series 3900/m metered adhesive application...

SERIES 3900/MMetered Adhesive

Application Systemwith Variable Speed AC Drive, and MultiScan� Controller

Customer Product Manual − Part 106 587H

NORDSON CORPORATION � AMHERST, OHIO � USA

� 1999 Nordson CorporationAll rights reserved

41-3000Issued 2/99

01EN−01−[39−MAC3]−6

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

Address all correspondence to

Nordson Corporation11475 Lakefield Drive

Duluth, GA 30097

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1993. No partof 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, FoamMix, 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 ofValues are trademarks of Nordson Corporation.

Viton is a registered trademark of E.I. DuPont de Nemours & Co.

Parker Lubricant is a registered trademark of Parker Seal.

Never Seez is a registered trademark of Bostik Corporation.

Loctite is a registered trademark of Loctite Corporation.

Introduction


41-3000Issued 2/95

O1EN−02−[NO−CONF]−22

Applicator Identification

This product manual is specific to your applicator. Refer to the ID platelocated on the hose end of your applicator, and write the appropriateidentification numbers and power requirements in the illustration below.

4103326

NORDSON CORP. , AMHERST, OHIO, USAUNIT NO.

SERIAL NO.

POWER REQUIREMENTSVOLTS (ac)

HZ AMPS (Max.)

WATTS (Max.)0/

ID Plate Information

Introduction


41-3000Issued 2/95

O1EN−02−[NO−CONF]−22

Introduction


41-3000Issued 9/94

O1EN−03−[XX−CONG]−1

Congratulations on the Purchase ofYour Nordson Product

Nordson equipment is engineered and manufactured in accordance withstrict specifications, using high-quality components and state-of-the-arttechnologies that assure reliable, long-term performance. Your productwas thoroughly tested for proper operation prior to shipment.

Before unpacking and installing your new equipment, please read thismanual. It is your guide to safe installation, productive operation andeffective maintenance. We recommend that you keep the manualavailable for future reference.

Carefully read the safety instructions in the Safety section. Your productis designed for safe operation when used according to the publishedinstructions. However, potential hazards exist when operatinginstructions are not followed.

This introductory section provides general information includingrecommended spare parts and how the parts can be ordered.

Part A includes safety instructions as well as descriptions of productinstallation, operation, maintenance and general troubleshootingprocedures.

Part B contains detailed information concerning the product and itssubassemblies.

Parts C, D and E provide information covering hot melt hoses, guns andaccessories.

The glossary and index at the end of the manual explain technical termsand assist in locating specific information.

Data and specifications included in this manual are accurate at the timeof publication. Nordson reserves the right to change the contents of thismanual and/or specification without notice.

Nordson is committed to providing product manuals that meet the needsof its valued customers. We invite you to use the Comments andCorrections page included in this section to offer suggestions forcontinued improvement of this manual.

Your Safety is Important toNordson

It’s Easy to Use ThisProduct Manual

We Welcome YourSuggestions

Introduction


41-3000Issued 9/94

O1EN−03−[XX−CONG]−1

Table of Contents i


41-3000Issued 2/95

O1EN−04−[39−MAC3]−4

ManualTable of Contents

Nordson Customer Service Centers O-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Spare Parts and Supplies O-3. . . . . . . . . . . . . . . . . . . . . . . .

General Hot Melt Material Processing Instructions O-7. . . . . . . . . . . . . . . . .

Operator’s Card Order Form O-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Card Reference Copy

Safety A 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description A 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation A 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation A 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance A 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting A 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulics B 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control B 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reservoir and Grid B 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction

Part AGeneral

Part BSubassemblies

Table of Contentsii


41-3000Issued 2/95

O1EN−04−[39−MAC3]−4

For more information, see this Part.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For more information, see this Part.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Filter Screens E 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Guage E 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sub-Base E 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Casters E 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter Unit E 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote sleep Actuator and Ready Indicator E 6-1. . . . . . . . . . . . . . . . . . . .

Grid Screen E 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nordson Glossary F 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index F 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part CHoses

Part DHoses

Part EAccessories

Part FAppendix

O-1Introduction


41-3000Issued 11/95

O1EN−05−[XX−SERV]−1

Nordson Customer Service Centers

Order replacement parts through your local Nordson representative or bycontacting one of the Customer Service Centers. When ordering parts,please use the description shown in the parts list, the part or service kitnumber (if available) and the quantity required.

Country Phone Fax

Argentina 54-1-925-0301 54-1-924-3206

Australia 61-2-838-7144 61-2-838-7394

Austria 43-1-707-5517 43-1-707-5517

Belgium 32-2-720-9973 32-2-720-7371

Brazil 55-11-725-2004 55-11-725-6698

Bulgaria 35-92-739953 35-92-720518

Canada:Markham 905-475-6730 905-475-8821Montreal 514-628-6770 514-628-4414

Chile 56-2-555-7190 56-2-551-7549

China 86-21-324-6260 Ext. 816 86-21-325-7636

Colombia 574-288-8507 574-288-3830

Costa Rica 506-257-2355 506-221-5245

Czech Republic/Slovak Republic 42-5-4121-4924 42-5-4121-6817

Denmark 45-42-648-500 45-42-641-101

Egypt 20-2-261-9299 20-2-260-7097

Finland 358-0-507-2266 358-0-507-2545

France 33-1-64-121-400 33-1-64-121-401

Germany: Lüneburg 49-4131-894-0 49-4131-894-250

Greece 30-1-930-7907/7906 30-1-930-7905

Guatemala 502-234-2678 502-234-7150

Hong Kong 852-2687-2828 852-2687-4748

Hungary 361-252-0473 361-251-7422

India 91-22-557-1726 91-22-557-1334

Indonesia 62-21-555-1175 62-21-668-0090

Ireland:Northern 44-232-683-261 44−232-662-157Republic 353-1-289-6766 353-1-289-6878

Israel 972-3-319931/310563 972-3-323-984

Italy 39-2-9078-2340 39-2-9078-2485

How to Order Parts

Customer Service Centers

O-2 Introduction


41-3000Issued 11/95

O1EN−05−[XX−SERV]−1

Country Phone Fax

Japan 81-3-3450-8818 81-3-3472-3301

Korea 82-347-66-8328 82-347-66-8320

Malaysia 603-734-6281 603-735-2977

Mexico:Mexico City 525-301-1032/1923 525-300-3004/3160Guadalajara 52-36-22-9008 52-36-22-9032Monterrey 528-347-5302/5362 528−347−5242

Morocco 212-2-206933 212-2-206904

Netherlands 31-30-6377812 31-30-6374189

New Zealand 644-568-3109 644-568-5236

Norway 47-22-656-100 47-22-658-858

Pakistan 92-21-444-551 92-21-496-556

Panama 507-607798/605078 507-605-055

Philippines 632-635-0680/0695 632-635-0703/0696

Poland 48-22-331-145 48-22-333-861

Portugal 351-2-941-3874 351-2-941-5843

Puerto Rico 809-787-2474 809-786-4660

Russia 7-812-227-2369 7-812-227-2369

Saudi Arabia (S.E.T.E.C.) 966-1-477-5042 966-1-477-7326

Singapore 65-778-2511 65-778-3151

Slovenia 386-66-34627 386-66-34228

South Africa 27-21-237-883 27-21-237-888

Spain 34-6-370-5013 34-6-370-5004

Sri Lanka 94-1-509-451 91-1-509-556

Sweden 46-40-680-4550 46-40-932-882

Switzerland 41-61-411-3838 41-61-411-3818

Taiwan 886-2-908-7066 886-2-908-7022

Thailand 66-2-514-1159 66-2-539-4924

Turkey 90-216-384-40 85/92 80 90-216-372 15 28

United Arab Emirates (GAEP) 97-1-481-5331 97-1-481-5334

United Kingdom 44-1844-213-171 44-1844-215-358

USA: Continental (800) 241-8777 (770) 497-3733Alaska & Hawaii (770) 497-3700

Venezuela 58-4-132-9232 58-4-132-6407

Vietnam 84-8-396-349 84-8-395-349

Eastern Europe, Africa &Middle East, contact:

DED Erkrath, Germany (49) 211-9205-0 (49) 211-254652

Pacific South, contact:

Amherst, Ohio, USA (216) 988-9411 (216) 985-3710

Customer Service Centers(contd.)

O-3Introduction


41-3000Issued 2/95

O1EN−06−[39−MAC3]−4

Recommended Spare Parts and Supplies

Nordson Uptime Plus packs provide parts for fast repair of yourapplicator. Major parts can be quickly replaced, resulting in maximumproductive operation. The following packs are recommended for yourapplicator.

Major Assemblies

O-4 Introduction


41-3000Issued 2/95

O1EN−06−[39−MAC3]−4

Description Recommended Quantity for:

1 system 5 systems 10 systems

Fuses

P/N 158 105 Fuse service kit. Contains:

P/N 939 683 Four 6.3 amp fuses,

P/N 939 708 Four 1 amp fuses,

P/N 310 905 Four 0.125, Fast-acting, 250 V,

P/N 939 491 Four 25 amp fuses,

P/N 138 707 Two 100 MA fuses,

1 1 2

Resistance Temperature Detector (RTD) & Thermostat

P/N 105 721 RTD

P/N 135 072 Thermostat

1

1

2

2

2

2

Manifold:

P/N 158 099 Service kit contains:

P/N 940 121 O-ring

P/N 440 281 O-ring, 1.38 x 1.50 x 0.063 (pkg of 4)

P/N 940 157 O-ring, 0.562 x 0.688 x 0.063 (pkg of 4)

P/N 940 172 O-ring, 1.38 x 1.50 x 0.063

P/N 940 161 O-ring 5/8 x 3/4 x 1/16

P/N 940 113 O-ring, 0.312 x 0.438 x 0.063

P/N 940 274 O-ring, 1 5/16 x 1 7/16 x 1/16

P/N 954 036 Backup ring, 1/4 x 3/8 (pkg of 4)

P/N 940 101 O-ring, 0.250 x 0.375 x 0.063 (pkg of 4)

P/N 941 201 O-ring 1 x 1.19 x .093

P/N 134 017 Filter screen, 0.020, 5.38 in. (pkg of 2)

P/N 161 093 Solenoid

P/N 158 104 Directional valve rebuild kit

P/N 900 493 Parker Lubricant, High Temp

1

1

1

1

1

1

1

1

2

2

2

2

Pump

P/N 117 762 Gear pump assembly

P/N 120 375 O-ring for crossover tube (pkg of 4)

P/N 120 376 Backup ring for crossover tube (pkg of 4)

1

1

1

2

2

2

2

2

2

Motor Drive

P/N 154 879 Coupling sleeve 1 2 2

Consumables and WearItems

O-5Introduction


41-3000Issued 9/94

O1EN−07−[XX−PROC]−1

General Hot Melt MaterialProcessing Instructions

NOTE: Before processing hot melt material, carefully read the materialmanufacturer’s Material Safety Data Sheet (MSDS) or materialinformation sheet. Nordson supplies only general processing instructionsand is not liable for hazards associated with or damage caused by theuse of hot melt material.

Store the material in dry areas at room temperature. Keep it in covered,dust-protected containers.

Keep the substrate at room temperature, dry, and free of dust andgrease. Perform tests to determine the suitable hot melt material,optimum operating conditions, and preliminary treatment of the substratefor the application.

Some substrates contain plasticizers and other ingredients whichdissipate over time. In some cases, surfaces are treated with waxes,anti-stick oils, etc. Without adequate pretreatment, the hot melt bond inthese applications may be defective at the time of dispensing.

The application temperature of the hot melt material at the nozzle iscrucial for effective bonds.

Refer to the material manufacturer’s MSDS or material information sheet.

Avoid unnecessary thermal stress. If the work is interrupted, reduce themelting temperature.

Avoid heating the hot melt material above the prescribed processingtemperature. Higher temperatures may cause charring of the hot meltmaterial. This results in downtime. In addition, material may generatedangerous vapors at excessively high temperatures. Remove thesevapors by using appropriate exhaust systems.

Storage

Preparations for MaterialApplication/Coating

Processing Temperature

O-6 Introduction


41-3000Issued 9/94

O1EN−07−[XX−PROC]−1

Be careful when using hot melt materials. These materials are solid atroom temperature. For proper application, they may be heated totemperatures of up to 230 �C (450 �F). Refer to the safety instructions inthe Safety section.

Avoid mixing different hot melt materials. Refer to Changing the Hot MeltMaterial in the Maintenance section.

Refer to the supplier’s MSDS or material information sheet.

Danger of Burns

Mixing Hot Melt Materials

Disposal of Hot Melt Material

O-7Introduction


41-3000Issued 9/92

O1EN−08−[XX−USER]−1

User Comments

Nordson welcomes your evaluation of this product manual. Yourcomments and suggestions help us to continuously improve ourdocumentation. Please circle one number for each of the statementsbelow. Give additional comments on the back of this page. Thank youfor your input.

Please enter your configuration code or Part Number___________________________

StronglyAgree

Agree Neutral Disagree StronglyDisagree

The manual is well organized 1 2 3 4 5

Information can be quickly located 1 2 3 4 5

Instructions are easy to understand 1 2 3 4 5

Instructions are complete 1 2 3 4 5

The manual is clearly written 1 2 3 4 5

The manual is accurate 1 2 3 4 5

Concepts and vocabulary are easy tounderstand

1 2 3 4 5

Illustrations are clear and helpful 1 2 3 4 5

The manual contains enough illustrations 1 2 3 4 5

Layout and format makes the manualeasy to use

1 2 3 4 5

Name

Department

Company

Address

Phone Fax

Send this sheet to: All European countries : All other countries including USA/Canada:

Nordson Engineering GmbH Nordson CorporationAbteilung Dokumentation Attn: Technical CommunicationLilienthalstrasse 6 Technology Park/Johns CreekD-21337 Lüneburg 11475 Lakefield DriveGermany Duluth, GA 30136, USAPhone 49-4131/8940 Phone (404) 497-3400Fax 49-4131/894149 Fax (404) 497-3610

O-8 Introduction


41-3000Issued 9/92


Your Comments

O-9Introduction


41-3000Issued 9/92


User Corrections and Additions

Nordson values the opinions of its customers. Please use this page toreport errors and to offer your suggestions on how we can make thismanual more useful to you.

Configuration code or Part Number_____________________________

(Please note page number and issue date for each page, and include amarked copy of the page, if possible)

Send this sheet to: All European countries : All other countries includingUSA/Canada:

Nordson Engineering GmbH Nordson CorporationAbteilung Dokumentation Attn: Technical CommunicationLilienthalstrasse 6 Technology Park/Johns CreekD-21337 Lüneburg 11475 Lakefield DriveGermany Duluth, GA 30136, USAPhone 49-4131/8940 Phone (404) 497-3400Fax 49-4131/894149 Fax (404) 497-3610

O-10 Introduction


41-3000Issued 9/92


Corrections and Additions

O-11Introduction


41-3000Issued 2/95

O1EN−09−[39−MAC3]−4

Operator’s Card Order Form

This product manual was shipped with a laminated operator’s card forSeries 3900/M Metered Adhesive Application System. To obtainadditional operator’s cards, send this form to your local Nordsonrepresentative or contact one of the Nordson Customer Service Centers.

Name ____________________________________________

Department ____________________________________________

Company ____________________________________________

____________________________________________

Address ____________________________________________

____________________________________________

Phone ________________ Fax _______________________

Language required (check box):

� EnglishP/N106 574

� FrenchP/N 106 575

� GermanP/N 106 576

� ItalianP/N 106 577

� SpanishP/N 106 578

� JapaneseP/N 106 604

O-12 Introduction


41-3000Issued 2/95

O1EN−09−[39−MAC3]−4

A

## TABSHEET ##

Table of Contents i


41-3000Issued 7/98

A0EN−01−[39−MAC3]−3

Part A, GeneralTable of Contents

1. Operate Safely A 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety Symbols A 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Qualified Personnel A 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Intended Use A 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Installation and Electrical Connections A 1-4. . . . . . . . . . . . . . . . . . . . .

6. Operation A 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Less-Obvious Dangers A 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Action in the Event of Unit Malfunction A 1-5. . . . . . . . . . . . . . . . . . .

Danger of Burns A 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Maintenance/Repair A 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Cleaning A 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Thermoplastic Hot Melt Material A 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Equipment and Material Disposal A 1-8. . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction A 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intended Use A 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Features A 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Options A 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Overview of System Components A 2-3. . . . . . . . . . . . . . . . . . . . . . . . .

3. Overview of MultiScan Controller Indicators and Displays A 2-4. . . . .

4. Schematic—Hydraulic A 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section A 1Safety

Section A 2Description

Table of Contentsii


41-3000Issued 7/98

A0EN−01−[39−MAC3]−3

1. Setting Up the Unit A 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Electrical A 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ID Plate A 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing from ′F to ′C A 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System-Ready Delay A 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parent Machine Interlock (PMI) and System Fault Connections A 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Overtemperature Setting on MultiScan Controller A 3-8. . . . . . . . . . . .

4. Hose Installation A 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Air Supply Installation A 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Gun Installation A 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Timer A 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Setting the Clock A 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Preparation for First Operation A 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Setting the Clock for SLEEP Mode (On/Off) A 4-5. . . . . . . . . . . . . . . . .

3. Forcing the Clock ON and OFF A 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Force the System into the SLEEP Mode A 4-7. . . . . . . . . . . . . . . . .

Force the System ON during the SLEEP Mode A 4-7. . . . . . . . . . .

1. Daily Maintenance A 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Weekly Maintenance A 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Manifold Filter A 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Removable Nozzles A 5-4. . . . . . . . . . . . . . . . . . . . . . . . . .

3. Semi-Annual Maintenance A 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Non-Scheduled Maintenance A 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General A 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Reducer A 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing the System Using Hot Melt Material A 5-6. . . . . . . . . . . . .

Flushing the System Using Type R Fluid A 5-7. . . . . . . . . . . . . . . . .

Cleaning the Gear Pump Assembly A 5-8. . . . . . . . . . . . . . . . . . . . .

5. Changing the Hot Melt Material A 5-10. . . . . . . . . . . . . . . . . . . . . . . . . .

6. Maintenance Record Form A 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Important Hints for Troubleshooting A 6-1. . . . . . . . . . . . . . . . . . . . . . . .

2. Inadequate Supply of Hot Melt Material A 6-1. . . . . . . . . . . . . . . . . . . .

3. Hot Melt Material Application not Correct A 6-2. . . . . . . . . . . . . . . . . . .

Section A 3Installation

Section A 4Operation

Section A 5Maintenance

Section A 6Troubleshooting


Issued 11/94 A1EN−02−[XX−SAFE]−1

Part A, Section 1

Safety

SafetyA 1-0


Issued 11/94A1EN−02−[XX−SAFE]−1

Safety A 1-1



Section A 1Safety

Safety instructions contained in this section and throughout thisdocument apply to tasks that may be performed with or on the unit.Warnings related to specific safety concerns are included within the textas appropriate. It is very important that these safety instructions arealways followed. Failure to do so could result in personal injury and/ordamage to the unit or other equipment.

With this in mind, here are some basic safety recommendations:

� Read and become familiar with this Safety section prior to installing,operating, maintaining, or repairing the unit.

� Read and follow the warnings which appear within the text and arerelated to specific tasks.

� Store this document within easy reach of personnel operating ormaintaining the unit.

� Wear personal protective equipment and clothing such as safetygoggles and gloves.

� Familiarize yourself with and follow all safety instructions prescribedby your company, general accident-prevention regulations, andgovernment safety regulations.

1. Operate Safely

SafetyA 1-2



The following symbols are used to warn against dangers or possiblesources of danger. Become familiar with them! Failure to heed awarning could lead to personal injury and/or damage to the unit or otherequipment.

WARNING: Failure to observe may result in personal injury,death, or equipment damage.

WARNING: Risk of electrical shock. Failure to observe mayresult in personal injury, death, or equipment damage.

WARNING: Disconnect equipment from the line voltage.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and/or heat-protective gloves depending on thesymbols shown.

WARNING: Risk of explosion or fire. Fire, open flames, andsmoking prohibited.

WARNING: System or material pressurized. Relieve pressure.Failure to observe may result in serious burns.

CAUTION: Failure to observe may result in equipmentdamage.

CAUTION: Hot surface. Failure to observe may result inburns.

2. Safety Symbols

Safety A 1-3



“Qualified personnel” is defined here as individuals who thoroughlyunderstand the equipment and its safe operation, maintenance, andrepair. Qualified personnel are physically capable of performing therequired tasks, familiar with all relevant safety rules and regulations, andhave been trained to safely install, operate, maintain, and/or repair theequipment. It is the responsibility of the company operating theequipment to see that its personnel meet these requirements.

The unit is designed and intended to be used only for the purposedescribed in the Description section. Uses not in accordance with thatsection or as described in this document are considered unintended usesand not in accordance with governing regulations.

WARNING: Use of this equipment in ways other thandescribed in this document may result in personal injury, death,or equipment damage.

The following actions of the owner or operator of the unit are some, butnot all, examples of unintended use which would permit Nordson to claimit is not responsible for personal injury or property damage arising fromsuch unintended use:

� Unapproved modifications or changes to the unit

� Failure to comply with the safety instructions

� Failure to comply with instructions concerning installation, use,operation, maintenance, or repair, or when these tasks are carried outby unqualified personnel

� Use of inappropriate or incompatible foreign materials or auxiliaryequipment

� Failure to observe workplace safety rules or regulations issued bygovernment authorities or safety councils

3. Qualified Personnel

4. Intended Use

SafetyA 1-4



WARNING: Failure to follow the safety procedures can result ininjury or death.

� All electrical, pneumatic, gas, and hydraulic connections andinstallations of hot melt equipment may only be carried out byqualified personnel. Be sure to observe installation instructions forcomponents and accessories.

� Equipment must be properly grounded and fused according to itsrated current consumption (see ID plate).

� Cables which run outside the unit must regularly be checked for wearor damage.

� Power supply wire gauge and insulation must be sufficient to handlerated current consumption.

� Cables must never be squeezed or pinched. Do not locate cables orhoses in high traffic areas.

The unit should be operated by qualified personnel in accordance withthe instructions presented in this document.

WARNING: Failure to follow the safety procedures can result ininjury or death.

� Never allow the unit to be operated by personnel under the influenceof substances which reduce their reaction times, or who are not ableto operate the equipment for physical reasons.

� Prior to each start-up of the unit, check protection and warningdevices and make sure they are fully functional. Do not operate theunit if these devices are not functioning properly.

� When the removal of safety equipment is required for installation,maintenance, or repair of the unit, it must be re-connectedimmediately upon completion of the work.

� Prior to start-up of the unit, check to make sure all safety guards andsafety equipment are in place and functioning properly.

5. Installation and ElectricalConnections

6. Operation

Safety A 1-5



� In a humid environment, only equipment featuring a correspondingclass of protection may be operated.

� Do not operate the unit in an explosive environment.

� Keep parts of the body or clothing away from rotating parts. Do notwear loose articles of clothing when operating or servicing units withrotating parts. Take off wrist watches, rings, necklaces, or similarpieces of jewelry and pin up or cover long hair before performing anywork on or with the unit.

� To carry out measurements on work pieces, switch off the unit andwait until it comes to a standstill.

� Never point hand guns or applicator nozzles at yourself or otherpersons.

WARNING: An operator or service technician working with theunit should be aware of less-obvious dangers that often cannotbe completely minimized at production sites:

� Exposed surfaces of the unit which cannot be practicallysafeguarded. They may be hot and take time to cool after the unithas been operating.

� The possibility that electrical potentials may remain in the unit afterthe unit was de-energized

� Hot melt material and vapors

� Hydraulically or pneumatically operated parts of the unit

� Parts winding something up or down which are not covered

If the unit malfunctions, switch it off immediately.

� Turn the circuit breaker or main power switch OFF.

� Have the unit repaired by qualified personnel only.

6. Operation (contd.)

Less-Obvious Dangers

Action in the Event of UnitMalfunction

SafetyA 1-6



Contact with hot melt materials or hot areas of the unit may produce asevere skin burn.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and/or heat-protective gloves depending on thesymbols shown.

� Be extremely careful when using hot melt material. Even solidifiedmaterial may still be very hot.

� Always wear protective clothing which safely covers all exposed partsof the body.

In case of burns:

� Immediately cool affected skin areas using cold, clean water.

� Do not forcefully remove hot melt material from the skin.

� Immediately seek medical attention.

Allow only qualified personnel to perform the procedures described in thisdocument. When performing such tasks, wear protective clothing, andequipment.

WARNING: Even when the circuit breaker or main powerswitch is OFF, the unit is still electrically energized. Completethe following steps prior to maintenance or repair:

� Disconnect, lock out, and tag external power supply.

� To ensure the external power supply is disconnected, attempt tooperate the unit. If the unit does not energize, proceed withmaintenance or repair work.

� If the unit energizes, repeat the disconnect, lock out, and tagprocedure. Re-test the unit.

Danger of Burns

7. Maintenance/Repair

Safety A 1-7



� Follow the specific instructions provided in this manual to relieve thesystem pressure in the entire unit.

� Secure pneumatically- or hydraulically-operated equipment againstuncontrolled movement.

� Only use parts which do not compromise the safety of the unit. Onlyuse genuine Nordson parts.

� Always use tools with insulated handles when removing or installingcomponents.

NOTE: Always refer to the material manufacturer’s Material Safety DataSheet (MSDS) or material information sheet before working with anymaterial.

WARNING: Never clean any aluminum part or flush anysystem using halogenated hydrocarbon fluids. Examples ofcommon halogenated hydrocarbons are: dichloromethylene,1,1,1-trichloroethylene, and perchloroethylene. Halogenatedhydrocarbons may react violently with aluminum parts.

WARNING: Fire, open flame, and smoking are prohibited whencleaning fluids are used. Observe all explosion preventionregulations. Cleaning fluids may only be heated usingtemperature-controlled and explosion-protected heaters.

� Never use an open flame to clean the unit or components of the unit.

� Use only cleaning fluids designed or intended to be used with the hotmelt material being used in the unit. Never use paint fluids under anycircumstances.

� Note the flash point of the cleaning fluid used. Only use a controlledheating method to heat fluids.

� Ensure sufficient room ventilation to draw off generated vapors.Avoid prolonged breathing of vapors.

