ultra foam mix cube c6 - emanuals.nordson.comemanuals.nordson.com/adhesives/english_manuals/... ·...

Ultra Foam Mix Cube C6

Manual 110811834//003-- English --

Nordson Deutschland GmbH D Buchholz--Mendt D GERMANY

P/N 7542078 E 2010 Nordson Deutschland GmbHUltra Foam Mix Cube C6

Part numberP/N = 7542078

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2010.

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

© 2010 All rights reserved.

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

AeroDeck, AeroWash, Apogee, ATS, Auto-Flo, AutoScan, BetterBook, CanNeck, Chameleon, CheckMate, ColorMax, Controlled Fiberization, ControlWeave, CPX,Dry Cure, DuraBlue, Dura-Coat, DuraPail, Dura-Screen, Easy Clean, Eclipse, EcoDry, e.DOT, E-Nordson, Equi=Bead, ESP, e Stylized, Fillmaster, Fill Sentry, Gluie,HDLV, iControl, iFlow, Ink-Dot, iON, Iso-Flex, iTrend, KVLP, Lacquer Cure, March, Maxima, MicroFin, MicroMax, Minimeter, Multifil, OptiStroke, Origin, PatternPro,PluraMix, Powder Pilot, Powercure, Primarc, Printplus, Process Sentry, Pulse Spray, PurTech, Ready Coat, Scoreguard, Select Series, Sensomatic, Shaftshield,SheetAire, Spectral, Spectronic, Speedking, Spray Works, Summit, SureBead, Sure Brand, Sure Clean, Sure-Max, Swirl Coat, Tempus, ThruWave, Trade Plus,Trak, Ultrasmart, Universal, Vantage, Viper, Vista, Web Cure, 2 Rings (Design) are trademarks -- T -- of Nordson Corporation.

Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes,could lead to violation of the owners’ rights.

Table of Contents I

P/N 7542078E 2010 Nordson Deutschland GmbH Ultra Foam Mix Cube C6

Table of ContentsSafety Instruction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Description 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using Hotmelt 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glue Tank 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Instructions 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Area of Use (EMC) 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Restrictions 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unintended Use -- Examples -- 2-2. . . . . . . . . . . . . . . . . . . . . . . . . .Residual Risks 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Note on Manual 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Series Overview 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Explanation of Type Designation 2-4. . . . . . . . . . . . . . . . . . . . . . . . .ID--Plate 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Software Notice 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Notice on Electrical Engineering 2-5. . . . . . . . . . . . . . . . . . . . . . . . .Health--Endangering Media 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lockable main switch 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emergency Stop Button (Optional for Stand--Alone Operation) 2-7. . .

Temperature Control 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Undertemperature Interlock 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . .Undertemperature Indication 2-8. . . . . . . . . . . . . . . . . . . . . . . . . .Overtemperature Indication / Shutdown 2-8. . . . . . . . . . . . . . . .Temperature Setback 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Description 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Functional Diagram 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foam Station 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor and Gear Pump 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure sensor 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Safety Valve 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Covers 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control system 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switch Cabinet Light Tower ( optional ) 2-15. . . . . . . . . . . . . . . . . . .Electrical Cabinet Ventilation 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .Hose connection X1 / X2 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface X8.1 / X8.2 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface Profibus (Optional) 2-16. . . . . . . . . . . . . . . . . . . . . . . . . .Door Lock 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connector Allocation 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assignment: 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface X10 / X 100 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsII


Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transport 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating conditions 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation: 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air humidity: 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air temperature: 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation and Alignment 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lifting (Unpacked Unit) 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhausting Adhesive Vapors 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Laying Cable 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Line Voltage 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External control and signal circuits 3-3. . . . . . . . . . . . . . . . . . . . . . .Pilot Voltage / Tach Generator 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical installation 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assignment of temperature controllers to temperature sensors 3-4. . . . .

Connecting Hoses 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Second Open-jawed Wrench 3-5. . . . . . . . . . . . . . . . . . . . . . . . .

Connecting 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disconnecting 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving Pressure 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start--up 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparation for start--up 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turning the machine on 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pre--condition: 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

User interface MP 277 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Mode 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual/Automatic Operation 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .General Note! 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Status ”Manual” 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Status ”Automatic” 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature settings 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting of pump / nozzle in automatic mode 5-3. . . . . . . . . . . . . . .Overview screen 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Values and Parameters -- Notes -- 5-3. . . . . . . . . . . . . . . . . . .Temperatures 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Password level 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Password level 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

User interface MP 277 B 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service --weekly timer-- 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual mode --Ultra Foam Mix-- 5-10. . . . . . . . . . . . . . . . . . . . . . . . .Automatic mode 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic mode --Ultra Foam Mix-- 5-13. . . . . . . . . . . . . . . . . . . . . .

Switching System ON/OFF 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Start--up 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Switch--off 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switching Off in an Emergency 5-15. . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents III


Maintenance 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Danger of burns 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving Pressure 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Pressure 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regular Maintenance 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance gear pump (optional) 6-2. . . . . . . . . . . . . . . . . . . . . . .Retightening of fastening screw 6-2. . . . . . . . . . . . . . . . . . . . . . . . .Inspection for External Damage 6-2. . . . . . . . . . . . . . . . . . . . . . . . .External Cleaning 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Over--temperature Thermostat 6-3. . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Type of Adhesive 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging with Cleaning Agent 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Cabinet Ventilation Maintenance 6-4. . . . . . . . . . . . . . . . . .

Replacement and Cleaning of Filter Mat 6-4. . . . . . . . . . . . . . . .Continuous Checks 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Checks 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .For heating elements with ceramic insulation: 6-5. . . . . . . . . . . . .Lubricant Recommendations for Threaded Connectors 6-5. . . . .

Motor / Gear 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Commissioning and Operation 6-6. . . . . . . . . . . . . . . . . . . . . . . .During Operation 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Intervals 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shaft sealings: 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting/Failure Corrective Action 7-1. . . . . . . . . . . . . . . . .

Some Hints 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting with Control System 7-2. . . . . . . . . . . . . . . . . . . . . . .Signal lamps and switch cabinet light tower 7-2. . . . . . . . . . . . . . .Automatic Mode 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual Mode 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshootingtables 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Device malfunctioning 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insufficient adhesive 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One channel (heating zone) does not heat 7-3. . . . . . . . . . . . . . . .No adhesive (no motor rotation) 7-4. . . . . . . . . . . . . . . . . . . . . . . . .Motor superheated 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Incorrect motor speed characteristics in automatic mode 7-4. . . .No adhesive (with motor rotation) 7-5. . . . . . . . . . . . . . . . . . . . . . . .No master reference voltage 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Spare Parts 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 8-1. . . . . . . . . . . . . . . . . . . . . . . . . .Example 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame for attaching parts 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foam unit 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear pump GP 300 P/N 7521775 8-6. . . . . . . . . . . . . . . . . . . . . . .Gas injection unit -- 150 P/N 7530752 8-7. . . . . . . . . . . . . . . . . . . .Foam Mixer Drive 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foam--Mixer unit C6 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Add--on kit Pump packing P/N 7522135 8-13. . . . . . . . . . . . . . . . . .Shielding 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pneumatic unit P/N 7547428 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions and Weight 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instruction 1-1


Chapter 1Safety Instruction

General Description

Safety InformationThe equipment described is intended for use in industrial electrical drivesystems.

The electrical equipment and machines described in this manual aremanufacturing resources used in industrial high--voltage current facilities.

This equipment can endanger life through rotating machinery and highvoltages, therefore it is essential that guards for both electrical andmechanical parts are not removed.

The following points should be observed for the safety of the personnel:

S Only qualified personnel familiar with the equipment are permitted toinstall, operate and maintain the devices.

S System documentation must be available and observed at all times.

S All non--qualified personnel are kept at a safe distance from theequipment.

S The system must be installed in accordance with local regulations.

A qualified person is a person who based upon his professional training,expertise and professional experience as well as on his knowledge of theaccident prevention and employee protection regulations is familiar with allsafety notes and established safety practices, with the installation, operationand maintenance of this equipment and the hazards involved. For moredetailed definitions see IEC 364.

It is recommended that anyone who operates or maintains electrical ormechanical equipment should have a basic knowledge of First Aid.

As a minimum, they should know where the First Aid equipment is kept andthe identity of the official First Aiders.

These safety notes do not represent a complete list of the steps necessaryto ensure safe operation of the equipment. If you wish further information,please contact your nearest representative.

Safety Instruction1-2


Using Hotmelt

Temperature

The temperature must not exceed or fall below the specified temperatureranges; continuous temperature monitoring is appropriate. Excessively hightemperatures may give rise to odours and impair the quality of the hotmelt.

Excessively low temperatures also have negative effects. Shouldsatisfactory results be achieved only at a temperature other than thespecified application temperature, please be sure to contact us.

