoam, 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, RBX, Rhino, Saturn, Saturn with rings, Scoreguard, SC5, S. design stylized, Seal Sentry, Sealant Equipment & Engineering, Inc., SEEand design, See‐Flow, Select Charge, Select Coat, Select Cure, Servo‐Flo, Shot‐A‐Matic, Signature, Slautterback, Smart‐Coat, Smart‐Gun, Solder Plus,Spectrum, Speed‐Coat, Spraymelt, Spray Squirt, Super Squirt, SureBead, Sure Clean, Sure Coat, Sure‐Max, Sure Wrap, Tela‐Therm, Tip‐Seal, Tracking Plus,TRAK, Trends, Tribomatic, TrueBlue, TrueCoat, Tubesetter, Ultra, UniScan, UpTime, u‐TAH, Value Plastics, Vantage, Veritec, VersaBlue, Versa‐Coat,VersaDrum, VersaPail, Versa‐Screen, Versa‐Spray, VP Quick Fit, Walcom, Watermark, When you expect more., X‐Plane are registered trademarks - ® - ofNordson Corporation.

Accubar, Active Nozzle, Advanced Plasma Systems, AeroDeck, AeroWash, Allegro, AltaBlue, AltaSlot, Alta Spray, AquaCure, Artiste, ATS, Auto‐Flo, AutoScan,Axiom, Best Choice, BetterBook, Blue Series, Bravura, CanNeck, CanPro, Celero, Chameleon, Champion, Check Mate, ClassicBlue, Classic IX, Clean Coat,Cobalt, ContourCoat, Controlled Fiberization, Control Weave, CPX, cSelect, Cyclo‐Kinetic, DispensLink, DropCure, Dry Cure, DuraBraid, DuraCoat, e.dot+,E‐Nordson, Easy Clean, EasyOn, EasyPW, Eclipse, Equalizer, EquiBead, Exchange Plus, FillEasy, Fill Sentry, Flow Coat, Fluxplus, Freedom, 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, MonoCure, Multifil, MultiScan, Myritex, Nano, OmniScan, OptiMix, OptiStroke, Optix, Origin, Partnership+Plus, PatternJet, PatternPro, PCI,PharmaLok, Pinnacle, Plasmod, PluraMix, Powder Pilot, Powder Port, Powercure, Process Sentry, Pulse Spray, PURBlue, PURJet, PurTech, Quad Cure,Quantum, Ready Coat, RediCoat, RollVIA, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, Smartfil, SolidBlue, Spectral, Spectronic,SpeedKing, Spray Works, StediFlo, StediTherm, Summit, Sure Brand, SureFoam, SureMix, SureSeal, Swirl Coat, TAH, Tempus, ThruWave, TinyCure, TradePlus, Trilogy, Ultra FoamMix, UltraMax, Ultrasaver, Ultrasmart, Universal, ValueMate, Versa, Viper, Vista, WebCure, YESTECH, 2 Rings (Design) are trademarks- � - of Nordson Corporation.

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

Table of contents I

P/N 7179962_02� 2014 Nordson Corporation

Table of contents

Nordson International O‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Europe O‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distributors in Eastern & Southern Europe O‐1. . . . . . . . . . . . . . . . .Outside Europe O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Africa / Middle East O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Asia / Australia / Latin America O‐2. . . . . . . . . . . . . . . . . . . . . . . . . .China O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Japan O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .North America O‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Instructions Regarding Working with ApplicationMaterials 0‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Definition of Terms 0‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manufacturer Information 0‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liability 0‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Risk of Burns 0‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vapors and Gases 0‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Substrate 0‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Processing Temperature 0‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 1‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Alert Symbols 1‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Responsibilities of the Equipment Owner 1‐2. . . . . . . . . . . . . . . . . . . .

Safety Information 1‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions, Requirements, and Standards 1‐2. . . . . . . . . . . . . . . .User Qualifications 1‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicable Industry Safety Practices 1‐4. . . . . . . . . . . . . . . . . . . . . . . .Intended Use of the Equipment 1‐4. . . . . . . . . . . . . . . . . . . . . . . . . .Instructions and Safety Messages 1‐4. . . . . . . . . . . . . . . . . . . . . . .Installation Practices 1‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Practices 1‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance and Repair Practices 1‐5. . . . . . . . . . . . . . . . . . . . . . .

Equipment Safety Information 1‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Equipment Shutdown 1‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure 1‐7. . . . . . . . . . . . . . . . . .De‐energizing the System 1‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . .Disabling the Applicators 1‐7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Warnings and Cautions 1‐8. . . . . . . . . . . . . . . . . . .Other Safety Precautions 1‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid 1‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contentsII


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

Unintended Use - Examples - 2‐1. . . . . . . . . . . . . . . . . . . . . . . . . . .Residual Risks 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Note on Manual 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Definition of Terms 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Applicator 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Melter 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Module 2‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of Components / Functioning 2‐3. . . . . . . . . . . . . . . . . . . .TrueCoat®® HP with Control Modules 2‐3. . . . . . . . . . . . . . . . . . .TrueCoat®® HP with Throttle Screws 2‐4. . . . . . . . . . . . . . . . . . . .Material Flow 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Material Distribution 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Modules 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Throttle Screws 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating 2‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slot Nozzle or Nozzle with Rotating Bar 2‐6. . . . . . . . . . . . . . . . . . .Filter Cartridge 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ID plate 2‐6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transport 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal 3‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhausting Material Vapors 3‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Connections 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Laying Cable 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Heater 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Solenoid Valves 3‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic Connections 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation with Nonlubricated Compressed Air 3‐4. . . . . . . . . . . . .Conditioning Compressed Air 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Compressed Air 3‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Heated Hose 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disconnecting 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Pressure 3‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using Two Open‐end Wrenches 3‐6. . . . . . . . . . . . . . . . . . . . . . .

Table of contents III


Operation 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Triggering Solenoid Valve 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Temperatures 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enter Standby 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Control Air Pressure 4‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Material Pressure 4‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Positioning the Applicator 4‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Calculating Material Quantity 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sample Calculation 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Customer-specific Values 4‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Correcting Material Quantity and Material Distribution 4‐4. . . . . . . . .Adjusting needle stroke 4‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting Material Distribution Evenly with Stem StrokeAdjustment 4‐5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulating Material Distribution with the Throttle Screws 4‐6. . . .Optimizing Material Application with Temperature Setpoints 4‐7.

Correcting Nozzle Concavity 4‐7. . . . . . . . . . . . . . . . . . . . . . . . . .Correcting Nozzle Convexity 4‐8. . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Rotating Bar Speed 4‐8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Settings Record 4‐9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Settings Record - Spare Copy 4‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving Pressure 5‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regular Maintenance 5‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Visual Inspection for External Damage 5‐3. . . . . . . . . . . . . . . . . . . .External Cleaning 5‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspecting Control Module 5‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Changing Type of Material 5‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging with Cleaning Agent 5‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembling and Cleaning Slot Nozzle 5‐5. . . . . . . . . . . . . . . . . .Disassembling and Cleaning Nozzle with Rotating Bar 5‐7. . . . . .Replacing Rotating Bar 5‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inserting New Shim Plate 5‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refacing Nozzle 5‐10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Filter Cartridge 5‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Filter Cartridge 5‐11. . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Filter Cartridge 5‐12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembling and Cleaning Filter Cartridge 5‐12. . . . . . . . . . . .

Maintenance Record 5‐13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Record Form ‐ Spare Copy 5‐14. . . . . . . . . . . . . . . . . . . .

