manual, automatic melter/feeder series...

Automatic Melter/Feeder Series 2000

Part 104 472A

NORDSON CORPORATION. AMHERST, OHIO. USA

Nordson Corporation welcomes requests for information, comments and inquiries about its products.

Address all correspondence to

Nordson Corporation 11475 Lakefield Drive

Duluth, GA 30136

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1987. No part of this document may be photocopied, reproduced, or translated to another language without the prior written

consent of Nordson Corporation. The information contained in this publication is subject to change without notice.

* Trademarks

AquaGuard, Blue Box, Control Coat, Equi=Bead, FloMelt, FoamMelt, IFoamMix, Helix, Hot Shot, Hot Stitch, Meltex, MicroSet, MultiScan, Nordson, the Nordson logo, OmniScan, Porous Coat, Posi-Stop, RBX, Sure-Bond,

UniScan, UpTime, and Versa-Spray are registered trademarks of Nordson Corporation.

BetterBooksM, CF, Controlled Fiberization, Easy-Screen, Fibermelt, Flo-Tracker, PrintGuard, and Package of Values are trademarks of Nordson Corporation.

Manual 46-11 104 472A Issued 12/88

0 1988 Nordson Corporation All Rights Reserved

TABLE OF CONTENTS 46-11-01

SAFETY SUMMARY Introduction. . . . . . . . . . . . . . . . . . .40-1-l Explanation of Terms and Symbols. . . . . . . . .40-1-l Safety During Installation

Electrical . . . . . . . . . . . . . . . . .40-l-2 Pneumatic. . . . . . a . . . . . . . . . . .40-l-2 Gas-System (Foam Melt Applicators only . . . . . . . . . . . . . . . . . . . -40-l-2

Safety During Operation . . . . . . . . . . . . -40-l-2 Safety During Servicing . . . . . . . . . . . . -40-l-3 Safety When Using Hot Melt Adhesives and Solvents

Hot Melt Adhesives . . . . . . . . . . . . .40-l-4 Heating Solvents . . . . . . . . . . . . . -40-l-4 Halogenated Hydrocarbon Solvents . . . . .40-l-5

If Molten Material Comes in Contact With'Skin . .40-l-5

IDENTIFICATION AND USE OF NORDSON FITTINGS . . . . . .40-2-l

EQUIPMENT FAMILIARIZATION Introduction. ................. .46-11-l Functional Description. ............ -46-11-3 Specifications. ................ .46-ll-5/6

PREPARATION FOR USE Introduction. ................. -46-11-7 Unpacking and Inspection. ........... .46-11-8 Physical Setup

HM IV, V, VII and IX ........... .46-11-10 HM 2200. .. .. ..

Level Calibration -- All Units. .................. .46-11-12 .46-11-14

Operation -- All Units. ............ .46-ll-17/18

MAINTENANCE Introduction. . . . . . . . . . . . . . . . . . Preventive Maintenance

Periodic Inspection/Cleanup. . . . . . . . Hopper CleanoutJMaterial Changeover. . . .

Corrective Maintenance Equipment Troubleshooting

Applicator Tank Does Not Fill . . . . Applicator Tank Overfills . . . . . . Grid Heater Overheats . . . . . .

Disassembling the Control Enclosure'and Grid Heater Control Assemblies . . . . . . Reassembling the Control Enclosure and Grid Heater Control Assemblies . . . . . .

-46-11-19

.46-11-21

.46-11-21

.46-11-23

.46-11-27

.46-11-28

.46-ll-29/30

.46-ll-29/30

DIAGRAMS AND TABLES. . . . . . . . . . . . . . . . . -46-11-31

46-1lmIssued 12/88=ONordson Corporation I988

46-11-02

TABLE OF CONTENTS (Continued)

ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . .46-11-33

MISCELLANEOUS TECHNICAL DATA . . . . . . . . . . . . .59-O-O

LIST OF ILLUSTRATIONS

Figure

1

2

3

4

5

6a

6b

7a

7b

8

9a

9b

10

Page

Nordson Automatic Melter/Feeder. . . . . . .46-11-2

Automatic Melter/Feeder Dimensions . . . . .46-ll-5/6

Electronic Level Control (end view). . . . .46-11-14

Automatic Melter/Feeder Wiring Diagram . . .46-11-31

Automatic Melter/Feeder Schematic (all models) . . . . . . . . . . . . . . . .46-11-32

Automatic Melter/Feeder (P/N 276 661 and 276 674) Assembly Drawing -- Front View . . . . . . . . . . . . . . . . .46-11-34

Automatic Melter/Feeder (P//N 276 661 and 276 674) Assembly Drawing -- Side View. . . . . . . . . . . . . . . . . .46-11-35

Automatic Melter/Feeder (P//N 276 676) Assembly Drawing Front View. . . . . . . . .46-11-38

Automatic Melter/Feeder (P/N 276 676) Assembly Drawing Side View . . . . . . . . .46-11-39

Control Assembly, Automatic Melter/Feeder Assembly Drawing (all models). . . . . . . ,46011-43

Material Level Probe Assembly Drawing (Melter/Feeder P/N 276 661 and 276 674). . .46-11-46

Material Level Probe Assembly Drawing (Melter/Feeder P/N 276 676). . . . . . . . .46-11-48

Heater Assembly Enclosure Assembly Drawing (all models) . . . . . . . . . . . . . . . .46-11-50

46-1lmIssued 12/88=ONordson Corporation 1988

46-11-l

SECTION I EQUIPMENT FAMILIARIZATION

INTRODUCTION

The Nordson Automatic Melter/Feeder is an accessory unit for use with Nordson Models IV, V, VII, IX, and 2200 hot melt applicators. There are three versions of the Automatic Melter/Feeder:

n P/N 276 661 is used with applicator Models HM IV and V.

n P/N 276 674 is used with applicator Models HM VII and IX.

n P/N 276 676 is used with applicator Model 2200.

