Melt Adhesive Applicator PH 200 Manual 110586659/001 -- English -- NordsonDeutschlandGmbHDBUCHHOLZ--MENDTDGERMANY Note Thismanualappliestotheentireseries. Partnumber P/N=7542400 Notice ThisisaNordsonCorporationpublicationwhichisprotectedbycopyright. Originalcopyrightdate2009. Nopartofthisdocumentmaybephotocopied,reproduced,ortranslatedtoanotherlanguagewithoutthepriorwritten consentofNordsonCorporation. Theinformationcontainedinthispublicationissubjecttochangewithoutnotice. ©2009Allrightsreserved. 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AeroDeck,AeroWash,Apogee,ATS,Auto-Flo,AutoScan,BetterBook,CanNeck,Chameleon,CheckMate,ColorMax,ControlledFiberization,ControlWeave,CPX, DryCure,DuraBlue,Dura-Coat,DuraPail,Dura-Screen,EasyClean,Eclipse,EcoDry,e.DOT,E-Nordson,Equi=Bead,ESP,eStylized,Fillmaster,FillSentry,Gluie, HDLV,iControl,iFlow,Ink-Dot,iON,Iso-Flex,iTrend,KVLP,LacquerCure,March,Maxima,MicroFin,MicroMax,Minimeter,Multifil,OptiStroke,Origin,PatternPro, PluraMix,PowderPilot,Powercure,Primarc,Printplus,ProcessSentry,PulseSpray,PurTech,ReadyCoat,Scoreguard,SelectSeries,Sensomatic,Shaftshield, SheetAire,Spectral,Spectronic, Speedking,SprayWorks,Summit,SureBead,SureBrand,SureClean,Sure-Max,SwirlCoat,Tempus,ThruWave,TradePlus, Trak,Ultrasmart,Universal,Vantage,Viper, Vista,WebCure,2Rings(Design)aretrademarks--T--ofNordsonCorporation. Designationsandtrademarksstatedinthisdocumentmaybebrandsthat,whenusedbythirdpartiesfortheirownpurposes, couldleadtoviolationoftheowners’rights. P/N7542400 PH200--2xPE220--2 E2009 NordsonDeutschlandGmbH TableofContents I Table of Contents SafetyInstruction ....................................... 1-1 GeneralDescription ...................................... 1-1 SafetyInformation ..................................... 1-1 UsingHotmelt ........................................... 1-2 Temperature .......................................... 1-2 GlueTank ............................................ 1-2 SafetyInstructions ....................................... 1-3 GeneralInstructions ................................... 1-3 Introduction ............................................ 2-1 Introduction ............................................. 2-1 Introduction ............................................. 2-1 IntendedUse ............................................ 2-2 AreaofUse(EMC) .................................... 2-2 OperatingRestrictions ............................... 2-2 UnintendedUse -- Examples -- .......................... 2-2 Theunitmaynotbeusedtomeltandfeedthefollowingmaterials: 2-2 ResidualRisks .......................................... 2-3 NoteonManual.......................................... 2-3 SeriesOverview ......................................... 2-4 ExplanationofTypeDesignation ......................... 2-4 ID--Plate.............................................. 2-4 SoftwareNotice....................................... 2-5 NoticeonElectricalEngineering ......................... 2-5 Health--EndangeringMedia ............................. 2-5 Dangerouspointsandsafetydevices. ...................... 2-6 Dangerouspointsonthehot--meltadhesiveapplicator ...... 2-6 Safetydevicesonthehot--meltadhesiveapplicator ........ 2-7 LockableMainSwitch .................................. 2-7 DoorLock .......................................... 2-8 EmergencyStopButton(OptionalforStand--AloneOperation) ... 2-8 ElectricalSafetyValve ................................. 2-8 GeneralDescription ...................................... 2-9 Meltingthehotmelt .................................... 2-9 Modularconcept ...................................... 2-9 Deliveringandmeteringthehot--melt .................. 2-10 Machine--speed--adaptedoperationwithoneproductionline .... 2-10 Standardversion ...................................... 2-11 Modularconcept .................................... 2-11 Steeltank ............................................ 2-11 TemperatureControl ................................... 2-12 UndertemperatureInterlock ........................... 2-12 OvertemperatureIndication/Shutdown ................ 2-12 TemperatureSetbac ................................. 2-12 GeneralDescription ...................................... 2-13 FunctionalDiagram ...................................... 2-16 DescriptionofFunctionalElements ......................... 2-17 Drive................................................. 2-17 E2009W.PuffeHotmelt--Technology PH200--2xPE220--2 P/N7542400 II TableofContents MotorandGearPump ................................. 2-17 Pressuresensor ....................................... 2-17 BasicFrame .......................................... 2-17 Covers ............................................... 2-17 Pumpstation.......................................... 2-17 ElectricalCabinetVentilation ............................ 2-17 Hoseconnection ...................................... 2-18 InterfaceProfibus ................................... 