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Hot--melt adhesive extruderEEX200--P3D9X1XXXXQXS

Manual 7541426-- English --

W.PUFFE HOTMELT--TECHNOLOGY D Buchholz--Mendt D GERMANY

E 2009 W.PUFFE Hotmelt--TechnologyAll rights reserved

EEX200--P3D9X1XXXXQXSIssued 06/09

Order number 7541426

Seriennummer110543191/001

Part numberP/N = 7541426

NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 2009.

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.

© 2009 All rights reserved.

TrademarksAccuJet,AeroCharge,AquaGuard,Asymtek,Automove,Autotech,Baitgun,BlueBox,CanWorks,Century,CF,CleanCoat,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 7541426E 2009 W. Puffe Hotmelt--Technology EEX200--P3D9X1XXXXQXS

Table of Contents

Safety Instruction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Description 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Information Leaflet on the Use of PUR--Hotmelts 1-3. . . . . . . . . . . . .Safety Instructions 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Instructions 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dangerous Points and Safety Devices 2-6. . . . . . . . . . . . . . . . . . . . . .Dangerous Points on the Hotmelt Adhesive Extruder 2-6. . . . . . .Danger Points in the Vicinity of the Extruder 2-7. . . . . . . . . . . . . . .Covers 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety equipment on the extruder 2-7. . . . . . . . . . . . . . . . . . . . . . . .Important safety notice: 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lockable main switch 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Black Main Switch (Special Model) 2-8. . . . . . . . . . . . . . . . . . . .Door Lock 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emergency Stop Button (Optional for Stand--Alone Operation) 2-9. . .

Temperature Control 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Undertemperature Interlock 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . .Under--temperature Indication 2-9. . . . . . . . . . . . . . . . . . . . . . . . .Overtemperature Indication / Shutdown 2-10. . . . . . . . . . . . . . . .Temperature Setbac 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Safety Valve 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Description 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Description (cont.) 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Functional Diagram 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of Functional Elements 2-14. . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsII

P/N 7541426 E 2009 W. Puffe Hotmelt--TechnologyEEX200--P3D9X1XXXXQXS

Drive 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Basic Frame 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling Area 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Covers 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screw 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screw Cylinder 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switch Cabinet Light Tower ( optional ) 2-15. . . . . . . . . . . . . . . . . . .Control System 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Cabinet Ventilation 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .Hose connection X1 / X2 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface X8 / X9 / X10 / X100 2-16. . . . . . . . . . . . . . . . . . . . . . . .Door Lock 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Feed Cooling 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder Feed Cooling in Screw Cylinderswith Inner Resin Cladding (depending on order) 2-18. . . . . . . . . . .Cylinder feed cooling 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump station 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manometric switch 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor and Gear Pump 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure sensor 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unpacking 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transportation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Attaching Light Tower (optional) 3-1. . . . . . . . . . . . . . . . . . . . . . . . .Exhausting Hot Melt Adhesive Vapours 3-1. . . . . . . . . . . . . . . . . . .Installation and Alignment 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setup 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting (Unpacked Unit) 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Laying Cable 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Line Voltage 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External control and signal circuits 3-3. . . . . . . . . . . . . . . . . . . . . . .Interface X10 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pilot Voltage / Tach Generator 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . .Notice on the use of ground fault circuit interrupters 3-4. . . . . . . .Electrical installation 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assignment of temperature controllers to temperature sensors 3-5. . . . .

Connecting Heated Hoses 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Second Open-jawed Wrench 3-6. . . . . . . . . . . . . . . . . . . . . . . . .

Connecting 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disconnecting 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving Pressure 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connector Allocation 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assignment: 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interface X10 / X 100 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water installation 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water specifications 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating conditions 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation: 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air humidity: 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air temperature: 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents III


Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start--up 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparations for Start--up 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting into operation 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- Electrical connection 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-- General control functions 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .External control functions 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Microprocessor -- temperature control 4-3. . . . . . . . . . . . . . . . . . . . . .Adjusting the temperatures 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Selecting the program level 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Beginning production 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure Manual operation 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .Hotmelt delivery via one or several nozzles 4-5. . . . . . . . . . . . . . .Desired pressure setting on the extruder (pre--pressure pumps) 4-6. . . . .Procedure Automatic operation 4-6. . . . . . . . . . . . . . . . . . . . . . . . . .Hotmelt application with automatic, speed -- dependent metering. 4-6. . .

Application Mode 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intermittent Hotmelt application 4-7. . . . . . . . . . . . . . . . . . . . . . . . . .Selector Switch Pressure / Speed Control 4-8. . . . . . . . . . . . . . . . .Selection Speed Control 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Selection Pressure Control 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . .

Continuous hotmelt application 4-8. . . . . . . . . . . . . . . . . . . . . . . . . .Error messages 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry--run protection 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching System ON/OFF 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Start--up 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily Switch--off 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switching Off in an Emergency 4-9. . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Danger of burns 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Relieving Pressure 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Decommissioning 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the Screw 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Setting into operation 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection for External Damage 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .Regular Maintenance 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance gear pump 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Cleaning 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Over--temperature Thermostat 5-5. . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Type of Adhesive 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purging with Cleaning Agent 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Cabinet Ventilation Maintenance 5-5. . . . . . . . . . . . . . . . . .

Replacement and Cleaning of Filter Mat 5-5. . . . . . . . . . . . . . . .Continuous Checks 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .For heating elements with ceramic insulation: 5-7. . . . . . . . . . . . .Service and Maintenance 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Lubrication 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricant Recommendations for Threaded Connectors 5-9. . . . .Fault Rectification 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Checks 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of ContentsIV


Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting/Failure Corrective Action 6-1. . . . . . . . . . . . . . . . .

Some Tips 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting with Control System 6-2. . . . . . . . . . . . . . . . . . . . . . .Troubleshooting tables 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Device malfunctioning 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Signal lamps and switch cabinet light tower 6-3. . . . . . . . . . . . . . .Red Signal Lamp Flashing 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No adhesive (no motor rotation) 6-4. . . . . . . . . . . . . . . . . . . . . . . . .Motor superheated 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No master reference voltage 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .No adhesive (with motor rotation) 6-5. . . . . . . . . . . . . . . . . . . . . . . .Incorrect motor speed characteristics in automatic mode 6-5. . . .Insufficient adhesive 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .One channel (heating zone) does not heat 6-5. . . . . . . . . . . . . . . .

Removing 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General remarks 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and Inserting the Screw 7-1. . . . . . . . . . . . . . . . . . . . . . . . .Important Note: 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insertion 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 8-1. . . . . . . . . . . . . . . . . . . . . . . . . .Example 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Frame for attaching parts 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Extruder unit 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump station 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear pump PU25/85R D25 PN 7541422 8-9. . . . . . . . . . . . . . . . .Pressure relief valve 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Module SD Ø5 x 83 P/N 7537391 8-12. . . . . . . . . . . . . . . .Insulating cover pump unit 8-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Extruder covers 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water connection 8-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connection, Start--up: 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Data 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Data 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperatures 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimension 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Technical Data 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instruction 1-1


Chapter 1Safety Instruction

General Description

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

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 is familiar with all safety notes andestablished safety practices, with the installation, operation andmaintenance of this equipment and the hazards involved. For more detaileddefinitions 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 inhot state. 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


Information Leaflet on the Use of PUR--HotmeltsWhen working with PUR--hotmelts, there are some special productcharacteristics to be taken into account in order to guarantee a smooth andproblem--free operation of your melting unit.

PUR--hotmelts are characterised by the fact that after the purely physicalsetting where the material solidifies, a subsequent reaction with humidityoccurs which triggers chemical crosslinking. This phenomenon is alsocaused by processing the material at too high temperatures and / or bythermal strain over too long a period of time. In order to avoid or at least tolimit these increases in viscosity, we recommend the following measures:

S PUR--hotmelts must always and by all means be protected againsthumidity (ambient air) whether during production, storing or use.

S Never process PUR--hotmelts at higher temperatures thanrecommended!

S Prevent local over--heating.