Automatic Melter/Feeder features includie:

= Storage of up to 150 lbs. of non-blocking* granular or pelletized hot melt material; melted material is fed on demand directly into the applicator tank.

. Melt rate of up to 40 lbs. per hour.

n Thermostatically controlled aluminum heating grid for protection against overheating of the grid and overfilling of the applicator tank.

. Manual or automatic operation.

n Rugged construction.

n Easy serviceability.

Resists sticking together at low temperatures.

46-ll=Issued 12/88+Nordson Corporation 1988

46-11-2

7-

6 .

5

4

Figure 1 - Nordson Automatic Melter/Feeder.

-1

. 2

3

46-ll=Issued 2/87@Nordson Corporation 1987

46-11-3

FUNCTIONAL DESCRIPTION

The Automatic Melter/Feeder shown in Figure 1 is representative of all three Automatic Melter/Feeder models. Note that a hot melt applicator unit is NOT shown.

The hinged cover (1) at the top of the melter/feeder unit is raised and material loaded into the hopper (2). The level of material in the hopper can be checked through the glass inspection port (3). As the material heats and becomes molten, it flows directly into the holding tank in the applicator unit below.

Two probes on the Automatic Melter/Feeder extend into the applicator tank:

. The temperature sensor probe (4) prevents the melter/feeder grid heaters from cycling ON until hot melt material in the applicator tank reaches a minimum temperature of 350°F (177OC) or operator-set point; the melter/feeder thermostat is adjustable.

n The material level probe (5) controls the flow of hot melt from the Automatic Melter/Feeder into the applicator tank.

The FILL light on the control panel (6) indicates that the melter/ feeder unit is in operation and the grid heaters are ON.

A MANUAL FILL switch (7) located on the melter/feeder control box panel allows the equipment operator to bypass the temperature probe and material level probe circuits and feed hot melt material to the applicator unit at will.

To manually fill the applicator tank, ho:Ld the melter/feeder MANUAL FILL switch in until the material in the applicator tank reaches the desired level. Then release the switch.

0 Note that there is a time delay from when the MANUAL FILL switch is pressed and when material begins to flow from the hopper into the applicator tank.

0 The delay also occurs from when the MANUAL FILL switch is released and when material stops flowing from the hopper into the tank.

A Be careful not to allow hot me:Lt material to overflow when manually filling the tank,, could create a fire hazard.

Overflowing the tank

46-ll=Issued 12/88=ONordson Corporation 1988

46-11-4

To check the amount of hot melt in the applicator tank, lift out the fluid indicator (8) and observe the level of material on the rod.

0 Applicator Models HM IV and V have a three-piece hood arrangement and no fluid indicator. You must physically look inside the unit to check the material level.

46-1lUssued 2/87mONordson Corporation 1987

46-ll-5/6

NORDSON AUTOMATIC MELTER/FEEDER SPECIFICATIONS

A complete parts listing and equipment specifications are located towards the rear of this manual.

Hopper Capacity:

Adhesive Form:

Melt Rate:

Operating Temperature Range:

Electrical Requirements:

Dimensions:

Height with door open:

59 0.3

(PIN 276 66 1 8

276 674)

I

57 ra’

(P/N 276 676)

5

:’

, T-

-

-a

L-

t

150 lbs. (68 kg).

Non-blocking granuals or pellets are recommended, but the unit is capable of melting solid parti- cles up to one square inch in any dimension (6.45 sq.cm.).

Up to 40 lbs (18.14 kg) per hour, depeniding on the adhesive.

3oo" - 400°F (15OO - 205OC); optio:nal thermostats for 100' - 200°F and 200° - 300°F operation.

230 VAC, 1 Phase, 60 Hertz.

73" (P/N 276 661 and 276 674) 71.75" (P/N 276 676)

56 03’

(PIN 276 661 8

276 674) I

54 ?a’ (PIN 276 676)

Figure 2 - Nordson Automatic Melter/Feeder Dimensions.

46-1lmIssued 12/88mONordson Corporation 1988

46-11-7

SECTION II PREPARATION FOR TJSE

INTRODUCTION

This chapter is divided into five major sections. They are:

n Unpacking and Inspection (all units).

n Physical Setup for applicator Models HM IV, V, VII and IX.

n Physical Setup for applicator Model HM 2200.

n Startup Procedures (all units).

n Operation (all units).

You will probably need to refer to the applicator manual for your particular unit during the Physical Setup and Startup procedures in this section.

46-1lmIssued 12/88mONordson Corporation IL988

46-11-8

UNPACKING AND INSPECTION -- ALL UNITS

Use normal care when unpacking the Automatic Melter/Feeder. Do not leave packing materials in the hopper.

After the Automatic Melter/Feeder has been removed from its shipping container and all packing materials removed:

m Refer to the specific ship with list (below) for your unit to determine if all of the required parts have been included:

AUTOMATIC MELTER/FEEDER (P/N 276 661) SHIP WITH LIST

Part No. Description Q~Y l

981 208 Screw, Hex Head, l/4-20 x 0.63 in. 4 244 524 Bracket, Retainer 4 242 628 Gasket, Cover 1 981 155 Screw, Fil Head, lo-24 x 0.75 in. 10 983 120 Washer, Lock, Split, #:LO 10 984 121 Nut, Hex, Machined, lo-24 1


Part No. Description Qtu -

981 208 Screw, Hex Head, l/4-20 x 0.63 in. 4 244 524 Bracket, Retainer 4 983 140 Washer, Lock, Split, 0.25 in. 13 273 079 Gasket, Cover 1 981 214 Screw, Fil Head, l/4-20 x 0.75 inch 9 273 098 Dip Stick (fluid indicator) 1


Part No. Description Q~Y l

981 326 Screw, Hex Head, 5/16-118 x 0.50 in. 4 276 687 Dip Stick (fluid indicator) 1


46-11-9

n Inspect melter/feeder surfaces folr evidence of dents, scratches or other physical damagre.

n Check for loose connections in thle melter/feeder control box and heater box.

n Inspect all fasteners and mechanical connectors for tightness.