Glue Tank

Do not leave the glue tank in heated state for a prolonged period withoutremoving the adhesive (thermal damage to the hotmelt).

When the machine is to remain out of operation for a prolonged period, theheating should be shut down or the temperature lowered. Glue tanks mustbe covered, in order to prevent contamination with paper dust, moisture anddirt.

We recommend regular cleaning of the melting and applicationsystems.

Should you have any doubts or experience any difficulties when using thehotmelt, please call us: We want to help before any damage occurs.

Caution -- Danger of Injury

Protect the operating personnel against burns when handling hotmelts in hotstate. Unfortunately, injuries occur when precautionary measures areignored. Protective gloves are to be worn.

Medical advice when hotmelt in hot state has come into contact withthe skin:

S Cool burn immediately with clean and cold water.

S Do not remove hotmelt residues from the skin.

S Cover burn with clean and moist compresses and consult a doctorimmediately.

Hotmelt adhesives also give off fumes at the specified applicationtemperature. This often gives rise to unpleasant smells.

In case of temperatures substantially below the specified applicationtemperatures, there is a danger that harmful decomposition products mayform.

Measures to remove the fumes via appropriate extraction areimperative.

Safety Instruction 1-3


Safety Instructions

Status as per January 1st, 2010Every person concerned with the transportation, mounting, operation,maintenance and repair of this machine is obliged to have carefully readand understood these operating instructions.

General InstructionsWork may only be carried out on this machine by duly trained staff and/or bystaff who have been correspondingly familiarized with its operation.

CAUTION: Improper use may pose risks to life and limb, to the machineitself and any ancillary equipment connected to it, and to the operationalefficiency of the machine.

The installed equipment may only be used for the purposes determined bythe manufacturer or for purposes customary for the type of machine. Themachine may only be operated by authorized staff with a suitableprofessional background and corresponding technical qualifications.

A professionally suitable person may, based upon his professional training,expertise and professional experience as well as on his knowledge of theaccident prevention and employee protection regulations, assess andexecute the tasks he has been charged with, recognizing possible hazards,provided he also fulfils the necessary personal (executive) prerequisites forhis work, e.g. capacity to work independently.

In order to avoid accidents, operation of the machine is only to be carriedout provided that the machine is in perfect working order.

No third--party equipment is to be used in conjunction with operating themachine since this would undermine the required level of operational safety.All working methods which impair the machine’s operational safety are to berefrained from.

The operator is obliged to immediately report any changes affectingmachine performance (and impairing operational safety) to the competentsupervisory staff.

In the event of a disruption which impairs staff safety, the operator is obligedto immediately shut down the machine. The machine may only be restartedonce the disruption has been remedied.

No safety features may be dismounted, manipulated, or renderedinoperative.

Such checking procedures must be carried out by staff who has been dulyfamiliarized with the machine’s operation.

The operating company is obliged to provide the required protective gear foroperating staff and is also obliged to ensure that this is used by all staffmembers.

All covers protecting driving parts must stay in place until the dangerousrotating movements have ceased. Before restarting the machine they haveto be installed properly

Safety Instruction1-4


Introduction 2-1

P/N 7542078� 2010 Nordson Deutschland GmbH Ultra Foam Mix Cube C6

Chapter 2

Introduction

IntroductionThese operating instructions are written so that those who are in charge ofoperating the machine described read, understand, and observe theinstructions given herein in every respect.

A complete copy of the technical documentation should always be kept inthe vicinity of the machine.

Particularly important details concerning the deployment of this machineshall be specially referred to in these operating instructions.

WARNING: The machine may only be used for the purposes describedhere in.

Non compliant use is strictly prohibited!

The operator shall be solely responsible for the consequences of anydeviations from the above.

Only by reading and knowing these operating instructions can machinedefects and mistakes in handling be avoided, thus ensuring trouble--freeoperation. It is thus very important that these operating instructions are trulyknown and understood by the people responsible.

Careful reading of these operating instructions prior to start--up is stronglyrecommended by us, since we shall not accept any liability for damages anddisruptions of operations which result from non--observance of theseoperating instructions!

We reserve the right to amend descriptions and details given in theseoperating instructions as may become necessary within the scope ofmaking technical improvements to the machine.

Introduction2-2

P/N 7542078 � 2010 Nordson Deutschland GmbHUltra Foam Mix Cube C6

Intended UseMelters in the series Ultra Foam Mix may be used only to feed hot meltadhesives.

CAUTION: Only suitable adhesives may be used!

WARNING: Polypropylene may not be processed!

Any other use is considered to be non--compliant. Nordson will not be liablefor personal injury or property damage resulting from unintended use.

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

Area of Use (EMC)

The units are designed to be used in industrial areas (Also refer to includedDeclaration of Conformity).

Operating Restrictions

When using in residential, business or industrial areas, the equipment maycause interference with other units, e.g. radios.

Unintended Use - Examples -

The unit may not be used under the following conditions:

� In defective condition

� When changes or modifications have been made by the customer

� Without heat protection and protective panels

� With electrical cabinet door open

� In a potentially explosive atmosphere

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

The unit may not be used to melt and feed the following materials:

� Explosive and flammable materials

� Erosive and corrosive materials

� Food products.

Introduction 2-3


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

� Risk of burns from hot adhesive

� Risk of burns from hot machine parts.

� Risk of burns during maintenance work which requires the equipment to

be heated up.

� Risk of burns from hot accessories, e.g. heated hoses and hot melt

application heads

� Material fumes can be injurious to health. Do not inhale.

Note on ManualNOTE: The position numbers in the illustrations do not correspond to theposition numbers in the technical drawings and parts lists.

NOTE: The actual machine may differ from the pictures in this manual.

Introduction2-4


Series OverviewThe following units are included in the series.

Unit Motors /

Pumps

Hose connection

Ultra Foam Mix Cube C6 2 1 Input

1 Output

Explanation of Type Designation

The unit Ultra Foam Mix is used as an example..

Ultra Foam Mix Cube C6

Type / Version

Designation for Nordson Melt AdhesiveApplicator that process adhesive.

ID-Plate

Buchholz - MendtNordson Deutschland GmbH

PHONE: +49 (0)2683 9467-0TYPE: UFM Cube C6

SERIAL NO.: 100811834/003PERFORMANCE: 17.000 Watt

MAXIMUM VOLTAGE: 3x 400VAC + N + PEYEAR OF CONSTRUCTION: 11 /2010

MADE IN GERMANY

Fig. -1 ID--Plate

Introduction 2-5


Software NoticeChanges to software provided by Nordson may only be made afterconsultation with the members of our staff charged with the maintenance ofthe software.

In the event of unauthorized changes being made to our software withoutour explicit approval, we for our part shall be exempt from any liability for allthus incurred cases of damage or loss, whether these be indirectly ordirectly connected to such changes.

Notice on Electrical Engineering

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

The machine and its accessories must be duly connected in compliancewith electrotechnical regulations. Regulations DIN EN1) 60 204 (Part 1) andDIN/VDE2) 0113 (Part 1) are to be observed.

Safety features (such as an emergency cutout switch, a limit switch, akey--operated switch, or light barriers, etc.) may neither be removed,bypassed, or impaired in any other way as regards their operationalfunctionality.

All safety--switch devices are to be periodically and systematically subjectedto an operational check.

The control system of the unit may only be handled by duly trained staff whohave been familiarized with the unit’s operation.

Maintenance and repair work may only be carried out if the machine isswitched off (power--off condition) and may only be carried out by a skilledelectrical worker.

A skilled electrical worker is defined as someone who, due to his specializedtraining, knowledge, and experience and due to his knowledge of therelevant rules and regulations, is able to properly assess the tasks he hasbeen assigned to do and is able to recognize possible hazards.

Health-Endangering Media

CAUTION: Gases, fumes, or types of dust which pose a hazard to healthmust be sucked off and possibly decontaminated. Highly inflammable andhazardous waste materials must be immediately removed from the workingarea.

All working processes which involve direct exposure of hot--melt to ambientair set free low--molecular decomposition products which may lead tonuisances caused by obnoxious odours and may, in higher concentrations,lead to mucous membrane irritations. Extraction facilities must thus beinstalled in the immediate vicinity of the machines.

DIN EN = harmonized European standard which has been transposed into German law.

DIN = Deutsches Institut für Normung (German Institute for Standardization)

DIN/VDE = Verband deutscher Elektrotechniker. (Association of German Electrical Engineers)

Introduction2-6


Lockable main switch

A lockable main switch is located on the control cabinet or control console ofthe Ultra Foam Mix. The colour identification is a red handle on a yellowbackground. This switch has the same function as an ”Emergency Stop”switch.

This main switch must be switched off if any work is carried out on the UltraFoam Mix (fitting, repair and maintenance work). Any person working on theinterior of the system must secure the main switch with a lock (e.g.padlock).

In case maintenance work has to be carried out with main switch connectedup, safety measures have to be taken acc. to your internal safetyprocedures.