S When changing to a different type of adhesive, do check whether theproducts are compatible. Contact your adhesive supplier for furtherinformation. Otherwise there may be a chemical reaction which resultsin an unmeltable compound!

S Completely use up the molten material within about 4 hours!

Always contact your adhesive supplier / producer and observe strictly theinstructions and information given in the material safety data sheet!

Our machines are very well apt for the processing of PUR--hotmelts.However, please take into account that there are some special features tobe observed when it comes to the use and maintenance of your meltingunit:

S When processing the glue in tank melting units, you need a constantgas injection on the molten material with dry inert gas in order avoidchemical reactions with the ambient air (humidity).

S All melting units and application equipment (like coating heads, nozzles,hoses, etc. ) have to be cleaned and / or flushed thoroughly in case of amachine standstill / production break or when changing to a differenttype of adhesive. The remnants of the flushing agent have to beexpelled completely from the system before restarting the machine.

When processing reactive hotmelts your adhesive supplier or our companyshall be glad to advise you. When observing the hints given above, youshould have no problems working with PUR--hotmelts. However, we are notin a position to enter into a warranty or give guarantees in case ofunprofessional use of this sensitive material or the non--observance of therecommendations given either above or by your adhesive supplier.

Safety Instruction1-4


Safety Instructions

Status as per January 1st, 2009Every 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 thepurposes determined by the manufacturer or for purposes customary for thetype of machine. The machine may only be operated by authorized staffwith a suitable professional background and corresponding technicalqualifications.

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--partyequipment is to be used in conjunction with operating the machine since thiswould undermine the required level of operational safety. All workingmethods which impair the machine’s operational safety are to be refrainedfrom.

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.The operating company is obliged to ensure that an operationalcheck of the machine’s safety devices is carried out both before the firststart--up as well as prior to every recommencing of operations thereafter.Such checking procedures must be carried out by staff who have 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.

Introduction 2-1


Chapter 2Introduction

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.

WARNING: Particularly important details concerning the deployment of thismachine shall be specially referred to in these operating instructions.

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


Intended UseMelters of the series EEX -- hereafter also referred to as system -- may onlybe used to melt and feed suitable materials. When in doubt, seekpermission from Nordson / Puffe.

CAUTION: Use only suitable materials!

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

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

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

Operating RestrictionsWhen 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:

S In defective condition

S When changes or modifications have been made by the customer

S Without heat protection and protective panels

S With electrical cabinet door open

S With filling hopper lid open

S In a potentially explosive atmosphere

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

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

S Explosive and flammable materials

S Erosive and corrosive materials

S 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:

S Risk of burns from hot adhesive

S Risk of burns in the vianity of the screw cylinder

S Risk of burns when filling the hopper

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

S Risk of burns from hot accessories, e.g. heated hoses and hot meltapplication heads

S Danger of being pulled in by screw! The extruder must not be operatedwithout the filling hopper!

S Material fumes can be hazardous. Avoid inhalation.

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 / Pump station

EEX200--P3D9X1XXXXQXS 2

Explanation of Type DesignationThe unit EEX200--P3D9X1XXXXQXS is used as an example.

EEX 200 -- P 3 D 9 X 1 X X X X Q X S

with Special

no additionals Hose /Gun connectors

with protection frame

no casters

no protective grid

no Week / Day timer

no Standby / setback

1 level sensor hooper empty

no cooling device

Hose connection Ø 20mm

2 Pump PU25/85R D25

with double pump station

PT100 Temperature sensor

200 l/h max per pump

Designation for Puffe Melt Adhesive Extruder.EX = Extruder

ID-Plate

a wholly owned subsidiary of Nordson Deutschland GmbH W. PUFFE HOTMELT-TECHNOLOGY

PHONE: +49 (0)2683 9467-0TYPE: EEX200-P3D9X1XXXXQXS

SERIAL NO.: 110543191/001PERFORMANCE: 73.000 Watt

MAXIMUM VOLTAGE: 3x 400VAC + N + PEYEAR OF CONSTRUCTION: 08 /2009

MADE IN GERMANY

Fig. 2-1 ID--Plate

Introduction 2-5


Software NoticeChanges to software provided by Puffe may only be made after consultationwith the members of our staff charged with the maintenance of the 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 EngineeringWARNING: 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 anemergency cutout switch, a limit switch, a key--operated switch, or lightbarriers, etc.) may neither be removed, bypassed, or impaired in any otherway as regards their operational functionality. All safety--switch devices areto be periodically and systematically subjected to 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 MediaCAUTION: 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.

1) DIN EN = harmonized European standard which has beentransposed into German law.

2) D = Deutsches Institut für Normung (German Institutefor Standardization)

VDE = Verband deutscher Elektrotechniker (Association ofGerman Electrical Engineers)

Introduction2-6


Dangerous Points and Safety DevicesThe dangerous points on the hotmelt adhesive extruder are protected bycorresponding safety devices.

WARNING: In the event that a safety device has to be dismantled (e.g. formaintenance or cleaning work), it is imperative that these OperatingInstructions are strictly observed

The safety device must be correctly re--installed, and its performancechecked, after the work has been completed.

Dangerous Points on the Hotmelt Adhesive ExtruderWhen the extruder is operational, particular attention must be paid to thefollowing danger points:

Danger ofburning!

Danger ofbeing pulled in!

Fig. 2-2 Dangerous points

1. Danger of burning in the vicinity of the heated screw cylinder.

2. Danger of being pulled in by screw! The extruder must not beoperated without the filling hopper!

3. Danger of burning in the vicinity of the pump station.

Introduction 2-7


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

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

Danger Points in the Vicinity of the ExtruderWARNING: Danger of accidents caused by operating personnel slipping,tripping or falling!

There is a danger of accidents occurring if operating personnel slip, trip orfall because of adhesive granulate lying on the floor or due to electrical andwater system cables and pipes. It is therefore necessary to keep theenvironment of the extruder clean and to lay the electrical and water lines inducts.

CoversThe covers may be removed in order to be able to tighten the heating bandsor remove the screw.

For installation or maintenance purposes, protective covers may beremoved.

WARNING: Do not operate extruder without the covers in place!

Safety equipment on the extruder

Important safety notice:On principle, our machines are always equipped with overtemperaturefuses.

As soon as 240° C are being exceeded, the electric heating system isinterrupted.

The fuses are mounted on each controlled heating circuit -- apart from theworm -- and should be checked / replaced if necessary if the machine doesnot heat up.

NOTE: Upon mounting over--temperature--fuse, they have to be fastenedwith a torque of max. 1Nm!

Introduction2-8


Lockable main switchA lockable main switch is located on the control cabinet or control console ofthe extruder. 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 theextruder (fitting, repair and maintenance work). Any person working on theinterior of the extruder 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.

Fig. 2-3If several persons are working at the same time on the extruder at differentactivities (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.

S Used to switch on/off the unit.

S Position 0/OFF = Unit is switched off.

S 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 switched on!

Door Lock


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.

Introduction 2-9


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

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

Reset of emergency stop via button “ Malfunction reset “

NOTE: Before using the reset function, all interference factors that havelead to the pressing of the Emergency Cut--Out Button have to be checkedand eliminated carefully!

Fig. 2-4

Temperature ControlAlso refer to manual Control System. The temperature is measured bysensors and is electronically controlled by the control system.

NOTE: To avoid damaging the machine by starting up when too cold, theheating zone temperatures must first be checked and compared with thenominal temperatures set.

After longer downtimes, the extruder ”heat--through” time must expire afterthe set nominal temperatures have been reached

(minimum 10 minutes after temperature release, adhesive--dependent).

Also refer to manual Control System.

Undertemperature InterlockThe undertemperature interlock prevents the unit or system from beingstarted up before the adhesive has exceeded the temperature setpointminus undertemperature value.

However, every time initial heating occurs, the interlock is not released untilthe actual temperature is 10 °C (5.4 °F) below the temperature setpoint.

Under--temperature Indication

The undertemperature interlock locks the motors, solenoid valves and, insome cases, other components of the hot melt application system.

Refer to the wiring diagram to determine which components are locked.

Introduction2-10


Overtemperature Indication / ShutdownThe 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.