Troubleshooting 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 6‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting Table 6‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 7‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing Control Module with 4/2 Air Valve 7‐1. . . . . . . . . . . . . . .Replacing Control Module with 3/2 Air Valve 7‐2. . . . . . . . . . . . . . .

Removing Control Module 7‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . .Installing Control Module 7‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Heater Cartridge or Temperature Sensor 7‐4. . . . . . . .Processing Materials 7‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contentsIV


Technical Data 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air pressure 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 8‐1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions and Weights 8‐2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torques 8‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control modules 8‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nozzle 8‐3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clamps 8‐4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O‐1Introduction

��2012 Nordson CorporationAll rights reserved

NI_Q-1112-MX

Nordson International

http://www.nordson.com/Directory

Country Phone Fax

EuropeAustria 43‐1‐707 5521 43‐1‐707 5517

Belgium 31‐13‐511 8700 31‐13‐511 3995

Czech Republic 4205‐4159 2411 4205‐4124 4971

Denmark Hot Melt 45‐43‐66 0123 45‐43‐64 1101

Finishing 45‐43‐200 300 45‐43‐430 359

Finland 358‐9‐530 8080 358‐9‐530 80850

France 33‐1‐6412 1400 33‐1‐6412 1401

Germany Erkrath 49‐211‐92050 49‐211‐254 658

Lüneburg 49‐4131‐8940 49‐4131‐894 149

Nordson UV 49‐211‐9205528 49‐211‐9252148

EFD 49‐6238 920972 49‐6238 920973

Italy 39‐02‐216684‐400 39‐02‐26926699

Netherlands 31‐13‐511 8700 31‐13‐511 3995

Norway Hot Melt 47‐23 03 6160 47‐23 68 3636

Poland 48‐22‐836 4495 48‐22‐836 7042

Portugal 351‐22‐961 9400 351‐22‐961 9409

Russia 7‐812‐718 62 63 7‐812‐718 62 63

Slovak Republic 4205‐4159 2411 4205‐4124 4971

Spain 34‐96‐313 2090 34‐96‐313 2244

Sweden 46‐40-680 1700 46‐40‐932 882

Switzerland 41‐61‐411 3838 41‐61‐411 3818

UnitedKingdom

Hot Melt 44‐1844‐26 4500 44‐1844‐21 5358

IndustrialCoatingSystems

44‐161‐498 1500 44‐161‐498 1501

Distributors in Eastern & Southern Europe

DED, Germany 49‐211‐92050 49‐211‐254 658

O‐2 Introduction

��2012Nordson CorporationAll rights reserved

NI_Q-1112-MX

Outside Europe

For your nearest Nordson office outside Europe, contact the Nordsonoffices below for detailed information.

Contact Nordson Phone Fax

Africa / Middle East

DED, Germany 49‐211‐92050 49‐211‐254 658

Asia / Australia / Latin America

Pacific South Division,USA

1‐440‐685‐4797 -

China

China 86-21-3866 9166 86-21-3866 9199

Japan

Japan 81‐3‐5762 2700 81‐3‐5762 2701

North America

Canada 1‐905‐475 6730 1‐905‐475 8821

USA Hot Melt 1‐770‐497 3400 1‐770‐497 3500

Finishing 1‐880‐433 9319 1‐888‐229 4580

Nordson UV 1‐440‐985 4592 1‐440‐985 4593

Introduction 0‐3

HMIPUR01_EN_C-0108� 2014 Nordson Corporation

General Hot Melt Material ProcessingInstructions

(With instructions regarding PUR application materials)

Definition of TermApplication materials are considered to be e.g. thermoplastic hot melt adhesives, adhesives, sealants, liquid adhesives and similar application materialsthat are also referred to as materials in the following text.

NOTE: The materials that may be processed using your Nordson productare described in the manual under Intended and Unintended Use. When indoubt, consult your Nordson representative.

Manufacturer InformationMaterials may be processed only when the manufacturer's product descriptions and Safety Data Sheets are observed.

Among other things, they give information on correct processing of the product, transport, storage and disposal. Information regarding reactivity and potentially hazardous decomposition products, toxic properties, flash points,etc. can also be found there.

LiabilityNordson will not be liable for danger or damage resulting from the materials.

Risk of BurnsThere is a risk of burns when handling heated materials. Work carefully andwear appropriate safety equipment.

Vapors and GasesEnsure that vapors and gases do not exceed the prescribed limits. Exhaustvapors and gases with appropriate devices when necessary and/or ensuresufficient ventilation of the work area.

SubstrateThe substrate should be free of dust, grease and dampness. Experiment toselect the suitable material and to determine the optimum working conditionsand any pretreatment that may be needed for the substrate.

Introduction0‐4

HMIPUR01_EN_C-0108 � 2014 Nordson Corporation

Processing TemperatureWhen processing tempered materials, the prescribed processing temperature must be complied with to ensure high‐quality application. The temperature may not be exceeded! Overheating may cause charring or cracking ofthe material, which could lead to downtime or damage to the unit.

The material should always be melted gently. Avoid long, unnecessary exposure to heat. When work is interrupted, the temperature should be reduced.The temperature in the tank of the unit should be coordinated with the material consumption. When a large amount of material is consumed, the temperature should be set close to the prescribed processing temperature; lowerconsumption means a lower temperature.

When processing cold material, consider the influence of shear heat and ambient temperature. Cool if necessary.

Important Note for Polyurethane Materials (PUR)When processing polyurethane materials (PUR), the following additionalinstructions must be followed:

� When the maximum level of harmful substance concentration is exceeded, use a gas mask and air purifying equipment.

� During production stoppages or breaks, reduce the temperature andclose the applicator nozzle as well as possible. Cover the remainingopening with high-temperature grease or high-temperature tape.

� Before the application system is shut down for a longer period of time,rinse it with a suitable cleaning agent. Use only a cleaning agent recommended by the material manufacturer.

� Close open material connections so that they are airtight.

Safety 1‐1

� 2014 Nordson Corporation Safe_PPA1011LUE_EN

Section 1

Safety

Read this section before using the equipment. This section containsrecommendations and practices applicable to the safe installation, operation,and maintenance (hereafter referred to as “use”) of the product described inthis document (hereafter referred to as “equipment”). Additional safetyinformation, in the form of task‐specific safety alert messages, appears asappropriate throughout this document.

WARNING! Failure to follow the safety messages, recommendations, andhazard avoidance procedures provided in this document can result inpersonal injury, including death, or damage to equipment or property.

Safety Alert Symbols

The following safety alert symbol and signal words are used throughout thisdocument to alert the reader to personal safety hazards or to identifyconditions that may result in damage to equipment or property. Comply withall safety information that follows the signal word.

WARNING! Indicates a potentially hazardous situation that, if not avoided,can result in serious personal injury, including death.

CAUTION! Indicates a potentially hazardous situation that, if not avoided,can result in minor or moderate personal injury.

CAUTION! (Used without the safety alert symbol) Indicates a potentiallyhazardous situation that, if not avoided, can result in damage to equipment orproperty.

Safety1‐2

� 2014 Nordson CorporationSafe_PPA1011LUE_EN

Responsibilities of the Equipment Owner

Equipment owners are responsible for managing safety information, ensuringthat all instructions and regulatory requirements for use of the equipment aremet, and for qualifying all potential users.

Safety Information� Research and evaluate safety information from all applicable sources,

including the owner‐specific safety policy, best industry practices,governing regulations, material manufacturer's product information, andthis document.

� Make safety information available to equipment users in accordance withgoverning regulations. Contact the authority having jurisdiction forinformation.

� Maintain safety information, including the safety labels affixed to theequipment, in readable condition.