46-11-10

PHYSICAL SET-UP

Install the Automatic Melter/Feeder with the control and heater enclosures and the hopper cover accessible for operation and troubleshooting.

Avoid installing and using the unit where temperatures below 20°F (-6OC) or above 120°F (49OC) occur. The unit should not be installed outdoors or in a drafty area. The unit should be protected from severe dust conditions and vibration.

To prevent electrical shock and possible equipment damage, do not make any electrical connections until completing installation of the melter/feeder and applicator units.

Applicator Models HM IV, V, VII and IX (See Figure 1 of this manual; refer also to the operationsmanual for your Nordson applicator if necessary.)

1. Remove the applicator unit loading lid securing screws (2 on the HM IV and V and 3 on the HM VII and IX); then lift the lid from the applicator unit top panel.

2. Lift the strainer out from the applicator tank.

3. At this point: m On Models HM IV and HM V, remove the five condensate pan

securing screws and lift the condensate pan from the applicator top panel. Then remove the two top panel screws to the left of the applicator unit pump.

n On Models HM VII and HM IX, remove the six screws from the top panel.

4. Remove the four material level probe securing screws and lift the probe assembly free from the melter/feeder mounting cover plate.

5. Remove the lower locknut that secures the temperature sensor probe conduit to the melter/feeder cover plate; carefully lift the conduit and probe free from the melter/feeder mounting cover plate.

6. Remove the fluid indicator from the melter/feeder mounting cover plate. (Applicator Models HM VII and HM IX only).

7. Insert the mounting cover unit into the melter/feeder hood (at the base of the hopper).


46-11-11

8.

9.

10.

11.

12.

13.

With the mounting cover unit raised into the hood as far as possible, position the applicator unit onto the melter/feeder base. Attach -- but do NOT tighten -- the applicator unit retaining brackets.

Position the cover gasket on the applicator unit top panel around the tank opening. Guide the melter/feeder mounting cover plate down onto the gasket. Be sure the screw holes in the mounting cover, gasket and applicator cover correspond. Then reinstall and tighten all top panel screws removed earlier.

Tighten the retaining brackets.

Insert the fluid indicator, materia:L level probe and temperature sensor probe in the mounting cover plate. (Applicator Models HM VII and HM IX only).

0 Refer to your hot melt applicator operations manual for procedures required to complete installation and set-up of the applicator unit.

With installation of the applicator complete, connect the input electrical wires as shown in the wiring diagram.

Locate the adjustable thermostat in the melter/feeder Control Assembly (upper box). This thermostat controls the heater grid assembly. Set this thermostat to match that of the hot melt applicator.

A The Automatic Melter/Feeder contains energized electrical components which could prove fatal if mishandled. Use extreme caution when installing, operating and troubleshooting this equipment.

14. Locate the adjustable thermostat in the heater enclosure assembly (lower box). This thermostat leads to the temperature sensing probe that extends into the applicator tank. Set this thermostat to applicator temperature minus (-) 25OF to 50°F.

A

The Automatic Melter/Feeder contains energized electrical

'I

components which could prove fatal if mishandled. Use extreme caution when installingf, operating and troubleshooting this equipment.

Proceed now to Startup Procedures with applicator Models HM IV, V, VII and IX.


46-11-12

PHYSICAL SET-UP

Applicator Model HM 2200 (See Figure 1)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Remove the two applicator loading lid securing screws and lift the lid from the applicator unit top panel.

Lift the strainer out from the applicator tank.

Remove the six screws from the applicator top panel around the tank opening.

Remove the upper and lower locknuts that secure the material level probe housing to the melter/feeder mounting cover plate; carefully lift the probe housing free of the mounting cover plate.

Remove the upper and lower locknuts that secure the temperature sensor probe conduit to the melter/feeder cover plate; carefully lift the conduit and probe free of the melter/feeder mounting cover plate.

Remove the fluid indicator from the melter/feeder mounting cover plate.

Slide the mounting cover plate and sleeve down and free of the melter/feeder hood.

Remove the screws which secure the melter/feeder hood to the melter/feeder heater grid flange; then remove the hood.

Position the melter/feeder mounting cover plate on the applicator top panel over the tank opening and place the hood on top of the mounting cover sleeve.

Position the applicator unit on the melter/feeder base so that the cover plate can be lifted slightly.

Insert the temperature sensor probe through its hole in the cover plate and thread the lower locknut onto the bottom of the conduit.

Insert the level control probe through its hole in the cover plate and thread the lower locknut onto the bottom of the conduit.

Position the applicator unit so the hood aligns with the melter/feeder heater grid flange. securing screws removed in step 8.

Reinstall and tighten the

4601lmIssued 12/88mONordson Corporation 1988

46-11-13

14.

15.

16.

17.

A The Automatic Melter/Feeder contains energized electrical components which could prove fatal if mishandled. Use extreme caution when installing, operating and troubleshooting this equipment.

18. Locate the adjustable thermostat in the heater enclosure assembly (lower box). This thermostat leads to the temperature sensing probe that extends into the applicator tank. 25OF to

Set this thermostat to applicator temperature minus (0) 50°F.

A t

The Automatic Melter/Feeder contains energized electrical components which could prove fatal if mishandled. Use extreme caution when installing, operating and troubleshooting this equipment.

19. Refer to the Daily Startup Procedure in your Series 2000 applicator manual.

Install and tighten the hex head screws that secure the applicator to the melter/feeder base.

0 This step requires tilting the applicator unit with the mounting cover plate and hood attached. Be careful not to damage the melter/feeder or applicator unit.

Tighten the level probe and temperature sensor probe upper locknuts. Reinstall the fluid indicator (dip stick).

0 Refer to your applicator manua:L for the procedures required to complete the installation and setup of the unit.

With installation of the applicator complete, connect the input electrical wires as shown in the wiring diagram.

Locate the adjustable thermostat in the melter/feeder control assembly (upper box). This thermostat controls the heated grid assembly. Set this thermostat to match that of the applicator.