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

S Excess temperature switch--off is by thermostat(s) or an excesstemperature 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 Setbac

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

Electrical Safety ValveThe extruder is equipped with a safety valve that measures the meltpressure at the screw tip. The pressure sensor is located at the end of thescrew cylinder in the cylinder itself or in a separate, screwed--on component(e.g. screw--on flange) and is connected to the warning and switch--offsystem of the extruder drive.

WARNING: Danger of bursting! The extruder must not be operatedwithout the safety valve!

Important note:

If the extruder is not started up as described in Chapter 4 (Start--up), thepressure sensor will be unable to operate.

The maximum permissible mass pressure (100--700 bar, depending onsensor equipment) and the heat--through time for the extruder can be foundin the Technical Data.

WARNING: The pressure sensor must not be damaged during fitting orcleaning work on the screw cylinder.

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.

Fig. 2-5

Introduction 2-11


General DescriptionThe extruder is used for the continual processing of thermoplastic adhesivegranulate. The raw material is fed to the screw through the hopper. It ispassed through the screw and melted in the heated screw cylinder.

15

7

65

43

21

17

18

8

14

13

12

11

10

9

16

20

19

Fig. 2-6 The actual machine may differ from the pictures in this manual.

1 Just feet

2 Drive motor

3 Bearing plate

4 Delivery screw

5 Shaft cylinder

6 Temperature sensor

7 Heating cuff

8 Brace frame

9 Pressure sensor

10 Manometric switch

11 Electrical cover

12 Pump connecting block

13 Gear pump

14 Coupling

15 Motor pump station

16 Filling hooper

17 Tank lid

18 Dissipator

19 Exuipment base

20 Level sensor

Introduction2-12


General Description (cont.)

35

34

38

21

36

37

25

24

23

22

28

31

29

33

32

39

30

27

26

40

Fig. 2-7 The actual machine may differ from the pictures in this manual.

21 External cabinet ventilation

22 Operator panel FP13

23 Lamp --Undertemperature--

24 Enable lamp ( System Ready )

25 Lamp --Overtemperature--

26 Luminous button--Malfunction reset--

27 Switch Extruder (Manu / 0 / Auto)

28 Speed indicator pump 1

29 Motor potentiometer pump 1

30 Switch nozzle 2

31 Speed indicator pump 2

32 Motor potentiometer pump 2

33 Switch pump 1

34 Main switch

35 Interface plug XDP

36 Power supply

37 Light tower

38 Switch pump 2--Control Pressure Speed--

39 Switch pump 1--Control Pressure Speed--

40 ID--Plate

Introduction 2-13


Functional Diagram

TI1

=C

oolin

g w

ater

cyl

inde

r zon

eTI

C2

=C

ylin

der z

one

TIC

3=

Cyl

inde

r zon

e TI

C4

=C

ylin

der z

one

TIC

5=

Cyl

inde

r zon

e TI

C6

=P

ump

conn

ectin

g bl

ock

TIC

7=

Pum

p 1

TIC

8=

Pum

p 2

OT

1-2

=P

ump

conn

ectin

g bl

ock

OT

3=

Pum

p 1

OT

4=

Pum

p 2

1 2 3 4

EV

1=

Elec

trica

l val

ve

PIC

1=

Out

put p

ress

ure

extru

der

PS1

=M

anom

etric

sw

itch

extru

der

M1.

1=

Mot

or e

xtru

der

M1.

2=

Mot

or fa

n ex

trude

rM

2.1

=M

otor

pum

p 1

M2.

2=

Mot

or fa

n pu

mp

1M

3.1

=M

otor

pum

p 2

M3.

2=

Mot

or fa

n pu

mp

2

LI1

=Le

vel s

enso

r hop

per e

mpt

y

PIC

2=

Out

put p

ress

ure

pum

p 1

PIC

3=

Out

put p

ress

ure

pum

p 2

LEG

EN

DE

:

TI TIC

LI PIC

PI EV OT

PS

=Te

mpe

ratu

re s

enso

r=

Tem

pera

ture

con

trol c

ircui

t=

Fill

leve

l sen

sor

=Pr

essu

re c

ontro

l circ

uit

=Pr

essu

re c

ontro

l=

Elec

trica

l val

ve=

Ove

rtem

pera

ture

fuse

=M

anom

etric

sw

itch

M=

Mot

or

Hos

es /

Gun

s w

ithou

t he

atin

g an

d va

lve

cont

rol.

“Ext

erna

l con

trol c

usto

mer

”N

ot in

clud

ed in

sco

pe o

f del

iver

y.

Fig. 2-8 Functional diagram.

Introduction2-14


Description of Functional Elements

DriveThe electro--mechanically--actuated drive is a rpm--controlled three--phasedrive consisting of a three--phase geared motor and frequency converter.

Basic FrameThe basic frame serves to hold the components.

Filling AreaThe filling area consists of a water--cooled filling piece (depending on order)and a filling hopper. The adhesive is supplied via the filling hopper.The hopper has a non--stick coating.

WARNING: Danger of being pulled in by screw! The extruder must not beoperated without the filling hopper!

Do not reach into the filling aperture!

Keep all types of metal components away from the filling area. Danger ofdamage to the extruder screw.

CoversWARNING: Do not operate extruder without the covers in place!

The covers may be removed in order to be able to tighten the heating bandsor remove the screw.

For installation or maintenance purposes, protective covers may beremoved.

ScrewWARNING: Note rotation direction of screw. Incorrect rotation direction cancause damage!

Air or water--cooling can be used as required for the screw. The coolant issupplied to the screw via a revolving seal and a coolant pipe.

The screw cooling must be set according to the process engineeringconditions, while complying with the maximum permissible mediumtemperatures. (Maximum temperature setting for this extruder is 250°C,higher values depend on application specification).

ZONE SOLLWERT / W ISRWERT / X

FWATCHDOGC

Introduction 2-15


Screw CylinderDepending on the order, the inner bore of the screw cylinder is nitrided,specially nitrided or made of bimetal. In certain sections, it can be equippedwith a resin bushing. These designs are important for the processing ofabrasive and/or corrosive adhesives.

The screw cylinder is equipped with adjustable heating zones and,optionally, with air--cooling. Heating is implemented via electrical resistanceheating cuffs.

Switch Cabinet Light Tower ( optional )

Red Collective fault

flashing light System is heating up / Standby

Yellow min one drive is enabled

Green ready for operation ( Manual mode )

flashing light nearly empty

NOTE: The level indication lamp on the electrical cabinet lights up whenthe granulate level in the hopper falls below the level sensor. This occurswhen there is less than five liters of granulate in the hopper. The hoppermust be refilled to prevent an interruption in operation. The lamp goes off assoon as the hopper is refilled.

WARNING: Risk of injury from rotation auger. Neve reach into the hooperwhen the motor is running.

Fig. 2-9

Control SystemOn the control system FP 13, values and parameters are set, and operatingmodes and faults are displayed.

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

Introduction2-16


Hose connection X1 / X2They 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.

Interface X8 / X9 / X10 / X100Serves as a connection between the system and external devices.

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).

Door LockWARNING: 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 electricalcabinet is open.

Introduction 2-17


Cylinder Feed CoolingThe cylinder feed cooling affects the output, which can differ according toproduct and adhesive. The cooling intensity is controlled electronically.

Cooling water supply

Cooling water return

Fig. 2-10 Screw with heating cuffs

Introduction2-18


Cylinder Feed Cooling in Screw Cylinders with Inner Resin Cladding(depending on order)

The screw cylinder can be supplied with an inner resin cladding as a specialdesign.

The extruder is then equipped with a multi--part screw cylinder. The feedsection and another component of the screw cylinder are sheathedinternally with a wear--resistant resin cladding. This resin is very sensitive toknocks (danger of dislodgment) and temperature change shocks (danger ofshattering!).

To avoid damage in this area, the following rules must be complied with:

1. The screw must be fitted into and removed from the screw cylinder verycarefully (see Chapter 6).

2. Always start up the cylinder feed cooling before switching on the cylinderheating, as the heating--up of the Cylinder should be a slow andcontinuous process. Therefore:

3. Only start cylinder feed cooling when the temperature in this area is stillbelow 40 °C! At higher temperatures, there is a danger that the feedsection with the resin bushing may burst when cold water is passedthrough.