Instructions, Requirements, and Standards� Ensure that the equipment is used in accordance with the information

provided in this document, governing codes and regulations, and bestindustry practices.

� If applicable, receive approval from your facility's engineering or safetydepartment, or other similar function within your organization, beforeinstalling or operating the equipment for the first time.

� Provide appropriate emergency and first aid equipment.

� Conduct safety inspections to ensure required practices are beingfollowed.

� Re‐evaluate safety practices and procedures whenever changes aremade to the process or equipment.

Safety 1‐3


User Qualifications

Equipment owners are responsible for ensuring that users:

� receive safety training appropriate to their job function as directed bygoverning regulations and best industry practices

� are familiar with the equipment owner's safety and accidentprevention policies and procedures

� receive equipment‐ and task‐specific training from another qualifiedindividual

NOTE: Nordson can provide equipment‐specific installation,operation, and maintenance training. Contact your Nordsonrepresentative for information

� possess industry‐ and trade‐specific skills and a level of experienceappropriate to their job function

� are physically capable of performing their job function and are notunder the influence of any substance that degrades their mentalcapacity or physical capabilities

Applicable Industry Safety Practices

The following safety practices apply to the use of the equipment in themanner described in this document. The information provided here is notmeant to include all possible safety practices, but represents the best safetypractices for equipment of similar hazard potential used in similar industries.

Intended Use of the Equipment� Use the equipment only for the purposes described and within the limits

specified in this document.

� Do not modify the equipment.

� Do not use incompatible materials or unapproved auxiliary devices.Contact your Nordson representative if you have any questions onmaterial compatibility or the use of non‐standard auxiliary devices.

Safety1‐4


Instructions and Safety Messages� Read and follow the instructions provided in this document and other

referenced documents.

� Familiarize yourself with the location and meaning of the safety warninglabels and tags affixed to the equipment. Refer to Safety Labels and Tagsat the end of this section.

� If you are unsure of how to use the equipment, contact your Nordsonrepresentative for assistance.

Installation Practices� Install the equipment in accordance with the instructions provided in this

document and in the documentation provided with auxiliary devices.

� Ensure that the equipment is rated for the environment in which it will beused. This equipment has not been certified for compliance with theATEX directive nor as nonincendive and should not be installed inpotentially explosive environments.

� Ensure that the processing characteristics of the material will not create ahazardous environment. Refer to the Material Safety Data Sheet (MSDS)for the material.

� If the required installation configuration does not match the installationinstructions, contact your Nordson representative for assistance.

� Position the equipment for safe operation. Observe the requirements forclearance between the equipment and other objects.

� Install lockable power disconnects to isolate the equipment and allindependently powered auxiliary devices from their power sources.

� Properly ground all equipment. Contact your local building codeenforcement agency for specific requirements.

� Ensure that fuses of the correct type and rating are installed in fusedequipment.

� Contact the authority having jurisdiction to determine the requirement forinstallation permits or inspections.

Operating Practices� Familiarize yourself with the location and operation of all safety devices

and indicators.

� Confirm that the equipment, including all safety devices (guards,interlocks, etc.), is in good working order and that the requiredenvironmental conditions exist.

� Use the personal protective equipment (PPE) specified for each task.Refer to Equipment Safety Information or the material manufacturer'sinstructions and MSDS for PPE requirements.

� Do not use equipment that is malfunctioning or shows signs of a potentialmalfunction.

Safety 1‐5


Maintenance and Repair Practices� Allow only personnel with appropriate training and experience to operate

or service the equipment.

� Perform scheduled maintenance activities at the intervals described inthis document.

� Relieve system hydraulic and pneumatic pressure before servicing theequipment.

� De‐energize the equipment and all auxiliary devices before servicing theequipment.

� Use only new Nordson‐authorized refurbished or replacement parts.

� Read and comply with the manufacturer's instructions and the MSDSsupplied with equipment cleaning compounds.

NOTE: MSDSs for cleaning compounds that are sold by Nordson areavailable at www.nordson.com or by calling your Nordson representative.

� Confirm the correct operation of all safety devices before placing theequipment back into operation.

� Dispose of waste cleaning compounds and residual process materialsaccording to governing regulations. Refer to the applicable MSDS orcontact the authority having jurisdiction for information.

� Keep equipment safety warning labels clean. Replace worn or damagedlabels.

Equipment Safety Information

This equipment safety information is applicable to the following types ofNordson equipment:

� hot melt and cold adhesive application equipment and all relatedaccessories

� pattern controllers, timers, detection and verification systems, and allother optional process control devices

Safety1‐6


Equipment Shutdown

To safely complete many of the procedures described in this document, theequipment must first be shut down. The level of shut down required varies bythe type of equipment in use and the procedure being completed. If required, shut down instructions are specified at the start of the procedure.The levels of shut down are:

Relieving System Hydraulic Pressure

Completely relieve system hydraulic pressure before breaking any hydraulicconnection or seal. Refer to the melter‐specific product manual forinstructions on relieving system hydraulic pressure.

De‐energizing the System

Isolate the system (melter, hoses, applicators, and optional devices) from allpower sources before accessing any unprotected high‐voltage wiring orconnection point.

1. Turn off the equipment and all auxiliary devices connected to theequipment (system).

2. To prevent the equipment from being accidentally energized, lock andtag the disconnect switch(es) or circuit breaker(s) that provide inputelectrical power to the equipment and optional devices.

NOTE: Government regulations and industry standards dictate specificrequirements for the isolation of hazardous energy sources. Refer to theappropriate regulation or standard.

Disabling the Applicators

NOTE: Adhesive dispensing applicators are referred to as “guns” in someprevious publications.

All electrical or mechanical devices that provide an activation signal to theapplicators, applicator solenoid valve(s), or the melter pump must bedisabled before work can be performed on or around an applicator that isconnected to a pressurized system.

1. Turn off or disconnect the applicator triggering device (pattern controller,timer, PLC, etc.).

2. Disconnect the input signal wiring to the applicator solenoid valve(s).

3. Reduce the air pressure to the applicator solenoid valve(s) to zero; thenrelieve the residual air pressure between the regulator and the applicator.

Safety 1‐7


General Safety Warnings and Cautions

Table 1‐1 contains the general safety warnings and cautions that apply toNordson hot melt and cold adhesive equipment. Review the table andcarefully read all of the warnings or cautions that apply to the type ofequipment described in this manual.

Equipment types are designated in Table 1‐1 as follows:

HM = Hot melt (melters, hoses, applicators, etc.)

PC = Process control

CA = Cold adhesive (dispensing pumps, pressurized container, andapplicators)

Table 1‐1 General Safety Warnings and Cautions

EquipmentType Warning or Caution

HM

WARNING! Hazardous vapors! Before processing any polyurethanereactive (PUR) hot melt or solvent‐based material through a compatibleNordson melter, read and comply with the material's MSDS. Ensurethat the material's processing temperature and flashpoints will not beexceeded and that all requirements for safe handling, ventilation, firstaid, and personal protective equipment are met. Failure to comply withMSDS requirements can cause personal injury, including death.

HM

WARNING! Reactive material! Never clean any aluminum componentor flush Nordson equipment with halogenated hydrocarbon fluids.Nordson melters and applicators contain aluminum components thatmay react violently with halogenated hydrocarbons. The use ofhalogenated hydrocarbon compounds in Nordson equipment cancause personal injury, including death.

HM, CAWARNING! System pressurized! Relieve system hydraulic pressurebefore breaking any hydraulic connection or seal. Failure to relieve thesystem hydraulic pressure can result in the uncontrolled release of hotmelt or cold adhesive, causing personal injury.