46-11-14

LEVEL CALIBRATION PROCEDURE -- ALL UNITS

1. Locate the Electronic Level Control in the melter/feeder control enclosure (upper box). Then locate the three potentiometers (or "pots") labeled DIFF (differential), TD (Time Delay) and ZERO and the LED to the direct left of the ZERO pot.

P.C. BOARD

/ \

\ ZERO

DIFFERENTIAL

ADJUSTING SCREW LE.0. LIGHT

TIME DELAY

ADJUSTING SCREW

ADJUSTING SCREW

Figure 3 -- Electronic Level Control (end view).

0 These are 200turn potentiometers used to set the HIGH and LOW level set points. There are no stops at either end of the pot adjustment ranges; instead, you will feel a click signalling the end of a range during the adjustment operation.

2. Fill the Automatic Melter/Feeder hopper with non-blocking hot melt adhesive.

A Make sure the hose is not electrically connected at this time. Heating an empty hot melt hose may cause premature hose failure.

0 Note that there is a time delay from when the MANUAL FILL switch is pressed and when material begins to flow from the hopper into the applicator tank.

0 The delay also occurs from when the MANUAL FILL switch is released and when material stops flowing from the hopper into the tank.

A s

Be careful not to allow hot melt material to overflow when manually filling the tank. Overflowing the tank could create a fire hazard.

3. Turn the Automatic Melter/Feeder and the applicator power ON.

4601lmIssued 2/8710Nordson Corporation 1987

46-11-15

4. Use the Automatic Melter/Feeder MANUAL FILL button to fill the applicator tank to the desired high level, but not closer than one inch from the top of the tank. Use the fluid indicator or visually check to determine the level. Use the tank drain to remove excess hot melt material from the applicator tank.

A Relieve system pressure by triggering the applicator gun

0 before attempting to drain the tank. Failure to do so

+ c* could result in serious burns when hot melt material is

forced through the drain valve under pressure.

5.

6.

7.

8.

9.

Turn the TD potentiometer (2) to its furthest counterclockwise position (approximately 20 turns). This disables the time delay function.

Turn the DIFF (4) and ZERO (3) potentiometers to their furthest counterclockwise position (approximately 20 turns).

Turn the ZERO potentiometer clockwise until the LED comes ON.

Turn the ZERO pot counterclockwise until the LED just goes OFF,

0 This is the HIGH level set point. The Automatic Melter/ Feeder grid heater will deactivate when hot melt material in the applicator tank reaches this point on the level control probe.

Turn the DIFF potentiometer to its furthest clockwise position (approximately 20 turns).

10. Drain material from the tank until the desired LOW level set point on the level control probe is reached (usually one to two inches below the HIGH level set point).

A Relieve system pressure by triggering the applicator gun

0 before attempting to drain the tank. Failure to do so

4 &IL could result in serious burns when hot melt material is

forced through the drain valve under pressure.

0 Drained material should be discarded. Do NOT place drained hot melt material back in the melter/feeder hopper.

11. Turn the DIFF potentiometer counterclockwise until the LED comes ON.

0 This is the LOW level set point. The Automatic Melter/Feeder grid heater will activate when the level of hot melt material reaches this point on the level control probe.


46-11-16

12. Repeat these steps as necessary to obtain the desired HIGH and LOW level set points.

13. Complete electrical connections to the hoses, then complete applicator startup procedures given in the applicator operations manual.

14. Refill the melter/feeder hopper as required.

15. The Automatic Melter/Feeder and hot melt applicator units are now ready for operation.


460ll-17/18

OPERATION -- ALL UNITS

m Follow the daily startup instructions for the applicator given in the applicator operations manual; then turn the Automatic Melter/Feeder power ON.

n Add material to the melter/feeder hopper as required.

n Turn the melter/feeder OFF at the circuit breaker on the control panel; power the applicator unit down according to instructions in the applicator operations manual.


46-11-19

SECTION III MAINTENANCE

INTRODUCTION

Your Nordson Automatic Hot Melter/Feeder was designed and constructed to serve reliably in the most demanding circumstances. Even so, it would be wise to develop and follow a preventive maintenance program. In this way, it is possible to maintain the highest quality performance and keep equipment malfunction to a minimum.

This section covers both PREVENTIVE and CORRECTIVE maintenance procedures.

PREVENTIVE maintenance includes:

. Periodic inspection/cleanup.

n Hopper cleanout/material changeover.

CORRECTIVE maintenance includes:

n Equipment troubleshooting.

. Removal and replacement of assemblies.

n Disassembly, repair of components and reassembly.

The Automatic Melter/Feeder contains energized electrical components with potentials that could be fatal. Dis- connect and lock out input electrical power before per- forming maintenance on this equipment. Only qualified personnel shall operate this equipment.

A e

Wear safety glasses, safety gloves (P/N 902 514) and protective clothing to prevent injury from hot automatic melter/feeder and applicator parts.

A Never heat any component with a torch or other open flame. If it becomes necessary to heat components for maintenance or repair, use an electric oven with forced air circulation or a flameless electric heat gun.

Halogenated hydrocarbon solvents are dangerous when used

A to clean components in a pressurized fluid system. See the Safety Summary, Section 40-1, for further details. Use of halogenated hydrocarbon solvents in this system could result in an explosion.

46-ll=Issued 2/87mONordson Corporation 1987

46-U-20

In addition, remember the following tips and recommendations:

. Standard test equipment and procedures shall be used.

n The system indicator light (SD) remaining OFF at power up does not necessarily indicate a complete electrical failure.

n Verify 230 VAC input power to the automatic melter/feeder.

n Open the control and heater enclosures to visually inspect for exposed wire shorted to ground, to another wire, or to a terminal.

n Do not use a battery-type test light to check continuity of heaters. This type of test light will not indicate continuity.

n Remove and lock out electrical power when testing for continuity or resistance values. Isolate the component from the circuit before checking resistance.