4. Never switch on the cylinder feed cooling after start--up or duringproduction. In these cases, the temperature always exceeds 40 °C inthe feed part and therefore there is an increased danger of shattering.

5. Always maintain a steady and constant flow of coolant water for thecylinder feed cooling. Interrupting the water flow causes the temperaturein the feed part to rise, leading to renewed danger of shattering.

6. Only use ”treated water” as per the water specifications.

Ensure that the tool connection piece is correctly aligned to the screwcylinder when mounting the pump station on the extruder, i.e. the sealingsurfaces of the connection piece must be parallel to the cylinder end. Theprecise centering position must also be ensured (height and lateral offset).

Introduction 2-19


Cylinder feed coolingThe cylinder feed cooling affects the output, which can differ according toproduct and adhesive. The cooling intensity is controlled electronically.

A decision must be made before starting up the extruder whether the feedzone should be operated ”HOT“ or ”COLD”. This is dependent on the rawmaterial to be processed. If operation should be ”HOT”, the temperature inthe cooling zone must be raised. The temperature in the feed zone isdependent on the creep heat from the cylinder zone TI 1 and from thefriction heat produced by the screw. Zone description, , page 2.15).

If the feed cooling is required for the product, cooling must always beswitched on before switching on the cylinder heating. It is essential that thetemperature in the feed zone is a maximum of 40 °C.

The stop valve must be opened and the necessary water volume must beset with the manual control valve (see Technical Data). The flow and volumecan be read off from the water meter. The temperature in the feed zone willnow increase slightly during the heating up process. After production hasstarted, the temperature increases again depend on the product andfrictional heat of the screw. During operation, the temperature will stabilizeand remain relatively constant as long as speed, water volume and watersupply temperature remain constant.

If the temperature increases in the cooling zone (over--temperaturewarning), check immediately why the temperature has increased and ifthere is a lack of water, which can be seen from the water meter, correctimmediately. If the cause cannot be rectified directly or if there is no waterflow at all and the temperature has increased by another 20 °C, the systemmust be shut down and the fault rectified.

The applicable installation instructions for screw cylinders with flangeconnection can be found in the relevant installation diagram.

In all cases, the fixing screws on the flange connection must be tightened ina controlled manner with a torque wrench (see diagram specification). If thesituation is unclear or data is missing, please contact Fa. Puffe.

Ensure that the tool connection piece is correctly aligned to the screwcylinder when mounting the pump station on the extruder, i.e. the sealingsurfaces of the connection piece must be parallel to the cylinder end. Theprecise centering position must also be ensured (height and lateral offset).

1

3

5

4

6

7

8

10

9

2

Introduction2-20


Pump stationThe gear pump station meters out exact quantities of glue and feeds theminto the hoses and coating heads. The pumps are driven by separatelycontrolled A.C. drives.

The extruder itself feeds into the pump station and maintains a constantprimary pressure. When operating in automated mode, this primarypressure allows to feed variable quantities into the nozzles. A pressure --regulated system guarantees a constant supply of the pumps.

1. Motor Pump station

2. Coupling

3. Gear pump GP 160

4. Pump connecting block

5. Extension

6. Lid for inspection

7. Hose connection block

8. Electrical cover

9. Pressure sensor

10.Manometric switch

11. Temperature sensor

Fig. 2-11

Manometric switchIn case an overpressure of 90 bars is exceeded, a manometric switch (10)shuts down the extruder drive.

Motor and Gear PumpThe electronically controlled motor drives the gear pump.

CAUTION: Never let gear pumps run dry.

CAUTION: The long--term rpm of motors / pumps should not to be lowerthan 5 min--1 and not higher than 80 min--1 in order to avoid excessive wearand tear.

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

See manual on pressure sensor.

Installation 3-1

P/N 7541426E 2005 W. PUFFE Hotmelt--Technology EEX200--P3D9X1XXXXQXS

Section 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 hotmelt adhesive extruder, a check is to becarried out to see whether the applicator has been delivered in perfectworking order. Damages incurred in transit must be confirmed in writing bythe shipping agent and immediately reported to Fa. Puffe.

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

TransportationS The Extruder must be transported in a horizontal position!

S Use only suitable transport devices.

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

S Protect from damage, moisture and dust with suitable packingmaterial.

S Avoid jolts and vibrations.

Attaching Light Tower (optional)The light tower must be screwed onto the electrical cabinet (It was removedfor transport).

Exhausting Hot Melt Adhesive VapoursMake sure that hot melt adhesive vapours do not exceed the prescribedlimits. Exhaust the vapours if necessary.

Provide sufficient ventilation in the area where the machine is set up.

Installation3-2

P/N 7541426 E 2005 W. PUFFE Hotmelt--TechnologyEEX200--P3D9X1XXXXQXS

Installation and AlignmentThe installation and alignment of the extruder is non--critical. Thedimensions of the extruder can be found in the dimensions sheet. Theposition and nominal values for the water inlets and outlets can also befound in the dimensions sheet.

The extruder is normally delivered with the screw inserted.

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

Each extruder is set up ready for production, aligned and pre--calibrated atthe factory before delivery. A horizontal installation area is a pre--requisite.

Setup

S Set up only in an environment that corresponds to the stated Degreeof Protection (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 it 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.

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 wiringdiagram 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.

Interface X10Serves as connection between machine and external components. You willfind the correct allocation in the electrical diagram.

NOTE: Only use screened cables. Connect screening in accordance withEMV 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.

Installation3-4


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: The pilot voltage may not exceed (0--10) VDC.

Failure to observe will result in damage to succeeding components.

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

NOTE: Some models with two pump drives have separate pilot voltageinputs for both pump drives.

Notice on the use of ground fault circuit interruptersNOTE: In some countries respectively for some applications there areregulations which prescribe the use of ground fault circuit interrupters. Inthis case please adhere to the following:

S The ground fault circuit interrupter must be inserted between the mainspower supply and the machine.

S You may only use ground fault circuit interrupters which respond topulsed currents or to all currents (> 30 mA).

Installation 3-5


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 The extruder screw must rotate to the left when seen in the workingdirection.

S All heating elements on the extruder must be retightened after theinitial 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 TechnicalData for maximum permissible mass pressure).

If test runs have already been implemented in the factory with the originalcustomer 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 on the screwcylinder as per the controller numbering. Heat the sensor tip, e.g. with alighter, but not with any fluid. An increase in temperature should bedisplayed by the display of the controller connected to this temperaturesensor.

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

Installation3-6


Connecting Heated HosesWARNING: Hot! Risk of burns. Wear heat-protective gloves.

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

Attach connecting cable extruder / hose

Fig. 3-12

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.

Fig. 3-13

NOTE: Close unused hose connections with Nordson port plugs.

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

Relieving Pressure1. 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 localregulations.

Socket

Plug

Installation 3-7


Connector AllocationA 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. 3-14

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. 3-15

Fig. 3-16

Installation3-8


InstallationX9 Enable socket for the internal enable signal in automatic operation

Fig. 3-17

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 connectorPin 1 + 2 Undertemperature signal

Pin 3 + 4 System ready

Pin 5 + 6 Overtemperature signal

Plug connector Socket connector

Fig. 3-18

Installation 3-9


Interface X10 / X 100Serves 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).

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

The above layout shows the standard allocation.

In case of deviations, please refer to the information and data contained inthe electrical diagramm (documentation see chapter 8 ).

In case of modifications the plug is named X 10 / X 100.

Installation3-10


Water installationThe extruder is equipped (depending on the order) with various coolingsystems:

S Cylinder cooling

S Cylinder feed cooling

S Screw cooling

WARNING: Water must not come into contact with the heating cuff (heatingelements, plugs and cable connections). This must be avoided in particularwith the water supplies to/from the cylinder feed cooling!

The cooling water must include an anticorrosive.

The water of the cooling systems has to have an operational pressure rangeof 2 -- 4 bars and a feeding temperature of 18�C maximum. The maximumdeviation permitted for the cylinder feed cooling is +/-- 0.2 bars. As to flowrate refer to the Technical Data

Important:

All water return lines must have unpressurized outlets, using stop valves isnot permitted. When using separate tempering units for cylinder feedcooling or screw cooling, these connections must remain in place.