Continued...

Safety1‐8


General Safety Warnings and Cautions (contd.)

Table 1‐1 General Safety Warnings and Cautions (contd)


HMWARNING! Molten material! Wear eye or face protection, clothing thatprotects exposed skin, and heat‐protective gloves when servicingequipment that contains molten hot melt. Even when solidified, hot meltcan still cause burns. Failure to wear appropriate personal protectiveequipment can result in personal injury.

HM, PC

WARNING! Equipment starts automatically! Remote triggering devicesare used to control automatic hot melt applicators. Before working onor near an operating applicator, disable the applicator's triggeringdevice and remove the air supply to the applicator's solenoid valve(s).Failure to disable the applicator's triggering device and remove thesupply of air to the solenoid valve(s) can result in personal injury.

HM, CA, PC

WARNING! Risk of electrocution! Even when switched off andelectrically isolated at the disconnect switch or circuit breaker, theequipment may still be connected to energized auxiliary devices.De‐energize and electrically isolate all auxiliary devices beforeservicing the equipment. Failure to properly isolate electrical power toauxiliary equipment before servicing the equipment can result inpersonal injury, including death.

HM, CA, PC

WARNING! Risk of fire or explosion! Nordson adhesive equipment isnot rated for use in explosive environments and has not been cerfifiedfor the ATEX directive or as nonincendive. In addition, this equipmentshould not be used with solvent‐based adhesives that can create anexplosive atmosphere when processed. Refer to the MSDS for theadhesive to determine its processing characteristics and limitations.The use of incompatible solvent‐based adhesives or the improperprocessing of solvent‐based adhesives can result in personal injury,including death.

Continued...

Safety 1‐9


Table 1‐1 General Safety Warnings and Cautions (contd)


HM, CA, PCWARNING! Allow only personnel with appropriate training andexperience to operate or service the equipment. The use of untrainedor inexperienced personnel to operate or service the equipment canresult in injury, including death, to themselves and others and candamage to the equipment.

HMCAUTION! Hot surfaces! Avoid contact with the hot metal surfaces ofapplicators, hoses, and certain components of the melter. If contactcan not be avoided, wear heat‐protective gloves and clothing whenworking around heated equipment. Failure to avoid contact with hotmetal surfaces can result in personal injury.

HM

CAUTION! Some Nordson melters are specifically designed toprocess polyurethane reactive (PUR) hot melt. Attempting to processPUR in equipment not specifically designed for this purpose candamage the equipment and cause premature reaction of the hot melt. Ifyou are unsure of the equipment's ability to process PUR, contact yourNordson representative for assistance.

HM, CA

CAUTION! Before using any cleaning or flushing compound on or inthe equipment, read and comply with the manufacturer's instructionsand the MSDS supplied with the compound. Some cleaningcompounds can react unpredictably with hot melt or cold adhesive,resulting in damage to the equipment.

HM

CAUTION! Nordson hot melt equipment is factory tested with NordsonType R fluid that contains polyester adipate plasticizer. Certain hot meltmaterials can react with Type R fluid and form a solid gum that canclog the equipment. Before using the equipment, confirm that the hotmelt is compatible with Type R fluid.

Safety1‐10


Other Safety Precautions� Do not use an open flame to heat hot melt system components.

� Check high pressure hoses daily for signs of excessive wear, damage, orleaks.

� Never point a dispensing handgun at yourself or others.

� Suspend dispensing handguns by their proper suspension point.

First Aid

If molten hot melt comes in contact with your skin:

1. Do NOT attempt to remove the molten hot melt from your skin.

2. Immediately soak the affected area in clean, cold water until the hot melthas cooled.

3. Do NOT attempt to remove the solidified hot melt from your skin.

4. In case of severe burns, treat for shock.

5. Seek expert medical attention immediately. Give the MSDS for the hotmelt to the medical personnel providing treatment.

Introduction 2‐1


Section 2

Introduction

Intended UseHot melt applicators of the series TrueCoat ® HP - hereafter also referred toas Applicator - may be used only for contact surface application of hot meltadhesives and similar hot melt products (including PUR).

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.

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

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

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

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

Introduction2‐2


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

� 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.

Note on Manual

Definition of Terms

ApplicatorThe term application head is also used in Nordson literature.

MelterGeneral term for tank melters and bulk melters.

Control ModuleThe term module is also used in Nordson literature.

Introduction 2‐3


Description of Components / Functioning

TrueCoat® HP with Control Modules

1

2

14

9

12

67

4

13

1

15

10

3

8

11

5

Fig. 2‐1

1 Electrical connection (bodyheater)

2 Solenoid valve plug

3 Solenoid valve

4 Control module

5 Filter cartridge

6 Eye-bolt

7 Clamp fixing screw

8 Clamping screw

9 Centering clamping screw

10 Control air connection

11 Clamp

12 Nozzle

13 ID plate

14 Fastening bolts

15 Hose connection (material)

Introduction2‐4


TrueCoat® HP with Throttle Screws

1

2

8

2

1

3

7

4

16

17 18

15

6

14

6

109

66

6

13

12

5

11

Fig. 2‐2 TCHP with rotating bar exchangeable nozzle and throttle screws

1 Cable harness temperaturesensors

2 Cable harness heating zones

3 Cable harness solenoid valves

4 Hose connection (material)

5 Fastening bolts

6 Air Relief Valve

7 Rotating bar

8 Stop plate for exchangeablenozzle

9 Clamping screw


11 Throttle screw

12 Exchangeable nozzle

13 Clamp

14 Eye-bolt

15 Filter cartridge

16 Control module

17 Solenoid valve

18 Control air connection

Introduction 2‐5


Description of Components / Functioning (contd.)

Material Flow

The material is pumped through a heated hose into the applicator. In theapplicator the material flows through the filter cartridge(s) and the materialchannels to the nozzle. The material supply to the nozzle is regulated eitherby control modules or throttle screws. A slot nozzle or a nozzle with rotatingbar applies the material in a contact coating process.

The application pattern is determined by grooves in the mouthpiece or by ashim plate. The shim plate is located between the nozzle mouthpiece and themouthpiece receptacle. The application pattern also depends on the speedat which the substrate moves, the quantity of material and the materialtemperature.

In addition, the quality of the application is influenced by the the anglebetween the nozzle and the substrate. Refer to page 4‐2, PositioningApplicator.

Material Distribution

The material supply to the nozzle and material distribution across theapplication width are regulated by control modules or throttle screws.

Control Modules

The control modules open and close the material supply to the nozzle byraising or lowering the nozzle stem. A compression spring in the controlmodule closes the outlet when the control air pressure drops, preventingmaterial from escaping.

Refer to page 4-5, Setting Material Distribution Evenly with Stem Stroke

Adjustment.

Throttle Screws

Refer to page 4‐6, Regulating Material Distribution with the Throttle Screws.

Heating

The applicator is heated with electrical heater cartridges. The temperature iscontinuously measured by temperature sensors and is controlled withelectronic temperature controllers. Temperature controllers are not part ofthe applicator.

Introduction2‐6


Slot Nozzle or Nozzle with Rotating Bar

The nozzle or the rotating bar touches the substrate, causing them tonaturally wear. The nozzle may need to be refaced, the rotating bar replaced.Refer to page 5‐10, Refacing Nozzle or page 5‐10, Replacing Rotating Bar.

Filter Cartridge

The material flows from the inside of the filter cartridge (14, Fig. 2‐1) to theoutside. Thus dirt particles remain in the filter cartridge. The filter cartridgemust be cleaned or replaced regularly (Refer to page 5‐11).