7. Maintenance/Repair (contd.)

8. Cleaning

SafetyA 1-8



NOTE: Always refer to the material manufacturer’s Material Safety DataSheet (MSDS) or material information sheet before working with any hotmelt material.

� Ensure the work area is adequately ventilated.

� Do not exceed recommended processing temperatures. Doing socreates a danger to personnel due to decomposition of the material.

Dispose of equipment and materials used in operation and cleaningaccording to local regulations.

9. Thermoplastic Hot MeltMaterial

10.Equipment and MaterialDisposal


41-3000Issued 7/98

A2EN−03−[39−MAC3]−4

Part A, Section 2

Description

DescriptionA 2-0


41-3000Issued 7/98

A2EN−03−[39−MAC3]−4

Description A 2-1


41-3000Issued 7/98

A2EN−03−[39−MAC3]−4

Section A 2Description

4103700

Fig. A 2-1

DescriptionA 2-2


41-3000Issued 7/98

A2EN−03−[39−MAC3]−4

The 3900/M Metered Adhesive Application systems may be only used tomelt, transfer, and apply hot melt material. They are not intended forPolyurethane Reactive hot melt material.

The applicator melts adhesives in a PTFE-coated aluminum grid andreservoir. The adhesive passes through a pump into a distributionmanifold. Material then flows through a filter into a heated hose andextrusion gun.

The grid, tank, hose and gun are electrically heated. The grid has acast-in, resistive heater in the blades. The tank has a cast-in, resistiveheater in its aluminum wall. A spiral-wound element heats the hose. Thegun has a cartridge heater. Resistance temperature detectors (RTDs)are used to sense the temperature in the grid, tank, hose, and gun.

The following features are standard on all 3900/M systems.

� Overtemperature protection

� Enhanced control flexibility and accuracy with the MultiScan controlsystem

� Programmed sequential startup of applicator, hose, and gun reducesstartup component stress

� Parent machine interlock (PMI) prevents line activation before the hotmelt material reaches application temperature

� Output contacts are available to connect optional remote alarms

� A 45� manifold face allows efficient and convenient routing of thehose

� Electrical quick-disconnects on hose for easy installation andmaintenance

� Directional valve and 24 Vdc solenoid on the manifold allows uniformbead deposit

For MultiScan control options, refer to the Control section.

1. Introduction

Intended Use

Features

Options

Description A 2-3


41-3000Issued 7/98

A2EN−03−[39−MAC3]−4

See Figure A 2-2. A typical Nordson metered adhesive applicationsystem consists of the applicator (also called the unit), a heated hose andgun for dispensing the adhesive, and a timer to control an automatic gunif used.

5

6

1

7

8

9

10

3

4

2

4103693

Fig. A 2-2

1. Hopper enclosure2. Manifold 24 Vdc solenoid3. Filter assembly, Directional valve,

Flow control valve

4. Circuit breaker (ON/OFF switch)5. Controls6. Electrical enclosure7. PC40 DC pattern control

8. Gun solenoid (recommend 24 Vdc solenoid)

9. H20 LBS gun10. Hose

2. Overview of SystemComponents

DescriptionA 2-4


41-3000Issued 7/98

A2EN−03−[39−MAC3]−4

4103701

CONTROL ON

SYSTEM READY

REMOTE SHUTDOWN

SETBACK ON

SYSTEM FAULT

TEMP. WARNING

MOTOR FAULT

OVERTEMPERATURE

HIGH

OK

LOW

OPEN SENSOR

SHORTED SENSOR

SCAN

HOLD

STEP

MICROSET

1

4

3

5

8

9

101112

13

7

6

2

Fig. A 2-3

1. Hose temperature control2. Gun temperature control3. System status indicators4. Reservoir and grid temperature

controls5. Channel status indicators

6. Digital display7. Temperature setback8. Temperature High/low monitor9. Motor speed control

10. Motor ON/OFF switch11. Motor Tachometer12. SLEEP button13. Clock

3. Overview of MultiScanController Indicators andDisplays

Description A 2-5


41-3000Issued 7/98

A2EN−03−[39−MAC3]−4

4103702

RESERVOIR

10:1 M

PRESSURERELIEF

PUMP GEAR REDUCER

FILTER

FILTERDRAIN

HOSE

FLOWCONTROL

AC MOTOR

NOZZLEDIRECTIONALVALVE

H−20 GUN

Fig. A 2-4

4. Schematic—Hydraulic

DescriptionA 2-6


41-3000Issued 7/98

A2EN−03−[39−MAC3]−4


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

Part A, Section 3

Installation

InstallationA 3-0


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

4103703

Installation A 3-1


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

Section A 3Installation

WARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis section and in the Safety section.

WARNING: Fingers and hands may be injured. Use suitablelifting equipment, if available. Lift the unit only at the frame, notat the hose connectors. For weight information, refer toTechnical Data in the Overview section.

1. Check that the plug and screw connections are tight.

2. Protect the unit from humidity, vibration, and excessive dust. Protectgun from cold drafts.

3. Operate the unit only at ambient temperatures of 0� to 50�C(32� to 120�F).

4. Allow space to open the lid.

5. See Figure A 3-2. Allow space to open and drain the manifold drainvalve. Clearance is 62 mm (2.4 in.).

6. Allow space to remove the filter assembly. Clearance is 207 mm(8.2 in.).

7. Allow space to lift off the hopper enclosure. Clearance is 660 mm(26.0 in.).

8. Allow space to open the control door. Clearance is 406 mm (16.0 in.)Fig. A 3-1

1. Setting Up the Unit

4103705

InstallationA 3-2


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

9. Four bolt holes are located in the base of the applicator for mounting.Nordson recommends using 8 mm mounting bolts. A sub baseassembly is available as an accessory. Refer to the Accessoriessection.

4103308

Fig. A 3-2

WARNING: Allow only qualified personnel to perform electricalconnections. Observe the safety instructions.

NOTE: Operate the unit only when connected to the line voltage statedon the ID plate. See Figure A 3-7.

1. See Figure A 3-3. Open the electrical enclosure door.

2. Remove the appropriate knock-out in the bottom or back side of theelectrical enclosure.

Fig. A 3-3

1. Setting Up the Unit (contd.)

2. Electrical

4103340

4103211

Installation A 3-3


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

3. See Figure A 3-4. Route the service line through the hole. A strainrelief must be used.

Fig. A 3-4

4. See Figure A 3-5. Locate the seven-station input terminalblock (XT1).

Fig. A 3-5

5. See Figure A 3-6. Make the connections at the terminal blockaccording to Figure A 3-6.

4130803

1 2

Fig. A 3-6

1. 200−240 V unit connections 2. 400 V unit connections

4103415

InstallationA 3-4


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

The ID plate is located on the hose end of the unit.

4103326

NORDSON CORP. , AMHERST, OHIO, USAUNIT NO.

SERIAL NO.

POWER REQUIREMENTSVOLTS (ac)

HZ AMPS (Max.)

WATTS (Max.)0/

Fig. A 3-7

1. See Figure A 3-8. Open the control swing panel and locate thefive-position dip switch (SW1) on top of the main control board.

SW1

4103216

Fig. A 3-8 Top view

2. See Figure A 3-9. To change the digital display from �F to �C, moveDIP switch 5 to the OFF or OPEN position.

Fig. A 3-9

ID Plate

Changing from �F to �C

Installation A 3-5


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

This adjustable delay provides time for material to become adequatelymelted after the reservoir and other channels reach their setpointtemperatures. This delay works in two different ways, depending on thereservoir and grid temperatures at startup.

� At startup, if the reservoir and grid temperatures are more than 19�C(35�F) below their setpoints, all channels begin to heat in sequence.The grid begins to heat first. When it is within 19�C (35�F) ofsetpoint, the tank and hose begin to heat. The gun begins to heatlast. After all channels are within 3�C (5�F) of setpoint, thesystem-ready time delay begins. The yellow indicators for eachconnected channel begin to flash on the control panel. When thedelay period ends, the SYSTEM READY indicator comes on.

� At startup, if the reservoir and grid temperatures are within 19�C(35�F) of their setpoints, continuous power goes to all channelheaters until the channels are within 3� C (5�F) of setpointtemperatures. Then channel heating becomes proportional as shownby the flashing yellow channel indicators. The delay period isbypassed, and the SYSTEM READY indicator comes on immediately.

The unit is shipped with the delay set at 46 minutes. The recommendedlength of the delay depends on the type of material used. The delay canbe reset within the range of 0 to 58 minutes. To reset this delay:

1. See Figure A 3-10. On the top of the main control panel, locate thefive-position dip switch (SW1).

SW1

4103216

Fig. A 3-10 Top view

System-Ready Delay

4103337

InstallationA 3-6


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

2. Using the following chart, set DIP switches 1, 2, 3 and 4 for thedesired time delay.

NOTE: See Figure A 3-11. Moving a switch towards the main controlboard is the ON position. Moving a switch away from the board is theOFF position.

Fig. A 3-11

DELAY(min.) 1 2 3 4 5

0 ON ON ON ON This switch isfor changingthe digitaltemperaturedisplay.(�F = ON, �C = OFF)

2 ON ON ON OFF

6 ON ON OFF ON

10 ON ON OFF OFF

14 ON OFF ON ON

18 ON OFF ON OFF

22 ON OFF OFF ON

26 ON OFF OFF OFF

30 OFF ON ON ON

34 OFF ON ON OFF

38 OFF ON OFF ON

42 OFF ON OFF OFF

46 OFF OFF ON ON

50 OFF OFF ON OFF

54 OFF OFF OFF ON

58 OFF OFF OFF OFF

System-Ready Delay (contd.)

4103217

4103218

XT1−1

XT1−2

XT1−3

XT1−4

Installation A 3-7


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

The MultiScan control system provides two sets of normally-open, drycontacts which imitate the condition of two system-status indicators onthe control panel.

The parent machine interlock (PMI) contacts close when the SYSTEMREADY indicator on the control panel is illuminated. PMI can preventoperation of the parent machine before the applicator is ready to deliverhot melt material.

The system fault contacts close when the SYSTEM FAULT indicator isilluminated on the control panel. The contacts can activate a remotealarm which alerts the operator that a fault condition exists.

The contacts are rated at 28 Vdc/240 Vac at 2 amperes and are notpolarity-sensitive. Connections are made through a two-part terminalblock on the top of the control board next to switch SW1.

1. Lock out electrical power and open the electrical enclosure door.

2. See Figure A 3-12. Locate the two-part terminal block at the top ofthe main control board. Carefully pull on the plug part of the terminalblock until the two parts separate.

3. Route the leads for the PMI and warning and fault contact closuresthrough the knock-out next to the cord connector.

Fig. A 3-12

4. See Figure A 3-13. Connect the leads to the plug as follows:

� PMI and Ready to XT1-1 and XT1-2� Fault to XT1-3 and XT1-4

5. Reconnect the plug to its receptacle.

Fig. A 3-13

Parent Machine Interlock (PMI)and System Fault Connections

4103382

4103707

InstallationA 3-8


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

The MultiScan controller is shipped with a factory overtemperaturesetting of 218�C (425�F). This setting can be changed by moving theposition of jumper JMP1 on the main control board. For furtherinformation refer to Control in the subassemblies section.

1. See Figure A 3-14. Remove the plug from the manifold hose port.Unused manifold hose ports must be closed by plugs.

NOTE: Keep the dust cap for use during servicing and maintenanceprocedures.

Fig. A 3-14

2. See Figure A 3-15. Hose connection fittings are supplied with theapplicator. Apply Never Seez on the threads and screw the fitting intothe threaded port. Refer to the information sheet supplied with thehose for correct handling instructions.

4103338

Fig. A 3-15

3. See Figure A 3-16. Connect the hose to the first hose port. Failure toconnect a hose to the rear-most port creates a dead end in themanifold where char builds up. Char buildup can cause downtime.

Fig. A 3-16

3. Overtemperature Settingon MultiScan Controller

4. Hose Installation

4103708

Installation A 3-9


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

1. See Figure A 3-17. Install an air supply line to the solenoid on themanifold.

2. Connect the air supply line to a regulator. This air supply line can beconnected to the same regulator used for the gun.

NOTE: Use an air supply that is capable of providing 4.15 bar (60 psi) tothe applicator. Be sure that the air supply is filtered and unlubricated.Nordson recommends installing a shutoff valve with lock-out in the supplyline to isolate the applicator from the air supply for maintenanceprocedures.

Fig. A 3-17

Refer to the gun product manual.

Connect a timer to the gun solenoid and the manifold solenoid. Thesame timer can be used for both. Follow the installation instructions thatcame with the timer.

5. Air Supply Installation

6. Gun Installation

7. Timer

InstallationA 3-10


41-3000Issued 2/99

A3EN−04−[39−MAC3]−6

Use the following procedure to set the clock.

� Press and hold the MODE key (1) for at least one second.

� Press the d key (2) until the cursor is under the proper day of theweek.

� Press and hold the h key (3) until the present hour appears.

� Press and hold the m/PWD key (4) until the present minutes appear.

� Press the WRITE key (5).

� Press the MODE key (6) three times. This returns the clock to theRUN mode.

1 2 3

4 5 64103709

Fig. A 3-18

8. Setting the Clock


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

Part A, Section 4

Operation

OperationA 4-0


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

4103302

4103328

4103287

Operation A 4-1


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

Section A 4Operation

WARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis document and all other related documentation.

WARNING: Refer to General Hot Melt Material ProcessingInstructions at the beginning of this manual.

1. Fill the hopper with clean hot melt material to a point 25 mm (1 inch)below the top of the hopper.

2. Close the lid immediately after filling.

Fig. A 4-1

3. Set all temperature dials to the settings recommended for the specifichot melt material.

Fig. A 4-2

4. Remove the gun nozzle.

Fig. A 4-3

1. Preparation for FirstOperation

4103710

4103329

I

O

4130705

OperationA 4-2


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves. Hot melt materialmay be released forcefully.

5. Check that the clock is in the ON position.

Fig. A 4-4

6. Turn on power to the applicator. Allow it to reach operatingtemperature.

7. Increase the air pressure to the gun to 2.4 bar (35 psi).

Fig. A 4-5

8. Set the motor speed to 30%. The minimum recommended motorspeed is 200 rpm.

Fig. A 4-6

1. Preparation for FirstOperation (contd.)

4103711

4103712

ÂÂ

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

ÂÂÂÂÂÂ

ÂÂ

Â

Operation A 4-3


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

9. Place a container under the manifold and open the drain valve.

10. Turn the motor ON and allow hot melt material to flow. This removesair trapped in the filter.

11. Turn the motor OFF.

12. Remove and clean the manifold filter according to instructions inWeekly Maintenance in Part A.

13. Close the drain valve.

14. Trigger the guns, keeping them open so no pressure builds up in thesystem.

Fig. A 4-7

15. Turn the motor ON and allow adhesive to flow out of the gun until alltrapped air, cleaning solution, and impurities are flushed out of thesystem.

16. Stop triggering the guns.


18. Trigger the gun momentarily to relieve trapped hydraulic pressure.

19. Attach the nozzles to the guns.

20. Install the pressure gauge in one of the manifold ports.

21. Set the motor speed dial to 30%.

22. Set the timer for the gun and manifold solenoids for constanttriggering.

23. Turn the flow adjustment screw fully counterclockwise to open thisvalve.

24. Turn the motor ON.

Fig. A 4-8

4103761

4130389

A

B

C

D

OperationA 4-4


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

25. Trigger the gun.

26. Adjust the motor speed to obtain the desired output. Note thepressure gauge reading.

27. Stop triggering the gun.

28. Slowly turn the flow adjustment screw clockwise until the pressuregauge reading is the same as in step 26.

Fig. A 4-9

29. Trigger the gun several times to verify uniform bead size. Use theflow adjustment screw to increase or decrease the recirculatingpressure.

30. Tighten the locknut on the flow adjustment valve to maintain the valvesetting.

31. Remove the pressure gauge from the manifold and install a hose plugwith O-ring in the unused hose port.

32. Set the time for production schedule using the instruction in the timerproduct manual.

Fig. A 4-10

A. Bead with correct recirculatingpressure

B. Bead with recirculating pressureset too high

C. Bead with recirculating pressureset too low

D. Direction of gun travel

1. Preparation for FirstOperation (contd.)

4103713

4103714

4103715

4103716

Operation A 4-5


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

The SLEEP mode turns off the SYSTEM READY indicator and all heatingelements. The system cools to room temperature. The control system isstill on and monitors the channels for fault conditions.

1. Press the mode key for one second.

2. Press the mode key again to get to the OPERATION TIME SETTINGfunction. The up arrow is flashing.

Fig. A 4-11

3. Press the h and m/PWD keys to set the time the system turns on.

4. Press the WRITE key.

Fig. A 4-12

5. The down arrow is flashing.

Fig. A 4-13

6. Press the h and m/PWD keys to set the time the system turns off.

7. Press the WRITE key.

8. Press the MODE key to set the operation day function.

Fig. A 4-14

2. Setting the Clock forSLEEP Mode (On/Off)

4103717

4103718

4103719

OperationA 4-6


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

9. The operation days are set for Sunday through Saturday.

10. Press the d key and move the cursor to the day that the system is notin operation.

Fig. A 4-15

11. Press the WRITE key. The WRITE key works as a toggle between onand off.

12. Press the MODE key.

Fig. A 4-16

13. The clock is in the RUN mode. The system will turn on the SLEEPmode function at the next set time. The example shows that theSLEEP mode will turn ON at 8:30 p.m.

14. Set the clock for AUTO.

Fig. A 4-17

2. Setting the Clock forSLEEP Mode (On/Off) (contd.)

4103720

4103721

4103722

4103723

Operation A 4-7


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6

Follow the procedures below to force the clock on and off.

1. Press the SLEEP button to put the system into the SLEEP modebefore the scheduled time.

2. The Remote Shutdown indicator turns on. All heating elements turnoff. The System Ready indicators turn off. The control systemcontinues to scan channels for fault conditions.

3. The system starts at the next scheduled time.

Fig. A 4-18

To force the system back on:

4. Slide the clock ON/OFF switch to OFF and then switch back toAUTO. The clock will continue with the present cycle.

Fig. A 4-19

1. Slide the clock ON/OFF switch to ON.

2. The Remote Shutdown indicators turn off. The heating elements turnon. The System Ready indicators turn on when the system hasreached set temperatures and the ready delay has lapsed.

Fig. A 4-20

To continue the SLEEP mode:

3. Slide the switch back to AUTO. The Remote Shutdown indicatorturns on. All heating elements turn off. The System Ready indicatorsturn off.

4. The clock will start the system at the next scheduled time.

Fig. A 4-21

3. Forcing the Clock ONand OFF

Force the System into theSLEEP Mode

Force the System ON duringthe SLEEP Mode

OperationA 4-8


41-3000Issued 7/98

A4EN−05−[39−MAC3]−6


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

Part A, Section 5

Maintenance

MaintenanceA 5-0


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

4130718

Maintenance A 5-1


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

Section A 5Maintenance


WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves. Hot melt materialmay be released under pressure.

WARNING: System or material pressurized. Relieve pressure.Failure to observe may result in serious burns.

� Clean the exterior surfaces of the applicator and guns.

� Check the O-rings and gaskets for leaks.

� Flush the manifold filter. This procedure must be done before theclock turns on the SLEEP mode.


2. Trigger all guns to relieve trapped hydraulic pressure.

Fig. A 5-1

1. Daily Maintenance

4103711

4130718

4103711

MaintenanceA 5-2


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

3. Open the drain valve (CCW) over a container.

4. Turn the motor ON until hot melt material flows from the drainvalve.


6. Close the drain valve (CW).

Fig. A 5-2


1. Heat the system to operating temperature.

2. Turn the pump motor OFF.

Fig. A 5-3

3. Trigger all guns to relieve trapped hydraulic pressure.

4. Open the drain valve (CCW) over a container.

Fig. A 5-4

1. Daily Maintenance (contd.)

2. Weekly Maintenance

Cleaning the Manifold Filter

4103724

4103725

4103726

Maintenance A 5-3


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

5. Turn the motor ON until a clean, steady flow of hot melt materialflows from the drain.


7. Loosen the filter with a socket-type wrench.

Fig. A 5-5

8. Turn the filter assembly knob.

Fig. A 5-6

9. Pull the filter assembly out of the manifold.

Fig. A 5-7

4103419

4103727

4103711

MaintenanceA 5-4


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

10. Remove the screw in the back of the filter assembly and separatethe filter screen from the assembly.

11. Clean the screen in heated cleaning solution, or with an electricheat gun. Scrub with a soft bristle brush.

12. Inspect the screen and O-ring for damage. Replace if necessary.

Fig. A 5-8

13. Assemble the filter.

14. Check that the applicator is heated to operating temperature.

15. Slide the filter assembly into the manifold and tighten theassembly finger-tight only.

16. Purge the manifold by turning the motor ON until a clean, steadyflow of hot melt material flows from the drain. Turn the motorOFF.

Fig. A 5-9

17. Close the drain valve (CW).

18. Tighten the filter assembly until it seats. Do not over tighten.

1. Heat the gun to operating temperature.


3. Trigger all guns to relieve any trapped hydraulic pressure.

4. Open the drain valve.

5. Reduce the gun air pressure to 0 (automatic guns only).

Fig. A 5-10

Cleaning the Manifold Filter (contd.)

Cleaning Removable Nozzles

4103287

4103289

4103728

Maintenance A 5-5


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

6. Remove the nozzles.

7. Place the nozzles in a container of Type-R fluid and heat thecleaning solution to the melting temperature of the hot meltmaterial.

Fig. A 5-11

8. Clean the nozzle bore with the appropriate probe. Insert the probeinto the nozzle in a direction opposite to the flow of hot meltmaterial.

Fig. A 5-12

9. Wipe the end of the probe, then remove it from the nozzle.

10. Reassemble the nozzles onto the guns.

11. Restore the unit to operation.

Fig. A 5-13

4130718

MaintenanceA 5-6


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

� Inspect gun and applicator wiring.

These maintenance activities are performed as required by productionconditions.

� Clean inside of electrical cabinet.� Check electrical connections and terminal blocks.� Check hose connections.

� After the first month of service, drain lubricant from reducer gearbox.Fill the reducer gearbox up to the oil level hole. Use Mobil SHC 634oil.

� Change oil in reducer gearbox every 1500 hours. Use Mobil SHC634 oil. Refill up to oil level hole.

The entire hot melt material applicator system must be flushedperiodically to remove excess dirt and charred material. Also flush thesystem when old and new hot melt material are incompatible.



3. Trigger the guns to relieve system pressure.

4. Remove all hot melt material from the system using one of thefollowing:

Fig. A 5-14

a. Remove a nozzle from its gun and pump the hot melt material outthrough the gun.

b. Open the manifold drain valve and pump the hot melt material outthrough the manifold.

c. Disconnect a hose from its gun. Replace the dust cover over theelectrical receptacle. Pump the hot melt material out through thehose.

NOTE: The dust covers were removed from the electricalreceptacles during initial installation.

3. Semi-AnnualMaintenance

4. Non-ScheduledMaintenance

General

Speed Reducer

Flushing the System Using HotMelt Material

4130707

4130718

Maintenance A 5-7


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

5. Place several pounds of fresh, uncontaminated hot melt material intothe empty tank.

6. Wait for the system to reach operating temperature.

7. Place the hose over the hopper and secure it.

8. Turn the motor ON and pump the hot melt material through thesystem for 15 minutes.

Fig. A 5-15

Type-R fluid may be used instead of hot melt material to flush the system.



3. Trigger the guns to relieve system pressure.

4. Remove all hot melt material from the system using one of thefollowing methods:

Fig. A 5-16

a. Remove a nozzle from its gun and pump the hot melt materialthrough the gun, or

b. Open the manifold drain valve and pump the hot melt materialthrough the manifold, or

c. Disconnect a hose from its gun. Place the dust cover over theelectrical receptacle. Pump the hot melt material through thehose.

NOTE: The dust covers were removed from the electricalreceptacles during initial installation.

WARNING: Do not pump Type-R fluid through the hoses. Fluidabsorbed by char in the hoses may leach out or cause largepieces of char to break off and clog the nozzles during lateroperation.

5. Pour Type-R fluid into the empty tank.

Flushing the System UsingType-R Fluid

4103711

4103317

MaintenanceA 5-8


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4


7. Open the manifold drain valve.

8. Turn the motor ON and allow the cleaning solution to flow through thetank, pump and manifold.


10. Trigger the guns to relieve trapped hydraulic pressure.

Fig. A 5-17

11. Remove and clean the manifold filter according to the instructions atthe beginning of this section.

12. If this procedure does not remove all the charred material, it may benecessary to remove the reservoir and grid. Refer to Part B for thecorrect procedure for removing the reservoir and grid from your unit.

13. Scrub the PTFE-coated reservoir and grid with a stiff bristle brush.Do not use a metal brush or scraper.

The gear pump has no field serviceable parts. The following procedure isfor cleaning the gear pump assembly. Refer to Part B for information onhow to remove the gear pump assembly from the applicator.

1. Remove the two screws from the bottom of the gear pump assembly.Carefully pull the gear pump assembly out of the bearing housing.

Fig. A 5-18

Flushing the System UsingType-R Fluid (contd.)

Cleaning the Gear PumpAssembly

4103318

4103360

4103729

Maintenance A 5-9


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

2. Remove the pressure control return tube from the pump assembly.

3. Unscrew the crossover tube from the bottom of the gear pump.

Fig. A 5-19

4. Slide the coupling, key and adapter plate off the gear pump.

Fig. A 5-20

5. Remove the four socket head screws from the gear pump.

6. Punch out the two dowel pins and separate the three plates. If theplates do not separate, use a heat gun or other flameless device tomelt the adhesive on or in the pump assembly.

7. Remove the drive shaft, idler shaft spur gears and steel balls.

8. Place the components in a container of Type-R fluid and heat to themelting point of the adhesive.

WARNING: Do not clean components in halogenatedhydrocarbon cleaning solutions. Using these solutions couldcause an explosion.

Fig. A 5-21

4103729

4103318

MaintenanceA 5-10


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

9. Assemble the gear pump components. The three plates are markedT = top, C = center, and B = bottom.

10. Tighten the four socket head screws. Apply torque of19.78−20.91 N�m (175−185 in.-lb)

NOTE: The drive shaft must rotate a full revolution without bindingprior to applying torque.