2-18 DoorLock .......................................... 2-18 SwitchCabinetLightTower(optional) ................... 2-18 ControlSystem........................................ 2-18 Installation ............................................. 3-1 Unpacking .............................................. 3-1 Transport ............................................... 3-1 Lifting(UnpackedUnit) ................................. 3-1 Removal ............................................. 3-1 Storage .............................................. 3-2 Disposal.............................................. 3-2 InstallationandAlignment .............................. 3-2 AttachingLightTower .................................. 3-2 ExhaustingHotMeltAdhesiveVapors .................... 3-2 Electricalinstallation...................................... 3-3 Assignmentoftemperaturecontrollerstotemperaturesensors ..... 3-3 ElectricalConnections .................................... 3-4 LayingCable .......................................... 3-4 LineVoltage .......................................... 3-4 PilotVoltageatProfibus ................................ 3-4 Externalcontrolandsignalcircuits ....................... 3-4 InterfaceX100 ........................................ 3-4 PilotVoltage/TachGenerator ........................... 3-5 InterfaceProfibus(Option) .............................. 3-5 Operatingconditions ..................................... 3-5 Installation: ........................................... 3-5 Airhumidity: .......................................... 3-5 Airtemperature: ....................................... 3-5 ConnectingHeatedHoses ................................ 3-6 RelievingPressure .................................. 3-6 Connectinghosesandnozzles .......................... 3-7 Connectingthehose: ................................ 3-7 ConnectorAllocation ................................... 3-8 Installation ............................................ 3-9 Assignment: .......................................... 3-9 Procedure ............................................ 3-10 InterfaceX10/X100 .................................. 3-10 Theabovelayoutshowsthestandardallocation. ........... 3-10 Pressureadjustmentofbypass .......................... 3-11 Riskofburns ....................................... 3-11 Readoutdiagramm .................................... 3-12 Readoutdiagramm .................................... 3-13 Operation .............................................. 4-1 Settingintooperation ..................................... 4-1 PreparationsforStart--up ............................... 4-1 Electricalconnection ................................... 4-2 Generalcontrolfunctions ............................... 4-2 Externalcontrolfunctions ............................... 4-2 Beginningproduction................................... 4-3 Procedure ............................................ 4-3 P/N7542400 PH200--2xPE220--2 E2009W.PuffeHotmelt--Technology TableofContents III Settingintooperation .................................. 4-4 Errormessages ....................................... 4-4 SwitchingSystemON/OFF ................................ 4-5 SwitchingOffinanEmergency .......................... 4-5 DailyStart--up ......................................... 4-5 DailySwitch--off ....................................... 4-5 Operation .............................................. 5-1 Start--up ................................................ 5-1 PreparationsforStart--up ............................... 5-1 Settingintooperation .................................. 5-1 UserInterfaceMP277.................................... 5-2 Service............................................... 5-2 Weektimetimer ....................................... 5-3 Service............................................... 5-5 ManualMode ......................................... 5-6 Automaticmode ....................................... 5-8 Maintenance ........................................... 6-1 Dangerofburns ......................................... 6-1 RelievingPressure..................................... 6-1 RelievingPressure .................................. 6-1 RegularMaintenance ..................................... 6-2 Maintenancegearpump ................................ 6-2 ExternalCleaning ........................................ 6-2 InspectionforExternalDamage ......................... 6-3 Tank ................................................... 6-3 Manualcleaningoftank ................................ 6-3 OvertemperatureThermostat ........................... 6-3 ChangingTypeofAdhesive ............................. 6-3 PurgingwithCleaningAgent ............................ 6-4 ElectricalCabinetVentilationMaintenance .................. 6-4 ReplacementandCleaningofFilterMat ................ 6-4 GeneralChecks ....................................... 6-4 ContinuousChecks ...................................... 