NOTE: Nordson recommends keeping a supply of replacement filtercartridges to prevent production stoppage.

ID plate

1. field Type

2. field Serial number

3. field Nordson order number

4. field Year of construction

5. field Operating voltage [V], rated current [A], Operating voltagefrequency [Hz]

Fig. 2‐3

Installation 3‐1


Section 3

Installation

ATTENTION: 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.

TransportThe applicator is a high precision, valuable part. Handle very carefully!Protect the nozzle from damage. Do this e.g. by placing it back in the originalpackaging.

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

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

Installation3‐2


InstallingObserve the following when installing the applicator:

� Protect from humidity, vibrations, dust and drafts.

� Ensure access to parts relevant for maintenance and operation.

� To achieve optimum material application, install the applicator in theparent machine such that the essential angle between the nozzle and thesubstrate can be varied.

� The applicator bracket must allow for heat expansion.

� Cables, air hoses and heated hoses may not be bent, pinched, torn off orotherwise damaged.

Exhausting Material Vapors

Ensure that material vapors do not exceed the prescribed limits. Exhaustmaterial fumes when necessary. Provide sufficient ventilation of the locationwhere the unit is installed.

ATTENTION: It is imperative that the following additional safety regulationsare followed when processing polyurethane hot melt adhesives (PUR) (Referto General Hot Melt Material Processing Instructions).

1

Installation 3‐3


Electrical Connections

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

Laying Cable

ATTENTION: Do not pinch cables and check regularly for damage. Replacedamaged cables immediately!

Connecting Heater

Insert the voltage plug into the corresponding receptacle on the melter orterminal box. If the heater lines are integrated into the material hose, thecorresponding receptacle is located directly on the material hose. Secure thevoltage plug with the clamp if necessary.

Connecting Solenoid Valves

The solenoid valves on the control modules are controlled either by anexternal power supply, e.g. control unit, or through the valve control lines ofthe heated hose. Secure the plug connection with the screw (1, Fig. 3‐1).

Fig. 3‐1

Installation3‐4


Pneumatic ConnectionsNordson recommends using dry, controlled and nonlubricated compressedair.

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.

NOTE: It must be ensured that the compressed air supply to the applicatorshas been converted to absolutely nonlubricated operation.

NOTE: No oil from a possibly defective compressor may be permitted topenetrate the compressed 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

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

Maximum air pressure:

10 bar 1 MPa 145 psi

2. Connect the control modules to the air conditioning unit.

3. Set control air pressure:

Approx. 5 to 6 bar Approx. 0.5 to 0.6MPa

Approx. 72.5 to 87 psi

MXHH001S050B0997

1 32

Installation 3‐5


Connecting Heated Hose

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

Connecting

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

1. First connect the hose (3) electrically.

2. Heat the unit and hose until the material softens (approx. 80 �C / 176 �F).

3. Screw on heated hose.

CAUTION: Always connect the hose to the side of the body where the filtercartridge is. This is the only way to ensure that the material is filtered.

Fig. 3‐2

Disconnecting

Relieving Pressure

ATTENTION: System and material pressurized. Before removing heatedhoses and applicators, relieve system pressure. Failure to observe can resultin serious burns.

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

1. Set the motor speed of the unit feeding the material to 0 min‐1; switch offthe motor(s).

2. Place a container under the nozzle of the applicator.

MXHH002S033A0295

Installation3‐6


Relieving Pressure (contd.)

3. Relieving pressure:

� On an applicator with throttle screws, use the screws to open thematerial supply to the nozzle.

� On an applicator with solenoid valves, activate the solenoid valveselectrically or manually (Refer to Figure 3‐3). Do not use sharpobjects! Repeat until no more material flows out.

Fig. 3‐3

4. Re‐use the material or dispose of it properly according to localregulations.

Using Two Open‐end Wrenches

Use two open‐end wrenches when connecting and disconnecting the heatedhose. This prevents the hose connection on the unit from turning.

Fig. 3‐4

Operation 4‐1


Section 4

Operation


Triggering Solenoid ValveCAUTION: Trigger the solenoid valves only when the applicator is heated tooperating temperature!

Setting TemperaturesNOTE: The basis for temperature setting is the processing temperaturestipulated by the material manufacturer (usually 150 to 180 ° C / 302 to 356° F). The maximum operating temperature of the product described here maynot be exceeded.

The applicator temperature required is set on the melter (maximum 200 ° C /392 ° F).

Enter Standby

CAUTION: When processing PUR adhesives, enter standby whenproduction is to cease for longer than 30 minutes.

Setting Control Air PressureThe control air pressure is set to suit each application on an air conditioningunit. The air conditioning unit with pressure control valve is not part of theapplicator.

Set control air pressure:

Approx. 5 to 6 bar Approx. 0.5 to 0.6MPa

Approx. 72.5 to 87 psi

Nordson will assume no warranty or liability for damage caused by anincorrect pressure setting.

Operation4‐2


Setting Material Pressure

The material pressure is generated by the melter pumps. The maximummaterial pressure may not be exceeded:


Positioning the ApplicatorTrueCoat® HP applicators can be used to coat against a roll.

5+10°

-5°

1 2 3 4

5

1 2 3 4

Fig. 4‐1

1 Applicator

2 Nozzle

3 Coating Roll

4 Substrate

5 Contact line Nozzle/substrate

The optimum angle of incidence of the applicator depends on variouscustomer-specific parameters. It is within the range of - 5° to + 10° .

The contact line (5 ) should be at the line at which the substrate (4 ) runs ontothe roll (3 ). The nozzle always has contact to the substrate (Refer to Fig.4‐1).

Ensure that contact is only on the dark gray segment of the coating roll (Fig.4‐1, right); otherwise the applied material could drip.

Operation 4‐3


Calculating Material Quantity

Sample Calculation

Nordson recommends following the sample calculation before starting up theapplicator and making a note of the application-specific values for applicationweight and width, substrate speed and pump output capacity in the tableCustomer-specific Values. These values can be used to calculate the pumpspeed and material quantity. Nordson also recommends entering results ofthe calculations in the table. This ensures that all values can be reproducedat any time.

NOTE: The material quantity for intermittent application is calculated thesame as for continuous material application.

Application weight (grammage) m = 20 g/m2

Application width of each material track b = 10 mm = 0.01 m

Substrate speed v = 500 m/min

Material quantity M = m � b � v = 20 g/m2 � 0.01 m � 500 m/min = 100.0 g/min

Output capacity of pump D = 2.4 g/revolution

Pump speed n = M � D = 100.0 g/min � 2.4 g/revolution � 42 rev/min

Customer-specific Values

Application weight (grammage) m

Application width b

Substrate speed v

Material quantity M = m � b � v

Output capacity of pump D

Pump speed n = M � D

Operation4‐4


Correcting Material Quantity and Material Distribution

Adjusting Needle Stroke

NOTE: Only the Control module DC-D5, P/N 7106788, offers the stemstroke adjustment feature.

CAUTION: The control module stem stroke adjustment is preset at thefactory. It may be modified only when material is distributed unevenly acrossthe application width.

The material flow quantity is regulated with the stem stroke adjustment (1,Fig. 4‐2). By setting the nozzle stem stroke differently on the individualcontrol modules, the material distribution can be corrected.


1 2

Fig. 4‐2

Operation 4‐5


Setting Material Distribution Evenly with Stem Stroke Adjustment

1. Identify the control module through which too much or too little material isflowing.

2. Release the stem stroke adjustment locknut (2, Fig. 4‐2) on this controlmodule.

3. Turn the stem stroke adjustment all the way clockwise. The controlmodule is now closed.

CAUTION: The maximum that the stem stroke adjustment can be moved istwo revolutions. Turning farther against the stop will destroy the controlmodule.