= The heaters are wired in series. Therefore, if one unit fails, the entire heater grid will remain cold.

n Typical individual heater resistance values are:

Part No. Description Voltage Cold Resistance

938 109 Grid Heater 48 VAC 6.4 - 7.5 ohms


46-11-21

PREVENTIVE MAINTENANCE

Periodic inspection/cleanup:

n Keep the unit clean at all times.

n Keep the hot melt adhesive material supply clean and free from contaminants.

n Inspect the unit periodically for loose electrical and mechanical connections.

Always disconnect and lock out input electrical power before opening the control or heater enclosures.

Hopper

l

n

n

cleanout/material changeover:

Follow material changeover and system cleaning instructions provided in the applicator operations manual.

Open the hopper clean-out door -- located just below the hopper glass inspection port -- and remove all unmelted material from the hopper.

Wear safety glasses, safety gloves (P/N 902 514) and protective clothing to prevent injury from hot melter/- feeder and applicator parts.

Fill the hopper with only new non-blocking pellet or granular hot melt material; restore the system to normal operations.

46-1lmIssued 2/87m@Nordson Corporation 1987

46-11-22

CORRECTIVE MAINTENANCE

Generally, replacement of broken wires, missing fasteners and similar items is not considered part of corrective maintenance. Unless failure caused by these items presents an immediate hazard to personnel or equipment, they should be noted and eliminated during the preventive maintenance cleaning and inspection procedures.

Equipment Troubleshooting

The flow charts on the following pages provides orderly "road maps" for finding and diagnosing several possible situations.

Use the illustrated parts lists, electrical schematic and the wiring diagram as aids when using the troubleshooting flow charts.


46-11-23

APPLICATOR TANK DOES NOT FILL

1. Main switch ON. Control panel SYSTEM light not ON.

.Go to step 2.

Control panel SYSTEM light ON.

.Go to step 3.

2. Disconnect and lock out power to unit; check continuity line and load on each side of circuit breaker.

Continuity OPEN. Replace circuit breaker, restore system to normal operation.

Continuity good. .Replace SYSTEM light bulb, restore system to normal operation.

3. Power to unit ON, press MANUAL FILL switch.

Adhesive flow light ON-Adhesive flow

@Restore system to normal operation

Adhesive flow, light OFF.

*Replace bulb, go to step 4.

No adhesive flow. -Go to step 7.

46-1lmIssued 2/87QNordson Corporation 1987

46-U-24

APPLICATOR TANK DOES NOT FILL (Continued)

4. Check ground circuit to level control probe.

Ground circuit faulty.

.Correct fault, restore system to normal operation.

Ground circuit OK. *Go to step 5.

5. Run level control calibration procedure.

Level control LED :ates properly.

*Restore system to normal operation.

Level control procedure not OK.

*Replace level control, restore system to normal

6. (a) Power to unit OFF. (b) Replace resistor

between terminals 4 and 5 of time delay with jumper wire.

(c) Power to unit ON. (d) Wait one minute,

check for normal operation.

operation.

Grid heats, adhesive flows.

@Replace resistor, restore system to normalmoperation.

No adhesive flows. *Replace time delay, restore system to normal operation.


46-11-25


Continuity good. 7. (a) Power to unit OFF.

(b) Remove MANUAL FILL wire 4 or 6.

. Go to step 8.

(c) Check continuity. Continuity OPEN. or partial.

-Replace switch, go to step 3.

32.0 to :37.5 ohms. 8. Check grid heater 4 Go to step 9.

resistance; TB2, terminal 1 to terminal 10.

TV Less than 32.0 ohms.

-Check resistance of each heater, replace faulty heater, restore system to normal operation.

9. Check overheat thermostat disconnect wire 5, check continuity across thermostat. Continuity OPEN.

l Reset thermostat, restore system to normal operation.

46-ll=Issued 2/87mONordson Corporation 1987

46-11-26


A Continuity good. 10. Wire 5 disconnected, *

check continuity across control relay terminals v-- 3 and 5.

T Continuity open.

Il. Check relay coil: (a) Disconnect wire 10

or 20. (b) Check resistance

across relay terminals 1 and 2.

Resistance = zero or infinite.

Cold resistance 1080 to 1320 ohms.

No obstruction. 12. Check for obstructions o+-- IF l

between relay contacts.

Obstruction found.

Replace relay, restore system to normal operation.

Go to step 11.


Go to step 12.

Go to step 13.

Clean contacts or replace relay; restore system to normal operation.

13. Check temperature control continuity (read between COMM and NC).

Continuity good.

Continuity open. l

l

Check for broken or loose wires, tighten/replace as necessary; restore system to normal operation.

Replace temperature control restore system to normal operation.


46-11-27

APPLICATOR TANK OVERFILLS --. -- -__ --.___

1. Run material level calibration procedure.

Not OK -. Replace material

control, restore system to normal operation.

LED and procedure OK

-------Restore system to normal operation.

2. Check material level ground circuit.

Not OK *Correct fault, restore system to normal operation.

OK - Reset level control,

restore system to normal operation.


46-11-28

GRID OVERHEATS

Continuity good. 1. (a) Remove power to unit.

(b) Press RESET button (resets overheat thermostat).

(c) Disconnect wire 5 from control relay box.

(d) Check continuity across . relay terminals 3 and 5.


Continuity open. l G0 to step 2.

2. Check for dead short in heater circuit: (a) Disconnect wire 19

from TB2. (b) Check resistance

across TB2, terminals 1 and 10.

Resistance = 32.0 to :37.5 ohms.

4 Replace temperature control, restore system to normal operation.

Resistance less than 32.0 ohms.

, Check resistance of each heater, replace faulty heater, restore system to normal operation.

46-1lUssued 2/87mONordson Corporation 1987

46-ll-29/30

Disassembling the Control Enclosure and Grid Heater Control Assemblies

n The temperature control and overheat thermostat are each attached to the inside of the control enclosure with two screws.

n To remove the temperature control or thermostat, first remove the two screws attaching the device to the control enclosure.

n Remove the probe from the grid.