Specifications

Water specificationsWater used for the cooling system must meet the following specifications:

Raw water Treated water

Total hardness max. 12° dH Total hardness max. 5° dH

Permanent hardness max. 5° dH Permanent hardness max. 5° dH

pH value 8 -- 9,5 pH--Value 8--9,5

Fe max. 0,04 mg/l

The water must be free of algae and particulates and must not contain anygaseous components such as chlorine, ozone, etc. or opacifiers.

If particulates are present in the water, we recommend that a filter isinserted in the Water supply line.

Raw water can be used for gear oil cooling. Treated water must be used forthe filling aperture cooling, cylinder feed cooling and screw cooling.

Installation 3-11


Operating conditions

Machine installation requirements:

Installation:Up to maximum 1000 m above sea level, in rooms that are as dustfree 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

Installation3-12


Operation 4-1

P/N 7541426E 2009 W.Puffe Hotmelt--Technology EEX200--P3D9X1XXXXQXS

Chapter 4Operation


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

Start--up

Preparations for Start-upThe electrical installation must be checked in accordance with the providedelectrical documentation. The following points are of extreme importance:

S Check the effectiveness of the Emergency Stop and safety cutouts, e.g.electrical safety valves.

S Adjust the limit values for warnings or switch--off as per processrequirements. The maximum permissible mass pressure for the extruderand the heat--through time of the extruder (without screen changer andtool) can be found in the Technical Data.

S The rotation direction of the screw must be checked.

S Electrically connect the hotmelt hoses and dispenser heads.

These components must be at operating temperature to lay the hosesand fit the heads.

WARNING: The cold connection points between pump station, hoses anddispenser heads cannot yet be connected together.

Operation4-2

P/N 7541426 E 2009 W.Puffe Hotmelt--TechnologyEEX200--P3D9X1XXXXQXS

Setting into operationWARNING: The extruder may only be operated with the filling hopper andelectrical safety valve, in place!

S Open feed for cylinder feed cooling.

S The current cooling temperature can be read off the operator unit FP 13,Zone 1.

S Filling melt adhesive / hotmelt into the filling hopper.

S Check that the pumps and nozzle switches are set at ”0”.

S Turn the speed potentiometer to ” 0 ” .

S Switch on main switch.

S Check the heating zones at FP 13 and set them if necessary.

S Wait until the temperature release occurs.

- Electrical connectionProvide a protective ground for the line and protect it after the overalldrawing of current ( refer to the nameplate ). Tension fluctuations may beaccepted up to + / -- 5%.

The cable and plug connection will be provided at the customer‘s inaccordance with the local regulations.

The wiring diagrams are contained in the control cabinet as well as in thelast section of the operating instructions ( Chapter 8 ).

- General control functionsStandard design : self -- contained unit

Please note the wiring diagram for the drivers / pumps and nozzles.

The standard electric wiring in the factory is such that the pump and thenozzle can be separately switched (solenoid valve control via hotmelt hose).

External control functions

S Automatic start of the hotmelt applicator together with the start ofthe mother machine:

Since most melting units are connected to production machines, thestart/stop signals for the extruder, pumps and nozzles are activated bythe production machine. In this case potential--free contacts can beapplied to the socket X10 / X 100. (see circuit diagram for contactassignment), Observe the switch--on sequence.

Operation 4-3


S Activating nozzles equipped with solenoids :

The same X10 / X100 socket also provides the contacts for the controlof the solenoids on the nozzles. Please note the voltage for the magnetcoil. All applicators are of standard design for controlling 24 V d.c.valves. The hotmelt hose is used for a standard control.

S Hotmelt dosage in accordance with the machine--speed variations :

For a varying continuous material speed of the mother machine, a tacho-- generator may be mounted ( connection to the X8 tachometer socketon the control panel ) to adapt the speed of the gear pump to the varyingproduction speeds.

Refer to the electrical diagram X8 socket.

Microprocessor -- temperature control


FWATCHDOGC

[ E ] [ A ] [ B ] [ C ] [ D ]Fig. 4-1

Adjusting the temperatures

S Use the [ A ] and [ B ] keys to select channel 1.

S Use the [ C ] and [ D ] keys to set the desired temperature ( the desiredtemperature flashes in the display ).

S Use the [ E ] key to save the adjusted setpoint ( the setpoint isdisplayed permanently ).

S Use the [ B ] key to select channel 2 and to enter the setpoint for thischannel correspondingly.

S Use the [ E ] key to save.

Proceed as follows to select an other temperature program.

Operation4-4


Selecting the program level

S Press the [ A ] keys until the �P � is shown on the panel display. ( Thesetpoint display shows the currently active program level ).


FWATCHDOGC

[ A ]Fig. 4-2

S Use the [ C ] + [ D ] keys to set the desired program level ( 1 -- 4 ).


FWATCHDOGC

[ C ] [ D ]Fig. 4-3

S Use the [ E ] key to activate the set program level.

S Move into control zone by activating key [ B ]

S The valid temperature parameters can now be entered in the newlyactivated program level.

CAUTION: Important

Free channels which have no temperature sensor connected to them mustbe set below 20°C ( ------ ) in the setpoint and saved with the [ E ] key.(Deactivates the under -- temperature blocking )

Operation 4-5


Beginning productionFirst check whether the set temperature setpoints have been reached.These setpoints have been reached, when the enable lamp ( green ) in themiddle lights up on the control panel front and the red �undertemperature� lamp is extinguished


FWATCHDOGC

Collectivemalfunction signal

Overtemperaturered

System ready green

Undertemperaturered

Fig. 4-4

Procedure Manual operation

Hotmelt delivery via one or several nozzles

S Turn the speed potentiometer to ” 0 ”.

S Turn the ” Extruder ” switch on and set it to ” MANUAL ” position.

S Turn the ” Pump ” switch on and set it to ” MANUAL ” position.

S Turn the ” NOZZLE ” switch on and set it to ” MANUAL ” position.

S Turn up the speed potentiometer until the desired speed is reached andthe required hotmelt volume is being pumped.

S The extruder operates pressure--controlled(Works setting 5 bar)

S The pumps are only started when the extruder has reached the requiredpreset pressure.

43

Operation4-6


Desired pressure setting on the extruder (pre-pressure pumps)The pre--pressure for the pumps is set with the potentiometer (Pos. 2 / 9R4)on the switch cabinet.

The standard pressure is 5 bar which equals the potentiometer setting --2--

Maximum pressure is 25 bar which equals the potentiometer setting --10--

The actual pressure can be read off the pressure measuring transducer(Pos. 3 / 12A1)

Procedure Automatic operationIf the nozzle application is in connection with a production machine,” Start / Stop Pump ” and ” Open / Close Nozzle ” should be via apotential -- free contact between the two machine parts ( connection socketX 10 ).

( Condition : The above -- mentioned tacho -- adjustment has beenperformed )

S The extruder switch in the switch cabinet must be adjusted at the” Auto” setting when the filling hopper is filled with heated adhesive.

S Turn the ” Pump ” switch on and set it to ” Auto ” position.

S Turn the ” Nozzle ” switch on and set it to ” Auto ” position.

S Turn the speed potentiometer to ” max Wert ” .

S Turn the speed potentiometer (Pos.2 / 9R4) to a level until the desiredhotmelt rate is delivered.

S Convey the required amount of hotmelt via the external guide voltage,connector X8 (0 -- 10V).

The dosage itself must be determined at constant speed conditions. Thereduction of speed subsequently lowers the application rate to a pumpstandstill when the machine is stopped.

Under production conditions, the signals for external ” Start / Stop Pumps” and ” Open / Close Nozzle ” are provided via a potential -- freecontact between the two machines ( refer to the electric diagram of the X10/ X100 socked ).