4. Turn the stem stroke adjustment counterclockwise approx. one quarter ofa revolution.

5. Measure the application weight:

6. If the application weight under the control module is too little, turn thestem stroke adjustment another one quarter of a revolutioncounterclockwise.

7. Repeat steps 5. and 6. until the desired application weight is achieved. Iftoo much material is being applied, turn the stem stroke adjustment backless than a quarter of a revolution.

8. Measure the application weight after every correction to the stem strokeadjustment. Continue to correct the stem stroke adjustment in smallerand smaller steps until the application weight setpoint is achieved withthe desired precision.

9. Tighten the stem stroke adjustment locknut (2, Fig. 4‐2) again.

Operation4‐6


Regulating Material Distribution with the Throttle Screws


The material supply into the nozzle can be altered using the throttle screws.Individually adjust the throttle screws to achieve uniform material distribution.

� Turn throttle screws clockwise: less material

� Turn throttle screws counterclockwise: more material.

NOTE: The throttle screw thread pitch is 1 mm.

1. Turn all throttle screws all the way clockwise to achieve a defined startingpoint.

2. Unscrew all throttle screws two complete revolutions.

3. Measure the material distribution across the entire application width.

4. Optimize the setting step by step. Depending on how greatly themeasurement result deviates from the desired material distribution, turnsingle screws or all of the screws farther out or back in. When doing this

� Turn the screws in or out only a quarter to half revolution with eachstep

� Measure material distribution again after each step.

5. Make a note of the optimum setting for all throttle screws.

Throttle screw settings

Note: The number of throttle screws depends on the application width.

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18

19 20 21 22 23 24 25 26 27

28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45

Operation 4‐7


Optimizing Material Application with Temperature Setpoints

NOTE: Only possible when applicators have heated manifolds.

If material is properly applied to the outer edges of the application pattern butnot in the middle, the applicator nozzle is concave (hollow) to the coating roll.

If the material is applied properly in the middle but not near the edges, thenozzle is convex (spherical).

These deviations from the parallel path can be corrected by setting differenttemperature setpoints for the manifolds on the back of the applicator than forthe remaining heating zones.

Correcting Nozzle Concavity

Fig. 4‐3 Nozzle is hollow (concave)

1. Set the temperature setpoints for the manifolds one to two degrees lowerthan the setpoints for the remaining heating zones.

The lesser heat expansion of the heating zones on the back of the applicatorcompensates for the concavity on the nozzle side.

2. As long as material application is not uniform across the applicationwidth, continue to adjust the temperature setpoints in steps. Thetemperature difference between the heating zones should never exceed10 °C.

Operation4‐8


Correcting Nozzle Convexity

Fig. ‐4 Nozzle is spherical (convex)

1. Set the temperature setpoints for the manifolds one to two degreeshigher than the setpoints for the remaining heating zones.

The greater heat expansion of the heating zones on the back of theapplicator compensates for the convexity on the nozzle side.

2. As long as material application is not uniform across the applicationwidth, continue to adjust the temperature setpoints in steps.

Setting Rotating Bar Speed

The speed of the rotating bar drive is either set manually or is a factor of theline speed signal (key‐to‐line).

In an application system with Nordson components, the control element usedto set the speed setpoint in manual mode (e.g. potentiometer or controlpanel) is located either on the melter or on a separate control box.

Speed controlled by the line speed signal can also be adjusted with the samecontrol element.

Set the speed [min-1] to approx. 10% of the web speed [m/min].

Operation 4‐9


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 body

Heated hose

Pump speeds Melter

Motor controller (setpoint)

Material pressure Melter


Notes

Form filled out by:

Name Date

Operation4‐10


Settings Record - Spare Copy

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 body

Heated hose

Pump speeds Melter


Material pressure Melter


Notes

Form filled out by:

Name Date

Maintenance 5‐1


Section 5

Maintenance


Relieving PressureATTENTION: System and material pressurized. Before removing heatedhoses and applicators, relieve system pressure. Failure to observe can resultin serious burns.

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

1. Set the motor speed of the unit feeding the material to 0 min‐1; switch offthe motor(s).

2. Place a container under the nozzle of the applicator.

3. Relieving pressure:

� On an applicator with throttle screws, use the screws to open thematerial supply to the nozzle.

� On an applicator with solenoid valves, activate the solenoid valveselectrically or manually (Refer to Figure 5‐1). Do not use sharpobjects! Repeat until no more material flows out.

Fig. 5‐1

Maintenance5‐2


Relieving Pressure (contd.)

4. Re‐use the material or dispose of it properly according to localregulations.

Regular Maintenance

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

Unit part Activity Interval Refer to

Entire applicator Inspect for damage Daily Page 5‐3

External cleaning Daily Page 5‐3

Purge with cleaning agent Daily when using PUR adhesives

Page 5‐4

Control modules Check for leakage Daily -

Nozzle Cleaning Regularly, or when the application pattern deteriorates

Page 5‐5

Replace shim plate When damaged Page 5‐10

Have it refaced

Replace

Cordset Inspect for damage Every time maintenance is performed

-

Air hoses

Control modules Check detection holes Daily Page 5‐3

Filter Clean filter cartridge and replace filter screen

Depending on degree of material pollution.

Recommendation: Every 100hours of operation

Page 5‐11

Maintenance 5‐3


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 Cleaning

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

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 softcloth.

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.

Inspecting Control Module

If material escapes from the detection hole, the interior seals are worn.Replace the control module when this occurs. Refer to page 7‐1, ReplacingControl Module with 4/2 Air Valve or page 7‐2, Replacing Control Modulewith 3/2 Air Valve..

Changing Type of Material

NOTE: 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. Refer to page 5‐4.

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

Maintenance5‐4


Purging with Cleaning Agent

CAUTION: 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. Rinse out cleaning agent just before beginningproduction again.

1. Maintain operating temperature.

2. Place a container under the nozzle.

3. Relieve pressure (Refer to page 5‐1).

4. Detach heated hose from applicator (Refer to page 3‐5).

5. Purge melter and heated hose if necessary (Refer to separate manuals).

6. Connect purging hose to the applicator.

7. Purge the applicator until the material has been flushed out completely.

NOTE: When PUR adhesive is used, do not proceed until right beforeproduction is to begin again.

8. Unscrew purging hose.

9. Screw the heated hose onto the applicator again.

10. Purge applicator (and, when appropriate, melter and hose) with thematerial currently in use to flush out the cleaning agent.

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

Maintenance 5‐5


Disassembling and Cleaning Slot Nozzle

6

22 3

1

5

7 68

4

Fig. 5‐2

1 Clamp

2 Fixing screw

3 Centering clamping screw (option)

4 Clamping screw

5 Nozzle

6 Mouthpiece

7 Shim plate

8 Mouthpiece receptacle

Maintenance5‐6


Disassembling and Cleaning Slot Nozzle (contd.)


The nozzle must be regularly disassembled (mouthpiece, shim plate andmouthpiece receptacle) and cleaned. Material residue affects the quality ofthe application. It must be removed.

1. Heat applicator until material is soft.

2. Before releasing the clamping screws, ensure that the nozzle (5 , Fig.5‐2) can not fall off.

3. Release all clamping screws (4 , Fig. 5‐2) and - if applicable - thecentering clamping screw (3 , Fig. 5‐2). Now the nozzle can be extractedout the side. If there is not enough space to the side of the applicator:Unscrew all of the clamps (1 , Fig. 5) and extract the nozzle out the frontof the unit.