If several persons are working at the same time on the Ultra Foam Mix atdifferent activities (e.g. engineer, electrician), each one must use his lockingequipment. A maximum of three locking devices can be used.

NOTE: The main switch must be set to I/ON when using the week timer.

� Used to switch on/off the unit.

� Position 0/OFF = Unit is switched off.

� Position I/ON = Unit is switched on.

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

Black Main Switch (Special Model)

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

Emergency Stop Button (Optional for Stand--AloneOperation)

The colour identification of the Emergency Stop button is a red knob on ayellow background. When the Emergency Stop button is pressed:

� the drive is switched off immediately and the heating circuit of themachine is disconnected.

� The valves are disconnected

In order to re--start the machine after the emergency--off has beenactivated, the button has to be unlocked. The Ultra Foam Mix has then to bere--started.

Reset of emergency stop via button “ Malfunction reset “

NOTE: Before making a reset, all malfunctions which have triggered the emergency--off have to bechecked carefully and remedied.

Introduction 2-7


Temperature Control

Also refer to manual Control System MP 277. The temperature is measuredby sensors and is electronically controlled by the control system.

Undertemperature Interlock

Die Untertemperaturverriegelung verhindert die Inbetriebnahme der Anlagebzw. des Systems bei noch zu kaltem Klebstoff, bis der Temperatur-Sollwertminus Untertemperaturwert überschritten wurde. Wird im laufenden Prozessdurch Störfall etc. diese Temperaturgrenze unterschritten, erfolgt eineAbschaltung mit entsprechender Meldung.

Undertemperature Indication

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

Overtemperature Indication / Shutdown

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

A distinction is made between excess temperature signalling and excesstemperature switch--off.

� Overtemperature indication through temperature controller: When the

temperature setpoint plus overtemperature value has been reached, therelay output Collective fault is switched and the red indication lampCollective fault lights. The unit remains ready for operation.

� Excess temperature switch--off is by thermostat(s) or an excess

temperature fuse as a hardware safeguard; and where hardwareprotection is not possible by an electronic (software) excess temperaturesafeguard: Functions as an emergency OFF in the event that the excesstemperature switch--off of the temperature controller is not workingproperly.

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

Temperature Setback

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

Introduction2-8


General Description

15

14

11

12

8

10

9

7

6

5

4

1

3

2

14

12

16

17

13

Fig. -2

1 Equipment base

2 Driving motor foam

3 Air deflector

4 Air defection system Foam unit

5 Fan

6 Temperature sensor

7 Heating plate

8 Pressure sensor

9 Hose adapter output

10 Gear pump

11 Hose adapter input

12 Support panel

13 Motor support panel

14 Driving motor pump

15 Pneumatik unit

16 Coupling pump drive

17 Basic frame

Introduction 2-9


General Description (cont.)

18

23

19

20

21

31

22

24

25

2726

28

30

29

Fig. -3 Pneumatic unit

18 Coupler plug

19 Manometer

20 Filter -- regulating valve

21 Fine filter

22 Air dryer with membrane

23 Fastening angle

24 Socket

25 Solenoid coil

26 Solenoidvalve

27 Sound absorber

28 Pressure swtich

29 Socket

30 Valve plug

31 Super fine filter

Introduction2-10


General Description (cont.)

42

32

34

35

36

37

5333

39

38

41

40

43

44

Fig. -4

32 Signal lamp

33 Switch carbine

34 Dissipator

35 Interface plug --XDP--

Extruder Profibus

36 External carbinet ventilation

37 Power supply

38 Touch pen

39 Touch panel TP177

40 Luminous button --Fault Reset --

41 Emergency Stop button

42 Main switch

43 Interface plug --X1--

Hose 1 /VDK 1

44 ID--Plate

Introduction 2-11


Functional Diagram

TI1

=C

oolin

g w

ater

cyl

inde

r zo

neTI

C2

=C

ylin

der

zone

1TI

C3

=C

ylin

der

zone

2TI

C4

=C

ylin

der

zone

3TI

C5

=C

ylin

der

zone

4TI

C6

=F

lang

eTI

C7

=H

ose

TIC

8=

Pum

p st

atio

nTI

C9

=P

ump

1TI

C10

=P

ump

2

OT

1 -

2=

Pum

p st

atio

nO

T 3

=P

ump

1O

T 4

=P

ump

2

LI1

=Le

vel h

oppe

r ne

arly

em

pty

LI1

=Le

vel h

oppe

r em

pty

PIC

1=

Out

put p

ress

ure

extr

uder

PIC

2=

Out

put p

ress

ure

pum

p 1

PIC

3=

Out

put p

ress

ure

pum

p 2

PS

1=

Man

omet

ric s

witc

h ex

trud

er

M1.

1=

Mot

or e

xtru

der

M1.

2=

Mot

or fa

n ex

trud

erM

2.1

=M

otor

pum

p 1

M2.

2=

Mot

or fa

n pu

mp

1 M

3.1

=M

otor

pum

p 2

M3.

2=

Mot

or fa

n pu

mp

2

EV

1

=In

ject

ion

unit

hopp

erE

V

2=

Pre

ssur

e re

lief v

alve

TI

1=

Mel

t Tem

pera

ture

Mix

er u

nit

TIC

1=

Foa

m u

nit f

ront

TIC

2=

Foa

m u

nit r

ear

TIC

3=

Mix

er u

nit

TIC

4=

Hos

e

PIC

1=

Inpu

t pre

ssur

e U

FM-C

ube

PIC

2=

Out

put p

ress

ure

UF

M-C

ube

PS

1=

Man

omet

ric s

witc

h ga

s in

ject

io

EV

1

=G

as in

ject

ion

UFM

M1.

1=

M2.

1=

M3.

1=

M3.

2=

Mot

or fa

n F

oam

uni

tM

4.1

=M

oto

1 (

UF

M =

> P

S)

Mot

or L

oad

pum

pM

otor

Foa

m p

ump

Mot

or M

ixer

uni

t

BF

TL

r fan

LE

GE

ND

E:

TI

TIC

LI

PIC

PI

EV

OT

PS

M

=Te

mp

erat

ure

sens

or

=Te

mp

erat

ure

cont

rol c

ircui

t

=F

ill le

vel s

enso

r=

Pre

ssur

e co

ntro

l circ

uit

=P

ress

ure

cont

rol

=E

lect

rica

l va

lve

=O

vert

empe

ratu

re f

use

=M

anom

etric

sw

itch

=M

otor

Introduction2-12


Foam StationThe foam station meters out exact quantities of glue and feeds them into thehoses and coating heads. The pumps are driven by separately controlledservo drives.

The foam unit maintains a constant primary pressure and serves a feedsystem for the pump station. When operating in automated mode, thisprimary pressure allows to feed variable quantities into the nozzles. Apressure--regulated system guarantees a constant supply of the pumps.

1. Motor Pump station

2. Coupling

3. cover plate

4. Pump connecting block

5. Gear pump

6. Blind plug gas injection

7. Hose connection input

8. Heating plate

9. Motor support

10. Temperature sensor

11. Pressure sensor

1

9

2

3

5

4

6

7

10

11

8

Motor and Gear Pump

The electronically controlled motor drives the gear pump. The speed is shownon the MP 277. As to adjustment of motor speed see manual MP 277.

NOTE: Never let gear pumps run dry.

CAUTION: The long--term rpm of motors / pumps should not to be lower

than 5 min--1 and not higher than 80 min--1 in order to avoid excessive wearand tear.

Pressure sensor

The pressure sensor is placed directly at the mixer exit and allows apressure--regulated operation of the unit.

The pressure is adjusted and shown on the MP 277 control system.

See manuals on MP 277 and pressure sensor.

Introduction 2-13


Electrical Safety Valve

The Ultra Foam is equipped with two pressure sensors that measure andcontrol the melt pressure at the entrance and the exit of the mixer unit.

2

1

Fig. -5

WARNING: Danger of bursting! Maximum gas injection pressure mustnot exceed 10 bars!

Important note: If the Ultra Foam Mix is not started up as described inChapter 4 (Start--up), the pressure sensor will be unable to operate.

The max. admissible operation pressure is 100 bars.

WARNING: The pressure sensor must not be damaged during fitting orcleaning work on the Ultra Foam Mix.

If the pressure sensor is defective, it may only be replaced by an intactpressure sensor of the same type and pressure measuring range. Astopping plug must not be used to replace the defective pressure sensor.

Introduction2-14


Covers

WARNING: Do not operate Ultra Foam Mix without the covers in place!

The covers must be removed in order to be able to tighten the heatingbands or remove the screw.

Control system

On the control system MP 277, values and parameters are set, andoperating modes and faults are displayed.

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

Switch Cabinet Light Tower ( optional )

Red Collective fault

Yellow Drive on

Green System ready

Fig. -6

Electrical Cabinet Ventilation

Electrical cabinet ventilation (fan with filter) reduces the temperature insideof the electrical cabinet. The filters must be serviced regularly. Refer toMaintenance.