To ensure proper operation of the heater temperature control, take care not to kink or sharply bend the capillary tube when removing or installing the probe.

n Carefully remove the probe from its conduit and into the control enclosure. It may be necessary to loosen or remove the conduit fittings.

Reassembling the Control Enclosure and Grid Heater Control Assemblies

n Route the probe from the control enclosure, through the conduit and into the heater enclosure. It may be necessary to loosen or remove the conduit fittings.

To ensure proper operation of the heater temperature control, take care not to kink or sharply bend the capillary tube when removing or installing the probe.

m Install the temperature control or overheat thermostat in the control enclosure using the screws removed in the disassembly procedure.

n Tighten all conduit fittings, close the enclosure doors and restore the system to normal operation.


46-11-31

SECTION IV DIAGRAMS AND TABLES

I

I

I

I

I

i

I

I

I I I

CONTROL BOX COVER

--- - I

1

I

I I I I

I I

L-_---- --A 4RlD #&47ER 80X

Figure 4 -- Automatic Melter/Feeder Wiring Diagram.

46-1lmIssued 2/87@Nordson Corporation 1987

46-11-32

Figure 5 -- Automatic Melter/Feeder Schematic (all models).

ELECTRICAL PARTS LIST (Figures 4 and 5)

Symbol Part No. Description Qty.

LC 271 065 CR 937 064 LF 939 249 TBl 933 074 TB2 933 267 Sl 939 531 SL 939 257 FL 939 229 s2 939 530 TC2 937 102 TCl 937 090 OT 937 276 Hl-5 938 109

Level Control 1 Control Relay 1 Line Filter 1 Terminal Block, 8-Station 1 Terminal Block, lo-station 1 Breaker, 2-Pole 1 Light, SYSTEM (White) 1 Light, FILL (Amber) 1 Push Button Switch, Normally Open 1 Temperature Control 1 Temperature Control 1 Thermostat (Overheat) 1 Grid Heater 5

46-1lmIssued 2/87mONordson Corporaticln 1987

46-11-33

SECTION V ILLUSTRATED PARTS LISTS

INTRODUCTION

The Illustrated Parts Lists detail and illustrate the assemblies and components of the Automatic Melter/Feeder. Those configurations defined in the Equipment Familiarization section of this manual are detailed in the following lists.

COLUMN IDENTIFICATION

FIGURE ITEM COLUMN

The Figure Item column indicates the cal:Lout number in the asso- ciated figure. A hyphen (-) in this column denotes that no callout has been made for that part.

PART NUMBER COLUMN

The Part Number column indicates the Nordson part number for the physical part or assembly. A hyphen (-) in this column indicates a nonsaleable part or a nonsaleable subassembly of a saleable assembly.

DESCRIPTION COLUMN

The Description column provides the component name and, when possible, additional data such as size, temperature, voltage, etc.

REQ'D COLUMN

The Req'd column specifies the quantity of the part required per unit or assembly. A hyphen (-) in this column indicates that no specific quantity is required. The term IrRef" in this column indicates the part or assembly has been included for reference only.


46-11-34

4, 11 --

6, 9 .

10 \ \ \

1 \

5, 6, 7

41

39

8

I ---- -

I 5. 6, 7

_- /

/

-~ 47

_-- - .- 4, 36 or 4, 37

(see parts list)

--- 38

-~- - 2, 3. _ --

Figure 6a -- Automatic: Melter/Feeder (P/N 276 661 and 276 674)

Assembly Drawing --. Front View


46-11-35

25.

32 - --

23

30

44

45

46

16

17

18

19

20

21

22

48

24, 25'

26

20

27

42

35

28

29

-----~

Figure 6b -- Automatic Melter/Feeder (P/N 276 661 and 276 674)

Assembly Drawing -- Side View

46-ll*Issued 2/87=ONordson Corporation 1987

46-11-36

Automatic Melter/Feeder (P/N 276 661 and 276 674) Parts List

Item No. Part No. Description Req'd

276 661

276 674

1 241 280 2 981 208

3 4 983 140

4 983 140

5 981 314

6 983 150 7 984 140 8 241 305 9 981 309

10 241 977 11 981 214

12 241 282 13 901 576 14 981 136 15 981 145 16 981 060 17 740 506 18 740 507 19 981 220

20 981 131

21 241 287 22 270 046 23 981 762

24 270 050 25 900 411 26 241 303 27 273 158 28 276 665

28 276 675

Automatic Melter/Feeder Assembly, HM IV and V

Automatic Melter/Feeder Assembly, HM VII and IX

n Hopper Base n Screw, Hex Head, l/4-20 x

0.63 in. n Retaining Bracket n Lockwasher, Split, 0.25 in.

(P/N 276 661) n Lockwasher, Split, 0.25 in.

(P/N 276 674) n Screw, Hex Head, 5/16-18 x

3.50 in. n Lockwasher, Split, 0.31 in. . Nut, Hex Head, Reg., 0.31-18 n Hopper Support n Screw, Hex Head, 5/16-18 x

0.75 in. n Spacer, Column n Screw, Fil Head, l/4-20 x

0.75 in. n Hopper Colver n Plastic Handle n Screw, Fil Head, lo-24 x 2 in.