4. Place the nozzle aside, somewhere out of harm's way.

5. Reduce the nozzle to the individual components: mouthpiece receptacle(8 , Fig. 5‐2), mouthpiece (6 Fig. 5‐2) and shim plate (7 , Fig. 5‐2).

6. Clean the individual parts. Refer to the data sheet from the materialmanufacturer for information on cleaning agents.

7. Reassemble the nozzle.

8. Install the nozzle in the applicator again by logically reversing steps 1 to4. When nozzles have a centering clamping screw, insert it in the centerclamp.

Maintenance 5‐7


Disassembling and Cleaning Nozzle with Rotating Bar

1

2

3

4

6

5

9

7

8

1

Fig. 5‐3 Example of an applicator with rotating bar exchangeable nozzle, shown without rotating bar motor


2 Clamp

3 Clamping screw

4 Nozzle

5 Mouthpiece receptacle

6 Rotating bar

7 Shim plate

8 Mouthpiece

9 Bar

1

Maintenance5‐8


Disassembling and Cleaning Nozzle with Rotating Bar (contd.)


The nozzle must be regularly disassembled (mouthpiece, shim plate,mouthpiece and, when applicable, rotating bar) and cleaned. Removematerial residue. Material residue affects the quality of the application.


2. Switch off the rotating bar motor (6 , Fig. 5‐3) and detach the rotating barfrom the motor. Refer to page 5‐10 Replacing Rotating Bar.

3. Remove all clamping screws (3 , Fig. 5‐3). Now the nozzle can beextracted out the side. If there is not enough space to the side of theapplicator: Unscrew all of the clamps (2 , Fig. 5‐3) and extract the nozzleout the front of the unit.

4. Place the nozzle aside, somewhere out of harm's way.

5. Extract the rotating bar sideways out of its track.

6. Unscrew the bars (9 , Fig. 5‐3). Ensure that the bars are not mixed upwhen reinstalling at a later time.

7. Reduce the nozzle to the individual components: mouthpiece receptacle(5 , Fig. 5‐3), mouthpiece (8 Fig. 5‐3) and shim plate (7 , Fig. 5‐3).

8. Clean all individual parts. Refer to the data sheet from the materialmanufacturer for information on cleaning agents.

NOTE: Nordson supplies a test pin with every rotating bar (1, Fig. 5‐4). Ithelps to optimally adjust the position of the the rotating bar. The diameter ofthe test pin is 0.02 mm larger than that of the rotating bar For information onhow to use the test pin, refer to 9. and 12.

NOTE: If necessary, order a new test pin, � 8 mm, P/N 7171775.

Fig. 5‐4

9. Clean the rotating bar seat. If there are stress marks visible on therotating bar seat, polish them with cutting oil. To do this, emery paper canbe wrapped around the test pin and used as a polishing tool.

10. Re-assemble to mouthpiece receptacle, mouthpiece and shim plate.

Maintenance 5‐9


Disassembling and Cleaning Nozzle with Rotating Bar (contd.)

11. Put the bars back into place and secure with screws. Use a torquewrench to tighten the bar fastening screws. Refer to the table for torque:

Thread size Property class Torque

M5 8.8 6 Nm

M6 8.8 12 Nm

12. Slide the test pin through the rotating bar seat, with the side that is notbeveled leading. If this is not possible, loosen the fastening screwssomewhat in the tight places and re-position the bars. If the test pin hastoo much leeway, tighten the fastening screws somewhat.

13. Extract the test pin and save it for later use.

14. Slide the rotating bar under the doctor blade.

15. Install the nozzle in the applicator again by logically reversingsteps 1 to 3.

16. Connect the rotating bar to its motor again.

Reface

Maintenance5‐10


Replacing Rotating Bar

The way in which the rotating bar drive is connected to the applicator is afactor of the available space in the parent machine and other conditionsspecific to the customer. Thus the procedure to detach the rotating bar drivecannot be described precisely here. In general:


1. Stop the material supply to the applicator and stop the rotating bar motor.

2. Detach the protective covers from moving drive elements if necessary.

3. Disconnect the drive from the rotating bar.

4. Refer to page 5‐7, Disassembling and Cleaning Nozzle with RotatingBar, step 3. ad the following steps, for instructions on how to proceed.

Inserting New Shim Plate

The nozzle must be removed from the applicator and disassembled toreplace the shim plate. Refer to page 5‐5, Disassembling and CleaningNozzle.

1. Disassemble nozzle.

2. Fit new shim plate between mouthpiece and mouthpiece receptacle. Theshim plate is held in place by two or more cylinder pins.

3. Screw nozzle halves together.

NOTE: The shim plate protrudes 0.1 to 0.3 mm out of the nozzle.

4. The shim plate must be ground until it is even with the mouthpiece andthe mouthpiece receptacle.

5. Screw the nozzle onto the applicator again.

Fig. 5‐5

Refacing Nozzle

The nozzle touches the substrate, causing it to naturally wear.

The nozzle may need to be refaced to compensate for wear.

NOTE: Nordson will assume no warranty or liability for damage resultingfrom incorrect refacing. The nozzle should be sent to Nordson for refacing.

Maintenance 5‐11


Replacing Filter Cartridge

NOTE: Remove the filter cartridge only when the nozzle filter is hot and notpressurized. Install only when nozzle filter is hot.


ATTENTION: System and material pressurized. Relieve system of pressurebefore replacing filter cartridge. Failure to observe can result in seriousburns.

Removing Filter Cartridge


2. Relieve pressure. Refer to page 5‐1.

3. Insert a screw with M8 thread into the center tapped hole (Fig. 5‐6).

Fig. 5‐6

4. Place a container under the filter bore.

5. Unscrew the filter cartridge counterclockwise with an open‐end wrench orring wrench (Fig. 5‐7).

Fig. 5‐7

6. Use pliers to remove the filter cartridge (Fig. 5‐8).

7. Purge the filter bore with material by allowing the melter pump to runslowly. This rinses out particles of dirt that may still be in the filter bore.

8. Properly dispose of material according to local regulations.

Fig. 5‐8

1

23

4

5

6

37

89

Maintenance5‐12


Installing Filter Cartridge



2. Slide the filter cartridge into the filter bore.

3. Screw in the filter cartridge with an open‐end wrench or ring wrench.Tighten only hand‐tight; do not use excessive force (Fig. 5‐9).

Fig. 5‐9

Disassembling and Cleaning Filter Cartridge


The filter cartridge can be disassembled only when it is warm. If the filtercartridge is not disassembled immediately after removal, it must be heated(e.g. with an air heater).

NOTE: Use only a cleaning agent recommended by the hot melt materialmanufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

NOTE: Always replace the filter screen (5).

1. Disassemble the filter cartridge.

2. Replace the filter screen (5).

3. Clean all other parts.

4. Check O‐rings (3 and 6) and sealing ring (2); replace if necessary.

5. Properly dispose of the cleaning agent according to local regulations.

Fig. 5‐10

1 Filter screw

2 Sealing ring

3 O‐ring 44x3

4 Filter sheath

5 Filter screen

6 O‐ring 35x2

7 Perforated disk

8 Serrated lock washer

9 Nut

Maintenance 5‐13


Maintenance Record

Unit part Activity Date Name Date Name

Applicator External inspection andcleaning

Nozzle Cleaning

Replace nozzle

Replace shim plate

Control module External cleaning

Replace control module

Filter cartridge Replace filter screen

Maintenance5‐14


Maintenance Record Form ‐ Spare Copy

Unit part Activity Date Name Date Name

Applicator External inspection andcleaning

Nozzle Cleaning

Replace nozzle

Replace shim plate

Control module External cleaning

Replace control module

Filter cartridge Replace filter screen

Troubleshooting 6‐1


Section 6

Troubleshooting


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.