Hose connection X1 / X2

They are used for the connection of two heating zones each (heated hoseand application head). Depending on the design of the unit one or morehose connections are wired.

Introduction 2-15


Interface X8.1 / X8.2

Serves as a connection between the system and external devices.

Interface Profibus (Optional)

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

Door Lock

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

The electrical cabinet can be opened for installation, maintenance andrepair. Store the included key such that it is accessible only to qualified andauthorized personnel.

The system may not be operated when the electrical cabinet is open.

Socket

Plug

Introduction2-16


Connector Allocation

A synchronisation of the applicator with other machines is effected via theX8 plug.

To do so, apply an external control voltage ( d.c. Voltage ) to the X8 plug.

Fig. -7

An external desired value may be coupled through X8 as reference voltagefor dosing the hotmelt in accordance with the machine speed.

Direct current -- dependent on machine speed:

Pin 1 +VDC 1 adjustable from 0 Volt through 200 Volt

Factory alignment ( 0 -- 10 ) Volt

Pin 2 0 VDC

Pin 3 not connected

Pin 4 PE Ground

Fig. -8

Fig. -9

Introduction 2-17


Installation

X9 Enable socket for the internal enable signal in automatic operation

Fig. -10

The X9 socket is used to supply three different internal output signals of theapplicator. A potential -- free contact switches between Pins 3 and 4 tosignal that the melt adhesive applicator is ready for production. Thetemperature state signals are present on pins 1, 2 and 5, 6.

Assignment:

Plug connector Socked connector

Pin 1 + 2 Undertemperature signal

Pin 3 + 4 Machine enable signal

Pin 5 + 6 Overtemperature signal

Plug connector Socket connector

Fig. -11

Introduction2-18


Procedure

Plug X 10 / X 100 for external control functions on automated production

X 100

Interface X10 / X 100

Serves as a connection between the system and external devices.

For valid allocation please refer to wiring diagram.

NOTE: Only use screened cables. Connect screening in accordance withEMC to ground.

NOTE: Inductive loads (like solenoid valves) to be connected to themachine have to be equipped with a protective device (e.g. free--wheeldiode) that renders the induced voltage arising upon shutting down aninductive load inoperative (contact manufacturer if necessary).

Introduction 2-19


Installation 3-1


Abschnitt 3Installation

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

UnpackingImmediately on arrival of the Ultra Foam Mix, a check is to be carried out tosee whether the applicator has been delivered in perfect working order.Check for any damage caused during shipping. Damages incurred in transitmust be confirmed in writing by the shipping agent and immediatelyreported to Fa. Nordson.

Save special pallet and angle brackets for later use. Reuse packagingmaterials or dispose of properly according to local regulations.

TransportPlease note:The Ultra Foam Mix must be transported in a horizontalposition!

S Use only suitable transport devices.

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

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

S Avoid jolts and vibrations.

Operating conditionsMachine installation requirements:

Installation:Up to maximum 1000 m above sea level, in rooms that are as dust free anddry as possible.

Dripping, spray or hose water must not be present in the vicinity of theextruder.

Air humidity:Formation of condensed water must be avoided, otherwise specialmeasures must be implemented.

Air temperature:+15 °C to +40 °C

Installation3-2


Installation and AlignmentThe installation and alignment of the Ultra Foam Mix is non--critical. Thedimensions of the applicator can be found in the dimensions sheet.

The basic frame is sufficiently rigid torsionally. Damage within the system isalmost entirely impossible.

Each Ultra Foam Mix is set up ready for production, aligned andpre--calibrated at the factory before delivery. A horizontal installation area isa pre--requisite.

S Set up only in an environment that corresponds to the stated Degree ofProtection (Refer to section Technical Data).

S Do not set up in a potentially explosive atmosphere!

S Protect from vibration

S Remove transport protection (if present)

S Check all plug and screw connections for tightness

S Leave enough free space around the unit.

Lifting (Unpacked Unit)Refer to the Technical Data for weight. Lift only at the unit frame usingsuitable lifting equipment or a forklift.

Removal1. Run the unit until empty,

2. In case of a long--term shut--down clean the unit with cleaning agent(see chapter maintenance).

3. Separate all connections from the unit, and allow the unit to cool down.

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

DisposalProperly dispose of unit according to local regulations.

Exhausting Adhesive VaporsMake sure that adhesive vapors do not exceed the prescribedlimits. Exhaust the vapors if necessary. Provide sufficient ventilation inthe area where the machine is set up.

Installation 3-3


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

Laying CableWARNING: Only lay temperature--resistant cables within the hot area of theinstallation.

Ensure that cables do not touch rotating and/or hot unit components. Do notpinch cables and check regularly for damage. Replace damaged cablesimmediately!

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

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

NOTE: The cross-section of the power cable must correspond to the ratedcurrent. Refer to ID plate for rated current.

The mains terminals are located in the electrical cabinet.

Refer to wiring diagram for connecting arrangement.

External control and signal circuitsWARNING: Connect the external control and signal circuits withappropriate cables in conformity with NEC Class I. To avoid short circuits,lay the cables in such a manner that they do not come into contact withprinted--circuit boards.

Pilot Voltage / Tach GeneratorFor key-to-line mode, pilot voltage must be connected to X8. The pilotvoltage can be supplied e.g. by a tach generator (accessory) driven by theparent machine.

WARNING: Master reference voltages 0 -- 10 V DC envisaged as standard.

Higher signal voltages are possible, but this requires a special adaptationcard.

CAUTION: Master reference voltages >12 V DC without adaptation cardcan destroy the input assemblies.

Installation3-4


Electrical installationThe technicians must familiarize themselves with the circuit documentationbefore starting installation work. The operator is responsible for correctdimensioning and implementation of the electrical system.

All power cables must be laid separately from the signal lines within thecable ducts or cableways. Power cables and signal lines are appropriatelymarked. The cables in the control cabinet must be correctly connected,using the connection terminals, to the cable support rails to safeguardagainst tensile loads.

The individual wires must be laid according to their target designations.Ensure that the terminal connections are tight and secure.

WARNING:

S All drives are set up for clockwise rotary fields.

S All heating elements on the Ultra Foam Mix must be retightened afterthe initial start--up. Retightening of ceramic heating bands must becarried out with extreme care.

S Electrical safety valves must be recalibrated according to processengineering specifications before the initial start--up (see Technical Datafor maximum permissible mass pressure).

S If test runs have already been implemented in the factory with theoriginal customer adhesives, the last two points are not required.

Assignment of temperature controllers to temperature sensorsThe assignment of temperature controllers to temperature sensors must bechecked (e.g. after repairs). The applicable controller must be set to 60 °Cfor this test.

WARNING! Before carrying out this test, ensure that the heating isdisconnected (switch off the automatic heating circuit breakers).

Remove the temperature sensor from the corresponding bore as per thecontroller numbering. Heat the sensor tip, e.g. with a lighter, but not with anyfluid. An increase in temperature should be displayed by the display of thecontroller connected to this temperature sensor.

All other zones should be checked as described above. Switch theautomatic circuit breakers back on when tests are complete.

The connecting sockets and plugs of the heating bands and correspondingtemperature sensors must be numbered for tools and tool connections. Thecorrect allocation of heating band connections to the temperature controllersmust be checked carefully. To do this, insert each plug in turn in the heatingbands of the zone being checked. A power consumption must be noted onthe ammeter of the corresponding temperature controller.

1 2 3

Installation 3-5


Connecting Hoses

Second Open-jawed Wrench

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

ConnectingIf cold material can be found in the hose connection, these components(1, 2) must be heated until the material softens (approx. 80 _C, 176 _F).

1. First connect the hose (3) electrically to the unit. For more than onehose: Every hose connection is allocated to a corresponding receptacle.Do not mistakenly exchange!

2. Heat the system and hose to approx. 80 _C (176 _F).

3. Screw on heated hose.

NOTE: Close unused hose connections with suitable port plugs.

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

Relieving Pressure

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

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

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

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

Installation3-6


Operation 4-1


Chapter 4Operation


WARNING: After each transport, check and tighten motor, coupling andgear pump if necessary

Start--upNOTE: Before pressing the main switch and actuating the control functions, the documentation has to beread carefully and the safety instructions have to be strictly adhered to!

NOTE: Special care is to be taken in the manual operation mode as this is a non--locke working status.Only specially authorised staff may use the Ultra Foam Mix manual operation mode.

Preparation for start-upAfter set--up of the machine as prescribed, it can be started. A more detaileddescription of the steps to follow can be found later on in thisdocumentation.

Connect dry, clean and unoiled compressed air / gas to the injection port.

1. Adjust compressed air supply to 5 bars.

2. Contacts may loosen during transport. Before and during the firststart--up these contacts have to be controlled and fastened if necessary.