6-5 MotorLubrication ...................................... 6-5 LubricantRecommendationsforThreadedConnectors ..... 6-5 FaultRectification ..................................... 6-5 MaintenanceRecordForm .............................. 6-6 Troubleshooting ........................................ 7-1 Troubleshooting/FailureCorrectiveAction ................. 7-1 SomeHints ............................................. 7-2 TroubleshootingwithControlSystem ....................... 7-2 Signallampsandswitchcabinetlighttower ............... 7-3 AutomaticMode .................................... 7-3 ManualMode ....................................... 7-3 Troubleshootingtables.................................... 7-3 RedSignalLampFlashing .............................. 7-4 Devicemalfunctioning .................................. 7-4 Onechannel(heatingzone)doesnotheat ................ 7-4 Noadhesive(nomotorrotation) ......................... 7-5 Motorsuperheated .................................... 7-5 Nomasterreferencevoltage ............................ 7-5 Noadhesive(withmotorrotation) ........................ 7-6 Incorrectmotorspeedcharacteristicsinautomaticmode .... 7-6 Insufficientadhesive ................................... 7-6 E2009W.PuffeHotmelt--Technology PH200--2xPE220--2 P/N7542400 IV TableofContents Adhesiveresiduesintank............................... 7-6 Adhesivecureswithinthetank .......................... 7-6 Removing .............................................. 8-1 Dangerofburns..................................... 8-1 Disassemblyandassembly ............................... 8-1 Generalremarks .................................... 8-1 Howtotakeoutthemotor .............................. 8-1 Motoralignment ......................................... 8-2 Verticaladjustment: ................................. 8-2 Horizontaladjustment: ............................... 8-2 Shaftspacing: ...................................... 8-2 DismountingtheMeltpump ............................. 8-3 DisassemblyofthePump............................... 8-4 Cleaning ............................................. 8-6 Assembly............................................. 8-6 Dismantlingandclaeningofthecontrolvalve(bypass)...... 8-7 Exchangingthepressurespringinthecontrolvalve(by--pass). ..... 8-8 Changingafilter ....................................... 8-9 ChangingPTFEO--rings ............................... 8-10 Changingtheheatingcartridgeinthepremeltregister ...... 8-11 Mounting ........................................... 8-11 SpareParts ............................................ 9-1 Introduction ............................................. 9-1 UsingtheIllustratedPartsList .......................... 9-1 Example ............................................. 9-1 FrameforAttachingParts .............................. 9-2 Heatingelements ...................................... 9-4 Heatingplate P/N7534066 ............................. 9-5 Heatingplate P/N7056082 ............................. 9-6 Heatingplate P/N7056085 ............................. 9-7 HeatingregisterP/N7504003 ........................... 9-8 Tankcover............................................ 9-10 Tankcover............................................ 9-11 FilterUnit ............................................. 9-12 FiltercartridgeMW0,8(complete)P/N7056447 .......... 9-14 Thefilterscreenisavailableindifferentsizes. ............. 9-15 PumpDriveGP220 ................................... 9-16 Foam--PumpblockGP220P/N7542736 ................. 9-18 GearPumpGP220M2 ................................ 9-20 Gasinjectionunit P/N7056079 ......................... 9-21 ControlmoduleSD(specialdesign)Ø5/8mmP/N7058450 9-22 LiftadjustmentP/N7058442 ............................ 9-24 BypassP/N7058053 .................................. 9-25 Sidepanelling ......................................... 9-27 Sensorhoopguard .................................... 9-29 Pneumatikunit ........................................ 9-30 PneumatikunitStation1................................ 9-31 PneumatikunitStation2................................ 9-33 TechnicalData.......................................... 10-1 GeneralData ............................................ 10-1 ElectricalData ........................................... 10-1 Temperatures ........................................... 10-1 Dimension .............................................. 