In the column Corrective action, the remark that defective parts should bereplaced is generally not included.

Troubleshooting6‐2


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 Separate manualMelter

Melter pump is not working Check Separate manualPump

Applicator has not yetreached operatingtemperature

Wait until temperature hasbeen reached; checktemperature setting ifnecessary

Separate manualTemperature

controller

Applicator cold or not yetwarm enough

Refer to Applicator does notheat

- -

Compressed air notconnected

Connect Page 3‐4

Nozzle clogged Clean nozzle Page 5‐5

Nozzle stem is stuck Replace control module Seite 7‐1 or 7‐2

Filter cartridge is clogged Clean or replace filterscreen if necessary

Page 5‐12

Solenoid valves do notswitch

Refer to Solenoid valves donot switch

- -

Applicator doesnot heat

Temperature is not set Set on temperaturecontroller

Separate manualTemperature

controller

Plug not connected Connect Page 3‐3

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

- -

Heater cartridge(s) inapplicator defective

Replace Page 7‐4


Applicator doesnot reach the settemperature

Heater cartridge(s) inapplicator defective

Replace Page 7‐4

Ambient temperature toolow

Increase ambienttemperature

- -

Solenoid valvesdo not switch

Control unit not switched on Switch on Separate manualControl Unit

Plug not connected or loose Secure plug connectionswith a screw.

Page 3‐3

Troubleshooting 6‐3


Problem Refer toCorrective actionPossible cause

Thickened material at end of application pattern

Note: Material thickening can not be prevented; it can only be reduced.

Stem stroke too high Check stem stroke betweenpiston and socket block

Setpoint at DC-D3: 0.5 mm

Setpoint at DC-D5: 1.0 mm

- -

Applicationpattern not exact

Temperature not setprecisely on melter

Correct setting Separate manualMelter

Temperature of applicatornot set precisely

Correct setting Page 4‐1

Material quantity/pressurenot set precisely

Correct setting Page 4‐2

Control unit notprogrammed correctly

Correct programming Separate manualControl Unit

External pollution on nozzle Clean Page 5‐5

Pollution inside of nozzle

Nozzle damaged Replace nozzle

Application quantity andsubstrate processing speednot attuned to one another

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

Page 4‐3

Material unsuitable Ask manufacturer Data sheet of materialmanufacturer

Troubleshooting6‐4


Troubleshooting Table (contd.)


The open time* istoo long

Application temperature toohigh

Set temperature lower Separate manualTemperature

controller


The open time* istoo short

Application temperature toolow

Set temperature higher Separate manualTemperature

controller


* The open time is the time from when the material leaves the nozzle until ithardens on the substrate.

Repair 7‐1


Section 7

Repair


Replacing Control Module with 4/2 Air Valve


2. Detach the solenoid valve plug, release the control air connection andunscrew the material hose.

3. Extract the four screws M8 (1, Fig. 7‐1).

4. Extract the old control module from the warm applicator.

5. Apply high temperature grease (Refer to the page 7‐4, ProcessingMaterials) to the new control module:

� To the O‐rings� To the screw threads� Under the screw heads.

6. Insert the new control module, screw it into place and connect it.

1

2

Fig. 7‐1

Repair7‐2


Replacing Control Module with 3/2 Air Valve

Nordson recommends keeping a supply of control modules to preventproduction stoppage.

CAUTION: The control module is a high precision, valuable part. Handle verycarefully!

Removing Control Module


2. Release screws (M4).

1

Fig. 7‐2

3. Use a suitable tool, e.g. a screwdriver, to detach the control module fromthe air bar (instant plug connection) (1, Fig. 7‐2).

4. Extract the control module from the warm applicator.

Repair 7‐3


Replacing Control Module with 3/2 Air Valve (contd.)

Installing Control Module

NOTE: Required tool: Torque wrench.

1. Apply high temperature grease (Refer to page 7‐4, ProcessingMaterials) (Figure 7‐3):

� To the O‐rings� To the screw threads� Under the screw heads.

2. Insert the new control module. Do not tilt! The control module ispositioned correctly when the cylindrical part rests evenly on the body,below the detection holes. The gap between the square part and thebody is then 2 mm. Also compare to the adjacent control modules or toFigure 7‐3.

3. Screw in the screws by hand. Do not tighten yet.

Fig. 7‐34. Alternately tighten the two screws with a torque wrench.

a. Tighten both screws to 1.0 Nm.

b. Tighten both screws to 2.0 Nm.

c. Tighten both screws to 2.7 Nm.

5. Re-connect air and electrical connection.

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

Repair7‐4


Replacing Heater Cartridge or Temperature Sensor


1. Heat applicator to material processing temperature.

2. Disconnect the applicator from the voltage supply.

3. Unscrew electrical equipment cover of the affected heating zone.

4. Disconnect the heater cartridge or temperature sensor.

5. Extract temperature sensor from the hole. Use a suitable pin to push theheater cartridge out of the hole. If a heater cartridge or temperaturesensor firmly sticks, drill open the hole.

6. Connect the new heater cartridge or temperature sensor.

7. Apply PTFE grease to the new heater cartridge or temperature sensor,e.g. GLS 595/NZ, order number: P/N 783959.

8. Insert the new heater cartridge or temperature sensor.

9. Screw on electrical equipment cover.

10. Reconnect the voltage supply.

Processing Materials

Designation Order number Use

High temperature grease Apply to O-rings and threads

NOTE: The grease should not bemixed with other lubricants.Oily/greasy parts must be cleanedbefore application.

� Can 10 g P/N 394769

� Tube 250 g P/N 783959

� Cartridge 400 g P/N 402238

Technical Data 8‐1


Section 8

Technical Data

General Data

Type of heating Electrical resistance heating elements

Possible temperature sensors FeKo thermalelement

Pt 100 Ni 120

Max. closing pressure withoutcompressed air

15 bar 1,5 MPa 218 psi

Max. closing pressure withcompressed air


Max. locking pressure withoutcompressed air

100 bar 10 MPa 1450 psi

Max. locking pressure withcompressed air

100 bar 10 MPa 1�450 psi

Max. processable viscosity 80�000 mPas 80�000 cP

Air Pressure

Control air Approx. 5 to 6 bar Approx. 0.5 to 0.6MPa

Approx. 72.5 to 87psi

Temperatures

Max. ambient temperature 60 ° C 140 °F

Max. operating temperature 200 ° C 392 °F

Technical Data8‐2


Electrical DataATTENTION: The applicator is designed for only one operating voltage.Operate only at the operating voltage shown on the ID plate.

Operating voltage 230 VAC

Operating voltage frequency 50/60 Hz

Degree of protection IP 30

Power consumption Refer to ID plate

Voltage for solenoid valve 24 VDC

Dimensions and Weights

Dimensions Refer to technical drawing

Weight See consignment note

Technical Data 8‐3


Torques

Control Modules

Fig. 8‐1

Alternately tighten the two screws with a torque wrench.

1. Tighten both screws to 1.0 Nm.



Nozzle

Thread size Property class Torque

M5 8.8 6 Nm

M6 8.8 12 Nm

M8 8.8 25 Nm

M12 12.9 100 Nm

Technical Data8‐4


Clamps

M10: 10 Nm

M8: 25 Nm M8: 25 Nm

Fig. 8‐2

M12: 20 Nm

M12: 100 Nm

M12: 100 Nm

Fig. 8‐3

hot melt applicators truecoat hp -...

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