Hotmelt application with automatic, speed - dependent metering.In this case the gear pump rotation is adapted to the machine speed. Thisadjustment is only possible if a tacho -- generator which provides a controlvoltage for the motor control system of the applicator is attached to thepump drive.( Control voltage 0--10V )

WARNING: If the adjustments for a speed -- dependent adhesive rate havenot been done in the factory in consultation with the customer, anappropriate test and / or balance between the tacho control voltage and themotor control system must be performed. This measure is described at theend of this chapter ( refer to tacho -- adjustment ).

IN

Operation 4-7


Application Mode

Intermittent Hotmelt applicationAn application only for individual zones requires the use of a programmingunit, providing the control commands for opening and closing the nozzlesfrom the control unit via the melt unit control panel and the hotmelt hose tothe solenoid valves mounted to the nozzles.

Signal receivers may be detectors mounted to an appropriate place on theproduction machine, such as photocells, inductive proximity switches etc.

For varying machine speeds, an additional so called displacement sensormust be provided. A wide range of control units is available for that.

3 4 21

Put in the bridge XS (1) for intermittent application.

Hotmelt is intermittent conveyed while the extruder, the pumps and thenozzles are being controlled.

XD

OUT

Operation4-8


Selector Switch Pressure / Speed Control

Selection Speed ControlFor speed control, press bridge XD (2).

The extruder operates only in speed controlled mode (e. g. for cleaning ofworm or when feeding into a tank melting unit).

Use only without gear pump station or with pump block open.

Speed can be adjusted via Lenze Keypad (frequency parameter C37; Jogvalue 1, max. 50 Hz).

Selection Pressure ControlFor pressure control, pull out bridge XD (2).

Reestablish the standard settings as described above.

WARNING: When switching from speed to pressure control, the jog value1 has to be adjusted to 5 Hz.

Continuous hotmelt applicationRemove the bridge XS(1) for continous application.

Hotmelt is continuously conveyed while the extruder, the pumps and thenozzles are being controlled.

Error messagesGroup alarms of the drive controls, pressure sensors, excess temperaturesafeguards and dry--run protection are displayed by the ”Fault Reset”momentary--contact control switch (7S7 / 8H1). After the fault has beenremedied, the group alarms must be acknowledged by actuating themomentary--contact control switch.

Dry- run protectionIf the flow of material is interrupted during production, then the extruder isturned off after a preset time. (Pressure / Time)

Operation 4-9


Switching System ON/OFFNOTE: Before initial startup, 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 theweek 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!

Operation4-10


Maintenance 5-1


Chapter 5Maintenance


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

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

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 localregulations.

Maintenance5-2


Decommissioning1. Open shut--off valve on filling hopper, remove granulate and operate

extruder until empty. In general, the feed area of the screw should alsobe run till empty to facilitate restarting.

If the motor current consumption decreases, reduce screw rpm to 20 min--1

and empty screw for a maximum of 1 minute.

Switch off all heating zones via the main switch or reduce the temperatureof the heating zones as per the process requirements.

2. Close water supplies.

Cleaning the ScrewIf the extruder needs cleaning for process reasons, the following proceduremust be followed before the final switch--off:

3. Reduce the screw cylinder temperature to the processing temperature ofthe cleaning granulate.

4. Stop the extruder drive.(Slow down extruder drive so that the screw continues to turn slowly.)

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

Danger of inhaling toxic substances!

There is a possibility that toxic vapours escape from the screw cylinderduring maintenance or cleaning work at the end of the screw cylinder.

5. Disassemble lid of inspection opening.

Operate screw with suitable cleaning granulate as recommende by theadhesive manufacturer until empty. The granulate feed must be dosed andthe screw should be operated at a low rpm. Do not exceed the maximumcurrent consumption value of the screw drive motor.

Maintenance 5-3


6. Insert granules slowly, best manually. Take care that the screw is alwaysvisible, meaning that it may not be covered completely with granules.Otherwise the extruder may get stuck!Therefore always make pauses between filling in of the cleaninggranules, e. g. observe filling cycles that allow about 30 cm of the screwto be free from granules!

7. After cleaning has been finished, the cleaning granules have to bedriven out of the extruder completely.

8. Stop extruder drive an clean inspection opening manually using clothand / or soft metallic brushes (copper / brass).

It is very important that NO cleaning granules get into the pumps and /or the hoses! (The granules are very hard and, if processed properly,do not melt so that they might damage e. g. the pumps!)

Usually, the screw needs not be pulled out. In case you have to, please follow instructions of - section 7- for dismounting of screw. Clean screw (wooden or PTFE spatula or soft brushes).

Cleaning the ScrewThe cylinder bore must be thoroughly cleaned with a round wire brush. Thebore must then be cleaned with a cloth soaked in petroleum.

CAUTION: Do not use metallic tools. Do not use wire brushes.Use soft cloth if necessary.

Finally, the screw must be cleaned with a soft cloth and finegrain polishingpaste until the metal is bright. If the screw is to be stored for longer periods,it should be coated with Vaseline or sprayed with a protective coating.

WARNING: Make sure that no impurities or remnants of the cleaningmaterial are left in the cylinder when the screw is being re--inserted.

Mount screw as described in - section 7--.

Setting into operationS Refill hopper with fresh, dry granules.

S Disconnect the hoses and let the extruder run slowly (<5RPM) in RPMmode until set pressure is reached.

S Stop the extruder and switch to pressure control mode.

S Start the extruder in pressure control mode and start the outer pumps with5 RPM until clean, bubble--free adhesive leaks out of the connections.

S Stop the extruder and re--connect the hoses.

S After this has been finished, the extruder may be brought back intonormal operating condition.

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 Puffespare parts.

1

2

3

Maintenance5-4


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 Extruder External cleaning Daily

Inspection for external damage Daily

Geared motor Change of lubricant Respect manufacturerer’srecommendations.

Filling hopper Visual inspection for pollution in hopper;clean if necessary

Before filling every time

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

Electrical CabinetVentilation

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

Pressure sensor Refer to separate manual

Maintenance gear pumpGear 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.

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

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

S Thoroughly remove warm adhesive with a cleaning agent and / or softcloth.

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

Maintenance 5-5


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

NOTE: Depending on the type of adhesive used, the overtemperaturethermostats of the tank may need to be adapted to the maximumprocessing temperature of the adhesive (This may mean replacing it). Referto Technical Data.

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.

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.

Maintenance5-6


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

closed.

S Check water flow in all water cooling systems. Check connections forpossible leaks.

S Check oil level in gears.

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 to avoidsubsequent 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 5-7


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.

Fig. 5-5 Heating cuffs

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

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

Maintenance5-8


Service and MaintenanceWARNING: All service and maintenance work may only be carried outwhile the machine is in a power--off condition!

Please only use the lubricants recommended in the manufacturer’sdirections and observe the specified maintenance breaks. Please alsoobserve the attached rules and regulations of the suppliers. The timely andconscientious maintenance of the machine not only ensures its trouble--freeoperation, it also avoids costly repairs.The gear oil used for topping up mustbe at room temperature, however, at least 15°C.

2

3

1

Fig. 5-1

Operating hours Lubricant pursuant to DIN

cm Liter

a. r.

Item

.

250

1000

Mai

nten

ance

Qua

ntity

Maintenance partLubrication point

Manufacturer

Filling quantityper lubrication

pointapprox.

123

E

R!

3

a. r.

Maintenance 5-9


Motor LubricationThe extruder drive motor is equipped either with permanently lubricatedbearings or with semi--lubricated bearings that should be replaced followingdefects or large motor overhauls (see manufacturer documentation).

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 beapplied without any gaps to thread flanks and roots, and head/nut contactsurfaces.

Fault RectificationFaults during production should not arise if these operating instructions areobserved carefully, the system operated correctly and the requiredmaintenance work implemented as necessary.

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.

Maintenance5-10


Troubleshooting 6-1

P/N 7541426E 2009 EEX200--P3D9X1XXXXQXS

Chapter 6Troubleshooting



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 extruder may only be restarted if thereason for the disruption has been established and the disruption or faulthas been remedied.

In cases of uncertainty, Puffe 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 )

Wolfgang Puffe, Hotmelt--TechnologyZweigstelle der Nordson Deutschland GmbH

Industriepark Nord 23, 53567 Buchholz--Mendt / Germany

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

Troubleshooting6-2

P/N 7541426 E 2009EEX200--P3D9X1XXXXQXS

Some TipsBefore systematic troubleshooting is begun, the following should bechecked:

S Are all parameters set correctly?