11. Position the adapter plate on the gear pump and set the key in placeon the drive shaft.

12. Push the coupling onto the drive shaft.

Fig. A 5-22

13. Secure the crossover tube and pressure control return tube to thegear pump.

14. Slide the pump assembly into the bearing housing.

15. Attach the gear pump assembly to the bearing housing with the twoscrews removed in step 1. Apply torque of 7.23−9.04 N�m(64−80 in.-lb).

Fig. A 5-23

If the old and new adhesives are compatible, add the new adhesive tothe hopper. If the old and new adhesives are not compatible, flush thesystem using the procedures described in this section. Contact theadhesive supplier for information on the compatibility of adhesives andacceptable flushing cleaning solutions.

Cleaning the Gear PumpAssembly (contd.)

5. Changing the Hot MeltMaterial

Maintenance A 5-11


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4

Use this form to keep a record of the performed maintenance. Makecopies before using this form the first time.

Weekly Name Date Name Date

Cleaning manifold filter

Cleaning removablenozzles

Semi-annually

Inspect guns andapplicator wiring

Non-scheduled

Change oil in reducerevery 1500 hours

Clean inside of electricalcabinet

Check electricalconnections and terminalblocks

Check hose connections

Clean and inspect thegear pump assembly

6. Maintenance RecordForm

MaintenanceA 5-12


41-3000Issued 2/99

A5EN−06−[39−MAC3]−4


41-3000Issued 2/99

A6EN−07−[39−MAC3]−4

Part A, Section 6

Troubleshooting

TroubleshootingA 6-0


41-3000Issued 2/99

A6EN−07−[39−MAC3]−4

Troubleshooting A 6-1


41-3000Issued 2/99

A6EN−07−[39−MAC3]−4

Section A 6Troubleshooting


The following tables provide general information for the troubleshootingof basic adhesive application problems. Sometimes more detailedinformation, circuit diagrams or measuring devices are also needed fortroubleshooting.

Problem Possible Cause Corrective Action

1. Not enough hot meltmaterial comes out ofthe nozzle

Hopper is empty Fill the hopper.

Filter assembly clogged/contaminated Clean/replace the filter cartridge.

Gun nozzle clogged Unscrew the warm nozzle and clean it.

Solenoid valve does not switch Check the power supply, air supply andcoil of the solenoid valve.

Hose completely or partly clogged byhot melt material build-up

Open the manifold drain valve to relievepressure. Disconnect the hose from themanifold. Close the drain valve. Whilekeeping a low pump pressure, check ifhot melt material comes out of themanifold port. If it does, replace thehose.

1. Important Hints forTroubleshooting

2. Inadequate Supply of HotMelt Material



41-3000Issued 2/99

A6EN−07−[39−MAC3]−4


2. Waviness in beaddeposit

Hot melt material in the hopper is toocold

Set the temperature to an appropriatevalue.

Ambient temperature below 0�C(+32�F)

Increase the ambient temperature.

Guns and nozzles are exposed to draft Prevent all drafts.

Rated gun or hose temperature too low Set the temperature to an appropriatevalue.

Nozzle too far from substrate Set the nozzle 13 mm (0.5 in.) fromsubstrate.

3. Excessive hot meltmaterial at beginningof bead

Constant pressure setting too high Set the flow valve to a lower pressure.

Motor speed too low Adjust the motor speed dial.

Nozzle too far from substrate Set the nozzle 13 mm (0.5 inch) fromsubstrate.

Nozzle partially clogged Clean the nozzle.

Air pressure to gun insufficient Increase the gun air pressure.

4. Excessive hot meltmaterial at end of bead

Motor speed too low Adjust the motor speed dial.

Hot melt material too cold Set the temperature to an appropriatevalue.

Insufficient air pressure to gun Increase the gun air pressure.

5. Air or moisturebubbles within hot meltmaterial application

Fluid level in the hopper too low Fill the hopper.

Hot melt material viscosity too high Compare the rated temperature with thesupplier statement.

Check if the hot melt material is suitablefor the application.

Moist substrate Pre-heat the substrate.

3. Hot Melt MaterialApplication not Correct



41-3000Issued 2/99

A6EN−07−[39−MAC3]−4


6. Hot melt materialdrooling from gun

Ball-and-seat mechanism worn Clean or replace it or replace themodule, if necessary. Replace the sealwhen using a manual gun.

Triggering mechanism needs adjustment For H20 guns, replace the module. ForH200 guns, increase the spring tension.Turn the load screw on top of the gunmodule clockwise.

7. Gelling of hot meltmaterial

Changed to an incompatible hot meltmaterial without proper system flushing

Drain the hot melt material and clean thesystem.

Hot melt material heated too long Ask the hot melt material supplier forinformation concerning thermal stability.

Hot melt material temperature too high Set the temperature to an appropriatevalue.

Type R fluid used to clean system Pump the adhesive out of the systemand flush with clean hot melt material.

8. Hot melt materialbouncing or splashingfrom substrate

Hot melt material temperature too low Set the temperature to an appropriatevalue.

Special coating on substrate Ask the hot melt material supplier or useother hot melt material.

Not enough hot melt material beingapplied

Increase the temperature or use anozzle with a higher flow rate.

Hot melt material viscosity too high Compare the rated viscosity withstatements of hot melt material supplier.


9. Hot melt materialpenetration notsufficient

Hot melt material temperature too low Set the temperature to an appropriatevalue.

Special coating on substrate Ask the hot melt material supplier or useother hot melt material.

Not enough hot melt material beingapplied

Increase the temperature or pumppressure or use a nozzle with a higherflow rate.

Hot melt material viscosity too high Compare the rated viscosity withstatements of hot melt material supplier.




41-3000Issued 2/99

A6EN−07−[39−MAC3]−4


10. Hot melt material isfuming or smoking

Grid and/or reservoir temperature toohigh

Decrease the temperature. Observetemperature statements of hot meltmaterial supplier.

Hot melt material quality unstable Keep the tank lid closed. Ask hot meltmaterial supplier.

11. Hot melt material ischarring in hopper

Grid temperature too high Decrease the temperature. Observe thetemperature statements of the hot meltmaterial supplier.

Grid overheats Check the RTD wiring and check thediagnostic indicators.

Hot melt material level within the hoppertoo low

Always keep the tank more than 50%full.

Hot melt material oxidizes within thehopper

Keep the hopper lid closed. Ask hotmelt material supplier.

12. Unequal depositbetween nozzles

Nozzle is clogged Clean the nozzle.

Foreign material in module orball-and-seat mechanism

Remove the nozzle and trigger the gunseveral times.

13. Angel hair Nozzle too far from substrate Set the nozzle 13 mm (0.5 inch) fromthe substrate.

Hot melt material viscosity too high Compare the rated temperature to thestatements of the hot melt materialsupplier.


Hot melt material temperature too low Increase the temperature.

Gun operating speed too slow Install a faster gun with a pre-setsolenoid valve or mount a solenoid valvewith a short pipe nipple directly at thegun.

Hot melt material not fresh enough Do not keep the hot melt materialheated too long.

3. Hot Melt MaterialApplication not Correct(contd.)



41-3000Issued 2/99

A6EN−07−[39−MAC3]−4


14. Concentric circles inbead deposit

Hot melt material temperature too high Set the temperature to a suitable value.

Hot melt material viscosity too low Compare the rated viscosity with thestatements of the hot melt materialsupplier.

Speed of application extremely high Check if the hot melt material is suitablefor the application.

Decrease the application speed.



41-3000Issued 2/99

A6EN−07−[39−MAC3]−4

B## TABSHEET ##

Table of Contents i


41-3000Issued 2/99

B0EN−01−[39−MAC3]−4

Part B, SubassembliesTable of Contents

1. Technical Data B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viscosity Range B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank Volume B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank Capacity B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Melt Rate B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Pumping Rate B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Pump Displacement B 1-1. . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Pump Speed B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum Pump Speed B 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work Place Ambient Temperature Range B 1-1. . . . . . . . . . . . . . . .

Hot Melt Material Temperature Range B 1-2. . . . . . . . . . . . . . . . . . .

Temperature Control Accuracy B 1-2. . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Working Hydraulic Pressure B 1-2. . . . . . . . . . . . . . . . . . .

Enclosure Protection Rating B 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight, Empty B 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Service B 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise Level B 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Unit Dimensions B 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Heater Electrical Data for Tank, Grid, Hoses, and Guns B 1-7. . . . . .

4. How to Read Wiring Diagrams and Electrical Schematics B 1-9. . . . .

5. Wiring Diagrams for 200−240 Vac Units B 1-10. . . . . . . . . . . . . . . . . . .

6. Schematics for 200−240 Vac Units B 1-12. . . . . . . . . . . . . . . . . . . . . . .

7. Wiring Diagrams for 400V Units B 1-16. . . . . . . . . . . . . . . . . . . . . . . . . .

8. Schematic for 400V Units B 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section B 1Overview

Table of Contentsii


41-3000Issued 2/99

B0EN−01−[39−MAC3]−4

9. How to Read the Parts Lists B 1-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List B 1-21. . . . . . . . . . . . . . . . . . . . . . . . .

10. Applicator Enclosure B 1-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Labels and Tags B 1-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction B 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Troubleshooting B 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Test Procedures B 2-3. . . . . . . . . . . . . . . . . . . . . . .

Relieving System Hydraulic Pressure B 2-3. . . . . . . . . . . . . . . . .

Measuring Motor Winding Resistance B 2-3. . . . . . . . . . . . . . . . .

Measuring Motor Winding Resistance (contd.) B 2-4. . . . . . . . .

Measuring Relay Coil Resistance B 2-4. . . . . . . . . . . . . . . . . . . . .

3. Repair B 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation B 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Pump Replacement B 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Pump and Drive Assembly B 2-6. . . . . . . . . . . . . . . .

To Remove the Motor and Reducer Assembly B 2-6. . . . . . . . . .

To Remove the Coupling B 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove and Disassemble the Pump Assembly B 2-10. . . . .

Assembling the Pump and Drive Assembly Components B 2-12. .

To Assemble the Seal and Small Bearing Housing B 2-12. . . . .

To Assemble the Gear Pump B 2-13. . . . . . . . . . . . . . . . . . . . . . . .

Installing the New Pump and Drive Assembly B 2-14. . . . . . . . . . . .

To Install the Pump Assembly B 2-14. . . . . . . . . . . . . . . . . . . . . . .

To Install the Bottom Coupling B 2-14. . . . . . . . . . . . . . . . . . . . . . .

To Install the Top Coupling B 2-15. . . . . . . . . . . . . . . . . . . . . . . . . .

To Install the Motor and Reducer Assembly B 2-16. . . . . . . . . . .

Restoring the Applicator to Normal Operation B 2-16. . . . . . . . . . . .

Motor Replacement B 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the RPM Sensor B 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Reducer Replacement B 2-20. . . . . . . . . . . . . . . . . . . . . . . . .

Relief Valve Replacement B 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section B 1Overview (contd.)

Section B 2Hydraulics

Table of Contents iii


41-3000Issued 2/99

B0EN−01−[39−MAC3]−4

Replacing the Couplings B 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Top Coupling B 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coupling Sleeve B 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bottom Coupling B 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Assembly Coupling B 2-26. . . . . . . . . . . . . . . . . . . . . . . . . .

Replace the Bearing and Seal B 2-27. . . . . . . . . . . . . . . . . . . . . . . . .

O-ring Replacement B 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Replacing the Directional Control Valve B 2-31. . . . . . . . . . . . . . . . . . .

5. Parts B 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Motor and Drive B 2-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Pump Assembly B 2-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold B 2-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Uptime Pack for Manifold B 2-38. . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold B 2-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Assembly B 2-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Directional Control Valve Service Kit B 2-43. . . . . . . . . . . . . . . . . . . .

1. Introduction B 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Preparation for Repairs B 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Removal of the Tank, Grid, and Manifold B 3-2. . . . . . . . . . . . . . . . . . .

4. Rebuilding the Tank, Grid, and Manifold B 3-5. . . . . . . . . . . . . . . . . . . .

5. 3900/M Tank and Grid Assembly B 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction B 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Description of MultiScan Control System Functional Areas B 4-2. . . .

System Status Indicators B 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tank and Grid Temperature Controls B 4-3. . . . . . . . . . . . . . . . . . . .

Digital Temperature Display and Channel Status Indicators B 4-4.

Motor Controls B 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Setback Control and High/low Monitor Band B 4-5. .

Hose and Gun Temperature Controls B 4-6. . . . . . . . . . . . . . . . . . . .

Section B 3Tank

Section B 4Control

Table of Contentsiv


41-3000Issued 2/99

B0EN−01−[39−MAC3]−4

3. Temperature Control B 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequential Startup B 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overtemperature Protection B 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Setback B 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Temperature Display B 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

High/Low Temperature Monitoring B 4-10. . . . . . . . . . . . . . . . . . . . . .

Changing the Factory Set Overtemperature Limit B 4-11. . . . . . . .

4. Input/Output Board (I/O) B 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Features B 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Features B 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Troubleshooting B 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Channel Fault B 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Module B 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistance Temperature Detector (RTD) B 4-15. . . . . . . . . . . . . . . .

Ribbon Cable B 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Watchdog B 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Circuit B 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Troubleshooting Tables B 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alarm Display B 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Replacement of Boards and Power Modules B 4-23. . . . . . . . . . . . . . .

Replacement of Hose and Gun Control Board B 4-23. . . . . . . . . . .

Replacement of Main Control Board and/or Control PanelAssembly B 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of Hose/Gun, Grid or Tank Power Modules B 4-26. .

8. Replacing the Motor Control Interface Board B 4-27. . . . . . . . . . . . . . .

9. Replacing the Circuit Breaker B 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Replacing the Tank or Grid RTD and Thermostat B 4-29. . . . . . . . . . .

11. Replacing the AC Drive Inverter B 4-32. . . . . . . . . . . . . . . . . . . . . . . . . .

12. Replacing the RPM Readout B 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. Programming the AC Inverter B 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. MultiScan Control System B 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section B 4Control (contd.)

Table of Contents v


41-3000Issued 2/99

B0EN−01−[39−MAC3]−4

Uptime Pack B 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Uptime Plus Pack B 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MultiScan Controller B 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. How to Read the Parts Lists B 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


16. Applicator Enclosure B 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17. Labels and Tags B 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsvi


41-3000Issued 2/99

B0EN−01−[39−MAC3]−4


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Part B, Section 1

Overview

OverviewB 1-0


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Overview B 1-1


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Section B 1Overview


1000 to 30,000 mPa�s (up to 30,000 cps)

32.4 liters (1980 in3)

31.8 kg (70 lb)

45.5 kg/hr (100 lb/hr)

Pump Type RateAC Gear pump 0.41 kg/min (0.90 lb/min)

Pump Type RateAC Gear pump 0.212 in.3/rev (3.47 ml/rev)

Pump Type RateAC Gear pump 146 rpm

Pump Type RateAC Gear pump 20 rpm

0−50�C (32−120�F)

1. Technical Data

Viscosity Range

Tank Volume

Tank Capacity

Melt Rate

Maximum Pumping Rate(Based on material density 0.03 lb/in3 [0.85 g/ml] Specific gravity = 0.85)

Maximum Pump Displacement

Maximum Pump Speed

Minimum Pump Speed

Work Place AmbientTemperature Range

OverviewB 1-2


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

71−232�C (160−450�F)

+/− 0.5�C (+/− 1�F)

103.5 bar (1500 psi)

Meets IP-54 requirements

149.40 kg (332 lb)

200−240 Vac, 50/60 Hz, 3 ∅

380−415 Vac, 50/60 Hz, 3 ∅

71 dB(A) at maximum pump speed and pressure, measured at a distanceof 1 m from the surface of the unit and at a height of 1.6 m from the floor

1. Technical Data (contd.)

Hot Melt Material TemperatureRange

Temperature ControlAccuracy

Maximum Working HydraulicPressure

Enclosure Protection Rating

Weight, Empty

Electrical Service

Noise Level

Overview B 1-3


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Use the following table to calculate the maximum hose and gun capacity.

Table B 1-1 Individual Component Power in Watts

Individual Component 200� Vac 220�/380Y Vac 230�/400Y Vac 240�/415Y Vac

Auto Hose (0.6 m, 2 ft) *45 41 45 49

Auto Hose (1.2 m, 4 ft) *100 92 100 109

Auto Hose (1.8 m, 6 ft) *155 141 155 169

Auto Hose (2.4 m, 8 ft) *205 188 205 223

Auto Hose (3 m, 10 ft) *265 242 265 289

Auto Hose (3.6 m, 12 ft) *315 288 315 343

Auto Hose (4.8 m, 16 ft) *420 384 420 457

Auto Hose (7.2 m, 24 ft) — 581 635 691

Manual Hose (2.4 m, 8ft) *205 188 205 223

Manual Hose (4.8 m, 16 ft) *420 384 420 457

H201 Gun (T or T-L) 125 128 140 152

H202 Gun (T or T-L) *210 192 210 229

H204 Gun (T or T-L) 235 237 260 283

H208 Gun (T or T-L) 365 371 405 440

H202 Gun (T-E or T-E-L) 330 307 335 365

H204 Gun (T-E or T-E-L 320 320 350 381

H202 Gun (T-LP or T-LP-L) 170 169 185 201

H204 Gun (T-LP or T-LP-L) 260 261 285 310

H208 Gun (T-LP or T-LP-L) 350 357 390 424

H20 Gun (T or T-L) *180 124 135 147

H20 Gun w/Micro (T) 150 146 160 174

Notes:

*These wattages are for hoses or guns specially designed for 200 Vac operation.

Actual line voltage in a plant may vary from nominal voltage by as much as +/− 15 percent. To calculate the actualpower requirements at other line voltages, use the formula:

PL � PN� �ELEN�2

Here PL is wattage at line voltage, PN is the wattage at nominal voltage, EL is the line voltage, and EN is thenominal voltage.

OverviewB 1-4


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Table B 1-2 Maximum Total Wattage

200� Vac 220�/380Y Vac 230�/400Y Vac 240�/415Y Vac

Maximum IndividualHose or Gunchannel

870 957 1000 1043

MaximumCombination Hose& Gun channels (2)

1071 1179 1233 1286

Table B 1-3 Power and Current Rating at 200� Vac 3∅ Operation (Used Primarily in Japan)

Current

Series No. of Hosesand Guns

TypePower

CombinedHose/Gun

Power ModuleMaximum

(watts)

Tank, Grid,Motor Power

(watts)

SystemPower

Maximum(watts)

3 Phase(AMPS)

200� Vac

3900 1 3∅ 1071 6066 7137 25

Table B 1-4 Power and Current Rating at 220� /380Y Vac 3∅ Operation(Used Primarily in Europe)

Current

Series No. ofHoses and

Guns

Type Power CombinedHose/Gun

PowerModule

Maximum(watts)

Tank, Grid,MotorPower(watts)

SystemPower

Maximum(watts)

3 Phase(AMPS)

220� Vac

3 Phase (AMPS)

220�/380Y Vac

3900 1 3∅ 1179 7240 8419 27 18

1. Technical Data (contd.)

Overview B 1-5


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Table B 1-5 Power and Current Rating at 230�/400Y Vac 3∅ Operation(Used Primarily in North America and Europe)

Current

Series No. of Hosesand Guns

TypePower

CombinedHose/Gun

Power ModuleMaximum

(watts)

Tank, Grid,MotorPower

(watts)

System PowerMaximum

(watts)

3 Phase(AMPS)

230� Vac

3900 1 3∅ 1233 7865 9098 28

Table B 1-6 Power and Current Rating at 240�/415Y Vac 3∅ Operation (Used Primarily in the British Commonwealth)

Current

Series No. ofHoses and

Guns

Type Power CombinedHose/Gun

PowerModule

Maximum(watts)

Tank, GridMotorPower(watts)

SystemPower

Maximum(watts)

3 Phase(AMPS)

240� Vac

3 Phase(AMPS)

240�/415Y Vac

3900 1 3∅ 1286 8516 9802 30 20

OverviewB 1-6


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Figure B 1-1 shows the clearances required to operate and maintain the3900/M metered adhesive application system. Optional sub-base andsub-base with casters dimensions are included.

4103862

207 mm(8.16 in)

406 mm(16 in)

660 mm(26 in)

982 mm(38.66 in)

568.33 mm(22.38 in)

428 mm(16.85 in)

356.36 mm(14.03 in)

774.70 mm(30.50 in)

1048 mm(41.26 in)

54 mm(2.13 in)

291 mm(11.44 in)

17.27 mm(0.68 in)

266.70 mm(10.50 in)

128.59 mm(5.06 in)

142.88 mm(5.63 in)

Fig. B 1-1

2. Unit Dimensions

Overview B 1-7


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Table B 1-7 Heater Electrical Data for Tank, Grid, Hoses and Guns for 3900/M

Series Description Voltage Resistance*3900 Reservoir 200–240 17.09–19.94

Grid 200–240 11.96–13.96Hose P/N Description Voltage Resistance*274 790 Automatic Hose, 2 ft 220–240 1048–1158274 791 Automatic Hose, 4 ft 220–240 503–556274 792 Automatic Hose, 6 ft 220–240 320–354274 793 Automatic Hose, 8 ft 220–240 237–262274 794 Automatic Hose, 10 ft 220–240 181–200274 795 Automatic Hose, 12 ft 220–240 150–166274 796 Automatic Hose, 16 ft 220–240 109–120274 797 Automatic Hose, 24 ft 220–240 76–84276 150 Automatic Hose, 2 ft 200 792–876276 151 Automatic Hose, 4 ft 200 381–421276 152 Automatic Hose, 6 ft 200 242–267276 153 Automatic Hose, 8 ft 200 172–190276 154 Automatic Hose, 10 ft 200 136–151276 155 Automatic Hose, 12 ft 200 105–116276 156 Automatic Hose, 16 ft 200 78–87Gun P/N Description Heater Voltage Resistance*274 596 1 Module H201T 938 123 220–240 345–402274 597 2 Module H202T 938 124 220–240 230–268274 600 4 Module H204T 938 126 220–240 185–216274 603 8 Module H208T 938 132 220–240 118–127274 606 2 Module H202T-E 938 125 220–240 142–165274 609 4 Module H204T-E 938 127 220–240 136–159276 440 2 Module H202 T-LP 938 149 220–240 399–465**276 541 4 Module H204 T-LP 938 152 220–240 296–346**274 594 8 Module H208 T-LP 938 128 220–240 246–287**274 702 1 Module H20 T 938 053 220–240 289–338274 728 1 Module H20 T w/Micro 938 053 220–240 289–338276 093 1 Module H201 T-L 938 142 200 289–334274 598 2 Module H202 T-L 938 110 200 172–199274 601 4 Module H204 T-L 938 141 200 154–178274 604 8 Module H208 T-L 938 136 200 99–115274 607 2 Module H202 T-E-L 938 114 200 109–127274 610 4 Module H204 T-E-L 938 140 200 113–131276 094 2 Module H202 T-LP-L 938 137 200 328–380276 095 4 Module H204 T-LP-L 938 139 200 241–279**274 595 8 Module H208 T-LP-L 938 138 200 206–239**276 096 1 Module H20 T-L 938 121 200 201–232

*In Ohms at 24�C (75�F)** These guns have two heaters wired in parallel. Resistance shown above is for a single heater. The resistancereading for both heaters should be half the number shown above.

3. Heater Electrical Data forTank, Grid, Hoses, andGuns

OverviewB 1-8


41-3000Issued 7/98

B1EN−02−[39−MAC3]−6

Overview B 1-9


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

Every wire connected to the same electrical potential has the same wirenumber. That is, all wires which are connected together will have acommon wire number unique to that group of wires. Each individualsegment of wire in a group is distinguished by a segment letter. Thus,wire 8G is electrically equivalent but physically different from wire 8B.Wire numbers and segments are designated by an alphanumericindicator.

Each page of the schematic shows a specific portion of the overallelectric design. Cross referencing designators appear on the lines whichremain constant throughout, and which appear at the extreme left or rightof the page.