Ref

Ref

1

4 4 12

21

8 16 12 1

n Screw, Pan Head, lo-24 x 0.50 in. 6 n Screw, Pan Head, 8-32 x 0.50 in. 4 n Ring, Inspection Port 1 n Glass, Inspection Port 1 n Screw, Skt Head, l/4-28 x

0.63 in. 2 n Screw, Hex Head, lo-32 x

0.63 in. 18 n Hopper Insulator 1 n Grid Melter 1 n Screw, Pan Head, lo-32 x

0.88 in. 2 n Plate, Heater Retainer 1 n Sealant, Rubber n Gasket, Male Sleeve 1 n Hood, Melter Feeder 1 n Cover, Mounting, HM IV and V 1

(P/N 276 6161) n Cover, Mounting, HM VII and

HI4 IX (P/N 276 674) 1


46-11-37

Automatic Melter/Feeder (P/N 276 661 and 276 674) Parts List (Continued)

29 29 30 31

32

33

34 35 36

36

37

38

39 40

41

42

43

44

45

46

47

242 628 273 079 273 967 241 274

276 666

985 111

276 157 981 155

981 214

983 120

984 121

273 059 981 211

273 997

243 030

276 667

273 080

984 101

983 102

273 098

273 097 273 099 900 439 901 582

48 981 160

n Gasket, Cover (P/N 276 661) 1 n Gasket, Cover (P/N 276 674) 1 n Insulator, Electric Enclosure 2 n Hopper, w/Cleanout Door 1

n CONTROL ASSEM:BLY, MELTER/FEEDER Ref

n Rivet, Pop, 3/32 x 0.03-0.13 in. 2

n Information Plate 1 n Sleeve, Female 1 n Screw, Fil Head, lo-24 x

0.75 in. (P/N 276 661) 10 n Screw, Fil Head, l/4-20 x

0.75 in. (P/N 276 674) 9 n Lockwasher, Split, 10

(P/N 276 661 only) 10 m Nut, Hex, lo-24

(P/N 276 661 only) 1 m Mounting Gasket, Probe Assembly 1 n Screw, Hex Head, l/4-20 x

0.75 in. 4 n Heater Assembly, 0.30 x 7.25,

48V 5 n Warning Plate, Hot 4

n HEATER ASSEMBLY ENCLOSURE Ref

n MATERIAL LEVEL PROBE ASSEMBLY Ref

n Nut, Hex Head, Machine, 6-32 2

n Lockwasher, Split, 6 1

n FLUID INDICATOR ASSEMBLY -- (Applicator Model HM IX only) 1

mm Rod, Fluid Indicator 1 mm Cover, Fluid Indicator 1 mm Adhesive, Thread Lock mm Knob, 1.12 dia. x 0.88 in. 1

n Screw, Pan Head, lo-32 x 0.50 2

46-1lmIssued 5/88mONordson Corporation 19,88

46-11-38

5, 6, 7 39 6, Q 4. 36

39

41.

8

37.

40

5, 6, 7

3. 28

2, 6, 7, 46

Figure 7a -- Automatic Melter/Feeder (P/N 276 1676)

Assembly Drawing -I- Front View


46-11-39

32

25.

25

Figure 7b -- Automatic Melter/Feeder (P/N 276 676)

Assembly Drawing -- Side View


46-11-40

Automatic Melter/Feeder Parts List


276 676

1 241 280 2 981 326

3 985 114 4 983 140 5 981 314

6 983 150 7 984 140 8 241 305 9 981 309

10 276 694 11 276 703 12 241 282 13 901 576 14 981 136 15 981 145

16 981 060

17 740 506 18 740 507 19 981 225

20 981 131

21 241 287 22 270 046 23 981 762

24 25 26 27 28 29 30 31 32

270 050 900 411 241 303 273 104 276 696

273 967 241 274 276 666

33 985 111

Automatic Melter/Feeder Assembly, HM 2000

n Hopper Base n Screw, Hex Head, 5/16-18 x

0.50 in. n Rivet, Pop n Lockwasher, Split, 0.25 in. n Screw, Hex Head, 5/16-18 x

3.50 in. n Lockwasher, Split, 0.31 in. n Nut, Hex Head, Reg., 0.31-18 n Hopper Support n Screw, Hex Head, 5/16-18 x

0.75 in. n Heat Barrier n Adapter, Fill Melter. n Hopper Cover n Plastic Handle n Screw, Fil Head, lo-24 x 2 in. n Screw, Pan Head, lo-24 x

0.50 in. n Screw, Pan Head, 8-32 x

0.50 in. n Ring, Inspection Port n Glass, Inspection Port n Screw, Skt Head, l/4-20 x

0.63 in. n Screw, Hex Head, lo-32 x

0.63 in. n Hopper Insulator n Grid Melter l Screw, Pan Head, lo-32 x

0.88 in. n Plate, Heater Retainer n Sealant, Rubber n Gasket, Male Sleeve n Hood, Melter Feeder n Lid n Flange m Insulator, Electric Enclosure n Hopper w/Cleanout Door

Ref

1

4 10 4

8 20 16 1

6

4 1 1

2

22 1 1

4 1

1 1 1 1 2 1

n Assembly, Control, Melter/Feeder 1 (Figure 8)

n Rivet, Pop, 3/32 x 0.03 in. 2


460ll-41/42

Automatic Melter/Feeder Parts List (Continued)


34

35

36 981 214

37 276 678

38 276 667

39 241 977 40 939 613 41 273 997

42 43 44 45

46 983 527

276 687 276 690 983 010 276 689 901 582

276 688 243 030

981 160

n Information I?late

n Assembly, Fluid Indicator mm Rod, Fluid Indicator mm Washer, Flat mm Stopper Plug, Silicon, Rubber mm Knob, 1.12 in. x 0.88 in,

n Screw, Fil Head, l/4-20 x 0.75

n Assembly, Material Level Probe (Figure 9b:)

n Assembly, Heater Enclosure (Figure 10:)

n Spacer, Column m Locknut l Heater Assembly, 0.38 x

7.25 in., 48V m Support, Dip Stick n Warning Plate, Hot Not Used n Screw, Pan Head, lo-32 x

0.50 in. n Washer, Flat

1

1 1 1 1 1

4

1

1

2 4

5 1 4

2 4


46-11-43

P--e- -- -/ -f -,&f-f - - 1-7

a

m P

Figure 8 -- Control Assembly, Automatic Melter/Feeder Assembly Drawinq (all models)


46-11-44

Control Assembly, Automatic Melter/Feeder Parts List (all models)