3. All accessories like hoses, applicator heads, etc. have to be connectedmechanically.

4. All switches on the operation panel have to be set to ”0” or ”OFF”,emergency cut--out is to be unlocked.

5. Emergency cut--out is to be unlocked.

6. Connect external emergency cut--out chain. ( interface connector X 10/X100 )

7. Assign interface connector X10 / X100 according to electrical diagram.

8. Switch on main switch.

9. Wait for machine to start.

10. Check the good working order of the emergency cut--out and safetyswitch--off. The electrical installation is to be checked according to theenclosed electrical diagram.

Operation4-2


Turning the machine on

Pre--condition:1. Reset button is flashing. Acknowledge new Start--up by pressing the

reset button.

S is flashing on the initial screen. By activating this key, you

can read operating notifications and error messages.

S For further operations it is imperative to first renedy the faultsindicated and to acknowledge them one by one by activating thereset button.

2. Set the required temperatures using the MP 277 control panel. In thisconnection, see operating instructions on MP 277 (Chapter 5).

3. Wait for temperature clearance (all TIC green).

S Operational Message: Machine is currently heating up; it isoperational only after expiry of apre--defined follow--up time. The greenlight of the light tower shines.

User interface MP 277 5-1


Chapter 5User interface MP 277


Operating Mode

Manual/Automatic Operation

General Note!

The machine is generally to be operated either in manual operating mode(password) or in automatic operating mode.

WARNING: Mixed operating modes are not admitted.

Inactive temperature Zones (operator’s guide MP 277 in manual mode) arenot allowed for in the temperature interlock.

All machine parts that come into contact with the adhesive have to beheated before starting the pump.

Check whether the control for these heating Zones has been turned ” ON “in the respective operation menu of the MP 277.

User interface MP 2775-2


Operating Status ”Manual”The manual mode is protected by a password. It is only intended formaintenance and testing operations.

All functions of the unit can be selected individually.

By pressing the . key, switch from the basic mask to the main menu”Manual operation”. This mode is purely for set--up and testing operations.

Precondition for continuing operation:

S Temperature clearance must have been given (green TIC).

The pump may be pressure controlled as shown in the mask of theoperator’s guide.

The yellow signal lamp on the control cabinet indicates the pump’s operativecondition as soon as the pump starts.

By entering the nominal values on the MP 277 operation panel, the pumpspeed may be adjusted from 0 to 100 rpm.

S The mixer unit can also be operated via speed control.

Optional

The nozzle is controlled via the MP 277 by activating the button ” NozzleOpen / Closed”.

Operating Status ”Automatic”

This is the standard operating mode. By pressing the key, switch

from the basic mask to the main menu for automatic operation.

Choose operational mode, depending on the application either foam orcompact mode.

Pre--condition:

S Pressure control PID parameters must have been entered.

S Nominal values for pressure and speed must have been set.

S Temperature clearance must have been given.

Pre--condition for foam mode:

S ”Switch Foam ” ON / OFF ” has been turned to ” ON ”

S ”X100 start signal for foam unit must have been given.



Temperature settings

S Display of actual and set values; desired temperature values areadjustable.

S By further choosing the menu for adjusting the PID parameters

-- temperature controllers (protected by password).

Setting of pump / nozzle in automatic mode

S Desired start--up rpm for filling the mixer unit

S Desired pressure (exit)

S Desired rpm for mixer

S If foam mode has been chosen, the foam ratio has to be adjusted on theoperational unit.

S PID parameters, pressure controller (password)

The release and control functions in this mode are given via the interfaceplug X100 of the external control (see allocation of interface plugs inelectrical diagram)

The operational pressure are controlled by zero--potential contacts on X100( nozzle control ).

Overview screenOperational values nozzles / pumps. In automatic mode the start / stopcontrol for the pumps as well as the open / closed control of the nozzles ismade by the corresponding interface plug. Allocation see electrical diagram.

Precondition:

S Temperature release must have been given, (green TIC).

Setting Values and Parameters -- Notes --Values and parameters -- except air pressures for the pneumatics -- are seton the control system MP 277.

For additional information, refer to manual for control system MP 277 used.

TemperaturesCAUTION: The temperature setting is determined by the processingtemperature prescribed by the adhesive supplier. The maximum operatingtemperature for the product described here and heated components maynot be exceeded.

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



Password levelUser Name

Factory SettingName Shownon MP/TP

PasswordFactory Setting

Authorization

AA Operator 222 Set temperaturesStandby (temperature reduction)

BB Operator (higher level) 555 Manual modeConfirm messagesMixer settingsRead, write recipeFoam parametersService customerSet speedSet pressureSet temperaturesStandby (temperature reduction)Times (weekly timer)

CC Foreman 666 DiagnosisThreshold pressureThreshold temperatureManual modeConfirm messagesMixer settingsPID pressurePID temperaturesRead, write recipeRecipe new, save, clear, cardFoam parametersService customerSet speedSet pressureSet temperatureenStandby (temperature reduction)System settingsTimes (weekly timer)Password level

DD Maintenance 888 DiagnosisThreshold pressureThreshold temperatureManual modeInstandhaltung AllgemeinConfirm messagesMixer settingsPID pressurePID temperaturesRead, write recipeRecipe new, save, clear, cardFoam parametersService customerSet speedSet pressureSet temperaturesStandby (temperature reduction)System settingsTimes (weekly timer)



Password levelUser Name

Factory SettingName Shownon MP/TP

PasswordFactory Setting

Authorization

Admin Administrator 999 DiagnosisThreshold pressureThreshold temperatureManual modeGeneral maintenanceConfirm messagesMixer settingsPID pressurePID temperaturesRead, write recipeRecipe new, save, clear, cardFoam parametersService customerSet speedSet pressureSet temperaturesStandby (temperature reduction)System settingsTimes (weekly timer)Password level



User interface MP 277 B

Service

Fig. 5-1



Service -weekly timer-

Fig. 5-2



Service

Fig. 5-3



Manual mode

Fig. 5-4



Manual mode -Ultra Foam Mix-

Fig. 5-5



Manual mode -Ultra Foam Mix-

Fig. 5-6



Automatic mode

Fig. 5-7



Automatic mode -Ultra Foam Mix-

Fig. 5-8



Automatic mode -Ultra Foam Mix-

Fig. 5-9



Switching System ON/OFFNOTE: Before initial start--up, read and observe the instructions in InitialStart--up. Start up only as described under Initial Start--up.

NOTE: The main switch must be set to I/ON (switched on) when using theweekly timer. Refer to separate manual.

NOTE: When external system release via interface plug X10 is used, themain switch must be set to I/ON (switched on).

Daily Start-upNOTE: Gear pumps may not be operated without hot melt material. Beforeswitching on the motor, ensure that the tank is filled.

1. Set main switch to I/ON.

2. Wait until the unit is ready for operation.

3. Switch on motor.

Daily Switch-off1. Switch off motor.

2. Set main switch to 0/OFF.

3. If necessary, secure main switch with padlock against unauthorizedaccess.

4. Make daily inspection.

Switching Off in an EmergencyWARNING: Switch off the unit immediately in any emergency situation.

1. Set main switch to 0/OFF.

2. After standstill and before switching the unit on again, have themalfunction remedied by qualified personnel.

Black Main Switch (Special Model)

Systems with a black main switch are normally supplied with power by ahigher--ranking system; the higher--ranking main switch is on that system.

The black main switch does not perform the EMERGENCY OFF function.Connected components can still be live!

Maintenance 6-1


Chapter 6Maintenance


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

Danger of burnsSome maintenance work can only be done when the machine is heated--up.

WARNING: Danger of burns from hot components and escaping hotadhesive! Wear protective gloves, clothing and shoes!

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

Relieving Pressure

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

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

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

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

1

2

3

Maintenance6-2


Regular MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on operating environment, production conditions and hours ofoperation, other scheduled maintenance tasks may prove necessary.

Unit part Activity Interval

Entire Ultra Foam Mix External cleaning Daily

Inspection for external damage Daily

Geared motor Change of lubricant Respect manufacturerer’srecommendations.

Gear pump Check pump for leakages Hours of operation 500 h.

Condensate collector ofair maintenance unit

Empty As necessary

Electrical CabinetVentilation

Clean fan screens, clean or replace filter Daily, if dust accumulation issevere

Pressure sensor Refer to separate manual

Pneumaticsmaintenance unit

Control operational pressures and waterseparator

weekly

Maintenance gear pump (optional)Gear pump maintenance is limited to the tightening of the seat screw for thepacking gland. (1). This has to take place whenever adhesive leaksbetween the shaft and the seat. A quarter turn of the screw is mostlysufficient.

Unscrew the safety plate (2, 3), readjust the packing gland, readjust thesafety plate and fasten.

The safety plate prevents the gland from loosening through vibration.

If no further tightening is possible the pump has to be replaced.

WARNING: When using highly viscous adhesives and / or adhesives withfillers, the gear pumps are subject to increased wear and tear. Please talk tous first. We can recommend specially hardened pumps as an alternativewith comparatively higher service lives.

Retightening of fastening screwDue to thermal influences ( heating up / cooling down of the machine ),fastening screws might become loose.