4. How to Read WiringDiagrams and ElectricalSchematics

OverviewB 1-10


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

4103755

G3

PT1

12

7B

G6

2121

6

11

1

4

SLEEP

G4

5D

5A

G7

(OPTIONAL)

A

1PC1

HOSE/GUN 1&2

106A

A B L1 L2 L3 N

GN

D

DISPLAY BOARD

J3J1J2

J3J2

BOARDCONTROLMOTOR/PUMP

J1

J1

J2

J4

J5

J2 J3

J1

NC

1

11

9

128352 6 N

C 4

J3

TB1

J2J1 5 643

2

1J3

TB1

J2J1 6

2

1

6NC

3GH2

9

5

1

12

8

4

35

36 32

39

NC

20 376D4D

NC

NC

5B 9A 8 NC

7A7BNC

14A

13D 13B

13E

13C

6B

5

1

8

7

6

3

2

J7J6 J5J4 J8

SW1

TB1

J3J2J1

7−DAY TIMERBSB1

43

2

131412

9

85

4

KA3200/220_VAC

XT1

XT2

AP5 J2AP1.1 J8XS1−XS2AP7: J2 AND J3

AP7AP2

CONNECTIONS

CUSTOMER

SE

E D

ETA

IL "

A"

FO

R J

2 A

ND

J3

DETAIL �B"DETAIL �A"

TANKPOWER MODULE POWER MODULE

HOSE/GUN CABLE

DETAIL �D"DETAIL �C"

BLOCKTERMINAL

MAIN

AP4

I/O BOARD

J1

AP3

(10)

4C

13F

GRIDPOWER MODULE

21225D

18

17

XS

2

XS

1

4D

7D7C

5J

5B

4C4B

49C 45E

G8

G1

G11

44A

43A

G9 G9

G7

G4

G3

G5

G5

45A

36

35

5051

44B

5J 4F45

B

43C

5248

43E43B

TB1−2

TB1−1

TB

1−9

43D

47T

B1−

10

49A

(16)

5H

4F

13E 13

155A

11

GH

2G

H1

G1321

6

5

4

6B

AP1.2

AP1.1

(10)

(10)

MICROSET(R) MULTISCAN(R)MAIN CONTROL BOARD

FOR J8"C"

SEE DETAIL

AP6

(20)

(16)

CONTROL BDH/G−1&2

6C

4B

L1 L3L2

11

(16)

X3 (ENCLOSURE)

X2 (MOUNTING PANEL)

X1 (MOUNTING PANEL)

X5 (DOOR)

(20)

AP1.3

543

A

B

C

D

EF

G

H

I

12 9

8

7

5

4

2

10

3 1 2 3 4

5 6 7 8

9 10 11 12

1 4

5

6

7

8

9

10

11

12

13

15

2

3

14

39

7

6

5

4

2

1

8

1 2

3 4 5

1

6A 6C

4E

6D 6J

GND

PANEL)(ACCESSX6

J

Notes:

1. Details shown for reference only and should not be interpreted literally.

2. Wire No. 3C required only with Izumi breaker.

3. See applicable system schematic for additional printed circuit board related notes.

Fig. B 1-2

5. Wiring Diagrams for200−240 Vac Units

Overview B 1-11


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

4103756

5F

GND

ENCLOSURE)

45A 45D45C45B

44C44A44B

876

54

3 2

7A

40

W

37

SEE

"D"

43A

XX

1817

1

EH1

TAN

K_H

EAT

ER

BT1

TANK_RTD

ST1

21

1211

XX

13F

BA

SB2

GRID_RTD

BT2

GR

ID_H

EAT

ER

EH2

GRID_THERMOSTAT

ST2

C3

C2

C1

C6

C5

C4

G/N

L3L2

L1

321

NC

NCXX

7D13

(MITSUBISHI)AC DRIVE

PRPVUTSR

FUSU

OH

AU RT

RES

MRS

STR

STF

RH

RM

RL

RUNSE

SD SD45210SDFMCB

U1

KA2KA1

876

54

3 2

P2P1

T3

T2

T1

MOTORAC

M1

BR1

MOTORCONTROLINTERFACEBOARD

DETAIL

J1

F1

F2

J2 JMP1

J3

TB

1

J5

21

6 5 4 3 2 1

AP5

2

3

4

VD2VD1

HL4

HL4−REMOTE UNIT READYHL3−FAULT (RED)HL2−UNIT READY (GREEN)

QF1HL1HL2HL3

HL1−POWER ON (WHITE)

XT3

SLEEPREADY

(OPTIONAL)REMOTE BOX

SE

E D

ETA

IL "

B"

COR

TANK_THERMOSTAT

SEE NOTE 2

7C

22

21

COR

XS2

XS1

XS2

XS1

NC

NCXX

5H

49C 45E

G10

G8

G12

G1241

42

G6

5150 20

13H

9B

424140

G10

39 32

WB

R

3

1

5248

43E47

44C

49B

49A45D

46

45C

44E

43B

44D

43D43C

13H

9B9A

3C

3C

64

321

13B

13C

13D

15

10

14A8

AP8

4E

5

POWER LINE FILTER

L1

L2

L3

(16)

(HOPPER

X7

SHIELD

SHIELD

MOTOR GNDX4 (BASE)

A

B

C

D

E

F

G

H

J

46

44D 44E

CO

RC

OM

OO

R

1 2 3 1 2

1 1

T1

200/220 VACBOOST TRANSFORMER

I

6J

53 6B 5F

G2

53

6B

H4H3

H2

H1

X4

X3

X1

X2

(OPTIONAL)

Fig. B 1-3

OverviewB 1-12


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

4103757

137

PWR MOD

52

(1)

J2

J1

J1

POWER MODULE

1

51

ST1

J2

J1 J3

DISPLAY BOARD

J2J12

6

1

5GRID

4CH CONT BDH/G_1&2

J3 J2

CONTROL BOARDMOTOR/PUMP

J1

GN

D

J4 J5

H/G−1&2

GND N L3 L2 L1XT1 B A

562 J1 J2

TANK

AU

X

QF1

1A 1A

14 10 11 7 8 6 5 3

1

212

4

15

ST2

COR

ONREADYALARM

J2−6

J2−8

J2−4 J2−1

J2−9J2−3

AC/DC DRIVE

J1

AP5

AP1.1

AP6

AP1.2

MULTISCAN (R)

NOTE: MAIN CONTROL BOARD AP1.1JUMPER JMP3 MUST BE PRESENT

SOLENOID

JMP3

TB1 CONTACT CONNECTIONS FORCUSTOMER INTERFACING.

J7J3

4 3 2 1

READYFAULT

TB1

J8

MAIN CONTROL BOARD

J8

J8 J8 J1

J6

J5J4 J2

HL4

HL1HL2HL3

F1F2

WHITEGREENRED

OVERTEMPERATURETANK

THERMOSTAT

3C

7

7

4

6

3 2 1

AP3

5 4 4

SEE DETAIL "C"

GRID AND

AP1.3

SEE DETAIL "E"

ONLY WITH IZUMI BREAKER.NOTE: WIRE NO. 3C REQUIRED

*

* −THIS BOX REPRESENTS THE LINE FILTER AND THE SCHEMATIC IS SHOWN IN DETAIL "H".

AP7

AP2

FAULT READY

14 1313

9

9

MICROSET (R)

SEE DETAIL "A

SEE DETAIL "B"

8 13

SHUTDOWN

U1

PT1

KA3

1 2

STF

SD

35

36

25

37

37

20

20

6 5

REMOTE − READY(OPTIONAL)

3635

50S

RT

5

5 4

(OPTIONAL)

7−DAY TIMER

13

DRIVEAC MTR

5

5

54

5

6 4

4

6

4

6

PWR MOD

AP4

TB1−1

TB1−9

TB1−10

TB1−2

SEE DETAIL "G"

(OPTIONAL)

I/O BOARD

J1

PT1BR1 PC1

VD2

KA2

SB2SB1

KA2

KA2

VD1 KA1

KA1

SLEEPREMOTE

SLEEP

46

(OPTIONAL)

TACH

43 (RED)

52 (BLK)

48 (WHT)

PICKUPRPM (2)

(4)

(3)

44

44 44

47

43

43 43

44

49

49

49

45

45 454545

48

6

4

6

6

6

6

5H4

X4/H1

X1T1 5

4

Fig. B 1-4

6. Schematics for 200−240Vac Units

Overview B 1-13


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

4103758

GUN 1

TB1

345162

AP3G

RID

_HE

ATE

R

EH

2

4

240VAC

2221

HEATER

4

4

5

J1

J3

1 2

3

2

1

518

DETAIL "C"

2

G

4

11

3

2

G

HOSE 1G

RID

−RT

D

BT

2

17

GRID POWER MODULE CONNECTIONS

RTD

5

3

5RTD

3

2

G

HEATER

3

11

10

11

10

F3

F4

F1

F2

J5

J4

J2

J1J3

12

1

7

6

3

4

5

10

9

16

14

19

13

17

15

11

20

18

12

12

8

2

4

5

9

3

2

6

1

7

8

8

7

1

6

2

3

9

5

4

11

12

10

4

5

3

1

2

G

8

5

9

1

2

7

6

4

HEATER

RTD

11

12

10

8

5

9

3

1

2

7

6

4

HEATER

4

5

1

RTD

XS1

XS2

AP7

HOSE 2

GUN 2

CABLES

HOSE/GUN POWER MODULE CONNECTIONS

DETAIL "A"

HOSE/GUN POWER MODULE

4

5

J1

TB1J3

1 2 345162

3

2

1

BT

1

TAN

K−R

TD

EH

1

TAN

K−H

EAT

ER

AP2

56

240VAC

TANK POWER MODULE CONNECTIONS

DETAIL "B"

11 12 15 10

Fig. B 1-5

OverviewB 1-14


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

4103759

5

2

P2

P1

THERMOSTAT

MOTOR OVERTEMPOOR

TB1−6

TB1−5

TB1−3

TB1−2

TB1−3

TB1−2

TB1−1

DC−

DC+

COM

SIG

COM

SIG

+12V

TACHVOLTAGE

TACHMAGNETIC

ENCODERPULSE

12 VOLT

2. ON AP5, JUMPER JMP1 (OVERTEMPERATURE PROTECTION)

JMP2 (GAIN CONTROL) SHOULD BE IN POS. 2 & 3. SHOULD BE IN POS. 1 & 2 FOR OOR THERMOSTAT.

NOTES:

SHOULD NOT BE INTERPRETED LITERALLY.

1.DETAILS SHOWN FOR REFERENCE ONLY AND

MITSUBISHI AC DRIVE

SD

STF

AC

W

V

U

MOTORM1

5

(U1)

2

3

1

42

41

40

51

51

50

TRACKING (KTL SYSTEMS ONLY)

CONNECTIONS FOR LINE SPEED

OPTIONAL INTERFACE BOARD

(OPTIONAL)

J2−4

J2−5

J2−2

SPEED (DC)

DC−

DC+

MAG

COM

ENC

+12V

20

37

32

39

TB1

1

1

J3−1J3−17

JMP1

I

V

ADJUSTGAIN

JMP2

VF

J2−1

COR

OOR

+12V

LPF

(SEE NOTE 2)

DETAIL "E"

J2−7

J5−1

J5−2

+12V

12 11 10 9 8 7 6 5 4 3 2 1

.315

A

.315

A

TB1TB2

+12V

+12V

J1−6

J1−9

J1−1

0

+12V

J1−8

J1−1

1

J1−1

2

J1−1

4

J1−5

J1−1

5

J1−4

J1−3

+12V

F2

F1

AP4

AC

TIV

E C

ON

TAC

TS

MO

TOR

AU

TO M

OD

E

STA

RT

EN

AB

LE

RE

MO

TE

MO

TOR

PU

MP

DR

IVE

STO

P E

NA

BLE

RE

MO

TE

MO

TOR

MA

NU

AL

MO

DE

EN

AB

LE

RE

MO

TE

MO

TOR

SE

TB

AC

K E

NA

BLE

RE

MO

TE

TE

MP

ER

ATU

RE

ON

CO

NTA

CT

S

SLE

EP

MO

DE

EN

AB

LE

I/O OPTION BOARD CONNECTIONS

DETAIL "G"

− + − + − + − +− +

V+

V−

AC

TIV

E C

ON

TAC

TS

TE

MP

ER

ATU

RE

SE

TB

AC

K

UN

IT P

OW

ER

WA

RN

ING

CO

NTA

CT

ST

EM

PE

RAT

UR

E

CO

NTA

CT

SM

OTO

R O

N

ALA

RM

CO

NTA

CT

SF2

F1

J1−4

J1−3

J1−2

J1−1

J2−6

J2−8

J1−14

J1−12

J1−13

J1−11

J1−8

J1−15

J1−10

J1−16

J1−9

J1−7

J2−3

J2−9

J1−6

J1−5

FAULTMOTOR

I MTR

MOTOR CONTROL INTERFACE MODULE

230VAC

(PWM)SPEED

STOP

START

MOTOR ON

−12V

+12V

+12V

AP5

MOTOR CONTROL INTERFACE BOARD

9

14

13

KA3

36

35

50

12 11 10 9 8 7 6 5 4 3 2 1

1

2

3

4

5

6

DETAIL H

LINE FILTER ASSEMBLY

C5

C6 C4

C1

C2

C3

L1L2L3G

Fig. B 1-6

6. Schematics for 200−240Vac Units (contd.)

Overview B 1-15


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

OverviewB 1-16


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

25D

4130804

G3

PT1

12

7B

G6

2121

6

11

1

4

SLEEP

G4

5D

5A

G7

(OPTIONAL)

A

1PC1

HOSE/GUN 1&2

106A

A B L1 L2 L3 N

GN

D

DISPLAY BOARD

J3J1J2

J3J2

BOARDCONTROLMOTOR/PUMP

J1

J1

J2

J4

J5

J2 J3

J1

NC

1

11

9

128352 6 N

C 4

J3

TB1

J2J1 5 643

2

1J3

TB1

J2J1 6

2

16NC

3GH2

9

5

1

12

8

4

35

36 32

39

NC

20 3725

B

5E

NC

NC

5B 9A 8 NC

7A7BNC

14A

13D 13B

13E

13C

6B

5

1

8

7

6

3

2

J7J6 J5J4 J8

SW1

TB1

J3J2J1

7−DAY TIMERBSB1

43

2

131412

9

85

4

KA3200/220_VAC

XT1

XT2

AP5 J2AP1.1 J8XS1−XS2AP7: J2 AND J3

AP7AP2

CONNECTIONS

CUSTOMER

SE

E D

ETA

IL "

A"

FO

R J

2 A

ND

J3

DETAIL �B"DETAIL �A"

TANKPOWER MODULE POWER MODULE

HOSE/GUN CABLE

DETAIL �D"DETAIL �C"

BLOCKTERMINAL

MAIN

AP4

I/O BOARD

J1

AP3

(10)

4C

13F

GRIDPOWER MODULE

21225D

18

17

XS

2

XS

1

4H

7D7C

5J

5B

4C

49C 45E

G8

G1

G11

44A

43A

G9 G9

G7

G4

G3

G5

G5

45A

36

35

5051

44B

5J 4F45

B

43C

5248

43E43B

TB1−2

TB1−1

TB

1−9

43D

47T

B1−

10

49A

(16)

4F

13E 13

155A

11

GH

2G

H1

G1321

6

4

6B

AP1.2

AP1.1

(10)

(10)

MICROSET(R) MULTISCAN(R)MAIN CONTROL BOARD

FOR J8"C"

SEE DETAIL

AP6

(20)

(16)

CONTROL BDH/G−1&2

5C

25A

L1 L3L2

11

(16)

X3 (ENCLOSURE)

X2 (MOUNTING PANEL)

X1 (MOUNTING PANEL)

X5 (DOOR)

(20)

AP1.3

543

A

B

C

D

E

F

G

H

12 9

8

7

5

4

2

10

3 1 2 3 4

5 6 7 8

9 10 11 12

1 4

5

6

7

8

9

10

11

12

13

15

2

3

14

39

7

6

5

4

2

1

8

1 2

3 4 5

1

6A 6D

PANEL)(ACCESSX6

I

25A 25B

7E

5H5 5E

5K5C 5L

2525C

5N G

Fig. B 1-7

7. Wiring Diagrams for 400VUnits

Overview B 1-17


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

4130805

ENCLOSURE)

45A 45D45C45B

44C44A44B

876

54

3 2

7A

40

W

37

SEE

"D"

43A

XX

1817

1

EH1

TAN

K_H

EAT

ER

BT1

TANK_RTD

ST1

21

1211

XX

13F

BA

SB2

GRID_RTD

BT2

GR

ID_H

EAT

ER

EH2

GRID_THERMOSTAT

ST2

321

NC

NCXX

7D13

(MITSUBISHI)AC DRIVE

PRPVUTSR

FUSU

OH

AU RT

RES

MRS

STR

STF

RH

RM

RL

RUNSE

SD SD45210SDFMCB

U1

KA2KA1

876

54

3 2

P2P1

T3

T2

T1

MOTORAC

M1

BR1

MOTORCONTROLINTERFACEBOARD

DETAIL

J1

F1

F2

J2 JMP1

J3

TB

1

J5

21

6 5 4 3 2 1

AP5

2

3

4

VD2VD1

HL4

HL4−REMOTE UNIT READYHL3−FAULT (RED)HL2−UNIT READY (GREEN)

QF1HL1HL2HL3

HL1−POWER ON (WHITE)

XT3

SLEEPREADY

(OPTIONAL)REMOTE BOX

SE

E D

ETA

IL "

B"

COR

TANK_THERMOSTAT

SEE NOTE 2

7C

22

21

COR

XS2

XS1

XS2

XS1

NC

NCXX

5H

49C 45E

G10

G8

G12

G1241

42

G6

5150 20

13H

9B

424140

G10

39 32

WB

R

3

1

5248

43E47

44C

49B

49A45D

46

45C

44E

43B

44D

43D43C

13H

9B9A

3C

3C

64

321

13B

13C

13D

15

10

14A8

25C

25

(16)

(HOPPER

X7

SHIELD

SHIELD

MOTOR GNDX4 (BASE)

A

B

C

D

E

F

G

I

46

44D 44E

CO

RC

OM

OO

R

1 2 3 1 2

1 1

H

G

C3

C2

C1

C6

C5

C4

GL3

L2L1

POWER LINE FILTER

L1

L2

L3

N

AP8

N

4321

3 TB2 TB1

54

21

AP9

OVER−VOLTAGESENSOR BOARD

5L7E

5K6D25D4H

Fig. B 1-8

OverviewB 1-18


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

SHUTDOWN

J4

137

PWR MOD

52

(1)

J2

J1

J1

POWER MODULE

1

51

ST1

J2

J1 J3

DISPLAY BOARD

J2J12

6

1

5GRID

4CH CONT BDH/G_1&2

J3 J2

CONTROL BOARDMOTOR/PUMP

J1

GN

D

J5

H/G−1&2

GND N L3 L2 L1XT1 B A

562 J1 J2

TANK

AU

X

QF1

1A 1A

14 10 11 7 8 6 5 3

1

212

4

15

ST2

COR

ONREADYALARM

J2−6

J2−8

J2−4 J2−1

J2−9J2−3

AC/DC DRIVE

J1

AP5

AP1.1

AP6

AP1.2

MULTISCAN (R)

NOTE: MAIN CONTROL BOARD AP1.1JUMPER JMP3 MUST BE PRESENT

SOLENOID

JMP3

TB1 CONTACT CONNECTIONS FORCUSTOMER INTERFACING.

J7J3

4 3 2 1

READYFAULT

TB1

J8

MAIN CONTROL BOARD

J8

J8 J8 J1

J6

J5J4 J2

HL4

HL1HL2HL3

F1

F2

WHITEGREENRED

OVERTEMPERATURETANK

THERMOSTAT

3C

7

7

4

6

3 2 1

AP3

5 4 4

SEE DETAIL "C"

GRID AND

AP1.3

SEE DETAIL "E"

ONLY WITH IZUMI BREAKER.NOTE: WIRE NO. 3C REQUIRED

*

* −THIS BOX REPRESENTS THE LINE FILTER AND THE SCHEMATIC IS SHOWN IN DETAIL "H".

AP7

AP2

FAULT READY

14 1313

9

9

MICROSET (R)

SEE DETAIL "A

SEE DETAIL "B"

8 13

U1

PT1

KA3

1 2

STF

SD

35

36

25

37

37

20

20

6 5

REMOTE − READY(OPTIONAL)

3635

50S

R5

5 4

(OPTIONAL)

7−DAY TIMER

13

DRIVEAC MTR

5

5

4

5

5 25

25

25

6

PWR MOD

AP4

TB1−1

TB1−9

TB1−10

TB1−2

SEE DETAIL "G"

(OPTIONAL)

I/O BOARD

J1

PT1BR1 PC1

VD2

KA2

SB2SB1

KA2

KA2

VD1 KA1

KA1

SLEEPREMOTE

SLEEP

46

(OPTIONAL)

TACH

43 (RED)

52 (BLK)

48 (WHT)

PICKUPRPM (2)

(4)

(3)

44

44 44

47

43

43 43

44

49

49

49

45

45 454545

48

5

6

5

7

7

5 12

34

5

OVER−VOLTAGESENSOR BOARD

TB2 TB1AP9

4

3

2

1

5

6

25

4

25

25

5 5

5

25

5

4130806

Fig. B 1-9

8. Schematic for 400V Units

Overview B 1-19


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

GUN 1

TB1

345162

AP3

GR

ID_H

EAT

ER

EH

2

4

240VAC

2221

HEATER

4

4

5

J1

J3

1 2

3

2

1

518

DETAIL "C"

2

G

4

11

3

2

G

HOSE 1

GR

ID−R

TD

BT

2

17

GRID POWER MODULE CONNECTIONS

RTD

5

3

5RTD

3

2

G

HEATER

3

11

10

11

10

F3

F4

F1

F2

J5

J4

J2

J1J3

12

1

7

6

3

4

5

10

9

16

14

19

13

17

15

11

20

18

12

12

8

2

4

5

9

3

2

6

1

7

8

8

7

1

6

2

3

9

5

4

11

12

10

4

5

3

1

2

G

8

5

9

1

2

7

6

4

HEATER

RTD

11

12

10

8

5

9

3

1

2

7

6

4

HEATER

4

5

1

RTD

XS1

XS2

AP7

HOSE 2

GUN 2

CABLES

HOSE/GUN POWER MODULE CONNECTIONS

DETAIL "A"

HOSE/GUN POWER MODULE

4

5

J1

TB1J3

1 2 345162

3

2

1

BT

1

TAN

K−R

TD

EH

1

TAN

K−H

EAT

ER

AP2

56

240VAC

TANK POWER MODULE CONNECTIONS

DETAIL "B"

11 12 15 10

4130807

Fig. B 1-10

OverviewB 1-20


41-3000Issued 7/98

B1EN−03−[39−MAC3]−4

5

2

THERMOSTAT

MOTOR OVERTEMPOOR

TB1−6

TB1−5

TB1−3

TB1−2

TB1−3

TB1−2

TB1−1

DC−

DC+

COM

SIG

COM

SIG

+12V

TACHVOLTAGE

TACHMAGNETIC

ENCODERPULSE

12 VOLT

2. ON AP5, JUMPER JMP1 (OVERTEMPERATURE PROTECTION)

JMP2 (GAIN CONTROL) SHOULD BE IN POS. 2 & 3. SHOULD BE IN POS. 1 & 2 FOR OOR THERMOSTAT.

NOTES:

SHOULD NOT BE INTERPRETED LITERALLY.

1.DETAILS SHOWN FOR REFERENCE ONLY AND

MITSUBISHI AC DRIVE

SD

STF

AC

W

V

U

MOTORM1

5

(U1)

2

3

1

42

41

40

51

51

50

TRACKING (KTL SYSTEMS ONLY)

CONNECTIONS FOR LINE SPEED

OPTIONAL INTERFACE BOARD

(OPTIONAL)

J2−4

J2−5

J2−2

SPEED (DC)

DC−

DC+

MAG

COM

ENC

+12V

20

37

32

39

TB1

1

1

J3−1J3−17

JMP1

I

V

ADJUSTGAIN

JMP2

VF

J2−1

COR

OOR

+12V

LPF

(SEE NOTE 2)

DETAIL "E"

J2−7

J5−1

J5−2

+12V

12 11 10 9 8 7 6 5 4 3 2 1

.315

A

.315

A

TB1 TB2

+12V

+12V

J1−6

J1−9

J1−1

0

+12V

J1−8

J1−1

1

J1−1

2

J1−1

4

J1−5

J1−1

5

J1−4

J1−3

+12V

F2

F1

AP4

AC

TIV

E C

ON

TAC

TS

MO

TOR

AU

TO M

OD

E

STA

RT

EN

AB

LE

RE

MO

TE

MO

TOR

PU

MP

DR

IVE

STO

P E

NA

BLE

RE

MO

TE

MO

TOR

MA

NU

AL

MO

DE

EN

AB

LE

RE

MO

TE

MO

TOR

SE

TB

AC

K E

NA

BLE

RE

MO

TE

TE

MP

ER

ATU

RE

ON

CO

NTA

CT

S

SLE

EP

MO

DE

EN

AB

LE

I/O OPTION BOARD CONNECTIONS

DETAIL "G"

− + − + − + − +− +

V+

V−

AC

TIV

E C

ON

TAC

TS

TE

MP

ER

ATU

RE

SE

TB

AC

K

UN

IT P

OW

ER

WA

RN

ING

CO

NTA

CT

ST

EM

PE

RAT

UR

E

CO

NTA

CT

SM

OTO

R O

N

ALA

RM

CO

NTA

CT

S

F2

F1

J1−4

J1−3

J1−2

J1−1

J2−6

J2−8

J1−14

J1−12

J1−13

J1−11

J1−8

J1−15

J1−10

J1−16

J1−9

J1−7

J2−3

J2−9

J1−6

J1−5

FAULTMOTOR

I MTR

MOTOR CONTROL INTERFACE MODULE

230VAC

(PWM)SPEED

STOP

START

MOTOR ON

−12V

+12V

+12V

AP5

MOTOR CONTROL INTERFACE BOARD

9

14

13

KA3

36

35

50

12 11 10 9 8 7 6 5 4 3 2 1

1

2

3

4

5

6

DETAIL H

LINE FILTER ASSEMBLY

C5

C6

C4

C1 C2 C3

L1 L2 L3 N G

AP8

4160808

Fig. B 1-11

8. Schematic for 400V Units(contd.)

Overview B 1-21


41-3000Issued 7/98

B1EN−04−[39−MAC3]−5

To 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.

Numbers 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 six-digit number in the Part column is the Nordson Corporation partnumber. A series of dashes in this column (- - - - - -) means the partcannot be ordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.

Item Part Description Quantity Note

— 000 000 Assembly 1

1 000 000 � Subassembly 2 A

2 000 000 � � Part 1

� If you order the assembly, items 1 and 2 will be included.� If you order item 1, item 2 will be included.� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list.Notes contain important information about usage and ordering. Specialattention should be given to notes.

9. How to Read the PartsLists

Using the Illustrated Parts List

OverviewB 1-22


41-3000Issued 7/98

B1EN−04−[39−MAC3]−5


1 - - - - - - Enclosure assembly, hopper 1

2 154 891 Enclosure, electrical 1

3 983 404 Washer, lock, split, M8 12

4 983 414 Washer, flat, narrow, M8 13

5 982 049 Screw, hex, cap, M8 x 25 mm 8

6 - - - - - - Circuit breaker tag 1 A

7 160 073 Sub-base assembly 1

8 158 595 Handle, hopper, enclosure 1 B

9 - - - - - - Cover assembly, RTD 1

10 982 434 Screw, chez head, M3 x 5 mm 8

11 982 473 Screw, chez head, M6 x 16, BL 4

12 159 450 Protector, hose connector 1

13 - - - - - - Tag accessory kit 1 A

14 159 850 Manifold cover assembly 1

15 983 409 Washer, lock, M6, split 4

16 159 752 Service kit, lid assembly 1 B

17 901 576 Handle, lid, plastic 1 B

18 982 255 Screw, chez head, slotted, M6 x 50 mm 2 B

19 132 686 Washer, lock, split (package of 4) 2 B

20 132 685 Nut, hex, M6 (package of 4) 2 B

21 107 284 Insulation, reservoir, grid 1

22 107 283 Insulation, grid 1

23 107 282 Insulation, hopper, grid 1

24 107 829 Insulation, reservoir, hose end 1

25 984 707 Nut, hex, M8 6

26 - - - - - - Panel, hose connection 1 A

27 131 353 Protector, drain valve 1

28 982 251 Screw, pan, rec, M5 x 8 mm 10

29 983 422 Washer, lock, external, M5 6

NOTE A: Labels and tags are available in several languages and can be purchased in kits. Refer to the table atthe end of this section for part numbers of kits.