10-2 P/N7542400 PH200--2xPE220--2 E2009W.PuffeHotmelt--Technology SafetyInstruction 1-1 Chapter 1 Safety Instruction General Description Safety Information Theequipmentdescribed isintendedforuseinindustrialelectricaldrive systems. Thisequipmentcanendangerlifethroughrotatingmachineryandhigh voltages,thereforeitisessentialthatguardsforbothelectricaland mechanicalpartsarenotremoved. Thefollowingpointsshouldbeobservedforthesafetyofthepersonnel: S Onlyqualifiedpersonnelfamiliarwiththeequipmentarepermittedto install,operateandmaintainthedevices. S Systemdocumentationmustbeavailableandobservedatalltimes. S Allnon -- qualifiedpersonnelarekeptatasafedistancefromthe equipment. S Thesystemmustbeinstalledinaccordancewithlocalregulations. Aqualifiedpersonisapersonwhoisfamiliarwithallsafetynotesand establishedsafetypractices,withtheinstallation,operationand maintenanceofthisequipmentandthehazardsinvolved.Formoredetailed definitionsseeIEC364. Itisrecommendedthatanyonewhooperatesormaintainselectricalor mechanicalequipmentshouldhaveabasicknowledgeofFirstAid. Asaminimum,theyshouldknowwheretheFirstAidequipmentiskeptand theidentityoftheofficialFirstAiders. Thesesafetynotesdonotrepresentacompletelistofthestepsnecessary toensuresafeoperationoftheequipment.Ifyouwishfurtherinformation, pleasecontactyournearestrepresentative. E2009NordsonDeutschlandGmbH PH200--2xPE220--2 P/N7542400 1-2 SafetyInstruction Using Hotmelt Temperature Thetemperaturemustnotexceedorfallbelowthespecifiedtemperature ranges;continuoustemperaturemonitoringisappropriate.Excessivelyhigh temperaturesmaygiverisetoodoursandimpairthequalityofthehotmelt. Excessivelylowtemperaturesalsohavenegativeeffects.Should satisfactoryresultsbeachievedonlyatatemperatureotherthanthe specifiedapplicationtemperature,pleasebesuretocontactus. Glue Tank Donotleavethegluetankinheatedstateforaprolongedperiodwithout removingtheadhesive(thermaldamagetothehotmelt). Whenthemachineistoremainoutofoperationforaprolongedperiod,the heatingshouldbeshutdownorthetemperaturelowered. Gluetanksmustbecovered,inordertopreventcontaminationwithpaper dust,moistureanddirt. Werecommendregularcleaningofthemeltingandapplication systems. Shouldyouhaveanydoubtsorexperienceanydifficultieswhenusingthe hotmelt,pleasecallus:Wewanttohelpbeforeanydamageoccurs. Caution -- DangerofInjury Protecttheoperatingpersonnelagainstburnswhenhandlinghotmeltsinhot state.Unfortunately,injuriesoccurwhenprecautionarymeasuresare ignored.Protectiveglovesaretobeworn. Medicaladvicewhenhotmeltinhotstatehascomeintocontactwith theskin: S Coolburnimmediatelywithcleanandcoldwater. S Donotremovehotmeltresiduesfromtheskin. S Coverburnwithcleanandmoistcompressesandconsultadoctor immediately. Hotmeltadhesivesalsogiveofffumesatthespecifiedapplication temperature.Thisoftengivesrisetounpleasantsmells. Incaseoftemperaturessubstantiallybelowthespecifiedapplication temperatures,thereisadangerthatharmfuldecompositionproductsmay form. Measurestoremovethefumesviaappropriateextractionare imperative. P/N7542400 PH200--2xPE220--2 E2009NordsonDeutschlandGmbH SafetyInstruction 1-3 Safety Instructions Status as per January 1st, 2009 Everypersonconcernedwiththetransportation,mounting,operation, maintenanceandrepairofthismachineisobligedtohavecarefullyread andunderstoodtheseoperatinginstructions. General Instructions Workmayonlybecarriedoutonthismachinebydulytrainedstaffand/orby staffwhohavebeencorrespondinglyfamiliarizedwithitsoperation. CAUTION:Improperusemayposeriskstolifeandlimb,tothemachine itselfandanyancillaryequipmentconnectedtoit,andtotheoperational efficiencyofthemachine. Theinstalledequipmentmayonlybeusedforthepurposesdeterminedby themanufacturerorforpurposescustomaryforthetypeofmachine.The machinemayonlybeoperatedbyauthorizedstaffwithasuitable professionalbackgroundandcorrespondingtechnicalqualifications. Aprofessionallysuitablepersonmay,baseduponhisprofessionaltraining, expertiseandprofessionalexperienceaswellasonhisknowledgeofthe accidentpreventionandemployeeprotectionregulations,assessand executethetaskshehasbeenchargedwith,recognizingpossiblehazards, providedhealsofulfilsthenecessarypersonal(executive)prerequisitesfor hiswork,e.g.capacitytoworkindependently. Inordertoavoidaccidents,operationofthemachineisonlytobecarried outprovidedthatthemachineisinperfectworkingorder. Nothird--partyequipmentistobeusedinconjunctionwithoperatingthe machinesincethiswouldunderminetherequiredlevelofoperationalsafety. Allworkingmethodswhichimpairthemachine’soperationalsafetyaretobe refrainedfrom. Theoperatorisobligedtoimmediatelyreportanychangesaffectingmachine performance(andimpairingoperationalsafety)tothecompetent supervisorystaff. Intheeventofadisruptionwhichimpairsstaffsafety,theoperatorisobliged toimmediatelyshutdownthemachine.Themachinemayonlyberestarted oncethedisruptionhasbeenremedied. Nosafetyfeaturesmaybedismounted, manipulated,orrendered inoperative. Suchcheckingproceduresmustbecarriedoutbystaffwhohasbeenduly familiarizedwiththemachine’soperation. Theoperatingcompanyisobligedtoprovidetherequiredprotectivegearfor operatingstaffandisalsoobligedtoensurethatthisisusedbyallstaff members. Allcoversprotectingdrivingpartsmuststayinplaceuntilthedangerous rotatingmovementshaveceased.Beforerestartingthemachinetheyhave tobeinstalledproperly. E2009NordsonDeutschlandGmbH PH200--2xPE220--2 P/N7542400 1-4 SafetyInstruction P/N7542400 PH200--2xPE220--2 E2009NordsonDeutschlandGmbH
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