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

S For automatic mode: setpoints are supplied by profibus?

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

S Automatic fault display in the temperature section

S Service display Error in the motor section

S LEDs on the modules and boards.

Troubleshooting tablesThe 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.

Troubleshooting 6-3


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:

Red Signal Lamp Flashing

Problem Possible Cause Corrective Action

Under--temperatueduring operation

Refill filling hopper Wait until temperature has beenreached.

Ambienttemperature toohigh

Ambient temperature too high Lower ambient temperature throughventilating or cooling

Filter of switch cabinet ventilation dirty Clean or exchange

Fan of switch cabinet defective Exchange

Short circuittemperaturesensor

! Exchange

Interruptiontemperaturesensor

!cable break Exchange

Main contactordefective or fallenoff

!Temperature sensor defective !Control sensor, replace if necessary

Pneumatic input pressure falls under 2bars

Check pneumatic connection

Alarm messagespeed

!Pollution -- blockage of: adhesivechannels,

hose -- coating

head -- nozzle

!starting from application system

Remove hot--melt hose, deliver, watchpressure.

Troubleshooting6-4


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

Motor not preset Preset motor and switch on subsequently

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

Speed not set Set speed

Automatic mode selected, however, manual moderequired

Switch to manual 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.

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

No master reference voltage


Master machine not operating Activate master machine

Tachogenerator (equipment) defective Replace

Faulty polarization of master reference voltage Reverse polarity

Troubleshooting 6-5


No adhesive (with motor rotation)


Filling hopper empty Refill filling hopper

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

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

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

Extruder’s operating pressure (pre--pressure)too low

--Set the operating pressure with the potentiometer(9R4)

--Check the extruder temperature

--If necessary clean the extruder screw

One channel (heating zone) does not heat


Channel switched off Switch on

Channel/heating zone defective Remove sensor break / defect

Troubleshooting6-6


Removing 7-1


Chapter 7Removing


WARNING: Hot! Risk of burns. Wear safety goggles and heat-protectivegloves.

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

General remarks

S In order to disassemble certain machine parts, the adhesive in themelter has to be soft. This means that the equipment has to be heateduntil the necessary temperatures have been reached. In some casesyou may also use a heat gun.

S Only use original spare parts (see spare parts list).

S Please also read instruction manuals of the spares as included in thedelivery.

Removing and Inserting the ScrewImportant Note:

The screw and screw cylinder are coated with a corrosion protection agentfor shipping and must be cleaned with petroleum before commissioning(does not apply to systems which come with adhesive test).

WARNING: The screw may only be removed and inserted when themachine is warm and switched off!

Removing7-2


RemovalThe clean screw can be removed without any ejection equipment (e.g. foralignment). The emptied screw must be removed with ejection equipment(e.g. for cleaning work). To do this, proceed as follows:

1. Unfasten cover of pump station

2. Detach heated hose

3. Disassemble lid of inspection opening.

4. To unfasten the extruder screw loosen screw Pos. 1 and remove washer(2) and retaining ring (3).

32

1

5. Insert ejection tool into the orifice of the pressure bearing

6. Slowly push screw to the front or pull it out carefully using the ejectiontool.

Removing 7-3


WARNING: Hot! Risk of burns. Wear heat-protective clothing, safetygoggles, and heat-protective gloves.

Remove material residues on the screw with a copper spatula and brassbrush. Do not use hard or sharp--edged tools.

Finally, the screw must be cleaned with a soft cloth and finegrain polishingpaste until the metal is bright. If the screw is to be stored for longer periods,it should be coated with Vaseline or sprayed with a protective coating.

WARNING: When removing/inserting the screw, ensure that the screwshaft does not damage the sealing surfaces of the screw cylinder (do nottilt).

InsertionBoth screw and screw cylinder must be at room temperature beforeinsertion. They can then be heated up together.

1. Before inserting the screw into the screw cylinder, clean the screw shaftand grease with roller bearing grease.

2. Insert the screw into the screw cylinder and push it through to the screwdrive shaft.

WARNING: Insert the screw into the screw cylinder very carefully to avoiddamage to the screw, the screw drive shaft and the sealing surfaces of thescrew cylinder.

3. The screw must be pushed without force into the screw cylinder.

WARNING: Danger of injury through shearing when inserting the screw intothe screw cylinder!

Fingers and hands can be injured through inattention!

Wear heat--resistant protective gloves!

4. Refit covers

Removing7-4


Spare Parts 8-1


Chapter 8Spare Parts

IntroductionTo order parts, call the Nordson Customer Service Center or your localNordson representative. Use this five-column parts list, and theaccompanying illustration, to describe and locate parts correctly.

Wolfgang Puffe, Hotmelt--TechnologyZweigstelle der 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 partnumber applies to all parts in the illustration.

The number in the Part column is the Puffe part number. A series of dashesin this column (- - - - - -) means the part cannot be ordered separately.

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

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.

Spare Parts8-2


Frame for attaching parts

15

3

1

56

19

10

2

12

11

13

16

7

15

14

9

4

98

18

17

15

Fig. 8-1

Spare Parts 8-3


Frame for attaching parts

Item Part Description Quantity1 7525662 Basic frame 12 7524983 Mounting plate 13 7524878 Bearing plate 14 7525090 Brace frame 15 7524882 Axial cylinder toller bearing 16 7524946 Circlip DIN 472--90x3 17 7524752 Feet 18 7055861 Hexagonal screw DIN 912 M10 x50 29 7055334 Hexagonal nut ISO 4032 M10 410 7055346 Hexagonal nut ISO 4034 M16 411 7055086 Washer DIN 125 A 17 812 7052258 Cylinder screw DIN 912 M16 x65 413 7055463 Cylinder screw DIN 912 M16 x45 314 7056073 Cylinder screw DIN 912 M10 x35 215 7055134 Washer DIN 125 A 10,5 816 ------ Hexagonal nut M24 417 7525195 Sensor hoop guard 118 7055199 Cylinder screw DIN 912 M10 x30 419 7537407 Drip tray 1

Spare Parts8-4


Extruder unit

18

2221 20

2

1

12

34

56

1716

14

7

19

2311

8

9

10

1513

Fig. 8-2

Spare Parts 8-5


Extruder unit

Item Part Description Quantity1 7525017 Shaft cylinder Ø 75 x 26 D 12 7524887 Extruder worm Ø 75 x 26 D 13 7525072 Feather key 18 x 12 14 7525068 Retaining ring 15 7055134 Washer DIN 125 A 10,5 16 7055646 Cylinder screw DIN 912 M10 x 45 17 7524973 Filling hopper Ø 550 18 7525143 Lid Ø 550 19 7059129 Handle 110 7055136 Cylinder screw DIN 912 M8 x 20 211 7524935 Heating cuff Ø 130 x 185 812 7050045 Temperature sensor PT100 M14 x 1,5 x 3000mm 813 7520715 Locking screw G 2” 114 7055372 Cylinder screw DIN 912 M8 x 35 415 7055050 Washer DIN 125 A 8,4 416 7526975 Cylinder screw DIN 912 M12 x 60 417 7055098 Washer DIN 125 A 13 418 7052258 Cylinder screw DIN 912 M16 x 65 619 7535837 Locking screw M18 x 1,5 220 7525285 Motor 22kW 121 7056248 Hexagonal screw DIN 7990 M16 x40 422 7055086 Washer DIN 125 A 17 423 7539867 Proximity switch 1