B: These items are included in the Hopper enclosure assembly.

10.Applicator Enclosure

Overview B 1-23


41-3000Issued 7/98

B1EN−04−[39−MAC3]−5

4103199

2

3

4

5

6

7

8

9

10

11

1214

15

16

17

1819

20

25

1

5

3

4

10 13

23

22

21

24

8

2928

26

28

27

Fig. B 1-12

OverviewB 1-24


41-3000Issued 7/98

B1EN−04−[39−MAC3]−5

Labels and tags for the 3900/M applicator are available in tag accessorykits. Each kit contains the following tags:

� Drain valve warning tag� Input power tag� Hose connection label� Circuit breaker tag� Sleep tag� Hydraulic schematic label� Warning and caution tag� Pressure warning tag

Labels, tags, and tag accessory kits are available in the followinglanguages:

Japanese Spanish French Swedish Dutch Portuguese Italian German

Tag accessory kit(See Note A)

159 858 160 239 161 085 164 650 164 651 164 652 164 654 167 127

NOTE A: Tag accessory kits contain one (1) of each of the above tags and label mounting instructions.

11. Labels and Tags


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Part B, Section 2

Hydraulics

HydraulicsB 2-0


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Hydraulics B 2-1


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Section B 2Hydraulics


The hydraulic system consists of a motor/speed reducer assembly, agear pump assembly, and a manifold assembly. The motor/reducerassembly includes a 3/4 HP motor, an RPM sensor, and a 10:1 ratioreducer.

The manifold assembly is indirectly heated by the tank heaters. Themanifold assembly consists of an aluminum manifold, a filter assembly, adrain valve, solenoid, and hose ports with 45� connecting elbows.

4103731A

1

2

3

4

5

Fig. B 2-1

1. Motor2. RPM sensor3. Reducer

4. Pump mount and gear pumpassembly

5. Manifold assembly

1. Introduction

HydraulicsB 2-2


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

WARNING: Allow only qualified personnel to performtroubleshooting procedures.

The following table provides general information for troubleshooting basicpump problems.


1. Pump notturning butmotor running

Speed reducer shaft not rotating Replace speed reducer.

Worn or damaged drive shaftcouplings

Replace couplings.

Worn bearing or seal Replace bearing or seal.

2. Motor fails tostart

SYSTEM READY LED not on:SYSTEM READY time delay notexpired

Wait for green SYSTEM READY LED beforeproceeding.

Clock not reached next ON cycle Wait for next cycle or set clock ON/OFF switch to ONposition.

Motor ON LED not illuminated:Fuse blown on motor controlinterface board.

Replace fuses.

Damaged motor control interfaceboard

Replace motor control interface board.

Remote motor stop input ON Change remote input.

Motor overtemperature thermostatopen

Wait several minutes for motor to cool.

Motor ON LED illuminated: Looseor damaged motor connections

Tighten or repair connections.

Motor winding open Measure resistance of the motor. If >30 ohms,replace motor.

Damaged ribbon cable betweenmotor control interface board andmotor control board

Test continuity of ribbon cable. Replace damagedribbon cable.

Relay at KA3 damaged Test relay coil. If damaged, replace.

2. Troubleshooting

4130718

4103711

4103705

Hydraulics B 2-3


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Test procedures are used with the troubleshooting charts to solveproblems with the hydraulic section of the applicator.

Relieving System Hydraulic Pressure

WARNING: System or material pressurized. Relieve systempressure. Failure to observe may result in serious burns.


2. Trigger all guns.

Fig. B 2-2

3. Open the manifold drain valve.

Fig. B 2-3

Measuring Motor Winding Resistance

WARNING: Disconnect equipment from line voltage.

1. Disconnect and lock out electrical power to the unit.

2. Open the electrical enclosure.

Fig. B 2-4

Troubleshooting TestProcedures

4103762

4103705

4103732

HydraulicsB 2-4


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Measuring Motor Winding Resistance (contd.)

3. Locate the inverter on the back panel.

4. Push the tab on the top of the inverter and remove the cover.

5. Disconnect wires 40, 41 and 42.

6. Use an ohmmeter to test the resistance between wires 40 and 41, 41and 42, and 40 and 42.

7. If the resistance is greater than 30 ohms on any of the readings,replace the motor. Refer to Motor Replacement in this section.

Fig. B 2-5

Measuring Relay Coil Resistance




Fig. B 2-6

3. Locate the relay at KA3 on the back panel.

4. Disconnect wire 35 or wire 36 from KA3.

5. Use an ohmmeter to measure resistance from KA3 position 13 toposition 14.

6. If resistance measures less than10 K ohms or more than 30 K ohms,replace KA3.

Fig. B 2-7

Hydraulics B 2-5


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

WARNING: Allow only qualified personnel to perform repairs.


Flush the system before disassembly. If the pump does not work, but theheating system does, then heat the applicator to operating temperature tofacilitate disassembly. If the heating system does not work, then use aheat gun or other flameless heating device to melt the solidified hot meltmaterial in or on the system parts.

Use the following procedure to prepare the system for gear pumpreplacement.

WARNING: Hot! Risk of burns! Hot applicator parts, splashedhot melt material, and hot gun surfaces can cause severe burns.Wear long-sleeved, heat-protective clothing, safety goggles, andheat-protective gloves. Hot melt material may be releasedforcefully.

The gear pump has no field serviceable parts. Refer to Part A, Section 5for information on how to clean the gear pump assembly.

1. Turn on the applicator and allow it to reach operating temperature.

2. Drain hot melt material from the hopper and reservoir through themanifold drain valve or the reservoir drain plug.

3. Shut off the motor, hose, and gun.

3. Repair

Preparation

Gear Pump Replacement

4103314

HydraulicsB 2-6


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

WARNING: Even when switched off, Nordson applicators,hoses, and guns contain electrical potentials that can causedeath. Disconnect and lock out power to the applicator.

WARNING: Risk of burns. System or material pressurized.Relieve pressure. Air trapped in hoses and guns can spit outmolten adhesive that can cause severe burns.

4. Relieve hydraulic pressure. Refer to Relieving Hydraulic Pressure inthis section.

5. Disconnect and lock out electrical power to the applicator.

6. Loosen the two flat head screws on the top of the hopper enclosure.

7. Lift the enclosure and disconnect the ground wire. Set the enclosureaside.

Fig. B 2-8

Follow this procedure to remove the pump and drive assembly from theapplicator and to disassemble and discard the appropriate pump parts.

To Remove the Motor and Reducer Assembly

1. Disconnect the RPM sensor plug.

4103369

Fig. B 2-9

Gear Pump Replacement(contd.)

Removing the Pump and DriveAssembly

Hydraulics B 2-7


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

2. Remove the mounting screws and washers that secure the motor andreducer assembly to the pump mount. Save the screws and washersfor later use.

4103319

Fig. B 2-10

3. Loosen the set screw on the top half of the coupling (the half that themotor shaft passes through).

HydraulicsB 2-8


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

To Remove the Motor and Reducer Assembly (contd.)

4. Remove the motor and reducer assembly and the heat shield fromthe applicator. Set the assembly aside with the vent facing up.

4103320

Fig. B 2-11

To Remove the Coupling

1. Remove the top half of the coupling from the motor shaft. Discard thecoupling and shaft key.

4130788

2

3

1

Fig. B 2-12

1. Top coupling2. Set screw

3. Shaft key

Hydraulics B 2-9


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

2. Loosen the set screw on the bottom half of the coupling (the half thatthe pump shaft passes through) and remove the coupling and spiderfrom the pump shaft. Discard the coupling, spider, and shaft key.

4130789

1

2

3

4

Fig. B 2-13

1. Spider2. Bottom coupling

3. Set screw4. Shaft key

HydraulicsB 2-10


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

To Remove and Disassemble the Pump Assembly

1. Remove the mounting screws and lock washers that secure the pumpmount to the applicator. Discard the screws and washers.

4130790

1

2

3

Fig. B 2-14

1. Screw2. Washer

3. Pump mount

2. Remove the pump mount, pump assembly, gaskets, and pan from theapplicator. Discard the gaskets, and pan.

3. Clean the grid’s pump-mounting surface, removing any hot meltmaterial.

4. Remove the screws and lock washers that secure the pumpassembly and large bearing housing to the pump mount. Save thescrews and washers for later use.

5. Remove the screws that secure the large bearing housing to thepump assembly. Discard the screws.

Hydraulics B 2-11


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

4103358

Fig. B 2-15

6. Remove the crossover tube and return tube from the pump assembly.Save the crossover tube, return tube, securing screws, and washersfor later use. Discard the crossover tube O-ring and back-up ring.

4130791

1

2

3

4

5

Fig. B 2-16

1. Crossover tube2. Back-up ring3. O-ring

4. Return tube5. Securing screw

7. Discard the rest of the pump assembly.

4130792

1

2

3

4

HydraulicsB 2-12


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Follow this procedure to assemble the new pump and drive assemblycomponents from the service kit.

To Assemble the Seal and Small Bearing Housing

NOTE: The service kit contains a PTFE seal, small bearing housing,large bearing housing, large bearing housing O-ring, and all associatedscrews and washers.

1. Install the O-ring on the large bearing housing.

2. Place the PTFE seal exactly over the center of the hole in the largebearing housing. This is the same hole that the pump shaft passesthrough.

3. Using the small bearing housing as a pressing tool, gently press theseal into its hole in the large bearing housing. If the seal does not gointo place easily, do not force it. Realign the seal and try again.

NOTE: Make sure that the sleeve Rulon J bearing material is insidethe small bearing housing.

4. Install the small bearing housing in the large bearing housing and turnthe small bearing housing so that the three holes align with thetapped screw holes in the large bearing housing.

5. Secure the small bearing housing to the large bearing housing withthe three short screws and washers from the kit. Torque the screwsto 1.81−2.71 N�m (16−24 lb-in.).

Fig. B 2-17

1. Small bearing housing2. PTFE seal3. O-ring4. Large bearing housing

Assembling the Pump andDrive Assembly Components

4130793

1

2

4

5

3

4130794

1

2

3

Hydraulics B 2-13


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

To Assemble the Gear Pump

NOTE: The service kit contains a crossover tube O-ring and back-upring, a pump assembly, and all associated screws and washers. Thecrossover tube and return tube removed from the old pump are reused.

1. Install the following components on the new pump assembly:

� New crossover tube back-up ring and O-ring from the kit� Crossover tube from the old pump� Return tube from the old pump

2. Carefully insert the pump shaft through the bearing housingassembly.

Fig. B 2-18

1. Pump assembly2. Crossover tube3. Back-up ring4. O-ring5. Return tube

3. Secure the pump assembly to the large bearing housing with thetwo 55-mm hex-head screws (the longest screws) and washers fromthe kit (see Figure B 2-19). Torque the screws to 7.2−9.0 N�m(64−80 lb-in.).

4. Apply threadlocking adhesive to the four socket-head screws thatsecure the large bearing housing to the pump mount then use thescrews to secure the housing to the pump mount. Torque the screwsto 6.8−9.0 N�m (60−80 lb-in.).

Fig. B 2-19

1. Pump assembly2. Large bearing housing3. Pump mount

4130797

4130798

1

3

2

4

HydraulicsB 2-14


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Follow this procedure to install the new pump and drive assembly on theapplicator.

To Install the Pump Assembly

1. Remove all hot melt material from the crossover tube and manifoldinlet port.

2. Position the crossover tube in the manifold inlet port.

3. Take one of the gaskets and place it on the grid mounting surface sothat the gasket holes line up with the mounting surface holes.

4. Align the pan and a second gasket in the same way.

5. Align the pump mount with the pan and gaskets so the mountingholes match up.

6. Secure the pump mount to the grid using the four 45-mm screws andwashers from the kit. Torque to 10.85−13.56 N�m (8−10 ft-lb).

Fig. B 2-20

To Install the Bottom Coupling

NOTE: The service kit contains a new coupling, which includes a topcoupling, bottom coupling, spider, two shaft keys, and two extra setscrews.

1. Slide the bottom coupling (the coupling with the smallest insidediameter) onto the pump shaft. You may need to loosen the couplingset screw first.

2. Insert the pump shaft key (the smallest key) into the bottom coupling.

3. Insert the spider into the bottom coupling.

Fig. B 2-21

1. Shaft key2. Pump shaft3. Bottom coupling4. Spider

Installing the New Pump andDrive Assembly

4103803

Hydraulics B 2-15


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

4. Align the top of the coupling with the top of the pump shaft as shownin Figure B 2-22 and tighten the coupling set screw. Torque to8.8−9.8 N�m (78−87 lb-in.).

5. Add the extra set screw and hand-tighten it (see Figure B 2-21).

Fig. B 2-22 t

To Install the Top Coupling

1. Install the top half of the coupling on the motor shaft. You may needto loosen the coupling set screw first.

2. Insert the motor shaft key into the top half of the coupling.

3. Hand-tighten the coupling set screw. Do not add the extra set screwat this time.

4130795

2

3

1

Fig. B 2-23

1. Top coupling2. Shaft key

3. Extra set screw

HydraulicsB 2-16


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

To Install the Motor and Reducer Assembly

1. Position the heat shield on top of the pump mount.

2. Position the motor and reducer assembly on the pump mount, turningthe shaft on the motor until the top and bottom coupling halves aligncorrectly and lock together.

3. Secure the motor and reducer assembly to the pump mount using thefour hex-head screws and lock washers removed earlier(see Figure B 2-10). Tighten the screws hand-tight; then tighten thescrews in the following way: tighten one of the screws, then tightenthe screw diagonally opposite the first one, then tighten the remainingtwo screws. Finally, torque the screws to 10.85−13.56 N�m(8−10 ft-lb).

4. Adjust the top coupling, leaving a 0.5−1.0-mm (0.02−0.04-in.) gapbetween the top and bottom couplings. Torque the coupling setscrew to 8.8−9.8 N�m (78−87 in-lb).

5. Add the extra set screw to the top coupling and hand-tighten thescrew (see Figure B 2-23).

Follow this procedure to restore the applicator to normal operation afterreplacing the pump assembly.

1. Reconnect the RPM sensor plug (see Figure B 2-9).

2. Attach the ground wire to the hopper enclosure.

3. Set the hopper enclosure in place and tighten the two flat headscrews.

4. Remove the lock-out and restore power to the applicator.

5. Restore the applicator to normal operation by following thePreparation for First Operation instructions in the Operation section.

Restoring the Applicator toNormal Operation

4103315

Hydraulics B 2-17


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Follow this procedure to replace the motor.



2. Disconnect and lock out electrical power to the applicator.



5. Remove the cover from the conduit box located on the motor.

6. Note the number and location of each wire. Disconnect all wires.

7. Remove the conduit jam nut and unscrew the conduit elbow from thebox.

8. Remove the bolts and washers from the bottom of the motorassembly.

9. Lift the motor off the RPM sensor ring.

10. Align the bolt holes in the RPM sensor ring with the bolt holes in thereducer. Make sure the sensor lines up with the reducer vent.

11. Set the motor on the RPM sensor ring. Use a drift or bolt to align thebolt holes. Align the motor conduit box with the reducer vent.

12. Secure the motor to the reducer. Tighten the bolts to6.78−8.14 N�m (5−6 ft-lb).

13. Open the conduit box on the new motor. Install the conduit elbow onthe conduit. Secure the elbow with the conduit jam nut.

Fig. B 2-24

14. Connect all wires. If necessary, refer to Wiring Diagrams forconnection information.

15. Replace the conduit box cover.

16. Connect the ground wire to the hopper enclosure.


18. Resume operation.

Motor Replacement

4103315

HydraulicsB 2-18


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Follow this procedure to replace the RPM sensor.

1. Shut off the motor, hose and gun.





5. Disconnect the RPM sensor plug.

4103369

Fig. B 2-25

6. Remove the bolts from the bottom of the motor assembly.

7. Lift the motor off the RPM sensor ring. Set the motor aside.

Fig. B 2-26

Replacing the RPM Sensor

4103370

4103371A

0−0.89 mm

(0−0.035 in.)

4103368

Hydraulics B 2-19


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

8. Loosen the retaining screw and the set screw on the ring.

9. Slide the sensor wire out of the wire retainer and remove the sensor.

10. Insert the new sensor.

11. Set the ring on the motor.

Fig. B 2-27

12. Use a feeler gauge to set the gap between the sensor tip and thegear to 0−0.89 mm (0−0.035 in.).

13. Tighten the set screw.

14. Slide the sensor wire under the wire retainer and tighten the screw.

Fig. B 2-28

15. Place the sensor ring on the reducer. Line up the sensor with thereducer vent.

16. Place the motor on the sensor ring. Line up the conduit box with thesensor.

17. Secure the motor and sensor ring to the reducer. Tighten the boltsto 13.56−16.27 N�m (10−12 ft-lb).

18. Connect the sensor plug.




Fig. B 2-29

4103315

4103734

HydraulicsB 2-20


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Follow this procedure to replace the speed reducer.

1. Shut off the motor, hose and gun.





5. Remove the bolts and washers from the bottom of the motorassembly.

6. Lift the motor. Set the motor and the RPM sensor ring aside.

Fig. B 2-30

7. Remove the bolts and washer that hold the reducer to the pumpmount.

8. Lift the reducer off the pump mount.

NOTE: Make sure the heat shield is in place between the pumpmount and the reducer.

9. Position the new reducer on the pump mount with the vent facing theback of the unit. Secure the reducer with the bolts and washersremoved in step 7.

10. Check the level of the oil in the reducer. Fill the reducer to the correctlevel with Mobil lubricant SHC 63.

Fig. B 2-31

Speed Reducer Replacement

4103368

4103735

Hydraulics B 2-21


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

11. Set the sensor ring and the motor on top of the reducer with thesensor and the conduit box in alignment with the reducer vent.

12. Secure the motor and sensor ring with the bolts and washersremoved in step 5. Tighten the bolts to 6.78−814 N�m (5−6 ft-lb).




Fig. B 2-32

Follow this procedure to replace the relief valve.

1. Heat the unit to operating temperature.

2. Check the adhesive level. Drain the adhesive until it is 12.5 mm(1/2-in.) below the bottom of the grid.






7. Remove the insulation that covers the plug on the grid.

8. Use an Allen wrench to remove the plug. The pressure relief valve ison the bottom of the reservoir.

Fig. B 2-33

Relief Valve Replacement

4103736

HydraulicsB 2-22


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

9. Use a 9/16-in. socket wrench, with an extension and universal joint, toremove the relief valve.

NOTE: To keep the relief valve from falling into the reservoir, put afew drops of adhesive or other tacky substance in the bottom of thesocket wrench.

10. Install the new relief valve.

11. Replace the plug in the grid.




Fig. B 2-34

Use the following procedures to replace the top coupling, couplingsleeve, bottom coupling, or motor assembly coupling.




3. Turn the two flat head screws on the top of the hopper enclosure.

4. Lift the hopper enclosure and disconnect the ground wire. Set theenclosure aside.

5. Remove the bolts and washers holding the reducer to the pumpmount.

Relief Valve Replacement(contd.)

Replacing the Couplings

Hydraulics B 2-23


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

4103319

Fig. B 2-35

6. Lift the motor/reducer assembly off the pump mount.

7. Set the motor/reducer assembly aside, with the reducer vent facingup.

8. Remove the heat shield from the pump mount.

4103320

Fig. B 2-36

4103365

HydraulicsB 2-24


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Top Coupling

Inspect the top coupling. If it is worn or damaged, or fits loosely on themotor shaft, replace it as follows:

1. Use an Allen wrench to loosen the two set screws.

2. Pull the top coupling (1) and key (2) off the shaft.

3. Set the new key in place on the shaft and slide on the new coupling.

4130795

2

3

1

Fig. B 2-37

1. Top coupling2. Shaft key

3. Extra set screw

4. Position the inner face of the coupling 6.35 mm (1/4-in.) below the endof the shaft and tighten the set screw on top of the key.

5. Place the heat shield in position on top of the pump mount.

6. Set the motor and reducer assembly on the pump mount.

Fig. B 2-38

4103361

4103362

Hydraulics B 2-25


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

7. Secure the reducer to the pump mount. Tighten the bolts to10.85−13.56 N�m (8−10 ft-lb).

8. Loosen the set screw and slide the coupling over the coupling sleeve.

9. Tighten both set screws.


11. Set the enclosure in place. Turn the two screws on top to secure theenclosure in place.

Fig. B 2-39

Coupling Sleeve

1. Lift the coupling sleeve off the bottom coupling.

2. Inspect the coupling sleeve. Replace it if it is worn or damaged.

3. Install the motor/reducer assembly on the pump mount as describedpreviously.

Fig. B 2-40

4130798

1

3

2

4

4103360

HydraulicsB 2-26


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Bottom Coupling

Inspect the bottom coupling. If it is worn or damaged, replace it asfollows:

1. Use an Allen wrench to loosen the two set screws.

2. Pull the coupling and key off the shaft.

3. Insert the pump shaft key (the smallest key) into the bottom half ofthe coupling.

4. Insert the spider into the bottom half of the coupling.

5. Tighten both set screws. The inner face of the coupling and the keyshould be flush with the end of the shaft.

6. Install the motor/reducer assembly as described previously.

Fig. B 2-41

1. Shaft key2. Pump shaft3. Bottom coupling4. Spider

Motor Assembly Coupling

1. Remove the gear pump. Refer to Gear Pump Replacement, steps 1through 11.

2. Pull the coupling off the gear pump drive shaft.

3. Inspect the coupling and key for wear or damage. Replace both thekey and coupling if either are worn or damaged.

4. Insert the key into the drive shaft key way. Press the coupling inplace over the key and drive shaft.

5. Slide the gear pump assembly into the bearing housing.

6. Continue with the assembly procedures in To Install the Motor andReducer Assembly and Restoring the Applicator to Normal Operation.

Fig. B 2-42

4103316

4103317

4103358A

Hydraulics B 2-27


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

Remove the motor and reducer assembly. Refer to Replacing theCouplings, steps 1 through 7 in this section.

1. Remove the bottom coupling.

2. Remove the bolts and washers holding the pump mount to the grid.

3. Lift the pump mount and the gear pump assembly out of the tank.

Fig. B 2-43

4. Remove the two screws from the bottom of the gear pump assembly.Carefully pull the gear pump assembly out of the bearing housing.

Fig. B 2-44

5. Remove the four screws holding the bearing housing to the pumpmount.

6. Pull the bearing housing out of the pump mount. Set the housing on afirm surface.

Fig. B 2-45

Replace the Bearing and Seal

4103359

4103388

4103317

HydraulicsB 2-28


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

7. Use a punch or similar tool to knock out the bearing.

Fig. B 2-46

8. Remove the retaining ring and the seal.

9. Inspect the bearing and the seal for wear or damage. Replace ifnecessary.

10. Lubricate the seal and press it into the housing. Insert the retainingring.

11. Pack the bearing with high temperature grease and press into thehousing.

Fig. B 2-47

12. Secure the housing to the pump mount with the four screws removedin step 5.

13. Attach the gear pump assembly to the bearing housing. Tighten thebolts to 7.23−9.04 N�m (64−80 in.-lb).

Fig. B 2-48

Replacing the Bearing andSeal (contd.)

4130797

Hydraulics B 2-29


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

14. Take one of the gaskets and place it on the grid mounting surface sothat the gasket holes line up with the mounting surface holes.

15. Align the pan and a second gasket in the same way.

16. Align the pump mount with the pan and gaskets so the mountingholes match up.

17. Hold the pump mount and gear pump assembly over the grid.

18. Position the crossover tube in the manifold inlet port.

19. Secure the pump mount to the grid using the four 45-mm screws andwashers from the kit. Torque to 10.85−13.56 N�m (8−10 ft-lb).

20. Secure the pump mount to the grid. Tighten the bolts to 10.85−13.56N�m (8−10 ft-lb).

Fig. B 2-49

21. Set the key in place on the shaft and slide the bottom coupling inplace.

22. Tighten both set screws. The inner face of the coupling and the keyshould be flush with the end of the shaft.

23. Place the coupling sleeve on top of the bottom coupling.

24. Place the heat shield in position on top of the pump mount.

25. Set the motor/reducer assembly on the pump mount.

26. Secure the reducer to the pump mount. Tighten the bolts to10.85−13.56 N�m (8−10 ft-lb).


28. Set the enclosure in place. Turn the two flat head screws on top tosecure the enclosure in place.

4103397

4103398

HydraulicsB 2-30


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

WARNING: Relieve hydraulic pressure and drain tank beforeperforming this procedure.

Replace the O-rings on the hose connectors and O-ring plugs wheneverthey are removed or leak.

1. Use an open-end wrench to remove the hose connector.

2. Remove the O-ring on the hose connector adapter.

3. Make sure the new O-ring and the groove are clean. Lubricate thegroove with PTFE paste.

NOTE: Use only the O-rings listed in the parts lists in this section.Other O-rings may leak.

Fig. B 2-50

4. Stretch the O-ring and roll it over the threads into the groove in thehose connector. Do not stretch the O-ring more than necessary.

5. Lubricate the fitting threads with PTFE paste.

6. Thread the fitting by hand into the threaded port in the manifold.

7. Tighten the fitting only enough to seat, stopping when the body of themetal fitting contacts the manifold surface. Make sure the fitting isoriented properly. Tighten the fitting to 0.79−1.13 N�m (7−10 in.-lb).

8. Purge the system of entrapped air by removing the nozzles on theguns and triggering the guns.


Fig. B 2-51

O-ring Replacement

4130751A

4130718

Hydraulics B 2-31


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3


CAUTION: Do not remove the socket screws in the recessedcorners of the end cap. Removing these screws will result inleakage and failure of the directional valve under pressure.