NOTE: Retighten these screws only with machine cooled down completelyusing only a torque wrench ( 35 Nm).

Inspection for External DamageWARNING: When damaged parts pose a risk to the operational safety ofthe unit and / or safety of personnel, switch off the unit and have thedamaged parts replaced by qualified personnel. Use only original Nordsonspare parts.

Maintenance 6-3


External CleaningExternal cleaning prevents impurities created by production from causingunit malfunctions.

CAUTION: Observe manufacturer‘s instructions when using cleaningagent.

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

Only remove adhesive remnants with cleaning agents recommended by theadhesive manufacturer. If necessary heat cold Ultra Foam Mix untiladhesive is liquid.

Thoroughly remove warm adhesive with a cleaning agent and / or soft cloth.

Vacuum off dust, fluffs etc. or remove them with a soft cloth.

Cleaning

Usually cold material can be torn off the machine parts. If necessary heatcold Ultra Foam Mix until adhesive is liquid.

NOTE: Do not use metallic tools. Do not use wire brushes. Theanti--adhesive coating will be damaged if you do so.

Use soft cloth if necessary.

Over- temperature ThermostatThe over--temperature thermostats (1) serve as an automatic switch--off incase the over--temperature shutdown of the temperature controller does notfunction properly.

NOTE: Depending on the type of adhesive used, the over--temperaturethermostats of the unit may need to be adapted to the maximum processingtemperature of the adhesive (this may mean replacing it). Refer to TechnicalData.

NOTE: Upon mounting, the overtemperature fuse, they have to be fastenedwith a torque of max. 1Nm!

Changing Type of AdhesiveRemove the old adhesive by running until empty or by draining the unit.

NOTE: Before changing the type of adhesive, determine whether the newadhesive may be mixed with the old adhesive.

S May be mixed: Remaining old adhesive can be flushed out using thenew adhesive.

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

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

Maintenance6-4


Purging with Cleaning AgentCAUTION: Use only a cleaning agent recommended by the adhesivemanufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

Before starting production again, flush out cleaning agent residue using thenew adhesive.

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

Electrical Cabinet Ventilation MaintenanceThe electrical cabinet fan is maintenance-free. The filter must be cleaned orreplaced, depending on dust accumulation.

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

Replacement and Cleaning of Filter MatRemove cover to replace filter mat.

Wash filter mat in water of up to 40°C, with a mild detergent added ifnecessary. It is also possible to beat, vacuum or to blow with compressedair.

In case of greasy substances:

Wash filter mat in benzine, trichorethylene or warm water with greasesolvent added. Do not wring nor use sharp jet.

Continuous ChecksS Check safety equipment functionality. The control cabinet door must

be closed.

S Check whether all cable connections are tightly connected to theterminals and whether all fuses are securely held by the clips. Heatcaused by poor contacts can damage both the fuses and the clips.

WARNING: Important: If terminal blocks are not tightly connected there isgrave danger of overheating which may result in cable fire!

S Check the fit of thermo--elements.

S Check the electrical conductance of all heating zones. The insulationresistance should lie above 1000 Ohm/Volt.

S Check the symmetrical power input under load conditions in the 3phases of the thyristor board. Use an ammeter.

The values of the 3 phases should not differ by more than 10 %.

S Check heating and thyristor contactors for correct condition andfunction. Worn contacts must be replaced as soon as possible toavoid subsequent damage.

Check the condition of all patch cords for nozzles or tools. Ensure that theearthing terminals have a resistance lower than 0.1 Ohm to the steel of thetool.

Maintenance 6-5


General Checks

S Check all connections, tighten terminals where necessary.

S Mains connection should only be implemented with a clockwise rotaryfield, check using a rotary field indicator.

S Permissible mains voltage deviation at 400 V: +6% / --10%.

S Check on--state of all circuit breakers and automatic circuit breakers.

S Check condition of controller and fault signals.

S Check all fuses for throughput.

WARNING: Do not replace special semi--conductor fuses with normalfuses. Check motor connections in terminal box.

For heating elements with ceramic insulation:During the initial heating procedure check and retighten, where necessary,the clamping screws at regular intervals until the operating temperature hasbeen reached. Any tightening required must be carried out with particularcare. Too high a pre--stress can lead to the ceramic stones being damaged.The aluminium cooling elements located between the heating elementsmust also be checked for correct fit and retightened if necessary.

NOTE: When mounting the Heating cuffs, they are to be fastened with atightening torque of 1,5Nm!

WARNING: Danger of burns from hot components! Wear protectivegloves, clothing and shoes!

Lubricant Recommendations for Threaded ConnectorsAll threaded connectors exposed to high temperatures must be correctlytreated with suitable lubricants. The correct selection of solid lubricantsfacilitates easy tightening of all connections and loosening in assemblywork.

All connections, screws and nuts must be cleaned before applying therecommended Molykote Paste HSC Plus. This paste must be appliedextremely thinly with a hard brush.

The Molykote lubricant film must be applied without any gaps to threadflanks and roots, and head/nut contact surfaces.

Maintenance6-6


Motor / Gear

Commissioning and Operation

NOTE: The drive may be set up for operation by qualified personnel only!

Before starting do check:

S whether the mechanical fastenings are OK

S whether all electrical connections are OK

S whether all rotating parts and all surfaces that may reach hightemperatures have been protected against contact.

During OperationYou should institute regular controls also during operation. Pay specialattention to:

S unusual noises or temperatures

S leakages

S fastening elements that may have become loose

S condition of electrical connections / cables

Maintenance Intervals

The motor(s) / gear(s) of your machine have been filled before delivery withlubricants specifically adapted to their purpose and design.

This ready--to--use original filling is one of the lubricants as named under thetype of gear stated in the reference table of Lenze (manufacturer).

The quantity of lubricant used depends on the installation position anddesign of motor / gear as specified at the time of order.

Lenze recommends to also renew the grease of the bearings as well as theradial seals when exchanging the motor lubricant.

The mechanical power transmission system is maintenance--free.

NOTE: Lubricant should be regularly exchanged with gears from size 05.

S The type of lubricant is noted on the type plate. Only use identicallubricant!

S Maintenance Intervals: Please refer to manufacturer’s instructions.

Shaft sealings:

S Their durability depends on the operating conditions;

S renew seals when leaking in order to avoid subsequent damages.

Troubleshooting 7-1


Chapter 7Troubleshooting


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

Troubleshooting/Failure Corrective ActionProvided these operating instructions are conscientiously adhered to,provided the machine is properly and expertly operated, and provided thespecified maintenance work is carried out, operational disruptions are not tobe expected.

WARNING: Should unforeseeable disruptions nevertheless occur, thetechnical safety instructions must be strictly observed in resolving them.

After a disruption has occurred, the machine may only be restarted if thereason for the disruption has been established and the disruption or faulthas been remedied.

In cases of uncertainty, Nordson is to be consulted. In so doing, please giveexact information about the disruptive effects, e.g. details on the respectivestatus of signal lamps and readings. Furthermore, the complete serialnumber or constructor’s number is to be stated.

Acknowledgement of malfunction signals with Fault reset button ( necessaryfor further operation of machine )

Nordson Deutschland GmbH

Industriepark Nord 23, 53567 Buchholz--Mendt / Germany

Phone +49 2683 9467--0, Fax +49 2683 9467--50

Troubleshooting7-2


Some HintsBefore systematic troubleshooting is begun, the following points should bechecked:

S Are all parameters set correctly?

S Has the interface X10 / X 100 been wired correctly?

S For automatic mode: Is pilot voltage X8 present?

S Do all plug connections have sufficient contact?

S Have fuses been activated?

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

S Have external inductive loads (e.g. solenoid valves) been equipped withfree--wheel diodes? These diodes have to be grouped directly togetherwith the inductive load, e. g. by means of luminous sealings.

Troubleshooting with Control SystemThe control system offers the following troubleshooting aids, described inthe manual Control System:

S Indication lamps and light tower

S Diagnosis program in the temperature section SPS (Touch Panel)

S Automatic fault display in the Touch Panel

S Service display Error in the motor section

S LEDs on the modules and boards.

Signal lamps and switch cabinet light towerThe signal lamps and lights show (apart from the yellow lamp of the switchcabinet lights) the same operational modes as the control system:

Automatic Mode

S Continuous Red Light = shows a malfunction / unit is in stand--by

S Continuous Yellow Light = external release and release MP 277

S Flashing Yellow Light = external release, no release MP 277

S Continuous Green Light = ready for operation. The green light onlyshines when all channels have reached their temperature set value.

S Flashing Green Light = operating

Troubleshooting 7-3


Manual Mode

S Continuous Red Light = shows a malfunction / unit is in stand--by

S Continuous Yellow Light = motor on

S Continuous Green Light = ready for operation.

S Flashing Green Light = operating

TroubleshootingtablesThe troubleshooting tables are an orientation aid for qualified personnel;however, they cannot replace targeted troubleshooting using for examplecircuit diagrams or measuring devices. They do not cover all possiblemalfunctions, but only those which could presumably occur.)