276 666

1 273 061 2 939 249 3 983 111 4 981 064

5 981 039

6 7 8 9

10 11 12

937 064 984 101 983 102 273 067

242 687 981 247

13 271 065 14 981 020

15 274 113 16 274 112 17 933 282 18 273 272

19 981 000

20 937 276

21 273 068 22 981 729

23 983 121 24 937 090

25 981 024

26 933 078 27 273 051

28 933 075 29 273 060

30

Control Assembly, Automatic Melter/Feeder

n Harness, Melter Feeder n Filter, ILine, Power n Lockwasher, Split, 8 n Screw, Pan Head, 38-32 x

0.38 in. n Screw, Pan Head, 6-32 x

0.31 in. n Relay, SI?ST, 120/240 VAC n Nut, Hex Head, Machine, 6-32 n Lockwasher, Split, 6 n Bracket, Level Control n Control Enclosure, Painted n Latch, Cabinet n Screw, Fil Head, l/4-28 x

0.63 in. n Level Control n Screw, Pan Head, l/4-20 x

1.13 in. n Spacer, Relay Cover n Screw, Standoff n Terminal Lug, Flat n Spacer, Standoff, 0.38 x

1.75 in. n Screw, Fil Head, 5-40 x

0.25 in. n Temperature Sensing Switch,

510'F n Panel w/Inserts, Control Encl. n Screw, Pan Head, lo-32 x

0.38 in. n Lockwasher, Ext, 10 n Thermostat, Tank, Adj.,

300-400°F n Screw, Pan Head, 6-32 x

0.19 in. m Conduit Connector n Strip Marker, 8-Station,

Power Input n Strip Marker, 8-Station m Conduit, 0.38 in.ID x

20LG. Flex n Spacer, Sltandoff

Ref

1 1 4

4

2 1

46-1lmIssued 2/87m@Nordson Corporaticln 1987

46-11-45

Control Assembly, Automatic Melter/Feeder (all models) Parts List (Continued)


31 933 172

32 273 081 33 273 091 34 242 654 35 939 229

36 939 530 37 939 028 38 939 257

39 40 41 42 43 44 45 46

939 531

274 114 273 924 983 120 984 129 271 221 240 674

n Connector, 45 x 0.38 in., Conduit

n Wire Assembly, Ground, Probe n Probe Cable, Melter Feeder n Gasket, Cabinet, 16 x 14 in. n Rectangular Indicator Lamp,

Amber n Switch, Pushbutton n Nut, Dress n Rectangular Indicator Lamp,

White n Breaker, 2-Pole n Front Panel, Control Enclosure n Relay Cover n Stud, Self-Clinching, lo-32 m Lockwasher, Split, lo-N1 n Nut, Hex Head, Machine, lo-32 n Terminal Lug, Ground n Ground Tag

1 1 1

3.8

1 1 1

1 1 1 1 1 2 3 2 2


46-11-46

Figure 9a -- Materiall Level Probe Assembly Drawing

(Melter/Feeders P/N 276 661 and 276 674)


46-11-47

Material Level Probe Palrts List (Melter/Feeders P/N 276 661 and 276 674)


1 2 3 4 5 6 7 8 9

10 11 12 13

14' 981 168

15 600 006

273 080 273 088 973 399 984 129 271 221 983 120 983 121 273 087 939 613 273 085 273 093 273 083 273 082 981 141

Probe Assembly n Enclosure, Conduit n Bushing, Pipe, 0.75 x 0.50 in. n Nut, Hex Headl, lo-32 n Terminal Lug, Ground n Lockwasher, SIplit, 10 n Lockwasher, 10 n Insulator, Probe n Locknut, Condluit n Mounting Plate, Probe Assembly n Capacitor Rod!, Probe n Outer Plate, Probe n Centering Insulator, Probe n Screw, Pan Head, lo-32 x

0.25 in. n Screw, Pan Head, lo-32 x

0.75 in. n Ground Tag

Ref 1 1 3 1 2 1 1 1 1 1 1 1


46-11-48

5

9

10

11

Figure 9b -- Material Level Probe Assembly Drawing

(Melter/Feeder P/N 276 676)

46-1lmIssued 2/87mONordson Corporation 1987 . ---

46-11-49

Material Level Probe Parts List (Melter/Feeder P/N 2'76 676)


276 678 Probe Assembly Ref 1 276 683 n Cover, 0.75~1Lb Enclosure 1 2 276 682 n Gasket, 0.75-lb Enclosure 1 3 276 681 n Housing, Electrical 1 4 973 399 n Bushing, 0.75 0.50 in., x 1 5 984 129 n Nut, Hex Head, lo-32 4 6 271 221 . Terminal Lug 2 7 983 120 8 Lockwasher, Split, 10 2 8 983 021 n Washer, Flat 3 9 276 679 n Probe Insulator 1

10 276 685 n Capacitor, Probe, Inner Plate 1 11 276 686 n Probe Support 1 12 276 680 n Centering Insulator 1 13 981 141 n Screw, lo-32 x 0.25 in. 1 14 981 168 n Screw, lo-32 x 0.75 in. 1 15 983 121 w Lockwasher, 10 Ext. Tooth 1


46-11-50

k2g.J ------

e-e--

3

Figure 10 -- Heater Assembly Enclosure Assembly Drawing (all models)


46-ll-51/52

Heater Assembly Enclosure Parts List (All Models)


276 667 1 2 3 4 5 6 7 8 9

10 11

276 669 933 078 273 979 273 977 240 674 983 120 984 129 983 021 271 221 937 102 981 597

Heater Control Assembly 8 n

n

n

n

n

8

n

n

8

m

Grid Heater Enclosure Assembly Conduit Connector Conduit, Flex Heater Enclosure Wire Group Ground Tag Lockwasher, Split, 10 Nut, Hex Head, Machine, lo-32 Washer, Flat Terminal Lug,, Ground Tank Thermostat Screw, Pan Head, 6-32 x

0.50 in. Nut, 6-32 Lockwasher, Split, 6 Thermostat Insulator

12 984 101 n

13 983 102 n

14 276 670 8

Ref 1 4 2 1 1 1 1 1 1 1


manual, automatic melter/feeder series...

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