1. Remove the two hex nuts from the end cap of the new directionalvalve.

2. Bring the system to operating temperature.

Fig. B 2-52

3. Ensure that the pump motor is turned OFF.

Fig. B 2-53

4. Replacing the DirectionalControl Valve

4103711A

4130752

HydraulicsB 2-32


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

4. Trigger all guns and open the drain valve (CCW) over a wastecontainer to relieve trapped hydraulic pressure.

5. Close the drain valve when hydraulic pressure is relieved.

6. Disconnect the air line from the elbow fitting on the old directionalvalve.

7. Place a waste container under the directional valve location at themanifold.

Fig. B 2-54

8. Use a flat-blade screwdriver to loosen the four screws that secure theold directional valve to the manifold, then remove the valve from themanifold.

Fig. B 2-55

9. Remove the elbow fitting from the old directional valve and install it inthe new valve.

10. Insert the new valve into the manifold, then tighten the two socketscrews to secure the valve in place. Torque both screws to2.94−3.95 N�m (26−35 in.-lb).

11. Connect the air line to the directional valve elbow fitting.

12. Remove the waste container.

4. Replacing the DirectionalControl Valve (contd.)

Hydraulics B 2-33


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

To 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.

Numbers 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 six-digit number in the Part column is the Nordson Corporation partnumber. A series of dashes in this column (- - - - - -) means the partcannot be ordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.


— 000 000 Assembly 1

1 000 000 � Subassembly 2 A

2 000 000 � � Part 1

� If you order the assembly, items 1 and 2 will be included.� If you order item 1, item 2 will be included.� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list.Notes contain important information about usage and ordering. Specialattention should be given to notes.

5. Parts

Using the Illustrated Parts List

HydraulicsB 2-34


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

See Figure B 2-56. Use the following table to order individual parts forthe motor and drive.

Item Part Description Quantity Note1 152 021 Motor, 230 V, 3/4 HP 1

2 270 739 Gear, spur, 60 tooth 1

3 981 101 Screw, socket set, 10-32 x 1.87 in., cup 1

4 - - - - - - Key 1

5 225 698 Ring, sensor, mounting 1

6 152 033 Speed reducer, in-line, 1

7 983 160 Washer, lock, E, split, 3/8 in. 4

8 981 407 Screw, hex head, 3/8-16 x 2 in., cap 4

9 152 614 Shield, thermal protector, motor 1

10 - - - - - - Mount, pump, machined, iron 1

11 983 160 Washer, lock E, split, 3/8 in. 4

12 981 408 Screw, hex head, 3/8-16 x 1.25 in., cap 4

— 324 110 Service kit, gasket, pan, 3900/M — A

13 101 795 � Gasket, grid, gear pump, 3900/M 2

14 304 511 � Pan, grid, gear pump, 3900/M 1

15 982 122 � Screw, hex, cap, M8 x 45 mm 4

16 983 404 � Washer, lock, M, split, M8 4

17 900 464 Adhesive, threadlocking — B

18 982 372 Screw, socket, M5 x 12 mm 4

19 982 290 Screw, set, cup, M4 x 4, stainless 1

20 159 856 Service kit, speed sensor, 3900M 1

21 310 449 Strap, wire 1

22 982 164 Screw, pan head, slotted, M4 x 6 1

NOTE A: Order part 324 110 to obtain a service kit with items 13 thru 16.

B: Apply to four screws.

Motor and Drive

Hydraulics B 2-35


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

4130875A

1

9

6

2

5

4

322

21

20

19

8

7

10

11

12

13

14

15

16

17, 18

Fig. B 2-56

HydraulicsB 2-36


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

See Figure B 2-57. Use the following table to order individual parts andservice kits for the gear pump assembly.


— 324 112 Service kit, seal and bearing, 3900M 1 A

— 304 515 Pump/Drive Assy 3900/M 1 B

— 324 106 � Service kit, housing w/bearing, 3900/M 1 C

1 182 111 � � Bearing, tape, Rulon J 1

2 152 491 � � Housing, bearing (small) 1

3 181 983 � Seal, PTFE, 0.625 in. x 0.875 in. 1

4 982 349 � Screw, socket, M4 x 16 mm 3

5 983 402 � Washer, flat, M, narrow, M4 3

6 940 023 � O-ring, Viton, 2.239 in. x 0.070 in. 1

7 310 327 � Housing, bearing, 3900/M (large) 1

8 - - - - - - � Pump gear, lo AC drive 1

9 954 013 � Back-up ring, single, 7/16 in. x 9/16 in. 1

10 940 133 � O-ring, Viton, 0.426 in. ID x 0.070 in. 1

11 120 462 � Screw, hex, cap, M6 x 55 mm (pkg of 4) 1

12 983 410 � Washer, flat, M, narrow, M6 2

13 231 215 � Key, square, 3/16 in. x 1.170 in. 1

14 304 512 � Coupling, shaft, 5/8 in. to 1/2 in. ID 1 D

15 981 213 � Screw, socket, set, 1/4-20 x 0.250 in. cup 2 E

16 109 915 � Key, square, 0.125 in. x 0.75 in. 1

17 982 372 Screw, socket, M5 x 12 mm 4

18 900 223 Lubricant, O-ring, Parker, 4 oz. —

19 900 341 Lubricant, Never-Seez, 16 oz. can —

20 900 464 Adhesive, threadlocking — F

21 - - - - - - Mount, pump, machined iron 1

22 100 097 Tube, crossover, gear pump 1

23 900 236 Sealant, paste —

24 110 985 Tube, pressure control, return 1

25 983 400 Washer, lock, M, split, M3 3

26 982 330 Screw, pan head, slotted, M3 x 20 mm 3

NOTE A: Order part 324 112 to obtain a service kit with items 1 thru 17.

B: Order part 304 515 to obtain a service kit with items 1 thru 12; and 17 thru 25.

C: Order part 324 106 to obtain a service kit with items 1 & 2 (Note, 1 & 2 also in 324 112 and 304 515)

D: This part includes the top and bottom coupling halves, the spider, and two set screws.

E: These are two extra set screws for the coupling.

F: Apply to four screws.

Gear Pump Assembly

Hydraulics B 2-37


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

4130876A

15

15

13

22, 23

7

4

5

1, 2

3

6, 18

8

9

10, 18

24

25

26

11

12, 1917, 20

14

16

21

Fig. B 2-57

HydraulicsB 2-38


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

See Figure B 2-58. Parts lists for the manifold consist of an Uptime Plusservice pack parts list and a standard parts list showing all serviceablecomponents.

Uptime Pack for Manifold

Item Part Description Quantity Note— 158 099 Service kit, meter manifold, Uptime 1

1 942 281 � O-ring, Viton, 1.00 x 2.250 x 2.500 in. 4 A

2 941 201 � O-ring, Viton, 1.188 x 0.094 in. 4 B

3 940 101 � O-ring, Viton, 0.239 ID x 0.070 in. wide 4

4 940 121 � O-ring, Viton, 0.364 ID x 0.070 in. wide 4 C

5 940 157 � O-ring, Viton, 0.562 x 0.688 x 0.063 in. 4 A

6 940 172 � O-ring, Viton, 0.676 ID x 0.070 in. wide 4

7 940 161 � O-ring, Viton, 0.614 ID x 0.070 in. wide 4 A

8 940 113 � O-ring, Viton, 0.312 x 0.438 x 0.063 in. 4

9 940 274 � O-ring, Viton, 1.313 x 1.438 in. 4

10 954 036 � Back-up ring, single, 1/4 x 3/8 4

11 134 017 � Service kit, filter screen, 0.020 in. 1

12 954 012 � Back-up ring, single, 0.375 x 0.500 in. 4

NOTE A: Use O-ring lubricant, part 900 223.

B: This item is included with the filter screen, part 134 017.

C: Use O-ring lubricant, part 900 493, included in pack.

Manifold

Hydraulics B 2-39


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

4103739A

11

2

5

5

9

128

6

5

4

3

10

1

7

Fig. B 2-58

HydraulicsB 2-40


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

See Figure B 2-59. Use the following table to order the parts for themanifold.

Item Part Description Quantity Note1 154 889 Manifold Assembly 1

2 331 951 Service kit, directional control valve 1 A

3 159 851 Service kit, flow control valve 1 A

4 159 854 Service kit, filter assembly 1 A

5 275 456 Adapter, filter bung/manifold 1

6 276 024 Valve assembly, drain 1

7 985 305 Pin, groove, type A, 0.078 x 0.500 1

8 982 096 Screw, pan head, slotted, M4 x 8 1 A

9 983 403 Washer, lock, M, split, M4 2

10 982 431 Screw, cheese head, slotted, M5 X 70 mm 4

11 983 401 Lockwasher, M5 4

12 973 576 Plug, O-ring, straight thread, 5/16-24 2 A

13 940 113 O-ring, Viton, 0.312 x 0.438 x 0.063 in. 2

14 105 415 O-ring plug, straight thread, 9/16-18 (pkg of 8) 15 A, C

15 105 526 O-ring, Viton, 0.38 tube (pkg of 8) 1 D

16 100 423 Elbow, male, 1/4 in. OD tube x 1/8 in. NPT 1

17 940 223 O-ring, Viton, 0.989 ID x 0.070 in. wide 1

18 954 036 Backup ring, 1/4 x 3/8 in. 1 F

19 105 521 Service kit, O-ring, 0.25 x 0.375 x 0.63 1

20 105 523 O-ring, Viton, 1.38 x 1.50 x 0.063 in. (pkg of 5) 2

21 940 121 O-ring, Viton, 0.364 ID x 0.070 in. wide 1 E

22 954 012 Back-up ring, single, 0.375 x 0.500 in. 1

23 111 795 Screw, special, hex head, M8 x 80 mm (pkg of 5) 5 A

24 111 797 Washer, flat, narrow, 8 mm (pkg of 5) 5

25 288 022 Valve, relief, 1600 psi, 3.50 in. long 1 B

26 973 583 Plug, O-ring, straight thread, 15/16-12 1 A

27 940 274 O-ring, Viton, 1.313 x 1.438 in. 1

28 288 109 Heat exchanger, MPL 1

29 161 093 Solenoid 1

30 156 993 Solenoid bracket 1

31 982 439 Screw, chez head, M4 x 25 mm 2

32 982 435 Screw, chez head, M4 2

33 310 717 Tube, PFA, 0.25 OD x 0.12 ID, 0.27 ft 1

34 972 119 Elbow, male, 0.25 in. tube x 1/8 in. NPT 2

35 940 161 O-ring, Viton, 0.614 ID x 0.070 in. wide 1

NOTE A: Apply Never Seez, part 900 341.

B: Apply Loctite adhesive #620, part 900 419.

C: O-ring plug includes O-ring, part 940 113.

D: O-ring plug includes O-rings in part 105 526.

E: O-ring plug includes O-ring, part 940 274.

F: Apply hi-temp lubricant, part 900 493.

Manifold

Hydraulics B 2-41


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

4103194A

25

7

5

4

20

1

14

15

14

15

26

28

31

27

22

34

29

23

24

33

16

932

30

12

13

1710

11

2

14

153

21

20

19

6

18

35

Fig. B 2-59

HydraulicsB 2-42


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

See Figure B 2-60. Use this table to order individual parts for the filterassembly.

Item Part Description Quantity Note— 159 854 Service kit, filter assembly, 3900M

1 981 747 Screw, round head, 10-32 x 6.25 in. 1 A

2 274 579 Filter core, 5.718 in. 1

3 134 017 Service kit, filter screen, 0.020 1 B

4 105 522 Service kit, O-ring, 1.00 x 1.19 x .093 in. (pkg of 4) 1

5 288 088 Bung, filter, standard 1

6 275 475 Cap, filter 1

7 983 414 Washer, flat, M, narrow, M8 1

8 986 013 Retaining ring, external, 34, basic 1

9 982 188 Screw, flat head, M5 x 16 mm 3

10 275 479 Handle, filter 1

11 275 476 Driver, handle 1

NOTE A: Apply Never Seez, part 900 341

B: Service kit contains two screens, item 3, and two O-rings, item 4.

4103542A

6

78

10

11

9

5

2

4

1

3

Fig. B 2-60

Filter Assembly

Hydraulics B 2-43


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3

See Figure B 2-61. The following service kit is available to rebuild thedirectional control valve.

Item Part Description Quantity Note— 331 951 Service kit, directional valve 1

1 940 161 � O-ring, Viton, 0.614 ID x 0.070 wide 1 A


3 940 191 � O-ring, Viton, 0.813 x 0.938 x 0.063 1 A


5 940 151 � O-ring, Viton, 0.563 x 0.688 x 0.063 1 A

6 940 090 � O-ring, Viton, 0.208 ID x 0.070 wide, BR 1 A

NOTE A: Apply lubricant, part 900 223

4130829A

1

4

2

5

3

6

Fig. B 2-61

Directional Control ValveService Kit

HydraulicsB 2-44


41-3000Issued 2/99

B2EN−05−[39−MAC3]−3


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

Part B, Section 3

Control

ControlB 3-0


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

Control B 3-1


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

Section B 3Control


The control system monitors and controls the heating processes andsystem temperature. It tells the power modules when to apply heat to thetank, grid, hoses and guns, and prevents the start-up of cold equipment.

Features of the MultiScan control system are:

� Fault lights to assist with troubleshooting

� System-ready delay with parent-machine interlock to protect thepump

� Sequential startup for reduced component stress

� Overtemperature protection

� Temperature setback

� Digital display and high/low temperature monitoring

1. Introduction

ControlB 3-2


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

The control system consists of solid-state electronics. The controlsystem uses resistance temperature detectors (RTDs) to monitor andcontrol applicator, hose and gun temperatures within a range of70−230�C (160−450°F).

4103701A

CONTROL ON

SYSTEM READY

REMOTE SHUTDOWN

SETBACK ON

SYSTEM FAULT

TEMP. WARNING

MOTOR FAULT

OVERTEMPERATURE

HIGH

OK

LOW

OPEN SENSOR

SHORTED SENSOR

SCAN

HOLD

STEP

MICROSET

1

4

3

5

8

9

101112

13

7

6

2

Fig. B 3-1

1. Hose temperature control2. Gun temperature control3. System status indicators4. Tank and grid temperature controls5. Channel status indicators

6. Digital readout7. Temperature setback8. Temperature High/low monitor9. Motor speed dial

10. Motor On/Off switch11. Motor Tachometer12. Clock “Sleep” button13. Clock

2. Description of MultiScanControl SystemFunctional Areas

4103355

4103695

Channel fault LED (red)

Channel power on LED (yellow)

Channel scan LED (green)

Control B 3-3


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

NOTE: Refer to Temperature Control for daily operational informationconcerning these indicators. This group of indicators provides thefollowing system status information:

� The CONTROL ON (green) indicator is illuminated when the controlsystem is on.

� The SYSTEM READY (green) indicator is on when hoses, guns, tankand the grid are at operating temperature and the system-ready delaytime has elapsed.

Fig. B 3-2

� The REMOTE SHUTDOWN (yellow) indicator is on when all channelheaters are turned off by the remote shutdown feature. This indicatoronly works in combination with the I/O board and the clock.

� The SETBACK ON (yellow) indicator is on when the temperaturesetback feature is on.

� The SYSTEM FAULT (red) indicator is on when a fault conditionexists. The system fault lamp on the front of the applicator also turnson. When there is a system fault, refer to the channel fault andchannel status indicators for identification of the fault.

� The TEMP WARNING (yellow) indicator turns on when thetemperature of one or more channels is outside the temperaturemonitor band or, when the tank temperature is 19�C (35�F) belowsetpoint.

� The MOTOR FAULT (red) indicator is on when a motorovertemperature condition exists.

Use the control dials to set the tank and grid temperatures. The channelindicators are:

Yellow — Power is being applied to the channel heater.

Green — The channel is being scanned.

Red — A fault is present such as overtemperature or a sensor fault.

NOTE: Refer to Temperature Control for channel temperature controlinformation.

Fig. B 3-3

System Status Indicators

Tank and Grid TemperatureControls

4103349A

Channel status

Display mode switch

Digital readout

ControlB 3-4


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

NOTE: Refer to the Temperature Control and Control SystemTroubleshooting for daily operational information concerning theseindicators.

The digital display area can show one channel temperature continuouslyor all connected channels in sequence. The display mode switchfunctions are:

STEP — To scan the channels manually

HOLD — To display the selected channel continuously

SCAN — To scan all channels in sequence

Fig. B 3-4

Use the channel status indicators with the system status and channelfault indicators to identify fault conditions.

� The OPEN SENSOR indicator is on if a scanned channel contains anRTD with an open circuit.

� The SHORTED SENSOR indicator is on if a scanned channelcontains an RTD with a shorted circuit.

� The OVERTEMPERATURE indicator is on if the temperature of ascanned channel reaches the overtemperature limit.

NOTE: If a scanned channel contains a fault condition, then the followingindicators will turn on: Open sensor, shorted sensor or overtemperature;system fault and channel fault. In addition,

� The HIGH indicator is on if the temperature of a scanned channel ishigher than the range set at the high/low monitor band dial.

� The OK indicator is on if the temperature of a scanned channel iswithin the range set.

� The LOW indicator is on if the temperature of a scanned channel islower than the range set.

Digital Temperature Displayand Channel Status Indicators

4130704

1

3

2

4103352

Setback on/off switch

Setback dial High/low band dial

Control B 3-5


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

The motor controls are an ON/OFF rocker switch (1) and a motor speeddial (2). Use the dial to set the motor speed from 0% to 100% of therated pump output. The minimum speed setting is about 100 rpm. Thegreen LED indicator (3) is on when the motor is running.

Fig. B 3-5

Temperature setback reduces the temperature of all connected channelswithout turning the unit off. Setback is activated by the Setback on/offswitch.

High/low temperature monitoring provides a warning band temperaturerange from the setpoint temperature of all connected channels. Therange of the temperature band is set with the high/low band dial.

NOTE: Refer to Temperature Control for setback control and High/lowmonitor information.

Fig. B 3-6

Motor Controls

Temperature Setback Controland High/low Monitor Band

4103353

Channel fault LED (red)


Channel scan LED (green)

ControlB 3-6


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

Each hose and gun channel has an individual dial for setting or adjustingtemperature. The dial on the left controls the hose and the dial on theright controls the gun. The channel indicators are:

Yellow − Power is being applied to the channel heater.

Green − The channel is being scanned.

Red − A fault is present such as overtemperature or a sensor fault.

NOTE: Refer to Temperature Control for channel temperature controlinformation.

Fig. B 3-7

Hose and Gun TemperatureControls

4103350





Control B 3-7


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

The following section contains information on Temperature Control.

At startup of the unit, component heating occurs in four stages.

1. The grid begins to heat.

2. When the grid is within 19�C (35�F) of the application temperaturesetpoint, the tank and hose(s) begin to heat.

3. When the tank and hose(s) are within 19�C (35�F) of the applicationtemperature setpoint, the gun(s) begins to heat.

4. When all channels are within 3�C (5�F) of their setpoints, thesystem-ready delay begins. At this point:

a. The yellow indicators for each connected channel on the controlpanel begin to flash.

b. The system ready time delay begins.

c. When the delay period is over, the system ready indicators andready light on the front of the applicator turn on.

Fig. B 3-8

3. Temperature Control

Sequential Startup

4103351

ControlB 3-8


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

The control system has overtemperature protection. Theovertemperature limit is factory-set at 218�C (425�F).

NOTE: Refer to Changing the Factory Set Overtemperature Limit to setthe overtemperature limit to other than 218�C (425�F).

If the temperature of any channel reaches this limit, the following occurs:

� The channel fault indicator turns on.

� The OVERTEMPERATURE indicator turns on.

� The system fault indicator turns on.

� A two minute time delay begins.

� If the fault is not corrected, the circuit breaker trips and removeselectrical power from the unit.

� An additional two minute delay can be obtained by resetting thecircuit breaker until the tank or grid temperature reaches 260�C(500�F)

A secondary overtemperature protection is provided by thermostatsmounted on the tank and grid.

Fig. B 3-9

Overtemperature Protection

4103347

Setback on/off switch

4103348

4103349A

Channel status

Display mode switch

Digital readout

Control B 3-9


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

The following bullets describe Temperature Setback.

� The Setback on/off switch activates temperature setback.

Fig. B 3-10

� The ON position activates the setback indicator and turns off thesystem ready indicator and the ready light on the front of theapplicator.

� Each channel temperature is reduced by the amount selected withthe setback dial. The temperature reduction may be set from -28 to-83°C (-50 to -150°F).

NOTE: When the setback switch is off, the channels heat to applicationtemperature setpoints.

Fig. B 3-11

NOTE: When leaving the setback mode of operation, there is nosequential startup or system-ready time delay.

The digital temperature display continuously shows the temperature of asingle channel or all connected channels in sequence.

� Place the switch in the HOLD position to continuously display thetemperature of one channel.

� Place the switch in the SCAN position to sequentially display allconnected channels.

� Place the switch in the STEP position to manually step the digitaldisplay to the desired channel.

Fig. B 3-12

Temperature Setback

Digital Temperature Display

4103345

High/low band dial

4103346

ControlB 3-10


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

High/low temperature monitoring alerts the operator that the channeltemperatures have increased/decreased more than the set amount. Setthe warning band from �6 to �28°C (�10 to �50°F), as desired.

Example: If the warning band is set at �6°C, then the temperature of anychannel may go 6°C above or below the channel setpoint and the faultindicator will not turn on.

Fig. B 3-13

If the temperature of a channel is out of the high/low range, the followingoccurs:

� The temperature warning indicator turns on.

� Either the HIGH (overheating) or LOW (underheating) indicator turnson.

� The green (scan) indicator at the channel setpoint dial turns on.

� The temperature control system continues to scan all channels anddisplay whether each channel is within the high/low band.

� The temperature warning indicator remains on until the problem iscorrected.

Fig. B 3-14

High/Low TemperatureMonitoring

Control B 3-11


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

The factory-set overtemperature limit of 218�C (425�F) can be changedas follows:

1. Locate JMP1 on the main control board.

2. Move the jumper bar from position B to the position that correspondsto the desired overtemperature setting.

4103391

JMP

1

AB

CD

E

Fig. B 3-15

A. 246�C (475�F)B. 218�C (425�F)C. 191�C (375�F)

D. 163�C (325�F)E. 135�C (275�F)

Changing the Factory SetOvertemperature Limit

ControlB 3-12


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

The input/output board gives the operator a remote indication and controlof certain existing applicator features.

Each of the following outputs on the I/O board is a contact closure(contact = 28 Vdc or 250 Vac at 2A).

� Temperature Warning Status — The temperature warning featureallows the operator to set a high/low temperature warning band.When each channel is scanned, the channel status is displayed asHIGH, LOW or OK. If the temperature is below or above the setband, the yellow TEMP WARNING LED on the control panel comeson.

� Temperature Setback Status — The temperature setback featureprovides a way to reduce the temperature of the heating channelswithout changing all of the setpoints or shutting the unit down. Thisfeatures is activated on the control panel by a toggle switch. Whenthe switch is turned on, the SETBACK ON LED on the control panelcomes on.

� Power Status — Remote indication that the unit AC power is ON.

� Motor ON Status — Remote indication that the motor is ON.

� Pump Drive Alarm Status — The pump drive alarm occurs for one oftwo conditions: if a motor overtemperature is detected and or if theline reference frequency from the parent machine in a Key-to-Lineapplication exceeds the maximum set point. The contacts remainclosed until the condition is corrected.

The following input signals require a maintained 5−30 Vdc at 10mA.

� Temperature Setback ON/OFF — The control panel or the I/O boardcan activate the temperature setback. This feature will remain onuntil it is turned off at the same place it was turned on.

� Remote Sleep — Remote sleep can only be turned on by the I/Oboard. When the remote sleep is turned on, the system READY isturned on; all heating elements turn off; the REMOTE SHUTDOWNLED on the control panel comes on. The control panel continues tomonitor the system for faults.

The following signals require a momentary 5−30 Vdc at 10 mA.

� Remote Motor Start—This feature starts the motor. The motor startswitch must be on.

� Remove Motor Stop—This feature turns the motor off.

4. Input/Output Board (I/O)

Output Features

Input Features

Control B 3-13


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

The following information describes system fault conditions and specificprocedures for locating and identifying system faults.

If a channel fault exists, the following occurs:

� The SYSTEM FAULT indicator (1) turns on.

� The channel fault indicator (3) identifies the location of the fault.

� The channel status indicator (2) identifies the type of fault.

4103740A

CONTROL ON

SYSTEM READY

REMOTE SHUTDOWN

SETBACK ON

SYSTEM FAULT

TEMP. WARNING

MOTOR FAULT

OVERTEMPERATURE

HIGH

OK

LOW

OPEN SENSOR

SHORTED SENSOR

SCAN

HOLD

STEP

MICROSET

3

1

2

Fig. B 3-16

1. System fault indicator 2. Channel status indicator 3. Channel fault indicator

5. Troubleshooting

Channel Fault

ControlB 3-14


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

If there is more than one channel fault, the following occurs on the controlpanel:

� The SYSTEM FAULT indicator turns on.

� The channel fault and channel status indicators turn on.

� After a few seconds, the next channel fault indicator and its channelstatus indicators turn on.

� Two minutes after detection of the first fault, the circuit breaker trips.

� Turn the circuit breaker back on to obtain an additional two minutes.This can be repeated until the tank or grid temperature reaches260�C (500�F).

To identify a power module fault condition, first examine the diagnosticand channel fault indicators for the single channel power module and thefour channel power module. Then refer to the following chart.

Condition Number

If theSYSTEM FAULT

indicator is:

and the red LED at thepower module is:

and the neon at thepower module is:

then, the reason could bethat:

1 OFF OFF OFF Channel is cooling down.(normal)

2 OFF ON ON Channel is heating. (normal)

3 OFF Flashing Flashing Channel is at settemperature. (normal)

4 OFF ON OFF Fault. Open fuse or circuit.

5 OFF OFF ON Hose is disconnected, orshort circuit is causingpower module to stay on.

6 ON OFF OFF Fault. Open sensor in thiszone.

7 ON ON ON Fault. Shorted sensor in thiszone.

8 ON OFF ON Overtemperature conditioncaused by fault condition 5.

Channel Fault (contd.)

Power Module

Control B 3-15


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

Figure B 3-17 shows the location of diagnostic indicators for all powermodules.