Device malfunctioning

Possible Cause Corrective Action

No line voltage Establish line voltage supply.

Master switch not switched on Switch on master switch

Main switch defective Replace main switch

Master fuse triggered Check whether there is a short--circuit in device orin equipment.

Fuse control voltage triggered Check whether there is a short--circuit in device orin equipment.

Insufficient adhesive

Possible Cause Corrective ActionAdhesive inlet hole to the pump or suction hole ofpump partially blocked

Unfasten pump and clean inlet hole or suction hole

Worn pump block of gear pump Replace pump

Processing temperature too low Adjust temperature settings

One channel (heating zone) does not heat


Channel switched off Switch on

Channel/heating zone defective Sensor break / remedy

Troubleshooting7-4


No adhesive (no motor rotation)


Motor superheated Remedy cause.

Remove motor contamination

Device not yet ready for operation (insufficienttemperature during heat--up phase)

Wait until device is heated--up and green signallamp illuminates

Device temporarily inoperable (insufficienttemperature during operation). / Adhesive wasrefilled.

Wait until device is heated--up and green signallamp illuminates

Motor not switched on Switch on ( important: motor must already be presetin MP 277 )

Motor not preset Preset motor and switch on subsequently

Motor start--up protection activated Switch motor(s) on again

Speed not set Set speed

Manual mode selected, however, automatic moderequired

Switch to automatic mode

No external Release Motor via X10 / X100 interface Bridge or switch contacts of X 10 / X100 interface.

Automatic mode selected and no master referencevoltage available

Enable master reference voltage supply or useinternal master reference voltage.

Temperature lowering switched on Switch off or wait until the lowering time is expired.

Motor defective Replace

No voltage supply for motor Determine defect metrologically

Central module of motor block defect or misaligned Align or replace

Control panel circuit board of motor block defect ormisaligned

Align or replace

Motor superheated


Ambient temperature too high Lower ambient temperature by aerating or cooling

Cooling air suction grid soiled Clean

Pump blocked by contaminant Replace pump

Pump too tight Replace pump

Adhesive too cold Set temperature according

Incorrect motor speed characteristics in automatic mode


Incorrect setting of parameters Reset parameters

Fluctuation of master reference voltage despiteconstant machine speed

Slip of drive unit (i.e. V--belt) Remove slip

Troubleshooting 7-5


No adhesive (with motor rotation)


Tank / Drum empty Refill tank / replace drum

Adhesive inlet hole to the pump or suction hole ofpump blocked

Unfasten pump and clean inlet hole or suction hole

No pump rotation because of loosened couplingscrews

Tighten

No master reference voltage


Master machine not operating Activate master machine

Tachogenerator (equipment) defective Replace

Faulty polarization of master reference voltage Reverse polarity

Troubleshooting7-6


Spare Parts 8-1


Chapter 8Spare Parts

IntroductionTo order parts, call the Customer Service Center or your localrepresentative. Use this five--column parts list, and the accompanyingillustration, to describe and locate parts correctly.

Nordson Deutschland GmbH

Industriepark Nord 23, 53567 Buchholz--Mendt / Germany

Phone +49 2683 9467--0, Fax +49 2683 9467--50

Using the Illustrated Parts ListNumbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (--) is used when the part numberapplies to all parts in the illustration.

The number in the Part column is the Nordson part number. A series ofdashes in this column (-- -- -- -- --) means the part cannot be orderedseparately.

The Description column gives the part name, as well as its dimensions andother characteristics when appropriate. Indentions show the relationshipsbetween assemblies, subassemblies, and parts.

Example

Item Part no Designation Quantity1 0000000 Part 12 000000 S Assembly 23 000000 S S Subassembly 1

NOTE: Parts marked with an asterisk (*) are wearing parts and are excluded from our guarantee.

S If you order item 1 you will get the single spare part as described.

S If you order item 2, you will get the complete assembly group.

S If you order item 3, you will get the subassembly.

The column ”quantity” shows the order quantity as per machine, assemblyor subassembly. The abbreviaton AR (as required) is used if e. g. therequired part is cut goods or if the quantity per assembly varies according tospecial machine versions or types.

Spare Parts8-2


Frame for attaching parts

1

11 16

10

9

11

7

62

33

4

13

14

65

15

12

68

Fig. -1

Spare Parts 8-3


Frame for attaching parts

Item Part Description Quantity1 7536681 Basic frame C6 12 7521055 Distance bracket 13 7520587 Insulating plate SE 24 7521031 Hang bolt 25 ------ Hexagonal screw ISO 4018 M16 x 100--NN 26 ------ Washer DIN 125 A 17 57 ------ Hexagonal screw ISO 4032 M16 x 90--NN 18 ------ Hexagonal nut ISO 4032 M 16--D--N 29 7528100 Equipment base 410 7534450 Mounting plate 411 ------ Machine screw DIN 912 M8 x 25------25N 2012 ------ Washer DIN 125 A 8,4 813 7525330 Sheet plate 114 ------ Counter sunk screw DIN 4991 M8 x 16------16N 415 ------ Hexagonal nut ISO 4032 M 8--D--N 816 7536713 Sheet control cabinet 2

Spare Parts8-4


Foam unit

1122

23

2

10

9

7

19

18

26

14

7

18

19

8

13

15

3

24

4

6

1

17

2117

20

16

16

2021

5

25

27

28

12

22

23

Fig. -1

Spare Parts 8-5


Foam unit

Item Part Description Quantity1 7520565 Foam block 12 7544088 Driving motor right 13 7521815 Blind plug gas injection 14 7530752 S Gas injection unit 150 15 7544086 Driving motor left 16 7500209 S Gear pump GP300 27 7520959 Column GP300------M16 58 7521317 Support panel 01 19 7521325 Support panel 02 110 7543934 Motor support panel 111 7543938 Insulating shield rear 112 7543936 Insulating shield front 113 7500186 Coupling M32------Ø25 -- Ø30 214 7052825 Pressure sensor 100 bar 1/2” UNF------flexible 115 7540884 Hose adapter 1 1/16 UNF -- M30 x 1,5 116 7050097 * Temperature sensor M14 x 1,5------FeCuNi 217 7521450 * Heating plate 504 x 120 218 ------ Hexagonal nut ISO4032------M16------D--C 819 ------ Washer DIN125------A 17 820 ------ Machine screw DIN912------M6 x 30------30N 2021 ------ Washer DIN125------A 6,4 2022 ------ Machine screw DIN912------M4x 8------8N 423 ------ Washer DIN125------A 4,3 424 7055192 * O--ring--PTFE Ø20 x 2,0 225 7056168 Machine screw DIN 912 M8 x 120 1226 7056003 Eye bolt 227 ------ Machine screw ISO 4018------M8x 25------25N 828 ------ Washer DIN125------A 8,4 8


Spare Parts8-6


Gear pump GP 300 P/N 7521775

1

2

34

6

5

7

8

Fig. -2

Item Part Description Quantity7050059 Complete pump packing ( Pos. 1 -- 6 )

1 7058200 Stuffing box screw 12 7058199 Spring 13 7058196 Spring guide 14 7058197 * Sealing ring 15 7058198 Bush 16 7504810 * O--ring PTFE Ø 30 x 2,0 1

7 7504716 * O--ring Viton Ø 19 x 2,5 18 7504729 * O--ring Viton Ø 36 x 2,5 1

O--rings and seal item 4 are available separately.


Spare Parts 8-7


Gas injection unit - 150 P/N 7530752

1

2

Fig. -1

WARNING: The casing has left--hand thread. Turning in the wrongdirection will destroy the thread!