Spare Parts8-6


Pump station

2422

19

18

2

18

19

17

1

2726

43

4

29

4

47

6

36

21

10 8

1514

7

5

25

4546

13

23

36

20

9

3

333635

1626

27

3736

3839

44

4142

34

30 11

12

28

36

3231

40

4142

Fig. 8-3

Spare Parts 8-7


Pump station

Item Part Description Quantity1 7529103 Pump connecting block 12 7526287 Motor support panel 13 7058982 Heating cartridge Ø 10 x 130 x 300 124 7521781 Extension 65 7541422 Gear pump PU25/85R D25 26 7500186 Coupling M 32 27 7507036 Hose connection 3/4NPT -- 1/16UNF 28 7056368 Manometric switch KDS 05/60--400 19 7050045 Temperature sensor PT100 M14 x 1,5 x 3000 210 7050028 Pressure sensor 311 7520579 Overtemperature protection 280° C 212 7055322 Cylinder screw DIN 912 M3 x 16 213 7524465 Locking plug Ø 77 114 7524995 O--ring PTFE Ø 80 x 3 115 7524997 O--ring PTFE Ø 72 x 2,5 116 7535849 Locking plug Ø 40 117 7526321 Screw rod M16 x 220 418 7055086 Washer DIN 125 A 17 1219 7055346 Hexagonal nut ISO 4032 M16 1620 7050072 Motor 2,2 kW 221 7055372 Cylinder screw DIN 912 M8 x 35 822 7055134 Washer DIN 125 A10,5 423 7055052 Hexagonal nut ISO 4032 M8 824 7506524 Cylinder screw DIN 912 M10 x 30 425 7534030 Sealing plate 2426 7055452 O--ring PTFE Ø 44 x 3,0 227 7504816 O--ring PTFE Ø 35 x 2,5 228 7526447 Electrical cover 129 7526461 Extension 230 7526449 Retaining cover 231 7507345 Electrical screwing PG 16 132 7055027 Cylinder screw DIN 912 M8 x 16 233 7055118 Washer DIN 125 A4,3 834 7055618 Cylinder screw DIN 912 M4 x 8 635 7055018 Cylinder screw DIN 912 M8 x 25 836 7055050 Washer DIN 125 A8,4 1837 7537395 Lid for pressure relief valve 138 7055372 Cylinder screw DIN 912 M8 x 35 439 7537391 Control module SD Ø 5 x 83 140 7538929 Drip plate 141 7055064 Cylinder screw DIN 912 M5 x 8 242 7055121 Washer DIN 125 A5,3 243 7506768 Double nipple 1/4” 144 7538933 Protective grid 145 7055175 O--ring PTFE Ø 19 x 2,5 246 7055031 O--ring PTFE Ø 36 x 2,5 247 7531199 Sealing ring 1

Spare Parts8-8


Spare Parts 8-9


Gear pump PU25/85R D25 PN 7541422

3

4

5

2

5

7

6

1

8

Fig. 8-4

Item Part Description Quantity1 7541418 Gear pump PU25/85R D25 12 7050045 Temperature sensor PT100 M14 x 1,5 x 3000 13 7520579 Overtemperature protection 280° C 14 7052123 Ceramic terminal block 15 7055758 Cylinder screw M3 x 6 16 7538923 O--ring PTFE Ø 42 x 3,0 17 7055175 O--ring PTFE Ø 19 x 2,5 18 203586 O--ring PTFE Ø 35 x 3,0 1

Spare Parts8-10


Pressure relief valve

7

6

5

8

4

3

1

10

12

8

14

15

13

12

8

11

9

82

Spare Parts 8-11


Pressure relief valve

Item Part Description Quantity1 7537391 Control Module 12 7523424 Solenoid valve 13 7058864 Dejamming module 14 7504200 Valve plug 15 7504015 Mounting breacket 16 7507132 Bulkhead fitting 17 7055108 Coupler plug 1/4” A 18 7056353 Plug joint 1/8” -- 6 59 7055474 Sound absorber 1/8” 110 7055785 Sealing ring Alu 1/8” 111 7055472 Screwing 1/8” -- 6 112 7505592 Elbow union 1/8” -- 6 213 7505593 Connection 1/8” 114 7055046 Machine screw DIN 912 M6 x 20 215 7055055 Washer DIN 125 A6,4 2

Spare Parts8-12


Control Module SD Ø 5 x 83 P/N 7537391

Spare Parts 8-13


Control Module SD Ø 5 x 83 P/N 7537391

Item Part Description Quantity1 7058577 Air cylinder 12 7056056 Pressure spring 13 7504806* O--ring Viton 16 x 2,0 14 7504714* O--ring Viton 17 x 2,5 15 7050227* O--ring Viton 18 x 2,0 16 7055013* O--ring PTFE 22 x 2,0 17 7506701* Pressure disk 12 x 5,2 x 2 18 7506711* Circlip Ø 12 DIN 472 29 7055120 Machine screw M 4 x 55 410 7055061 Hexagonal nut M5 111 7055927 Retaining ring Ø 5,3 112 7058457 Control piston 113 7504833* Sealing Ekonol--Stepseal Ø 5mm 214 7504793* O--ring Fluoraz 6,07 x 1,78 215 7058459 Base module 116 7058507 Needle Ø 5mm x 83 mm lg. 117 7506702* Tapered pressure disk 118 7058496 Needle seat 119 7504813 O--Ring PTFE Ø 12 x 2,5 1

7506131 The positions marked with (*) is possible to order as

Renovation kit

Spare Parts8-14


Spare Parts 8-15


Insulating cover pump unit

2

5

1

4

3

Fig. 8-5

Item Part Description Quantity1 7537401 Insulating cover pump unit part 1 12 7537399 Insulating cover pump unit part 2 13 7506685 Knurled nut DIN 466 M5 44 7055096 Cylinder screw DIN 912 M8 x 12 45 7055050 Washer DIN 125 A 8,4 4

Spare Parts8-16


Extruder covers

2

2

1

57

4

3

6

Fig. 8-6

Spare Parts 8-17


Extruder covers

Item Part Description Quantity1 7521866 Covering hood extruder part 1 12 7524235 Covering hood extruder part 2 23 7525324 Cover plate 14 7526472 Angle bracket 1 15 7526474 Angle bracket 2 16 7056184 Countersunk screw DIN 7991 M 6 x 10 77 7525291 Rivet Ø 4 x 6 5

Spare Parts8-18


Water connection

2

1

1

2

Cooling water supply

Cooling water return

Item Part Description Quantity1 7521905 Twin nipple 1/2” -- 1” 22 7504212 Angled hose connection 1/2” x 3/4” 2

Technical Data 9-1


Chapter 9Technical Data

Description

Connection, Start-up:The electrical connection to the control cabinet is implemented with theconnection cable provided.

The water cooling connection is firmly installed; check for possible leaks.The hot melt hose can be connected after the heating procedure iscomplete. During operation, ensure that the feed area of the screw isalways kept covered with adhesive granulate to avoid any running dry.

As the temperature control system for the feed area maintains optimaltemperatures, all that is required is sufficient cooling water volumes(temperature ca. 15°C) through the cooling aggregate.

General Data

Adhesive pressure limitation 5 bis 100 bar / 0,5 bis 7 MPa / 72,5 bis 101,5 psiNoise emission 70 dBAMotor type A.C. motorSpeed setting range 0 to 100 min--1

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

Degree of protection IP 32

Technical Data9-2


Electrical DataCAUTION: The unit is designed for only one operating voltage. Operateonly at the operating voltage shown on the ID plate.

Operating Voltage 3 x 400 VAC+N+PEFrequency of operating voltage 50/60 HzProtection 100 AmperePower Consumption P 73000W

Max. Pilot Voltage (input voltage) The pilot voltage may not exceed 0 -- 10 V.

Non--observance will result in damages todownstream parts.

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

NOTE: Depending on the type of adhesive used, the overtemperaturethermostats of the components may need to be adapted to the maximumprocessing temperature of the adhesive (This may mean replacing it).

Technical Data 9-3


Dimensionca

.141

0,50

ca.1

570,

50

ca.3298

ca.2030

ca.1

234

ca.6

20

Technical Data

Type: EEX200--P3D9X1XXXXQXS

Supply voltage: 3x400VAC + N +PE 50 -- 60Hz

Connected load: Heating 80 kW

Amount of glue: 200 kg/h

Coolant: Water 20°C ca.0,5 L/min

Dimension: 3298 x 1234 x 1570 mm

Weight: see way bill

Drive: Three--phase AC

Extruder 22 kW

Pump station 2,2 kW

Technical Data9-4


hot--melt adhesive extruderemanuals.nordson.com/adhesives/english_manuals/... · trak, ultrasmart,...

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