Hose 1

Gun 1

Red control LED

Heater power neon

N = Heater power neonLED = Red control LED

4103893

Fig. B 3-17

To identify problems with an RTD circuit, perform the following steps:

1. Measure the resistance and temperature of the RTD.

2. Compare the resistance measurement to the resistance shown in theappropriate graphs on the following pages.

3. If the resistance is at or close to the correct value, test the continuityat each connection and wire in the RTD circuit. If no problem isobserved and the fault still exists, replace the control board.

Resistance TemperatureDetector (RTD)

ControlB 3-16


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

4103413

77 93 110 127 143 160 177 193 210 227 243 260

400

380

360

340

320

300

280

260

240

220

200

180

160

170 200 230 260 290 320 350 380 410 440 470 500

RE

SIS

TAN

CE

(O

HM

S)

TEMPERATURE (DEGREES F)

TEMPERATURE (DEGREES C)

MAX

MIN

Fig. B 3-18 Tank and Gun RTD Resistance vs. Temperature

Control B 3-17


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

4103412

77 99 121 143 166 188 210 232360

340

320

300

280

260

240

220

200

180

160

170 210 250 290 330 370 410 450

RE

SIS

TAN

CE

(O

HM

S)

TEMPERATURE (DEGREES F)

TEMPERATURE (DEGREES C)

MAX

MIN

Fig. B 3-19 Hose RTD Resistance vs. Temperature

4103507

ControlB 3-18


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

To identify problems with a ribbon cable, perform the following steps:

1. Test for continuity by placing a small-gauge solid wire into thecorresponding positions at each end of the connector and measuringthe resistance. Pin 1 usually has an arrow or mark in one carrier ofthe connector housing. The resistance should be less than 1 ohm ateach position.

2. Flex the cable to check for intermittent connections. If necessary, usea quick responding meter to detect an intermittent open circuit.

NOTE: It is possible for a cable to pass a continuity test and still bedefective due to an undetected intermittent open circuit.

3. For each position in the ribbon cable, check for short circuits at eitherside of the test position. For example: to test pin 8, check theresistance between pins 8 and 9 and between pins 8 and 7.

Fig. B 3-20

A watchdog circuit detects the failure of the microprocessor or thesoftware. When a watchdog fault occurs:

� The SYSTEM FAULT LED turns on

� The fault light on the front of the applicator turns on

� The SYSTEM READY LED turns off

� The reset LED (red) located on the main control board turns on

� The circuit breaker trips after 15 seconds

The reset LED may flash when the power to the unit turns on and off. Ifthis LED stays on, replace the main control board.

Ribbon Cable

Watchdog

Control B 3-19


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

When a heater circuit channel fault occurs, the problem may be due to:

� a faulty heater

� loose wiring

� a faulty power module

� a faulty power module fuse

Check the following components in order to identify the problem:

� For a tank or grid channel, check the power module fuse

� For a hose or gun channel, check the power module fuse

� Check for loose wiring or connectors between the power module andthe component. If secure, check the continuity of the heater circuit atthe power module. If continuity exists, replace the power module.

� Check for a faulty heater by measuring the heater resistance

The following tables provide general information for the troubleshootingof control system problems. Sometimes more detailed information, circuitdiagrams or measuring devices are also needed for troubleshooting.


1. Fault light comeson

Poor hose and/or gun connections Check that the hose and gun connections aresecure.

Identify fault condition by using the channel faultand system status indicators on control panel.Refer to Channel Fault for more information.

2. Circuit breakertrips about 15seconds afterfault indicatorturns on

Microprocessor failure Replace main control board. Refer toReplacement of Main Control Board and/or ControlPanel Assembly.

Heater Circuit

6. Troubleshooting Tables

ControlB 3-20


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6


3. Circuit breakertrips

Watchdog fault exists Refer to Problem 2.

Input line voltage out of normalrange

Correct problem in plant power supply.

Tank or grid thermostat defective Replace the thermostat.

Heated system componentoverheating

Observe channel fault and system status indicatorsto identify the fault. Refer to Channel Fault.

Short circuit or overcurrentcondition exists

Identify short circuit and correct it.

4. Unit fails to turnon

Component is overheating Wait two minutes, reset the circuit breaker, checkdiagnostic aids.

Tank or grid thermostat defective Replace the defective thermostat.

Open fuse on main circuit board Replace the fuse.

No power to unit Reconnect power to the unit.

5. Temperaturewarning indicatorcomes on

Temperature of one or morechannels is outside the monitorband

Observe channel fault and system status indicatorsto identify the fault. Refer to Channel Fault formore information.

6. Troubleshooting Tables(contd.)

Control B 3-21


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6


6. Tank, grid, hoseor gun fails toheat orunderheats

Temperature setpoint incorrect Move temperature dial to correct setpoint.

Main electrical switch off Turn the switch on.

Breaker tripped due to overheatingcomponent

Reset breaker and use the diagnostic aid totroubleshoot. Refer to Channel Fault for moreinformation.

No or insufficient power to unit Resolve problem in line voltage to unit.

Open fuse F1 or F2 on main controlboard

Replace the fuse or fuses.

Defective heater Replace the heater or component if heater is notcartridge type.

Defective ribbon cable Replace the ribbon cable.

Defective control board Replace the control board. Refer to Replacementof Gun Control Board and/or Control PanelAssembly.

Defective power module fuse orpower module

Replace open fuse or replace power module.Refer to Replacement of Hose/Gun, Grid or TankPower Modules.

Defective main control board Replace main control board. Refer toReplacement of Main Control Board and/or ControlPanel Assembly.

ControlB 3-22


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

If failure occurs during operation of the inverter, an alarm code isautomatically displayed on the PU readout as follows:

Display Code Description

EOC1 Inverter output current exceeded the overcurrent limit during ac-celeration.

EOC2 Inverter output current exceeded the overcurrent limit duringconstant speed operation.

EOC3 Inverter output current exceeded the overcurrent limit during de-celeration.

EOVT Braking regenerative power from motor exceeded the regenera-tive overvoltage limit.

ETHM Electronic thermal relay in the inverter was activated (current isbelow 150% of preset current).

ETHT Electronic thermal relay in the inverter was activated (current isover 150% of preset current).

E. BEBrake transistor in the inverter fault detection.

EOHT External thermal relay was activated.

EOLTStall prevention function was activated during constant speedoperation and stopped the motor.

E. PE Data memory in the inverter and corresponding to parameternumber is corrupted.

Alarm Display

4103705

4103344

12

Control B 3-23


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

WARNING: Allow only qualified personnel to perform repairs.

The following procedures are for replacing control system components.


WARNING: Risk of electrical shock. Failure to observe mayresult in personal injury or death.

CAUTION: Wear an anti-static wrist strap when handling thefollowing electrical equipment to avoid component damage.

Disconnect and lock out input electrical power to the unit before startingrepairs.

1. Open the control panel door and the electrical enclosure door.

Fig. B 3-21

2. Remove the screws (1) from the front of the hose and gun controlboard assembly (2).

3. Unplug the ribbon cables on each side of the hose and gun controlboard.

4. Remove the hose and gun control board and replace it with a newboard.

5. Attach the hose and gun control board to the enclosure door with thescrews removed in step 3.

6. Connect the ribbon cable connectors to the new control board. Notethat the polarization slot must be aligned with the tab on the ribboncable connector. Secure the ribbon cables in place.

Fig. B 3-22

7. Return to operation.

7. Replacement of Boardsand Power Modules

Replacement of Hose and GunControl Board

4103705

4103754

4103741

ControlB 3-24


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6


1. Open the control panel door and the electrical enclosure door.

Fig. B 3-23

2. Disconnect the white plug located at the bottom of the main controlboard.

3. Unplug all ribbon cables from the control boards by pressing down onthe ejector latches on each side of the connectors.

Fig. B 3-24

4. Remove the screws from the front of the control panel assembly.

Fig. B 3-25

Replacement of Main ControlBoard and/or Control PanelAssembly

3

1

2

4103380

Control B 3-25


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

5. Remove the screws (1) securing the main control board (2) to thecontrol panel assembly (3). Separate the main control board from thecontrol panel assembly by carefully pulling the two boards apart.

6. The main control board or the control panel assembly can now bereplaced. When replacing the control panel assembly, keep thestandoffs and screws from the old control panel assembly beforediscarding it.

NOTE: If the main control board is replaced, refer to TemperatureControl in this section for all proper settings on the board.

Fig. B 3-26

7. Carefully connect the main control board and the control panelassembly by pushing them together until they are secure. Take careto align the connectors between the boards.

8. Secure the two boards together with the screws removed in step 5.

9. Attach the control boards to the enclosure door with the screwsremoved in step 4.

10. Connect the ribbon cable connectors to the control boards. Note thatthe polarization slot must be aligned with the tab on the ribbon cableconnector.

11. Connect the white plug to the bottom of the main control boardassembly.

12. Secure the enclosure door and latch the control panel door.


4103705

4130706A

ControlB 3-26


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6


1. Open the control panel door and electrical enclosure door.

Fig. B 3-27

2. Inside the electrical cabinet, locate the power module that needs tobe replaced. If necessary, refer to Wiring Diagrams for power moduleidentification.

3. Note the number and location of each wire and connector to themodule. Remove all wires and connectors.

4. Note the orientation of the module. Remove the screws holding themodule to the electrical cabinet and remove the module.

5. Install the new module using the screws removed in step 4.

6. Reconnect all wires and connectors removed in step 3. If necessary,refer to Wiring Diagrams for connection information.



Fig. B 3-28

Replacement of Hose/Gun,Grid or Tank Power Modules

4103705

4103742

4103383

Control B 3-27


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6


WARNING: Failure to disconnect external power presents aserious shock hazard. Input terminals and terminal blocks arestill energized even through the circuit breaker is off.

1. Open the control panel door and electrical enclosure door.

Fig. B 3-29

2. Inside the electrical cabinet, locate the motor control interface boardon the back panel.

3. Note the number and location of each wire and connector to theboard. Remove all wires and connectors.

4. Note the orientation of the board on the bracket. Remove the screwsholding the board on the bracket.

Fig. B 3-30

5. Check the jumper positions on the new board.

6. Install the new board using the screws removed in step 4.

7. Reconnect all wires and connectors removed in step 3. If necessary,refer to Wiring Diagrams for connection information.



Fig. B 3-31

8. Replacing the MotorControl Interface Board

4103705

4103743

ControlB 3-28


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6


WARNING: Failure to disconnect external power presents aserious shock hazard. Input terminals and terminal blocks arestill energized even though the circuit breaker is off.

1. Open the control panel and the electrical enclosure door.

Fig. B 3-32

2. Remove the screws that secure the circuit breaker to the side of theelectrical cabinet.

3. Disconnect the wires to the three lamps.

4. Remove the cable clamp and push the boot back from the circuitbreaker.

Fig. B 3-33

9. Replacing the CircuitBreaker

4103514

4103705

Control B 3-29


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

5. Disconnect all wires at the six screw-type terminals and from the twopush-on terminals.

6. Connect all wires to the new circuit breaker.

7. Push the boot over the circuit breaker and secure the wires with acable clamp.

8. Connect the wires to the lamps.

Fig. B 3-34

9. Attach the circuit breaker to the side of the cabinet with the screwsremoved in step 2.

10. Secure the electrical enclosure door and latch the control panel door.



1. Open the control panel and the electrical enclosure door.

Fig. B 3-35

10.Replacing the Tank orGrid RTD andThermostat

4103312

4103332

4103333A

ControlB 3-30


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

2. Locate the Thermostat and RTD plugs. Remove the cable straps anddisconnect the two position RTD plug or the four position thermostatplug.

3. Tie a lead to the plug. This will be used to pull the new thermostat orRTD wires through the applicator base and electrical enclosure.

Fig. B 3-36

4. Remove the panel on the front of the applicator.

Fig. B 3-37

5. Fold back a section of the insulation. Locate the grid and tankthermostats and RTDs.

Fig. B 3-38

10.Replacing the Tank orGrid RTD andThermostat (contd.)

4103334

4103335

Control B 3-31


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

6. Replace the RTD.

a. Remove the RTD plate.

b. Pull the RTD away from the tank or grid.

c. Tie the lead from the old RTD to the new RTD.

d. Pull the RTD wires out of the applicator.

e. Apply a thermal compound on the new RTD.

f. Insert the new RTD in the slot in the tank or grid.

Fig. B 3-39

g. Secure the RTD plate to the tank or grid.

h. Pull the lead from inside the electrical cabinet and thread the RTDwires through the base and the cabinet.

i. Untie the lead and connect the plugs.

j. Secure the plugs with a cable tie.

7. Replace the thermostat.

a. Remove the screws holding the thermostat to the tank or grid.

b. Pull the thermostat wires out of the applicator.

c. Apply a thermal compound on the new thermostat.

d. Insert the new thermostat.

e. Secure the thermostat to the tank or grid.

f. Pull the lead and the thermostat wires through the base andenclosure.

g. Untie the lead and connect the plugs.

h. Secure the plugs with a cable tie.

Fig. B 3-40

8. Secure the panel on the front of the applicator.


4103705

4103744

ControlB 3-32


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6




Fig. B 3-41

2. Locate the inverter on the back panel.

3. Pull the tab on the top of the inverter and remove the cover.

4. Note the number and location of each wire and connector to theinverter. Remove all wires and connectors.

5. Remove the four screws holding the inverter to the back panel.

6. Set the new inverter in position and secure with the screws removedin step 5.

7. Connect all wires. Refer to the Wiring Diagrams for wiringinformation.

8. Replace the inverter cover.

Fig. B 3-42



11. Replacing the AC DriveInverter

4103705

Control B 3-33


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6




2. Remove the wires from the RPM readout.

3. Remove the nut from the RPM readout bracket on the electricalenclosure door.

4. Discard the old RPM readout.

5. Pry open the small cover on top of the new RPM readout.

6. Use a small blade screwdriver to change the switch and dials to readDIVIDE 0 0 1.

Fig. B 3-43

7. Reconnect the wires to the new RPM readout. Refer to WiringDiagrams as needed.

8. Restore power and return to operation.

12.Replacing the RPMReadout

ControlB 3-34


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

Use the parameter unit to check, clear or program the AC inverter.Nordson Corporation recommends reprogramming the AC inverter withthe factory-set values provided in the chart below if the programmedparameters are incorrect or if it is suspected that they are incorrect.

1. Apply input power to the unit and switch the unit circuit breaker on.

2. Open the electrical cabinet and locate the AC inverter.

3. Complete each step as provided in the chart below, pressing eachkey in the key column.

NOTE: The LEDs above the SET, EXT OP and PU OP keys light whenthose keys are pressed.

Parameter Key Display

Enter programming mode PU OP 0.00

Reset to inverter to factory-set values SET Pr

2nd

8

READ

9

READ

WRITE

Pr

Pr 8

Pr 8

Pr 8.9

ALLC

ALLC flashes

Set the maximum line frequency to 60 Hz 1

READ

60

WRITE

Pr 1

Previously programmed value

60

Pr 1 and 60 flashing alternately

Set the minimum line frequency to 0 Hz 2

READ

0

WRITE

Pr 1


0


Set the deceleration rate to 4 seconds 8

READ

4

WRITE

Pr 8


4


13.Programming the ACInverter

Control B 3-35


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6


Set the audible sound to 0 2nd

10

READ

0

WRITE

Pr

Pr 10


0


Set the 10 Vdc speed signal 2nd

73

READ

1

WRITE

Pr

Pr 73


1


Prevent reverse rotation 2nd

78

READ

1

WRITE

Pr

Pr 78


1


Set the S-shaped acceleration/deceleration pattern 2nd

29

READ

1

WRITE

Pr

Pr 29


1


Set automatic reset and restart if inverter alarmoccurs

2nd

50

READ

3

WRITE

Pr

Pr 50


3


ControlB 3-36


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6


Set automatic reset to 10 tries if inverter alarmsounds

2nd

51

READ

10

WRITE

Pr

Pr 51


10


Set the wait-time for restart to 1.5 seconds afterinverter alarm sounds

2nd

52

READ

1.5

WRITE

Pr

Pr 52


1.5

Pr 52 and 1.5 flashing alternately

Exit programming mode EX OP 0.00

13.Programming the ACInverter (contd)

Control B 3-37


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

Nordson Uptime and Uptime Plus packs provide parts for fast, efficientrepairs. Buying Uptime and Uptime Plus packs costs less than buyingthe individual parts.

Uptime packs consist of maintenance parts for normal wear items. Theyeliminate the worry and expense of out-of-stock situations for regularmaintenance parts.

Uptime Plus packs provide protection for additional repairs that areneeded after long, hard usage. They enable quick replacement of majorparts, resulting in maximum uptime.

The Uptime Plus pack is available for the complete replacement of themain control board, a 4 channel board with heatsink, a 1 channel boardwith heatsink, a gun/hose module and all fuse replacement.

See Figure B 3-44. Use this list to order the Uptime Pack.


— 158 106 Service Kit, Uptime 1

— 105 583 � Service kit, lights 1

1 939 026 � � Lamp, neon, white 1

2 939 027 � � Lamp, neon, red 1

3 939 057 � � Lamp, neon, green 1

4 105 582 � Service kit, thermostat, replacement 1

— 158 105 � Service kit, fuses 1

5 121 008 � � Fuse, 4-channel board with Heatsink, 6.3 A 4

6 939 491 � � Fuse, 1-channel board with Heatsink, 25 A 4

7 121 007 � � Fuse, main control board, 1 A 4

8 310 905 � � Fuse, main control interface board, 0.125 A, fast acting 4

9 138 706 � � Fuse, 100 mA, input/output board 2

14.MultiScan ControlSystem

Uptime Pack

ControlB 3-38


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

4103207A

2

5

4

6

7

98

1

3

Fig. B 3-44

Uptime Pack (contd.)

Control B 3-39


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

See Figure B 3-45. Use this list to order the Uptime Plus Pack.


— 158 107 Service Kit, Uptime Plus 1

1 - - - - - - � Board, multiscan main control 1

2 158 105 � Service kit, fuses 1

2 121 008 � � Fuse, 4-channel board with Heatsink, 6.3 A 4

2 939 491 � � Fuse, 1-channel board with Heatsink, 25 A 4

2 121 007 � � Fuse, main control board, 1 A 4

2 310 905 � � Fuse, main control interface board, 0.125 A, fastacting

4

2 138 706 � � Fuse, 100 mA, input/output board 2

3 - - - - - - � Power module, 1-channel, 240 V, 25 A 1

4 - - - - - - � Power module, 4-channel, 240 V 1

5 - - - - - - � PCA-4-channel control, hose/gun, multiscan 1

Uptime Plus Pack

ControlB 3-40


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

4103122A

1

2

3

4

5

Fig. B 3-45

Uptime Plus Pack (contd)

Control B 3-41


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

See Figure B 3-46. Use the following table to order the individual itemsof the MultiScan Controller. The quantity listed for each item is the totalnumber you will need for the controller.


1 120 413 White neon lamp (pkg of 2) 1

2 120 414 Red neon lamp (pkg of 2) 1

3 120 415 Green neon lamp (pkg of 2) 1

4 258 959 Plexiglass door assembly 1

5 157 162 Clock, Japanese 1

5 147 573 Clock, English 1

6 153 833 Tachometer 1

7 152 333 Pushbutton switch 1

8 132 401 Display board, monitor/setback 1

9 982 435 Screw, chez hd, Rec, M4 x 10 mm, blk 13

10 183 837 Main control board assembly 1 A, C

11 121 007 Fuse, main control board, 1 AMP (pkg of 4) 2

12 108 934 Motor control board assembly 1

13 183 838 Hose/gun control module 1

14 105 582 RTD/thermostat replacement kit 1 B

NS 274 667 � Plate, retainer 1

NS 982 086 � Screw, pan, slot, M3 x 8 2

NS - - - - - - � Tank/grid, thermostat 1

NS 105 721 � Harness wire, RTD 1

NS 982 170 � Screw, chezhead, slot, M3 x 5 2

15 110 688 Circuit breaker 1

16 114 915 Circuit breaker cover 1

17 105 514 16 position ribbon cable (between items 10 and 13) 1

18 158 610 Spacer, circuit breaker 1

19 982 438 Screw, chez hd, M3 x 18, BL 4

NOTE A: Board includes fuses.

B: Apply a thermal compound.

C: MultiScan Main Control Board, part 119 928, may also be used for any unit. The improved MultiScanMain Control Board, part 183 837, requires the latest hose/gun control modules (available in ServiceKit, part 183 838), which are already installed in units with serial numbers beginning with AA- orAN96D or later.

NS: Not ShownContinued on next page

MultiScan Controller

ControlB 3-42


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

4103205A

416

15

18

19

9

1

3

2

1417

11

10

12

9

8

6

5

139

7

7

Fig. B 3-46

MultiScan Controller (contd)

Control B 3-43


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

See Figure B 3-47. Use the following table to order the individual itemsof the MultiScan Controller. The quantity listed for each item is the totalnumber you will need for the controller.


20 105 646 1 channel board with heatsink 2 A

21 939 491 Fuse, 1 channel board, 25 AMP 4

22 105 647 4 channel board with heatsink 1 A

23 121 008 Fuse, 4 channel board, 6.3 AMP (pkg of 4) 2

24 982 308 Screw, pan hd, rec, M4 x 10 mm 21

25 158 239 Service kit, MCIB, Multiscan 1 A

26 310 905 Fuse, 0.125 AMP, 5.2 mm x 20 mm long 2

27 154 393 Mounting bracket, motor control interface board 1

28 142 446 I/O board 1

29 982 341 Screw, pan hd, Rec, M3 x 10 mm 11

30 153 826 Relay, AC, 220/240 V 1

31 153 828 Relay, R10-T, 12 V 2

32 159 855 Service kit, Motor control, Prog. 1

33 133 964 Line filter with bracket 1

34 982 337 Screw, Pan Hd, Rec, M4 x 8 mm 2


36 114 310 10 position ribbon cable (at item 20) 1

37 121 445 16 position ribbon cable, 50 inches (between items 12and 25)

1



40 105 628 Hose/gun harness 1 or 2

NOTE A: Board includes fuses.

ControlB 3-44


41-3000Issued 2/99

B3EN−07−[39−MAC3]−6

4103220A

23

38

34

33

3224

24

25

24

29

28

31

29

31

29

30

29

21

20

35

36

39

37

26

27

40

22

24

Fig. B 3-47


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

Part B, Section 4

Tank

TankB 4-0


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

Tank B 4-1


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

Section B 4Tank


Adhesive or other thermoplastic materials, called hot melt materials, aremelted in a grid and cast aluminum tank with a cast-in resistive heatingelement. The tank and grid are PTFE-coated to prevent char build-up.Temperature controls are a resistance temperature detector (RTD)mounted on the tank and grid walls and solid-state circuitry located in theelectrical enclosure.

WARNING: Risk of electrical shock. Failure to observeelectrical safety procedures may result in personal injury ordeath. Allow only qualified personnel to perform the followingprocedures. Observe all high voltage indicators.

1. Heat the applicator to operating temperature before starting repairs.If the heating system is not functional, use a heat gun or some otherflameless heating device.

2. Flush the system before disassembly and remove all hot meltmaterial.

3. Remove the gear pump assembly. Refer to Gear Pump Replacementfor the procedure for removing the gear pump assembly from theapplicator.

1. Introduction

2. Preparation for Repairs

4103705

4103340

4103312

TankB 4-2


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

Follow the instructions in Preparation for Repairs before starting thisprocedure.

1. Open the electrical enclosure door.

Fig. B 4-1


2. Disconnect the external power supply. Loosen the strain relief andpull the incoming power line out through the cord connector hole.

Fig. B 4-2

3. Disconnect the RTD and Thermostat plugs. Remove the cable strapsecuring the wires together.

NOTE: Tie a lead to the end of the plugs. This will be used to pull theplugs through the applicator base and electrical enclosure duringassembly

4. Disconnect hose(s) from the hose port on the manifold.

Fig. B 4-3

3. Removal of the Tank,Grid, and Manifold

4103708

4103745

4103375

Tank B 4-3


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

5. Disconnect the air line from the solenoid on the manifold.

6. Remove the solenoid from the base and the manifold.

Fig. B 4-4

7. Open the manifold cover and remove the filter assembly, the drainvalve, the flow control valve, and the pressure control valve.

Fig. B 4-5

8. Remove the screws that secure the hopper to the grid. Discard theViton seal.

9. Lift the hopper off the applicator and set aside.

Fig. B 4-6

4103374

4103747

4103746

TankB 4-4


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

10. Disconnect the heater leads from the tank and grid.

11. Remove the screws and washers that secure the grid, tank, andmanifold assembly to the base.

12. Lift the assembly away from the base.

WARNING: Touching the insulation may cause itching and orskin irritation. Wear protective eye wear, gloves, and protectiveclothing.

Fig. B 4-7

13. Remove all insulation from the grid and tank.

14. Remove the screws that secure the grid to the tank. Lift the grid andthe grid insulator off the tank.

Fig. B 4-8

15. Remove the screws that secure the manifold to the tank.

16. Discard the grid insulator. Replace the grid insulator any time it isseparated from the grid.

Fig. B 4-9

3. Removal of the Tank,Grid, and Manifold (contd.)

4103746

4103747

4103748

Tank B 4-5


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

1. If replacing the tank with a new one, remove the RTD and thermostatfrom the old tank and insert into the new tank.

2. Secure the manifold to the bottom of the tank. Apply torque of5.42−6.78 N�m (4−5 ft-lb).

Fig. B 4-10

3. Set the new grid insulator on the tank.

4. Set the grid on top of the insulator. Apply torque of 5.42−6.78 N�m(4−5 ft-lb).

5. If replacing the grid, remove the RTD and thermostat from the old gridand insert into the new grid.

6. Lubricate the new Viton seal and place on top of the grid.

7. Wrap the insulation around the grid, tank, and manifold assembly.Use high temperature glass fiber tape to secure the insulation inplace.

Fig. B 4-11

8. Set the grid and tank assembly in position in the base.

9. Secure the assembly to the base with the screws and washers.Apply torque of 10.85−13.56 N�m (8−0 ft-lb).

10. Connect the heater leads to the grid and tank heaters.

11. Thread the RTD and thermostat leads through the base and upthrough the bottom of the electrical cabinet. Connect the RTD andthermostat plugs.