Item Part Description Quantity1 7537609 Casing 150 / 9 12 7543374 * Gas injection unit 1


Spare Parts8-8


Foam Mixer Drive

13

1

26

25

32

33

24

23 2422 21

29

28

2434

32

2724

32 3224

3130

16 15

2

6

5

7

8

9

10

1112

12

14

4

317

1819 20

34

Fig. -1

Spare Parts 8-9


Foam Mixer Drive

Item Part Description Quantity1 7534586 Drive motor GKR05--2M HBR 100C32 D2 207,7 U_min 12 7521110 Motor fitting 13 7050215 * Coupling 14 7542086 Foam Unit 15 7521127 Driving shaft C5 16 7521131 Adjusting ring 01 17 7521133 Adjusting ring 02 18 ------ Threaded pin DIN 916 M6 x 8--N 19 ------ Threaded pin DIN 916 M6 x 6--N 110 7521145 Feather key DIN 6886 8 x 7 x 25 111 7521141 Feather key DIN 6886 8 x 7 x 70 112 ------ Machine screw DIN 912 M4 x 10------10 313 7521118 Insulating plate 01 114 7521606 Insulating shield front 215 ------ Machine screw DIN 912 M6 x 16------16N 216 ------ Washer DIN 125 A 6,4 217 ------ Machine screw DIN 912 M8 x 25------25N 618 ------ Washer DIN 125 A 8,4 619 7521122 Insulating bush 420 ------ Machine screw DIN 912 M10 x 30------30N 421 7522002 Air deflector C5 122 7522010 Sheet lock C5 123 ------ Hexagonal nut ISO 4032 M 5--D--N 224 ------ Washer DIN 125 A5,3 825 7521080 Air jacket 01 126 7521082 Air jacket 02 127 7538667 Air jacket 03 128 7538671 Air jacket 04 129 7050189 Fan 40 BFTL 130 ------ Machine screw DIN 912 M 4 x 12--N 431 ------ Washer DIN 125 A 4,3 432 ------ Machine screw DIN 912 M5 x 16------16N 733 7520027 Rivet nut M5 734 7520019 Rivet nut M4 4


Spare Parts8-10


Foam-Mixer unit C6

36

25

30 29

31

17

17

1

15

14

2

3

4

5

12

27 26 2835 34 37

38

39

23

14

6

24

13

18

16

9

32

33

20

7

2240

21

1011

8

19

Fig. -1

Spare Parts 8-11


Foam-Mixer unit C6

Item Part Description Quantity1 7520597 Foam casing C5 12 7520613 Foamer C5 13 7523144 Sealing lid C5 / bearing 14 7523152 Stuffing box casing with cooling Ø25 15 7541816 Bearing housing 2--fach 16 7522135 * Pump packing 17 7523168 Driving shaft 18 7523185 Feather key DIN 6885 6 x 6 x 20 19 7541806 * Bearing SKF--3204 A 110 7523178 * Bearing SKF--61804 -- 18 111 7523180 Retaining ring B27.7M -- 3BM1--32 112 ------ Machine screw DIN 912 M10 x 110 613 7522175* Bearing ring Ø 38 114 7521737 * PTFE O--ring Ø 84 x 2,0 215 7059125 * Bearing ring Ø 80 116 7050209 Inner ring IR70 x 80 x 25 117 7521739 * PTFE O--ring Ø 105 x 2,0 218 7521743 * PTFE O--ring Ø 71 x 2,0 119 7521745 * PTFE O--ring Ø 78 x 2,0 120 7520877 Adapter cover C5 121 7520879 End plate C5 122 ------ Machine screw DIN 912 M10 x 65------65N 623 7055276 * Bearing ring Ø 26 124 7059120 * Bearing ring Ø 35 125 7521062 Sleeve C5 126 7521051 Connection 127 7055013 * PTFE O--ring Ø 22 x 2,0 228 7504672 * Viton O--ring Ø 14 x 2,0 229 7056441 Sensor screw 1/2” UNF 130 7050097 * Temperature sensor PT 100 M14 x 1,5 131 7050076 Pressure sensor 0--350 bar 132 7521047 * Ceramic heating cuff Ø 139 x 340 1500W 133 7050097 * Temperature sensor PT 100 M14 x 1,5 134 7521037 Mixer holding 135 7521041 Insulating plate C5 136 7521039 Counter plate 137 ------ Machine screw DIN 912 M10 x 35------35N 238 ------ Machine screw DIN 912 M10 x 30------30N 139 7055341 Countersunk screw DIN 7991 M10 x 25------25N 240 7540884 Schlauchanschluss 1 1/16UNF -- M30 x 1,5 1


Spare Parts8-12


Spare Parts 8-13


Add-on kit Pump packing P/N 7522135

2

1

3

4

5

6

Fig. -1

Item Part Description Quantity1 7522133 Stuffing box screw 12 7058199 Spring 13 7058196 Spring guide 14 7058197 * Carbon sealing ring 15 7058198 Bush 16 7504810 * O--ring--PTFE Ø 30 x 2,0 1


Spare Parts8-14


Shielding

32

14

13

7

1110

516

11

9

8

10

17

4

1510

6

1

14

1312

Fig. -1

Spare Parts 8-15


Shielding

Item Part Description Quantity1 7524433 Covering hood front 12 7524417 Covering hood back 13 7536607 Cover plate 14 7538677 Shielding right 15 7538679 Shielding left 16 7530921 Ventilation grid front 17 7530923 Ventilation grid rear 18 7521838 Handle 29 ------ Counter sunk screw DIN 7991 M4 x 12------7.6N 810 ------ Washer DIN 125 A5,3 1011 ------ Machine screw DIN 912 M5 x 12------12N 412 7059124 Closure clamp GN851 160 T2 413 ------ Machine screw DIN 912 M4 x 12------12N 2614 ------ Washer DIN 125 A4,3 2615 ------ Machine screw DIN 912 M5 x 8------8N 616 7520027 Rivet nut M5 417 7520019 Rivet nut M4 34


Spare Parts8-16


Pneumatic unit P/N 7547428

2322

4

20

19

18

17

3

25

16

1223

5 24

8

2

6

131

2728

21

X 8 - 6

26

8 14

11

107

7

15

15

9

Fig. -1

Spare Parts 8-17


Pneumatic unit P/N 7547428

Item Part Description Quantity1 7536619 Filter regulating valve 162727 LFR -- 1/4 -- D -- 5 Mini -- A 12 7536623 Cut--in valve, electrically 172956 HEE -- D -- Mini -- 24 13 7536631 Pressure swtich 10773 PEV -- 1/4 -- B 14 ------ Valve plug 15 7536645 Fastening angle 159593 -- HFOE -- D -- MIDI -- MAXI 16 7055112 Socket MSSD -- EB 17 7529932 Quick connector screw 3561 -- CK -- M5 -- PK3 28 7536625 Sound absorber 6841 -- U -- “1/8” -- B 19 7536615 Solenoidvalve 7958 -- MFH -- 3 -- “1/8” -- S 110 7508860 Solenoid coil 34411--MSFG--24 DC -- 42 AC -- OD 111 7507901 Socket 30937 -- KMF -- 1 -- 24 -- 5 -- LED 112 7536669 L--Connection 193421 -- QS -- F -- G 1/4 -- 6 113 7055108 Coupler plug 2154 -- KS -- 4 -- “1/4” -- A 114 7545528 Mounting plate 215 7056492 L--Connection QSL -- F -- G 1/8 -- 6 116 7506768 Straight screw connection 1/4” 217 7536629 Branch module 170684 -- FRM -- D -- Mini 118 7536633 Fine filter LFMB--D_MINI--DA 119 7536635 Super fine filter LFMB--D_MINI--DA 120 7536647 Adapter plate--Set 1/4 -- 525033 -- LRBAS -- PBL 121 7502985 Isolating plate Ø20 POM 422 7536655 Straight screw connection QS -- F -- G 1/4 -- 6 223 7536653 Reducer 197633 -- D 1/4 I -- 1/2 A 224 7536641 Air dryer with membran 197509 -- LDM 1--1/2--D -- MAXI -- A 125 7055106 Sealing ring PVC 1/4” 226 7530616 Pressure relief valve 1/8” 127 ------ Machine screw DIN 912------M5 x 16------16N 428 ------ Washer DIN 125------A 5,3 429 7056353 Connection QS 1/8--6 130 7055787 L--Connection QSL 1/8--6 231 ------ Machine screw DIN912------M5 x 30------30N 232 ------ Machine screw DIN912------M4 x 8------8N 8


Spare Parts8-18


Technical Data 9-1


Chapter 9Technical Data

General Data

Adhesive pressure limitation Bis 80 bar / 0,5 bis 7 MPa / 72,5 bis 101,5 psiNois emission 70 dBAMotor type A.C motorSpeed setting range RPM range 5.0 -- 200 min --1

In automatic mode the mixer unit is beingpermanently operated with a minimum rpm of 5 rpm.When choosing ”foam”, the rpm is adjustedautomatically according to the adhesive flow within arange of 5 -- 200 RPM.

Protection class IP 32

Electrical DataCAUTION: The machine may only be used with one operating voltage, i. e.the voltage shone on the type plate.

Operating voltage 3 x 400 VAC+N+PEOperating voltage frequency 50/60 HzFuse protection 16 AmperePower consumption P depending on operation state chosenPower consumption Pmax 19.000WConnected load per hose connection socket (2channels)

Heated hoses 1000 WattApplicator head 500 Watt

Max. pilot voltage (input voltage) 160 VDC 10 VDC up to 160VDCThe pilot voltage may not exceed 160 VDC. Failureto observe will result in damage to succeedingcomponents.

or 0 - 10 V

The pilot voltage must be adjusted (Refer tomanual Control System).

Technical Data9-2


Temperatures

Min. ambient temperature 10 °CMax. ambient temperature 40 °CMin. operating temperature 50 °CStandard 240 °C

NOTE: Depending on the adhesive used the overtemperature thermostateshave to be aligned to the max. processing temperature of the adhesive, i. e.they have to be exchanged.

Dimensions and WeightDimensions Length ca. 1100 mm

Width ca. 887 mm

Height ca. 1903 mmWeight see waybill

~156

3

~190

3

~887 ~1100

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