Fig. B 4-12

4. Rebuilding the Tank,Grid, and Manifold

4103375

4103745

TankB 4-6


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

12. Set the hopper on the grid. Secure with the screws and washersremoved previously. Apply torque of 4.07−5.42 N�m (3−4 ft-lb).

13. Wrap the insulation around the hopper. Use high temperature ducttape to secure the insulation in place.

Fig. B 4-13

14. Insert the filter assembly, flow control valve, drain valve, and pressurecontrol valve into the manifold.

15. Secure the solenoid to the manifold and base.

Fig. B 4-14

4. Rebuilding the Tank,Grid, and Manifold (contd.)

4103708

Tank B 4-7


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

16. Connect the air line to the solenoid.

17. Install the gear pump. Refer to Gear Pump Replacement for thisprocedure.

18. Connect the hose(s) to the hose port.


20. Set the enclosure in place. Turn the two screws on top to secure theenclosure.

Fig. B 4-15

21. Connect the power supply service line to the terminal block. Makethe connections at the terminal block according to Figure B 4-16.

22. Secure the electrical cabinet door and latch the control panel door.


41308031 2

Fig. B 4-16

1. 200−240 Vac unit connections 2. 380−415 Vac unit connections

TankB 4-8


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

Use the following table to order individual parts.


1 100 015 Hopper 1

2 131 391 Gasket, hopper (pkg of 2) 1

3 132 370 Seal, Viton, 12.56 ID x 0.139 in. (pkg of 2) 1

4 132 690 Screw, hex head, cap, M8-1.25 x 40 mm (pkg of 5) 12

5 132 692 Washer, flat, 0.344 ID x 0.875 in. OD (pkg of 5) 58

6 120 388 Lockwasher, split (pkg of 4) 29

7 120 384 Nut, hex, M8, steel (pkg of 5) 31

8 101 795 Gasket, grid 3

9 101 798 Pan, pump 1

10 101 796 Spacer 1

11 100 177 Grid 1

12 111 939 Screw, hex head, cap, M8-1.25 x 50 mm (pkg of 4) 3

13 132 693 Screw, hex head, M8 x 1.25 x 80 mm (pkg of 4) 14

14 101 242 Insulator, grid 1

15 100 863 Assembly, tank/reservoir/manifold 1

16 155 799 Spacer with set screw, tank 1

17 120 388 Lockwasher, split, M8 (pkg of 4) 3

18 983 414 Washer, flat, narrow, 8 mm 3

19 982 240 Screw, hex head, cap, M8 x 20 mm 2

20 159 857 Assembly, tank drain valve 1

21 982 050 Screw, hex head, cap, M8 x 35 mm, black 1

5. 3900/M Tank and GridAssembly

Tank B 4-9


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

4103749

2

1

4

5

3

5

6

7

12

5

14

20

15

5

6

716

19

17

18

17

18

21

5

6

7

11

13

5

8

10

8

9

8

Fig. B 4-17

TankB 4-10


41-3000Issued 2/99

B4EN−08−[39−MAC3]−4

C

## TABSHEET ##


41-3000Issued 8/94

C0EN−01−[3X−XXXX]−1

Part C

Hoses

HosesC 1-0


41-3000Issued 8/94


Hoses C 1-1


41-3000Issued 8/94


Insert the manual that came with your equipment here.

HosesC 1-2


41-3000Issued 8/94


D

## TABSHEET ##


41-3000Issued 8/94

D0EN−01−[3X−XXXX]−1

Part D

Guns

GunsD 1-0


41-3000Issued 8/94


Guns D 1-1


41-3000Issued 8/94


Insert the manual that came with your equipment here.

GunsD 1-2


41-3000Issued 8/94


E

## TABSHEET ##

Table of Contents i


41-3000Issued 2/95

E0EN−01−[39−MAC3]−3

Part E, AccessoriesTable of Contents

1. Optional Filters E 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Pressure Gauge E 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Pressure Gauge Parts List E 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Installation E 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Installation E 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Description E 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Purpose E 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Provided by Nordson E 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Cable Specifications E 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Location of Connections E 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Purpose E 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section E 1Manifold Filter Screens

Section E 2Pressure Gauge

Section E 3Sub-Base Assembly

Section E 4Casters

Section E 5Parameter Unit

Section E 6Remote Sleep Actuatorand Ready Indicator

Section E 7Grid Screen

Table of Contentsii


41-3000Issued 2/95

E0EN−01−[39−MAC3]−3


41-3000Issued 2/99

E1EN−02−[3X−XXXX]−1

Part E, Section 1

Manifold Filter Screens

Manifold Filter ScreensE 1-0


41-3000Issued 2/99


Manifold Filter Screens E 1-1


41-3000Issued 2/99


Section E 1Manifold Filter Screens

All manifolds are supplied with a standard 0.006 inch mesh filter screen.Listed below are the optional filter kits available for your manifold.Nordson recommends that the o-ring be replaced each time the filterscreen is replaced. The following filter screen kits include the filterscreen and o-ring necessary for correct replacement.

Manifolds A, F and J

Part Number Description

133 695

105 434

133 696

133 699

133 700

133 701

0.004 in. mesh screen






Manifolds B, K, O, R and S

134 013

109 729

134 014

134 015

134 016

134 017







Manifolds C, L, P, T and U (Reverse flush filters)

136 340

105 445

136 341

136 343

135 068

136 344







1. Optional Filters

Manifold Filter ScreensE 1-2


41-3000Issued 2/99



41-3000Issued 2/95

E2EN−03−[39−MAC3]−2

Part E, Section 2

Pressure Gauge

Pressure GaugeE 2-0


41-3000Issued 2/95

E2EN−03−[39−MAC3]−2

Pressure Gauge E 2-1


41-3000Issued 2/95

E2EN−03−[39−MAC3]−2

Section E 2Pressure Gauge

P/N 160 687

A pressure gauge service kit can be ordered through your NordsonCustomer Service center. The pressure gauge is used during set-upprocedures.

4103206

3 2

1

45

Fig. E 2-1


1 167 125 Pressure gauge, service kit 1 A

2 973 560 Swivel 1

3 972 646 Connector 1 C

4 167 114 Cuff 1 B

5 167 323 Tags sheet 1

NOTE A: Cuff and tag sheet are included

B: Tag sheet not included; when ordering cuff must also order P/N 167 323

C: Adhesive P/N 900 419 is required for gauge assembly connections

1. Pressure Gauge

2. Pressure Gauge PartsList

Pressure GaugeE 2-2


41-3000Issued 2/95

E2EN−03−[39−MAC3]−2


41-3000Issued 2/95

E3EN−04−[39−MAC3]−1

Part E, Section 3

Sub-Base Assembly

Sub-Base AssemblyE 3-0


41-3000Issued 2/95

E3EN−04−[39−MAC3]−1

4103864

12.70 mm(0.5 in)

109.22 mm(4.30 in)

142.88 mm(5.63 in)

4103750

Sub-Base Assembly E 3-1


41-3000Issued 2/95

E3EN−04−[39−MAC3]−1

Section E 3Sub-Base Assembly

P/N 160 073

A sub-base is available for the Series 3900/M applicators. The sub-baseis mounted underneath the applicator to raise it up off the floor. Thesub-base can be ordered with casters instead of legs, P/N 160 071.

1. Remove all packing material.

2. Locate the mounting bolts, washers and nuts that are shipped withthe assembly.

3. Set the applicator on the sub-base.

Fig. E 3-1

NOTE: The hole pattern for the front of the sub-base is 12.70 mm(0.50 in.). The hole pattern for the back of the sub-base is 109.22 mm(4.30 in.). Align sub-base hole patterns properly before proceeding tonext step.

4. Secure the applicator base to the sub-base with the bolts, washersand nuts as shown.

Fig. E 3-2

1. Installation

Sub-Base AssemblyE 3-2


41-3000Issued 2/95

E3EN−04−[39−MAC3]−1


41-3000Issued 2/95

E4EN−05−[39−MAC3]−1

Part E, Section 4

Caster Kit

Caster KitE 4-0


41-3000Issued 2/95

E4EN−05−[39−MAC3]−1

4103863

(5.06 in)128.59 mm

Caster Kit E 4-1


41-3000Issued 2/95

E4EN−05−[39−MAC3]−1

Section E 4Caster Kit

P/N 158 124

A set of four casters is available for the Series 3900/M sub-base. Thecasters make it easier to move the applicator.

Fig. E 4-1

1. Remove the legs from the sub-base.

2. Locate the mounting bolts, washers and nuts that are shipped withthe kit.

3. Secure the casters to the sub-base with the bolts, washers and nuts.

1. Installation

Caster KitE 4-2


41-3000Issued 2/95

E4EN−05−[39−MAC3]−1


41-3000Issued 2/95

E5EN−06−[39−MAC3]−1

Part E, Section 5

Parameter Unit

Parameter UnitE 5-0


41-3000Issued 2/95

E5EN−06−[39−MAC3]−1

Parameter Unit E 5-1


41-3000Issued 2/95

E5EN−06−[39−MAC3]−1

Section E 5Parameter Unit

P/N 156 338

The parameter unit is used on the Series 3900/M to set or clear theparameters of the AC inverter. Procedures for using the parameter unitare included in the Control Section of this manual.

1. Description

Parameter UnitE 5-2


41-3000Issued 2/95

E5EN−06−[39−MAC3]−1


41-3000Issued 2/99

E6EN−07−[39−MAC3]−1

Part E, Section 6

Remote Sleep Actuator and Ready Indicator

Remote Sleep Actuator and Ready IndicatorE 6-0


41-3000Issued 2/99

E6EN−07−[39−MAC3]−1

Remote Sleep Actuator and Ready Indicator E 6-1


41-3000Issued 2/99

E6EN−07−[39−MAC3]−1

Section E 6Remote Sleep Actuator and Ready Indicator

P/N 160 352

The capability for remote READY indication and enabling SLEEPremotely in the 3900/M unit has been provided to meet a specificcustomer request. This enables the system operator to work at adistance from the applicator unit and still see when system READY isreached and then be able to access the SLEEP mode. Other remotesystem inputs and outputs are accessible at the I/O board mounted onthe panel inside the applicator. (See the unit product manual for detailsabout the I/O board.)

Nordson provides a remote SLEEP button and a remote READYindicator lamp housed in an industrial enclosure. Inside the electricalenclosure of the applicator, Nordson provides accessible points for easyconnection of the remote SLEEP and READY features. Nordson alsosupplies up to 3 meters of cable attached to the remote enclosure toreach from the unit to the desired remote location. The wires are alreadyterminated with the proper connectors and attachment fittings.

4103751

Fig. E 6-1

1. Purpose

2. Provided by Nordson

Remote Sleep Actuator and Ready IndicatorE 6-2


41-3000Issued 2/99

E6EN−07−[39−MAC3]−1

The cable that is supplied is 20 AWG, 300 Vac, 60�C, four-conductorcable with PVC jacket.

Shown on the system wiring diagram are wires 49C, 45E, 9B, and 13Hwhich connect the remote SLEEP button and the remote READYindicator lamp to the applicator unit. Each of the four conductors isterminated with a 20 AWG, 0.250 inch quick-connect female tab on oneend and a 20 AWG wire ferrule on the other.

3. Cable Specifications

4. Location of Connections


41-3000Issued 2/95

E7EN−08−[39−MAC3]−1

Part E, Section 7

Grid Screen

Grid ScreenE 7-0


41-3000Issued 2/95

E7EN−08−[39−MAC3]−1

Grid Screen E 7-1


41-3000Issued 2/95

E7EN−08−[39−MAC3]−1

Section E 7Grid Screen

P/N 154 886

The grid screen is available for the Series 3900/M as an accessory.Place the grid screen on the grid to keep objects larger than 0.19 mmfrom falling into the tank. When the grid screen is used, the melt rate isreduced.

1. Purpose

Grid ScreenE 7-2


41-3000Issued 2/95

E7EN−08−[39−MAC3]−1

F

## TABSHEET ##


41-3000Issued 9/92

F0EN−01−[3X−XXXX]−1

Part F

Appendix

Appendix0


41-3000Issued 9/92


Appendix i


41-3000Issued 9/92


Part F, AppendixTable of Contents

Glossary F 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index F 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1Nordson Glossary

Section 2Index

Appendixii


41-3000Issued 9/92



41-3000Issued 4/94


Part F, Section 1

Nordson Glossary

GlossaryF 1-0


41-3000Issued 4/94


Glossary F 1-1


41-3000Issued 4/94


Section F 1Nordson Glossary

Any material that can be used to adhere or “stick” one surface to another.

Fine threads of adhesive caused by incomplete transfer of the adhesivemass from applicator to substrate, followed by elongation of theconnecting bridges. May be caused by improper nozzle shutoff with ahigh viscosity adhesive.

That part of the hot melt system that is used to heat adhesive to itsrequired application temperature and pump it to the hose(s) and gun(s).It consists of a tank or reservoir, pump, filter, distribution manifold andtemperature controlled heating system.

An automatically actuated valve which is opened by fluid flow in onedirection and closed by flow in the opposite direction.

The width of an adhesive bead which has been deposited on a substrate.The measurement is taken before the bead has been flattened byadhering it to another surface.

See Heater Cartridge.

A non-replaceable heating element specifically shaped to provide auniform thermal profile in the heated object.

The degradation of a fluid that occurs as a result of time and exposure toatmospheric air and/or heat.

An electronic device that acts to shut down a powered AC circuit whencurrent draw (amps) exceeds some preselected value or when certainfault conditions exist.

A temperature control device that closes, completing an electronic circuitupon reaching a specific temperature.

The tube that connects the outlet port of a pump to the distributionmanifold of a hot melt applicator.

Adhesive

Angel Hair

Applicator

Ball Check Valve

Bead Thickness

Cartridge Heater

Cast-in Resistive HeatingElement

Charring in Tank

Circuit Breaker

Close-on-rise Thermostat

Crossover Tube

GlossaryF 1-2


41-3000Issued 4/94


The time between when the gun is signaled to stop and when theadhesive flow actually does stop.

A pump that delivers material on both the upstroke and the downstroke.

A manufacturer’s statement of the maximum level of some externalcondition, such as water or dust level, that the enclosure is capable ofwithstanding.

A speed-sensing device which outputs a frequency of pulses proportionalto the measured line speed.

A spring-loaded triggering device for dispensing or depositing material.There are two basic types of guns, the manual gun which is actuated byhand and the automatic gun which is actuated by process controls.

That part of a filter assembly external to the unit to which the filteringelement is attached, or contained within the unit. It is also used foraccess or cleaning.

The amount of material flowing through the system per unit of time. Theamount may be expressed in gravimetric (weight) or volumetric terms.Examples: grams/minute, ml/min, lb/hour, gallons/hour.

A valve typically used to pressurize one side of a double acting cylinderwhile opening a exhaust path for the opposite side.

See Key-to-line.

A cross-linked, insoluble material which can form in a hot melt applicatorunder extended thermal stress.

A wire that connects all AC powered devices to earth ground.

The device that dispenses a material (adhesive) onto a substrate orproduct.

A replaceable resistive heating element, tubular in shape, designed to fitin a machined hole in the object to be heated.

The volume that is heated and thermally controlled by a single controldevice.

A container allowing non-melted adhesive to be supplied on a continuousbasis to a melt zone.

Drop-out Time

Dual-acting Piston Pump

Enclosure Rating

Encoder

Extrusion Gun

Filter Bung

Flow Rate

Four-way Air Valve

Gear-to-line

Gel

Ground Wire

Gun

Heater Cartridge

Heating Bong

Hopper

Glossary F 1-3


41-3000Issued 4/94


The adhesive or thermoplastic material dispensed by the hot meltsystem.

The applicator, hose(s), gun(s) and timing mechanism.

A system that regulates flow rate in proportion to the substrate (line)speed.

A device that shows the level of material in a tank, reservoir or hopper.

A device that converts applied voltage to light. LEDs appear as coloredlights that indicate operating conditions.

See Level Indicator.

The device that distributes fluid and/or air.

The highest cycle rate of the gun that produces a repeatable pattern.

The maximum adhesive flow rate achievable without exceeding anyoperating limits. The maximum pumping rate is measured at themanifold outlet. The rate is based on an adhesive with a given viscosity.

The rate at which a material can be melted continuously on a long-termbasis while maintaining the output fluid temperature within a desiredtemperature band. Commonly expressed in units of grams/minute,grams/hour, lb/min or lb/hr.

The extrusion tip, the point at which the adhesive exits the gun. Thenozzle controls the adhesive stream’s volume, shape and direction.Nozzles may have single or multiple orifices.

The time after adhesive is applied during which a serviceable bond canbe made. Many factors affect open time, including temperature,substrate, the adhesive used and the amount of adhesive applied.

The pressure at which the pump and/or guns are operated. See productspecifications.

The range of temperatures in which the specific material or adhesive inuse functions satisfactorily in a particular application.

A product feature that shuts down the unit or produces an alarm whentemperatures are outside a specified band.

Hot Melt Material

Hot Melt System

Key-to-line

Level Indicator

Light Emitting Diode (LED)

Low Level Indicator

Manifold

Maximum Operating GunSpeed

Maximum Pumping Rate

Melt Rate

Nozzle

Open Time

Operating Air Pressure

Operating Temperature Range

Overtemperature Protection

GlossaryF 1-4


41-3000Issued 4/94


A product feature that prevents the parent machine from operating beforethe hot melt system is ready.

A device that controls the dispensing of material.

An adhesive that remains tacky after curing or setting.

The time between when the gun is signaled to start and when theadhesive flow actually begins.

Output signal frequency, often from an encoder, tach generator or similardevice.

The amount of material a pump can deliver per unit of time.

A Nordson program which offers factory rebuilt equipment at a reducedcost in exchange for the customer’s old equipment.

An adjustable device for maintaining pressure at the preset valve.

A safety device designed to release pressure if it exceeds a preset level.

A temperature-sensing device that changes resistance at apredetermined rate in response to changes in temperature.

A special case of Key-to-line or Gear-to-line, often applied to air controlfor piston pumps.

Part of an automatic extrusion gun, the service block supplies the neededair, adhesive and heat to make the gun operate.

The time required for a material to reach a set state after being applied ina fluid state.

A mechanical or electrical device used to switch a 4-way air valve.

A common shape of adhesive.

A nozzle that applies a film of adhesive instead of a bead.

An air control valve actuated by an electromagnetic coil.

Parent Machine Interlock (PMI)

Pattern Control

Pressure-Sensitive Adhesive

Pull-in Time

Pulses Per Minute

Pumping Rate

Rebuild and Exchange (RBX)

Regulator

Relief Valve

Resistance TemperatureDetector (RTD)

Run-up

Service Block

Setting Time

Shifter Assembly

Slats

Slot Nozzle

Solenoid Valve

Glossary F 1-5


41-3000Issued 4/94


An electronic circuit whose operation depends upon any combination ofoptical, electrical or magnetic phenomena within a solid. Specificallyexcluded are circuits that depend upon physical movement, as well asthose requiring either contact with or avoidance of other solids, liquids,gases or plasmas.

A device whose electrical functions are performed by semiconductors orotherwise completely static components such as resistors and capacitors.The device may contain components that do not depend on electronicconduction in a vacuum or gas.

In the Nordson context, a material used to dissolve hot melt adhesive tofacilitate system cleaning.

A defect in adhesive application characterized by hair-like fibers ofadhesive emanating from the trailing edge of the bead. Stringing mayproduce continuous fibers attached to the nozzle. It is most often causedby the gun temperature being too cold.

The material or product on which the adhesive is applied.

The amount of material that the tank can hold with the fluid level 25 mm(1 inch) from the top of the hopper or tank.

A product feature that helps keep large pieces of foreign material out ofthe pump.

The volume that the tank can hold when it is filled. The displacement ofthe pump is taken into account in this measurement.

That part of a temperature control system that detects the temperatureand feeds this information to the control device.

A product feature by which the system temperature may be automaticallyreduced to a preset number of degrees.

A synthetic material which is solid at room temperature, becomes softwhen heated, and returns to solid form upon cooling.

See Pattern Control.

Operator interface.

Air free of oil.

A physical measurement of resistance to flow.

Solid State Circuitry

Solid State Device

Solvent

Stringing

Substrate

Tank Capacity

Tank Strainer

Tank Volume

Temperature Sensor

Temperature Setback

Thermoplastic Material

Timing Device

Touch Pad

Unlubricated Air

Viscosity

GlossaryF 1-6


41-3000Issued 4/94



41-3000Issued 2/99

F2EN−03−[39−MAC3]−27

Part F, Section 2

Index

IndexF2-0


41-3000Issued 2/99

F2EN−03−[39−MAC3]−27

Index F2-1


41-3000Issued 2/99

F2EN−03−[39−MAC3]−27

Section F 2Index

A

AC Inverter, Replacement, B 3-32

AC Inverter, Clearing the settings, B 3-34

AC inverter, Alarm displays, B 3-22

AccessoriesCasters, E 4-1Grid Screen, E 7-1Parameter Unit, E 5-1Remote Sleep Actuator and Ready Indicator, E 6-1

Air Supply, Installation, A 3-9

C

Channel fault, Troubleshooting, B 3-13

Channel status indicators, B 3-4

Circuit breaker, Replacement, B 3-28

CleaningManifold filter, A 5-2Nozzles, A 5-4Safety instructions, A 1-7

Clock, Setting, A 3-10

Control board replacementHose and gun, B 3-23Main control board, B 3-24

Control panel assembly, Replacement, B 3-24

D

Digital display, Indicators, B 3-4

Digital temperature display, Controls, B 3-9

Dimensions, Unit, B 1-6

EElectrical

Functional areas, B 3-2Installation, A 3-2Schematics, B 1-12Temperature control, B 3-7Troubleshooting, B 3-13Wiring diagrams, B 1-10

FFeatures, A 2-2

Filter screens, E 1-1

FlushingSystem flushing using Type R fluid, A 5-7System using hot melt material, A 5-6

GGear Pump, Cleaning, A 5-8

Gear Pump Assembly, Parts list, B 2-36

GridRemoval, B 4-2Temperature controls, B 3-3

Grid Screen, E 7-1

HHeater circuit, Troubleshooting, B 3-19

Heater electrical data, B 1-7

High/low monitoring bandControls, B 3-10Indicators, B 3-5

Hose, Installation, A 3-8

Hose and gun temperature controls, B 3-6

Hot Melt Material, Changing, A 5-10

IndexF2-2


41-3000Issued 2/99

F2EN−03−[39−MAC3]−27

IID Plate, A 3-4

Input/Output BoardInput features, B 3-12Output features, B 3-12

Input/Output Board (I/O), B 3-12

InstallationAir supply, A 3-9Electrical, A 3-2

Changing from Celsius to Fahrenheit, A 3-4Hose, A 3-8Parent machine interlock, A 3-7System fault connections, A 3-7System-ready delay, A 3-5Timer, A 3-9

Intended Use, A 2-2

MMaintenance

Changing the hot melt material, A 5-10Cleaning manifold filter, A 5-2Cleaning the gear pump, A 5-8Daily, A 5-1Non-scheduled, A 5-6Nozzles, A 5-4Record form, A 5-11Semi-annual, A 5-6Weekly, A 5-2

ManifoldFilter screens, E 1-1Parts list for filter assembly, B 2-42Replacement, B 4-2

Motor and drive system, Parts list, B 2-31

Motor Control Interface Board, Replacement, B 3-27

Motor controls, B 3-5

MultiScan controllerCircuit breaker replacement, B 3-28Control panel assembly replacement, B 3-24Digital display, B 3-9Functional areas, B 3-2Hose and gun control board replacement, B 3-23Hose and gun temperature controls, B 3-6Main control board replacement, B 3-24Motor control interface board replacement, B 3-27Motor controls, B 3-5Overview, A 2-4Parts list, B 3-37Power module replacement, B 3-26Replacement of boards and power modules, B 3-23RTD replacement, B 3-29Sequential startup, B 3-7Temperature controls, B 3-7Temperature setback, B 3-9Thermostat replacement, B 3-29

OOperating instructions, First use, A 4-1Operator card order form, O-11Options, A 2-2Overtemperature protection, B 3-8

Changing the setting, B 3-11

PPart list, How to read the parts lists, B 1-21Parts lists

Applicator enclosure, B 1-22Gear pump assembly, B 2-36Manifold filter assembly, B 2-42Motor and drive system, B 2-31MultiScan controller, B 3-37Tank and Grid, B 4-8

Power moduleReplacement, B 3-26Troubleshooting, B 3-14

RRemote Ready Indicator, E 6-1Remote Sleep Actuator, E 6-1Resistance temperature detector (RTD)

Replacement, B 3-29Troubleshooting, B 3-15

Ribbon cable, Troubleshooting, B 3-18RMP readout, Replacement, B 3-33

Index F2-3


41-3000Issued 2/99

F2EN−03−[39−MAC3]−27

SSafety

Cleaning, A 1-7Installation and electrical connections, A 1-4Maintenance/Repair, A 1-6Operation, A 1-4Symbols, A 1-2Thermoplastic, A 1-8

Schematic, Hydraulic, A 2-5

Schematics, B 1-12

Sequential startup, B 3-7

Setting the Clock, A 3-10

Spare parts and supplies, O-3

Speed Reducer, Maintenance, A 5-6

System components, Overview, A 2-3

System status indicators, B 3-3

System-ready delay, Changing, A 3-5

TTank

Removal, B 4-2Temperature controls, B 3-3

Tank and Grid, Parts list, B 4-8

Technical data, B 1-1

Temperature setbackControls, B 3-9Indicators, B 3-5

Thermostat, Replacement, B 3-29

TroubleshootingAlarm displays, B 3-22Channel fault, B 3-13Electrical, B 3-13Heater circuit, B 3-19Hot melt application not correct, A 6-2Important hints, A 6-1Inadequate supply of hot melt material, A 6-1MultiScan controller, B 3-13Power module, B 3-14Resistance temperature detector (RTD), B 3-15Ribbon cable, B 3-18Watchdog, B 3-18

Troubleshooting tablesAdhesives, A 6-1Control system, B 3-19

WWatchdog, Troubleshooting, B 3-18

Weekly Maintenance, Speed reducer, A 5-6

Wiring diagrams, B 1-10

IndexF2-4


41-3000Issued 2/99

F2EN−03−[39−MAC3]−27

SERIES 3900/MMetered Adhesive Application System




























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